Standard Practice C501

Citation Standard Practices Manual (Rev 1)
20-00-00-0 (Rev 1)
STANDARD PRACTICES AIRFRAME - GENERAL

1. Scope
A. This chapter gives all applicable standard maintenance practices to maintain and repair parts, components, and systems
of the airframe that are typical to more than one area or system. This section gives a list of the sections included in this
chapter and a tool and equipment list for the chapter.
B. Maintenance practices that are specific to a system or a subject are given in the related chapter of the applicable
Maintenance Manual.
2. Description
A. This chapter is divided into sections to help maintenance personnel find data. The sections that follow are included in this
chapter:
• Material and Tool Cautions
• Airplane Hardware
• Electrical/Electronic Practices
• Solvents, Sealants and Adhesives
• Adhesives, Cements and Sealants Shelf Life and Storage.
3. Tools and Equipment
A. Table 1 gives a list of the tools and equipment that are used to complete some of the maintenance procedures in this
chapter.
NOTE: You can use equivalent tools or equipment.
Table 1. Tools and Equipment
Name Number Manufacturer Use
Abrasive Blasting Tool Educt-0-Matic Model 10 Clemco Industries Corp. To do the mechanical paint
One Cable Car Drive stripping.
Washington, MO 63090
Adhesive Loctite-Super Bond 495 Henkel Corp. To hold the tubing in the
2850 Willow Pass Road Permaswage fittings.
Bay Point, CA 94565
Aerodynamic Fairing Bondtite Premium 80 Light Oatey Co. To correct the contour,
Compound (Type I, Polyester Body Filler 4700 W 160th St. roughness, and dimensional
Resin and Styrene Cleveland, OH 44135 deviations before painting.
Monomer) White Diamond Body Filler Oatey Co. To correct the contour,
roughness, and dimensional
deviations before painting.
Loctite EA960F Aero Henkel Corp. To correct the contour,
Dynalite #494, #496 Dynatron To correct the contour,
Rage Xtreme #122 Evercoat To correct the contour,
Illinois Tool Works Inc. roughness, and dimensional
Division deviations before painting.
6600 Cornell Road
Cincinnati, OH 45242
Techniglaze DF-715 PPG Aerospace/PRC- To correct the contour,
DeSoto roughness, and dimensional
2750 114th Street deviations before painting.
Grand Prairie, TX 75050
Copyright © Textron Aviation Inc. Page 1 of 10

Retain printed data for historical reference only. For future maintenance, use only current data. Print Date: Mon Jan 21 08:50:56 CST 2019
20-00-00-0 (Rev 1)
Metal Glaze, Finishing and Evercoat To correct the contour,

Blending Putty #100416 roughness, and dimensional
Aerodynamic Fairing Aluminum Putty (F) - 10610 - ITW Devcon To correct the contour,
Compound (Type II, 1 gallon 30 Endicott Street roughness, and dimensional
Polyester Resin with Danvers, MA 01923 deviations before painting.
Aluminum Powder)
Aerodynamic Fairing Epoxy Filler Putty 467-9 Akzo Nobel Aerospace To correct the contour,
Compound (Type III, Epoxy Coatings roughness, and dimensional
Resin) 1 East Water Street deviations before painting.
Waukegan, IL 60085
Loctite EA 9394 PT Aero Henkel Corp. To correct the contour,
Quantum1 Large Repair Evercoat To correct the contour,
#497 - 3 Gallon Pail roughness, and dimensional
Catalyst #457 and #455 deviations before painting.
Use with #171 Putty Pusher -
X530004
Quantum1 Large Repair Evercoat To correct the contour,
#490 - 0.5 Gallon Pail roughness, and dimensional
Catalyst #457 and #455 deviations before painting.
10:1 BPO Catalyst Fast Evercoat To correct the contour,
#457 - 2.8 oz. roughness, and dimensional
Use with Quantum1 #490 deviations before painting.
and #497
10:1 BPO Catalyst Very Fast Evercoat To correct the contour,
#455 - 2.8 oz. roughness, and dimensional
Use with Quantum1 #490 deviations before painting.
and #497
Quantum1 Fast #492 - 825 Evercoat To correct the contour,
mL Cartridge roughness, and dimensional
Use with #835 Dispenser - deviations before painting.
X530003
Aerodynamic Smoothing P/S 870, 6 oz. Frozen B-2 PPG Aerospace/PRC- To fill and seal gaps and
Compound DeSoto seams between the skins of
the airplane exterior.
WS-8070, 2.5 oz. Frozen B- Royal Adhesives and To fill and seal gaps and
2. Sealants seams between the skins of
2001 West Washington St. the airplane exterior.
South Bend, IN 46628
Alkaline Cleaner (General Eldorado ED-500 PRC-DeSoto International, To do general cleaning of the
Cleaning) Inc. airplane's external surface.
12780 San Fernando Road
Sylmar, CA 91342
Alkaline Cleaner (Local Ardrox 1900-BD Brent America Inc. To do local cleaning of the
Cleaning) 16961 Knott Ave. airplane's external surface.
La Mirada, CA 90638-6015
Allen Wrench Commercially Available To remove and install non-
flare fittings.

20-00-00-0 (Rev 1)
Antiseize Compound TT-A-580 Commercially Available To install instant fittings.

Anti-Static Coating (Type II) Base: 528x306 PPG Aerospace/PRC- Gives a protective coating on
Activator: 910x464 DeSoto the nose radome surface.
Base: CA7870 PPG Aerospace/PRC- Gives a protective coating on
Activator: 910x464 DeSoto the nose radome surface.
Anti-Static Coating (Type IV) Base: CA7850A PPG Aerospace/PRC- Gives a protective coating on
Activator: CA7850B DeSoto the fuel access door surface.
Balance/Scale Commercially Available To weigh out adhesive and
sealant ratios.
Bearing Removal/Installation Commercially Available To remove and install
Tools bearings.
Bergen BM Series Safety Bergen Cable Technology, To install safety cable.
Cable Kit LLC
343 Kaplan Drive
Fairfield, NJ 07004
Blast Cleaning Materials Commercially Available To do the mechanical paint
stripping.
Borescope Commercially Available To inspect flight control
cables.
Box Wrench Commercially Available To remove and install non-
flare fittings.
Buffing Compound Formula No. 1187 MET-ALL Industries To do the mechanical finish
231 Locust St. buffing.
Canal Fulton, OH 44614
SS-17 Kocour To do the mechanical finish
4800 S St. Louis Ave. buffing.
Chicago, IL 60632
SS-47 Kocour To do the mechanical finish
buffing.
Cable Tie Tool GS2B Panduit To install the cable ties.
18900 Panduit Drive
Tinley Park, IL 60487
Cheesecloth Commercially Available To clean the tubing.
Chem Film Solution Eldorado Dorado Kote #1 PPG Aerospace/PRC- To prepare the exterior
DeSoto airplane surface before
Alumigold (Liquid) Henkel Corp. painting.
2850 Willow Pass Road
Bay Point, CA 94565
Alumigold (Solid) Henkel Corp.
Bonderite M-CR 600RTU Henkel Corp.
Chemical Paint Stripper PR-4028 PRC-DeSoto International, Spray or brush on aluminum,
Inc. cadmium, steel, and titanium.
Turco 6017 Henkel Corp. Spray or brush on aluminum,
cadmium, steel, and titanium.
Strypeeze Savagran Spray or brush on aluminum,
P.O. Box 130 cadmium, and steel.
Norwood, MA 02062

20-00-00-0 (Rev 1)
Turco 5873 NC Henkel Corp. Spray or brush on aluminum,

cadmium, magnesium, steel,
and titanium.
Chipless Tube Cutter D12530-001, D12531-001, Permaswage To cut the tubing ends.
D12532-001 14800 S. Figueroa St.
Gardena, CA 90248
Cloth Commercially Available To find broken wires on
control cables.
To clean components.
Conductive Coating (Type III) Base: 528x310 PPG Aerospace/PRC- To give a conductive coating
Activator: 910x464 DeSoto to the composite surface.
Corrosion Protection Primer 513x419 PPG Aerospace/PRC- To give a corrosion prevention
910x492 DeSoto coating between the paint and
the airplane surface.
02-Y-40 DEFT To give a corrosion prevention
02-Y-40 CATA 17451 Von Karman Ave. coating between the paint and
Irvine, CA 92614 the airplane surface.
U-1201F Sterling Lacquer Mfg. Co. To give a corrosion prevention
U-1202F 3150 Brannon Avenue coating between the paint and
St. Louis, MO 63139 the airplane surface.
Base: 10-P20-13 International Paint LLC To give a corrosion prevention
Catalyst: EC-213 6001 Antoine Dr. coating between the paint and
Houston, TX 77091 the airplane surface.
Base: 10P8-11 Akzo Nobel Aerospace To give a corrosion prevention
Catalyst: EC-286 Coatings coating between the paint and
the airplane surface.
Crocus Cloth Commercially Available To polish the nicks and
scratches in tubing.
Crimping Tool (Wristlock) WT110M Thomas & Betts Corporation To crimp quick disconnect
8155 T&B Boulevard non-environmentally resistant
Memphis, TN 38125 splices (S341).
Crimping Tool (Hand) 59250 Commercially Available To crimp permanent non-
59239-4 environmentally resistant
splices.
Crimping Tool (Hand) AD-1377 Commercially Available To crimp permanent
environmentally resistant
splices.
Crimping Tool (Hand) 58433-3 TE Connectivity To crimp insulation restricting
59824-1 1455 Adams Court terminals.
Menlo Park, CA 94025
Crimping Tool (Hand) AMT4001 Daniels Manufacturing To crimp AWG 22 thru 10
Corporation standard terminals.
526 Thorpe Road
Orlando, FL 32824-8133
Crimping Tool HH80C (Tool) Daniels Manufacturing To crimp AWG 8 thru 2
TBHD1M (Head) Corporation standard terminals.
Crimping Tool AN3427 Burndy LLC To crimp flag terminals.
47 East Industrial Park Drive
Manchester, NH 03109

20-00-00-0 (Rev 1)
Daniels DMC Series Tool Daniels Manufacturing To install safety cable.

and Parts Kit Corporation
Deburring Tool D10210, D9851, D9850, Permaswage To remove burrs and sharp
D9849 edges from the tubing ends.
Deoxidizer Eldorado AC-12 PPG Aerospace/PRC- To remove oxidation from the
DeSoto airplane surface before
painting.
Deutsch Axial-Swage Tool DAT03AEXXXXXX Permaswage To swage aluminum
(DAT) Kit DeutschLite fittings.
Deutsch Axial-Swage Tool DAT02AEXXXXXXX Permaswage To swage titanium
Deutsch Axial-Swage Tool DAT05AEFKT300X Permaswage To swage stainless steel
Dust-Proof Polyethylene Commercially Available To prevent contamination.
Bags
Ecco-Strip 93 Emerson/Cuming Specialty To remove the paint/primer
Polymer Family Grace WR from the tubing ends before
Co. you swage them.
869 Washington St.
Canton, MA 02021-2513
Emery Cloth Fine Grade (400 -600 grit) Commercially Available To polish the nicks and
scratches in tubing.
To be used for electrical
bonding surface preparation if
Scotchbrite is not abrasive
enough.
Epoxy Enamel 560 thru 569 Series Akzo Nobel Aerospace To topcoat the surface.
Coatings
Epoxy Primer Base: 10P8-11 Akzo Nobel Aerospace To prepare the surface for
Catalyst: EC-286 Coatings epoxy enamel.
EPX Applicator Gun (or 2:1 9170 3M To squeeze out side by side
ratio equivalent) 3M Center mixing cartridges of sealant
St. Paul, MN 55144 and adhesive.
Extraction Tool Commercially Available To extract wire contacts from
the wire connector housing.
Filler Putty AKZO 28-C-1 Epoxy Akzo Nobel Aerospace To fill local depressions, pits,
Coatings pin holes, and other small
surface defects to make a
smooth surface for painting.
AKZO 467-9 Epoxy Akzo Nobel Aerospace To fill local depressions, pits,
Shell Epon 815 Epoxy Hexion Specialty Chemicals, To fill local depressions, pits,
Inc. pin holes, and other small
P.O. Box 4500 surface defects to make a
Houston, TX 77210-4500 smooth surface for painting.
Fine and Medium Grit Commercially Available To sand the surface of the
Sandpaper airplane.

20-00-00-0 (Rev 1)
Flame Control Coating No. 173 Flame Control Coatings, To give maximum fire
LLC protection to lightweight
4120 Hyde Park Blvd metals.
Niagara Falls, NY 14305
Flashlight Commercially Available To inspect components in low-
light conditions.
Grease MIL-G-23827 Commercially Available To lubricate the roller stake.
Heat Gun 275°F (135°C) Output Commercially Available To apply identification tape,
and accelerate adhesive and
sealant cure times.
To shrink heat shrink tubing
and splice sleeves.
To fabricate placards.
Hand Installation Tool D( )T860 Huck International Inc. To install rivetless nutplates.
Assembly Aerospace Fastener
Division
3274 East Columbia Street
Tucson, AZ 85714
Hot Melt Gun Commercially Available To heat and apply Type IX Hot
Melt Adhesive.
Identification Tag Commercially Available To identify parts and
components for installation.
Identification Tape CM3582-X-X Cessna Aircraft Company To identify fluids and gases in
Refer to Identification Tape - Citation Marketing Division tubing and hoses.
Maintenance Practices for Department 579
the specific dash numbers P.O. Box 7706
that are related to the system Wichita, KS 67277
and the function.
Insertion Tool Commercially Available To insert wire contacts into the
wire connector housing.
Lint-Free Cloth Commercially Available To clean components.
Low Friction Sleeve Commercially Available To install wraps.
Masking Materials Protex 10V - Latex Mask-Off Company, Inc. To cover windows and
Impregnated Paper with 345 West Maple Avenue windshields.
Liner (10 mils) Monrovia, CA 91016-1148
No. 483 - Masking Tape 3M To protect the areas where
(Black) Industrial Adhesives and paint and chemicals are not
Tapes Division wanted.
St Paul, MN 55144-1000
No. 226 - Plastic Tape 3M To protect the areas where
(Black) Industrial Adhesives and paint and chemicals are not
Tapes Division wanted.
Type I, Class A - Waxed Commercially Available To cover windows and
Kraft Paper windshields.
Megohmmeter Commercially Available To measure resistance.
Metal Container Commercially Available To catch fluid or spills.
Methyl n-Propyl Ketone Commercially Available To clean the surface of the
airplane.

20-00-00-0 (Rev 1)
Micro-Ohmmeter Model 580 or equivalent Keithley Instruments, Inc. To measure resistance.

Cleveland, OH 44139
Mirror Commercially Available To inspect components in
areas that are difficult to see.
Mop Commercially Available To apply cleaning solutions to
the airplane.
Multimeter Commercially Available To measure the resistance of
the anti-static coating.
Mylar Tape Commercially Available To protect the primed
surfaces.
Oil Commercially Available To use with emery cloth and
crocus cloth to polish the nicks
and scratches in tubing.
PA-1 Applicator Commercially Available To install wraps.
Petrolatum VV-P-236 Commercially Available To lubricate and install the
instant fitting.
Photo Placards Commercially Available To fabricate photo placards.
Exposure/Developer
Equipment
Plastic Squeegee Commercially Available To remove the paint and the
chemical paint stripper.
To fabricate and install
placards, decals, and wraps.
Pneumatic Polishing/Buffing Commercially Available To do the mechanical finish
Tool polishing/buffing.
Polishing Compound Nushine II, Grade C Nuvite Chemical To do the mechanical finish
Nushine II, Grade S. Compounds polishing.
85 Jetson Lane
Central Islip, NY 11722
Polycarbonate Primer JetFlex WR San Tan Beige Sherwin Williams Aerospace To prime the polycarbonate
(F09676) Coatings (Lexan) surface.
415 East Commerce St.
Andover, KS 67002
Polycarbonate Topcoat JetFlex WR CM0981400 Sherwin Williams Aerospace To topcoat the polycarbonate
Series Coatings (Lexan) surface.
Polypropylene Bristle Brush Commercially Available To do the chemical paint
stripping.
Portable Sprayer Commercially Available To apply the cleaner solution
to the airplane.
Positioner Commercially Available To use with the crimp tool to
crimp wire contacts.
Preset Tool Commercially Available To preset the sleeve for the
MS flareless fitting.
Press Commercially Available To remove and install
bearings.
Protective Caps and Plugs Commercially Available To prevent contamination.
Radius Blocks Commercially Available To bend tubing.

20-00-00-0 (Rev 1)
Removal Tool RB6527- ( ) Huck International Inc. To remove the nut element
from the rivetless nutplate.
Rivet Brush Commercially Available To install decals and wraps.
Rosan Fitting Tools ORTXXX - O-ring Installation Alcoa Fastening Systems To remove/install Rosan
Tool 800 S State College Blvd. fittings.
RF69XXW - Wrench Fullerton, CA 92831
RF98XXDW - Combination
Wrench and Drive Tool
RF98XXDEK - Lock Ring
Drive Tool
RFXXLPDE - Lock Ring
Removal Tool
Rubber Roller Commercially Available To install placards.
Safety Wire Pliers Commercially Available To install lock wire.
Sanding/Sealer Primer 467-9 Akzo Nobel Aerospace To prime the sanding surfacer.
Coatings
Sanding Surfacer AKZO 464-3-1 Akzo Nobel Aerospace To fill local depressions, pits,
Hyperthane Base: 82X03 Diamond Vogel Paints To fill local depressions, pits,
Curing Agent: 81C1 1110 Albany Place SE pin holes, and other small
Orange City, IA 51041 surface defects to make a
Base: 531K012 PRC-DeSoto International, To fill local depressions, pits,
Catalyst: 930K082 Inc. pin holes, and other small
Blue Base: 482-300 Sherwin Williams Aerospace To fill local depressions, pits,
Tan Base: 487-600 Coatings pin holes, and other small
Curing Agent: 120-900 surface defects to make a
Base: U1761 Sterling Lacquer Mfg. Co. To fill local depressions, pits,
Curing Agent: U1762 pin holes, and other small
Sandpaper 80 to 600 Grit Commercially Available To install the nylon tubing into
the instant fitting.
To install V-type couplings.
To sand the surface of the
airplane.
Scotchbrite Pads Pads and discs 3M To prepare a surface for
electrical and adhesive
bonding.
To sand the exterior surface of
the airplane.
Scotchbrite Disc Holder 45101 3M To hold a scotchbrite disc.
45102

20-00-00-0 (Rev 1)
Semco Hand-Operated Model 850 PPG Aerospace/PRC- To apply sealant.

Sealing Gun DeSoto
Semco Pneumatic Sealing Model 250 PPG Aerospace/PRC- To apply sealant.
Gun DeSoto
Semco Nozzles Various Part Numbers PPG Aerospace/PRC- To apply sealant.
DeSoto
Silicone Grease 5565450-28 Commercially Available To lubricate the pressure
seals for control cables.
Sleeve Installation Tool 6286004-1 (-8 Sleeve) Cessna Aircraft Company To help install clamp type
6286004-2 (-16 Sleeve) Citation Marketing Division couplings (Wiggins).
6286004-3 (-20 Sleeve)
6286004-4 (-24 Sleeve)
Small Paddle-Shaped Tool Commercially Available To shape or smooth
aerodynamic smoothing
compound.
Soft Bristle Brush Commercially Available To scrub the surface of the
airplane.
Soft Mallet Commercially Available To install V-type couplings.
Solvent P-D-680 Commercially Available To clean and flush tubing.
Solvent Sotoclean 110 Courtaulds Aerospace To clean and flush tubing.
1608 4th St.
Berkeley, CA 94710
Spatula Commercially Available To remove placards, decals,
and wraps.
Spray Equipment Commercially Available To apply spray coatings to the
airplane.
Staking Tools Commercially Available To stake bearings and races.
Support Fabricate Locally To install the nut element on
the rivetless nutplate.
Supports (Press) Commercially Available To remove and install
bearings.
Swage Tooling DLT Permaswage To swage the tubing.
Swage Tooling D12000 Permaswage To swage the tubing.
Tape Commercially Available To install the nylon tubing into
the instant fitting.
Teflon Tape Commercially Available To install pipe thread fittings.
Topcoat/Stripe Paint Topcoat: Jet Glo 570 Series Sherwin Williams Aerospace To give a protective coating to
Base Coatings the airplane surface.
Stripe: Acry Glo 571 Series
Base
Topcoat: Alumigrip 4200 HS Akzo Nobel Aerospace To give a protective coating to
Base Coatings the airplane surface.
Stripe: Alumigrip 4200 HS
Base
Topcoat: Sterling 76-U Base Sterling Lacquer Mfg. Co. To give a protective coating to
Stripe: Sterling 78-U Color the airplane surface.

20-00-00-0 (Rev 1)
Torque Putty Commercially Available To inspect for movement of

fasteners.
Torque Wrench Commercially Available To tighten fasteners to the
correct torque.
Tube Cutter Commercially Available To cut the nylon tubing.
Tube Flaring Tools Commercially Available To do the tube flaring.
V-Shaped Rod Commercially Available To make the seams visible in
aerodynamic smoothing
compound.
Wire Brush Wire diameter of 0.0008 Commercially Available To prepare a surface for
inch (0.02 mm) or less electrical bonding.
Wire Stripper, Coaxial 45-162 Ideal Industries Inc.
The strip electrical wires and
45-163 1375 Park Avenue
cables.
45-165 Sycamore, IL 60178
Wire Stripper, Thermal 45-130 Ideal Industries Inc. The strip electrical wires and
45-141 cables.
Wooden Dowel Rod 0.25 Inch (6.35 mm) Commercially Available To do the bleed air coupling
Diameter, 24.0 Inches leak check.
(0.609 m) Long
Yarn 6.0 Inches (152.4 mm) Long Commercially Available To do the bleed air coupling
leak check.
Zinc Chromate Epoxy Primer 454-4-1 - Base Akzo Nobel Aerospace To install Rosan fittings.
CA 109 - Activator Coatings
21 Element Static Mixing MA6.3-21-S Henkel Corp. To mix and apply adhesives
Nozzle and sealants to surfaces from
side by side cartridges.
3M Conductive Electrical 3M To measure the resistance of
Tape the anti-static coating.

20-00-00-2 (Rev 1)
STANDARD PRACTICES AIRFRAME - MAINTENANCE PRACTICES

1. Safe Ground Maintenance
A. The section contains the necessary procedures to prepare an airplane prior to completing maintenance or inspections.
The technician must make sure that the airplane is correctly configured for the application of electrical or hydraulic power
before they do maintenance on the airplane.
B. Special Tools and Equipment
NOTE: Equivalent substitutes may be used.
(1) Wheel Chocks
(2) Ground Power Unit
(3) Circuit Breaker Clips
2. Safe Ground Maintenance Procedure
A. Prepare for Safe Ground Maintenance Procedures
(1) Review the airplane maintenance logs.
(2) Remove any foreign objects from the maintenance area.
(3) Make sure that all fire extinguishing equipment is present and operates correctly.
B. External Safe Ground Maintenance Procedures
(1) Install wheel chocks (as necessary).
(2) Make sure that the parking brake is set (as necessary).
(3) Connect the static ground wire (as necessary).
(4) Remove the ground protective covers on the Angle of Attack (AOA) vane, Pitot tube(s), Ram Air Temperature (RAT)
probes as necessary.
C. Internal Safe Ground Maintenance Procedures
CAUTION: The overboard drain heaters are powered directly from the airplane's DC bus. If power is not
disengaged during maintenance, drain heater failures may occur, resulting in smoke discoloration
to the skin of the airplane.
(1) In the cockpit, make sure that the PITOT & STATIC SWITCH, and the ANTI-ICE/DE-ICE switch are set to the OFF
position.
(2) Make sure that the cockpit switches are in the off or normal position (as necessary).
(3) Make sure that all unnecessary system circuit breakers are disengaged.
(a) For the following airplanes, before application of electrical power, do the following:
1 Model 500 (Airplanes -0001 thru -0274) Disengage the CABIN LIGHT AND FLUSH TOILET circuit breaker
(CB114) installed on the right aft power J-box in the tailcone.
2 Model 500 (Airplanes -0275 and On) Disengage the CABIN LIGHT AND FLUSH TOILET circuit breaker
(CB258) installed on the right aft power J-box in the tailcone.
3 Model 525 (Airplanes 525-001 thru 525-640) Disengage the FLUSH TOILET circuit breaker installed on
the aft circuit breaker panel.
4 Model 525 (Airplanes 525-640 and On) Disengage the TOILET/DRAIN HEATERS circuit breaker installed
on the aft circuit breaker panel.
5 Model 525A (Airplanes -0001 thru -0347) Disengage the DRAIN HEATER/FLUSH TOILET circuit breaker
installed on the aft circuit breaker panel.
6 Model 525A (Airplanes -0348 and On) Disengage the TOILET/DRAIN HEATER/ circuit breaker installed
on the aft circuit breaker panel.
7 Model 560 (Airplanes -0002 thru -0538) Disengage the TOILET circuit breaker (CB280) installed on the
right power J-box in the tailcone.
8 Model 560 (Airplanes -0539 and On) Do one of the following:
a For airplane maintenance where interior power will not be required, put the DC POWER switch in the
OFF position

20-00-00-2 (Rev 1)
b
For airplane maintenance where interior power will be required, disengage the DRAIN HEATERS
circuit breaker (CB284V) installed on the interior J-box, located in the lower left side of the pressure
bulkhead.
9 Model 650 (Airplanes 650-0001 thru 650-0092) For airplane maintenance where interior power will not be
required, place the INTERIOR MASTER switch to the OFF position, and disengage the DRAIN HEATERS
circuit breaker (CB235), installed in the left power J-box located in the tailcone.
10 Model 650 (Airplanes 650-0001 thru 650-0092) For airplane maintenance where interior power will be
required, disengage the DRAIN HEATERS circuit breaker (CB235), installed in the left power J-box
located in the tailcone.
11 Model 650 (Airplanes 650-0093 and On, and Airplanes 650-7001 and On) For airplane maintenance
where interior power will be required, disengage the DRAIN HEATERS circuit breaker (CB505), installed
in the left power J-box located in the tailcone.
(4) Make sure that circuit breaker clips are installed (as necessary).

20-00-10-0 (Original Issue)
MATERIAL AND TOOL CAUTIONS - DESCRIPTION AND OPERATION

1. General
A. This section gives warnings, cautions, and other data for materials and tools.
2. Titanium
CAUTION: Cadmium plated tools must not be used on titanium parts. This is very important if the parts are
attached where temperatures can increase to more than 250°F (121°C). Small cadmium deposits which
can stay on the titanium parts will react when heated which will result in brittleness and possible
cracks.
CAUTION: Cadmium plated fasteners must not be used in contact with titanium parts.
3. Mercury
CAUTION: Thermometers and other test equipment that contain mercury must not be used on the airplane.
A. Mercury, by the amalgamation process, can go through any crack in the finish, paint, or sealing coating of a metal structural
element. An oxide coating on a dry metallic surface can prevent an immediate action while a bright, polished, shining, or
scratched surface will make the process faster. Moisture will also help the amalgamation process. Soils, greases, or other
inert contaminants, present on the metal surfaces will prevent the start of the action. The corrosion and damage which
results from an initial penetration can be extremely fast in structural members under load. After the amalgamation process
starts initially, there is no known method of stopping it. Complete destruction of the load carrying capacity of the metal will
result.
4. Asbestos
WARNING: Asbestos fibers are harmful if they go into your body. Obey the steps that follow when you work with
parts that contain asbestos.
A. Use one of the methods that follow to prevent breathing dust that has asbestos fibers.
(1) Use engineering controls, which includes work in a correctly filtered exhaust chamber or use wet procedures to keep
employee exposures to below Occupational Safety and Health Administration (OSHA) personnel exposure limits.
(2) Use respiratory protection, including high efficiency filters coveralls, gloves, and eye protection.
B. Dispose of all asbestos containing material in accordance with local, state, and federal regulations.
5. Cadmium Plated Fasteners
CAUTION: Cadmium plated fasteners used in areas where contact with jet fuel is possible, must be completely
covered with fuel tank sealant to prevent contact with the jet fuel. All paths that fuel can move to reach
the head or shank of a fastener must be sealed. Cadmium fasteners, when in continuous contact with
jet fuel, can remove cadmium from the fastener into the fuel system, which will damage the engines.
6. Maintenance Precautions
WARNING: Obey the correct precautions to prevent injury due to the many materials and environments found
during maintenance, repair, and service procedures to the airplane.
A. Carefully read and follow all instructions. It is important to obey all cautions and warnings given by the manufacturer of the
product that is used. Use the correct safety equipment as necessary, which includes goggles, face shields, breathing
apparatus, respirators, protective clothing, and gloves. Fuel, engine oil, solvents, volatile chemicals, adhesives, paints, and
strong cleaning agents can cause injury when they touch the skin or eyes, or when fumes are breathed. Use a sufficiently
ventilated area and the correct respirator when sanding composites or metals or otherwise working in an area where dust
particles occur.
7. General Use Solvents
A. Airplane maintenance procedures often require the use of solvents. A solvent is defined as a substance, usually a liquid,
that dissolves or can dissolve another substance. An example would be the reaction that is given when salt is added to
water. The salt is dissolved by the water. Examples of general use solvents include the following:
• Isopropyl Alcohol
• Methyl n-Propyl Ketone
• Naptha.
B. These solvents are usually colorless, evaporate more quickly than water, and higher quantities of the fumes are produced
as their temperature increases. The fumes are usually heavier than air, which causes them to collect in low areas or push

normal oxygen and air out of a confined area. This can cause low oxygen atmospheres. Many general use solvents are
also flammable.
C. Solvents are dangerous to work with because of their flammability, rate of evaporation, and reaction to oxidizers. Solvents
can also cause injury to the skin and eyes.
D. Solvent flammability can be caused by a single spark, a burning cigarette, or even atmospheric conditions can cause
ignition of gasoline fumes. The fumes can also flash back to the initial source which can explode. The same reaction can
take place with toluene or isopropyl alcohol. The lower the flash point of the chemical, the more likely it is to become
flammable. Generally, flash points of less than 100°F (38°C) are considered flammables. Examples of solvent flash points
are shown below:
Solvent Flash Point
Isopropyl Alcohol 53.6°F (12°C)
Methyl n-Propyl Ketone 45°F (7.2°C)
E. The rate of evaporation has a close relation to flammability because the fumes must occur to ignite the liquid. Vaporization
also allows the solvents, even those that are not flammable, to get into the air and into the body’s bloodstream through the
lungs.
F. Solvents can explode when mixed with oxidizers (chemicals which release oxygen). A very violent and uncontrollable
reaction takes place which generates heat very quickly. For this reason, it is very important for each person to know the
specific chemicals in use in the work area, and to know the container labels. Chemical manufacturers are required to label
each container with a diamond shaped symbol. The color red shows flammable and yellow shows oxidizer.
G. Solvents can also damage the hands and skin. Solvents dry out skin and dissolve the natural oils. The condition can cause
an irritation or, if left untreated with continuous touching, can cause dermatitis. Damaged skin lets other contaminants
make the condition worse, because it is easier for the contaminants to get to the lower levels of the skin. In serious cases,
blood poisoning is also possible.
H. The best way to prevent skin irritation is not to get solvents on the skin. Frequently, it is hard not to get solvents/chemicals
on the skin. The human body can filter small amounts of solvents out of itself. This filtration function takes place in the liver.
The liver receives blood which can be contaminated with solvents from both the lungs and the skin. If the quantities are low
enough and not too frequent, the liver can filter out the contaminants. This is one of the scientific facts on which OSHA
based its Permissible Exposure Limits. However, when exposures are constantly above these levels over an extended
period of many years, the filter (liver) becomes clogged and the solvents can then affect other parts of the body.
8. National Emissions Standards for Hazardous Air Pollutants (NESHAP)
A. NESHAP Requirements
NOTE: The NESHAP standards have restricted and prohibited the use of some chemicals and solvents.
NOTE: For complete details of the regulatory standards, refer to the Federal Register, 40 CFR Part 63, [Ad-
FRL-5636-1], RIN 2060-AG65.
NOTE: Refer to Exterior Finish - Cleaning/Painting for the most current acceptable replacements for
chemicals that could have been previously restricted or prohibited by NESHAP. These chemicals
will supersede any which can be specified in other sections of the applicable Maintenance Manual.
(1) Hand-Wipe Cleaning
(a) All hazardous air pollutants or organic compounds that release dangerous fumes that are used as hand-wipe
cleaning solvents must meet a composition requirement and have a vapor pressure less than or equal to 1.75
inHg at 69°F (5.92 kPa at 20°C).
(b) You can obey the requirements specified with an alternative compliance plan used by the permitting authority
and approved under Section 112(1) of the Clean Air Act.
(2) Primer Application
(a) The organic hazardous air pollutant content limit is 2.9 pounds/gallon (347 grams/liter), less water, as applied.
(b) The volatile organic compound limit is 2.9 pounds/gallon (347 grams/liter), less water, as applied.
(c) Use coatings below the content limit or use monthly volume-weighted averaging to get the content limits to obey
content limits.
(3) Topcoat Application

(a) The base coat organic hazardous air pollutant content must be less than 3.5 pounds/gallon (419 grams/liter),
less water, as applied.
(b) The volatile organic compound limit is 3.5 pounds/gallon (419 grams/liter), less water, as applied.
(c) The topcoats must obey the requirements of MIL-C-85285.
(d) Stripe paint requirements are the same as the base coat requirements. If the recommended supplier cannot be
used, then use base coat materials to paint stripes.
NOTE: All paints and primers must have specific application techniques. If an alternative is
supplied, use only the materials that are less than or equal in emissions, to less than the
high-volume, low-pressure (HVLP) or electrostatic spray application techniques.
NOTE: Operate all application equipment according to the manufacturer’s specifications,
company procedures, or locally specified operating procedures.
(4) Paint Removal
(a) Paint removal operations apply to the outer surface of the airplane and do not apply to parts or components
normally removed. Fuselage, wings, and stabilizers are included. Radomes and parts normally removed do not
apply to the requirements that follow:
1 No organic hazardous air pollutants must come from chemical strippers or softeners.
2 Inorganic hazardous air pollutant fumes must be at a minimum during periods of non-chemical based
equipment malfunctions.
3 The use of organic hazardous air pollutant material for spot stripping and decal removal must be at a
minimum of 190 pounds per airplane per year.
(b) Operating requirements for paint removal operations that give airborne inorganic hazardous air pollutants
include control with particulate filters or water wash systems.
(c) Mechanical and hand sanding do not apply to these requirements.
9. Facilities and Equipment
A. Facilities
(1) You must use a facility to collect processing waters to treat or to remove chromium and pH.
(2) The facilities must have correct safety equipment.
B. Equipment
(1) Applied spray of cleaning solvents, paint removers, or color chemical film treatment solutions is to be prevented
unless all requirements of NESHAP are obeyed.
(2) Spray equipment to wash the airplane with alkaline cleaner can be used. This equipment should be sufficient to spray
deoxidizers, chemical film solutions, and rinse water.
(3) A high-pressure washer is recommended, with or without hot water.
(4) Respirators and/or dust masks must be used.

AIRPLANE HARDWARE - DESCRIPTION AND OPERATION

1. General
A. This section gives maintenance data for the general hardware used throughout the airframe and the systems of the
airplane. This includes the following:
(1) Maintenance procedures for tubing, hoses, fittings, packing, backup rings, and cables.
(2) The criteria for tube bending, safetying with lockwire, cotter pins, and locking clips.
(3) Maintenance procedures for non-flare fittings and nylon tubing.
(4) Procedures to check cables, seals, and pulleys.
(5) The general torque requirements for bolts, screws, nuts, etc.
2. Description
A. This section is divided into subjects that give more information on specific tasks common to many of the maintenance
practices throughout the applicable Maintenance Manual. The subjects that follow are included in this section:
(1) Tubing, Hose and Fittings includes a description, precautions, standard maintenance practices, tubing
removal/installation, hose assembly removal/installation, fitting removal/installation, clamp type coupling
removal/installation, damaged tubing criteria, damaged hose criteria, hydraulic tubing chafing and clamping, and
hydraulic, pneumatic and bleed air line, duct and hose inspection.
(2) Identification Tape includes a description and identification tape application.
(3) Tube Bending Criteria and Permaswaging includes tube bending maintenance practices, tube bending, tube flaring,
and Permaswaging.
(4) MS Flareless Fittings includes MS flareless fitting installation, repair with MS flareless fittings, and repair 21-6-9
stainless steel tubing with 304 or 21-6-9 stainless steel tubing.
(5) Conical Seals includes the conical seal installation.
(6) Non-Flare Fittings and Nylon Tubing includes nylon tubing removal/installation, non-flare fitting removal/installation,
and nylon tubing repair.
(7) Packing and Backup Ring includes packing installation, backup ring installation, packing and backup ring storage,
and Lock-O-Seal.
(8) Bleed Air Couplings includes clamp-type coupling removal/installation, V-type coupling removal/installation, and
bleed air coupling leak check.
(9) Safetying includes safety wiring, cotter pin safetying, turnbuckle safetying, lock washer, self-locking nut, and safety
cable.
(10) Control Cables, Seals and Pulleys includes control cable, pressure seal removal/installation, pulley, and flight control
cable, pressure seal, and pulley inspection.
(11) Rivetless Nutplate includes a description, Deutsch rivetless nutplate inspection, Deutsch rivetless nutplate nut
element removal/replacement, and Deutsch rivetless nutplate assembly removal/replacement.
(12) Bearings includes bearing removal/installation and bearing staking methods.
(13) Torque Data includes precautions, torque data, and torque procedure.
(14) Rosan Fittings includes a description and Rosan fitting removal/installation.
(15) DeutschLite Fittings includes a description, DeutschLite fitting installation, DeutschLite fitting troubleshooting, and
damaged tubing replacement with DeutschLite fittings.

TUBING, HOSE AND FITTINGS - MAINTENANCE PRACTICES

1. General
A. This section gives the maintenance practices for tubing, hose and fittings. Not all tubing, hoses and fittings used on the
airplanes are specifically identified in this section.
NOTE: For maintenance of non-flare fittings and nylon tubing used in the low-pressure pneumatic
systems, such as the environmental and vacuum systems, refer to Non-Flare Fittings and Nylon
Tubing - Maintenance Practices.
NOTE: For maintenance of the instrument hoses and pitot-static systems, refer to Chapter 34 - Navigation
in the applicable Maintenance Manual.
NOTE: For maintenance of the oxygen lines and fittings, refer to Chapter 35 - Oxygen in the applicable
Maintenance Manual.
2. Description
A. The primary part of the tubing assemblies used in the airplane are machine formed aluminum or steel.
B. Hoses are used in areas of the airplane where a flexible line is more suitable for the installation, the connecting component
must be free to move, and/or the area of installation is subjected to vibration. Fuel hoses are used in the engine nacelle
area. Hydraulic hoses are used in the engine nacelle areas, landing gear areas, and wing areas for spoiler actuators.
Pneumatic hoses are used in the landing gear areas, instrument panel, and main entrance door seal.
C. Fluid fittings used in the airplane are grouped in the categories that follow:
• Angle Fittings with Jam Nuts
• Unions
• Pipe Threads.
D. During installation of the oxygen lines, hydraulic lines, and fuel lines (applicable during the initial installations and finished
line routing modifications and/or repairs), be careful to make sure that the oxygen system will not be contaminated by fuel
leakage, oil, hydraulic fluid, and/or oxygen. Oxygen lines, fittings, and equipment must be installed above and at least 6.0
inches (0.15 m) away from the fuel, oil, and hydraulic fluid systems. Deflector plates must be used where necessary to
keep fluids away from the oxygen lines, fittings, and equipment.
3. Precautions
A. Obey the safety and technical precautions given throughout the Maintenance Manual while you do the following:
maintenance, repair, or service on any fluid or pneumatically operated system, such as contaminate spills on personnel
and equipment, fire prevention for flammable fluids, and over pressurization ruptures.
B. Make sure that systems which operate from fluids or pneumatics under pressure are fully depressurized before a line or a
component is opened or disconnected.
4. Standard Maintenance Practices
A. A list of standard maintenance practices are given to help maintenance personnel during the removal, installation, and the
repair of tubing, hoses, and fittings.
(1) Put a cap or a plug on all tubing, hoses, and fittings after it is disconnected to prevent system contamination.
(2) Chemical film must always be applied to the exterior surface of plumbing lines when the surface is to be primed
and/or painted. This does not apply to oxygen lines.
(3) Visually check for cleanliness and signs of contamination before the tubing or hoses are connected.
(4) Replacement hoses and tubing that did not have protective covers should be cleaned before installation.
(5) During the connection of rigid tubing, do not force the assembly to the installed position to prevent failure. If a
mismatch between connections occurs, refer to Figure 201 for the allowable mismatch.
(6) Never stretch a hose to make a connection. A hose of incorrect length will result in a malfunction or a failure.
CAUTION: Do not apply torque putty in fuel cavities or where it can go into the fluid system.
(7) After you torque the fittings and examine them for leaks, apply torque putty to the fittings. Torque putty must not be
applied in fuel areas. The torque putty can go into the fluid system when you do maintenance or touch system
components.
5. Tubing Removal/Installation

A. Tools and Equipment

NOTE: For the tool, equipment, and special consumable part numbers and the manufacturer data, refer to
Standard Practices Airframe - General. For the supplier publication part number and manufacturer
data, refer to the Introduction - Supplier Publication List in the applicable Maintenance Manual.
(1) Tools and Equipment
• Identification Tag
• Metal Container
• Protective Caps and Plugs.
(2) Special Consumables
• None.
(3) Reference Material
• Torque Data - Maintenance Practices
• Maintenance Manual
• Wiring Diagram Manual.
B. Prepare the Airplane for the Tubing Removal/Installation.
WARNING: Read and completely understand all of the applicable system safety precautions before you do the
system maintenance. Refer to the applicable Maintenance Manual.
(1) Obey the Standard Maintenance Practices in this section.
(2) Disconnect the electrical power from the airplane. Refer to the applicable Maintenance Manual.
(3) Disengage all of the applicable circuit breakers for the system. Refer to the applicable Maintenance Manual and the
applicable Wiring Diagram Manual.
(4) Release the pressure from the applicable system. Refer to the applicable Maintenance Manual.
(5) Remove access panels as necessary to get access to the applicable tubing. Refer to the applicable Maintenance
Manual.
(6) Put a metal container below the tubing ends to catch fluid.
C. Remove the Tubing.
(1) Carefully loosen the fittings on the tubing ends.
(2) Let the residual fluid drain from the tubing ends.
(3) Remove the hardware and the clamps that attach the tubing to the airplane.
(4) Remove the tubing from the airplane.
(5) Install protective caps and plugs on the open ports to prevent system contamination.
(6) Attach an identification tag to the tubing to help with the installation.
D. Install the Tubing (Refer to Figure 201).
(1) Examine the tubing including the flared ends, fittings, and bends for damage. Refer to Damaged Tubing Criteria in
this section.
(a) Replace or repair the damaged tubing as necessary.
(2) Make sure that the tubing is clean.
(3) Remove the protective caps and plugs from the ports.
(4) Put the tubing in its position in the airplane.
(5) Do the steps that follow to make sure that the fittings are correctly aligned:
(a) Tighten the fitting at one end of the tubing.
(b) Make sure that the angular mismatch at the opposite end of the tubing is parallel to the fitting within 2 degrees.
(c) Make sure that the radial mismatch at the opposite end of the tubing is in line with the fitting within 1/32 inch (0.8
mm) per 10 inches (0.25 m) of the tube length.
(d) Make sure that the length mismatch at the opposite end of the tubing matches the fitting cone within 1/32 inch
(0.8 mm) per 10 inches (254 mm) of the tube length.

(e) Loosen the fitting at the end of the tubing.

WARNING: Oxygen fittings must be torqued dry.
(6) Apply lubricant to the threads on the fittings as necessary.
(7) Tighten the fittings on the tubing ends to the correct torque as follows: Refer to Torque Data - Maintenance Practices.
(a) Refer to Table 201 for tubing/hose torque tolerances.
Table 201. Tubing/Hose/Pipe Thread Torque Tolerances
Tubing Flared or Flareless Fitting with Aluminum Flared or Flareless Fitting with Steel or
Outside Tubing and Hose with Aluminum Inserts Titanium Tubing and Hose with Steel
Diameter Inserts
(Inches) Minimum Torque in Maximum Torque in Minimum Torque in Maximum Torque in
Inch Pounds (N-m) Inch Pounds (N-m) Inch Pounds (N-m) Inch Pounds (N-m)
1/8 50 (5.6) 80 (9.0) 75 (8.4) 120 (13.5)
3/16 70 (7.9) 105 (11.8) 95 (10.7) 140 (15.8)
1/4 100 (11.2) 140 (15.8) 135 (15.2) 190 (21.4)
5/16 130 (14.6) 180 (20.3) 170 (19.2) 240 (27.1)
3/8 150 (16.9) 195 (22.0) 215 (24.2) 300 (33.8)
1/2 270 (30.5) 350 (39.5) 470 (53.1) 550 (62.1)
5/8 360 (40.6) 430 (48.5) 620 (70.0) 745 (84.1)
3/4 460 (51.9) 550 (62.1) 855 (96.6) 1055 (119.2)
1 700 (79.0) 840 (94.9) 1140 (128.8) 1400 (158.1)
1 1/4 850 (96.0) 1020 (115.2) 1520 (171.7) 1825 (206.2)
1 1/2 900 (101.6) 1080 (122.0) 1900 (214.6) 2280 (257.6)
2 1800 (203.3) 2000 (225.9) 2660 (300.5) 2940 (332.1)
NOTE 1: When any component of the joint (nipple or fitting end) is aluminum, use the values for
aluminum tubing.
(b) Refer to Table 202 for aluminum oxygen fitting torque tolerances.
Table 202. Aluminum Oxygen Fitting Torque Tolerances
Tubing Outside Diameter Minimum Torque in Inch Pounds Maximum Torque in Inch
(Inches) (N-m) Pounds (N-m)
1/4 75 (8.4) 90 (10.1)
5/16 100 (11.2) 125 (14.1)
3/8 200 (22.5) 250 (28.2)
1/2 300 (33.8) 400 (45.1)
(8) Install the clamps and the hardware that attach the tubing to the airplane.
E. Put the Airplane Back to its Initial Condition.
(1) Engage all of the applicable circuit breakers for the system. Refer to the applicable Maintenance Manual and the
(2) Do the servicing of the applicable system.
(3) Operate the system and make sure that there is no fluid leakage.
(4) Remove the metal container from below the tubing ends.
(5) Install the access panels as necessary. Refer to the applicable Maintenance Manual.
6. Hose Assembly Removal/Installation

• Metal Container
• None.
B. Prepare the Airplane for the Hose Assembly Removal/Installation.
(5) Remove access panels as necessary to get access to the applicable hose assembly. Refer to the applicable
Maintenance Manual.
(6) Put a metal container below the hose assembly ends to catch fluid.
C. Remove the Hose Assembly.
(1) Carefully loosen the fittings on the hose assembly ends.
(2) Let the residual fluid drain from the hose assembly ends.
(3) Remove the hardware and the clamps that attach the hose assembly to the airplane.
(4) Remove the hose assembly from the airplane.
(6) Attach an identification tag to the hose assembly to help with the installation.
D. Install the Hose Assembly.
CAUTION: Never stretch a hose assembly to make a connection. A hose assembly of insufficient length can
result in a malfunction or a failure.
CAUTION: If the hose assembly is installed in a fixed position, make sure that it is replaced in the same initial
position. Replace the hose assembly if it is permanently kinked or twisted.
CAUTION: Do not use spiral wrap on hose assemblies. A hose assembly under tension that touches another
will separate the spiral wrap and chafe. The hose assemblies must not be under tension and must
be correctly clamped.
CAUTION: Do not use tie straps to attach hose assemblies to tubing. Replace the hose assembly if you find tie
straps. Inspect the tubing and the hose assembly for damage and replace if necessary. Refer to
Damaged Tubing Criteria and Damaged Hose Criteria in this section. Refer to Hydraulic Tubing
Chafing and Clamping in this section for the correct clamping procedures.
(1) Inspect the hose assembly for damage. Refer to Damaged Hose Criteria in this section.
(a) Replace or repair the damaged hose assembly as necessary.
(2) Make sure that the hose assembly is the correct length, correct material, and clean.

(4) Put the hose assembly in its position in the airplane.

(5) Tighten the fittings on the hose assembly ends to the correct torque as shown in Table 201. Refer to Torque Data -
Maintenance Practices.
(6) Make sure that the hose assembly is not under tension and there are no signs of a twist.
(7) Install the clamps and the hardware that attach the hose assembly to the airplane.
(8) Make sure that the hose assembly is free to expand and contract and is free of all structure.
(9) Make sure that the hose assembly cannot chafe against structure and other components.
(4) Remove the metal container from below the hose assembly ends.
7. Fitting Removal/Installation
• Metal Container
• Teflon Tape.
B. Prepare the Airplane for the Fitting Removal/Installation.
(5) Remove access panels as necessary to get access to the applicable fitting. Refer to the applicable Maintenance
Manual.
(6) Put a metal container below the fitting to catch fluid.
C. Remove the Fitting.
(1) Carefully remove the hose assembly or the tubing that attaches to the fitting.
(2) Let the residual fluid drain from the fitting.
(3) Remove the fitting from the boss or the bulkhead fitting.
(4) Remove the fitting from the airplane.

(6) Attach an identification tag to the fitting to help with the installation.
D. Install the Positioning Type Fitting (Refer to Figure 202).
(1) Assemble the positioning type fitting as follows:
(a) Install the nut on the fitting past the thread relief.
(b) Install the backup ring against the nut on the fitting.
(c) Install the packing (O-ring) against the backup ring on the fitting.
CAUTION: Make sure that the packing (O-ring) is compatible with the applicable system fluid.
(d) Lubricate the male threads of fitting, packing, and backup ring with a small quantity of the applicable system
fluid.
(e) With the backup ring in the counterbore of the nut, turn the nut down until the packing pushes firmly against the
lower threaded section of the fitting.
(2) Remove the identification tag from the fitting.
(4) Install the fitting into the boss without turning the nut on the fitting until the packing touches the boss.
(5) Hold the nut with a wrench and turn the fitting clockwise 1.5 turns.
(6) Hold the fitting with a wrench and tighten the nut against the boss to the correct torque as shown in Table 203. Refer
to Torque Data - Maintenance Practices.
NOTE: A small extrusion of the packing will not cause damage.
Table 203. Jam Nuts and Fittings with packings (Inch-Pounds)
Tubing Jam Nuts and Fittings for Boss Installations Jam Nuts for Bulkhead Fitting Installations
Outside Minimum Torque in Maximum Torque in Minimum Torque in Maximum Torque in
Diameter Inch Pounds (N-m) Inch Pounds (N-m) Inch Pounds (N-m) Inch Pounds (N-m)
(Inches)
3/16 28 (3.2) 32 (3.6) 28 (3.2) 32 (3.6)
1/4 38 (4.3) 42 (4.7) 38 (4.3) 42 (4.7)
5/16 58 (6.6) 63 (7.1) 58 (6.6) 63 (7.1)
3/8 70 (7.9) 80 (9.0) 70 (7.9) 80 (9.0)
1/2 145 (16.4) 155 (17.5) 145 (16.4) 155 (17.5)
5/8 190 (21.5) 210 (23.7) 190 (21.5) 210 (23.7)
3/4 285 (32.2) 315 (35.6) 190 (21.5) 210 (23.7)
1 475 (53.7) 525 (59.3) 190 (21.5) 210 (23.7)
1 1/4 570 (64.4) 630 (71.2) 190 (21.5) 210 (23.7)
1 1/2 570 (64.4) 630 (71.2) 190 (21.5) 210 (23.7)
2 570 (64.4) 630 (71.2) 190 (21.5) 210 (23.7)
(7) Install the hose assembly or the tubing that attaches to the fitting.
E. Install the Non-Positioning Type Fitting (Refer to Figure 202).
CAUTION: Make sure that the packing (O-ring) is compatible with the applicable system fluid.
(1) Lubricate the packing with the applicable system fluid.
(2) Install the packing in the thread relief of the fitting.
(5) Install the fitting into the boss until the packing touches the boss.
(6) Tighten the nut against the boss to the correct torque as shown in Table 203. Refer to Torque Data - Maintenance
Practices.

F. Install the Pipe Thread Fitting.
CAUTION: Wrap the Teflon tape around the fitting two threads from the end to help to keep it out of the
system.
(3) Apply Teflon tape to the threads on the fitting as follows:
(a) Start the tape at or close to the narrow end of the threads (approximately two threads from the end) and wrap it
around the fitting in the direction of the threads.
1 For left hand threads, wrap the Teflon tape counterclockwise.
(b) Apply the Teflon tape with tension sufficiently so that it conforms to the shape of the threads.
(c) Overlap the Teflon tape up to 0.5 inch (12.7 mm) to get a sufficient seal on the pipe thread fittings up to 2.0
inches (51 mm) in diameter.
(4) Install the fitting into the boss and tighten to the correct torque as shown in Table 201. Refer to Torque Data -
G. Put the Airplane Back to its Initial Condition.
(4) Remove the metal container from below the fitting.
8. Clamp-Type Coupling Removal/Installation
NOTE: Clamp-type couplings are used extensively in the fuel system and environmental control system for
tube-to-tube and component-to-tube connections. The W900 Series coupling includes mating ferrules
with O-rings, a collar that is installed over the mating ferrules, and a retainer that incorporates bonding
wires. The retainer fits over the collar and is attached by the over-center latch with the safety spring.
NOTE: The connection between the tube assemblies and the components that use the clamp-type couplings
requires no bonding jumpers. Continuity bonding of the connection is completed when the retainer is
installed and latched. The retainer incorporates integral bonding wires.
• Metal Container
• Protective Caps and Plugs
• Sleeve Installation Tool.
• None.
B. Prepare the Airplane for the Clamp-Type Coupling Removal/Installation.


(5) Remove access panels as necessary to get access to the applicable clamp-type coupling. Refer to the applicable
Maintenance Manual.
(6) Put a metal container below the clamp-type coupling to catch fluid.
C. Remove the Clamp-Type Coupling (Refer to Figure 203).
(1) Compress the safety spring and the tab on the retainer with your thumb and first finger to release the latch.
(2) Lift the over-center latch and remove the ring from the hook on the retainer.
(3) Open the retainer and remove it from the collar and tube assemblies.
(4) Remove the collar from the tube assemblies.
(5) Remove and discard the O-rings from the ferrules.
D. Install the Clamp-Type Coupling (Refer to Figure 203).
(2) Lubricate the O-ring with the applicable system fluid.
(3) Install new O-rings in the ferrules.
(4) Install the collar on the tube assemblies.
NOTE: Install the collar over one ferrule until it is flush with the mating surface of the other ferrule.
(a) If necessary, use a sleeve installation tool to help install the collar over the ferrule.
(5) Slide the mating surfaces ferrules together.
(6) Install the collar at the approximate center of the mating ferrules.
(7) Install the retainer on the collar and tube assemblies.
(8) Put the ring on the hook and close the over-center latch on the retainer to the locked position.
(a) Make sure that the safety spring latches over the tab on the retainer.
NOTE: It is not necessary to safety the clamp-type coupling. The retainer latch incorporates a
safety spring that automatically locks the retainer when the latch is fully closed.
(4) Remove the metal container from below the clamp-type coupling.
9. Damaged Tubing Criteria
• None.
• Crocus Cloth

• Emery Cloth - Fine Grade

• Oil.
• None.
B. Damage Tubing Criteria
(1) Replace the aluminum and stainless steel tubing that has nicks or scratches that exceed the maximum scratch depth
shown in Table 204.
NOTE: Scratches can only be in the hoop direction, not along the length of the tubing.
Table 204. Maximum Scratch Depth for Tubing
Wall Thickness Maximum Scratch Depth
Inch mm Inch mm
0.020 - 0.040 0.51 - 1.02 0.002 0.051
0.041 - 0.050 1.03 - 1.28 0.003 0.076
0.051 - 0.066 1.29 - 1.69 0.004 0.102
0.067 - 0.085 1.70 - 2.16 0.006 0.152
(2) Replace the pressure and return tubing that have dents deeper than 5% of the tubing outside diameter.
(3) For tubing that does not exceed the maximum scratch depth, do as follows:
(a) Use a fine grade of emery cloth and oil to polish the nicks and scratches.
(b) Use crocus cloth and oil to finish the polish.
(c) Use water to flush and remove all grit from the tubing.
10. Damaged Hose Criteria
A. Damaged Hose Criteria
(1) Replace the hose with fire-sleeve if nicks, cuts, or scratches in the sleeve are more than 0.030 inch (0.76 mm) in
depth.
(2) Replace the hose and sleeve if they are brittle, stiff, or cracked.
(3) Replace the hose if it is permanently deformed due to kinks or twists.
11. Hydraulic Tubing Chafing and Clamping
NOTE: This section gives standard maintenance practices for the attachment of hydraulic tubing with clamps
to prevent chafing.
A. Tubing Chafing Identification
(1) Hydraulic tubing chafing can occur any time a tube touches another tube, component, or structure. Tube chafing also
occurs where control cables are permitted to contact a tube. Tubes or cables that do not appear to touch in the static
condition can be close enough to rub during vibration. Cable movement can also touch tubing during very high cable
travel. These conditions should be considered during a check for tubing chafing. Correct routing and clamping of the
hydraulic tubing is necessary to prevent chafing.
B. Tubing Chafing Prevention and Corrective Action (Refer to Figure 204).
CAUTION: Hydraulic tubing chafed to a depth of 10% or more of the tubing wall thickness must be replaced,
then correctly clamped to prevent reoccurrence.
CAUTION: Do not use spiral wrap on hydraulic tubing. Tubing under tension that touches another will
separate the spiral wrap and chafe. The tubing must not be under tension and must be correctly
clamped.
CAUTION: Do not use tie straps to attach hydraulic tubing. Examine the tubing for damage and replace if
necessary. Refer to Damaged Tubing Criteria and Damaged Hose Criteria in this section. Refer to
Hydraulic Tubing Chafing and Clamping in this section for the correct clamping procedures.
(1) Hydraulic tubing that shows signs of chafing and/or touches other tubes, components, or structure, must be corrected
immediately.

(a) Separation of the tubing or the clearance of the tubing from components can be completed with the use of
clamps. To prevent side loads and strains on tubing, clamp one tube to another.
(b) Clamps can be separated with spacers or the spacers can be used as standoffs for the tube at the component
and/or structure.
NOTE: During the installation of a clamp to the structure, the use of existing holes is permitted,
but do not drill new holes in the structure.
(c) Clamps should be installed in regard to the correct angle to the tubing.
(d) The clamp mounting screw must be above the tubing when the clamp is attached to the structure.
(e) Always select the correct size and type of clamp for the tubing to be attached. Cushion-clamps should be
considered for tubing in a high-vibration area. Cushion-clamps that can be subject to deterioration from fluids
should be of a material that is resistant to oils and fuels. The clamp must be a bonded type when metal tubes are
attached.
(f) Make sure that electrical wiring is routed as far away as possible from the tubing.
(g) Where control cables are routed adjacent to tubing, operate the cable system to full travel in both directions and
do a check to make sure that there is sufficient cable-to-tube clearance. For example, the clearance through one
area of cable travel can be satisfactory while another area can touch a tube when the cable is turned off a bell
crank. Consideration should also be given to cables with incorrect tension, the use of cable rub blocks, and/or
tube position.
(h) Make sure that there is correct routing of the hydraulic tubing through the airframe with fittings, grommets, and
clamps as necessary for the specified installation.
(i) During installation of the clamps in congested areas, make sure that the clamp mounting screws are the correct
length to allow for two threads through the nut. The end of the screw or nut must not touch tubes, wire bundles, or
structure which can result in chafing.
12. Hydraulic, Pneumatic and Bleed Air Line, Duct, and Hose Inspection
WARNING: Do not let oil or grease near the oxygen system. This will help to prevent spontaneous combustion
and/or explosion when you work with oxygen under pressure.
CAUTION: Do not use spiral wrap on hydraulic tubing. Tubing under tension that touches another will separate the
spiral wrap and chafe. The tubing must not be under tension and must be correctly clamped.
CAUTION: Do not use tie straps to attach hydraulic tubing or hoses. Inspect the tubing for damage and replace if
necessary. Refer to Damaged Tubing Criteria and Damaged Hose Criteria in this section. Refer to
Hydraulic Tubing Chafing and Clamping in this section for the correct clamping procedures.
NOTE: It is necessary that you examine all the hydraulic, pneumatic and bleed air lines, ducts, hoses, and
related fittings when you do a check of a component or system. When you do work in a particular zone
on the airplane and you remove access panels or floorboards, the hydraulic lines, ducts, hoses, and
related fittings must be examined.
A. Do an inspection of the hydraulic, pneumatic and bleed air lines, ducts, hoses, and related fittings.
(1) Examine for correct routing and clamping.
NOTE: Tubing and ducts must be correctly supported to prevent fatigue cracks at the fittings.
(2) Do not use tie straps to attach hydraulic tubing or hoses. Examine the tubing for damage and replace if necessary.
Refer to Damaged Tubing Criteria and Damaged Hose Criteria in this section. Refer to Hydraulic Tubing Chafing
and Clamping in this section for the correct clamping procedures.
(3) Examine for signs of chafing and other damage.
(4) Chafing limits are as follows:
(a) Replace the aluminum and stainless steel tubing that has nicks or scratches that are more than the maximum
scratch depth shown in Table 204.
(b) Replace the pressure and return tubing that have dents deeper than 5% of the tubing outside diameter.
(c) Replace the hose with fire-sleeve if nicks, cuts, or scratches in the sleeve are more than 0.030 inch (0.76 mm) in
depth.
(d) Replace the hose and sleeve if they are brittle, stiff, or cracked.

(5) Examine hoses for twisting, weather cracks, or splitting.

(a) Make sure that hose assemblies have sufficient movement as necessary for their function and that they do not
chafe other components or structure during their normal range of movement.
(6) Examine for signs of fluid leakage.
NOTE: Hydraulic actuators are serviceable if the leak rate from the piston shaft seal is not more than
one drop per 25 cycles of usual operation.
NOTE: No leakage is permitted at any hydraulic or fuel line, or related fittings.
(a) Repair to a no-leak condition.
(7) Oxygen tubes are usually wrapped with heat shrinkable tubing before installation. Give special attention to oxygen
tube routing and clamping to prevent possible line rupture or arcing to adjacent wiring.
(8) Examine the bleed air plumbing for signs of leakage. Give special attention to connections.

Figure 201 : Sheet 1 : Tube Installation Mismatch

A99196
Measure the
mismatch with
the free end
clear of the fitting. Maximum permitted
2 Degrees Maximum mismatch is 1/32 inch
per 10 inches (0.8 mm
per 0.25 m) of tube length.
Angular Mismatch Radial Mismatch
Maximum permitted
Maximum permitted mismatch is 1/32 inch
mismatch is 1/32 inch per 10 inches (0.8 mm
per 10 inches (0.8 mm per 0.25 m) of tube
per 0.25 m) of tube length.
length.
Length Mismatch
5598T2004

Figure 202 : Sheet 1 : Universal Fitting Installation

A99195
Fitting Boss
Packing
Non−Positioning Type Fitting Installation
Fitting
Nut
Boss
Backup Ring
Packing
Positioning Type Fitting Installation
6280T1006
6280T1002

Figure 203 : Sheet 1 : Clamp-Type Coupling Installation

A99194
O−Ring
A
Bonding Wires
Tube Assembly
Tube Assembly
Collar
Retainer
O−Ring
Ferrule
Retainer
Ferrule Tube Assembly
Safety Spring
Over−Center Ferrule
Latch Hook Ring
DETAILA
W900 Series Coupler
6226T1007
A6280T1005

Figure 204 : Sheet 1 : Tubing Clamp Installation

A99191
Approved Grommet
Tubing−to−Tubing with Spacer

Tubing through Structure
Tubing−to−Tubing Multiple Tubing−to−Tubing
Tubing−to−Tubing
Line Clamp with Spacer
as Standoff
NOTE: Clamp position can change
with the tubing intersection. 6214T2035

Figure 204 : Sheet 2 : Tubing Clamp Installation

A99192
Plain Washer
Dangerous Angles
Self−Locking Nut
Clamp Security
45 Degrees
45 Degrees Maximum
Maximum
Safe Angles
Clamp Installation Angles
Zee Angle
Cushion
Clamp
Angles
Tubing−To−Tubing
Bracket
Angle and Bracket

6214T2035

IDENTIFICATION TAPE - MAINTENANCE PRACTICES

1. General
A. This section gives the maintenance practices for the use of identification tape on tubing that is used to move liquids and
gases. Identification tape or marking tape gives maintenance personnel the data to identify the function, content, hazard,
and direction of flow of the tubing and hoses installed on the airplane.
2. Description
A. Identification tape is between 0.98 and 1.27 inches (24.89 and 32.26 mm) wide. It has adhesive backing and is resistant
to fuel, hydraulic fluid, and anti-icing additives as applicable.
B. The part number for Identification tape is identified with a basic number, system symbol and color code (first dash
number), and function of system nomenclature (second dash number). Refer to Figure 201.
A99215
CM3582−3−4
Basic Number Function of System
Nomenclature
System Symbol (Second Dash Number)
and Color Code
(First Dash Number)
Figure 201
(1) The basic number (CM3582) identifies the standard part number for identification tape.
(2) The first dash number identifies the system symbol and color code. For example, -3 identifies the following:
• System - Hydraulic
• Symbol - Circle
• Color - Blue and Yellow.
(3) The second dash number (if applicable) identifies the function of the system nomenclature with black letters. The
nomenclature letters are 3/32-inch (2.38 mm) high with every other line inverted on the tape. Direction-of-flow arrows
are included with the nomenclature. Refer to the examples that follow:
• -2 - Gear Extend
• -8 - Drain
• -28 - Attenuator Deploy.
C. Refer to Table 201 for the identification tape data that is used for the different systems on the airplane.
NOTE: When more than one color is necessary to identify a system, the order of colors is from left to right
on the identification tape.
Table 201. Identification Tape Data
First Dash System Symbol Color Code Second Function Of System
Number Dash Nomenclature
Number
CM3582-1 Compressed Broad Diagonal Orange -1 AUX BRAKE
Gas Stripe -2 ACCUM CHG
CM3582-2 Pneumatic Continuous X- Orange, Blue -1 AUX BRAKE
Form Lattice -2 AUX GEAR
-3 VENT
-4 PRSRZN CONT
-5 ACCUM, A
-6 ACCUM, B
-7 EMERG BRAKE
-8 EMERG GEAR EXT
-9 OVBD GEAR
-10 OVBD BRAKE

-11 FILL
CM3582-3 Hydraulic Circle Blue, Yellow -1 GEAR RETR
-2 GEAR EXT
-3 SPD BRK RTR
-4 SPD BRK EXT
-5 PRESSURE
-6 RETURN
-7 SUCTION
-8 DRAIN
-9 VENT
-10 LH BRAKE
-11 RH BRAKE
-12 TR DEPLOY
-13 TR STOW
-14 EMERG PRESS
-15 EMERG SUCT
-16 SPOILER ACCUM PRESS
-17 STEERING RTN PRESS
-18 SPOILER BLOW DWN
-19 LDG GR BYP
-20 LDG GR RESTRICTOR
-21 ANTI SPIN BRK-LINE
-22 BRAKE
-23 FLAP RETR
CM3582-3 Hydraulic Circle Blue, Yellow -24 FLAP EXTEND
-25 ATTENUATOR RETRACT
-26 RESERVOIR PRESSURE
-27 ATTENUATOR STOW
-28 ATTENUATOR DEPLOY
-29 GEAR PRS, A
-30 GEAR RTN, A
-37 PRS, A
-38 PRS, B
-39 RTN, A
-40 RTN, B
-41 SUCTION, A
-42 SUCTION, B
-43 CASE DRAIN, A
-44 CASE DRAIN, B
-45 BRK METRNG PRS, A

-46 BRK METRNG RTN, A

-47 LH ANTISKID, A
-48 RH ANTISKID, A
-49 LH BRAKE, OUTBD, A
-50 LH BRAKE, INBD, A
-51 RH BRAKE, INBD, A
-52 RH BRAKE, OUTBD, A
-53 TR PRS
-54 TR RTN
-55 HT XCHG, A
-56 HT XCHG, B
-57 AUX PRS, A
-58 AUX RTN, A
-59 AUX SUCN
-60 AUX RELIEF
-61 ELEV PRS, A
-62 ELEV RTN, A
-63 ELEV PRS, B
CM3582-3 Hydraulic Circle Blue, Yellow -64 ELEV RTN, B
-65 AIL PRS, A
-66 AIL RTN, A
-67 AIL PRS, B
-68 AIL RTN, B
-69 EMP PRS
-70 EMP RTN
-71 PTU PUMP PRS
-72 PTU PUMP SUCN
-73 PTU MOTOR RTN
-74 PTU MOTOR PRS
-75 NWS PRS, A
-76 NWS RTN, A
-77 NWS CENTERING
-78 SLAT PRS, A
-79 SLAT PRS, B
-80 SLAT RTN, A
-81 SLAT RTN, B
-82 SLAT STOW
-83 SLAT DEPLOY
-84 ACCUM, A
-85 ACCUM, B
-86 BOOTSTRAP PRS, A

-87 BOOTSTRAP PRS, B

-88 RUDD PRS, A
-89 RUDD RTN, A
-90 RUDD PRS, B
-91 RUDD RTN, B
-92 RESERVOIR OVBD, A
-93 RESERVOIR OVBD, B
-94 SEAL DRAIN
-95 TR LATCH
-96 ACCUM BLEED
-97 HORIZ STAB UP
CM3582-3 Hydraulic Circle Blue, Yellow -98 HORIZ STAB DN
-99 BRK MTRG PRESS
-100 BRK PRESS
-101 NWS PRESSURE
-102 NWS RETURN
-103 RSVR RTN
-104 NLG EXT
-105 NLG RETR
-106 MLG EXT
-107 MLG RETR
-108 RSVR RTN A
-109 RSVR RTN B
-110 LH BRAKE, OUTBD, B
-111 RH BRAKE, OUTBD, B
-112 SPOILER PRS, A
-113 SPOILER RTN, A
-114 SPOILER PRS, B
-115 SPOILER RTN, B
-116 MLG DOOR OPEN
-117 MLG DOOR CLOSE
-118 AUX GEAR EXT
-119 SPOILER, EXT
-120 SPOILER, RETR
CM3582-4 Vacuum Vertical Wavy Gray, Orange, -1 PRSRZN VAC
Line Gray
CM3582-5 Air Conditioning Gravel Pattern Brown, Gray -1 AIR CONDTN
CM3582-6 Water Injection Inverted Red, Gray, Red -1 WATER INJ
Chevrons
CM3582-7 Lubrication Staggered Yellow -1 DRAIN
Squares -2 VENT

-3 PRESSURE
CM3582-8 Fuel Four-Point Star Red -1 DRAIN
-2 SUPPLY
-3 MOTIVE
-4 VENT
-5 SCAVENGE
-6 CROSSFEED
CM3582-9 Static Air Continuous Zig- Orange, Gray -1 PITOT
Zag Line -2 STATIC
CM3582-10 Anti-Ice Staggered Gray -1 PORT #1
Triangles -2 PORT #2
-3 PORT #3
-4 PORT #4
-5 PORT #5
-6 PORT #6
3. Identification Tape Application
• Heat Gun
• Identification Tape.
• None.
• None.
B. Apply the Identification Tape.
NOTE: These requirements are not for tubing installed inside fuel tanks or for hoses which are attached to
metal lines and fittings that have the necessary identification.
(1) Apply the identification tape near each end of the tubing and at intermediate points along its length as necessary to
let maintenance personnel follow the system.
(2) Tubing that is less than 24 inches (0.6 m) in length can be identified with one identification tape unless the tubing is
routed through more than one compartment.
(3) Tubing that goes through more than one compartment must have sufficient identification tape to be easily identified in
each compartment.
(4) It is necessary to heat cure polyester fluid tube identification tape (1-MIL Polyester) for correct adhesion and solvent
resistance.
(5) Make sure that you use the correct identification tape for the applicable tubing or hose assembly.
(6) Make sure that the direction-of-flow arrow points in the usual direction of pressurized flow if applicable.
(7) Wrap the identification tape around the tube that is to be identified.
(8) The heat gun must supply 275°F (135°C) for approximately 10 seconds to activate the adhesive on the tape.

20-10-15-2 (Rev 1)
TUBE BENDING CRITERIA AND PERMASWAGING - MAINTENANCE PRACTICES

1. General
A. This section gives the maintenance practices for tubing, tube bending, tube flaring, and permaswaging.
2. Tubing Maintenance Practices
• Dust-Proof Polyethylene Bags
• None.
• General Solvents/Cleaners - Maintenance Practices.
B. Cutting to Length
(1) Cut all tubing squarely and break all sharp edges to prevent cracking when flared.
(2) Remove all burrs but do not use metal wool.
C. Cleaning
(1) After fabrication of all tubing, the interior must be blown free of all chips, shavings, burrs, and liquids with clean dry air.
(2) Alternately, metal tubing, except oxygen tubing, can be flushed with clean P-D-680 solvent and drained to drip point.
Refer to General Solvents/Cleaners - Maintenance Practices.
(3) All open ports must be sealed after cleaning with protective caps or plugs.
(4) Metal tube assemblies can be packaged in clean dust-proof polyethylene bags in lieu of capping or plugging.
(5) Protective plugs, caps, or dust-proof polyethylene bags must be removed as necessary to make immediate
attachment to other components.
(6) During the time the components are open, care must be used to make sure that no contamination gets into the
openings.
(7) When work is completed or temporarily stopped in a system, seal all openings as applicable.
(8) Uninstalled components or assemblies without protection must be rejected and must be cleaned again and protected
against contamination before installation or returning to stock.
(9) Stainless steel tubing must be cleaned and passivated before flaring.
(10) Stainless steel tubing assemblies that contain non-removable cadmium plated or aluminum components such as
sleeves and connections must not be pickled or passivated.
(11) After tube bending, titanium tubing must be solvent cleaned followed by an alkaline clean and etch. Refer to General
Solvents/Cleaners - Maintenance Practices.
(12) Whenever interference between B-nuts and bending operations is encountered, passivation can be done before
flaring and bending operations if the non contaminating-type dies (not made of Kirksite or lead) are used to do the
forming, or that it can be demonstrated that contamination has not occurred if and when these (Kirksite or lead) dies
are used.
D. Visual Inspection
(1) Tube bends and flares must be visually examined after they are completed.
(2) Measure the tube bends and flares as necessary to make sure that the requirements of this section are obeyed.
(3) The wall thickness in the flared portion of the tube must not be reduced by more than 18%.
E. Pressure Testing
(1) The applicable airplane system must be correctly pressure tested after installation with no leakage.

20-10-15-2 (Rev 1)
3. Tube Bending
• Radius Blocks.
• None.
• None.
B. Tube Bending Precautions
(1) Tube bending must obey the standard SAE-AS33611.
(2) The tubing must be clean and free from burrs, scales, and foreign debris that could adversely affect the fabrication or
the performance of the tubing.
(3) When bending welded tubing, the weld seam shall be aligned along the neutral axis of the bend.
(4) Unless otherwise specified, the minimum distance between the tube bend at a point of tangency and the sleeve end,
as shown in Figure 201, must obey the requirements shown in Table 201.
Figure 201
Table 201. Recommended Distance Between the Tube Bend at the Point of Tangency
Tube Diameter (Inches) Dimension A (Inches)
0.125 - 0.625 0.750
0.750 - 1.000 0.875
1.125 - 1.500 1.000
1.750 - 2.000 1.250
C. Tube Bend Radii
(1) Unless otherwise specified, tubing used in plumbing and conduit lines, as shown in Figure 202, must have bend radii
that obey the values shown in Table 202 and Table 203.
Table 202. Recommended Bend Radii of Various Alloy Tubing
Tubing Material Temper/Condition Recommended Bend Radii
Aluminum Alloys All 3D or 4D
21-6-9 Stainless Steel All 3D or 4D
Austenitic Stainless Steels Annealed 3D or 4D
1/8 Hard
1/4 Hard
Ti-3AI-2.5V CWSR 4D
CP Titanium Annealed 3D
40 ksi (TYS)

20-10-15-2 (Rev 1)
A99311
Tube Outside
Diameter (D)
Bend Radii
Tube Centerline
6298T6025
Figure 202
Table 203. Tube Bend Radii
Tube Outside Diameter Recommended Bend Radii (Inches) Additional Bend Radii
(Inches) (Inches)
3D 4D 6D
0.125 0.375 0.500 0.750
0.1875 0.563 0.750 1.125
0.250 0.750 1.000 1.500
0.3125 0.938 1.250 1.875
0.375 1.125 1.500 2.250
0.4375 1.312 1.750 2.625
0.500 1.500 2.000 3.000
0.625 1.875 2.500 3.750
0.750 2.250 3.000 4.500
0.875 2.625 3.500 5.250
1.000 3.000 4.000 6.000
1.125 3.375 4.500 6.750
1.250 3.750 5.000 7.500
1.375 4.125 5.500 8.250
1.500 4.500 6.000 9.000
1.625 4.875 6.500 9.750
1.750 5.250 7.000 10.500
1.875 5.625 7.500 11.250
2.000 6.000 8.000 12.000
2.250 6.750 9.000 13.500
2.500 7.500 10.000 15.000
3.000 9.000 12.000 18.000
(a) It is recommended, when possible, to choose the bend radius based on the available radii blocks as shown in
Table 204 and Table 205.
NOTE: A good general rule for the minimum distance between bends (DBB) is that the DBB
should meet or exceed the radius block dimension or three times the tube diameter,
whichever is more. For example, a 2.000 inch radius block for a 0.500 inch diameter tubing
would require a minimum of 2.0 inches DBB.
Table 204. Available Radius Blocks for 3 Diameter and Greater
Tube Diameter (Inches) Equipment Type Available Radius Blocks (Inches)

20-10-15-2 (Rev 1)
0.250 Manual 0.750

Manual 1.000
0.312 Manual 0.937
Manual 1.000
0.375 Numerical Control and Manual 1.125
Numerical Control and Manual 1.500
Numerical Control 2.000
0.500 Numerical Control 1.500
Table 205. Available Radius Blocks for Minimum Diameters
Tube Diameter (Inches) Minimum Wall Equipment Type Available Radius Blocks
Thickness (Inch) (Inches)
0.312 - Manual 0.620
- Manual 0.850
0.375 0.049 Manual 0.750
0.049 Manual 0.8125
- Numerical Control and 0.937
Manual
0.500 0.065 Numerical Control 0.750

20-10-15-2 (Rev 1)

- Numerical Control 1.750
1.250 - Numerical Control 2.500
(2) Bend radii over 4D and up to 6D must be used only where fabrication or design difficulties preclude the use of
recommended bends. Applications do not require specific approval and are limited only by flatness, wrinkle, and
scratch requirements shown in Tubing Used as Housing, Conduit, or Ducting and Tubing Used as Fluid System.
D. Tubing Used as Housing, Conduit, or Ducting
(1) Embossed marks caused by pits and other minor imperfections in the bend blocks are permitted provided the depth
does not exceed 10% of the tube wall thickness.
(2) Mandrel bumps, flat spots, and dents without abrupt change of section, must not be cause for rejection if the tube
diameter is not increased or decreased by more than 5% of the nominal tube diameter or 0.030 inch, whichever is
more.
(3) Wrinkles are permitted if they do not exceed the depths shown in Table 206.
Table 206. Tube Wrinkle Limits with Tubing Used as Housing, Conduit, or Ducting
Tubing Outside Diameter (Inches) Depth of Wrinkle (Inch)
0.75 and Less 0.005 (NOTE 1)
1.00 - 1.75 0.020
2.00 - 2.75 0.030
3.00 - 3.75 0.040
4.00 and More 0.060
NOTE 1: It is permissible to allow 0.010 inch maximum for all titanium tubing.

20-10-15-2 (Rev 1)
E. Tubing Used as Fluid System

(1) Tubing used for the fluid system, as shown in Figure 203, must meet the requirements shown in Table 207 and Table
208.
Figure 203
Table 207. Tube Flatness Limits with Tubing Used as Fluid System
System Pressure (psi) Tube Nominal Outside Diameter Maximum Allowable Change in
(Inch) Outside Diameter (Inch)
1000 and More More Than 0.50 5% of Nominal Outside Diameter
0.50 and Less 0.020
Less Than 1000 More Than 0.50 10% of Nominal Diameter
0.50 and Less 0.020
Table 208. Wrinkle and Scratch Limits with Tubing Used as Fluid System
System Pressure (psi) Maximum Allowable Wrinkle or Maximum Allowable Scratch
Kink Depth (Inch) Depth (Inch)
500 and More 1% of Tube Outside Diameter 5% of Nominal Wall Thickness
Less Than 500 2% of Tube Outside Diameter 10% of Nominal Wall Thickness
4. Tube Flaring
• Tube Flaring Tools.
• None.
• None.
B. Tube Flaring Criteria
(1) Flares in tubing must be examined after forming for concentricity and alignment of the flare with the tube.
(2) Circumferential indications on double flares are acceptable in the areas shown in Figure 204.

20-10-15-2 (Rev 1)
Figure 204
(3) Longitudinal cracks are not permitted in single or double flared ends.
(4) The inside surface must be smooth and free from grooves, tool marks, or other surface defects.
(5) The flared end must retain at least 82% of the original wall thickness.
(6) Superficial marks or checks on the external surface of the flare are not cause for rejection.
(7) Sleeves must touch the flared surface when pushed together by hand and be free to turn when contacting the flare
without interference of the bend radius as shown in Figure 205.
Figure 205
(8) Form single flares in accordance with SAE-AS4330.
(9) Form double flares in accordance with SAE-AS33583.
(10) Double flare is preferred on all hydraulic tubing up to 0.049 inch (1.245 mm) wall thickness and up to 0.50 inch (12.70
mm) diameter.
(11) In high-pressure applications of 1500 psi (10,342 kPa) or more, titanium tubes 0.50 inch (12.70 mm) diameter and
larger must not be flared.
5. Permaswaging
NOTE: This procedure is applicable to Permaswage joints installed on stainless steel tubing (21-6-9) per AMS-
5561 and aluminum alloy tubing. The procedure includes 6061-T6 to AMS-4083, WW-T-700/6, or AMS-T-
7081. This procedure also includes titanium alloy 3A1-2.5V to AMS-4944, or AMS-4945.
A. General
(1) The Permaswage System makes a permanent tube connection by swaging a metal fitting onto the ends of metal

20-10-15-2 (Rev 1)
tubing with a hydraulic swaging tool. Grip rings on the outside of the fitting are radially driven into the tube with
swaging dies within the tool. The result is a deformation of the fitting and the tubing to make a permanent metal-to-
metal joint. An internal backup seal compensates for any tube surface imperfections.
NOTE: The Aeroquip Rynglok Tube Fitting System can be used as an alternate to the Permaswage
System for making repairs to tubing. Refer to the Aeroquip Rynglok Fitting System Installation
Guide for specific installation procedures and requirements or contact Aeroquip Corporation,
Aerospace Group, 300 S. East Avenue, Jackson, MI 49203-1972.
NOTE: The CryoFit Fitting System may also be used for tubing repairs. For this system, contact
Advanced Metal Components Inc. at P.O. Box 145, Benton, KS 67017.
(2) All tubing used must obey AMS-2203 for aluminum, AMS-2243 for corrosion and heat resistant steel, and AMS-2244
for titanium and titanium alloy.
(3) All fittings must be of Permaswage type and Deutsch part number or equivalent. All fittings must obey AS-4459.
(4) Fittings swaged to tube subassemblies, where one or more fitting ends stay unswaged, must have the unswaged
ends protected with caps or plugs to prevent contamination until swaged. The unswaged ends must not be subjected
to any cleaning processes.
(5) Fittings must stay in individual packages until just before installation.
(6) When replacing fittings, use aluminum alloy fittings on aluminum tubing (stainless steel can be used as an alternate).
Use stainless steel fittings on stainless steel tubing (no alternates). Use titanium fittings on titanium tubing (stainless
steel an acceptable alternate).
B. Tools and Equipment
• Chipless Tube Cutter
• Deburring Tool
• Swage Tooling - D12000 or DLT.
• Adhesive - Loctite-Super Bond 495
• Cheesecloth
• Ecco-Strip 93.
C. Prepare the Tubes for Swaging.
(1) The tubes must be free of grease, oil, and other contamination.
(a) Use Sotoclean 110 solvent to clean the tubing as necessary. Refer to General Solvents/Cleaners - Maintenance
Practices.
(2) The tubing end to which the fitting is to be installed must be smooth and free of burrs. Scratches can only be in the
hoop direction, not along the length of the tube. The scratch depth must be within the limits shown in Table 209.
Table 209. Maximum Allowable Scratch Depth
Wall Thickness (Inch) Maximum Scratch Depth (Inch)
0.020 - 0.040 0.002
0.041 - 0.050 0.003
0.051 - 0.066 0.004
0.067 - 0.085 0.006

20-10-15-2 (Rev 1)
(3) The tubing end must be square within four degrees for tubing up to and including 0.5 inch (12.70 mm) outside
diameter and within three degrees for tubing more than 0.5 inch (12.70 mm) up to and including 1.5 inches (38.10
mm) outside diameter.
(4) The tubing ends must be free of paint and primer to the distances as shown in Figure 206 and Table 210.
(a) Use Ecco-Strip 93 to remove the paint and primer from the tubing ends.
A99307
D 0.30 Inch
Witness Mark Paint

Paint Removed
Figure 206
Table 210. Distance Locations for the Witness Marks and Paint/Primer
Nominal Outside Tube Dimension D Distance to Dimension P Bare Tube Witness Marking Tool
Diameter (Inches) Witness Mark (Inches, + Minimum (Inches, + or -
or - 0.030 Inch) 0.20 Inch)
0.188 0.473 2.00 D9862-1
0.250 0.615 2.00 D9862-1
0.312 0.655 2.00 D9862-1
0.375 0.690 2.00 D9862-1
0.500 1.193 3.00 D9862-2
0.625 1.233 3.00 D9862-2
0.750 1.303 3.00 D9862-2
1.000 1.448 3.00 D986233
1.250 1.550 3.00 D9862-3
1.500 1.675 3.00 D9862-3
(5) A witness mark must be made on each tube end to which a Permaswage fitting is to be installed. Refer to Figure 206
and Table 210.
(a) Fittings must not be swaged on to tubes that do not have witness marks.
(b) If the tube is aluminum, the witness mark must be made after chemical film treating.
(c) The witness marks must be made with the applicable witness marking tool and the marking pen.
(d) The tube must be marked in at least three locations, approximately equally spaced around the tube
circumference.
(e) After applying witness marks, the tube ends must be protected with suitable closures, unless the fittings are to
be immediately installed.
(6) The fittings must stay in their individual package until just before installation.
(7) The yoke and die assemblies must be visually examined for cracks before use.
(8) Swaged fittings must obey the dimensional requirements of and engage the tube ends within the specified limits as
shown on Figure 207 and Table 211.

20-10-15-2 (Rev 1)
A99306
B
Figure 207
Table 211. Swaged Fitting Dimension
Fitting Dash Number Tube Diameter (Inches) Dimension B Swage Dimension A Swage
Length (Inches, + or - Diameter (Inches, + or -
0.004) 0.001)
-3 0.1875 0.340 0.2465
-4 0.250 0.460 0.315
-5 0.312 0.500 0.381
-6 0.375 0.530 0.447
-8 0.500 1.020 0.606
-10 0.625 1.020 0.735
-12 0.750 1.020 0.863
-16 1.000 1.160 1.143
-20 1.250 1.364 1.390
-24 1.500 1.420 1.680
D. Tooling Selection
(1) Select the correct size of swage tool assembly and power unit as shown in Table 212 for D12000 tooling or Table
213 for DLT tooling.
(a) Compare the upper and the lower die set dash numbers with each other and with the fitting/tubing size to make
sure that the correct tooling has been selected.
NOTE: The upper and the lower die sets are made for a specific fitting/tube size and the die set
dash number indicates the applicable fitting/tube size in 1/16-inch increments.
Table 212. Swage Tools for D12000 Tooling
Tube Fitting- Swage Swage Head Power Unit Inspection Gage Witness Marking
Size Tube Tool Assembly Tool
(Inches) Dash Assembly
Number
3/16 -3 D12203 D12203-56 D12710-52 D12-9892-3 D9862-1
1/4 -4 D12204 D12204-56 D12710-52 D12-9892-4 D9862-1
5/16 -5 D12205 D12205-56 D12710-52 D12-9892-5 D9862-1
3/8 -6 D12206 D12206-56 D12710-52 D12-9892-6 D9862-1
1/2 -8 D12208 D12208-56 D12010-52 D12-9892-8 D9862-2
5/8 -10 D12210 D12210-56 D12010-52 D12-9892-10 D9862-2
3/4 -12 D12212 D12212-56 D12012-52 D12-9892-12 D9862-2
1 -16 D12216 D12216-56 D12216-52 D12-9892-16 D9862-3
1-1/4 -20 D12220 D12220-56 D12216-52 D12-9892-20 D9862-3
1-1/2 -24 D12224 D12224-56 D12216-52 D12-9892-24 D9862-3

20-10-15-2 (Rev 1)
NOTE 1: Use the D10058 marking pen for D12000 tooling.

Table 213. Swage Tools for DLT Tooling
Tube Fitting- Swage Swage Head Power Unit Inspection Gage Witness Marking
Size Tube Tool Assembly Tool
(Inches) Dash Assembly
Number
3/16 -3 D12203 DLT05PSHA3003 DLT05MAPW0000 D12-9892-3 DLT5302-013-01
1 -16 D12216 DLT40PSHA3016 DLT40MAPW0000 D12-9892-16 DLT5302-040-01
1-1/4 -20 D12220 DLT40PSHA3020 DLT40MAPW0000 D12-9892-20 DLT5302-040-01
1-1/2 -24 D12224 DLT40PSHA4024 DLT40MAPW0000 D12-9892-24 DLT5302-040-01
NOTE 1: Use the DLT5301-000-01 marking pen for DLT tooling.
E. Placement of Tubing into Fitting
(1) Make sure that the tubing has the correct witness marks.
(2) Remove the fitting from its package.
(3) Install the tube ends into the fitting.
F. Application of Adhesive (If Required)
NOTE: Loctite-Super Bond 495 adhesive must be used only where necessary. This includes areas where
it is difficult to keep fittings from rotating while setting up to swage and those areas where the tube
and fitting must be removed from the airplane to swage.
(1) Prepare the surfaces to be bonded, apply adhesive, and cure as follows:
(a) Use Sotoclean 110 solvent and cheesecloth to clean the mating surfaces to be cemented so they are completely
free of grease, dirt, and other contamination. Refer to General Solvents/Cleaners - Maintenance Practices.
1 Wipe dry with a clean, dry cloth.
(b) Apply one to two drops of Loctite-Super Bond 495 adhesive to the bonding surface of the tube.
NOTE: If adhesive is accidentally applied to fingers, apply hot water vapor or warm water to
separate.
1 Do not roll or brush the adhesive onto the bonding surface.
2 Make sure that you close the container tightly after each use.
(c) Put the tubing into the correct location of the fitting and turn with light pressure to spread the adhesive, then
make the final alignment.
(d) Hold the parts in place by hand until the bond has started to set.
NOTE: Normal swaging can begin after the adhesive has cured sufficiently for the fitting to resist
turning by hand. This will normally occur within two minutes.
G. Placement of D12000 Tooling
(1) Slide the tool yoke over the fitting to be swaged with the silver side of the yoke assembly closest to the end of fitting to
be swaged.
(2) Insert the cover die holder into the tool yoke so that the silver face of the die holder corresponds to the silver side of
the yoke.

20-10-15-2 (Rev 1)
CAUTION: If the knurled nut is not snug, the yoke will deflect excessively during swaging resulting in
overstress and possibly destructive failure of the tool.
(3) Install the square connector part of the power unit into the tool yoke.
(a) Tighten the knurled nut hand tight.
(4) Install the fitting over the witness marks on the tube so that some portion of the mark is visible outside the fitting end
and some portion is covered by the fitting end.
(5) Move the tool toward the center of the fitting until the silver die plate end-stops make light contact with the end of
fitting, then back off the tool slightly until the end-stops are approximately 0.03 inch (0.76 mm) from the fitting end.
NOTE: Backing off the tool will prevent damage to the tool as the fitting is slightly extruded during the
swaging action.
(6) Visually make sure that some portion of the witness mark is visible with some portion of the mark covered by the
fitting. Also make sure that there is a small space between the die plate end-stops and the fitting end to be swaged.
H. Placement of DLT Tooling
(1) Install the yoke around the fitting and the coupling with the end stop closest and touching the fitting/coupling.
(2) Install the die onto the power unit by pushing down and snapping onto the power unit.
NOTE: The -16, -20, and -24 sizes need to have their release button pushed in during the slide-on
procedure.
(3) Slide the power unit on the yoke, knurled side to knurled side and smooth side to smooth side.
CAUTION: The tool can come free if it is not in the locked position.
(4) Push to the locked position and visually make sure that it is in the locked position.
I. Swaging
WARNING: Make sure that the output pressure gage has a current calibration label.
(1) Keep the tool in this position and apply 5500 psi, +250 or -250 psi for the D12000 swaging tool and power unit or
10,000 psi, +250 or -250 psi for the DLT swaging tool and power unit.
(2) Release the pressure.
(3) Gas fittings (nitrogen or oxygen) must be double swaged. Turn the tool a few degrees and do this swaging procedure
again.
(4) Remove tool from the tube assembly.
(5) Repeat the swaging on the remaining fitting ends to be swaged.
(6) Protect unswaged fitting ends of subassemblies with caps or plugs until removal is necessary for installation of the
unswaged fitting end.
J. Inspection
(1) Examine the swage with the applicable D12-9892 inspection gage. Refer to Figure 208.
A99305
D12-9892 Gage Shoulder Must
Inspection Gage Contact Fitting End
A portion of the witness mark

must be visible outside the
fitting end, and some portion
of the witness mark must be
under the fitting end.
Figure 208
(a) If swage does not obey the requirements with the inspection gage, refer to the Rework Procedure in this section.
(b) Make sure that some portion of the witness mark is covered by the fitting. If some portion of the witness mark is

20-10-15-2 (Rev 1)
not covered by the fitting, it is necessary to remove and replace that section of tubing. Refer to the Repair
Procedure in this section.
K. On-Assembly Installation
NOTE: On-assembly installation in the airplane will include either joining tube ends with a fitting or joining
a tube end to an unswaged fitting end of a fitting or tube subassembly. The following procedure
must be followed for both installations.
NOTE: For linear length adjustments, the Permaswage fitting is designed to have a small distance
between the tube ends. To get the correct distance, it is necessary to set in place a full run of
tubing prior to swaging. Tube end distance is not measurable. The tube ends have witness marks
and when the fittings are correctly located over the witness marks, the tube end distance will be
within the permitted limits.
(1) Attach tube subassemblies with threaded connectors to the attaching fitting or component.
(a) Tighten B-nuts finger tight and clamp tube in its position.
NOTE:
All tube clamps do not need be installed at this time. However, sufficient clamps must be
used to hold the tube in position. Visual inspection will determine if the omitted clamps
will fit, when installed, without too much force.
CAUTION: During the loose installation of the tube run, never twist a line to make it fit. This may inadvertently
cause a torsional force on a previously swaged fitting, which can cause the fitting to weep or leak
later.
(2) Install the fitting or mating tube subassembly by installing the tube end into the Permaswage fitting end. Clamp the
tube in place. Continue this procedure until the full length of tubing to the next threaded joint is in position.
NOTE:In areas which contain tees and/or crosses, the lines must also be in position to the next
threaded joint to ensure correct clocking of fittings.
CAUTION: Hold the fittings with the correct wrenches when torquing the threaded connector to avoid
damaging the tube or joint.
(3) Tighten all threaded connectors to the correct torque as shown in Table 214. Refer to Torque Data - Maintenance
Practices.
Table 214. Permaswage Threaded Fitting Torque (Inch Pounds)
Tube Size (Inch) Stainless Steel and Titanium Aluminum
Minimum Maximum Minimum Maximum
3/16 90 100 75 90
1/4 135 150 80 100
5/16 180 200 100 130
3/8 270 300 100 130
1/2 450 500 200 240
5/8 700 800 360 400
3/4 1100 1150 390 430
1 1200 1400 600 900
1-1/4 1300 1450 600 900
1-1/2 1350 1500 600 900
2 1500 1700 600 900
(4) Examine the loose installation to make sure that all fittings will be correctly located after swaging by verifying that
some portion of the witness mark is visible and some portion is covered by the fitting ends.
(a) Do not swage the fittings if the witness marks are not located correctly.
(b) Loosen tube clamps and adjust the tube end gaps to get the correct fit as necessary.
(c) Tighten the clamps.

20-10-15-2 (Rev 1)
(5) Check the loose installation to make sure that sufficient clearance will be kept between other tubes, components, and
structure.
(6) Swage each fitting end as applicable. Refer to Swaging in this section.
NOTE: To get sufficient tool clearance, it is permitted to loosen the tube clamps to let tubes be moved
away from obstructions during the swaging operation. However, movement of the tubes must
not cause misalignment between the tube and fitting. Make sure that no twisting force is
applied on any previously swaged fitting.
L. Rework Procedure
(1) Swaged fittings that do not obey the requirements of the applicable D12-9892 inspection gage must be reworked per
the corrective actions shown in Table 215.
Table 215. Rework Corrective Actions
Problem Precaution Corrective Action
Fitting does not swage correctly. Must have 5500 psi, +250 or -250 psi Check to make sure power supply is
supplied to D12000 tool or 10,000 functioning correctly.
psi, +250 or -250 psi supplied to DLT
tool.
Cannot use die blocks for larger size Install correct die blocks.
fitting.
Gage will not fit over swaged fitting Must reach 5500 psi, +250 or -250 Reswage (one time only).
outside diameter. psi for D12000 tool or 10,000 psi,
+250 or -250 psi for DLT tool at
pressure gage.
Must not try to read over flash marks. Turn gage off flash marks.
Die segments and walls of die blocks Carefully remove die from die blocks
must be clean. and:
(1) Clean between die sectors.
(2) Clean and lubricate die block side
surfaces and those surfaces in
contact with die segments with a light
film of TFE spray lubricant. Do not
use lubricant between die segments.
Gage shoulder does not touch end of End of fitting must be within 0.03 inch Reswage (one time only). Die plate
fitting. (0.76 mm) of end-stop before end-stops may be damaged. If so,
pressure is applied to tool. they must be replaced.
(2) If after rework, the fitting still does not obey the requirements of the applicable D12-9892 inspection gage, the tool
should be rejected and removed from service. The fitting or tube subassembly must also be rejected.
M. Repair Procedure (Refer to Figure 209 and Figure 210)
(1) Remove primer and paint from tube to be repaired. Refer to Figure 206 and Table 210.
(2) Tubing with a damaged area of 0.30 inch (7.62 mm) or less in length can be repaired by cutting tube in two at the
center of damaged area and swaging a sleeve over the cut.
NOTE: The replacement sleeve must be of the same size and type of material (aluminum, stainless
steel, or titanium) as the tube.
(3) Tubing with a damaged area longer than 0.30 inch (7.62 mm) must have the damaged section of the tube removed
and replaced with a new section of the same material, size, and wall thickness using two sleeves.
NOTE: The replacement sleeve and tube must be of the same size and type of material (aluminum,
stainless steel, or titanium) as the tube.
(4) When cutting a tube that is installed in the airplane, a chipless tube cutter and a deburring tool must be used. Refer to
Table 216 for chipless tube cutters and Table 217 for deburring tools.

20-10-15-2 (Rev 1)
Table 216. Chipless Tube Cutters (Deutsch MCD Part Numbers)

Tool 3/16 to 3/8 Inch (-3, -4, -5, 1/2 to 3/4 Inch (-8, -10, -12) 1 to 1-1/2 Inch (-16, -20, -
-6) 24)
Chipless Tube Cutter D12530-001 D12531-001 D12532-001
Hex Key D9802 D9802 D9803
NOTE 1: There are three sizes of chipless tube cutters that are used to cut tubing sizes from 3/16
through 1-1/2 inches. A hex key is used to tighten the cutter wheels during cutting operations.
Table 217. Deburring Tools (Deutsch MCD Part Numbers)
Complete Tool Component Parts Tube Wall Range (Inch)
Body Standard Optional Stem Size
Assembly Stem Assembly (Inches)
Assembly
D10210 (NOTE 1) 0.150
D9851 D9851-14 D9851-13-3 1/4 0.028 - 0.050
D9851-13-4 1/4 (NOTE 0.016 - 0.028
1)
D9851-13-5 5/16 0.016 - 0.035
D9851-13-6 3/8 0.016 - 0.035
D9851-13-7 3/8 0.035 - 0.058
D9850 D9850-14 D9850-13-8 1/2 0.016 - 0.042
D9850-13-9 1/2 0.042 - 0.065
D9850-13-10 5/8 0.016 - 0.058
D9850-13-12 3/4 0.016 - 0.065
D9849 D9849-15 D9849-13-16 1 0.020 - 0.083
D9849-13-20 1-1/4 0.024 - 0.065
D9849-13-21 1-1/4 0.065 - 0.109
D9849-13-24 1-1/2 0.028 - 0.083
NOTE 1: Can be used for 3/16 inch size tubing, dependent on tube wall thickness.
NOTE 2: Tubing with inside diameter less than 0.150 will have to use a solid spiral flute deburring tool.
NOTE 3: Deburring tools are used to remove burrs from the inside diameter of the tube ends. The
deburring tools includes a cutter, handle assembly, and stem assemblies.
(5) Swage the sleeve(s) and tube assembly as applicable. Refer to Swaging in this section.
N. Paint Touch Up
(1) After fitting installation, all unpainted, visible surfaces of the tubing must be solvent cleaned and touched up with the
same primer and topcoat as necessary to match the painted part of the tubing. Refer to General Solvents/Cleaners -
O. Pressure Testing

20-10-15-2 (Rev 1)
Figure 209 : Sheet 1 : Tube Repairs

A99304
Damage 0.30 Inch or Less
0.30 Inch Maximum Cut Center Dual Swage Sleeve

0.30 Inch Maximum Gap Between Witness Marks
Type 1 Repair Witness Marks (Typical)
Damage Longer Than 0.30 Inch

0.30 Inch (Typical)
Maximum
Gap
Type 2 Repair Witness Marks (Typical)
Damage In Bend Damaged or

0.30 Inch Leaking Tee
Maximum Gap
Alternate Repair
Witness Marks
0.30 Inch
Maximum Gap
(Typical)
Type 3 Repair
Dual Swage
Sleeve Fitting
Dual Swage Triple Swage

Elbow Fitting Tee Fitting

20-10-15-2 (Rev 1)
Figure 210 : Sheet 1 : Tube Repair Procedure

A99303
2 Rotate Deburring Tool
1 Remove Damaged Section Of Counterclockwise To
Tubing With Chipless Pipe Cutter Remove Burrs
Chipless Pipe Cutter
Deburring Tool
Handle Rotated
30 Degrees Minimum
When Making Cut
3 Apply Witness Marks

With Marking Tool 4 Center Dual Swage
Sleeve Between
Witness Marks
Witness Marking Tool Dual Swage Sleeve
Witness Marks
5 Swage Sleeve on to
Tubing With Swage Tool
6 Check Swaged Ends
Swage Tool With Inspection Gage
Inspection Gage

MS FLARELESS FITTINGS - MAINTENANCE PRACTICES

1. Effectivity
A. This section does not apply to the following Cessna Models:
• Model 510
• Model 525A
• Model 525B.
2. General
A. This section gives the maintenance practices for MS flareless fittings installation and repairs.
B. MS flareless fittings can be used to connect unflared tubing. An MS fitting has a counterbore in which the tube end is
installed. The MS flareless fitting has a 24-degree beveled edge in the counterbore of the fitting with a seat. The seat
makes a slope for the tube during the connection of one tube to another tube or for a tube to a component. The beveled
area causes the tube connector sleeve to seal the connection as the tube nut is tightened.
C. MS flareless fittings are made of aluminum alloy or steel. Aluminum alloy fittings can be identified visually by their yellow
color which is caused from the anodizing treatment. The cadmium plating on steel fittings are identified by letter-number
codes. For example, MS21900-4, is identified as follows:
• MS - Prefix for Military Specification
• 21900 - Design Part Number (Adapter, Flareless Tube to AN Flared Tube)
• 4 - Size of Fitting in Sixteenths of an Inch (4/16 Inch).
D. The material from which the MS flareless fittings are made is indicated by the presence or the absence of a letter at the
end of the MS number. For example:
• MS21900-4 is made of carbon steel.
• MS21900-8-D is made of aluminum alloy.
• MS21900-8-S is made of corrosion-resistant steel, class 347.
3. MS Flareless Fitting Installation
NOTE: This procedure is applicable to MS flareless fittings that are installed on stainless steel tubing 304 in
accordance with MIL-T-6845 and aluminum alloy tubing 6061-T6 in accordance with MIL-T-7081. This
procedure is not applicable for stainless steel tubing 21-6-9 (Nitronic 40) in accordance with AMS-5561
Class 1.
• Deburring Tool
• Preset Tool.
• Lubricant.
B. Prepare the Tubing for the MS Flareless Fitting Installation.
NOTE: All stainless steel tubing must obey AMS-2243 for tolerances. Aluminum alloy tubing must obey
Federal Specification 245.
NOTE: Tubing must be square in 0.5 degree or less when you install MS21921 nuts on the tube.
(1) Use a chipless tube cutter to cut the tubing end as applicable.
(a) The tubing end must be cut square to within 0.5 degrees.

(2) Use a deburring tool to remove the burrs and sharp edges from the inside and the outside of the tubing end.
(a) The break or chamfer on the outside or the inside corner must not exceed 25% of the thickness of the tube wall.
C. MS Flareless Fitting Presetting (Refer to Figure 201)
Figure 201
NOTE: The sleeve must be preset on the tubing before installation.
(1) Clamp the correct preset tool securely in a vice.
(2) Put the nut and the sleeve on to the tubing end.
(a) Make sure that you install the sleeve in the correct direction.
(3) Lubricate the sleeve, mating threads, and working surfaces of the preset tool with the correct lubricant as shown in
Table 201.
Table 201. Lubricants
Application Lubricant
Coolant (Ethylene Glyco) None
Coolant (Silicate Esters) None
Engine Fuel System Fluid
Engine Lubricant (Petroleum Base) System Fluid
Engine Lubricant (Phosphate Base) System Fluid
Hydraulic (Petroleum Base) System Fluid
Hydraulic (Phosphate Base) System Fluid
Oxygen None
Pneumatic MIL-G-4343 Grease
Vacuum None
Water VV-P-236 Petrolatum
(4) Put the tubing end firmly against the bottom of the seat of the preset tool and hold it in this position.
(5) Move the sleeve to its position against the preset tool.
(6) Thread the nut onto the preset tool.

(7) Use a wrench to slowly tighten the nut to the preset tool until the cutting edge of the sleeve grips the tube sufficiently to
prevent rotation of the tube by the thumb and fingers.
NOTE: When the sleeve first grips the tube, you have reached the starting position.
(8) From the starting position, tighten the nut the correct amount as shown in Table 202, Table 203, or Table 204 as
applicable.
Table 202. Number of Turns for Presetting Flareless Sleeves with Mandrels
Tube 0.125 0.188 0.250 0.312 0.375 0.500 0.625 0.750 1.000 1.250 1.500
Size
(Inches)
Number 1-1/6 1-1/6 1 1 5/6 5/6 2/3 2/3 2/3 2/3 2/3
of
Turns
Table 203. Number of Turns for Presetting Flareless Sleeves without Mandrels on 304 1/8 Hard Corrosion
Resistant Tubing
Wall Number of Turns for Tube Size (Inches)
Thickness 0.125 0.188 0.250 0.312 0.375 0.500 0.625 0.750 1.000
(Inch)
0.012 1-1/6
0.018 1-1/6 1-1/6 1-1/6 1-1/6
0.020 1-1/6 1-1/6 1-1/6 1-1/6 NOTE 1
0.022 1-1/6 1-1/6 1-1/6 1-1/6 1-1/6
0.025 1-1/6 1-1/6 1-1/6 1-1/6 1-1/6 NOTE 1 NOTE 1
0.028 1-1/6 1-1/6 1 1-1/6 1 1-1/6 1-1/6 NOTE 1
0.035 1-1/6 1 1 1-1/6 1-1/6 1-1/6 NOTE 1
0.042 1 1 1 1-1/6 1-1/6 1-1/6
0.049 1 5/6 1 1 1 1-1/6
0.058 5/6 1 5/6 1
0.065 5/6 5/6 5/6 1
0.072 5/6 5/6
0.083 5/6
NOTE 1: Use a mandrel for this size and thinner wall tubing.
Table 204. Number of Turns for Presetting Flareless Sleeves without Mandrels on Aluminum Alloy and
Annealed Corrosion Resistant Steel Tubing
Wall Number of Turns for Tube Size (Inches)
Thickness 0.125 0.188 0.250 0.312 0.375 0.500 0.625 0.750 1.000
(Inch)
0.018 1-1/6 1-1/6
0.020 1-1/6 1-1/6
0.022 1-1/6 1-1/6 NOTE 1
0.025 1-1/6 1-1/6 1-1/6 NOTE 1
0.028 1-1/6 1-1/6 1-1/6 1-1/6 NOTE 1 NOTE 1
0.035 1 1-1/6 1-1/6 1-1/6 1-1/6 NOTE 1 NOTE 1
0.042 1 1 1-1/6 1-1/6 1-1/6 1-1/6 NOTE 1
0.049 1 1 1 1-1/6 1-1/6 1-1/6

0.058 1 5/6 1 1 1 1-1/6

0.065 5/6 5/6 1 1 1-1/6
0.072 5/6 1
0.083 5/6 5/6
0.095 5/6
NOTE 1: Use a mandrel for this size and thinner wall tubing.
(9) Loosen the nut that attaches the tubing to the preset tool.
(10) Remove the tubing from the preset tool.
D. Preset Sleeve Inspection
(1) Make sure that the longitudinal movement is not more than 0.020 inch (0.508 mm).
NOTE: Sleeve movement around the tube is permitted.
(2) Make sure that the sleeve does not have cracks, nicks, or score marks.
(3) If necessary, use DeSoclean 110 solvent to clean the tube and fitting. Refer to General Solvents/Cleaners -
(a) Remove all solvent with clean, dry, compressed air.
E. Install the MS Flareless Fitting.
(1) Lubricate the sleeve, mating threads, and sealing surfaces of the fitting with the correct lubricant as shown in Table
201.
(2) Put the tube in its position with the sleeve seated in the mating fitting.
(a) Make sure that there is no preload on the tube at the mating fitting.
(b) Make sure that the tube is aligned correctly with the mating fitting.
(3) Thread the nut onto the mating fitting.
(4) Tighten the MS flareless fitting as follows:
NOTE: As an alternative to tightening the MS flareless fitting using the torque method, you can tighten
it using the nut-turn method.
(a) Tighten the MS flareless fitting with the torque method as follows:
1 Tighten the nut to the correct torque as shown in Table 205. Refer to Torque Data - Maintenance Practices.
Table 205. MS Flareless Fitting Torque (Inch Pounds, +5 or -5%)
Tube Outside Tube Wall Aluminum Fitting Steel Fitting Steel or Titanium
Diameter (Inch) Thickness (Inch) Aluminum Tube Annealed Fitting 304 1/8
Corrosion Hard Corrosion
Resistant Steel Resistant Tube
Tube
0.125 0.012 55
0.188 0.016 100
0.188 0.020 100
0.188 0.028 80
0.250 0.020 140 140
0.250 0.028 110 140
0.312 0.020 190 190
0.312 0.028 140 190
0.375 0.028 170 270
0.375 0.035 270
0.500 0.028 280

0.500 0.035 360 500

0.500 0.042 500
0.625 0.028 360
0.625 0.035 415
0.625 0.042 700
0.625 0.058 700
0.750 0.028 450
0.750 0.049 450
0.750 0.058 900
0.750 0.065 900
1.000 0.035 750
1.000 0.049 800
1.000 0.065 1200 1200
1.000 0.083 1200
(b) Tighten the MS flareless fitting with the nut-turn method as follows:
1 Tighten the nut until an increase in torque occurs.
CAUTION: Do not tighten the nut more than 1/3 additional turn.
2 Then, tighten the nut an additional 1/6 to 1/3 turn.
F. Leak Check
CAUTION: Do not tighten a correctly torqued MS flareless fitting that leaks.
(a) If leakage occurs, do the steps that follow:
1 Loosen the nut and remove the tube end from the fitting.
2 Examine the seal areas of the sleeve and the mating fitting for scratches, nicks, dents, foreign material, and
other damage.
3 Replace the parts as necessary.
4 Install the MS flareless fitting and do the leak check again.
4. Repair with MS Flareless Fittings
• Deburring Tool
• Metal Container.
• None.
• Tubing, Hose and Fittings - Maintenance Practices
• General Solvents/Cleaners - Maintenance Practices
B. Prepare the Airplane for the Repair with MS Flareless Fittings.

(1) Obey the Standard Maintenance Practices given in Tubing, Hose and Fittings - Maintenance Practices.
Manual.
(6) Put a metal container below the tubing to catch fluid.
C. Do the Repair with MS Flareless Fittings.
NOTE: When you make a repair with MS flareless fittings, the tubing must be of the same material,
diameter, and thickness as the tube that is replaced.
(1) Find the area of damage and the most applicable area to do the repairs.
CAUTION: Because many of the fittings installed on the airplane are Deutschlite fittings and need to be
disconnected for maintenance, a minimum of two MS21921 nuts and a union will be necessary to
do the repair. Also, because of the tolerances necessary for the connection of the tubing, it is very
important that you carefully measure the tubing before it is cut and the sleeves are preset on the
tubing. This is very important when elbows, tees, crosses, etc., must be used in the tubing.
(2) Use a chipless tube cutter to cut the damaged section out of the tubing.
(3) Use a deburring tool to remove the burrs and the sharp edges.
(4) Use DeSoclean 110 solvent as necessary to clean the tube ends. Refer to General Solvents/Cleaners - Maintenance
Practices.
(5) Use the applicable MS flareless fittings to install the correct length and type of tubing in the place of the damaged
section of tubing. Refer to MS Flareless Fitting Installation in this section.
D. Put the Airplane Back to its Initial Condition.
other damage.
4 Install the MS flareless fitting and do the leak check again.
(4) Remove the metal container from below the tubing.
5. Repair 21-6-9 Stainless Steel Tubing with 304 or 21-6-9 Stainless Steel Tubing
NOTE: When swage tools are not available to do a tubing repair, it is permitted to use 304 stainless steel tubing
with a flared-to-flareless adapters (MS21900). 304 or 21-6-9 stainless steel tubing (304 tubing
recommended) can be used for the repair with flared-to-flared unions (AN815).
NOTE: If a 21-6-9 stainless steel tube with two male MS ports (MS union-to-MS union) connections are to be
replaced, it is permitted to make a replacement tube assembly of 304 stainless steel tubing with
MS21921 nuts and MS21922 sleeves.

• Deburring Tool
• None.
• Tube Bending Criteria and Permaswaging - Maintenance Practices
B. Prepare the Airplane for the Repair of 21-6-9 Stainless Steel Tubing with 304 or 21-6-9 Stainless Steel Tubing.
Manual.
C. Repair 21-6-9 Stainless Steel Tubing with 304 Stainless Steel Tubing and Flared-to-Flareless Adapters (Procedure 1)
(Refer to Figure 202).
(1) Use a chipless tube cutter to cut the damaged section out of the 21-6-9 stainless steel tubing.
Practices.
(4) Install the nuts (AN818) and the sleeves (MS20819) on the cut ends of the 21-6-9 stainless steel tubing.
(5) Put a flare on the 21-6-9 stainless steel tubing ends. Refer to Tube Bending Criteria and Permaswaging -
Maintenance Practices, Tube Flaring.
(a) Make sure that the flares do not have cracks.
(b) If you find cracks, cut the tubing and put a flare on it again.
(6) Connect an adapter (MS21900) to the nut (AN818) on each end of the 21-6-9 stainless steel tubing.
(7) Measure and use a chipless tube cutter to cut the correct length of 304 stainless steel tubing to fit in place of the
damaged section.
Practices.
(10) Use two nuts (MS21921) and two sleeves (MS21922) to install the 304 stainless steel tubing in the place of the
damaged section of tubing. Refer to MS Flareless Fitting Installation in this section
D. Repair the 21-6-9 Stainless Steel Tubing with 304 or 21-6-9 Stainless Steel Tubing and Flared-to-Flared Unions
(Procedure 2) (Refer to Figure 202).

(1) Use a chipless tube cutter to cut the damaged section out of the 21-6-9 stainless steel tubing.
Practices.
(4) Install the nuts (AN818) and the sleeves (MS20819) on the cut ends of the 21-6-9 stainless steel tubing.
(5) Put a flare on the 21-6-9 stainless steel tubing ends. Refer to Tube Bending Criteria and Permaswaging -
(6) Connect a union (AN815) to the nut (AN818) on each end of the 21-6-9 stainless steel tubing.
(7) Measure and use a chipless tube cutter to cut the correct length of 304 or 21-6-9 stainless steel tubing to fit in place
of the damaged section.
NOTE: 304 stainless steel tubing is preferred.
Practices.
(10) Install two nuts (AN818) and two sleeves (MS20819) on the 304 or 21-6-9 stainless steel tubing.
(11) Put a flare on the 304 or 21-6-9 stainless steel tubing ends. Refer to Tube Bending Criteria and Permaswaging -
(12) Connect the nut (AN818) to the union (AN815) on each end of the 304 or 21-6-9 stainless steel tubing in the place of
the damaged section of tubing.
other damage.
4 Install the fitting and do the leak check again.

Figure 202 : Sheet 1 : 21-6-9 Stainless Steel Tubing Repairs

A99343
Damaged Area of 21−6−9 Stainless Steel Tubing
21−6−9 Stainless Adapter 304 Stainless Adapter 21−6−9 Stainless

Steel Tubing (MS21900) Steel Tubing (MS21900) Steel Tubing
Nut Sleeve Sleeve Nut Sleeve Sleeve Nut

(AN818) (MS20819) (MS21922) (MS21921) (MS21922) (MS20819) (AN818)
Procedure 1: Repair with 304 Stainless Steel

Tubing and Flared−to−Flareless Adapters
21−6−9 Stainless Nut 21−6−9 Stainless

Steel Tubing Sleeve Sleeve Steel Tubing
(MS20819) (AN818) (MS20819)
Nut Union Sleeve Sleeve Union Nut

(AN818) (AN815) (MS20819) (MS20819) (AN815) (AN818)
304 or 21−6−9
Stainless Steel
Tubing
Procedure 2: Repair with 304 or 21−6−9 Stainless Steel

Tubing and Flared−to−Flared Unions

CONICAL SEALS - MAINTENANCE PRACTICES

1. Effectivity
A. This section only applies to the following Cessna Models:
• Model 510
• Model 525B
• Model 560
• Model 560 Ultra
• Model Encore
• Model Encore+
• Model 560XL/XLS
• Model 650
• Model 680
• Model 680A
• Model 700
• Model 750
• Model 750+.
2. General
A. This section gives the maintenance practices for the conical seal installation.
3. Conical Seal Installation
NOTE: This section gives the procedure for the installation of S2692 (37 degrees flared) and S2693 (24 degrees
flareless) conical seals in fluid connections. Correct installation is necessary to prevent flow
restrictions and/or subsequent leakage.
NOTE: Conical seals are designed for one-time only use. Once a conical seal has been installed and the
assembly nut has been torqued, the seal is considered used. If the assembly nut is loosened for any
reason, whether it is to help with tube alignment or complete disassembly of the joint, the conical seal
must be replaced and the assembly nut torqued before any fluid is allowed to pass through the
connection.
• Lubricant.
B. Prepare the Airplane for the Conical Seal Installation.
CAUTION: To prevent flow restriction and/or subsequent leakage, it is important to install conical seals as
given in the steps that follow.
CAUTION: Do not use nickel conical seals on aluminum fittings or tubing to prevent corrosion.
NOTE: Conical seals must be used or replaced only if leakage is caused by damage (slight deformation) to
the male or female flareless fittings. Leakage caused by any other damage, such as cracked
fittings, cannot be corrected with conical seals. The other damage must be corrected by
replacement of the damaged part of the tubing.


(5) Remove access panels as necessary to get access to the applicable fitting. Refer to the applicable Maintenance
Manual.
(6) Put a metal container below the fitting to catch fluid.
(7) Select the correct conical seal material for the tubing and fitting material as shown in Table 201.
Table 201. Conical Seal Material
Tubing and Fitting Assembly Temperature Fluid to be Sealed Conical Seal Material
Material Range
Aluminum -420 to 275°F Helium Aluminum (A)
Hydraulic Oil
Hydrogen Peroxide
Hydrozine
Liquid Hydrogen
Liquid Nitrogen
Nitric Acid
Oxygen
Pneumatics
UDMH
Water
Steel -420 to 800°F Helium Copper (C) (NOTE 1)
Hydraulic Oil (Non-Sulphur
Based)
Hydrogen
Nitrogen
Oxygen
Pneumatics
Steel or Titanium -420 to 1500°F Hydraulic Oil Nickel (N)
JP-4
JP-5
Liquid Hydrogen
Liquid Nitrogen
Nitric Acid
Oxygen
Pneumatics
Water
NOTE 1: Copper is not recommended for use in systems that have fluids containing sulphur. The
copper can react adversely with the sulphur and form acid compounds that can be harmful to
the system. Phosphate ester based fluids contain sulphur as an anti-corrosion additive.

(8) Select the correct conical seal dash number for the tubing outside diameter as shown in Table 202.
Table 202. Conical Seal Dash Number
Tubing Outside Diameter (Inches) Conical Seal Dash Number Sample Part Number
1/8 -2
3/16 -3 S2692- (Dash Number) (Material)
1/4 -4
5/16 -5
3/8 -6 S2693- (Dash Number) (Material)
1/2 -8
5/8 -10 S2692-4A: 37 Degrees Flared
3/4 -12 Aluminum Conical Seal for a 1/4 Inch
1 -16 Aluminum Fitting/Tube
1-1/4 -20 S2693-8N: 24 Degrees Flareless
1-1/2 -24 Nickel Conical Seal for a 1/2 Inch
2 -32 Steel or Titanium Fitting/Tube.
C. Install the Conical Seal (Refer to Figure 201).
Figure 201
(1) Loosen the nut on the applicable fitting and remove the tube from the end of the fitting.
(2) Lubricate the threads of the assembly nut, threads of male fitting, and cone surface of male fitting with the correct
lubricant as shown in Table 203.


Oxygen None
Vacuum None
(3) For the S2692 (37 degrees flared) conical seal, install the conical seal on to the flared cone of the male fitting.
(4) For the S2693 (24 degrees flareless) conical seal, install the conical seal on to the sleeve or the fitting end of the tube
but not the male fitting.
(5) Thread the nut onto the mating fitting by hand until it is tight.
(a) If the nut cannot be tightened by hand, disassemble the connection and correct the problem to prevent damage
to the conical seal.
(6) Tighten the nut to the correct torque as shown in Table 204. Refer to Torque Data - Maintenance Practices.
Table 204. Flared and Flareless Fittings with Lubricated Threads Torque Values
Tubing Flared or Flareless Fitting Flared or Flareless Fitting Oxygen Tubing (Inch
Outside with Aluminum Tubing and with Steel or Titanium Tubing Pounds)
Diameter Hose with Aluminum Inserts and Hose with Steel Inserts
(Inches) Torque (Inch Pounds) Torque (Inch Pounds)
Minimum Maximum Minimum Maximum Minimum Maximum
1/8 50 80 75 120 - -
3/16 70 105 95 140 - -
1/4 100 140 135 190 75 90
5/16 130 180 170 240 100 125
3/8 150 195 215 300 200 250
1/2 270 350 470 550 300 400
5/8 360 430 620 745 - -
3/4 460 550 855 1055 - -
1 700 840 1140 1400 - -
1-1/4 850 1020 1520 1825 - -
1-1/2 900 1080 1900 2280 - -
2 1800 2000 2660 2940 - -
NOTE 1: When any component of the fitting (nipple or fitting end) is aluminum, the torque values for
aluminum tubing apply.
(7) After 15 seconds minimum, re-torque the nut again to the correct torque as shown in Table 204. Refer to Torque Data
- Maintenance Practices.
NOTE: Conical seals are subject to cold creep and it is necessary to torque the fitting a second time.
(4) Remove the metal container from below the fitting.

NON-FLARE FITTINGS AND NYLON TUBING - MAINTENANCE PRACTICES

1. General
A. This section gives the maintenance practices for non-flare fittings and nylon tubing. It also gives repairs for nylon tubing.
B. Instant fittings, Poly-Tite fittings, and Poly-Flo fittings let you quickly connect and disconnect the line-to-line and line-to-
component connections in the systems that use nylon tubing. Obey the procedures in this section to make sure of the
correct removal and installation procedures for the nylon tubing and the non-flare fittings.
(1) Instant fittings have a collet that grips to hold the tubing in its place and an O-ring to prevent leaks. Instant fittings
reduce the removal/installation time by eliminating the need for a sleeve and nut necessary in compression style
fittings.
(2) Poly-Tite fittings and Poly-Flo fittings are compression-type fittings. They are equivalents and have a brass body and
nut with a brass or plastic sleeve. The sleeve holds the nylon tubing in its place and resists creeping and stress
caused from compression. The nut turns around the sleeve as it tightens to the body to prevent a twisting and
weakening of the nylon tubing. Poly-Tite fittings and Poly-Flo fittings can be assembled and disassembled
repeatedly.
2. Nylon Tubing Removal/Installation
• Metal Container
• Petrolatum - VV-P-236
• Tube Cutter.
• Sandpaper - 400 Grit
• Tape.
B. Prepare the Airplane for the Nylon Tubing Removal.
(5) Remove access panels as necessary to get access to the applicable nylon tubing. Refer to the applicable
Maintenance Manual.
(6) Put a metal container below the nylon tubing to catch fluid.
C. Remove the Nylon Tubing (Refer to Figure 201 and Figure 202).
(1) Remove the nylon tubing from the instant fitting as follows:
CAUTION: Do not use a sharp edged tool to push the collet to prevent damage to the fitting and the
tubing.
(a) Use your fingers to push and hold the collet towards the instant fitting.
NOTE: As you push the collet in towards the instant fitting, the gripping ridge expands and
releases the nylon tubing.

(b) Remove the nylon tubing from the instant fitting.

(c) Release the collet on the instant fitting.
(2) Remove the nylon tubing from the Poly-Tite fitting or the Poly-Flo fitting as follows:
CAUTION: Do not let the nylon tubing twist while you loosen the nut.
(a) Loosen the nut sufficiently until the nylon tubing becomes free from the sleeve.
(b) Remove the nylon tubing from the Poly-Tite fitting or the Poly-Flo fitting.
D. Install the Nylon Tubing (Refer to Figure 201 and Figure 202).
(1) Install the nylon tubing in the instant fitting as follows:
CAUTION: Do not cut the nylon tubing with a tool that crimps or breaks to cut to prevent damage to the
tubing and an incorrect seal. If new tubing is to be installed or the remaining tubing has
damage, make sure that you cut the tubing straight with a tube cutter.
(a) If necessary, use a tube cutter to cut the nylon tubing at a 90 degree angle to the correct length.
1 Make sure that the tubing cut is square within 15 degrees.
2 Remove all burrs and sharp edges from the end of the nylon tubing.
(b) Make sure that the instant fitting is clean and free of debris.
(c) Use VV-P-236 Petrolatum to lubricate the outside diameter of the tubing from the end to approximately 1.0 inch
(25.40 mm) in length.
(d) Align the nylon tubing end straight with the instant fitting.
(e) Push the nylon tubing into the instant fitting fully.
1 Move the tubing a small distance from side to side while you push it in to make sure that it is fully installed.
NOTE: If the nylon tubing is installed at an angle to the instant fitting, the tubing can stop
before it gets to the tubing stop.
NOTE: If it is not easy to align the nylon tubing to the fitting, wrap a piece of tape around the
tubing to show when it is fully installed in the fitting.
NOTE: If the nylon tubing is not easy to hold or is in a position where a tight hand hold is not
easy, wrap 400 grit sandpaper around the tubing to give a better hand hold.
(f) Make sure that the inspection gap is approximately 0.13 inch, +0.06 or -0.06 inch (3.3 mm, +1.5 or -1.5 mm).
(2) Install the nylon tubing in the Poly-Tite fitting or the Poly-Flo fitting as follows:
(a) If necessary, use a tube cutter to cut the nylon tubing at a 90 degree angle to the correct length.
1 Make sure that the tubing cut is square within 15 degrees.
2 Remove all burrs and sharp edges from the end of the nylon tubing.
(b) Make sure that the Poly-Tite or the Poly-Flo fitting is clean and free of debris.
(c) Push the nylon tubing into the Poly-Tite or the Poly-Flo fitting fully until it is seated in the fitting.
(d) Tighten the nut finger-tight plus one full turn.
3. Non-Flare Fitting Removal/Installation


• Allen Wrench
• Box Wrench
• Antiseize Compound - TT-A-580
• Petrolatum - VV-P-236.
B. Prepare the Airplane for the Non-Flare Fitting Removal.
(5) Remove access panels as necessary to get access to the applicable non-flare fitting. Refer to the applicable
Maintenance Manual.
(6) Put a metal container below the non-flare fitting to catch fluid.
C. Remove the Non-Flare Fitting (Refer to Figure 201 and Figure 202).
(1) Remove the instant fitting as follows:
(a) Remove the nylon tubing from the instant fitting. Refer to Nylon Tubing Removal/Installation in this section.
CAUTION: Do not use pliers to remove an instant fitting to prevent damage to the fitting.
(b) For a straight instant fitting, install the correct size Allen wrench through the tube opening end of the fitting.
1 Turn the Allen wrench counterclockwise to remove the instant fitting from the component or mating fitting.
(c) For an elbow instant fitting, put the correct size open end box wrench on the flat part of the fitting.
1 Turn the box wrench counterclockwise to remove the instant fitting from the component or mating fitting.
(d) Remove the instant fitting from the airplane.
(2) Remove the Poly-Tite fitting or the Poly-Flo fitting as follows:
(a) Remove the nylon tubing from the Poly-Tite fitting or the Poly-Flo fitting. Refer to Nylon Tubing
Removal/Installation in this section.
(b) Put the correct size open end box wrench on the hex part of the fitting.
1 Turn the box wrench counterclockwise to remove the Poly-Tite fitting or the Poly-Flo fitting from the
component or mating fitting.
(c) Remove the Poly-Tite fitting or the Poly-Flo fitting from the airplane.
D. Install the Non-Flare Fitting (Refer to Figure 201 and Figure 202).
(1) Install the instant fitting as follows:
CAUTION: Do not use pliers to install an instant fitting to prevent damage to the fitting.
(a) Lubricate the tapered threads of the instant fitting that are installed in an aluminum boss with VV-P-236
Petrolatum.
(b) Install the instant fitting into the boss with your hand and then remove the fitting.
(c) Apply TT-A-580 antiseize compound to the threads of the instant fitting.
1 If applicable, lubricate the packing with VV-P-236 Petrolatum.

(d) For a straight instant fitting, install the correct size Allen wrench through the tube opening end of the fitting.
1 Turn the Allen wrench clockwise to install the instant fitting in the component or mating fitting.
(e) For an elbow instant fitting, put the correct size open end box wrench on the flat part of the fitting.
1 Turn the box wrench clockwise to install the instant fitting in the component or mating fitting.
(f) Install the nylon tubing in the instant fitting. Refer to Nylon Tubing Removal/Installation in this section.
(2) Install the Poly-Tite fitting or the Poly-Flo fitting as follows:
(a) Lubricate the tapered threads of the Poly-Tite fitting or the Poly-Flo fitting with TT-A-580 antiseize compound.
(b) Loosely thread the Poly-Tite fitting or the Poly-Flo fitting on the component or mating fitting.
(c) Install the nylon tubing in the Poly-Tite fitting or the Poly-Flo fitting. Refer to Nylon Tubing Removal/Installation in
this section.
(4) Remove the metal container from below the non-flare fitting.
4. Nylon Tubing Repair
NOTE: To prevent the removal/installation of the full length of damaged nylon tubing, the repair that follows is
recommended:
• Metal Container
• Tube Cutter.
• Petrolatum - VV-P-236.
B. Prepare the Airplane for the Nylon Tubing Repair.
(5) Remove access panels as necessary to get access to the applicable nylon tubing. Refer to the applicable
Maintenance Manual.
(6) Put a metal container below the nylon tubing to catch fluid.
C. Repair the Nylon Tubing (Refer to Figure 201).
NOTE: Nylon tubing that is damaged near the fittings can be cut and connected to the fitting when a

sufficient length of tubing is available without tension.

(1) Use a tube cutter to cut the damaged section at a 90 degree angle out of the nylon tubing.
(a) Make sure that the tubing cut is square within 15 degrees.
(b) Remove all burrs and sharp edges from the end of the nylon tubing.
CAUTION: Make sure that the nylon tubing does not have tension after the repairs to prevent damage and
leaks.
(2) Use two union fittings and cut a new section of nylon tubing to the correct length to make the repair.
(a) Make sure that the union fittings and the nylon tubing are clean and free of debris.
(b) Use VV-P-236 Petrolatum to lubricate the outside diameter of the nylon tubing from the end to approximately 1.0
inch (25.40 mm) in length.
(c) Connect the union fitting, new nylon tubing, and union fitting together.
(d) Connect the new nylon tubing assembly in place of the damaged section with the union fittings.
(e) Make sure that the inspection gap is approximately 0.13 inch, +0.06 or -0.06 inch (3.3 mm, +1.5 or -1.5 mm).
(4) Remove the metal container from below the nylon tubing.

Figure 201 : Sheet 1 : Instant Fitting Installation

A99353
0.80 Inch 1.00 Inch
Tape (20.3 mm) Tape (25.4 mm)
Radius with
Instant Instant No Burrs
Fitting Fitting
Inspection Gap 0.13 Inch, Inspection Gap 0.13 Inch,

+0.06 or −0.06 Inch +0.06 or −0.06 Inch
(3.3 mm, +1.5 or −1.5 mm) (3.3 mm, +1.5 or −1.5 mm)
1/4 Inch Diameter Tube 3/8 Inch Diameter Tube
Nylon
Tubing
Collet
Instant
Fitting
Locking
Slope
Gripping
Ridge
O−Ring
Tubing
Stop
Incorrect Incorrect Correct
6598T1006
Instant Fitting Tubing Connection 6598T1005

Figure 202 : Sheet 1 : Poly-Tite and Poly-Flo Fitting Installation

A99352
Body Nut
Sleeve Nylon Tubing
Body Nut
Sleeve
Nylon Tubing
Poly−Flo Fitting
Body Nut
Sleeve
Nylon Tubing
Poly−Tite Fitting
6598T1008
6598T1009

PACKING AND BACKUP RING - MAINTENANCE PRACTICES

1. General
A. This section gives the maintenance practices for packings and backup rings.
B. Packings and backup rings are installed on components that have close tolerance surface finishes. In critical surface finish
areas, scratches, abrasions, and surface deformities can cause unsatisfactory seals that result in functional failure and
leaks.
C. When packings are removed with a removal tool, try not to touch the grooves or adjacent areas.
D. When lines are disconnected to repair a fitting that leaks or to bleed a line, use a metal container to catch and hold fluid.
E. If fluid spills or leaks on any surface, immediately wipe the surface with a clean, dry cloth.
2. Packing Installation
• None.
• Lint-Free Cloth.
• Torque Data - Maintenance Practices.
B. Packing Installation Precautions
CAUTION: A clean work area is necessary when you install packings. Contamination by foreign matter,
materials, or chemicals will cause damage to systems and parts and can cause complete system
failure. To avoid failures, obey the rules that follow when you install packings.
(2) Fully clean the work area before you do the work.
(3) Make sure the parts and the components are clean before you install the packings.
(4) Fully clean your hands and tools.
(5) Use clean lint-free cloths to put packings on during buildup.
(6) Avoid contamination of fluids and lubricants when parts are cleaned and touched.
C. Install the Packing (Refer to Figure 201).

A99849
Packing
Backup Ring
5598T1006
Figure 201
(1) Carefully examine the grooves on the component where the packing will be installed for burrs, scratches, or other
defects.
NOTE: Small scratches can cause high leakage in high-pressure systems.
(2) Make sure that the packing material is compatible for the system where it is used. Refer to Table 201.
Table 201. Packings
Specification Number Packing Description Identification
MS9388 Preformed O-ring fabricated from MIL-R-83248 Color coding for identification
Class 1 75 Durometer Fluorocarbon Rubber. purposes are prohibited unless
This O-ring is high-temperature and fluid otherwise specified.
resistant. It is used for aircraft lubricating oils and
hydraulic fluids at temperatures above 500°F
(260°C).
MS28775 Preformed hydraulic O-ring fabricated from MIL- All identification data is on the
P-25732 70 Durometer Nitrile Rubber. This O- package. It looses its identity when it
ring is used with hydrocarbon hydraulic fluid from is removed from the package.
temperatures of -65°F to 275°F (-54°C to
135°C).
MS29512 Preformed boss O-ring fabricated from MIL-P- All identification data is on the
5315B 70 Durometer Nitrile Rubber. This O-ring package. It looses its identity when it
is hydrocarbon and fuel resistant. It is used for is removed from the package.
aircraft fuel systems with jet engines from
temperatures of -65°F to 200°F (-54°C to 93°C).
MS29513 Preformed O-ring fabricated from MIL-P-5315B All identification data is on the
70 Durometer Nitrile Rubber. This O-ring is package. It looses its identity when it
hydrocarbon and fuel resistant. It is used for is removed from the package.
aircraft fuel systems with jet engines from
temperatures of -65°F to 200°F (-54°C to 93°C).

MS29561 Preformed O-ring fabricated from MIL-R-7362 Temporary markings of O-rings for
70 Durometer Nitrile Rubber. This O-ring is the manufacturer's identification is
synthetic lubricant resistant. It is used for MIL-L- permitted at the time that it is made.
7808 fluids from temperatures of -65°F to 257°F
(-54°C to 125°C).
NAS617 Preformed straight thread tube fitting boss O-ring Temporary markings of O-rings for
fabricated from MIL-R-7362 Type 1 70 the manufacturer's identification is
Durometer Nitrile Rubber. This O-ring is synthetic permitted at the time that it is made.
lubricant resistant. It is used for MIL-L-7808 fluids
from temperatures of -65°F to 257°F (-54°C to
125°C).
(3) Examine each packing to make sure that it is not unserviceable.
(4) Make sure that the packing is formed correctly and free of blemishes, abrasions, mold flash, mismatch, cuts, or
punctures.
(5) Lubricate the packing with the correct lubricant as shown in Table 202.
Oxygen None
Vacuum None
CAUTION: Do not use hardened steel, pointed, or sharp edged tools to install a packing to prevent damage.
CAUTION: Do not stretch the packing more than necessary to install it to prevent damage.
(6) Use your fingers or a tool to install the packing in the groove on the applicable component.
NOTE: Tools made of soft metals such as brass or aluminum are recommended. Examine tools often
to make sure that their surfaces are well rounded, polished, and free of burrs.
(a) Make sure that you did not damage the packing during installation.
(7) Install the component and torque the fitting if necessary as shown in Table 203. Refer to Torque Data - Maintenance
Practices.
Table 203. Jam Nuts and Fittings with Packings Torque (Inch Pounds)
Tube Outside Jam Nuts and Fittings for Boss Jam Nuts Used with Bulkhead Fittings
Diameter (Inches) Installations
Minimum Maximum Minimum Maximum
3/16 28 32 28 32
1/4 38 42 38 42
5/16 58 63 58 63
3/8 70 80 70 80

1/2 145 155 145 155

5/8 190 210 190 210
3/4 285 315 190 210
1 475 525 190 210
1-1/4 570 630 190 210
1-1/2 570 630 190 210
2 570 630 190 210
3. Backup Ring Installation
• None.
• Lint-Free Cloth.
B. Backup Ring Installation Precautions
CAUTION: A clean work area is necessary when you install backup rings. Contamination by foreign matter,
materials, or chemicals will cause damage to systems and parts and can cause complete system
failure. To avoid failures, obey the rules that follow when you install backup rings.
(2) Fully clean the work area before you do the work.
(3) Make sure the parts and the components are clean before you install the backup rings.
(4) Fully clean your hands and tools.
(5) Use clean lint-free cloths to put backup rings on during buildup.
(6) Avoid contamination of fluids and lubricants when parts are cleaned and touched.
C. Install the Backup Ring (Refer to Figure 201).
NOTE: In some installations, backup rings are used to hold packings in their position. They prevent
deformation and bypass leakage. Backup rings are used most often in high-pressure systems, but
are frequently used in low-pressure systems to extend packing service life.
(1) Carefully examine the grooves on the component where the backup ring will be installed for burrs, scratches, or other
defects.
NOTE: Small scratches can cause high leakage in high-pressure systems.
CAUTION: Do not use backup rings that have damage to prevent leaks.
(2) Examine each backup ring to make sure that it is not unserviceable.
(3) Make sure that the backup ring is formed correctly and free of blemishes, abrasions, mismatch, cuts, or punctures.
(4) Lubricate the backup ring with the correct lubricant as shown in Table 202.
CAUTION: Do not use hardened steel, pointed, or sharp edged tools to install a backup ring to prevent
damage.
CAUTION: Do not stretch the backup ring more than necessary to install it to prevent damage.
(5) Use your fingers or a tool to install the backup ring in the groove on the applicable component.
NOTE: Tools made of soft metals such as brass or aluminum are recommended. Examine tools often

to make sure that their surfaces are well rounded, polished, and free of burrs.
(a) For installation around a piston, install with a clockwise direction or spiral and scarfed ends staggered.
(b) When a single backup ring is used, make sure that it is on the correct side of the packing, usually on the low side
of the groove.
(c) Make sure that you did not damage the backup ring during installation.
(6) Install the component and torque the fitting if necessary as shown in Table 203. Refer to Torque Data - Maintenance
Practices.
4. Packing and Backup Ring Storage
A. Keep the packings and backup rings in their initial heat-sealed envelopes in a cool, dry place until ready for use.
NOTE: The envelopes give preservation, protection, identification, and a cure date.
B. When packings and backup rings are stored or touched, do not let the following things occur:
• Parts stacked incorrectly
• Force against corners and edges of storage containers that cause creases
• Storage under heavy parts that cause compression and become flat
• Punctures caused by staples used to attach identification tags
• Deformation and contamination caused by hanging packings and backup rings from nails or pegs
• Contamination caused by adhesive tape put directly on packings and backup rings.
5. Lock-O-Seal
A. The Lock-O-Seal is a two-piece combination seal that includes a separately molded rubber seal fitted within a surrounding
metal retainer.
NOTE: The 250 Series Lock-O-Seal is designed for sealing straight tube fittings and bosses and NAS
banjo style fittings and bosses.
NOTE: The 800 Series Lock-O-Seal is designed for sealing under the head of a fastener.
(1) The rubber seal is installed on the fitting/component to be installed.
(2) A metal retainer is then installed around the rubber seal.
(3) As the fitting/component is tightened, the rubber seal is compressed and extruded within the metal retainer which
forms a seal.
(4) Lock-O-Seals are available in different seal compounds and retainer materials which lets them be used in many
different fluid systems. Refer to the Parker Hannifin Corporation, Composite Sealing Systems Division for the
different materials and uses.

20-10-40-2 (Rev 1)
BLEED AIR COUPLINGS - MAINTENANCE PRACTICES

1. Effectivity
• Model 500
• Model S550
• Model 650.
2. General
A. This section gives the maintenance practices for bleed air couplings. The bleed air couplings include the clamp-type
couplings and the V-type couplings.
B. Clamp-type couplings are used to connect two tubes together or a tube to a component. Clamp-type couplings have a
collar, two seal assemblies, and retainer. Ferrules on the two bleed air tubes are necessary for clamp-type couplings. The
retainer has bonding wires and is attached by a double-locking latch.
C. V-type couplings are used to connect two flanges of bleed air components and tubes together. The two V-type couplings
are the V-band coupling and the V-retainer coupling:
(1) V-band couplings that use a metal gasket or rubber O-ring between the two flanges to make a seal. These V-band
couplings have a T-bolt, nut, trunnion, retainer, strap, and metal gasket or O-ring. The retainer holds the two flanges
together with the T-bolt and nut (Refer to the airplane model Illustrated Parts Catalog for the applicable part number).
(2) V-band (J13 type) couplings do not use a gasket between the flanges. These V-band couplings have a T-bolt, nut,
trunnion, retainer, and strap. The retainer holds the two flanges together with the T-bolt and nut (Refer to the airplane
model Illustrated Parts Catalog for the applicable part number).
NOTE: There are some installations that use a Grafoil type seal. (Refer to the airplane model Illustrated
Parts Catalog for the applicable part number).
(3) V-retainer couplings use an E-seal between the two flanges. These V-retainer couplings have a T-bolt, nut, saddle
washer, top retainer, bottom retainer, and E-seal. The top and bottom retainers hold the two flanges together with the
T-bolt and nut (Refer to the airplane model Illustrated Parts Catalog for the applicable part number).
D. This section also gives a bleed air coupling leak check for the two types of couplings.
3. Clamp-Type Coupling Removal/Installation
NOTE: This procedure includes the clamp-type coupling.
• Protective Caps.
• None.
B. Prepare the Airplane for the Clamp-Type Coupling Removal.
WARNING: Do not touch the bleed air system components until you know that they are cool. The bleed air
system operates at high temperatures that can cause burn injuries to personnel.

20-10-40-2 (Rev 1)
(4) Remove access panels as necessary to get access to the applicable clamp-type coupling. Refer to the applicable
Maintenance Manual.
C. Remove the Clamp-Type Coupling (Refer to Figure 201).
(1) Lift the double-locking latches to disengage them from the clamp-type coupling.
(2) Open the clamp-type coupling halves to disconnect them from the bleed air tubes.
(3) Remove the clamp-type coupling from the bleed air tubes.
(4) Remove the collar from the ferrules on the bleed air tubes.
(a) If necessary, disconnect the opposite end of one of the bleed air tubes to give sufficient area to remove the
collar.
(5) Remove and discard the seal assemblies from the ferrules of the bleed air tubes.
(6) Install protective caps on the open bleed air tubes to prevent contamination.
D. Install the Clamp-Type Coupling (Refer to Figure 201).
(1) Remove the protective caps from the bleed air tubes.
(2) Make sure that the ferrules of the bleed air tubes are clean and free of dirt, debris, burrs, and rough edges.
(3) Install new seal assemblies on the ferrules of the bleed air tubes.
(a) Make sure that you install the seal assemblies so that the seal channels point in toward each other.
(4) Install the collar over one ferrule and then over the other ferrule until it is centered.
(5) Move the mating surfaces of the ferrules together toward the collar.
(a) If necessary, connect the opposite end of the bleed air tube.
(6) Open the clamp-type coupling and put it in its position on the bleed air tubes.
(7) Close the clamp-type coupling halves until the double-locking latches click to connect them to the bleed air tubes.
(8) Lift the clamp-type coupling halves to make sure that the double-locking latch is engaged correctly.
(2) Do the Bleed Air Coupling Leak Check in this section to make sure that there are no bleed air leaks.
4. V-Type Coupling Removal/Installation
NOTE: This procedure includes the V-band coupling with metal gasket, J13 type V-band coupling without
metal gasket, and V-retainer coupling.
• Protective Caps
• Soft Mallet.
• Sandpaper - 320 to 600 Grit.

20-10-40-2 (Rev 1)
B. Prepare the Airplane for the V-Type Coupling Removal.

(4) Remove access panels as necessary to get access to the applicable V-type coupling. Refer to the applicable
Maintenance Manual.
C. Remove the V-Type Coupling (Refer to Figure 202).
(1) Remove and discard the nut from the T-bolt that attaches the V-type coupling to the bleed air tubes.
(2) Open the V-type coupling halves to disconnect them from the flanges on the bleed air tubes.
(3) Remove the V-type coupling from the flanges on the bleed air tubes.
(4) For the V-band coupling that uses a metal gasket, remove and discard the metal gasket from between the flanges of
the bleed air tubes.
(5) For the V-retainer coupling, remove and discard the E-seal from between the flanges of the bleed air tubes.
(6) Install protective caps on the open bleed air tubes to prevent contamination.
D. Install the V-Type Coupling (Refer to Figure 202).
CAUTION: Do not install Grafoil gaskets in installations that use metal gaskets or E-seals.
(1) Remove the protective caps from the bleed air tubes.
(2) Make sure that the flanges of the bleed air tubes are clean and free of dirt, debris, burrs, and rough edges.
CAUTION: Be careful when you do work on an open bleed air system to prevent contamination.
(a) If necessary, use 320 to 600 grit sandpaper to remove burrs or rough areas from the flanges.
1 Use 600 grit sandpaper to finish polish the flanges.
CAUTION: Do not use the V-type couplings to align and pull the flanges together. This can cause damage to
the couplings and the flanges and increase the chance of leakage.
(3) Put the two flanges of the bleed air tubes together.
(4) For the V-band coupling that uses a metal gasket, install a new metal gasket between the flanges of the bleed air
tubes.
(5) For the V-retainer coupling, install a new E-seal between the flanges of the bleed air tubes.
(6) For J13 type clamps, it is permissible to use Grafoil gasket.
NOTE: If using a Grafoil gasket (adhesive backed) with the V-retainer coupling, install one to the
mounting surface on one side of the coupling only.
(7) Use the correct part number Grafoil gasket for a specific size V-type coupling as follows:
(a) For 1.00 inch (25.4mm) couplings use part number A4252P.
(b) For 1.50 inch (37.6mm) couplings use part number A2049.
(c) For 2.00 inch (50.8mm) couplings use part number A5437.
(d) For 2.50 inch (63.0mm) couplings use part number A3501.
NOTE: These seals may be obtained from Citation Parts Distribution.
CAUTION: Do not open V-band couplings too much. This can cause damage or kinks to the strap.
(8) Open the V-type coupling and put it in its position on the two flanges for the bleed air tubes.
CAUTION: Do not use high-speed power wrenches to install the nuts. This will prevent damage.
(9) Install a new nut on the T-bolt that attaches the V-type coupling to the bleed air tubes.
(10) Use a soft mallet to tap around the circumference of the V-type coupling to make sure that it is seated correctly.

20-10-40-2 (Rev 1)
CAUTION: Do not torque the V-type couplings too much. Too much torque can twist the flanges and increase
leakage.
(11) Tighten the nut to the correct torque value as shown on the V-type coupling. Refer to Torque Data - Maintenance
Practices.
(2) Do the Bleed Air Coupling Leak Check in this section to make sure that there are no bleed air leaks.
5. Bleed Air Coupling Leak Check
NOTE: This procedure is done after maintenance of bleed air couplings to make sure that there is no leakage.
• None.
• Wooden Dowel Rod - 0.25 Inch (6.35 mm) Diameter, 24.0 Inches (0.609 m) Long
• Yarn - 6.0 Inches (152.4 mm) Long.
• Approved Airplane Flight Manual.
B. Prepare the Airplane for the Bleed Air Coupling Leak Check.
(2) Attach a piece of yarn, approximately 6.0 inches (152.4 mm) long, to the end of a 0.25 inch (6.35 mm) diameter
wooden dowel rod that is approximately 24.0 inches (0.609 m) long.
(3) Remove access panels as necessary to get access to the applicable bleed air coupling. Refer to the applicable
Maintenance Manual.
(4) Move the airplane to an approved engine run area. Refer to the applicable Maintenance Manual.
(5) Start the engines. Refer to the applicable Approved Airplane Flight Manual.
C. Do the Bleed Air Coupling Leak Check.
(1) Operate the applicable system as necessary to make sure that the applicable bleed air coupling is pressurized with
bleed air.
WARNING: Do not use your hand to examine for leaks to prevent burns. Bleed air is very hot and dangerous.
(2) Use the wooden dowel rod to move the yarn around the bleed air coupling.
(a) Look for movement of the yarn that shows signs of a bleed air leak.
(3) Examine all of the applicable bleed air couplings with this procedure.
(a) If necessary, make a record of bleed air leaks.
(4) Stop the engines. Refer to the applicable Approved Airplane Flight Manual.

20-10-40-2 (Rev 1)
(5) If you find leaks at the clamp-type couplings, make sure that the clamp is serviceable and tightened to the correct
torque value.
(a) Make sure that the coupling is serviceable and there are no rough surfaces or burrs.
(b) Make sure that the retainer, collar, and seal assemblies are serviceable.
(6) If you found leaks at the V-type couplings, examine the nut to make sure that it is serviceable and tightened to the
correct torque value.
(a) If the nut is serviceable and the torque value is correct, do the steps that follow:
1 Remove the V-type coupling. Refer to V-Type Coupling Removal/Installation in this section.
2 Examine the metal gasket, Grafoil gasket (If installed) or the E-seal for burrs and rough surfaces.
a Replace the metal gasket or the E-seal as necessary.
b If the coupling is a V-band (J13 type) that does not already have a Grafoil gasket installed between the
flanges, it is permissible to install one on one flange face only. Refer to the correct part number Grafoil
gasket for a specific size V-type coupling.
3 Examine the flanges for burrs and rough surfaces.
a If necessary, use 320 to 600 grit sandpaper to remove burrs or rough areas from the flanges.
b Use 600 grit sandpaper to finish polish the flanges.
4 Install the V-type coupling. Refer to V-Type Coupling Removal/Installation in this section.
(7) Do the Bleed Air Coupling Leak Check in this section again.
6. Bleed Air Tube Protection
NOTE: Insulation, tape, sleeve material, shields, shrouds, and covers are used to give protection to personnel
and to the bleed air tubes, components, and adjacent airplane structure.
A. Remove the Bleed Air Tube Protection (Refer to Figure 203).
NOTE: The removal of the bleed air tube protection (insulation, insulation tape, aluminum tape, sleeve
material, shields, shrouds, and covers) is typical, as applicable to the different bleed air tube
assemblies.
(1) Before you remove a bleed air component, record the position and the type of bleed air tube protection that is
installed.
(a) Discard all insulation, insulation tape, aluminum tape, and sleeve material, that is unserviceable.
B. Install the Bleed Air Tube Protection (Refer to Figure 203).
NOTE: The installation of the bleed air tube protection (insulation, insulation tape, aluminum tape, sleeve
material, shields, shrouds, and covers) is typical, as applicable to the different bleed air tube
assemblies.
(1) Before you install the bleed air tube protection, do the Bleed Air Coupling Leak Check. Refer to Bleed Air Coupling
Leak Check in this document.
(2) Install insulation with Class IXA corrosion inhibiting compound. Refer to Chapter 51, Corrosion Inhibitor Compounds
(CIC) - Maintenance Practices.
(a) Install a continuous (where possible) section of aluminum tape to seal the overlap seam.
(b) Wind aluminum tape on the tube ends with a 1 inch (25.4 mm) overlap on the tube and a 1 inch (25.4 mm)
overlap on the end of the insulation.
(3) When you install insulation to cover a clamp, make a hole to let the clamp bolt go through.
(a) Apply a fillet seal (Type V) around the bolt. Refer to Chapter 20, Fuel, Weather, Pressure, and High-
Temperature Sealing - Maintenance Practices.

20-10-40-2 (Rev 1)
(b) Do not put sealant on the bleed air tube.

(4) Wind insulation tape around the bleed air tube with an overlap to seal the tape.
(a) Start the insulation tape 0.25 inch, +0.10 or -0.10 inch (6.35 mm, +2.54 or -2.54 mm) from the edge of bellows or
flanges.
(5) Wind aluminum tape around the bleed air tube one time before you install sleeve material.
(6) Wind sleeve material with a minimum 0.4 inch (10.16 mm) overlap.
(7) Install shields and shrouds in a position to prevent heat damage to the couplings, clamps, hydraulic lines, control
cables, adjacent components, and airplane structure.
(8) Wind aluminum tape around shrouds and covers with an overlap to seal the tape.

20-10-40-2 (Rev 1)
Figure 201 : Sheet 1 : Clamp-Type Coupling Installation

A99482
B
Retainer
Bonding Wires A
B Bleed Air Tube
Seal Assembly
Collar
Seal Assembly
Ferrule
Bleed Air Tube Clamp-Type Coupling
Seal Assembly
Double Locking Latch
Bleed Air Tube Bleed Air Tube Seal Channel

Ferrule Ferrule VIEWB-B
Retainer
VIEWA-A
6714T1034
AA6714T1034
BB6714T1034

20-10-40-2 (Rev 1)
Figure 202 : Sheet 1 : V-Type Coupling Installation

A99483
NOTE: If using a Grafoil gasket (adhesive backed)
with the V-Band coupling, install one to the
mounting surface on one side of the coupling only.
Flange
Trunnion
Nut
Retainer Bleed Air Tube
Flange
T-Bolt Metal Gasket Installation -

Grafoil Gasket (J13 Type)
Strap
Bleed Air Tube

V-Band Coupling
Flange
Saddle Washer
Nut
Bottom Retainer
Bleed Air Tube
Flange
E-Seal
T-Bolt
Top Retainer
Bleed Air Tube V-Retainer Coupling 6714T1034

7114T1158

20-10-40-2 (Rev 1)
Figure 203 : Sheet 1 : Bleed Air Tube Protection

A98334
B
A
C
DETAILA
Clamp
Insulation
0.25 Inch, +0.10 or −0.10 Inch

Sleeve (6.35mm, +2.54mm or −2.54mm)
Bleed Air Tube
Insulation
Insulation Tape
Clamp Bolt Bellows
Coupling Shield
Flange
DETAILE
Typical
DETAILB
Typical
Insulation
E
Cover
Sleeve
DETAILD
DETAILC
7410T1002
Typical A−B7454100−1
C−E7414440−1

SAFETYING - MAINTENANCE PRACTICES

1. General
A. This section gives the maintenance practices for safetying. Safetying includes safety wiring, cotter pin safetying, turnbuckle
safetying, lock washer, self-locking nut, and safety cable.
2. Safety Wiring
• Safety Wire Pliers.
• None.
• None.
B. Description
(1) Safety wire is used to prevent the relative movement of structural, electrical, or other critical components subjected to
vibration, tension, or torque.
(2) The basic safety equipment operation is something other than the failure or fracture of safety fastening. Safety
fastening can be used to secure equipment when the system is not in use but still permit the emergency operation of
the devices.
C. Safety Wire Material
(1) All safety wire material must obey the requirements of MS20995 as shown in Table 201.
Table 201. Safety Wire Material
Material Nominal Wire Diameter and Part Number (MS20995-XXX)
0.015 0.020 0.031 0.032 0.040 0.041 0.047 0.051 0.091
Nickel- NC20 NC32 NC40 NC51 NC91
Copper
Alloy
(Monel)
Nickel- N20 N32 N40 N51 N91
Chronium-
Iron Alloy
(Inconel)
Carbon F20 F32 F41 F47 F91
Steel Zinc-
Coated
Corrosion C15 C20 C32 C41 C47 C91
Resistant
Steel
Aluminum AB20 AB32 AB41 AB47 AB91
Alloy
(Blue)
Copper CY15 CY20
(Yellow)
NOTE 1: The dash numbers show the wire material and the diameter in thousandths of an inch.
NOTE 2: Monel wire (uncoated) is used for general lockwire at temperatures up to 700°F (371°C).

NOTE 3: Inconel wire (uncoated) is used for general lockwire at temperatures up to 1500°F (815°C).
NOTE 4: Copper wire is used for shear or sealing wire. Shear applications are those which purposely
break or shear the wire to permit operation or actuation of emergency devices. Seal
applications use a lead seal to prevent tampering.
NOTE 5: Aluminum alloy is used for lockwire with magnesium.
NOTE 6: Cadmium plated copper is not to be used in space applications.
(a) Example Part Numbers:
• MS20995-CY20 - Copper, Cadmium Plated, Yellow, Shear or Seal Wire, 0.020 inch diameter
• MS20995-AB32 - Aluminum Alloy, Anodized, Blue, 0.032 inch diameter.
(b) Nickel-copper alloy (Monel) safety wire can be substituted for carbon steel zinc-coated and corrosion-resistant
steel of the same diameter and length.
D. Safety Wire (Lockwire) Installation
(1) Parts must be safetied so that the lockwire is put in tension when the part tends to loosen. It must always be installed
and twisted so that the loop around the head stays down and does not tend to come up over the bolt head and leave
a slack loop. Castellated nuts with the slot close to the top of the nut can have a more secure wire if it passes along
the side of the stud. Lockwires must be tight but not overstressed.
(2) A pigtail of 0.25 to 0.50 inch (6.35 to 12.7 mm) long and three to five twists must be made at the end of the lockwire. It
must be bent back or under to prevent it from becoming a snag.
(3) New safety wire (lockwire) must be used for each application.
E. Safety Castellated Nut
(1) Tighten the castellated nut to the minimum specified torque range unless otherwise specified and, if necessary,
continue to tighten until a slot aligns with the hole. Do not tighten the castellated nut more than the maximum specified
torque range.
(2) Castellated nuts with cotter pins or lockwire are preferred on bolts or studs with drilled shanks. Self-locking nuts are
also permitted.
F. Blind Tapped Hole Application
(1) In blind tapped hole applications of bolts or castellated nuts on studs, install the lockwire as given in this section.
G. Hollow Head Bolt
(1) Hollow head bolts must be safetied in the same way as regular bolts.
H. Drilled Head Bolt
(1) Drilled head bolts and screws do not need lockwired if installed in self-locking nuts or lock washers that are installed
as given in this section.
I. Drain Plug
(1) Drain plugs and cocks can be safetied to a bolt, nut, or other part that has a free lock hole as given in this section.
J. Snap Ring
(1) External snap rings can be safetied as given in this section.
K. Electrical Connector Safety Wiring (Refer to Figure 201)
(1) The lockwire diameter of 0.020 inch must be used when lockwiring together the individual parts of electrical
connectors that have threaded coupling rings or plugs with screws or rings.
(2) Safety all electrical connectors independently. Do not safety one electrical connector to another.
L. Large Assemblies
(1) Large assemblies, such as hydraulic cylinder heads for which lockwire is necessary but not specified, must be
safetied as given in this section.
M. Wire Size
(1) Use 0.032 inch minimum diameter lockwire for general purpose use.
(2) Use 0.020 inch diameter lockwire as follows:
• Parts that have a nominal hole diameter of less than 0.045 inch

• Parts that have a nominal hole diameter between 0.045 and 0.062 inch with a space between the parts of less
than 2.0 inches
• Closely-spaced screws and bolts 0.25 inch diameter or less.
N. Single Wire Method (Refer to Figure 202)
(1) Single wire method of locking must use the largest nominal size lockwire that will fit the hole.
(2) The single wire method of safety wiring can be used in a closely-spaced, closed geometrical pattern, on parts in
electrical systems and in areas that would make the single wire method more advisable. Closely-spaced is defined
as a maximum of 2 inches (50.8 mm) between centers.
(3) The single wire method must be used for shear and seal wiring but the lockwire must be installed so that it can be
easily broken in case of an emergency.
O. Double Twist Method (Refer to Figure 202)
(1) Use the double twist method for widely-spaced multiple groups.
(2) Use the double twist method for multiple fasteners that are 4.0 to 6.0 inches (101.6 to 152.4 mm) apart, with a
maximum of three fasteners in a series.
(3) Use the double twist method on screws in closely-spaced geometric patterns which secure hydraulic or air seals,
hydraulic pressure, or are used in critical areas of clutch mechanisms and superchargers.
(4) With multiple fasteners more than 6.0 inches (152.4 mm) apart, use the multiple fasteners application only if the tie
points are given on adjacent parts to shorten the span of the lockwire to less than 6.0 inches (152.4 mm).
(5) With closely-spaced multiple fasteners, the maximum number of fasteners that can be safety wired together shall be
the number of fasteners that can be wired with a 24.0 inch (0.61 m) length of lockwire. The length is the original
single-strand length before any twisting.
(6) One end of the lockwire must be installed through one set of lockwire holes in the bolt head. The other end of the
lockwire must be looped firmly around the head to the next set of lockwire holes in the same unit and installed through
this set of lockwire holes. The other end can go over the head when the clearances around the head are obstructed
by adjacent parts.
(7) The strands, while tight, must be twisted until the twisted part is just short of the nearest lockwire hole in the next unit.
The twisted part must be within 0.125 inch (3.2 mm) of the holes in each unit. The actual number of twists will depend
on the wire diameter, with smaller diameters being able to have more twists than larger diameters. The twisting must
keep the wire tight without overstressing or allowing it to become nicked, kinked, or damaged. Abrasions from
commercially available safety wire twist pliers are permitted.
(8) The lockwire must be twisted to form a pigtail of 3 to 5 twists after wiring the last unit. The excess wire must be cut off.
The pigtail must be bent toward the part to prevent it from becoming a snag.
(9) Safety wiring multiple groups by the double twist, double hole method must be the same as the double twist, single
hole method, except the twist direction between subsequent fasteners can be clockwise or counterclockwise.
P. Peri-Seal Connector Assembly (Refer to Figure 203)
(1) Peri-seal connector assemblies must be safetied to the end fitting flange with one of the three different methods that
follow:
(a) The tangential slot-type, single safety wire hole method is the preferred method for one safety wire hole. Use
0.025 inch diameter corrosion-resistant steel safety wire minimum for this method. The direction of safety wire
twist is optional.
(b) The tangential slot-type alternate safety attachment method is an alternate method to the single safety wire hole
method. Use an MS27039-0804 screw and an MS21042-08 nut for this method.
(c) The radial slot-type, double safety wire hole method is the method used for two safety wire holes. Use 0.020 inch
diameter corrosion resistant steel safety wire minimum for this method. The direction of safety wire twist is
optional.
3. Cotter Pin Safetying

• None.
• None.
• None.
B. Description
(1) Cotter pins are used to prevent the relative movement of components subjected to vibration, tension, or torque.
C. Cotter Pin Material
(1) All cotter pin material must obey the requirements of MS24665.
(2) All cotter pin material must obey the temperature and service restrictions shown in Table 202.
Table 202. Temperature and Service Restrictions
Material Temperature Service
Carbon Steel Ambient Temperatures up to 450°F Normal atmospheres
(232°C) Cotter pins that touch cadmium plated
bolts or nuts
Corrosion Resistant Steel Ambient Temperatures up to 800°F Corrosive atmospheres
(427°C) Cotter pins that touch corrosion
resistant steel bolts or nuts
Nonmagnetic requirements
D. Cotter Pin Dimensions
(1) The cotter pin minimum and maximum length must obey the requirements as shown in Figure 204.
(a) For cotter pins up to 1.0 inch long, the length tolerance must be within 0.03 inch.
(b) For cotter pins longer than 1.0 inch, the length tolerance must be within 0.06 inch.
(2) The largest nominal diameter cotter pin, which the hole and the slots will accept, must be used. In no application to a
nut, bolt, or screw must the pin size be less than these sizes. Refer to Figure 205 and Table 203 and the related table
that follows:
• Refer to Table 204 for Brass Cotter Pin Dash Numbers.
• Refer to Table 205 for Steel Phosphate Coated Cotter Pin Dash Numbers.
• Refer to Table 206 for Steel Cadmium Plated Cotter Pin Dash Numbers.
• Refer to Table 207 for Corrosion Resistant Steel Cotter Pin Dash Numbers.
• Refer to Table 208 for Nickel Copper Alloy Cotter Pin Dash Numbers.
A99536
Hammer Lock Cotter Pin Plain Cotter Pin
L C L D C
B B A
A
0.015 Inch 0.015 Inch Point of Contact

Point of Contact Maximum with Hole
Maximum with Hole CSAM016
Figure 205
Table 203. Cotter Pin Diameters (Inch)
Diameter A B C D Hole Size
Maximum Minimum Minimum Maximum Minimum Minimum Recommended
0.031 0.032 0.028 0.06 0.032 0.022 0.01 0.047

0.047 0.048 0.044 0.09 0.048 0.035 0.02 0.062

0.062 0.060 0.056 0.12 0.060 0.044 0.03 0.078
0.094 0.090 0.066 0.19 0.090 0.069 0.04 0.109
0.125 0.120 0.116 0.25 0.120 0.095 0.06 0.141
0.156 0.150 0.146 0.31 0.150 0.116 0.07 0.172
0.188 0.176 0.172 0.38 0.179 0.137 0.09 0.203
0.250 0.225 0.220 0.50 0.225 0.176 0.11 0.266
Table 204. Brass Cotter Pin Dash Numbers
Nominal Diameter (Inch)
Length (L) 0.03 0.047 0.063 0.094 0.125 0.156 0.188 0.25
(Inch)
0.25 -35
0.50 -39 -103 -170 -315 -383
0.75 -41 -105 -172 -317 -385 -454 -526
1.00 -43 -107 -174 -319 -387 -455 -527 -651
1.25 -44 -108 -176 -321 -389 -457 -529 -652
1.50 -45 -109 -178 -323 -391 -459 -531 -653
1.75 -46 -110 -180 -325 -393 -461 -533 -654
2.00 -47 -111 -181 -336 -394 -462 -534 -655
Table 205. Steel Phosphate Coated Cotter Pin Dash Numbers
Length (L) 0.03 0.047 0.063 0.094 0.125 0.156 0.188 0.25
(Inch)
0.50 -814
0.75 -816 -830
1.25 -834
Table 206. Steel Cadmium Plated Cotter Pin Dash Numbers
Length (L) 0.03 0.047 0.063 0.094 0.125 0.156 0.188 0.25
(Inch)
0.25 -1 -65
0.50 -5 -69 -132 -281 -349
0.75 -7 -71 -134 -284 -351 -418 -490
1.00 -9 -73 -136 -285 -353 -419 -491 -621
1.25 -10 -74 -138 -288 -355 -421 -493 -622
1.50 -11 -75 -140 -289 -357 -423 -495 -623
1.75 -12 -76 -142 -291 -359 -425 -497 -624
2.00 -13 -77 -143 -292 -360 -426 -498 -625
Table 207. Corrosion Resistant Steel Cotter Pin Dash Numbers

Length (L) 0.03 0.047 0.063 0.094 0.125 0.156 0.188 0.25
(Inch)
0.25 -18 -82 -1010
0.31 -1001 -1011
0.375 -1002 -1012
0.428 -1003 -1013
0.50 -22 -86 -151 -298 -366
0.75 -24 -88 -153 -300 -368 -436 -508
1.00 -26 -90 -155 -302 -370 -437 -509 -636
1.25 -27 -91 -157 -304 -372 -439 -511 -637
1.50 -28 -92 -159 -306 -374 -441 -513 -638
1.75 -29 -93 -161 -308 -376 -443 -515 -639
2.00 -30 -94 -162 -309 -377 -444 -516 -640
Table 208. Nickel Copper Alloy Cotter Pin Dash Numbers
Length (L) 0.03 0.047 0.063 0.094 0.125 0.156 0.188 0.25
(Inch)
0.50 -189 -332 -400
0.75 -191 -334 -402 -472 -544
1.00 -193 -336 -404 -473 -545 -666
1.25 -195 -338 -406 -475 -547 -667
1.50 -197 -340 -408 -477 -549 -668
1.75 -199 -342 -410 -479 -551 -669
2.00 -200 -343 -411 -480 -552 -670
(3) The minimum cotter pin size must obey the requirements shown in Table 209.
Table 209. Minimum Cotter Pin Size Requirements
Nominal Bolt Thread Size Minimum Cotter Pin Size
6 0.028
8 0.044
10 0.044
1/4 0.044
5/16 0.044
3/8 0.072
7/16 0.072
1/2 0.072
9/16 0.086
5/8 0.086
3/4 0.086
7/8 0.086
1 0.086
1-1/8 0.116

1-1/4 0.116
1-3/8 0.116
1-1/2 0.116
E. Castellated Nut Cotter Pin Installation (Refer to Figure 204)
(1) New cotter pins must be installed on each application. Refer to Cotter Pin Dimensions in this section for the correct
material and size of cotter pin.
(2) Tighten the castellated nut to the minimum specified torque range unless otherwise specified and, if necessary,
continue tightening until a slot aligns with the hole. Do not tighten the castellated nut more than the maximum specified
torque range.
(3) Cotter pins must be installed through the bolt with one of the two different methods that follow:
(a) The preferred method is with the cotter pin bent parallel to the axis of the bolt.
(b) The alternate method is with the cotter pin mounted normal to the axis of the bolt. This method is used when the
preferred method could become a snag.
(4) Install the cotter pin with the head firmly in the slot of the castellated nut with the axis of the eye at right angles to the
bolt shank.
(5) If more than 50 percent of the cotter pin diameter is above the nut castellation, a washer must be used under the nut
or a shorter fastener must be used. A maximum of two washers can be used under the nut.
(6) Bend the prongs so that the head and the upper prong are firmly seated against the bolt. The upper prong can be cut
shorter to give sufficient clearance.
(7) Cadmium plated cotter pins must not be used in installations that let them touch fuel, hydraulic fluid, or synthetic
lubricants.
F. Pin Cotter Pin Installation
(1) New cotter pins must be installed on each application. Refer to Cotter Pin Dimensions in this section for the correct
material and size of cotter pin.
(2) For pin applications, install the cotter pin with the axis of the eye parallel to the shank of the pin or rod end.
(3) Bend the prongs around the shank of the pin or rod end.
4. Turnbuckle Safetying
• None.
• None.
• None.
B. Description
(1) Turnbuckles with locking clip grooves in both terminals and the turnbuckle body must be safetied with locking clips as
shown in Turnbuckle Locking Clip Installation. Turnbuckles without locking clip grooves in any or all components must
be safetied with lock wire as shown in Turnbuckle Lockwire Installation.
C. Turnbuckle Locking Clip Installation (Refer to Figure 206)
(1) Turnbuckle locking clips are for one time use only and must not be reused. New locking clips must be installed on
each application. Refer to Table 210 for the correct turnbuckle locking clip sizes.

Table 210. Turnbuckle Locking Clip Sizes

Nominal Cable Diameter Thread (UNF-3B) Locking Clip (MS21256) Turnbuckle Body
(Inch) (MS21251)
1/16 No. 6-40 -1 B2S
-2 B2L
3/32 No. 10-32 -1 B3S
-2 B3L
1/8 1/4-28 -1 B5S
-2 B5L
5/32 1/4-28 -1 B5S
-2 B5L
3/16 5/16-24 -1 B6S
-2 B6L
7/32 3/8-24 -2 B8L
1/4 3/8-24 -2 B8L
9/32 7/16-20 -3 B9L
5/16 1/2-20 -3 B10L
NOTE 1: Two locking clips are required for each turnbuckle.
(2) Make sure that the following steps are done before the turnbuckle locking clip installation:
(a) Make sure that the applicable cable system is adjusted correctly.
(b) Make sure that both terminals are threaded an equal distance into the turnbuckle body.
(c) Make sure that not more than three threads of the terminals are exposed outside of the turnbuckle body.
(d) Make sure that the slot indicator groove on the terminals and the slot indicator notch on the turnbuckle body are
aligned.
(3) Put the straight end of the locking clip into the terminal and the turnbuckle body.
(4) Open the locking clip so that the hook end is parallel with the straight end.
(5) Continue to push the straight end of the locking clip into the turnbuckle body until the hook loop is over the hole in the
center of the turnbuckle body.
(6) Push on the hook shoulder of the locking clip to install the hook loop into the hole of the turnbuckle body.
NOTE: Both locking clips can be installed in the same hole of the turnbuckle body or in opposite
holes.
(7) Make sure that the hook end of the locking clip expands and the hook lip latches in the hole of the turnbuckle body.
CAUTION: Do not use a tool to pull the locking clip to prevent damage.
(8) Between the loop end and the hook shoulder on the locking clip, use your fingers to pull out to make sure that it is
correctly seated in the turnbuckle body.
D. Turnbuckle Lockwire Installation
WARNING: Do not use lockwire on the turnbuckles designed for safety clips.
(1) Safety the turnbuckle with lockwire using one of the three methods shown in Figure 207.
5. Lock Washer

• None.
• None.
• None.
B. Lock washers can be used in the conditions that follow:
(1) When a self-locking feature cannot be used for an externally or internally threaded part.
(2) When a cotter pin cannot be used to prevent the rotation of internal threads with respect to the external threads.
(3) When lockwire cannot be used to prevent the loosening of threaded parts.
(4) When fastening is not used for the fabrication of the primary structure.
(5) When the loosening of threaded parts will not endanger the safety of the airplane or the passengers.
(6) When corrosion caused the edges of tooth-locked washers gouging aluminum or magnesium alloys will cause
failures of the parts that are fastened together.
6. Self-Locking Nut
• None.
• None.
• Illustrated Parts Catalog.
B. Self-Locking Nut Limitations
(1) Do not use self-locking nuts on threaded parts at joints in control systems at single attachments or where the loss of
the bolt would affect safety of flight. These must be attached by a positive locking device that requires shearing or
rupture of the material before torsional loads would release the initial stresses of the assembly.
(2) Do not use self-locking nuts on externally threaded parts that serve as an axis of rotation for another part, except for
the conditions that follow:
NOTE: Examples include pulleys, bell cranks, levers, linkages, hinge pins, and cam followers.
(a) There are no possible torsional loads which can be applied to the externally or the internally threaded part in
such a way as to release the initial stresses of the assembly.
(b) The threaded parts are attached by a positive locking device that requires shearing or rupture of the material
before torsional loads would relieve the initial stresses of the assembly.
(3) Do not use self-locking nuts with bolts or screws on jet engine airplanes in locations where the loose nut, bolt, or
screw could fall or be drawn into the engine air intake duct.
(4) Do not use self-locking nuts with bolts, screws, or studs to attach access panels, doors, or to assemble parts that are
routinely disassembled before or after each flight.
(5) Do not use self-locking nuts that depend on friction for their anchorage and torsional rigidity in structural applications.
These include single-rivet plate nuts and clip nuts.
(6) Do not use self-locking nuts that require embedding the non-approved shapes for their anchorage and torsional
rigidity in structural applications. The non-approved sharp shapes include polygons, teeth, and knurls.
(a) Standard or approved embedded shapes of self-locking nuts are permitted for use in structural applications.
Refer to the applicable Illustrated Parts Catalog for the correct part numbers.
(7) Cadmium-plated self-locking nuts must not be used in contact with titanium alloy bolts, screws, or studs, or in

applications where the operating temperatures exceed 450°F (232°C).

(8) Silver-plated self-locking nuts must not be used in contact with titanium and titanium alloy bolts, screws, or studs in
applications where the operating temperatures exceed 600°F (315°C).
(9) Silver-plated self-locking nuts must not be used with silver-plated bolts.
C. Self-Locking Nut Installation
(1) Bolts, studs, or screws, excluding Hi-Locks, must go through the self-locking nut for a length equal to two thread
pitches. This length includes the chamfer.
(2) Self-locking nuts that are attached to the structure must be attached to prevent the possibility of their rotation or
misalignment while tightening the bolt or the screw.
(3) Self-locking nuts must be attached to permit their removal and installation without damage to the structure.
(4) Self-locking nuts are for one time use only and must not be reused.
7. Safety Cable
• Bergen BM Series Safety Cable Kit
• Daniels DMC Series Tool and Parts Kit.
• None.
• AS4536
• Bergen Safety Cable Installation Instructions
• Daniels Safe-T-Cable Installation Practices Guide.
B. Description
(1) Safety cable is used to prevent the relative movement of structural, electrical, or other critical components subjected
to vibration, tension, or torque.
C. Safety Cable Requirements
(1) All safety cable kits, assemblies, and accessories must obey the requirements of AS4536.
CAUTION: Safety cable that is not of the correct type, length, and dimension can break. This can occur when
there is more than the specified tension limit for that type and dimension of safety cable.
(2) Make sure that you use the correct type and dimension of safety cable for the application.
(3) Safety cable ferrules must obey the minimum crimp requirements (pull-off load) as shown in Table 211.
Table 211. Safety Cable Ferrule Minimum Crimp Requirements
Nominal Cable Diameter (Inch) Minimum Crimp Requirement (Pounds)
0.020 30
0.032 70
0.040 110
(4) The installed safety cable must not flex more than the limits shown in Table 212 and Figure 208.
Table 212. Safety Cable Flex Limits
A B C
0.5 0.125 0.062
1.0 0.250 0.125
2.0 0.375 0.188

3.0 0.375 0.188

4.0 0.500 0.250
5.0 0.500 0.250
6.0 0.625 0.312
(5) Safety cable must be installed in a two-bolt pattern or a three-bolt pattern.
NOTE: The two-bolt pattern is the recommended method when there is an even number of fasteners.
(6) Install safety cable to hose and electrical coupling nuts with the same method as the tube coupling nuts.
(7) Install the safety cable through the holes supplied for safetying.
(8) Do not under-torque or over-torque the fastener to align the holes.
(9) Install the safety cable so that any tendency for a fastener to loosen will be counteracted by an additional tension on
the safety cable.
(a) It is recommended to avoid sharp turns (more than 90 degrees) as the safety is threaded through the fasteners.
This will give the installed safety cable with a positive or a neutral pull.
(10) After safety cable installation, the excess safety cable from the crimped ferrule must be cut off.
(a) The maximum permitted length of the safety cable that can extend from the ferrule is 0.031 inch (0.79 mm).
(11) The maximum length of the safety cable between two termination points is 6.0 inches (152.40), unless otherwise
specified.
(12) Any safety cable with a nick, fray, kink, or other damage found before, during, or after installation, at or between the
termination points, is not permitted. It must be replaced.
(13) Safety cables and ferrules are for one time use only and must not be reused.
D. Safety Cable Installation (Refer to Figure 209)
(1) Install the safety cable as follows:
(a) Refer to the Daniels Safe-T-Cable Installation Practices Guide for the correct safety cable kit, installation, and
operation of the Daniels Safety Cable Application Tool.
(b) Refer to the Bergen Safety Cable Installation Instructions for the correct safety cable kit, installation, and
operation of the Bergen Safety Cable Terminator Tool.

Figure 201 : Sheet 1 : Electrical Connector Safety Wiring

Figure 201 : Sheet 2 : Electrical Connector Safety Wiring

Figure 202 : Sheet 1 : Lockwire Safetying

A99531
Step 1: Insert the lockwire through bolt A and bend
it around the bolt. Twist the lockwires
Bolt A clockwise until they reach within
0.125 inch (3.2 mm) of bolt B.
Step 2: Insert one end of the lockwire through bolt B.

Bend the other end around the bolt. Twist
the lockwires counterclockwise 0.5 inch
(12.7 mm) or 6 twists. Clip the ends and bend
the pigtail back against the part.
Bolt B
Single Hole
Double Twist Method
Clockwise
Counter-
Clockwise
Clockwise
Counter-
Multiple Fastener Application Clockwise
Double Twist Method
Clockwise
NOTE: Right-Hand Threads Method Shown, Single Hole
Left-Hand Threads Method Opposite Double Twist Method
5598T2001
5598T1024

Figure 202 : Sheet 2 : Lockwire Safetying

A99532
External Snap Ring, Single Wire Method
Bolts in a Closely-Spaced, Closed Geometrical Pattern

Single Wire Method
Small Screws in a Closely-Spaced, Single Fastener Application

Closed Geometrical Pattern Double Twist Method
Single Wire Method
NOTE: Right-Hand Threads Method Shown,

Left-Hand Threads Method Opposite
5598T2001
5598T1024

Figure 203 : Sheet 1 : Peri-Seal Connector Assembly Safetying

A99533
End Fitting Flange Safety Wire
A A
A
Cable
Direction of Safety Wire

Twist Optional
B B
DETAILA
End Fitting Flange Tangential Slot-Type
Single Safety Wire Hole Method
Safety Wire
Cable
VIEWB-B
MS27039-0804 Screw
MS21042-08 Nut End Fitting Flange
End Fitting Flange Safety Wire

Cable
VIEWA-A
DETAILA
Tangential Slot-Type
6514T1135
NOTE: Use 0.025 inch diameter corrosion Alternate Safety Attachment Method A6514T1135
A6218T1164
resistant steel safety wire minimum. AA6514T1135
BB6218T1164

Figure 203 : Sheet 2 : Peri-Seal Connector Assembly Safetying
A99534
Direction of
Safety Wire
Twist Optional End Fitting Flange
End Fitting Flange
A
Cable
Alternate
Safety Wire
Pigtail Location
A
VIEWA-A
DETAIL A
Radial Slot-Type
Double Safety Wire Hole Method
NOTE: Use 0.020 inch diameter corrosion resistant steel safety wire minimum.
A6514T1135
AA6218T1165

Figure 204 : Sheet 1 : Cotter Pin Safetying

A99535
To provide clearance, the

prong can be cut here.
Preferred Method Alternate Method
Cotter Pin Installation Through

Castellated Nut and Bolt
Tangent to Pin
Maximum
Cotter Pin
Length
60º
60º
Minimum
Cotter Pin
Length Cotter Pin Installation Through Pin
Cotter Pin Length Tolerance
5598T1025

Figure 206 : Sheet 1 : Turnbuckle Locking Clip Installation

Figure 207 : Sheet 1 : Turnbuckle Lockwire Installation

Figure 208 : Sheet 1 : Safety Cable Flex Limits

A99539
C
B
For Three-Bolt Patterns

A= D+ E
Safety Cable Flex Limits
7180T1028

Figure 209 : Sheet 1 : Safety Cable Installation

A99540
Standard Hardware Safety Cable Installation
Tube Couplings Safety Cable Installation
7180T1028

CONTROL CABLES, PRESSURE SEALS AND PULLEYS - MAINTENANCE PRACTICES

1. General
A. This section gives the maintenance practices for control cables, pressure seals, and pulleys.
2. Control Cable
A. Definitions
• Center Wire - The center of all strands is an individual wire and is designated as a center wire.
• Lay (Twist) - The helical form taken by the wires in the strand and by the strand in the wire rope is characterized as
the lay (twist) of the strands or wire rope. In a right-hand lay, the wires of strands are the same direction as the
thread on a right-hand screw. For a left-hand lay, the strands or wires lay in an opposite direction.
• Regular Lay - Wire rope in which the direction of the lay of the wires in the strand is in an opposite direction to the
lay of the strand in the wire rope.
• Strand - Each group of wires helically twisted is designated as a strand.
• Strand Core - A strand core consists of a single straight strand made of wires similar to the other strands
comprising the cable in arrangement and number of wires.
• Wire - Each individual cylindrical element is designated as a wire.
• Wire Rope (Cable) - A group of three or more strands helically twisted is designated as a wire rope.
• Wire Rope Diameter - The diameter of wire rope is the diameter of the circumscribing circle, or the distance
across opposite strands.
B. Description
(1) Control cables include flight control cables, nose wheel steering control cables, and landing gear uplock manual
release cables. Control cables are flexible wire rope cables (MIL-DTL-83420).
(2) Control cables can be classified by function as follows:
(a) Class I - Cable assemblies designed for primary flight control systems.
(b) Class II - Cable assemblies designed for use in ordinance, other than primary control systems and in attaching
cables to quadrants, drums, etc., in the cable systems of aircraft.
(c) Class III - Cable assemblies designed for use in applications other than control systems where reduced load
carrying capacity is appropriate.
(3) Control cables can be classified by type as follows:
(a) Type I - Non-Jacketed
1 Composition A - Carbon Steel, Tin or Zinc Coated
2 Composition B - Corrosion Resistant Steel
(b) Type II - Jacketed
1 Composition A - Carbon Steel, Tin or Zinc Coated
2 Composition B - Corrosion Resistant Steel
(4) Lockclad cable (MIL-DTL-87218) is the resulting material of swaging aluminum alloy tubing onto MIL-DTL-83420,
Type I, non-jacketed wire rope to the extent necessary to comply with the elongation and coefficient of thermal
expansion properties. The types of Lockclad are as follows.
(a) Type I - Lockclad manufactured with MIL-DTL-83420, Type I, Composition A carbon steel, zinc or tin over zinc
coated wire rope.
(b) Type I - Lockclad manufactured with MIL-DTL-83420, Type I, Composition B corrosion resistant steel wire rope.
(5) Chromium nickel steel wire is helically twisted into strands and laid about other strands to form a flexible steel cable.
(6) The control cable diameter is calculated by the number of wires and number of strands in the cable. The control
cables are 3 x 7, 7 x 7, and 7 x 19 construction with regular lay for their related diameter.
(a) 3 x 7 control cable construction (1/32 inch diameter) is made of 3 strands of 7 wires each laid together without a
core. Each stand has a layer of 6 wires laid around a center wire in a left-hand direction. The 3 strands are laid
together in a right-hand direction.
(b) 7 x 7 control cable construction (1/16 and 3/32 inch diameter) is made of 6 outer strands of 7 wires each laid
around a strand core of 7 wires. The 6 outer strands shall have a layer of 6 wires laid around a center wire in a
left-hand direction. The strand core has a layer of 6 wires laid around a center wire in a right-hand direction. The

6 outer strands are laid around the core in a right-hand direction.

(c) 7 x 19 control cable construction (1/8 through 3/8 inch diameter) is made of six outer strands of 19 wires each
laid around a strand core of 19 wires. The 6 outer strands are a layer of 6 wires laid around a center wire in a
left-hand direction and a layer of 12 wires laid over the 7-wire strand in a left-hand direction. The strand core is a
layer of 6 wires laid around a center wire in a right-hand direction and a layer of 12 wires laid around the 7-wire
strand in the right-hand direction. The 6 outer strands are laid around the core in a right-hand direction.
(7) During assembly, each wire and strand of the control cable is coated with a friction-preventive, non-corrosive lubricant
to prevent friction and corrosion.
C. Control Cable Storage
(1) Control cable assemblies must be stored straight or in a coil with the coil inside diameter as shown in Table 201.
Table 201. Control Cable Diameters in Storage
Cable Diameter (Inch) Minimum Coil Diameter (Inch)
1/16 6
3/32 6
1/8 8
5/32 8
3/16 8
7/32 8
1/4 10
NOTE 1: This table is not applicable to Lockclad cable assemblies.
NOTE 2: For Type II cable, the cable diameter is the diameter of the cable with the nylon jacket.
(a) The coils must not become flat, twisted, or folded during storage or processing.
(b) The correct storage of the control cables must be kept until it is installed in its normal position in the airplane.
(c) If only a part of the cable is installed in an assembly, the cable storage procedures apply to the part of the cable
that is not installed.
(2) The clad portion of the Lockclad cables must be stored so that it is straight at all times.
3. Pressure Seal Removal/Installation
A. Description
(1) Pressure seals include the seal around the control cable where it goes through the pressure vessel from a
pressurized area to a unpressurized area.
(2) The pressure seal is molded synthetic rubber that is split longitudinally to the center. This is to allow its removal and
installation without the removal or the control cable.
(3) A light-consistency silicone grease is packed into the pressure seal. This helps to prevent friction between the control
cable and the pressure seal. It also helps as a seal between the control cable and the pressure seal.
• None.
• Silicone Grease (5565450-28).

C. Prepare the Airplane for the Pressure Seal Removal.

(3) Remove access panels and equipment as necessary to get access to the pressurized side and the unpressurized
side of the applicable pressure seal. Refer to the applicable Maintenance Manual.
D. Remove the Pressure Seal (Refer to Figure 201).
(1) For the S11K pressure seal, remove the three restraining rings from the pressure seal.
NOTE: There are two restraining rings on the pressurized side and one restraining ring on the
unpressurized side of the pressure seal.
(2) For the ESP-S11K pressure seal, remove the retainer clip from the pressurized side of the pressure seal.
(3) Remove the pressure seal from the bulkhead or the structure.
(4) Separate the pressure seal at the longitudinal parting line and remove it from the control cable.
E. Install the Pressure Seal (Refer to Figure 201).
CAUTION: Do not apply too much lubricant to the pressure seal. This will help to prevent dirt buildup and
subsequent cable wear and possible broken wires.
(1) Pack the pressure seal with silicone grease (5565450-28).
(a) Make sure that the control cable is lubricated for the full length of travel through the pressure seal.
(2) Separate the pressure seal at the longitudinal parting line and install it on the control cable.
(3) Install the pressure seal in the bulkhead or the structure.
(4) For the S11K pressure seal, install the three restraining rings on the pressure seal.
NOTE: There are two restraining rings on the pressurized side and one restraining ring on the
unpressurized side of the pressure seal.
(5) For the ESP-S11K pressure seal, install the retainer clip on the pressurized side of the pressure seal.
F. Put the Airplane Back to its Initial Condition.
(1) Move the applicable control cable system from stop-to-stop to make sure that it operates correctly and freely.
(2) Install access panels and equipment as necessary. Refer to the applicable Maintenance Manual.
4. Pulley
A. Description
(1) Pulleys are grooved wheels installed to give the control cables the correct routing with minimum friction or to change
the control cable direction.
(2) Pulleys are made from layers of cloth impregnated with phenolic resin and fused together under high temperatures
and pressures. They are extremely strong and durable and cause minimum wear on the cable passing over them.
(3) Pulleys have grease-sealed bearings and usually more lubrication is not necessary.
5. Flight Control Cable, Pressure Seal, and Pulley Inspection
• Borescope
• Flashlight
• Mirror.


• Cloth
• Silicone Grease (5565450-28).
• Safetying - Maintenance Practices
B. Prepare the Airplane for the Flight Control Cable, Pressure Seal, and Pulley Inspection.
(3) Remove access panels and equipment as necessary to get access to the flight control cables, pressure seals, and
pulleys. Refer to the applicable Maintenance Manual.
C. Do the Flight Control Cable Inspection (Refer to Figure 202).
(1) Visually examine all of the flight control cables along their full length for signs of damage, corrosion, or fraying. For
areas that are difficult to see, use a flashlight and a mirror or a borescope.
(a) Examine the cable routing at fairleads to make sure that deflection angles are not more than 3 degrees
maximum.
(b) Make sure that the cables do not rub the brackets or sides of the pulleys. Make sure that deflection angles are
not more than 3 degrees maximum.
(c) Cables must not rub on structures or plumbing. Make sure that the cables have 0.25 inch (6.35 mm) clearance
from the structure and plumbing in the static position.
(d) Control cables must be within 0.125 inch (3.18 mm) of the center of the penetration of a pressure vessel and be
within 3 degrees perpendicular to the structure that holds the pressure seal.
(e) On primary and secondary control cable systems, grommets are necessary around all sheet metal holes that
cables go through unless the cables clear the structure by a minimum of 0.50 inch (12.70 mm). Holes that are 10
inches (254.00 mm) or less from the pulley that the cables pass over do not need to have grommets, but one
cable diameter minimum clearance is necessary.
(f) When necessary, grommets must be installed in the applicable holes. Rigged cables must clear grommets by
one-half cable diameter minimum with the system in the neutral position. Rigged cables can touch grommets on
the unloaded side of the system during movement of the system. Control systems having Lockclad rod must
have a minimum of 0.25 inch (6.35 mm) clearance after grommets are installed with the system in the neutral
position.
(2) Move a cloth along the full length of all flight control cables including at all pulleys, fairleads, pressure seals, and other
locations that chafing can occur.
NOTE: It can be necessary to have a second person operate the applicable flight control system to
make sure that the full length of the cable is examined.
(a) Make sure that the cloth does not catch on any part of the flight control cables.
1 If the cloth catches on the flight control cable because of broken wires, you must release the tension,
remove the flight control cable, and do a loop test to find the number and location of the broken wires. Refer
to the applicable Maintenance Manual.
2 Do the loop test as follows:
CAUTION: Do not bend the control cable into a loop smaller than 50 cable diameters to prevent
damage.
a Bend the cable at the area where the cloth caught on the control cable.
b Visually examine the area for broken wires.

c
Broken wires are permitted in any cable if no more than three wires are broken in any ten inches in
cable length. Replace the cable if you cannot find the number of broken wires.
d Replace the cable if you find corrosion.
(3) Visually examine all cable terminal fittings including clevises, turnbuckles, anchors, and swagged balls for correct
installation, loose or missing hardware, and signs of damage.
(a) Make sure that all turnbuckles are safetied with lockwire or locking clips. Refer to Safetying - Maintenance
Practices.
D. Do the Pressure Seal and Pulley Inspection (Refer to Figure 201 and Figure 203).
(1) Visually examine the pressure seals where the control cables go into the pressurized areas for deterioration,
lubrication, and correct installation of the restraining clips.
(a) Replace the pressure seals that are unserviceable. Refer to Pressure Seal Removal/Installation in this section.
(b) If necessary, remove the pressure seal and pack it with silicone grease (5565450-28). Refer to Pressure Seal
Removal/Installation in this section.
(2) Examine all of the pulleys for correct installation, signs of damage, and make sure that they turn freely.
NOTE: An incorrect pulley size, misaligned pulley or cable, frozen bearing, and excessive cable
tension decreases the control cable service life.
(a) All pulleys must be correctly aligned in their mounting bracket so that the pulley does not rub the bracket.
(b) Cable guards must not touch the cables or the pulleys.
(c) Since most control cable pulleys only turn through a small arc, periodically turn the pulleys to give a new bearing
surface to turn on.
(d) Replace the pulleys that do not turn freely with usual cable movement because of bearing wear.
(3) Examine all of the pulleys for groove wear from excessive cable tension, pulley too large for cable, frozen bearing,
pulley misalignment, and cable misalignment.
NOTE: Pulleys with normal service wear in the grooves are serviceable if the general function is not
reduced.
(a) Replace the pulleys that are unserviceable.
(1) If necessary, install the flight control cable(s) that was removed. Refer to the applicable Maintenance Manual.
(2) Install access panels and equipment as necessary. Refer to the applicable Maintenance Manual.

Figure 201 : Sheet 1 : Pressure Seal Installation

A99548
Bulkhead or Structure
Pressure Seal
Restraining Ring
Control Cable
(Unpressurized Side)
Control Cable
(Pressurized Side)
Restraining Ring
S11K Pressure Seal
Retainer Clip
Bulkhead or Structure
Pressure Seal
Control Cable
(Pressurized Side)
ESP-S11K Pressure Seal
5598T1007
7060T1022

Figure 202 : Sheet 1 : Flight Control Cable Inspection

A99547
Broken wire not found when rubbed with a cloth along
the length of the cable.
Broken wire found visually when

A correct technique is to the cable was removed and bent.
bend the cable to inspect
for broken wires.
Loop Test
Center Wire
Strand Core
Wire
Strand
Diameter
Wire Rope
(Cable)
5561T1119

Figure 203 : Sheet 1 : Pulley Inspection

RIVETLESS NUTPLATE - MAINTENANCE PRACTICES

1. Effectivity
• Model 525
• Model 525A
• Model 525 M2.
2. General
A. This section gives the maintenance practices for Deutsch rivetless nutplates.
3. Description
A. The two common types of Deutsch rivetless nutplates that are used in some areas of the airplane are the Type SFN 6010
and the Type FF 6010. Refer to Figure 201.
(1) Type SFN 6010 rivetless nutplates are self-sealing, floating, rivetless nutplates. They are used in some areas in the
integral fuel tank areas. Additional sealing is not necessary because they incorporate a liquid tight seal. The sleeve
gives protection to the parent material and helps to move the fastener into the nut element.
(2) Type FF 6010 rivetless nutplates are floating, rivetless nutplates used in other areas of the airplane. These nutplates
can have the nut element replaced if it is damaged or if a different type of thread is necessary without the removal of
the complete assembly from the structure.
4. Deutsch Rivetless Nutplate Inspection
A. Inspect the Deutsch Rivetless Nutplate.
(1) Seating of Bracket
(a) For Type FF 6010 rivetless nutplates, the bracket component must be seated correctly so that a 0.002 inch
(0.051 mm) shim cannot be freely inserted between the bracket and the sheet surface.
(2) Pressure Test
(a) For SFN 6010 rivetless nutplates, they must not leak when pressure tested per the applicable system leak test.
(3) Sleeve Flare
(a) The flared section of the sleeve cannot have more than one medium crack for each 180 degrees as shown in
Figure 202.
(b) Heavy cracks are not permitted.
(c) The sleeve flare must be flush with the sheet surface.
5. Deutsch Rivetless Nutplate Nut Element Removal/Replacement
• Removal Tool - RB6527-( )
• Support.
• None.
• None.
B. Deutsch Rivetless Nutplate Nut Element Removal (Refer to Figure 203)
NOTE: It is necessary to replace the nut element with the conditions that follow:
• Locking no longer effective
• Threads incorrect (quad lead instead of single lead, locking instead of non-locking, cross-
threaded, missing threads, etc.)

• Material/finish incorrect (A-286 instead of carbon steel, dri-lubed instead of silver plate, etc.)
NOTE: The nut assembly must be solidly secured or mounted.
(1) Insert the prongs of the RB6527-( ) removal tool between the nut element base and the bracket.
CAUTION: Do not pry open the bracket too much because the bracket will stay open or it can crack and break.
(2) Apply a downward force and pry the nut element out by swinging the tool against the bracket to open it.
(3) Remove the nut element from the rivetless nutplate.
C. Deutsch Rivetless Nutplate Nut Element Replacement (Refer to Figure 203)
(1) Put a new nut element into the bracket, one ear first.
(2) Hold a support against the opposite side of the rivetless nutplate to prevent damage to the sheet surface.
(3) Strike the top of the nut element lightly with a small hammer or mallet to snap the second ear into place in the bracket.
6. Deutsch Rivetless Nutplate Assembly Removal/Replacement
• Hand Installation Tool - D( )T860.
• None.
• Huck International, Inc., Installation of Rivetless Nut Plates (S-3137).
B. Deutsch Rivetless Nutplate Assembly Removal (Refer to Figure 204)
NOTE: It is necessary to replace the Type FF 6010 rivetless nutplate with the conditions that follow:
• Torque-out performance under specification (NASM 25027)
• Heavy cracks on swage or flare
• Broken brackets
• Collapsed sleeves
• Wrong sleeve length installed.
NOTE: It is necessary to replace the Type SFN 6010 rivetless nutplate with the conditions that follow:
• Torque-out performance under specification (NASM 25027)
• Heavy cracks on swage or flare
• Broken brackets
• Collapsed sleeves
• Wrong sleeve length installed
• Leaks when pressure tested per the applicable system leak test.
NOTE: In general, any rivetless nutplate assembly can be removed by machining off the flare.
(1) Use one of the three methods that follow to remove the rivetless nutplate assembly.
• Method A (Preferred) - Mill the corner of the swage or flare using a countersink tool. You can use a hand drill
or stationary equipment.
• Method B (Alternate) - Mill the entire flange out. Use only with a drill press or milling machine. Be careful not to
touch the panel.
• Method C (Not Recommended) - Drill the swage or the flare out. Must be done at high speeds to prevent drill
flutes from grabbing the sleeve and making it turn, which will ream the hole.
(2) Remove the rivetless nutplate from the panel.
C. Deutsch Rivetless Nutplate Assembly Replacement (Refer to Figure 205)
NOTE: Refer to Huck International, Inc., Installation of Rivetless Nut Plates (S-3137) for more detailed

instructions.
(1) If the hole in the panel is reamed out, oversized, out of shape, or out of tolerance, replace the rivetless nutplate with a
repair nut or a standard riveted nutplate. Refer to Figure 206.
A99635
Standard
Riveted Nutplate
RFF6010
Repair Nut Rivet Damaged Hole CSAM023
Figure 206
(2) If there is no damage to the hole in the panel, install a new rivetless nutplate with the D( )T860 hand installation tool
assembly.
(3) Adjust the D( )T860 hand installation tool assembly to the correct grip length.
(a) Loosen the setscrew to permit free movement of the telescoping tube.
(b) Turn the adjusting knob clockwise or counterclockwise to get the correct grip length adjustment. This is indicated
when the mark opposite the grip length letter on the telescoping tube is in line with the edge of the tool handle.
1 If there is too much resistance while you turn the adjusting knob, close the handles while you turn the knob
and make sure that the setscrew does not push against the tube.
(c) Push the telescoping tube back toward the handle to make sure that the position is accurate.
(d) Tighten the setscrew.
(4) First Operation
(a) Move the pressure pad collets of the flaring nose assembly to the forward end of axial travel to give a recess for
the first operation.
(b) Turn the knurled collar so that the slot does not align with the stopping screw which gives a positive stop against
the screw plug. This prevents the pressure pad collets from retracting and opening up too soon.
(c) Put the rivetless nutplate assembly sleeve through the hole in the panel.
CAUTION: The pull stud must be fully threaded into the rivetless nutplate to prevent thread damage
during installation.
(d) Thread the pull stud from the hand installation tool assembly into the rivetless nutplate fully.
(e) Close the handles on the hand installation tool until the rivetless nutplate is fully seated in the panel.
1 Make sure that the bracket on the rivetless nutplate is seated firmly against the panel and the lobes are fully
engaged.
(f) Hold the handles in the closed position.
(5) Second Operation
(a) Turn the knurled collar on the nose assembly so that the slot aligns with the stopping screw.
(b) Open the handles of the hand installation tool assembly and retract the pressure pad by pulling it back against
the stop to expose the flaring tip surface.
NOTE: Exposing the flaring tip surface is necessary to make sure that there is full flaring
capability of the sleeve skirt.
CAUTION: Do not try to completely flatten the material to prevent damage to the hand installation tool
assembly.
(c) Close the handles again to flare or swage the sleeve skirt which holds the nut to the panel.
1 Make sure that you use sufficient pressure on the handles to form a flat upset against the panel.
(d) Open the handles of the hand installation tool assembly.

(e) Remove the pull stud on the hand installation tool assembly from the rivetless nutplate.
(f) Examine the flare and the rivetless nutplate for correct installation.

Figure 201 : Sheet 1 : Deutsch Rivetless Nutplates

A99640
Housing
Nut Element
Bracket
Seal
Lobes
Sleeve
Type SFN 6010 (Self-Sealing) Rivetless Nutplate
Nut Element
Bracket
Lobes
Sleeve
Type FF 6010 Rivetless Nutplate
6280T1014

Figure 202 : Sheet 1 : Classification of Cracks

A99639
Cracks
Acceptable Unacceptable Unacceptable
Light Medium Heavy
Cracks are closed Cracks are open and Cracks are open and
and on the periphery extend inwards on the extend into the cylindrical
of the swaged flange. swage flange. portion of the sleeve.
6280T1015

Figure 203 : Sheet 1 : Deutsch Rivetless Nutplate Nut Element Removal/Replacement

A99638
RB6527-( )
Removal Tool
Nut
Element
Bracket
Nut Element Removal
Ear
NOTE: Put a support under the nut before you tap it

with a small hammer or mallet.
Nut Element Replacement
6280T1016

Figure 204 : Sheet 1 : Deutsch Rivetless Nutplate Assembly Removal

A99637
100-Degree,
90-Degree, or 90-Degree or
82-Degree, 82-Degree
Countersink Tool Countersink Tool
100-Degree Flare
Method A
(Preferred)
Drill to Match
Swage Diameter
Method C Method B
(Not Recommended) (Alternate)
6280T1017

Figure 205 : Sheet 1 : Deutsch Rivetless Nutplate Assembly Replacement

A99636
Panel
First Operation - Sleeve Lobes are Pulled into Panel
Second Operation - Sleeve Skirt is Flared
Hand Installation
Tool Assembly
Setscrew
Telescoping Tube
Stopping Screw
Slot
Nose Assembly
Adjusting Knob
Pull Stud
S-3137

BEARINGS - MAINTENANCE PRACTICES

1. General
A. This section gives the maintenance practices for bearings. It includes bearing removal/installation and bearing staking
methods.
2. Bearing Removal/Installation
• Bearing Removal/Installation Tools
• Press
• Supports (Press).
• Clean Cloths.
• Anaerobic Adhesives - Maintenance Practices
• Component Maintenance Manual
• Maintenance Manual.
B. Remove the Bearing (Refer to Figure 201).
(1) Remove the bearing with its housing from the airplane. Refer to the applicable Maintenance Manual.
CAUTION: Make sure that you support the housing correctly to prevent damage.
(2) Use a press with supports or a bearing removal/installation tool to remove the bearing from the housing.
(3) If applicable, rework the original staked material on the side of the housing that the bearing was pushed out.
(a) Do not rework the staked material on the opposite side.
(4) Use an applicable solvent to clean the housing to remove all oil, grease, and other contamination. Refer to General
(a) Wipe the housing dry with a clean cloth.
(5) Examine the housing for wear, cracks, warps, bends, burrs, gouges, and other damage.
C. Install the Bearing (Refer to Figure 201).
(1) Obey the precautions that follow before you install the bearing.
(a) The dimensions of the housing bore must be within the fits and clearances specified in the applicable
Component Maintenance Manual.
(b) Make sure that the housing bore has no burrs.
(c) Make sure that the edges of the housing bore are square with no chamfer.
(d) Make sure that the finish for corrosion protection of the housing and the bore is within specifications. Refer to the
applicable Maintenance Manual, Chapter 51.
(e) Take bearings from stock only as required for use.
(f) New bearings should remain in their packages until the time of actual installation. The bearing installation
surfaces must be clean and ready for bearing installation before the bearing is removed from its package.
(g) Handle bearings carefully to prevent contamination by abrasive particles or fingerprints, and to prevent damage
from rough handling, dropping, etc.
(h) Work benches and tools must be clean. Grinding, filing, or similar operations must not be done in the area of
exposed bearings.
(i) Staking dies must be clean and free from foreign debris that can become imbedded in the staking groove.

(2) Remove the new bearing from its package.

(a) Make sure that the bearing surfaces are clean.
(b) If necessary, wipe the bearing with a clean cloth.
CAUTION: Do not let the anaerobic adhesive go into the bearing to prevent damage.
(3) If applicable, apply anaerobic adhesive to the outer surface of the bearing and the mating surface in the housing.
Refer to Anaerobic Adhesives - Maintenance Practices.
(4) Carefully put the bearing in the center of the housing on the side that it was pushed out.
(a) Make sure that the bearing is not canted in the housing.
CAUTION: Do not apply the load against the inner race or the shield to prevent damage.
(5) Use a press with supports or a bearing removal/installation tool to install the bearing in the housing.
(a) Make sure that you apply the load against the outer race only.
(b) Make sure that the bearing does not bind during installation.
(c) Make sure that the bearing is correctly centered in the housing or installed against the flange.
(d) If applicable, make sure that the lubrication passages are open.
(e) Make sure that the bearing rotates freely and without roughness.
NOTE: You can compare the installed bearing to a new bearing that is not installed.
(6) If applicable, stake the bearing in its place. Refer to Bearing Staking Methods in this section.
(7) Examine the staked bearing thoroughly for defects, radial or circumferential cracks, imbedded foreign material,
damaged bearing race, misalignment, and other damage.
(8) Examine the housing for cracks, seams, and other damage.
(9) If applicable, apply corrosion protection to the staking groove. Refer to the applicable Maintenance Manual, Chapter
51.
(10) Install the bearing with its housing in the airplane. Refer to the applicable Maintenance Manual.
(11) Do a check of the applicable system to make sure that the bearing operates correctly.
3. Bearing Staking Methods
• Press
• Staking Tools
• Supports (Press).
• Grease - MIL-G-23827.
• Anaerobic Adhesives - Maintenance Practices.
B. Select the correct bearing staking method as shown in Table 201.
Table 201. Bearing Staking Methods
Staking Method Housing Material Maximum Strength of Bearing Type
Housing (ksi)
Ball Staking - Method A Steel, Aluminum 200 Anti-Friction, Spherical and
Cylindrical Sleeve Assembly
Modified Ring Staking - Steel, Aluminum 200 Anti-Friction, Spherical and
Method B Cylindrical Sleeve Assembly

Staked Retainer Bushing - Steel, Aluminum 200 Only Those Listed on

Method C Engineering Drawings
Double Anvil Staking - Steel, Aluminum, Magnesium 200 Spherical or Sleeve
Method D Bearings with Grooved Outer
Races
Roller Staking - Method E Wrought and Cast 160 All Other Bearings
Magnesium, Aluminum
Casting
Punch Staking - Method F Wrought and Cast Aluminum, 160 All Other Bearings
Steel
C. Ball Staking - Method A
(1) The depressions must be concentric with the bore of the bearing, within 0.020 inch (0.51 mm) total indicator reading.
(2) The staked impressions must obey the requirements of Figure 202 and Table 202.
A99651
Spherical Radius
0.015 Inch, +0.006 or 0.094 Inch, +0.006
-0.004 Inch or -0.00 Inch
(0.38 mm, +0.15 Bearing Outside Diameter Plus
0.100 Inch, +0.006 or -0.00 Inch (2.39 mm, +0.15
or -0.10 mm) or -0.00 mm)
(2.54 mm, +0.15 or -0.00 mm)
Bearing
Housing Bearing Retention
Flange
5780T1010A
Figure 202
Table 202. Number of Stakes per Bearing Size
Bearing Outside Diameter (Inch) Number of Stakes
Up to 0.734 4
0.735 - 0.984 6
0.985 - 1.234 8
1.235 - 1.690 10
1.691 - 1.984 12
D. Modified Ring Staking - Method B
(1) The total staked length for modified ring staking must be 40 to 48 percent of the circumference.
(2) The minimum number of stakes for bearings 0.75 inch and larger must be eight and the minimum number of stakes
for bearings less than 0.75 inch must be six. Refer to Figure 203.
E. Staked Retainer Bushing - Method C
(1) This method must be used only where specified.
(2) The staking tools must produce a stake as shown in Figure 204.
(3) The stake depth indicator bosses must be included in the tool.
(4) The staking tip design must be as shown in Figure 205.

A99654
0.010 to 0.015 Inch
(0.254 to 0.381 mm)
Radius
Blended Radii
0.021 Inch, +0.000 or -0.003 Inch
(0.533 mm, +0.000 or -0.0762 mm)
Blended Radii
20 Degrees, +1 or -1 Degree
Figure 205
(5) Give support during staking as shown in Figure 206.
A99655
Staking Tool
Bearing Bushing
Housing
Support
Figure 206
CAUTION: Apply pressure to the outer race of the bearing only to prevent damage.
(6) Press the bearing wet into the bushing with primer and center carefully. Refer to Anaerobic Adhesives - Maintenance
Practices.
CAUTION: Apply pressure to the bushing only to prevent damage.
(7) Press the bearing and bushing assembly wet into the housing with primer and center carefully. Refer to Anaerobic
Adhesives - Maintenance Practices.
(8) Stake the bushing on both ends unless otherwise specified. The position of the stake marks at one end of the
bushing, compared to those at the other end, is optional.
(9) Restaking of a bushing is not permitted. A new bushing must be used if a bearing is removed and replaced.
F. Double Anvil Staking - Method D
(1) Spherical or sleeve bearing assemblies that have grooved outer races must be staked by the double anvil staking
method.
(2) Make sure that the staking tool being used is the correct number for the bearing to be staked.
(3) Press the bearing into the housing and put the staking tool on center.
NOTE: The edges of the housing bore must be chamfered.
(a) The staking pressure is applied to the outer wall of the groove.
(b) The staking tool must not touch the ball, inner spacer, or displace any race material inward toward the ball or
inner spacer.
(4) Align the bearing with the guide pin and position it as shown in Figure 207.

A99656
Top Punch
Guide Pin
Housing
Bearing
Bottom Punch
Figure 207
CAUTION: Do not use too much pressure to prevent bearing distortion and subsequent bearing failure.
(5) While gradually increasing pressure, stake the lip over the housing chamfer, remove pressure, rotate assembly 90
degrees, and re-apply the pressure.
(a) Do this operation at 90 degrees rotations to make sure of the 360 degrees uniformity of lip swaging.
(6) After staking, a slight gap may exist between the bearing race lip and the housing chamfer but is not a cause for
rejection. Refer to Figure 208.
A99657
Gap
Housing Race Bearing
Figure 208
G. Roller Staking - Method E
(1) The finished roller staked part must obey the dimensions and tolerances shown in Figure 209.
A99658
0.100 Inch, +0.005 or -0.005 Inch Radius
Housing Bore Radius 0.008 Inch, +0.005 or -0.003 Inch
Plus 0.050 Inch,
+0.005 or -0.005 Inch
Bearing
Housing
Figure 209
(2) When it is necessary to stake both sides of the bearing, it must be located as shown in Figure 210.

A99659
0.005 Inch, +0.008 or
-0.005 Inch Housing
Bearing
Bearing Thickness,
+0.020 or -0.020 Inch
0.005 Inch, +0.008 or

-0.005 Inch CSMP023
Figure 210
(3) Insert the roller staking tool into a driving chuck (drill press may be used) and set spindle speed so that the rollers
have a surface speed of 60 to 150 feet per minute.
(4) Set the surface to be staked perpendicular to the axis of the spindle.
(5) Check the bearing outer race for flushness. The bearing should be from 0.010 inch below the surface to flush with the
surface.
(6) Apply MIL-G-23827 grease to the area to be staked to prevent galling.
(7) Bring the tool in contact with the area to be staked, start the drill press, and exert enough force to stake bearing. The
stake is complete when the rollers burnish the housing around the outside of the stake path.
H. Punch Staking - Method F
(1) The finished punch staked part must obey the dimensions and tolerances shown in Figure 211 and Table 203.
Table 203. Bearing Outside Diameter Requirements
Bearing Outside Diameter (Inches) Dimension A
Up to 0.750 0.020
0.751 - 1.000 0.030
1.001 - 1.250 0.030
1.251 - 1.625 0.030
1.626 - 2.000 0.040
(2) The housing can be re-staked as many times as the un-staked surface is available around the bearing.
(3) Insert the punch staking tool in the into a driving chuck of the press.
(4) Set the surface to be staked perpendicular to the axis of the staking tool.
(5) Apply pressure as necessary to get the specified depth.

Figure 201 : Sheet 1 : Bearing Removal/Installation

A99650
Apply the load to the outer race of the bearing only.
Press
Housing
Bearing
Nut
Support
Washer
Sleeve
Bearing
Housing
Sleeve
Washer
Bolt
Bearing Removal/Installation Tool

Figure 203 : Sheet 1 : Modified Ring Staking - Method B

A99652 C A
A B
B Staking Tool
0.015 Inch, +0.005 or -0.005 Inch

(0.381 mm, +0.127 or -0.127 mm)
0.209 Inch (5.308 mm)

Minimum
VIEWA-A
0.125 to 0.187 Inch
(3.175 to 4.794 mm)
45 Degrees, +2 or -2 Degrees NOTE
VIEWB-B
0.015 Inch, +0.005 or -0.005 Inch
(0.381 mm, +0.127 or -0.127 mm)
Radius 68 Degrees, +2 or -2 Degrees
0.010 Inch, +0.005 or -0.000 Inch

(0.254 mm, +0.127 or -0.000 mm) VIEWC-C
NOTE: Break sharp edges on staking tool.

Figure 204 : Sheet 1 : Staked Retainer Bushing - Method C

A99653
20 Degrees 40 Degrees Housing A

Bushing
Stake
in Six Places
Bearing
Depth Indicator Mark

(NOTE)
Stake Diameter Equals the

Nominal Bearing Outside Diameter Plus
0.063 Inch, +0.005 or -0.005 Inch
(1.600 mm, +0.127 or -0.127 mm)
0.010 to 0.015 Inch

(0.254 to 0.381 mm)
Radius
60 Degrees
0.030 Inch
(0.762 mm) 0.020 to 0.025 Inch
(0.508 to 0.635 mm)
DETAILA
NOTE: The staking tool boss maximum height is 0.003 Inch (0.0762 mm).

Figure 211 : Sheet 1 : Punch Staking - Method F

A99660
Six Stakes Equally Spaced,

+0.03 or -0.03 Inch
Bearing Outside
Diameter/6
A A
Nominal Bearing Outside

Diameter Plus 0.124 Inch, 0.10 Inch Mininmum
+0.010 or -0.010 Inch
A
Dimension A, +0.007 or -0.007 Inch Before Staking
(NOTE)
VIEWA-A
45 Degrees,
0.015 Inch, +0.005 or +5 or -5 Degrees 0.032 Inch,
-0.005 Inch Radius +0.010 or -0.010 Inch
35 Degrees,
+5 or -5 Degrees
B
60 Degrees,
+5 or -5 Degrees
VIEWB-B 15 Degrees,
B +5 or -5 Degrees
DETAILA
NOTE: If the bearing is to be staked on both sides, dimension A applies to each side.
CSMP023

TORQUE DATA - MAINTENANCE PRACTICES

1. General
A. This section gives precautions, torque data, and the torque procedure for installing threaded fasteners and fittings.
B. For security of installation and to prevent overstressing components during installation, the torque data in this section and
other applicable sections of this manual must be used during installation and repair of components.
C. The torque data tables given in this section are standard torque values for the nut and bolt combinations shown. Specified
torque values for specific installations are given in the applicable component maintenance manual and maintenance
manual. Torque values and instructions for the installation of components such as hose clamps and duct clamps are given
in their applicable sections. Straight threaded fittings, such as flared tube and hose end fittings, must be torqued per
Tubing, Hose and Fittings - Maintenance Practices.
D. When you use an adapter that changes the distance from the torque wrench drive to the adapter drive, the indicated torque
reading must be adjusted to get the correct torque value. Refer to Torque Procedure.
2. Precautions
A. The data in this section does not apply to the threaded parts used for adjustment, such as turnbuckles and rod ends.
B. The data in this section does not apply to bolts, nuts, and screws used in installations where the necessary torque could
cause binding or could interfere with the correct operation of parts. On these installations, the assembly must be firm but
not binding.
C. Sheet metal screws must be tightened fully, but not to a specific torque value.
D. Screws attached to nutplates, or screws with threads not given in Table 201 must be tightened fully, but not to a specific
torque value. Screws used with dimpled washers must not be drawn tight enough to flatten the washer crown.
E. If not specified differently, screws and bolts not installed into nuts (screws/bolts installed into threaded components or Heli-
Coil inserts) must be tightened fully, but not to a specific torque value.
F. Straight threaded connections that use O-rings or gaskets for seals, such as AN924 nuts or AN6298 nuts, and fittings
conforming to MS33656, Style E, do not need to be tightened to a specific torque value, but must be installed in
accordance with AND10064.
3. Torque Data
A. Torque Wrenches
(1) A torque wrench must be used to apply the specified torque.
B. Cleanliness
(1) The torque values specified in this section are for clean non-lubricated parts, except for Taper-Lok fasteners.
(2) The threads must be free of dust, metal filings, etc.
(3) Lubricants, other than what is supplied on the nut, must not be used on bolt installations unless specified otherwise.
C. Standard Torque
(1) When the use of a torque wrench is necessary, if not specified differently, the standard torque values listed in Table
201 must be used for all the applicable nut types listed in Table 201.
Table 201. Standard Torque Limits for Oil-Free Cadmium-Plated Steel Nuts
Fine Thread Series Course Thread Series
Nut Size Torque in Inch Pounds (N-m) Nut Size Torque in Inch Pounds (N-m)
Tension Type Shear Type Nuts Tension Type Shear Type Nuts
Nuts (NOTE 1) (NOTE 2) Nuts (NOTE 3) (NOTE 4)
- - - 02-56 - 3-4 (0.3-0.5)
- - - 04-40 - 6-8 (0.7-0.9)
- - - 06-32 - 7-9 (0.8-1.0)
8-36 12-15 (1.4-1.7) 7-9 (0.8-1.0) 8-32 12-15 (1.4-1.7) 7-9 (0.8-1.0)
10-32 20-25 (2.3-2.8) 12-15 (1.4-1.7) 10-24 20-25 (2.3-2.8) 12-15 (1.4-1.7)
1/4-28 50-70 (5.6-7.9) 30-40 (3.4-4.5) 1/4-20 40-50 (4.5-5.6) 25-30 (2.8-3.4)

5/16-24 100-140 (11.3- 60-85 (6.8-9.6) 5/16-18 80-90 (9.0-10.2) 48-55 (5.4-6.2)
15.8)
3/8-24 160-190 (18.0- 95-110 (10.7- 3/8-16 160-185 (18.0- 95-110 (10.7-
21.5) 12.4) 20.9) 12.4)
7/16-20 450-500 (50.8- 270-300 (30.5- 7/16-14 235-255 (26.6- 140-155 (15.8-
56.5) 33.9) 28.8) 17.5)
1/2-20 480-690 (54.2- 290-410 (32.8- 1/2-13 400-480 (45.2- 240-290 (27.1-
78.0) 46.3) 54.2) 32.8)
9/16-18 800-1000 (90.4- 480-600 (54.2- 9/16-12 500-700 (56.5- 300-420 (33.9-
113.0) 67.8) 79.1) 47.5)
5/8-18 1100-1300 660-780 (74.6- 5/8-11 700-900 (79.1- 420-540 (47.5-
(124.3-146.9) 88.1) 101.7) 61.0)
3/4-16 2300-2500 1300-1500 3/4-10 1150-1600 700-950 (79.1-
(259.9-282.5) (146.9-169.5) (129.9-180.8) 107.3)
7/8-14 2500-3000 1500-1800 7/8-9 2200-3000 1300-1800
(282.5-339.0) (169.5-203.4) (248.6-339.0) (146.9-203.4)
1-14 3700-4500 2200-3300 1-8 3700-5000 2200-3000
(418.0-508.4) (248.6-372.9) (418.0-564.9) (248.6-339.0)
1-1/8-12 5000-7000 3000-4200 1-1/8-8 5500-6500 3300-4000
(564.9-790.9) (339.0-474.5) (621.4-734.4) (372.9-451.9)
1-1/4-12 9000-11,000 5400-6600 1-1/4-8 6500-8000 4000-5000
(1016.9-1242.8) (610.1-745.7) (734.4-903.9) (451.9-564.9)
NOTE 1: The part numbers for the fine thread tension type nuts are: AN310, AN315, AN345, MS17825,
MS20365, MS21044 thru MS21048, MS21078, NAS679, and NAS1291.
NOTE 2: The part numbers for the fine thread shear type nuts are: AN316, AN320, MS21025, MS21042,
MS21043, MS21083, MS21245, NAS1022, S1117, and MS14145.
NOTE 3: The part numbers for the course thread tension type nuts are: AN340, MS20341, MS20365, and
MS35649.
NOTE 4: The part number for the course thread shear type nut is: MS21042.
NOTE 5: Refer to Table 202 Alternate Torque Limits for Oil-Free Cadmium-Plated Castellated Steel Nuts
if the cotter pin slot does not align with the hole in the bolt.
D. Cotter Pin Hole Line-Up
(1) Castellated nuts, except MS17826 nuts, that use cotter pins must be tightened to the minimum torque value listed in
Table 201.
NOTE: MS17826 castellated nuts are tightened per Table 203.
(2) The torque can be increased to install the cotter pin, but must not exceed the alternate torque values listed in Table
202.
(a) Use the alternate torque values only if the cotter pin slot does not align with the hole in the bolt or replace the nut
if necessary.
Table 202. Alternate Torque Limits for Oil-Free Cadmium-Plated Castellated Steel Nuts
Nut Size Alternate Torque in Inch Pounds (N-m)
Tension Type Nuts (NOTE 1) Shear Type Nuts (NOTE 2)
8-36 - -
10-32 20-28 (2.3-3.2) 12-19 (1.4-2.1)
1/4-28 50-75 (5.6-8.5) 30-48 (3.4-5.4)
5/16-24 100-150 (11.3-16.9) 60-100 (6.8-11.3)

3/8-24 160-260 (18.1-29.4) 95-170 (10.7-19.2)

7/16-20 450-560 (50.8-63.3) 270-390 (30.5-44.1)
1/2-20 480-730 (54.2-82.5) 290-500 (32.8-56.5)
9/16-18 800-1070 (90.4-120.9) 480-750 (54.2-84.7)
5/8-18 1100-1600 (124.3-180.8) 660-1060 (74.6-119.8)
3/4-16 2300-3350 (259.9-378.5) 1300-2200 (146.9-248.6)
7/8-14 2500-4650 (282.5-525.4) 1500-2900 (169.5-327.7)
1-14 3700-6650 (418.0-751.4) 2200-4400 (248.6-497.1)
1-1/8-12 5000-10,000 (564.9-1129.8) 3000-6300 (339.0-711.8)
1-1/4-12 9000-16,700 (1016.9-1886.8) 5400-10,000 (610.1-1129.8)
NOTE 1: The part numbers for the fine thread tension type nuts are: AN310 and MS17825.
NOTE 2: The part number for the fine thread shear type nut is: AN320.
E. MS17826 Castellated Nuts
(1) MS17826 self-locking, castellated nuts must be torqued to the values listed in Table 203.
Table 203. Torque Limits for MS17826 Self-Locking Castellated Shear Nut
Nut Size Standard Torque in Inch Pounds Alternate Torque in Inch Pounds
(N-m) (N-m) (NOTE)
10-32 12-15 (1.4-1.7) 12-20 (1.4-2.3)
1/4-28 30-40 (3.4-4.5) 30-45 (3.4-5.1)
5/16-24 60-80 (6.8-9.0) 60-90 (6.8-10.2)
3/8-24 95-110 (10.7-12.4) 95-125 (10.7-14.1)
7/16-20 180-210 (20.3-23.7) 180-225 (20.3-25.4)
1/2-20 240-280 (27.1-31.6) 240-300 (27.1-33.9)
9/16-18 320-370 (36.2-41.8) 320-400 (36.2-45.2)
5/8-18 480-550 (54.2-62.1) 480-600 (54.2-67.8)
3/4-16 880-1010 (99.4-114.1) 880-1100 (99.4-124.3)
7/8-14 1500-1750 (169.5-197.7) 1500-1900 (169.5-214.7)
1-14 2200-2700 (248.6-305.1) 2200-3000 (248.6-339.0)
1-1/8-12 3200-4200 (361.6-474.5) 3200-5000 (361.6-564.9)
1-1/4-12 5900-6400 (666.6-723.1) 5900-7000 (666.6-790.9)
NOTE 1: Use the alternate torque values only if the cotter pin slot does not align with the hole in the bolt
or replace the nut if necessary.
F. Joints with Non-Metallic Materials
(1) Joints with wood, plastics, rubber, or rubberlike materials must be torqued to values approximately 80% of the torque
at which crushing is observed, or to the requirements of Table 201, whichever is lower, or unless specified differently.
G. Straight Threaded Fittings
(1) Straight threaded fittings, such as flared tube and hose end fittings, must be torqued per Tubing, Hose and Fittings -
H. Taper-Lok Fasteners
(1) Taper-Lok fasteners, TLN Series Washer-Nuts, and Self-Aligning Washer-Nuts must be torqued to the values listed in
Table 204. Fastener and nut must be lubricated before they are tightened.
Table 204. Torque Limits for Taper-Lok Fasteners

All Taper-Lok Fasteners Except TL500 Series TL500 Series Alloy Steel Taper-Lok
Fastener
Taper-Lok Fastener Taper-Lok Fastener Torque in Inch Taper-Lok Fastener Torque in Inch
Size Second Dash Pounds (N-m) Nominal Diameter Pounds (N-m)
Number
-3 or -5 20-40 (2.3-4.5)
-6 or -8 30-50 (3.4-5.6)
3/16 3/16 40-45 (4.5-5.1)
-9 or -12 40-60 (4.5-6.8)
-13 or -16 50-70 (5.6-7.9)
-3 or -5 80-100 (9.0-11.3)
-6 or -10 100-120 (11.3-13.6)
1/4 1/4 76-104 (8.6-11.8)
-11 or -20 120-140 (13.6-15.8)
-21 or -30 130-150 (14.7-16.9)
5/16 --- --- 5/16 180-210 (20.3-23.7)
-4 or -8 165-195 (18.6- 22.0)
-9 or -12 225-255 (25.4-28.8)
3/8 -13 or -18 245-275 (27.7-31.1) 3/8 270-295 (30.5-33.3)
-19 or -25 305-335 (34.5-37.9)
-26 or -36 335-365 (37.9-41.2)
7/16 --- --- 7/16 540-590 (61.0-66.7)
1/2 --- --- 1/2 650-720 (73.4-81.3)
--- --- 9/16 1125-1215 (127.1-
9/16
137.3)
NOTE 1: Lubricate the fastener and the nut with cetyl alcohol or Boelube.
I. Hi-Lok Fasteners
(1) Hi-Lok fasteners when used with MS21042 locking nuts must be torqued to the values listed in Table 205. 100
percent inspection is necessary.
Table 205. Torque Limits for Hi-Lok Fasteners with MS21042 Nuts
Hi-Lok Fastener Nominal Diameter Torque in Inch Pounds (N-m)
6-32 8-10 (0.9-1.1)
8-32 12-15 (1.4-1.7)
10-32 20-25 (2.3-2.8)
1/4-28 50-70 (5.6-7.9)
5/16-24 100-140 (11.3-15.8)
3/8-24 160-190 (18.1-21.5)
7/16-20 450-500 (50.8-56.5)
1/2-20 480-690 (54.2-78.0)
J. Thread Inserts
(1) Torque values for thread insert installation are the same as for steel nuts, in tension, of the same size and thread.
K. Threaded Electrical Hardware
(1) All threaded, electrical current-carrying fasteners for relay terminals, fuse limiter mount block terminals, shunt
terminals, and bus bar attachment hardware must be torqued to the values listed in Table 206.

Table 206. Torque Limits for Threaded Electrical Current-Carrying Fasteners

Fastener Size Torque in Inch Pounds (N-m)
6-32 8-12 (0.9-1.3)
8-32 13-17 (1.4-1.9)
10-32 20-30 (2.2-3.3)
1/4 40-60 (4.5-6.7)
5/16 80-100 (9.0-11.2)
3/8 105-125 (11.8-14.1)
1/2 130-150 (14.6-16.9)
(2) All threaded fasteners at airframe ground terminals must be torqued to the values listed in Table 207.
Table 207. Torque Limits for Threaded Fasteners at Airframe Ground
Fastener Size Torque in Inch Pounds (N-m)
5/16 130-150 (14.6-16.9)
3/8 160-190 (18.0-21.4)
L. MS-Type High-Pressure Pneumatic Service Valves
(1) The MS-type high-pressure pneumatic service valves must be torqued to the values listed in Table 208.
Table 208. Torque Limits for MS-Type High-Pressure Pneumatic Service Valve
Component Torque in Inch Pounds (N-m)
Body 65-75 (7.3-8.4)
Nut 50-60 (5.6-6.7)
Cap 20 (2.2)
(2) Make sure that the torque value is no higher than 70 inch-pounds, +5 or -5 inch-pounds (7.9 N-m, +0.57 or -0.57 N-m).
M. Hose Clamps
(1) Unless specified differently, the torque necessary to tighten hose clamps must be as follows:
(a) Hose clamps, except for miniature worm gear clamps (S2357), installed on fuel, oil, coolants, alcohol, and
water-alcohol systems including hose connections between the lines or systems and the engines, must be
torqued to 25-35 inch pounds (2.8-3.9 N-m). The miniature worm gear clamps must be torqued to 8-10 inch
pounds (0.9-1.1 N-m).
(b) Hose clamps, except for miniature worm gear clamps (S2357), installed on blast tubes, air ducts, vacuum lines,
deice tubes, drain lines, and vent lines must be torqued to 15-25 inch pounds (1.6-2.8 N-m). The miniature worm
gear clamps must be torqued to 8-10 inch pounds (0.9-1.1 N-m).
(c) Hose clamps installed on fuel bladder tank connections (fuel line to tank and vents) must be torqued as follows:
1 For fuel tanks with BTC-39 construction, torque to 20 inch pounds (2.2 N-m) maximum.
2 For fuel tanks with BTC-54 or BTC-67 construction, torque to 25-35 inch pounds (2.8-3.9 N-m).
3 For fuel tanks with BTC-85 construction with nipple fitting inside diameter 0.25 to 0.50 inch, torque to 12-16
inch pounds (1.3-1.8 N-m).
4 For fuel tanks with BTC-85 construction with nipple fitting inside diameter 0.75 to 1.00 inch, torque to 15-20
inch pounds (1.6-2.2 N-m).
(d) Hose clamps installed on air conditioner hoses must be torqued to 37-43 inch pounds (4.1-4.8 N-m).
N. Air Conditioning Fittings
(1) It is recommended that all air conditioning fitting flares be lightly coated with refrigerant oil.
(2) It is recommended that a small amount of thread sealant be applied to the fitting threads (male only) except the first
two or three threads.
(3) The air conditioning fittings must be torqued to the values listed in Table 209.

Table 209. Torque Limits for Air Conditioning Fittings

Fitting Size Tube Diameter Torque in Inch Pounds (N-m)
-4 0.250 50-65 (5.6-7.3)
-6 0.375 110-130 (12.4-14.6)
-8 0.500 230-260 (25.9-29.3)
-10 0.625 330-360 (37.2-40.6)
4. Torque Procedure
• Torque Wrench.
• Torque Putty.
• None.
B. Determine the correct torque values as given in Torque Data in this section.
C. When you use an adapter that changes the distance from the torque wrench drive to the adapter drive, the indicated torque
reading must be adjusted to get the correct torque value. Use the torque wrench adapter formula to find the adjusted
indicated torque reading. Refer to Figure 201.
D. Make sure that the bolt and nut threads are clean and dry unless specified differently.
E. Always tighten by turning the nut, if possible.
(1) When it is necessary to tighten from the bolt head, measure the shank friction with a torque wrench and add it to the
specified torque value. Do not exceed the maximum allowable torque value.
F. The running torque value must be added to the torque values given in Torque Data in this section.
(1) The running torque value is the torque value necessary to rotate a nut on a threaded shaft, without tightening. The
torque values listed in this section represent the torque values without running torque.
EXAMPLE: The torque value is 150 inch pounds (16.9 N-m) and the running torque is 25 inch pounds (2.8
N-m). The running torque must be added to the torque value to get a final torque of 175 inch
pounds (19.8 N-m).
G. Use the correct torque wrench to apply a smooth even pull when torqued. If chattering or a jerking movement occurs during
the final torque, loosen the nut one-quarter turn minimum and torque it again.
H. Self-locking nuts are for one time use only and must not be reused.
CAUTION: Do not apply torque putty inside a fluid system or where it could go into a fluid system.
I. Threaded fasteners and fittings that are torqued with a torque wrench must be marked with torque putty.

Figure 201 : Sheet 1 : Torque Wrench Adapter Formula

A99714
Legend:
Y = Indicated Torque Reading
T = Torque Value in Inch Pounds
L = Effective Lever Length in Inches
E = Effective Extension in Inches
Torque Wrench
Short Open-End Adapter Drive Centerline
Torque
Adapter Wrench
Drive
Centerline Handgrip Centerline
Setscrew Adapter
E L
Formula: Y = LT +x E
L
Example Shown with Positive Dimension E

Y = Indicated Torque Reading Y = 135 X 10.0
T = 135 Inch Pounds 10.0 + 1.5
L = 10.0 Inches Y = 117 Inch Pounds
Hose Clamp Adapter E = 1.5 Inches
Adapter
Drive
Centerline Handgrip
Torque Wrench Centerline
Drive Centerline
Open-End Wrench Adapter
E Torque
L Wrench
Flare Nut Wrench Adapter Formula: Y = T xL
L- E
Example Shown with Negative Dimension E

Y = Indicated Torque Reading Y = 135 X 10.0
T = 135 Inch Pounds 10.0 - 1.5
L = 10.0 Inches Y = 158 Inch Pounds
Spanner Wrench Adapter E = 1.5 Inches
5598T2005

Figure 201 : Sheet 2 : Torque Wrench Adapter Formula

A99715
L+E
E L
Formula: Y = T xL
L+E
L+E
E L
Formula: Y = T xL
L+E
Formula: Y = T
E L-E
Formula: Y = T xL
L- E
CSMP022

ROSAN FITTINGS - MAINTENANCE PRACTICES

1. Effectivity
• Model 525C
• Model 525 M2
• Model 650
• Model 680
• Model 680A.
2. General
A. This section gives the maintenance practices for Rosan fittings.
3. Description
A. Rosan fittings provide semi-permanent installations for use in valve and cylinder bodies, manifolds, fluid systems, etc.
Their primary use is for 3000 to 5000 psi hydraulic working pressure systems.
B. The lock ring is driven into the mating port serrations after the Rosan fitting has been torqued. This prevents the Rosan
fitting from turning in the port when the mating lines are attached or removed. It also eliminates the need to safety the
Rosan fitting with lockwire.
4. Rosan Fitting Removal/Installation
• Metal Container
• Protective Caps and Plugs
• Rosan Fitting Tools.
• Zinc Chromate Epoxy Primer.
B. Prepare the Airplane for the Rosan Fitting Removal.
WARNING: Read and fully understand all of the applicable system safety precautions before you do the
Manual.
(6) Put a metal container below the Rosan fitting to catch fluid.
(7) Disconnect the tubing or hose from the Rosan fitting.
(8) Install a protective cap or plug in the open port to prevent system contamination.
C. Remove the Rosan Fitting.
(1) If necessary, carefully remove the sealant to get access to the lock ring.

(2) Find the correct lock ring removal tool.

(a) For the Rosan adapter fitting, refer to Table 201.
Table 201. Rosan Adapter Fitting Data
Rosan Fitting O-ring Part O-ring Wrench Combination Lock Ring Installation
Part Number Number Installation Wrench and Removal Torque in Inch
Tool Drive Tool Tool Pounds (N-m)
RFK9904-13 AS568-010 ORT312 RF6904W RF9804DW RF04LPDE 60-100 (6.7-
11.2)
27.6)
57.6)
76.8)
106.7)
RFK9916-13 AS568-120 ORT1125 RF6916W RF9816DW RF16LPDE 1140-1260
(128.8-142.3)
NOTE 1: Rosan fittings require special tooling for correct installation.
(b) For the Rosan adapter-reducer fitting, refer to Table 202.
Table 202. Rosan Adapter-Reducer Fitting Data
Rosan Fitting O-ring Part O-ring Wrench Lock Ring Lock Ring Installation
Part Number Number Installation Drive Tool Removal Torque in Inch
Tool Tool Pounds (N-m)
RF9905-04- AS568-011 ORT375 RF6905W RF9805DEK RF05LPDE 100-120 (11.2-
13 13.5)
13 27.6)
13 57.6)
13 76.8)
13 106.7)
RF9916-04- AS568-120 ORT1125 RF6916W RF9816DEK RF16LPDE 1140-1260
13 (128.8-142.3)
13 (171.7-189.8)
13 57.6)
13 76.8)
13 106.7)
13 (128.8-142.3)


13 (171.7-189.8)
13 76.8)
13 106.7)
13 (128.8-142.3)
13 (171.7-189.8)
13 106.7)
13 (112.4-124.8)
13 (128.8-142.3)
13 (128.8-142.3)
13 (171.7-189.8)
13 (171.7-189.8)
13 (214.6-237.2)
NOTE 1: Rosan fittings require special tooling for correct installation.
(3) Spread the puller halves apart to retract the sleeve from the lock ring removal tool until the pin bottoms in the groove
of the sleeve. Refer to Figure 201.
(4) Hold the puller halves apart and put the lock ring removal tool over the protruding part of the Rosan fitting so that the
nylon pad rests on the top surface of the Rosan fitting.
(5) Release the puller halves and install them in the groove of the lock ring.
(6) Adjust the bolt on the lock ring removal tool up or down as necessary.
(7) Slide the sleeve over the puller halves and make sure that the puller halves are engaged correctly in the lock ring
groove.
(8) Hold the sleeve while you use a wrench to turn the bolt on the lock ring removal tool clockwise to pull the lock ring out
of the port counterbore.
(9) Continue to turn the bolt on the lock ring removal tool clockwise until the external serrations of the lock ring are free of
the boss surface.
(10) Loosen the bolt, lift the sleeve to disengage the puller halves, and remove the lock ring removal tool from the Rosan
fitting.
(11) Find the correct combination wrench and drive tool.
(12) Engage the serrations of the wrench with those of the lock ring.
(13) Use an open end wrench or socket wrench over the hex on the wrench to turn it counterclockwise to disengage the
Rosan fitting from the port.
(14) Remove the Rosan fitting from the port.
(15) Remove and discard the O-ring from the Rosan fitting.

(16) Install a protective plug in the open port to prevent system contamination.
D. Install the Rosan Fitting.
(1) Find the correct O-ring for the Rosan fitting.
(2) Make sure that the O-ring groove area on the Rosan fitting is free of scratches, dings, and rough marks.
(3) Submerge the Rosan fitting, O-ring installation tool, and O-ring in clean system fluid or a lubricant that is compatible
with the system fluid and all components.
(4) Put the O-ring installation tool on the Rosan fitting. Refer to Figure 202.
(5) Put a new O-ring on the small end of the O-ring installation tool.
(6) Slide the new O-ring over the O-ring installation tool to the O-ring groove on the Rosan fitting.
(7) Make sure that the O-ring is not twisted and is correctly seated in the O-ring groove on the Rosan fitting.
(8) Remove the O-ring installation tool from the Rosan fitting.
(9) Remove the protective plug from the port.
(10) Lubricate the internal surfaces of the port and the Rosan fitting assembly with clean system fluid or a lubricant that is
compatible with the system fluid and all components.
(11) Make sure that the O-ring contact area in the port is free of scratches, dings, and rough marks.
CAUTION: Do not turn the Rosan fitting counterclockwise after it is installed in the port to prevent O-ring
damage.
(12) Thread the Rosan fitting into the port by hand until it is seated.
(13) Find the correct combination wrench and drive tool.
(14) Engage the serrations of the wrench with those of the lock ring on the Rosan fitting. Refer to Figure 203.
(15) Put a torque wrench over the hex on the combination wrench and drive tool and tighten it to the minimum torque limit
specified as follows: Refer to Torque Data - Maintenance Practices.
(16) Make sure that the lock ring serrations and the pre-broached serrations in the port match.
(a) If the serrations do not match, continue to slowly torque the Rosan fitting toward the maximum torque limit
specified in Table 201 or Table 202 until the serrations match.
NOTE: This will usually take between 3 and 8 degrees of turn.
1 Do not tighten the Rosan fitting any more after the serrations match.
2 Do not exceed the maximum torque limit specified in Table 201 or Table 202.
(17) Remove the torque wrench from the combination wrench and drive tool.
(18) Apply a brush coat of zinc chromate epoxy primer sufficiently to the counterbore area of the port and below the fitting
lock ring so that it will be extruded out between external serrations of the lock ring and the serrations in the port when
the lock ring is installed.
(19) While the primer is still wet, use an open end wrench or a socket wrench on the combination wrench and drive tool to
turn it clockwise until it bottoms on the port surface as shown in Figure 204.
(a) Make sure that the combination wrench and drive tool is against the port surface fully.
NOTE: The lock ring is installed in the port when the combination wrench and drive tool bottoms
against the port surface fully.
(b) If a sudden increase in torque occurs before the combination wrench and drive tool bottoms against the port
surface, do the steps that follow:
NOTE: A sudden increase in torque before the combination wrench and drive tool bottoms may

indicate that the lock ring serrations and the port serrations are not aligned.
1
Turn the combination wrench and drive tool counterclockwise and remove it from the Rosan fitting.
2
Lift the lock ring.
3
Use the torque wrench and tighten the Rosan fitting clockwise until serrations in the port and the external
serrations on the lock ring are aligned as specified above.
4 Use an open end wrench or a socket wrench to install the lock ring as specified above.
(20) Turn the combination wrench and drive tool counterclockwise and remove it from the Rosan fitting.
(21) Make sure that Dimension P standoff distance is within the limit specified. Refer to Figure 205 and the tables that
follow:
NOTE: Dimension P is the distance between the top of the Rosan fitting and the port surface.
Table 203. Rosan Adapter Fitting Dimension P Standoff Distance
Rosan Fitting Part Number Dimension P Standoff Distance (± 0.0175 Inch)
RFK9904-13 0.587
RFK9906-13 0.609
RFK9908-13 0.702
RFK9910-13 0.765
RFK9912-13 0.838
RFK9916-13 0.838
Table 204. Rosan Adapter-Reducer Fitting Dimension P Standoff Distance
Rosan Fitting Part Number Dimension P Standoff Distance (± 0.0175 Inch)
RF9905-04-13 0.717
RF9906-04-13 0.735
RF9908-04-13 0.735
RF9910-04-13 0.735
RF9912-04-13 0.735
RF9916-04-13 0.744
RF9920-04-13 0.724
RF9908-06-13 0.751
RF9910-06-13 0.751
RF9912-06-13 0.751
RF9916-06-13 0.751
RF9920-06-13 0.740
RF9910-08-13 0.845
RF9912-08-13 0.845
RF9916-08-13 0.845
RF9920-08-13 0.833
RF9912-10-13 0.904
RF9914-10-13 0.916
RF9916-10-13 0.916
RF9916-12-13 0.979

RF9920-12-13 0.959
RF9920-16-13 0.959
RF9924-16-13 0.980
(1) Remove the protective cap or plug from the port.
(2) Connect the tubing or hose to the Rosan fitting.
(4) Do the servicing of the applicable system. Refer to the applicable Maintenance Manual.
(6) Remove the metal container from below the Rosan fitting.

Figure 201 : Sheet 1 : Lock Ring Removal Tool

A99720
Sleeve
Bolt
Pin
Puller Halves
Nylon Pad
Adapter
Lock Ring
Sleeve Retracted, Puller Halves Sleeve Over Puller Halves

Ready to be Located in Lock Ring Groove Ready for Torquing Bolt

Figure 202 : Sheet 1 : O-ring Installation Tool

A99719
Rosan Fitting
O-ring After Assembly
O-ring Installation Tool
O-ring Before Assembly

Figure 203 : Sheet 1 : Rosan Fitting Installation

A99718
Combination Wrench
and Drive Tool
Rosan Fitting
Port Lock Ring
O-ring
Apply zinc chromate epoxy

primer here after the Rosan
fitting is torqued.

Figure 204 : Sheet 1 : Lock Ring Installation

Figure 205 : Sheet 1 : Dimension P Standoff Distance

A99716
Rosan Fitting
P
Port Surface

DEUTSCHLITE FITTINGS - MAINTENANCE PRACTICES

1. Effectivity
• Model 525B
• Model 525C
• Model 525 M2
• Model 650
• Model 680
• Model 680A
• Model 700.
2. General
A. This section gives the maintenance practices for DeutschLite fittings. It includes DeutschLite fitting installation,
DeutschLite fitting troubleshooting, and damaged tubing replacement with DeutschLite fittings.
3. Description
A. Installation and inspection of DeutschLite fittings must be done by certified personnel only.
B. This section gives the requirements for the installation of aluminum, titanium, and stainless steel DeutschLite fittings using
Deutsch swage tooling for hydraulic tubing installed on the airplane.
C. DeutschLite is a tube fitting that is mechanically attached to the tube by axial swaging. It works by deforming the fitting into
the tube being joined by moving a ring, a component of the DeutschLite fitting, axially along the fitting length using a
Deutsch Axial-Swage Tool (DAT). This gives an interference fit between the fitting and the tube. Three marks are put on
the tube to show if the swaged fitting is installed in the correct position. An inspection gage is then used to make sure that
the swage is correct.
D. Swage and inspection tooling for aluminum have green markings, titanium have black markings, and stainless steel have
blue markings.
4. DeutschLite Fitting Installation
• Deutsch Axial-Swage Tool (DAT) Kit.
NOTE: DAT tool kits contain swage tools, marking templates, inspection gages, tube cutters,
deburring tools with stem assemblies, hex key, and a making pen. For the specific DAT
tool kit part numbers, refer to Permaswage.
• None.
B. Prepare the Tubing for the DeutschLite Fitting Installation.
(1) Dimension D is the recommended minimum straight length of tube for insertion into a DeutschLite fitting as shown in
Figure 201 and Table 201 for aluminum, Table 204 for titanium, and Table 207 for stainless steel. For unions, a 0.3
inch (7.62 mm) fitting position tolerance is used, so a straight tube length of (dimension C + dimension D)/ 2 is
acceptable. This allows for a gap of up to 0.3 inch (7.62 mm) between the tubes being connected.
NOTE: Swage and inspection tooling for aluminum has green markings, titanium has black markings,
and stainless steel has blue markings.

A99791
E
D
C
Verification Mark
(NOTE)
Positioning Mark
Inspection Mark
A
B
NOTE: The verification mark is used with fittings that allow

tube insertion beyond (covering) the positioning mark.
Figure 201
(a) For aluminum DeutschLite fittings, refer to Table 201, Table 202, and Table 203.
Table 201. Aluminum DeutschLite Marking Templates and Insertion Mark Locations
Tube Size Marking Template Insertion Mark End Locations in Inches, ±0.005 Inch
in Inches Part Number Dimension A Dimension Dimension Dimension Dimension E
(Size) (NOTE 3) B C D
1/4 (-04) DAT06AEMG1004 0.320 0.670 0.513 0.813 0.885
5/16 (-05) DAT06AEMG1005 0.420 0.770 0.643 0.943 1.100
5/16 (-05) DAT06AEMG1105 0.420 0.620 0.643 0.799 0.825
(NOTE 1)
5/16 (-05) DAT06AEMG1005A 0.455 0.805 0.643 0.799 0.825
(NOTE 2)
3/8 (-06) DAT06AEMG1006 0.525 0.875 0.792 1.092 1.185
1/2 (-08) DAT06AEMG1008 0.695 1.045 0.995 1.295 1.430
5/8 (-10) DAT06AEMG1010 0.710 1.060 1.000 1.300 1.480
3/4 (-12) DAT06AEMG1012 0.810 1.160 1.140 1.440 1.605
1 (-16) DAT06AEMG1016 1.080 1.430 1.510 1.810 2.045
1-1/4 (-20) DAT06AEMG1020 1.305 1.655 1.785 2.085 2.370
1-1/2 (-24) DAT06AEMG1024 1.585 1.935 2.145 2.445 2.785
1-3/4 (-28) DAT06AEMG1028 1.780 2.130 2.420 2.720 2.785
NOTE 1: For use with Deutsch part numbers DPLBU300D05, DPLB334D05, and DPLB335D05.
NOTE 2: For use with Deutsch part number DPLU744D05A.
NOTE 3: For use with Deutsch part number DLT5301-000-01 marking pen.
Table 202. Aluminum DeutschLite DAT Tools
Tube Size in Inches (Size) Swage Tool (DAT) Part Number
1/4 (-04) DAT06AETA1004
5/16 (-05) DAT06AETA1005
3/8 (-06) DAT06AETA1006
1/2 (-08) DAT06AETA1008

5/8 (-10) DAT06AETA1010

3/4 (-12) DAT06AETA1012
1 (-16) DAT06AETA1016
1-1/4 (-20) DAT06AETA1020
1-1/2 (-24) DAT06AETA1024
1-3/4 (-28) DAT06AETA1028
Table 203. Aluminum DeutschLite Inspection Gages and Lengths
Tube Size in Flat Inspection Gage Circular Inspection Gage
Inches (Size) Flat Inspection Dimension F Circular Inspection Dimension G
Gage Part Number Maximum in Inches Gage Part Number Maximum in Inches
1/4 (-04) DAT06AEIG1004 0.435 DAT06AECG1004 0.434
5/16 (-05) DAT06AEIG1005 0.512 DAT06AECG1005 0.512
5/16 (-05) (NOTE 1) - - DAT06AECG1105 0.512
3/8 (-06) DAT06AEIG1006 0.637 DAT06AECG1006 0.638
1/2 (-08) DAT06AEIG1008 0.800 DAT06AECG1008 0.800
5/8 (-10) DAT06AEIG1010 0.812 DAT06AECG1010 0.812
3/4 (-12) DAT06AEIG1012 0.897 DAT06AECG1012 0.899
1 (-16) DAT06AEIG1016 1.170 DAT06AECG1016 1.168
1-1/4 (-20) DAT06AEIG1020 1.385 DAT06AECG1020 1.385
1-1/2 (-24) DAT06AEIG1024 1.659 DAT06AECG1024 1.658
1-3/4 (-28) DAT06AEIG1028 1.857 DAT06AECG1028 1.855
NOTE 1: For use with DeutschLite part numbers DPLBU300D05, DPLB334D05, and DPLB336D05
only.
(b) For titanium DeutschLite fittings, refer to Table 204, Table 205, and Table 206.
Table 204. Titanium DeutschLite Marking Templates and Insertion Mark Locations - 4000 psi Series
Tube Size in Marking Insertion Mark End Locations in Inches, ±0.005 Inch
Inches Template Part Dimension A Dimension B Dimension C Dimension D Dimension E
(Size) Number (NOTE 1)
1/4 (-04) DAT06AEMG4004 0.300 0.650 0.485 0.785 0.890
3/8 (-06) DAT06AEMG4006 0.390 0.740 0.580 0.880 0.955
1/2 (-08) DAT06AEMG4008 0.520 0.870 0.730 1.030 1.140
5/8 (-10) DAT06AEMG4010 0.670 1.020 0.930 1.230 1.380
3/4 (-12) DAT06AEMG4012 0.810 1.160 1.105 1.405 1.575
1 (-16) DAT06AEMG4016 1.080 1.430 1.470 1.770 2.025
DAT06AEMG3020
1-1/4 (-20) 1.305 1.655 1.795 2.095 2.395
DAT06AEMG4020
1-1/2 (-24) DAT06AEMG3024 1.585 1.935 2.165 2.465 2.815
Table 205. Titanium DeutschLite DAT Tools - 4000 psi Series
Tube Size in Inches (Size) Swage Tool (DAT) Part Number Swage Tool (DAT) Part Number
02 Series

1/4 (-04) DAT02AETA4004 DAT06AETA4004

3/8 (-06) DAT02AETA4006 DAT06AETA4006
1/2 (-08) DAT02AETA4008 DAT06AETA4008
5/8 (-10) DAT02AETA4010 DAT06AETA4010
3/4 (-12) DAT02AETA4012 DAT06AETA4012
1 (-16) DAT02AETA4016 DAT06AETA4016
- DAT06AETA3020
1-1/4 (-20)
- DAT06AETA4020
1-1/2 (-24) - DAT06AETA3024
Table 206. Titanium DeutschLite Inspection Gages and Lengths - 4000 psi Series
Tube Size in Flat Inspection Gage Circular Inspection Gage
Inches (Size) Flat Inspection Dimension F Circular Inspection Dimension G
Gage Part Number Maximum in Inches Gage Part Number Maximum in Inches
1/4 (-04) DAT06AEIG4004 0.417 DAT06AECG4004 0.417
3/8 (-06) DAT06AEIG4006 0.474 DAT06AECG4006 0.474
1/2 (-08) DAT06AEIG4008 0.599 DAT06AECG4008 0.603
5/8 (-10) DAT06AEIG4010 0.740 DAT06AECG4010 0.743
3/4 (-12) DAT06AEIG4012 0.882 DAT06AECG4012 0.885
1 (-16) DAT06AEIG4016 1.170 DAT06AECG4016 1.172
DAT06AEIG3020 1.385 DAT06AECG3020 1.386
1-1/4 (-20)
DAT06AEIG4020 1.385 DAT06AECG4020 1.386
1-1/2 (-24) DAT06AEIG3024 1.659 DAT06AECG3024 1.659
(c) For stainless steel DeutschLite fittings, refer to Table 207, Table 208, and Table 209.
Table 207. Stainless Steel DeutschLite Marking Templates and Insertion Mark Locations - 3000 psi
Series
Tube Size in Marking Template Insertion Mark End Locations in Inches, ±0.005 Inch
Inches (Size) Part Number Dimension A Dimension B Dimension C Dimension D
(NOTE 1)
1/4 (-04) DAT05AEMG3004 0.430 0.770 0.570 0.870
3/8 (-06) DAT05AEMG3006 0.555 0.895 0.730 1.030
1/2 (-08) DAT05AEMG3008 0.760 1.160 0.970 1.320
5/8 (-10) DAT05AEMG3010 0.950 1.340 1.275 1.625
3/4 (-12) DAT05AEMG3012 1.105 1.495 1.445 1.790
1 (-16) DAT05AEMG3016 1.520 1.960 1.985 2.385
Table 208. Stainless Steel DeutschLite DAT Tools - 3000 psi Series
Tube Size in Inches (Size) Swage Tool (DAT) Part Number
1/4 (-04) DAT06AETA5004
3/8 (-06) DAT06AETA5006
1/2 (-08) DAT06AETA5008
5/8 (-10) DAT06AETA5010

3/4 (-12) DAT06AETA5012

1 (-16) DAT06AETA5016
Table 209. Stainless Steel DeutschLite Inspection Gages and Lengths - 3000 psi Series
Tube Size in Inches (Size) Flat Inspection Gage
Flat Inspection Gage Part Dimension F Maximum in Inches
Number
1/4 (-04) DAT05AEIG3004 0.443
3/8 (-06) DAT05AEIG3006 0.520
1/2 (-08) DAT05AEIG3008 0.696
5/8 (-10) DAT05AEIG3010 0.916
3/4 (-12) DAT05AEIG3012 0.988
1 (-16) DAT05AEIG3016 1.387
(2) Use the correct tube cutter to cut the tubing to the required length. Refer to Table 210.
Table 210. Tube Cutters
Tube Size in Inches (Size) Tube Cutter Part Number
1/4 to 3/8 (-04 to 06) D12530-001
1/2 to 7/8 (-08 to 14) D12531-001
1 to 1-1/2 (-16 to -24) D12532-001
(3) Use the correct deburring tool to remove the burrs and sharp edges from the inside and the outside of the tubing end.
Refer to Table 211.
Table 211. Deburring Tools and Stem Assemblies
Tube Size in Inches (Size) Deburring Tool Part Number Stem Assembly Part Number
1/4 (-04) D9851-14 D9851-13-04
5/16 (-05) D9851-14 D9851-13-05
3/8 (-06) D9851-14 D9851-13-06
1/2 (-08) D9850-14 D9850-13-08
5/8 (-10) D9850-14 D9850-13-10
3/4 (-12) D9850-14 D9850-13-12
1 (-16) D9849-15 D9849-13-16
1-1/4 (-20) D9849-15 D9849-13-20
1-1/2 (-24) D9849-15 D9849-13-24
(4) Make sure that the tube seal area is free of cracks, splits, seams, folds, scratches, and any other imperfection that is
detrimental to the performance of the swaged joint.
(5) Make sure that the tube seal area is free of any substances detrimental to fitting assembly such as point, glue, or
other contamination.
(6) Clean the tube seal area as applicable for the type of tubing. Refer to General Solvents/Cleaners - Maintenance
Practices.
WARNING: Deutsch Axial-Swage Tools (DAT) use high-pressure forces during operation. Keep your hands
and fingers away from the moving parts when pressurizing the DAT tool. Always make sure that
the DeutschLite fitting is in the correct position in the tool before and during the swaging
procedure. Incorrect use can cause tool failure and/or personal injury.
WARNING: Always wear eye protection when you install swaged fittings to prevent injury.
CAUTION: Only use DAT tools for the installation of DeutschLite fittings.

CAUTION: Do not hold the DAT tool by the quick-disconnect or the hose to prevent damage to the swivel.
CAUTION: Do not expose the DAT tool or its components to temperatures of more than 150°F (65°C).
CAUTION: Do not disassemble the DAT tool for any reason.
(7) Select the correct DAT tool for the fitting that will be swaged. Refer to Table 202 for aluminum, Table 205 for titanium,
and Table 208 for stainless steel.
(8) Visually examine the DAT tools to make sure that they are in good working condition.
(a) Examine the area between and around the jaws to make sure that there is no dirt or other debris lodged in the
tool. Look closely at the slot that guides the moveable jaw.
(b) Examine the jaws and surrounding areas to make sure that there are no cracks, nicks, or dings.
(9) Select the applicable hydraulic pump to connect to the DAT tool. Refer to Table 212.
Table 212. Hydraulic Pumps - 10,000 psi
Power Source Hydraulic Pump Part Number
Manual Hand Pump DLT05MAPM1000
Pneumatic (100 psi Shop Air) DLT02MAPP1000
Electric (12 VDC Battery) DLT06MAPE1000
Electric (110 VAC) DLT07MAPE1000
(10) Attach the hydraulic hose rated for 10,000 psi to the DAT tool and the hydraulic pump.
(11) Operate the hydraulic pump through two full cycles of operation without a DeutschLite fitting installed in the DAT tool
jaws.
(a) Make sure that the pressure gage on the hydraulic pump goes into the green range (10,000 psi, +250 or -250
psi).
(b) Make sure that the pressure relief valve on the hydraulic pump operates correctly as follows:
1 For the pneumatic or the electric operated hydraulic pump, make sure that it stops cycling.
2 For the manual hand pump, make sure that you hear a snapping noise.
(c) Make sure that the moveable jaw on the DAT tool moves smoothly and retracts fully.
(d) Make sure there is no fluid leakage from the DAT tools.
(e) Release the pressure as necessary.
C. Install the DeutschLite Fitting.
(1) Select the correct marking template for the fitting that will be swaged. Refer to Table 201 for aluminum, Table 204 for
titanium, and Table 207 for stainless steel.
(2) Put the marking template on the end of the tube. Refer to Figure 202.
(a) Use the sight hole to make sure that the marking template fits flush against the tube end.
CAUTION: Only use DeutschLite-approved pens to put the marks on the surface of the tube. Pens that
are not approved can cause corrosion in the swaged joint.
(b) Use the marking pen to make a mark along the sides of each slot.
NOTE: There is a slot for the verification mark, positioning mark, and inspection mark.
(c) Remove the marking template from the tube.
(d) Make sure that the three marks are clearly visible on the tube so that you can verify the position of the fitting
before and after the swaging.
(3) Select the correct DeutschLite fitting for the tube material that will be swaged as follows:
(a) For Aluminum 6061-T6 or Aluminum 5052-O fitting material and Aluminum 5052-O (AMS4071) tube material,
refer to Table 213.

Table 213. Aluminum 6061-T6 or Aluminum 5052-O Fitting Material and Aluminum 5052-O (AMS4071)
Tube Material
Max Tube Outer Diameter and Wall Thickness in Inches (Size)
Operating 3/16 1/4 (- 5/16 (- 3/8 (- 1/2 (- 5/8 (- 3/4 (- 7/8 (- 1 (-16) 1-1/4 1-1/2 1-3/4 2 (-
Pressure (-03) 04) 05) 06) 08) 10) 12) 14) (-20) (-24) (-28) 32)
(psi)
100 - - - - - - - - - - - 0.028 -
200 - - - - - - - - - 0.028 0.028 - -
300 - - 0.028 - - - 0.028 - 0.028 - - - -
500 - - 0.035 0.028 0.028 0.028 - - - - - - -
1000 - 0.028 - - - - - - - - - - -
1100 - - - 0.035 - - - - - - - - -
(NOTE
1)
1550 - 0.035 - 0.049 - - - - - - - - -
(NOTE (NOTE
1) 1)
0.049
(NOTE
1)
NOTE 1: The maximum operating temperature is 225°F (107°C).
NOTE 2: Unless otherwise noted, the maximum operating temperature of the aluminum tube is
160°F (71°C).
(b) For Aluminum 6061-T6 or Aluminum 5052-O fitting material and Aluminum 6061-T6 (AMS4083/MIL-T-7081)
tube material, refer to Table 214.
Table 214. Aluminum 6061-T6 or Aluminum 5052-O Fitting Material and Aluminum 6061-T6
(AMS4083/MIL-T-7081) Tube Material
Operating 3/16 1/4 (- 5/16 (- 3/8 (- 1/2 (- 5/8 (- 3/4 (- 7/8 (- 1 (-16) 1-1/4 1-1/2 1-3/4 2 (-32)
Pressure (-03) 04) 05) 06) 08) 10) 12) 14) (-20) (-24) (-28)
(psi)
200 - - - - - - - - - - 0.028 0.028 0.035
300 - - 0.020 - - - - - - 0.025 0.035 0.035 0.049
0.028
500 - - - 0.028 - 0.028 0.028 - 0.028 - 0.049 0.049 0.065
(NOTE (NOTE 0.035 0.035
1) 1) (NOTE
1)
700 - - -- -
0.028 0.028 - - - - - -
1000 - - - -
0.028 0.028 0.049 - 0.049 - - - -
0.035
1500 0.028 0.028 0.028 0.028 0.035 - - - - - - - -
0.035 0.035 0.035
(NOTE
1)
NOTE 1: The maximum operating temperature is 225°F (107°C).
NOTE 2: Unless otherwise noted, the maximum operating temperature of the aluminum tube is
160°F (71°C).

(c) For Titanium 6AI-4V (Supplier Standard DS503 4000 psi only) fitting material and Titanium 3AL-2.5V
(AMS4944, AMS4945) tube material, refer to Table 215.
Table 215. Titanium 6AI-4V (Supplier Standard DS503 4000 psi only) Fitting Material and Titanium 3AL-
2.5V (AMS4944, AMS4945) Tube Material
Operating 3/16 1/4 (- 5/16 (- 3/8 (- 1/2 (- 5/8 (- 3/4 (- 7/8 (- 1 (-16) 1-1/4 1-1/2 1-3/4 2 (-32)
Pressure (-03) 04) 05) 06) 08) 10) 12) 14) (-20) (-24) (-28)
(psi)
500 - - - - - - - - - - - - -
2000 - - - 0.020 0.020 0.023 0.027 - 0.036 - - - -
3000 - 0.016 - 0.019 0.026 0.032 0.039 - 0.051 - - - -
4000 - 0.018 - 0.028 0.035 0.044 0.052 0.061 0.070 0.087 - - -
0.020
5000 - - - - - - - - - - - - -
NOTE 1: Unless otherwise noted, the maximum operating temperature of the titanium tube is 275°F
(135°C).
(d) For Stainless Steel 21-6-9 fitting material and CRES 21-6-9 (AMS 5561) tube material, refer to Table 216.
Table 216. Stainless Steel 21-6-9 Fitting Material and CRES 21-6-9 (AMS 5561) Tube Material
Operating 3/16 (- 1/4 (- 5/16 (- 3/8 (- 1/2 (- 5/8 (- 3/4 (- 7/8 (- 1 (-16) 1-1/4 1-1/2 1-3/4 2 (-32)
Pressure 03) 04) 05) 06) 08) 10) 12) 14) (-20) (-24) (-28)
(psi)
3000 0.020 0.016 - 0.020 0.020 0.032 0.039 - 0.052 - - - -
0.020 0.026
4000 - - - - 0.035 - - - - - - - -
NOTE 1: Unless otherwise noted, the maximum operating temperature of the CRES tube is 275°F
(135°C).
(e) For Stainless Steel 21-6-9 fitting material and CRES 304 1/8 Hard (AMS-T-6845, MIL-T-6845) tube material,
refer to Table 217.
Table 217. Stainless Steel 21-6-9 Fitting Material and CRES 304 1/8 Hard (AMS-T-6845, MIL-T-6845)
Tube Material
Operating 3/16 (- 1/4 (- 5/16 (- 3/8 (- 1/2 (- 5/8 (- 3/4 (- 7/8 (- 1 (-16) 1-1/4 1-1/2 1-3/4 2 (-32)
Pressure 03) 04) 05) 06) 08) 10) 12) 14) (-20) (-24) (-28)
(psi)
3000 0.028 - - - 0.035 - - - - - - - -
2500 - - - - - 0.028 0.035 - - - - - -
1500 - - - - - - - - 0.028 - - - -
NOTE 1: Unless otherwise noted, the maximum operating temperature of the CRES tube is 275°F
(135°C).
(f) For Stainless Steel 21-6-9 fitting material and Titanium 3AL-2.5V (AMS 4945) tube material, refer to Table 218.
Table 218. Stainless Steel 21-6-9 Fitting Material and Titanium 3AL-2.5V (AMS 4945) Tube Material
Operating 3/16 1/4 (- 5/16 (- 3/8 (- 1/2 (- 5/8 (- 3/4 (- 7/8 (- 1 (-16) 1-1/4 1-1/2 1-3/4 2 (-32)
Pressure (-03) 04) 05) 06) 08) 10) 12) 14) (-20) (-24) (-28)
(psi)

3000 - 0.016 - 0.019 0.026 0.032 0.039 - 0.051 - - - -

NOTE 1: Unless otherwise noted, the maximum operating temperature of the titanium tube is 275°F
(135°C).
(g) For Stainless Steel 21-6-9 fitting material and Aluminum 6061-T6 (AMS 4083, MIL-T-7081) tube material, refer
to Table 219.
Table 219. Stainless Steel 21-6-9 Fitting Material and Aluminum 6061-T6 (AMS 4083, MIL-T-7081) Tube
Material
Operating 3/16 1/4 (- 5/16 (- 3/8 (- 1/2 (- 5/8 (- 3/4 (- 7/8 (- 1 (-16) 1-1/4 1-1/2 1-3/4 2 (-32)
Pressure (-03) 04) 05) 06) 08) 10) 12) 14) (-20) (-24) (-28)
(psi)
1500 - 0.035 - 0.035 0.035 - - - - - - - -
(NOTE
1)
1000 - - - - - 0.035 0.035 - 0.049 - - - -
NOTE 1:
The maximum operating temperature is 225°F (107°C).
NOTE 2:
Unless otherwise noted, the maximum operating temperature of the aluminum tube is
160°F (71°C).
CAUTION: Do not force the DeutschLite fitting on the tube. Make sure that the fitting and the tube are aligned
correctly to prevent damage.
(4) Slide the DeutschLite fitting on the tube to the correct position on the positioning mark. Refer to Figure 203.
(a) For a DeutschLite fitting with a tube stop, slide the fitting on the tube until it stops.
CAUTION: Do not force the DAT tool into position to prevent damage.
(5) Put the correct DAT tool on the DeutschLite fitting so that the fitting groove is bottomed against the swage tool and
the ring is nested within its jaws. Refer to Figure 204.
NOTE: The DAT tool can swage a DeutschLite fitting in the push or pull position but not all
DeutschLite fittings can be swaged in the pull position. For example, with a tee fitting, the
moveable jaw can interfere with the forging body in the pull position.
NOTE: Using the DAT tool in the pull position requires special attention to make sure that the
DeutschLite fitting does not move during the swaging process. For this reason, it is
recommended that at least one end of a DeutschLite fitting be swaged in the push position or,
for the case of a separable fitting, fasten before attempting a swage in the pull position.
(a) Make sure that the access area around the DAT tool is sufficient and its operation will not be restricted by
structure or other components in the area.
(b) Make sure that the longitudinal axis of the DAT tool and the DeutschLite fitting is parallel.
(6) Hold the DAT tool in position and operate the hydraulic pump until the pressure gage on the hydraulic pump goes into
the green range (10,000 psi, +250 or -250 psi). Make sure that as the hydraulic pump pressure increases, the DAT
tool jaw advances the fitting ring until it is flush with the fitting flange as shown in Figure 205.

Figure 205
(a) Make sure that the pressure relief valve on the hydraulic pump operates.
(7) Release the hydraulic pump pressure to retract the jaws on the DAT tool.
(8) Remove the DAT tool from the DeutschLite fitting.
(9) Do this procedure again for each DeutschLite fitting end to be swaged.
D. Examine the Swaged DeutschLite Fitting.
(1) Visually examine the position of the swaged fitting on the tube to make sure that at least two marks are visible on the
tube. Refer to Figure 206.
(a) Make sure that the verification mark is completely exposed.
(b) Make sure that the positioning mark is completely exposed or partly covered.
(c) Make sure that the inspection mark is partly/completely covered or just touching the swaged fitting.
(d) Make sure that there is no visible gap between the inspection mark and the swaged fitting. This would indicate
insufficient tube insertion.
(2) Select the correct inspection gage to examine the DeutschLite fitting. Refer to Table 203 for aluminum, Table 206 for
titanium, and Table 209 for stainless steel.
(3) Put the inspection gage on the completed swaged fitting. Refer to Figure 207.
A99797
Flat Inspection Gage
Fitting Flange/Fitting Ring

Deformation
Fitting Flange Fitting Ring
H H
J J
6980T1007
Figure 207
(a) For the flat inspection gage, make sure that it can fit all around the fitting ring and the fitting flange without forcing
it.

(b) For the circular inspection gage, make sure that it fits around the fitting ring and the fitting flange in at least one
location without forcing it.
(c) If the inspection gage does not fit around the fitting ring and the fitting flange, refer to DeutschLite Fitting
Troubleshooting in this section.
(4) Due to variables in tools, fittings, and tubes, it is possible to identify the following with the swaged fitting:
(a) A gap between the fitting flange and the fitting ring leading edge. This gap is permitted if the inspection gage fits
the swaged fitting.
(b) A fitting flange/fitting ring deformation of 0.030 inch (0.76 mm) maximum if no metal is removed from the
surface. Dimension H minus Dimension J must be 0.030 inch (0.762 mm) or less. Refer to Figure 207.
(c) Damage to the fitting ring composite overlay (if applicable) must not exceed the areas shown in Figure 208.
A99798 Composite
Overlay
Fitting = Area where damage

Ring is permitted.
Metal (NOTE 1)
Ring
(NOTE 2)
NOTE 1: Any type of composite damage, including the complete removal of the composite overlay,
is acceptable within this area.
NOTE 2: 0.062 inch (1.57 mm) maximum on size -04 and -06 fittings.
0.125 inch (3.17 mm) maximum on size -08 and larger fittings.
690T1008
Figure 208
(d) Replace any fitting that does not obey these requirements.
5. Damaged Tubing Replacement with DeutschLite Fittings
• DAT Tool Kit
• None.
B. Prepare the Airplane for the Damaged Tubing Replacement with DeutschLite Fittings.
WARNING: Read and fully understand all of the applicable system safety precautions before you do the

Manual.
C. Replace the Damaged Tubing with DeutschLite Fittings.
CAUTION: Use the same material and size of tube for the replacement tubing to prevent leakage and failure.
(1) Find the area of damage and the most applicable area to do the repairs.
CAUTION: Because of the tolerances necessary for the connection of the tubing, it is very important that you
carefully measure the tubing before it is cut.
(2) Use a tube cutter from the DAT tool kit to cut the damaged section out of the tubing.
(3) Use a deburring tool from the DAT tool kit to remove the burrs and the sharp edges from the tubing.
(4) Use the applicable solvent to clean the tube ends. Refer to General Solvents/Cleaners - Maintenance Practices.
(5) Use the applicable DeutschLite fittings to install the correct length and type of tubing in the place of the damaged
section of tubing. Refer to DeutschLite Fitting Installation in this section.
(a) Make sure that the tubing has the correct bends and alignment as necessary.
6. DeutschLite Fitting Troubleshooting
A. Refer to Table 220 for the DeutschLite fitting troubleshooting.
Table 220. DeutschLite Fitting Troubleshooting
Problem Possible Cause Solution
The inspection gage does not verify the The hydraulic pump pressure gage Check the output from the hydraulic
swaged fitting. (NOTE 1) does not go into the green range pump or relief valve setting. Refer to the
(10,000 psi, +250 or -250 psi). manufacturer's manual. (NOTE 2)
The incorrect tool is being used. Use the correct tool.
The jaws or the forks on the DAT are Clean the jaws and the forks.
not clean.
There is a quick-disconnect failure. Replace or repair the quick-disconnect.
The fitting and the tubing are not Use the correct fitting and tubing.
compatible.
The inspection mark is completely The fitting was not correctly located on Replace the fitting.
visible. the positioning mark before swaging.
The gap between the fitting flange and The fitting was not correctly positioned Cut out the damaged fitting.
the fitting ring exceeds the limits. in the DAT tool.
The fitting flange/fitting ring deformation
exceeds the limits.
The composite overlay damage
exceeds the limits.

After swaging, the moveable jaw does The fitting was not correctly positioned Cut out the damaged fitting.
not retract. in the DAT tool.
NOTE 1: The fitting must be re-swaged when the inspection gage does not verify the swaged fitting. Move
the DAT tool at least 90 degrees from the original swage position.
NOTE 2: 80 psi minimum shop air is required to operate the pneumatic pump.

Figure 202 : Sheet 1 : Marking Template and Tube Insertion Marks

A99792
Tube
Marking Template
Sight Hole
Tube
Verification Mark
Positioning Mark
Inspection Mark
6980T1005

Figure 203 : Sheet 1 : DeutschLite Fitting/Tube Position Before Swaging

Figure 204 : Sheet 1 : DAT Tool Position Before Hydraulic Pump Operation
A99794
Fitting Ring Nested Hydraulic Hose

Fitting Groove Bottomed Between Jaws
Against Swage Tool
DeutschLite
Fitting
Deutsch Axial-Swage Tool

(DAT)
Push Position - The moveable jaw pushes the ring into place.
Fitting Groove Bottomed

Against Swage Tool
DeutschLite
Fitting
Deutsch Axial-Swage Tool

(DAT)
Hydraulic Hose
Pull Position - The fixed jaw pulls the ring into place.
6980T1004

Figure 206 : Sheet 1 : DeutschLite Fitting/Tube Position After Swaging

ELECTRICAL/ELECTRONIC PRACTICES - DESCRIPTION AND OPERATION

1. General
A. This section gives maintenance data for the electrical and electronic practices used throughout the airframe and the
systems of the airplane. This includes the following:
(1) Maintenance procedures for electrical component cleaning and inspection.
(2) Maintenance procedures for electrical bonding and grounding.
(3) Maintenance procedures for wiring and resistors.
(4) Maintenance procedures for electrical and coaxial cable connectors.
(5) Maintenance procedures for splices, terminals and heat shrinkable tubing.
(6) Maintenance procedures for soldering.
(7) Maintenance procedures for electrostatic discharge sensitive components.
(8) Maintenance procedures for HIRF, EMI and EMC.
2. Description
A. This section is divided into subjects that give more information on specific tasks common to many of the maintenance
practices throughout the applicable Maintenance Manual. The subjects that follow are included in this section:
(1) Electrical Component Cleaning and Inspection includes a general description, wire bundles and electrical
components cleaning, wiring installation inspection, wiring replacement or repair, terminals and terminal blocks, fuses
and fuse holders, connectors, splices, junction boxes, bonds, switches, circuit breakers, diodes and transistors,
resistors, and relays.
(2) Electrical Bonding and Grounding includes a general description, tools and equipment, definitions, general
requirements, bonding classification, surface preparation, bonding methods, bond inspection, finishing and sealing,
and termination of shielded electrical cables.
(3) Wiring and Resistors includes a general description, wire types, wire specification, wire identification, reidentification
of wires, tools and equipment, removal/installation of wires, terminal board installation, wire repairs, and resistors.
(4) Electrical and Coaxial Cable Connectors includes a general description, electrical connector data, crimp tools and
positioner, wire stripping requirements, backshell installation torque, MS3106 series electrical connector assembly,
DBA-type electrical connector removal/installation, coaxial cable connector installation (threaded type), coaxial cable
connector with K-grip installation (swaged type), MIL-C-25516 (M25516/20-XX-XX) coaxial cable connector
assembly, and 2755-2-9 King K-grip coaxial cable connector assembly.
(5) Splices, Terminals and Heat Shrinkable Tubing includes a general description, tools and equipment, splices,
terminals, and heat shrinkable tubing.
(6) Soldering includes a general description, tools and equipment, work area, and soldering.
(7) Electrostatic Discharge Sensitive Components includes a general description, related documents, tools and
materials, quality assurance, definitions, requirements, and typical prime charge sources that must be avoided.
(8) HIRF, EMI and EMC includes a general description, tools and equipment, maintenance considerations, airplane
modifications, access panels and doors bonding, equipment bonding, wire bundle protection, visual check, and
electrical wire bundle assembly inspection.
3. General Warnings
WARNING: Xylene is toxic and flammable. Do not breathe the vapors. Use in a well ventilated area free from sparks,
flame, or hot surfaces. Wear splash goggles, solvent resistant gloves, and other protective equipment.
In case of eye contact, flush with water and seek medical attention. In case of skin contact, wash with
soap and water.
WARNING: Isopropyl alcohol is toxic. Do not breathe the vapors. Use in a well ventilated area free from sparks,
soap and water.
WARNING: 1,1,1 trichloroethane is toxic. Do not breathe the vapors. Use in a well ventilated area free from sparks,

soap and water.

WARNING: Acid chromate deoxidizing solution is corrosive to human tissue. Do not breathe the vapors. Use in a
well ventilated area. Wear chemical resistant clothing, gloves, splash goggles, and face shield. In case
of eye or skin contact, flush with water and seek medical attention.
WARNING: Chromate chemical conversion coating and nitric acid are both corrosive to human tissue. Do not
breathe the vapors. Use in a well ventilated area. Wear chemical resistant clothing, gloves, splash
goggles, and face shield. In case of eye or skin contact, flush with water and seek medical attention.
WARNING: Alcohol base rosin solder flux is flammable. Use in a well ventilated area free from sparks, flame, or hot
surfaces.
WARNING: When using compressed air for cleaning or drying, regulate the pressure to 29 psi or less. Wear
goggles or a face shield to protect eyes.
WARNING: Failure to comply with the manufacturer's or supplier's recommendations can result in serious injury,
physical disorder, or death.
A. Refer to the manufacturer's MSDS for all of the correct handling, storage, and disposal instructions before you use any
chemicals.
4. General Cautions
CAUTION: Solder type relay terminals where no leads are connected should be protected with heat shrinkable
tubing to prevent the possibility of shorting or grounding which results in erratic operation or damage.
CAUTION: Reduce all electrical power supplies to zero before connecting or disconnecting electrical devices.
CAUTION: Tag and identify wires as they are removed from the connector or any other electrical device to facilitate
reinstallation.
5. Printed Circuit Board Repair Precautions
A. Repair of printed circuit board assemblies by other than experienced technicians is not recommended. Unless a
malfunction can be localized to a particular component, an entire board should be replaced to correct a fault.
B. Semiconductor devices are heat sensitive. Use a suitable heat dissipater between the solder connection and the body of
the component when soldering or removing solder connections.
(1) All solder and solder removal tools must operate at a low wattage or 40 watts or less and low temperature of 750°F
(398°C) or less. Do not overheat the printed circuit board lands.
(2) To avoid heat damage, remove the solder joint within three seconds and solder a joint within two seconds.
(3) Excessive pressure from a solder or solder removal tool can delaminate the circuit pads or runs. Use a light touch
when using these devices.
(4) Avoid placing the hot soldering iron near components or printed circuitry when it is not in use.
C. Use only rosin core solder material conforming to Federal Specifications QQ-S-571, Composition Sn60. Use rosin solder
flux with an alcohol base. In no case is acid core solder or acid base flux to be used to install electrical components.
D. Do not use ultrasonic equipment, Methyl n-Propyl Ketone, or chlorinated hydrocarbon solutions to clean printed circuit
board assemblies.
E. Steel wool, steel wire brushes, and abrasives that contain iron or iron oxide must not be used for mechanical cleaning.
F. Use care when handling printed circuit board assemblies to avoid flexing and cracking boards and to avoid wire breakage
at soldered connections.
G. Special Handling of Static Sensitive Devices
(1) Integrated circuits and some other components used on printed circuit boards can be damaged by static electricity.
(2) Use precautionary procedures when you touch, remove, or install components and assemblies identified as being
electrostatic discharge sensitive.
(3) Static sensitive devices are sent from the manufacturer with conducting material shorting the leads. Maintain the short
on the device leads and case while storing or moving components.
(4) Keep static sensitive devices in their containers in the same configuration as they were originally shipped whenever
possible. Place the containers on a grounded metal plate at any station where operations are to be performed. Do
not remove container cover unless in a static free area.

(5) Repair personnel shall ground themselves before handling any static sensitive device.
(6) Personnel shall wear a conductive wrist strap connected to a ground having a resistance of 0.25 to 2 megohms.
(7) Handle devices only when necessary, and then by first grasping the ceramic body or the metal can before touching
any of the individual leads with tweezers or other tools. Do not handle by leads or terminals. Ceramic packages with
brazed leads require extra careful handling to avoid breaking off the leads since bending and twisting can fracture the
braze.
(8) Perform all assembly operations involving static sensitive devices on a grounded conductive surface having a
resistance of 100K ohms to 2 megohms/per square.
(9) Electrically ground all metal cabinets and conductive containers used for storing static sensitive devices.
(10) Personnel shall wear smocks made of cotton or antistatic nylon. Do not use smocks made from ordinary nylon or
other synthetic materials. Antistatic garments shall be plainly marked.
(11) All electrical assembly equipment (soldering irons and tips, insulation strippers, heat guns, etc.) must be grounded.
All solder and solder removal tools and equipment must also be grounded. Ionized air blowers can be used to reduce
charge buildup in areas where grounding is not possible or desirable.

ELECTRICAL COMPONENT CLEANING AND INSPECTION - MAINTENANCE PRACTICES

1. General
CAUTION: To prevent the possibility of fire or damage by an arc, it is necessary to disconnect all electrical power
before you do the electrical cleaning or inspections. Disconnect batteries and external electrical power.
A. This section gives the instructions necessary to clean and inspect the airplane's electrical system wiring and integral
components. It shows the system conditions that are to be checked. The correct use of these instructions will help
decrease the possibility that the system and/or components will become unserviceable. More data such as inspection
intervals or other related inspections are found in the applicable Maintenance Manual.
B. For the general and specific information on wire repair procedures, tools, installation of wiring, and high intensity radiated
fields (HIRF) wiring, refer to Wiring and Resistors - Maintenance Practices and HIRF, EMI and EMC - Maintenance
Practices.
2. Wire Bundles and Electrical Components Cleaning
NOTE: During standard airplane maintenance, it is necessary to clean the wiring, remove dust, lint, foreign
object debris (FOD), and/or clean electrical components adjacent to the electrical wiring. This process
must be completed with care and attention to detail.
NOTE: Cleaning the electrical wiring requires extreme care and use of proper maintenance procedures to
ensure safe and reliable performance. When cleaning an area, avoid movement of the harnesses and/or
equipment during cleaning contamination such as dust, dirt, or metal shavings.
NOTE: These cleaning procedures are not intended to move or loosen clamps or cut tie wraps unless you find
wire bundle contamination.
A. Do the Wire Bundles and Electrical Components Cleaning.
WARNING: Make sure that the area is well ventilated before you start the cleaning procedures to prevent
inhaling solvent fumes.
CAUTION: Never vigorously scrub a wire bundle. This could cause damage to the wire bundle, insulation, or
electrical connections.
(1) Gently clean the wire bundles with a vacuum cleaner.
(2) If necessary, use a clean natural fiber rag with isopropyl alcohol to carefully wipe the wire bundles and electrical
components. Refer to General Solvents/Cleaners - Maintenance Practices.
(3) If the movement of the wire bundles are necessary for correct the cleaning, release the wire bundle from the clamps
and tie wraps in a way that does not putt stress on the electrical connectors or support devices.
(a) For interior wire bundle contamination, remove the wire bundle tie wraps before separating the electrical wires.
(4) Examine for corrosion on the wiring and the adjacent electrical components during the cleaning process.
NOTE: Corrosion on wiring components can have a significant impact on system performance.
(5) If applicable, install the clamps and new tie wraps in their initial positions.
3. Wiring Installation Inspection
CAUTION: When wiring modification, repairs, or replacement is done, all materials used must be approved for the
environment in which they are installed.
A. Examine the wires and the cables for correct support, protection, and general condition as follows:
(1) Wires and cables supported by clamps, grommets, or other devices must be of a suitable size and type. The wires
and the cables must be held securely in place without damage to the insulation.
(2) Adequate standoff support must be provided to prevent chafing of wires when routed over structural members.
(3) Phenolic blocks, plastic liners, or rubber grommets must be installed in the holes of bulkheads, floors, or structural
members through which the wiring goes through.
(4) Wires and cables in junction boxes, panels, and bundles must be properly supported and laced to provide the correct
grouping and routing.
(5) Clamp retaining screws should be properly secured so the movement of wires and cables is restricted to the span
between points of support and not at soldered or mechanical connections to terminal posts or connectors.
(6) Wires and cables must be supported and bound to prevent interference with other wires, cables, and equipment.

(7) Wires and cables must be adequately supported to prevent excessive movement in areas of high vibration.
(8) Insulating tubing and tape should be secured in place by tying or with clamps.
(9) Tapes, such as friction tape that will dry out during service, produce chemical reactions with wire or cable insulation,
or absorb moisture must not be used.
(10) Moisture absorbent type material must not be used as "fill" for clamps or adapters. The correct size of clamps must
be used.
(11) Cable supports must not restrict the wires or cables in a manner that would interfere with the operation of equipment
shock mounts.
(12) Wires and cables must be routed in a way that chafing will not occur.
(13) Wires and cables must be adequately protected in wheel wells where they are exposed to rocks, ice, mud, etc.
(14) Wires and cables should be kept separate from high-temperature equipment such as resistors and engine bleed air
ducts.
(15) The minimum radius of bend for wires or cables must be ten times the outside diameter of the wire or cable, except
at terminal strips where the wire is correctly supported. Then, the radius can be three times the diameter of the wire or
cable. If it is impractical to install wiring or cables within these radius requirements, the bend should be in insulating
tubing.
(16) Coaxial cables should not be bent at a radius less than six times the outside diameter of the cable.
(17) Wires and cables that are attached to assemblies where relative movement occurs (such as at hinges, control
column, and control wheels) should be installed or protected in a way to prevent deterioration of the wires and cables
caused by the relative movement of the assembly parts.
(18) Wires and cables must be provided with sufficient slack to obey the requirements that follow:
(a) Make sure that the wires and the cables give easy maintenance.
(b) Make sure that there is no mechanical strain on the wires, cables, junctions, and supports.
(c) Make sure that there is free movement of the shock-and-vibration mounted equipment.
(d) Make sure that the equipment can move as necessary to complete alignment and servicing while installed in
airplane.
(19) Make sure that the wire bundles are tied together every 2 feet (0.6 m) minimum.
(a) Wire ties must be tight enough that they cannot be moved, but not too tight that they damage the wires.
(b) High temperature wire ties must be used where temperatures exceed 170°F (77°C).
(20) Unused wires should be individually dead-ended and secured into the bundle.
4. Wiring Replacement or Repair
A. Replace the wiring if you find any of the defects that follow:
(1) Wiring that has been exposed to high temperatures.
(2) Wiring that shows signs of overheating.
B. Repair the wiring if you find any of the defects that follow:
(1) Wiring that has been crushed or severely kinked.
(2) Shielded wiring on which the metallic shield is frayed and/or corroded.
(3) Wiring that has been damaged to the extent that the primary insulation has been broken.
5. Terminals and Terminal Blocks
A. Examine the terminals and the terminal blocks as follows:
(1) Make sure that no insulation is frayed or nicked.
(2) Make sure that insulating tubing is placed over terminals (except pre-insulated types) to provide electrical protection
and mechanical support and is secured to prevent slippage of the tubing from the terminal.
(3) Make sure that terminal blocks are securely mounted.
(4) Make sure that terminals are securely attached to the terminal blocks.
(5) Make sure that the terminals are secured to the terminal blocks in such a way that if the terminal is loosened, the top
stud nut will be tightened.

(6) Make sure that there are no signs of overheating on connections to the terminal block.
(7) Make sure that there is no physical damage to the studs or terminal blocks. Replace the damaged terminal block as
necessary.
(8) Make sure that terminal connections to terminal block studs are free of corrosion and signs of arcing.
(a) For terminal junctions with snap-in pin contacts, examine for pin contacts that were pulled from the terminal
junction, loose pin contacts, and pin contacts that pull free of the terminal junction easily.
(b) For a junction box with snap-in pin contacts, it can be removed from its installation position and visually checked
for loose contacts, corrosion, and arcing. Replace the terminal junction if the contact pins do not lock in securely.
6. Fuses and Fuse Holders
A. Examine the fuses and fuse holders for the conditions that follow:
(1) Make sure that the connections to the fuse holders are tight.
(2) Make sure that there are no signs of corrosion or overheating on fuses and fuse holders. Replace the corroded fuses
and clean the fuse holders.
(a) If you find signs of overheating, examine for the correct rating of fuse and the cause of the overheating condition.
(3) If necessary, make sure that you replace the spare fuses with fuses of the correct current rating.
(4) Make sure that there are no exposed fuses that are susceptible to shorts.
7. Connectors
A. Examine the connectors for the conditions that follow:
(1) Examine the connectors for pushed-back pins, bent pins, moisture corrosion, carbon arc, and shell damaged.
(2) Examine the connector backshells, if applicable, for security and signs of corrosion.
(3) Connector backshells
(a) Make sure that all connectors with a backshell have a bead of Type V, Class A sealant between the connector
and the backshell.
NOTE: This makes sure that the backshell is locked in position and will not move in flight.
NOTE: Type V, Class A sealant must not be used to replace the safety wire where it is necessary.
(b) Make sure that safety wire is installed on the connectors where necessary.
(4) Electrical Connector Backshell Locking Procedure (Refer to Figure 201).
(a) Make sure that the backshell is installed and tightened before you do the steps that follow:
(b) Remove dirt, grease, and moisture from the surfaces to be bonded. Allow to dry thoroughly.
(c) Apply a bead of Type V, Class A sealant as a fillet between the backshell locking nut and the connector body.
NOTE: The length of the bead should be approximately one quarter of the circumference around
the backshell locking nut where possible. A shorter length may be necessary to allow
clearance for mounting holes, etc.
(d) Section thickness of sealant bead should be limited to 0.25 inch (6.35 mm).
(e) Allow approximately 30 minutes for curing time and the sealant should be tack-free in about one hour.
(f) Normal cure time is 24 hours. The length of time for full cure depends upon the thickness of the application as
well as temperature and humidity. Follow the precautions on the sealant tube and always use appropriate
handling procedures.
(g) A damp paper towel may be used to smooth areas of the bead, in which spikes may protrude outward and
sometimes occur at the end of the bead when the nozzle is pulled away. This should be done before a skin-type
formation appears.
(h) Because there are many varied connector configurations, the bead of sealant may be applied between the
backshell locking nut and the backshell body, if necessary.
NOTE: Care should be taken to make sure that the sealant is applied to an easily accessible area
of the connector to allow sealant removal for connector repair.
(i) Make sure that sealant is applied only to the backshell locking nut and the connector body, or backshell body
areas.

CAUTION: To avoid circuit problems, do not allow sealant to touch the connector contacts, wire seal
grommets, or the shield termination areas of the backshell.
CAUTION: Make sure that no sealant is applied to areas where it could interfere with connector mounting
holes. Make sure that no sealant is applied to the connector locking nut.
(j) Removal of existing sealant will require the removal of the fillet seal to allow access to the connector wiring.
(k) Hold one end of the fillet with a suitable pair of long nose pliers and peel the fillet away from the connector.
Rotate the pliers toward the opposite end rather than directly away from the connector, this will help the sealant
to not tear.
(l) Once the major portion of the sealant is removed, the smaller portions left can usually be removed with the pliers.
(m) Upon completion of a repair or rework of a connector, the connector backshell should be tightened and sealant
applied to the same general location as before the repair or apply as listed in Figure 201.
(5) Examine the wires that lead to the connectors for deterioration from heat. Make sure that they are properly wrapped
where necessary to prevent chafing and proper clamping to provide strain relief.
(6) Examine the coax connectors for pushed-back or bent center conductor.
(a) Examine continuity of the coaxial cable.
(b) Examine the resistance between the conductor and the shield.
(7) Examine for loose contact pins by a slight pull on the wires. All wires that are loose or pull free of the locked position
require reinstallation. Use proper insertion and retraction tool and reinstall contact pin. If contact pin does not lock in,
replace the contact pin or the connector.
(8) Examine the solder contact for a good solder joint.
(9) Make sure that all unused pin holes of the connector are plugged with wire hole fillers or grommet sealing plugs. Refer
to Wiring and Resistors - Maintenance Practices.
(10) Make sure that the connectors are safetied as necessary.
8. Splices
A. Examine the crimp and disconnect splices as follows:
(1) Make sure that no splices are positioned under a cable clamp.
(2) Make sure that splices in the same wire group or bundle are staggered to where there is not excessive enlargement
of the group or bundle.
(3) Examine the wire in the immediate area of the disconnect splice for broken wire and damaged insulation.
(4) Lightly pull on wire splices to make sure there is still a good connection.
9. Junction Boxes
A. Examine the junction boxes as follows:
(1) Make sure that they are securely mounted.
(2) Clean internally and free of foreign objects.
(3) Make sure that all lid fasteners on junction boxes are securely fastened with safety wire, self-locking fasteners, or the
applicable self-locking device.
(4) Make sure that the terminal junctions, diodes, relays, resistors, fuses, wiring, etc., comply with the described electrical
inspection.
10. Bonds
A. Examine the bonds as follows:
NOTE: A bond is defined as any fixed union existing between two metallic objects that results in electrical
conductivity between them. For more information, refer to Electrical Bonding and Grounding -
Maintenance Practices. These bonds result from either physical contact between the conductive
surfaces of the objects or from the addition of a firm electrical connection between them.
Intermittent electrical contact between conducting surfaces, which can become part of a ground
plane or a current path, must be prevented either by bonding or by insulation, as applicable.
(1) Metallic conduit must be bonded to the airplane structure at each terminating and breaking point. The bonding path
can be through the equipment at which the conduit terminates.

(2) Bond connections must be secure and free from corrosion.

(3) Bonding jumpers must be installed in a way not to interfere with the operation of movable components of the airplane.
(4) Self-tapping screws must not be used for bonding purposes. Only standard threaded screws or bolts of appropriate
size must be used.
(5) Bonding jumpers must be kept as short and direct as possible.
(6) Bonds must be attached directly to the basic airplane structure rather than through other bonded parts.
11. Switches
A. If the following examinations show that a switch is unserviceable, replace the defective switch with a switch of the same
type and current rating.
(1) Visually examine the switches for physical damage and make sure that the switch is securely attached to the
mounting panel.
(2) Examine for loose or deformed electrical connections or signs of corrosion of the terminals, terminal lugs, or screws.
Examine for foreign material (metal chips, wire pieces, etc.) between the connections.
(3) Examine the manual operation by operating the switch several times. This also helps to remove any superficial
contamination or foreign deposits on the internal electrical contacts.
(4) Test for electrical continuity as measured across the external terminals with an ohmmeter. Intermittent or excessive
resistance usually indicates that the internal contacts are corroded. Electrically isolate the switch from the other
circuitry during the continuity check.
12. Circuit Breakers
A. If the following examinations show that a circuit breaker is unserviceable, replace the defective circuit breaker with circuit
breaker of the same type and current rating.
(1) Make sure that the circuit breaker case and mounting means are secure on the mounting panel and there are no
signs of physical damage.
(2) Examine for a loose electrical termination or signs of corrosion of the terminals, terminal lugs, or screws.
(3) Examine the manual operation by operating the circuit breaker several times. This operation also serves to remove
any superficial contaminates or foreign deposits on the surface of the internal electrical contacts.
(4) Examine for signs that the circuit breaker had been subjected to burning or overheating. The burned area is usually
caused by electrical arcing as a result of a combination of the presence of excessive moisture and poor dielectric
characteristics of the circuit breaker.
(5) Tripped circuit breakers show that an abnormal electrical overload occurred. Test and physically examine the related
wiring for short circuit.
13. Diodes and Transistors
A. If the following examinations show that a diode or transistor is unserviceable, replace the diode or transistor with the same
type and current rating.
NOTE: The semiconductor material is either germanium or silicon. Semiconductors have electrical
conductivity greater than insulators but less than good conductors. Transistors are highly shock
resistant, but can be damaged by a sharp blow or by being dropped.
(1) Make sure that stud mounted semiconductors are secure in their mount.
(2) Examine the soldered connections for broken leads and cold solder joints.
(3) Examine the mounting heat sink or radiator installation.
NOTE: Power transistors are usually mounted on a heat sink or on a radiator. The heat sink or
radiator normally is not part of the transistor, but power the transistor installation is not
complete, as far as power operation is concerned, until the power transistor is properly
mounted.
(4) Voltage checks and continuity checks can be used to determine the serviceable condition of the semiconductors.
14. Resistors
A. Examine the resistors as follows:
(1) Make sure that the power resistors are mounted in free air to dissipate heat.

NOTE: Free air is free from contacting wires, wire ties, closed spaces, and other components.
(2) Examine the wires in the immediate area for damaged insulation, broken wires, and proper routing.
(3) Make sure that soldered connections are secure and not a cold solder joint.
(4) Make sure that the resistor is not unserviceable, charred, or shows signs of overheating.
15. Relays
A. Examine the relays as follows:
(1) Examine the relays for secure installation.
(2) Examine the relays for cleanliness of the terminal contacts. Make sure that the screw contact connection is tight and
safety wired.
(3) Seal the terminals where necessary.
(4) Soldered connections must be checked for a good joint, single strands of wire that have separated from the wire, and
cleanliness.
(5) Examine the wires in the immediate area for damaged insulation, broken wires, and proper routing.

Figure 201 : Sheet 1 : Electrical Connector Backshell Locking Procedure




20-30-10-2 (Rev 1)
ELECTRICAL BONDING AND GROUNDING - MAINTENANCE PRACTICES

1. General
A. This section describes airplane electrical bonding requirements and procedures. This section also contains information on
the termination of shielded electrical cables.
B. Poor electrical bonding can cause or contribute to a variety of operational problems in electrical, avionics, and
communication systems, such as complete failure, reduced performance, electromagnetic interference (EMI), or radio
frequency interference (RFI) with navigation and communication systems.
C. Maintenance personnel must follow recommended practices for establishing, remaking, testing, and protecting electrical
bonds, particularly during routine maintenance activities.
NOTE: If a component is moved or the bond of an installed component is otherwise broken, the resistance
of the connection must be verified again after installation.
(1) Removal and installation of avionics and electrical equipment and mounting trays.
(2) Assembly and reassembly of supporting structure for avionics or electrical equipment.
(3) Reinstallation of control surfaces and removable fairings (including radome and stinger).
A. For the tools and equipment used for this section, refer to Standard Practices - General.
3. Definitions
A. Method A (Nonconductive) Bonding - The usual method to seal the surfaces. This is done by cleaning a surface area that
is larger than the connector that will be installed. A fillet seal of nonconductive sealant is then applied on and around the
connector and the metal bonding surface. To make sure that the finish is nonconductive, it is necessary that you use a
micro-ohmmeter to do an electrical bonding test.
(1) The cleaned area must be between 0.063 inch (1.60 mm) and 0.250 inch (6.35 mm) more than the connector.
(2) The sealant must not be applied on screws, rivets, or other mounting hardware.
B. Method B (Conductive) Bonding - A different method to seal the surfaces. This is done by cleaning a surface area that is
smaller than the connector that will be installed. A fay seal of conductive sealant is then applied between the connector and
the metal bonding surface.
(1) The cleaned area must not be more than, and not less than, the diameter of the contact area.
(2) The sealant must be applied between the connector and the bonding surface.
(3) The sealant on and around the bonding must then be removed and cleaned.
C. Bond (Electrical) - A fixed union existing between two objects that gives good electrical conductivity due to a low-
resistance path between the objects.
D. Bonding (Electrical) - The process of making the necessary connections to give good electrical conductivity between units
or between unit and structure ground.
E. Ground - The common connection of the electrical circuits of a system or subsystem to a conductive medium (airplane
primary structure) that becomes a common reference for all voltage potentials in the airplane.
F. Grounding - The process of making the necessary connection(s) to provide a ground for an electrical, electronic, or radio
frequency circuit.
G. Basic Structure - Load carrying members, such as skin, bulkhead, ribs, stringers, webs, etc.
H. Primary Structure - Load carrying members of the airframe, such as bulkheads, ribs, webs, and stringers, extending
through two or more bulkheads or ribs. All primary structure is considered to be airplane ground.
I. Secondary Structure - Sheet metal or extruded metal parts attached to primary structure (or to secondary structure that is
ultimately attached to primary structure) in at least two places by structural fasteners or by three or more rivets on each
location.
J. Air Frame - The complete structure of the airplane, which includes both the basic and primary structure but not the power
plant or accessories.
4. General Requirements
A. The general requirements that follow are specified to make sure that the airplane and its systems are electrically stable
and prevent harmful effects from such hazards as lightning, high intensity radiated fields, static discharge, and electrical

20-30-10-2 (Rev 1)
shock:
(1) Files, rotary, or otherwise, are prohibited.
(2) Hardware usage:
(a) Bolts, Nuts, and Screws
1 Cadmium plated steel is recommended for all areas other than fuel cell and engine compartment.
2 Corrosion-resistant steel is recommended for the engine compartment.
3 Aluminum is recommended for all areas other than the engine compartment.
4 Self-tapping, zinc plated, spring, self-locking, clip-in instrument mounting nuts, and wing nuts are not
allowed.
5 All nuts used for bonding must have some type of locking mechanism.
(b) Washers
1 NAS 1149, MS 35338, MS 35340 washers are recommended in all areas.
2 Anodized, zinc plated, unplated, and star washers are not allowed.
(c) Bonding Jumpers
1 S2876 (aluminum) bonding jumpers are recommended for bonding in fuel tanks. Bonding jumpers in fuel
tanks should be avoided if at all possible though.
2 MS 25083/S3798 (copper) bonding jumpers are recommended for all areas other than fuel tanks.
3 Use aluminum or tinned copper jumpers on aluminum alloys.
4 Use copper, brass, or bronze tinned coated jumpers on steel alloys. If the steel is cadmium plated,
aluminum jumpers may be used.
(d) Clamps
1 SAE-AS7351 clamps are recommended in all areas.
2 AN 742 clamps and cushion clamps are not allowed.
(e) Nut Plates
1 Cadmium and silver plated type (nonfloating and floating) nut plates are recommended for direct bonding
applications.
2 Dry film lubricant is not recommended.
3 Nonmetallic or adhesively bonded (rivetless) nut plates are not allowed.
4 Dry film lubricant type nut plates are not recommended for use in direct bonding applications, such as
antenna installations. Nonmetallic or adhesively bonded (rivetless) nut plates do not provide an electrical
bond path to structures and must not be used for direct bonding applications.
(3) Current Return Path
(a) This category of bonding is most important to the basic function and safety of the airplane. Special attention
must be given when creating such bonds.
(b) Current return bonds are bonds that are required to complete the ground return path to the battery and/or the
power generator source for all electrical and avionics equipment.
(c) This bond must be to the primary structure.
(d) In some cases where the equipment is internally case grounded, current return may be done by direct bonding of
mating surfaces and through the mounting hardware.
(4) Equipment
(a) When the mating surface of the equipment is used to bond the equipment to the structure, the maximum
allowable resistance across the bond surface must not be larger than the resistance of the equivalent 12 inches
of the gauge of wire which supplies power to the equipment. Refer to Table 201 for wire resistance by size.
(b) If the allowable mating surface bonding resistance cannot be met by direct surface bonding, then the equipment
must be cleaned, refer to Surface Preparation. If the resistance requirement still cannot be met, a bonding
jumper can be added, refer to Jumper or Strap Bonds.
(c) When standard hookup wire to ground equipment is used, the resistance and procedure must be as follows:

20-30-10-2 (Rev 1)
1 For wire lengths 12 inches (305 mm) or shorter, the size of the wire used will be of the same gauge (or
larger) as the wire that supplies power to the equipment.
2 For wire lengths between 1 and 4 feet (0.305 and 1.219 m), the size of the wire must be one gauge larger
than the wire that supplies power to the equipment.
3 Grounding equipment with wire longer than 4 feet (1.219 m) should be avoided if possible.
4 The resistance across the grounding junction must not be larger than the resistance in Table 201 for the
gauge of wire used.
Table 201. Wire Resistance By Size
Material Wire or Cable Size Maximum Allowable Maximum Allowable
Resistance (Ohms/Foot) Resistance
(Ohms/Meter)
AN-22 0.0159 0.0522
AN-20 0.0098 0.0322
AN-18 0.0061 0.2001
AN-16 0.0048 0.0157
AN-14 0.0031 0.0102
AN-12 0.002 0.0066
AN-10 0.0012 0.0039
Copper
AN-8 0.0007 0.0023
AN-6 0.0004 0.0013
AN-4 0.0003 0.00098
AN-2 0.0002 0.00066
AN-1 0.00014 0.00046
AN-0 0.00012 0.00039
AN-00 0.00009 0.00030
AL-8 0.0011 0.0036
AL-6 0.00064 0.0021
AL-4 0.00043 0.0014
Aluminum
AL-2 0.00027 0.00089
AL-0 0.00017 0.00056
AL-00 0.00013 0.00043
(5) Other
(a) Control surface and flaps which use an actuator-type design, must have a bonding jumper on both extremes
across each hinge of the actuator. Where necessary, additional jumpers can be used between the control
surface and structure to achieve the correct amount of resistance as defined in Table 202. Flaps and slats that
use a roller-track type design can be considered to be self-bonded as long as they meet the resistance
requirements of Table 202.
(b) Lines and tubes that carry fluids or air in motion that have a linear dimension of 2 feet (0.61 m) or more, installed
within 1 foot (0.305 m) of unshielded transmitting antenna lead-ins, must have a bond to structure as given in
Table 202.
5. Bonding Classification
A. Types - Electrical bonds are classified by the type of materials that are used to make the bond and the method used to join
the materials.
(1) Type I usually applies to metallic components bonded together with direct metal to metal contact. Some examples are
riveted skin bonds, equipment racks, and bulkhead connectors. This bond type is required to have a measured

20-30-10-2 (Rev 1)
resistance of less than or equal to 0.0025 ohm.

(2) Type II usually applies to aluminum or steel components (i.e., landing gear, doors, and airplane structure) bonded
together electrically by bonding jumpers. Type II can also be used when applied to bonds with multiple metal to metal
contacts, such as radome diverter strips to airplane structure or antennas mounted on metal fairings to the airplane
structure. This bond type is required to have a measured resistance of less than or equal to 0.005 ohms.
(3) Type III usually applies to adhesively bonded aluminum components bonded together electrically by rivets, fasteners,
or by bonding jumpers. This bond type is required to have a measured resistance of less than or equal to 0.005
ohms.
(4) Type IV usually applies to connections between expanded aluminum mesh (or similar material) and the airframe
through bonding jumpers and clips. This bond type is required to have a measured resistance of less than or equal to
0.005 ohms.
(5) Type V usually applies to connections between conductive composite structure such as Carbon Fiber Composite
(Graphite) and its metallic attachment hardware. This bond type is required to have a measured resistance of less
than or equal to 0.005 ohms.
(6) Type VI usually applies to connections for P-static protection between nonconductive materials and their metallic
attachment hardware and/or the airplane structure. This bond type is required to have a measured resistance of less
than or equal to 100,000 ohms.
(7) Type VI-A usually applies to connections for P-static protection between P-static paint and a high-resistive, low-
conductive gasket such as something used in non conductive fuel doors and the airplane structure and/or their
metallic attachment hardware. This bond type is required to have a measured resistance of less than or equal to
10,000,000 ohms
(8) Type VII usually applies to connections for P-static protection between nonconductive materials used in radomes or
electrically-heated windshields and their metallic attachment hardware and/or airplane structure. This bond type is
required to have a measured resistance between 1,000,000 and 100,000,000 ohms.
(9) Type VIII usually applies to connections for low conductive gaskets and metallic airplane structure. This bond type is
required to have a measured resistance of less than or equal to 1,000,000 ohms.
(10) Type IX usually applies to connections for hydraulic and fuel lines and tubes, metallic tubing, seat frames
(nonelectrical components) and electrical switches, circuit breakers, and ducts bonded to the airplane structure by
various means such as clamps or attachment screws. Because this type includes many different installations, the
maximum permitted resistance value can be different from one installation to another. These differences are
specified in Table 202.
(11) Type X usually applies to connections for different fuel system hardware such as fuel filler nozzle, fuel vents, and fuel
gages. Because this type includes many different installations, the maximum permitted resistance value can be
different from one installation to another. These differences are specified in Table 202.
(12) Type XI usually applies to connections for flaps, slats, piano hinged surfaces, and roller bearing surfaces. This type
includes several different installations. The maximum permitted resistance will be different from one installation to
another. These differences are specified in Table 202.
(13) Type XII usually applies to high current return path grounds and ground studs with direct metal to metal contact. This
bond type is required to have a measured resistance of less than or equal to 0.0005 Ohms.
B. Typical Resistance Values
(1) Table 202 contains typical resistance values for many different objects that are bonded on the airplane and the
associated bonding method. For more information about a bonding method, refer to Bonding Methods.
Table 202. Typical Resistance Values
Object To Be Bonded Method Of Bonding Maximum Bond Type
Allowable
Resistance Value
(Ohms)
All electrical and electronic equipment ground Direct metal case to 0.0025 I
return bonds to basic structure structure 0.005 II
Bonding jumper to structure 0.005 II

20-30-10-2 (Rev 1)
Antenna base Metal base to metal 0.0025 I

fuselage through fasteners
Metal base to metal screen 0.05 IV
or expanded metal
Metal base to composite 0.5 V
fairing through fasteners
Baggage/Avionics compartment door Bonding jumper across 0.005 II
hinge
Battery box cover Fastener to battery box 0.005 II
Battery box to basic structure Direct metal case to 0.0025 I
structure
Bearings (roller and ball) Piano hinged surfaces Bonding jumper 0.005 II
Metal to metal through 0.01 XI
bearing or hinge
Bulkhead feed-thru connectors Metal to metal 0.0025 I
Cable bundle shields Bonding jumper 0.005 II
Direct attachment to 0.0025 I
connector backshell
Composite aileron Bonding jumper across 0.005 II
hinge
Embedded metal 0.05 IV
screen/mesh to airplane
structure
Graphite composite to 0.5 V
airplane structure
Composite cowls (removable) Fastener to engine frame 0.5 V
Composite elevator Bonding jumper across 0.005 II
hinge
structure
airplane structure
Composite flap Bonding jumper across 0.005 II
actuator
airplane structure
Roller/track (loaded 0.5 XI
configuration)
Composite nacelle Fastener to engine frame 0.5 V
Composite nacelle with metallic tubing Tube runs which terminate 1 IX
in a direct metal to metal
contact
Composite rudder Bonding jumper across 0.005 II
hinge

20-30-10-2 (Rev 1)

structure
airplane structure
Control cables and rods to movable surfaces Bonding through attachment 0.01 IX
equipment hardware
Doors and Inspection plates Fastener to airplane 0.005 II
structure
Electric trim (actuator assembly) Direct metal to metal 0.0025 I
Bonding jumper 0.005 II
Electrical devices to enclosure Direct attachment through 0.0025 I
attachment hardware
Electrical motors to adjacent structure Direct metal to metal 0.0025 I
Electrical switches, circuit breakers, and Direct attachment through 0.10 IX
potentiometer in circuits exceeding 50 volts hardware
Engine to nacelle structure bond Direct attachment by 0.0025 I
fasteners (metal nacelle)
Direct attachment by 0.5 V
fasteners (composite
nacelle)
Engine Bonding jumper across 0.005 II
mount
Fuel filler nozzle Attachment through 0.005 X
fasteners
Fuel nozzle jumper ground receptacle Attachment through 0.003 X
fasteners
Fuel vents scoops Attachment through 0.005 X
fasteners
Generator electrical return ground studs Direct attachment through 0.0005 XII
ground stud
Ground Studs Base of the ground stud to 0.0005 XII
the aircraft structure
Honeycomb panel assemblies Direct metal to metal 0.0025 I
attachment by fasteners
Direct metal to metal 0.005 II
attachment by bonding
agent
Hoods and canopies Not applicable Not required Not required
Hydraulic cylinders Direct metal to metal or 0.01 IX
bonding jumper
Instrument panels to stationary panel Direct metal to metal 0.0025 I
Instruments Direct metal to metal 0.0025 I

20-30-10-2 (Rev 1)

Landing gear Bonding jumper 0.005 II
Landing gear doors Bonding jumper across 0.005 II
hinge
Metal aileron Bonding jumper across 0.005 II
hinge
Metal cowls - removable Fastener to engine frame 0.005 II
Metal ducts Direct metal to metal and 0.005 IX
attachment anchors
Metal ducts (nonelectrical: rigid and flexible) Bonding through clamp and 1.0 IX
attachment hardware
Metal elevator Bonding jumper across 0.005 II
hinge
Metal flap Bonding jumper across 0.005 II
actuator
Roller/track (loaded 0.5 XI
configuration)
Metal nacelle Fastener to engine frame 0.005 II
Metal Placard (Metal surface) Direct metal to metal 0.0025 I
Metal Placard (Composite surface) Direct metal to composite 0.5 V
surface and attachment by
fasteners
Metal rudder Bonding jumper across 0.005 II
hinge
Metallic tubing Feed-thru hardware direct 0.0025 I
metal to metal
Feed-thru hardware and 1.0 IX
attachment anchors
Metallic tube wiggins fittings Feed-thru hardware and 0.1 IX
attachment anchors
Nose wheel doors Bonding jumper across 0.005 II
hinge
Oil and Anti-Ice tank Attachment through 0.01 IX
fasteners
Oxygen cylinders Direct metal to metal or 0.1 IX
bonding jumper
Panel feed through plates Bonding jumper 0.005 II
Direct metal to adhesively 0.03 III
bonded honeycomb
Radio racks, shelves, and brackets to adjacent Direct metal to metal 0.0025 I
primary structure
Radiators and heat exchangers Bonding through attachment 0.01 IX
hardware

20-30-10-2 (Rev 1)
Radome Diverter strips through 0.010 II

radome frame to airplane by (NOTE 1)
attachment hardware
Radome external diverter strips Attachment to radome 0.005 II
frame
RFI noise filters (across joint) Direct metal to metal 0.0025 I
Rivet skin joints and breaks (across joint) or Direct metal to metal 0.0025 I
structural joints or breaks (across joint)
Seat frame Attachment through 0.01 IX
fasteners
Servos amplifier, gaging equipment instruments, Direct metal to metal 0.0025 I
etc. Bonding jumper 0.005 II
Shock mounts Direct metal to metal 0.01 IX
through attachment
hardware
Side console and electrical equipment panels to Direct metal to metal by 0.0025 I
basic structure fasteners
Slats Roller/track (loaded 0.5 XI
configuration)
Spoiler Bonding jumper across 0.005 II
hinge or directly through
hinge
Starters, generator, and alternator grounds (case Direct metal case to 0.0025 I
to engine frame) structure
Static wicks (composite surface) Direct metal to composite 0.5 V
surface and attachment by
fasteners
Static wicks (metal surface) Direct metal to metal 0.0025 I
Stationary instrument panels to primary structure Direct metal to metal by 0.0025 I
fasteners
Structural joints or breaks (across joint) Direct metal to metal 0.0025 I
Trim tab Bonding jumper across 0.005 II
hinge
Wing tie down and ground point Attachment through 0.0025 I
fasteners
Wing to fuselage Direct metal to metal or 0.0025 I
attachment bolts
Wire Bundle Shields Direct attachment to 0.0025 I
backshell
Bonding jumper to structure 0.005 II
NOTE 1: This measurement involves multiple bond paths. Therefore, the allowable resistance value is
twice standard Type II.
6. Surface Preparation
A. Requirements
(1) A clean area is required to be sure that there is a firm bond and to make inspection easier. A clean area also gives
the most accurate resistance measurement.

20-30-10-2 (Rev 1)
(2) All bonds between two metal surfaces and bonding jumper attachment points must be free of all non conducting
material such as paint, primer, grease, foil, corrosion proofing, tape, etc.
(3) Conducting material such as IVD coatings, etc. must not be removed. If a coating is present, you must make sure that
the coating is conductive.
(4) Files, rotary or otherwise, are prohibited.
(5) The method of cleaning a surface area greater than the chosen connector to be installed is Method A.
(a) Method A must be used in wet fuel cell applications, Type XII electrical bonds, and inside the cabin. Sealant is
not required within the cabin.
(6) The method of cleaning a surface area less than the chosen connector to be installed is Method B.
(a) Method B is required for all ground stud installations and all other bonding outside of the cabin except in wet fuel
cells and Type XII electrical bonds.
B. Steel and Aluminum Cleaning
(1) Method A
(a) Use medium Roloc surface condition disc pads (Scotchbrite) or medium EXL wheel 6A (Scotchbrite) that is not
more than 0.50 inch (12.70 mm) larger than the diameter of the bonding surface.
NOTE: You are permitted to use 400 through 600 grit emery paper or cloth, or an equivalent fine
sandpaper and/or aluminum oxide paper or cloth, stainless steel wool, or a stainless steel
or monel bonding brush. You can use aluminum wool only on aluminum.
(b) Use IPA, MPK, or equivalent to clean the bonding surfaces.
(c) When you clean aluminum for electrical bonding that is not for a bonding jumper, the area that you clean should
not extend from between 0.0625 and 0.25 inches (1.58 and 6.35 mm) past the contact area. If the cleaned area
is more than 0.25 inch (12.70 mm) more than the contact area, you must apply primer, let it dry, then clean it
again.
(d) When you clean an area to attach a bonding jumper, the area that you clean should be 1.5 times the diameter of
the bond jumper terminal.
(e) For bare aluminum, before an electrical bond is made, apply a chemical film treatment to the bonding surface,
this will give the bond electrical and some corrosion protection.
(2) Method B
(a) Use medium Roloc surface condition disc pads (Scotchbrite) or medium EXL wheel 6A (Scotchbrite) that is not
larger than the diameter of the bonding surface of the connector.
sandpaper and/or aluminum oxide paper or cloth, stainless steel wool, or a stainless steel
or monel bonding brush. Never clean more than one type of metal with a stainless steel
brush. Be careful not to remove excess metal. Deep scratches are not acceptable for an
electrical bond. You can use aluminum wool only on aluminum.
(c) The cleaned area must be at least half of the diameter of the bonding area but not larger than the diameter
bonding area. If the cleaned area is larger than the diameter of the bonding surface, the surface must be primed,
dried, then cleaned again.
(d) For bare aluminum, before an electrical bond is made, apply a chemical film treatment to the bonding surface,
this will give the bond electrical and some corrosion protection.
C. Magnesium Cleaning
CAUTION: Do not use steel wool, stainless steel wool, or aluminum wool to clean magnesium alloys.
(1) Method A
(a) Use medium Roloc surface condition disc pads (Scotchbrite) of medium coarseness or medium EXL wheel 6A
(Scotchbrite) that is no more than 0.50 inch (12.70 mm) larger than the diameter of the bonding surface.
sandpaper.

20-30-10-2 (Rev 1)
(2) Method B
(a) Use medium Roloc surface condition disc pads (Scotchbrite) of medium coarseness or medium EXL wheel 6A
(Scotchbrite), or a piloted stainless steel bonding brush that is no larger than the diameter of the bonding
surface of the connector.
sandpaper. Never clean more than one type of metal with a stainless steel brush. Be
careful not to remove excess metal. Deep scratches are not acceptable for an electrical
bond.
D. Additional Cleaning
(1) If additional cleaning procedures are needed, refer to General Solvents/Cleaners - Maintenance Practices.
7. Bonding Methods
A. General
(1) Bond connections must be installed so that vibration, expansion, contraction, or relative movement within normal
service use will not break or loosen the connecton.
(2) When direct metal-to-metal bonding of electrical equipment is done, all finishes which are nonconductive must be
removed from the contact area in the ground path before assembly. Refer to Surface Preparation. A bond check must
be done to determine if a finish is nonconductive.
(3) All AC ground must be connected separate from DC grounds.
(4) RF current returns must not be made through magnesium alloys.
(5) There are four ways to form an electrical bond joint between equipment and structure or between structural members.
In most cases a single method will meet the resistance requirements, but some may need more than one method.
The four bonding methods, in order of preference, are as follows:
(a) Direct conductive surface to conductive surface bond.
(b) Bonding jumpers or straps.
(c) Joining structure with driven rivets.
(d) Grounding equipment cases through connector contacts or terminals.
(6) After a bond is made, it must be checked. Refer to Bond Inspection.
(7) Metals from mating parts should be selected to be electrochemically compatible. If this is not possible, the interface
should be protected from the environment with sealant.
(8) If the bond is acceptable, the surface must be refinished and sealed, if applicable. Refer to Finishing and Sealing.
B. Direct Metal-to-Metal Surface Bonds
(1) Structure
(a) Direct metal-to-metal bonds must be able to carry the maximum fault current or lightning-induced current while
maintaining the bond resistance seen in Table 202. The maximum current is the current at which the circuit
breaker interrupts due to a fault or lightning-induced current.
(b) Figure 201 shows three examples of typical structural direct metal-to-metal surface bonding applications.
(2) Equipment
(a) If the attach fasteners are more than 3 inches (76.2 mm) apart, you only need to clean an area of 0.5 to 0.75
inches (12.7 to 19.1 mm) in diameter centered on the fastener holes on the mounting surface.
(b) The case bond must be isolated from, and independent of, current return grounds.
(c) Figure 202 shows a typical electrical bonding of equipment installed with mounting feet.
(3) Equipment Enclosures and Supports
(a) Metal modules or shielded enclosures that have electrical equipment should be bonded to the structure with a
th
minimum electrical contact area that is 1/8 of the mounting area.
(b) The supports for equipment enclosures of modules should have a minimum bonding area equal to the sum of the
bonding areas of the supported modules.

20-30-10-2 (Rev 1)
(c) The bracket supports for electronic parts can act as antennas and should be properly bonded to equipment
chassis or structure.
(d) Figure 203 shows a typical electrical bonding of equipment enclosures and supports.
(4) Feed-through Hardware
(a) For cabin feed-through hardware and all other hard-mounted hardware that requires an electrical bond that is
outside of the cabin (excluding wet fuel cell applications and Type XII electrical bonds), the nonconducting
surface finishes must be removed between the flange and the structure, refinished and sealed with Method B.
(b) For feed-through hardware and all other hard-mounted hardware that requires an electrical bond in wet fuel cell
applications or a Type XII electrical bond, the nonconducting surface finishes must be removed between the
flange and the structure, refinished, and sealed with Method A. If the hardware is mounted on the outer wall of the
fuel cell such that one side is wet and the other is dry, only the flange side needs to be cleaned per Method A,
but both sides need to be sealed per Method A.
(c) Figure 204 shows a typical electrical bonding of feed-through hardware.
(5) Inspection Plates, Access Doors, Cowls, etc.
(a) Hardware is normally considered good enough for electrical bonding of inspection plates, doors, cowls, and
other access areas, as long as all finishes which are non conducting are removed from the contact areas.
(b) If the hardware cannot achieve a good enough bond, a jumper may be added, refer to Jumper or Strap Bonds.
An example of this method can be seen in Figure 205.
(6) Antenna
(a) Hardware such as screws and nut plates which are used to secure radio antennas, such as ADF loop, marker
beacon, nav, comm, etc., are considered good enough as long as there is direct metal-to-metal contact with the
metal base of the antenna and the fasteners are used with nut plates that are riveted into the structure of the
airplane.
(b) All finishes which are nonconductive must be removed from the contact surfaces and fastening hardware, but it
is usually not required to remove the finish from the antenna mounting flange or bearing surface as long as the
antenna meets the resistance value to structure as defined in Table 202.
(c) For antennas installed on metal skin only, remove 0.50 to 0.75 inches (12.7 to 19.1 mm) diameter area of
nonconducting finishes centered on the fastener holes on the mounting surface per Method B. Do not remove
the finish within 0.0625 inches (1.59 mm) of the edge of the antenna base.
(d) If the antenna is mounted on a composite fairing, you must not remove the finish from the composite surface.
(e) For antennas mounted on composite fairing skin only, fay seal an area approximately 0.50 to 0.75 inches (12.7
to 19.1 mm) diameter area centered on the fastener holes on the mounting surface with conductive sealant with
Method B. Do not apply sealant within 0.0625 inches (1.59 mm) of the edge of the antenna base.
(f) When you check the bond between the fastener bearing surface or antenna connector to the structure, remove
one fastener.
(g) If a proper bond cannot be achieved, it may be required to remove and install the nut plate fasteners on the
inside doubler plate as well as clean the fasteners used to attach the antenna and countersink of the antenna
mounting flange.
(h) A typical example of antenna electrical bonding can be seen in Figure 206.
C. Jumper or Strap Bonds
(1) There should be as few jumper bonds as possible, and the ones installed should be as short and direct as possible.
(2) The guidelines that follow should be considered when installing a bonding jumper:
(a) Ground point locations should be chosen to make the best compromise of mechanical and electrical properties.
For best conduction, locate the ground on primary structure. If for structural reasons, holes can not be frilled in
the primary structure, the ground must be installed on secondary structure or on a tab that has been installed for
grounding.
(b) RF bonding jumpers should have a maximum length-to-width ratio of 5 to 1.
(c) Do not use jumpers in series to increase the overall length. Keep jumpers as short as possible.
(d) High-current jumpers or grounding wires cannot be directly connected to the airplane structure. These leads

20-30-10-2 (Rev 1)
must be connected to tabs that are the right size to bond to the basic structure.
(e) Shock mount jumpers must have one end installed between the isolator and structure. Bond straps over 0.03
inch (0.762 mm) thick require the isolator to be leveled with equivalent thickness washers.
(f) Jumpers should be located for protection from environment, vibration, expansion and contraction, and for easy
inspection access.
(g) Braided jumpers should not be used where too much vibration or motion occurs.
(h) Position suds and jumpers to avoid interference with moving parts. Special care must be taken when you install
jumpers on control surfaces, shock mounts, landing gear, landing gear doors, and similar items that involve
motion between attaching points.
(i) When you attach multiple jumpers to the structure with a single fastener, stack the jumpers from large to small
with the largest near the structure. Fan out all of the terminals. The limit for number of jumpers on a single
fastener is four.
(j) Bonding jumpers and equipment electrical grounds must never be connected to the same ground studs.
(k) All jumper connections should be made with No. 10 or 1/4 inch (6.35 mm) screws, with No. 8 as the preferred
minimum. Number 6 screws may be used where the edge distance will not allow you to use and of the previously
mentioned sizes.
(l) Typical examples of bolted type jumpers can be seen in Figure 207.
(m) The use of bonding jumpers to electrically bond metallic lines and tubes can be seen in Figure 208.
(n) The use of bonding jumpers with ground studs can be seen in Figure 209.
(o) The use of bonding jumpers installed with shock mounts can be seen in Figure 210.
D. Driven-Rivet Bonds
(1) An electrical bond can be achieved with 0.125 inch (3.175 mm) rivets that join two structural parts without direct
metal-to-metal contact joint preparation. This type of bond may require too many rivets to meet the resistance
requirements in Table 202.
8. Bond Inspection
A. Low Resistance Bond Inspection (Types I thru V and IX thru XII)
(1) This inspection is performed with a Keithley Model 580 Micro-ohmmeter or equivalent. Follow all manufacturer
instructions and safety precautions included with the meter.
(2) Direct contact between the micro-ohm meter probes and the metallic or conductive composite surface is necessary.
If it is necessary to remove the finish make sure that you refinish the surface after the bond is inspected, refer to
Finishing and Sealing.
(3) The bond should be inspected with each probe as close as possible to each other.
(4) In some installations, such as large panels, it is preferred that more than one check is made in different locations.
B. High Resistance Bond Inspection (Types VI thru VIII)
(1) This inspection is performed with a General Radio Company Megohmmeter Type 1862-C or equivalent. Follow all
manufacturer instructions and safety precautions included with the meter.
(2) For P-static paint, place a piece of metallic tape directly on the paint about 1.0 inch (25.4 mm) away from the
attachment hardware or airplane structure.
(3) Touch one probe to the metallic tape and the other probe to the attachment hardware or airplane structure.
(4) For the measurement of low-conductive gasket applications, you must touch one probe to the door or panel and the
other probe to the closest airplane structure.
(5) The measurement can be made with the megohmmeter, as long as the resistance requirement is met.
9. Finishing and Sealing
A. Finishing
NOTE: Make sure that you check the bond, and that it meets the requirements for that application, before
you finish the bonding surfaces.
(1) All electrically bonded surfaces that require a protective coating must be brushed with chem film and exposed areas
must be refinished with the original finish in as short of a time as possible. Refinishing is highly recommended within

20-30-10-2 (Rev 1)
24 hours.
(2) If the area already has chem film applied, it is not necessary to remove this finish and reapply unless the bonding
requirement cannot be met.
(3) Only refinish the area once the electrical bond has been inspected and approved.
(4) Bonding jumpers do not need to be painted.
B. Sealing
NOTE: Make sure that you check the bond, and that it meets the requirements for that application, before
you seal the bonding surfaces.
(1) For more information about sealants, refer to Fuel, Weather, Pressure and High-Temperature Sealing - Maintenance
Practices.
(2) Sealant is used to prevent moisture from getting into electrical contact areas, and in some cases it provides the
electrical bond.
(3) Some, but not all, typical areas where sealant may be required is as follows:
(a) Pressure bulkhead feed-thru connectors and hardware.
(b) Electrical ground studs.
(c) Antennas installed on the exterior of the airplane.
(d) Static wicks and bond jumpers.
(4) The bonded area must be finished before sealant is applied.
(5) Sealant is not required if Method A surface preparation was used inside the cabin.
(6) Method A (Nonconductive)
NOTE: Method A is to be used for wet fuel cell application and Type XII electrical bonds.
(a) Apply a fillet seal that extends between 0.0625 and 0.125 inch (1.59 and 3.18 mm) past the cleaned area given
for Method A in Surface Preparation.
(b) This is the only approved method for use when electrical bonding in wet fuel cells.
(c) The type of sealant to apply, in order of preference, is as follows:
1 Type X, Class B (Except in fuel tanks)
2 Type I, Class B
3 Type V, Class A or B.
(7) Method B (Conductive)
WARNING: Do not use conductive sealant in fuel tanks. Use only nonconductive sealants that are
approved for use in fuel tanks. The metal material in the conductive sealant can create a spark
(arcing) in the fuel tank.
NOTE: Method B is the required method of sealing all ground stud installations and all electrical
contact areas outside the cabin except in wet fuel cell applications and Type XII electrical
bonds.
NOTE: The Method B (Conductive) sealant procedure is not for high current grounds or high power
antennas.
(a) Apply a fay seal to the bonding area with Type XV, Class B sealant. Refer to Fuel, Weather, Pressure and High-
(b) Wipe away sealant squeeze-out but leave enough to tell that the bonding joint has been sealed.
(8) The typical installation of a static wick with sealant can be seen in Figure 211.
10. Termination of Shielded Electrical Cables
A. General Requirements
(1) Shields must be terminated at both ends of the wire bundle assembly with braids, unless otherwise specified.
(2) Shield terminations (jumper wires or braid strap) must be as short and as straight as possible to the back of a
connector or to a ground stud.
(3) Ground shields only where indicated by the applicable wiring diagram.

20-30-10-2 (Rev 1)
(4) There must be no more than two jumper wires (or braid straps) per ground terminal. If shown on a wire diagram, it is
permissible to have three braid straps per ground terminal.
(5) Only jumper shielded cables together as shown in the applicable Wiring Diagram Manual.
(6) Refer to Table 203 to determine proper solder sleeve for shielded cable to be terminated.
Table 203. Solder Sleeves for Shielded Cable
Wire and Jumper Diameter (Inch)
Solder Sleeve Raychem P/N
Minimum Maximum
0.035 0.105 S2974*1 D108-09
0.055 0.145 S2974*2 D108-10
0.085 0.200 S2974*3 D108-11
0.130 0.255 S2974*4
0.170 0.300 S2974*5 D108-12
0.225 0.450 D142-65
0.350 0.535 D142-66
B. Strip the shielded cable in accordance with dimensions in Figure 212.
(1) Use Ideal Coaxial Cable Stripper or Ideal Thermal Stripper (or equivalent) to cleanly cut the shield to required length.
(2) The fold back strip method is required for M27500 Type B shielded cable.
(3) The center strip method is used when terminating shields at a connector backshell, equipment rack or using a single
solder sleeve for several shielded cables.
C. Position the solder sleeve and jumper (or braid strap) and heat with a Raychem CV-5300 Zap Gun or equivalent, move
side to side until proper shrinking and soldering is observed. Refer to Figure 213.
NOTE: The Steinel HL 1802E, Steinel HL 1910E, and Master Proheat PH-1200 are approved equivalent heat
guns.
NOTE: The Raychem Model CV-4504 Shop Air Heater, Raychem IR-500 series or equivalent are approved
to use as an alternative to the Raychem CV-5300, Steinel HL 1802E, Steinel HL 1910E, and Master
Proheat PH-1200 if permitted for the installation.
NOTE: For MIL-W-16878 Type D shielded cable use shrink tube for a heat sink between the conductor
insulation and the shield.
(1) Solder sleeves must be used for conductor shielded wires when the extension of the metallic shield is required.
(2) There shall be no more than two jumpers (or braid straps) per solder sleeve.
(3) If using a single solder sleeve for several shielded cables, slip the shielded cables and all unshielded wires that
terminate at the same point through the solder sleeve.
D. Dead ending a shield. Refer to Figure 214.
(1) Strip shield braid between 0.5 and 1.5 inches (12.7 and 38.1 mm) from the end of the wire.
(2) Position a 0.75 inch (19.1 mm) long piece of heat shrink tubing over the center of the shield braid. Refer to Splices,
Terminals and Heat Shrinkable Tubing - Maintenance Practices.
(3) Heat the heat shrink tubing with a Raychem Zap Gun or Raychem Model CV-4504 Shop Air Heater (or equivalent),
move side to side until proper shrinking is observed.
E. Terminating shields at connector backshells or equipment racks. Refer to Figure 215.
(1) Solder sleeves shall be four inches or less from the connector.
(2) Only use S2974-X Solder Sleeves (with braid strap).
(3) Crimp braid strap(s) in terminal to match strain relief screws. Refer to Splices, Terminals and Heat Shrinkable Tubing
- Maintenance Practices, to determine terminal size required.
(4) Ensure connector backshell and strain relief clamp are properly tightened.
F. Terminating shields with a band clamp. Refer to Figure 216.
(1) Band clamps are used to terminate shields at a connector backshell or equipment rack. Band clamps are also used

20-30-10-2 (Rev 1)
to terminate shield overbraids that cover an entire wire bundle.

(2) Refer to Table 204 for band clamp and installation tool part numbers.
Table 204. Band Clamp and Installation Tool Part Numbers
Name Part Number Manufacturer Use
Band Clamp 600-052 BAND-IT - IDEX, Inc. Shield and shield overbraid
P.O. Box 16307 termination
Denver, CO 80216-0307
Tie-Dex II Tool A40199 BAND-IT - IDEX, Inc. Installation of band clamps
(3) When replacing band clamps, the following guidelines should be observed.
(a) Substitutions, such as tie wraps, are not allowed.
(b) Only use S2974-X Solder Sleeves (with braid strap) or braid straps when terminating shields with a band clamp.
(c) Ensure wires are not under the area to be clamped.
(d) Band clamps may not be reused. Band clamps must be replaced when removed for maintenance.
(e) After installation, the band clamp shall lay flat across the area to be clamped and shall be secure (cannot be
moved by hand).
(4) Removal of band clamps.
(a) Using a flat screwdriver, bend down the locking lip on the band clamp and slide the band through the band
clamp buckle.
(5) Installation of band clamps.
(a) Double wrap the band clamp around area to be clamped. Both wraps of the band clamp must pass through the
slot on the band clamp buckle.
(b) Squeeze the gripper release handle on the band clamp installation tool and insert the band into the installation
tool band slot.
NOTE: The cut-off handle (white handle) should be on the same side as the band clamp buckle.
(c) Repeatedly squeeze the pull-up handle (blue handle) until the handle locks against the installation tool body.
(d) Squeeze the cut-off handle (white handle) to crimp a locking lip on the band clamp and cut off excess band.
G. Resistance Values for Shield Terminations
(1) Resistance measured from a shield termination (braid strap) to a ground point shall be 0.010 ohms (10 milliohms) or
less. Refer to Figure 217.
(2) Resistance measured from a ground point to the connector body shall be 0.005 ohms (5 milliohms) or less. Refer to
Figure 217.

20-30-10-2 (Rev 1)
Figure 201 : Sheet 1 : Typical Structural Direct Metal-to-Metal Surface Bonds

A100242
Structure
Rivet
Sealant
(NOTE)
Structure
Clean Mating Area
(NOTE)
NOTE: Use Method A or Method B Cleaning and Sealing Procedures.

5580T2023

20-30-10-2 (Rev 1)

A100243
Sealant
(NOTE) Screw
Structure
Lock Washer
Washer
Nut
Structure
Sealant
(NOTE)
Structure
Clean Mating Surfaces
(NOTE)
NOTE: Use Method A or Method B Cleaning and Sealing Procedures.

5580T2023

20-30-10-2 (Rev 1)

A100244
Sealant
(NOTE)
Clean Mating Surface

(Method A)
Clean Mating Surface
(Method A or Method B)
Rivets
Secondary
Structure
Secondary
Structure
Primary
Structure
NOTE: Use Method A or Method B cleaning and sealing procedures.

5580T2023

20-30-10-2 (Rev 1)
Figure 202 : Sheet 1 : Typical Equipment Direct Metal-to-Metal Surface Bond

A99875
Method A: Fillet seal perimeter of bonding area with

Type I, Class B or Type V, Class A.
Method B: Do not fillet seal perimeter of bonding area.

Fay seal with Type XV, Class B.
Sealant shall be placed between item to be
bonded and bonding area. Wipe any sealant
squeeze out smooth.
Method A: Clean area must be between 0.0625 and

0.125 inches (1.59 and 3.18 mm) greater
than the contact area.
Method B: Clean area must not be greater than the
contact area and, must not be less
than one-half of the contact area.
NOTE: On items that have the bolts spaced more than 3 inches (76.2 mm)
apart, it is only necessary to clean an area of 0.5 to 0.75 inches
(12.7 to 19.1 mm) diameter centered on the fastener holes on the
mounting surface.
7418302-1

20-30-10-2 (Rev 1)
Figure 203 : Sheet 1 : Typical Equipment Enclosures and Supports Direct Metal-to-Metal Surface Bond
A99876
Area A
L
Area C
Area B
NOTE: The minimum bonding area must be 1/8 of Area A or Area B. For modules or enclosures
where 1/2 of the width of Area A and Area B is equal to 0.5 inch (12.7 mm) then a
flange width minimum of 0.5 inch (12.7 mm) along both edges of the longest dimension
must be specified. Assume Dimension L in the figure above is the longest dimension.

20-30-10-2 (Rev 1)
Figure 204 : Sheet 1 : Typical Feed-Through Hardware Direct Metal-to-Metal Surface Bond

20-30-10-2 (Rev 1)
Figure 204 : Sheet 2 : Typical Feed-Through Hardware Direct Metal-to-Metal Surface Bond

20-30-10-2 (Rev 1)
Figure 205 : Sheet 1 : Typical Inspection Plates and Access Door Direct Metal-to-Metal Surface Bond
A100300
Bond an Area That is 2.5 Times

That of the Diameter of The
Existing Hole (Minimum).
Bonding Jumper
Inspection Plate (NOTE)
Inner Surface
Bond an Area That is 2.5 Times

That of the Diameter of The
Existing Hole (Minimum).
Structure Existing Nutplate

Rivet
NOTE: This method is not applicable for use on fuel cell access panels.
5580T2023

20-30-10-2 (Rev 1)
Figure 206 : Sheet 1 : Electrical Bonding - Typical Antenna Bonding

A100301
Antenna Body
Antenna
Metal Base
Antenna Base
Metal Insert
Antenna
Gasket
Bonding Area Airplane Skin Airplane

(NOTE) Skin
Nutplate Bonding Area
Mounting (NOTE)
Screw Antenna
Connector
Housing
Antenna
Metal Base
Antenna Base
Metal Insert Antenna
Body
Airplane Skin
Antenna Gasket
Bonding Area Sealant
(NOTE) (NOTE)
Mounting
Screw
NOTE: Use method B cleaning and sealing procedures.

6280T1001

20-30-10-2 (Rev 1)
Figure 207 : Sheet 1 : Typical Bolted Type Bonding Jumper Direct Metal-to-Metal Surface Bond
A100302
Sealant
(NOTE)
Bonding Jumper
Screw
Lock Washer
Washer
Aluminium or Magnesium Nut
Structure
Sealant
(NOTE)
Sheet Metal Structure
Clean Area
(NOTE)
Bonding Jumper
NOTE: Use method A or method B cleaning and sealing procedures.

5580T2023

20-30-10-2 (Rev 1)
Figure 207 : Sheet 2 : Typical Bolted Type Bonding Jumper Direct Metal-to-Metal Surface Bond
A100303
Sealant
(NOTE)
Bonding Jumper
Screw
Lock Washer
Washer
Steel or Titanium
Structure Nut
Sealant
(NOTE) Steel or Titanium
Structure
Clean Area
(NOTE)
Bonding Jumper
NOTE: Use method A or method B cleaning and sealing procedures.

5580T2023

20-30-10-2 (Rev 1)
Figure 208 : Sheet 1 : Metallic Tube Bonding Jumper Direct Metal-to-Metal Surface Bonds
A100310
Clean Area
(NOTE)
Sealant
(NOTE)
Tube
A
Clamp
Bonding Jumper
Bolt
Washer
Tube
Bonding Jumper
Clamp
Lock Washer
Nut
VIEWA-A
NOTE: Use method A or method B cleaning and sealing procedures. 5580T2023

AA5580T2023

20-30-10-2 (Rev 1)
Figure 208 : Sheet 2 : Metallic Tube Bonding Jumper Direct Metal-to-Metal Surface Bonds
A100311
Tube
Number 2
Tube
Connection
Apply Sealant to the Clamps.

(Refer to Figure 206)
(NOTE) Clamp
Bonding Jumper
A
Tube
Number 1
Bolt
Washer
Bonding Jumper
Lock Washer
Tube Nut
Clamp
VIEWA-A
NOTE: Use method A or method B cleaning and Sealing Procedures. 5580T2023

AA5580T2023

20-30-10-2 (Rev 1)
Figure 209 : Sheet 1 : Electrical Bonding - Typical Permanent Ground Stud Installation
A100312
Primary Structure
Stud
Pulling Head
Adapter
Grooved Stem
Sleeve
(NOTE)
Grounding Stud Installation
Sleeve
Primary Structure
Nut
Grounding Wire Ring Terminal
Washer
Stud
Grounding Wire Installation
NOTE: Remove the primer sealant from this area. 6711T1090

20-30-10-2 (Rev 1)
A100313
Stud
Chemical-Filmed
Aluminium
Flat Washer
Clean and seal the bonding Airframe Finish Omitted

surfaces on both sides. or
(NOTE) Removed
Chemical-Filmed
Aluminium
Flat Washer
Lock Washer
Plain
or
Self-Locking Nut
NOTE: Method B is the only approved method for ground stud installations
except for wet fuel cell applications or Type XII electrical bonds. 7080T1018

20-30-10-2 (Rev 1)
A100314
Nut
Washer
Bulkhead Frame
Grounding Wires
Washer
Nut
Lock Washer
Washer
Clean and Seal the Bonding Surface on Both Sides.
Washer
Screw
NOTE: Method B is the only approved method for ground stud installations
except for wet fuel cell applications or Type XII electrical bonds. 7018T1165

20-30-10-2 (Rev 1)
Figure 210 : Sheet 1 : Typical Shock Mount Bonding Jumper Direct Metal-to-Metal Surface Bond

20-30-10-2 (Rev 1)
Figure 211 : Sheet 1 : Electrical Bonding - Typical Static Wick Installation

A100315
Static Wick
Static Wick
Base
Rivet
Sealant
(NOTE)
NOTE: Method B cleaning and sealing procedures are recommended for all applications,
but, if you cannot bond through the fastener, you must use method A.
6314T1080

20-30-10-2 (Rev 1)
Figure 212 : Sheet 1 : Shielded Cable Strip Dimensions

A100316 Solder Sleeve
Jumper or
Braid Strap
0.25 Inch Minimum 0.50 Inch Minimum
0.35 Inch Maximum 1.50 Inches Maximum (HIRF and IEL)
Braid Fold Back Method 2.00 Inches Maximum (All Others)
Jumper or
Braid Strap Solder Sleeve
0.25 Inch Minimum 0.50 Inch Minimum

0.35 Inch Maximum 1.50 Inches Maximum (HIRF and IEL)
2.00 Inches Maximum (All Others)
Braid End Strip Method
Jumper or Solder Sleeve

Braid Strap 0.75 Inch
Minimum Heated Shrink Tubing
0.25 Inch Minimum 0.50 Inch Minimum 0.50 Inch

0.35 Inch Maximum 0.75 Inch Maximum Minimum
1.50 Inches Maximum
0.35 Inch Maximum (HIRF and IEL)
Center Strip Method Using Braid Fold Back Dead End 2.00 Inches Maximum
(All Others)
Jumper or Solder Sleeve 0.75 Inch
Braid Strap Minimum
Heated Shrink Tubing
0.25 Inch Minimum 0.50 Inch Minimum 0.50 Inch

0.35 Inch Maximum 0.75 Inch Maximum Minimum
0.35 Inch Maximum 1.50 Inches Maximum
(HIRF and IEL)
2.00 Inches Maximum
Center Strip Method Using End Strip Dead End (All Others) 6718T1274

20-30-10-2 (Rev 1)
Figure 212 : Sheet 2 : Shielded Cable Strip Dimensions

A100317
4.00 Inches Maximum

(101.6 mm)
1.50 Inches 0.15 Inch

(38.1 mm) (38.1 mm)
0.50 Inch
(12.7 mm)
6718T1275

20-30-10-2 (Rev 1)
Figure 213 : Sheet 1 : Shielded Cable Terminations

A100318
Jumper or Braid Strap Solder Sleeve
NOTE: Only jumper shielded cables together

as shown on wiring diagram.
Multiple Shield Terminations
Solder Sleeve
Jumper or Braid Strap Jumper or Braid Strap
Single Solder Sleeve for Multiple Shielded Cables
6718T1276

20-30-10-2 (Rev 1)
Figure 214 : Sheet 1 : Dead End Shield Terminations

20-30-10-2 (Rev 1)
Figure 215 : Sheet 1 : Shield Terminations at Connector Backshells

20-30-10-2 (Rev 1)
Figure 216 : Sheet 1 : Band Clamp Installation

20-30-10-2 (Rev 1)
Figure 216 : Sheet 2 : Band Clamp Installation

20-30-10-2 (Rev 1)
Figure 217 : Sheet 1 : Resistance Values for Shield Terminations

20-30-15-2 (Rev 1)
WIRING AND RESISTORS - MAINTENANCE PRACTICES

1. General
A. This section gives the maintenance practices for wiring and resistors. Wiring and resistors includes wire types, wire
specification, wire identification, reidentification of wires, removal/installation of wires, terminal board installation, wire
repairs, and resistors.
B. The airplane wiring includes electrical (power) and electronic (avionics) wiring.
C. When an electrical circuit has been disconnected for maintenance or inspection, you must examine the circuit for integrity.
Do an operational check or continuity check of all applicable circuits.
2. Wire Types
A. There are four basic categories of wire used. Refer to Figure 201 for examples of the wire categories.
3. Wire Specification
A. Wire specifications are identified by a combination of letters and numbers that give the wire, number of cables, shield style
and material, and jacket material. This specification can be embossed on the wire jacket.
B. Replace wires with the type specified, if given in the applicable wiring diagram.
C. When the wire specification is not given in the applicable wiring diagram, use the procedure that follows to determine the
wire specification when you order a replacement.
(1) First, find the wire type. Refer to Figure 201.
(2) Refer to the wire identification number on the applicable wiring diagram to find the wire gage.
EXAMPLE: HJF162-96PF15(20) - wire gage is 20.
(3) Refer to the applicable wiring diagram to find the number of conductors.
(4) Use the procedure that follows for unshielded single-conductor wires.
NOTE: Use the data that follows to find the wire specification even if the wire being replaced has a
different wire specification than that shown. Because of specification changes and wire
specification numbers that are superseded, the wire specification of the wire being replaced
may not be used any longer.
(a) Refer to Table 201 to find the base part number. Refer to Table 202 to find the color codes. The part number is
(Base Part Number) - (Gage) - (Color).
Table 201. Single Conductor, Unshielded Wires
Specification Temperature AWG Use
Range
MIL-W-81044/12 -85 to 302°F (-65 24-12 All general airplane wiring: 24 to 12 gage.
to 150°C)
MIL-W-22759/3 -85 to 500°F (-65 10-00 General airplane wiring.
to 260°C)
MIL-W-22759/3 -85 to 500°F (-65 22-00 High-temperature wiring that does not include the
to 260°C) engine area and fire detection.
MIL-W-22759/41 -85 to 392°F (-65 24-00 High-abrasion resistance power cable.
to 200°C)
MIL-W-25038/1 -65.2 to 500°F (- 22-00 High-temperature and fire resistant for the engine area
54 to 260°C) and fire detection.
Table 202. Color Codes for Single Conductor, Unshielded Wires
0 = Black 1 = Brown 2 = Red 3 = Orange 4 = Yellow
5 = Green 6 = Blue 7 = Violet 8 = Gray 9 = White
EXAMPLE: HJF162-96PF15(22), single-conductor wire that does not require a high-temperature wire
and has a wire specification of M81044/12-22-9.
EXAMPLE: 3S183-SP227(20), single-conductor high-temperature wire and has a wire specification of
M22759/3-20-9.

20-30-15-2 (Rev 1)
EXAMPLE: GND17-ESG1(00), single-conductor starter-generator and has a wire specification of

M22759/41-00-9.
(5) For twisted unshielded wires, use part number M27500 - (GAGE) ML * U00.
Substitute * with the number of conductors.
EXAMPLE: Pair of wires, EJF28-MPF143(20) WHITE and FJF28-KPF143(20) BLACK (shown as a pair on
the diagram) has a wire specification of M27500-20ML2U00.
(6) For shielded single and multiconductor wire, use part number M27500 - (GAGE) ML * T08. Substitute * with the
number of conductors.
EXAMPLE: 9PT52-9PT54(22) (shown as shielded on the diagram) has a wire specification of M27500-
22ML1T08.
D. Single-Conductor Shielded, Jacketed, and Multiconductor Wires
(1) Refer to Figure 202 for an explanation of the MIL-C-27500 part numbers.
E. On avionic diagrams, twisted and shielded wires are called out by part number of Raychem Corporation. Refer to Figure
202 for an explanation of the Raychem part numbers.
(1) Single-shielded (SS on wire diagrams) 44A1111-(GAGE)-9-9.
(2) Shielded pair (SP on wire diagrams) 44A1121-(GAGE)-0/9-9.
(3) Shielded triple (ST on wire diagrams) 44A1131-(GAGE)-0/9/2-9.
(4) Twisted pair (TP on wire diagrams) 44A0121- (GAGE)-0/9.
(5) Twisted triple (TT on wire diagrams) 44A0131-(GAGE)-0/9/2.
F. Special Wires not used for General Airplane Wiring
(1) High-voltage used on indirect lighting, part number M16878DN20WHT.
(2) Alumel/chromel used on interturbine temperature indicator, MIL-W-5846 Type II, Class A.
(3) Flat multiconductor cable, for example, the cables to the pilot's and copilot's control wheels. Refer to Figure 202 for
part number explanation.
(4) Round multiconductor cables to pilot's and copilot's control wheels:
(a) Eight conductor, 22 gage, part number CMC0622.
• Available from Raychem Corporation.
4. Wire Identification
A. Identify each wire with characters at intervals not more than 15 inches (381.00 mm) for the length of the wire. Also, put
marks on the wire approximately 3 inches (76.20 mm) from each break or each terminal except that this distance can be
increased to install tie straps, clamps, connectors, support devices, or terminals.
B. No identification marks or numbers are necessary on external wires that are part of vendor supplied equipment.
C. It is not necessary to identify wires or cables that are less than 3 inches (76.20 mm) long.
D. Wire identification can have marks on the wire as follows:
(1) Hot embossing of a single wire.
(2) Hot embossing of pressure sensitive tape.
(3) Marks on vinyl sleeves.
(4) Marks on printing foils.
E. You can apply the identification code directly to the heat shrinkable tubing and install it in 3 inches (76.20 mm) or less of
the termination to identify coaxial cables.
5. Reidentification of Wires
A. The reidentification of a wire is necessary when you replace the wire routings or when you use the initial wire for new
functions.
section.

20-30-15-2 (Rev 1)
NOTE: You can use equivalent tools and equipment.

Aliphatic Naphtha TT-N-95 Commercially Available To use as a cleaning agent.
Braided Glass MIL-I-3190 Commercially Available To prevent damage to the wires
Sleeving from abrasion.
Cable Tie Tool GS2B Panduit To install the cable ties.
18900 Panduit Drive
Tinley Park, IL 60487
Fiberglass Cord MIL-Y-1140 Commercially Available To install the wires.
Glass Fabric Tape P31D Nitto Denko America High-temperature insulation.
5 Dakota Drive
New Hyde Park, NY 11042
Insulation Tubing MIL-I-23053/5 Raychem Corporation Heat shrinkable insulation.
300 Constitution Drive
Menlo Park, CA 94025
Lacquer MIL-L-7178 Commercially Available To apply a protective coating on the
ties.
Petrolatum AN-P-51 Commercially Available To help install the wires.
Red Glyptal Insulating 90-2 GC Electronics To apply a protective coating to
Varnish 1801 Morgan Street areas adjacent to wire bundles for
Rockford, IL 61102 insulation.
Sleeving MIL-I-7444B Type I Commercially Available Insulation and protection.
MIL-I-7444B Type II Commercially Available Identification of wires.
Tape, Adhesive MIL-I-7798 Commercially Available Insulation and wire repair.
Insulating
Tape, Thermosetable 365 3M High-temperature insulation and
Glass Cloth Industrial Adhesives and Tapes repair.
Division
St. Paul, MN 55144
Tie (Sta-Strap) MS3367 Commercially Available To attach wire bundles.
Twine MIL-T-713 Commercially Available To install the wires.
Vinyl Tape CT-93C Resin Industries Inc. To wind around the cables.
Santa Barbara, CA
7. Wire Installation
CAUTION: Install caps or other protection on electrical connectors that are disconnected. This will help to prevent
contamination with fluid and moisture.
A. Install the Wire.
NOTE: Obey the rules that follow when you install wires in open routings.
(1) Do not install crossovers, twists, and kinks.
(2) Wires must not be attached to or supported by plumbing lines that contain flammable liquids or oxygen. Where
possible, the wire routing must be above these lines.
(a) Wires and cables must be put a minimum of 6 inches (152.40 mm) from lines where possible.
(b) A separation of between 2 and 6 inches (50.80 and 152.40 mm) is permitted if the wire clamps are tightly
installed.
(c) When a minimum of 2 inches (50.80 mm) cannot be kept, a separation of between 0.5 to 2 inches (12.70 to

20-30-15-2 (Rev 1)
50.80 mm) is permitted if the electrical wire clamps are tightly installed and covered with an electrical insulating
material.
CAUTION: Make sure that fluid does not touch wires. Remove fluid from the wires and the hardware that holds
them, or avionics and electrical equipment. Collect and discard fluid spilled with cloths, plastic
sheets, and containers. Fluid contamination can cause wire insulator deterioration and short
circuits.
(3) Cables installed in locations where fluid can be caught must be protected against fluid contamination.
(a) You must supply protection from moisture deterioration to all wiring insulation. Use drain holes in the tubing,
sleeving, or conduit and keep wiring out of sumps and areas of too much moisture.
(b) You must put the cable routing in conduit when the cable routing is through areas where it can become soaked
with oil.
(4) The wire routing must not be closer than 3 inches (76.20 mm) to components that supply heat that is more than 140°F
(60°C).
(a) If you must connect the wires to components that supply heat, their routing must be away from the component a
minimum of 3 inches (76.20 mm).
(b) Wiring that operates in higher temperatures must be wound with tape or put in conduits.
(5) Wires and cables must be correctly installed or protected to keep them away from rough or irregular surfaces and
sharp edges.
(a) Use grommets, protective sleeves, correct support, and correct routing to protect the wiring from chafing.
(b) Put a layer of Glyptal on the surfaces of all screws or metal edges that are 0.20 inch (5.08 mm) or less from a
wire or cable. Also, use nylon caterpillar grommets or other protection.
(c) The wire routing must be away from parts that move to prevent damage.
(d) The wire routing must not go around sharp edges.
(e) Wire routing around rounded corners of cabinets must have a phenolic sheet installed on the corner to give
protection to the wiring. Refer to Figure 203.
(f) Make sure that the wire routing is correct so that it will not be crushed or pinched during installation.
CAUTION: Use a cloth to cover wires, avionics, or electrical equipment that is in a location where metal chips
or shavings can fall. Make sure that you remove metal chips or shavings from wires, avionics, and
electrical equipment. Contamination from metal shavings can cause wire insulator deterioration
and short circuits.
(6) Apply a light layer of Petrolatum or water on the wire before you pull it through the pressure feed-thru.
(7) Use nylon filler rods in the pressure feed-thru when a wire is removed and not replaced.
CAUTION: Set the drip loops so that the drip from the loop does not fall on equipment which can be damaged.
On moisture resistant connectors, it is not necessary to install drip loops where there is not
sufficient space. Coaxial cable assemblies identified as impedance matching units must be a
specified length. Do not decrease the cable length to remove unwanted slack.
(8) Keep sufficient slack in the wiring to do as follows:
• Let you do the terminal staking
• Easier maintenance
• Let the shock-mounted equipment move freely
• Prevent mechanical strain on the wiring and wiring supports
• Supply sufficient drip and service loops.
(9) Attach wire groups, bundles, sleeves, adapter clamps, and tape with a clove hitch knot and a square knot. Refer to
Figure 204.
(a) Only use MIL-T-713 twine and Sta-straps in operational temperatures of less than 200°F (93.33°C).
(b) The free ends of the MIL-T-713 twine must be a minimum of 3/8 inch (9.53 mm) long.
(c) Wire groups or bundles must be attached at intervals not more than 12 inches (304.80 mm).
(d) Insulating sleeving over splices and identification sleeves must be attached correctly at the two ends.
1 The ties must be made approximately 1/4 inch (6.35 mm) from the ends of the sleeves.

20-30-15-2 (Rev 1)
2 Sleeves over bare terminals must be attached at one end only or the tie must be made around the wire or
cable at the end of the sleeve away from the terminal.
(e) Wires or cables in conduit or insulating sleeving must not be attached together.
(f) Do not install a tie so tightly that it cuts or goes into the conductor jacket or the insulation.
(g) Do not use tying cord to hold the bundle.
(h) Two or more wire groups can be attached to each other and installed in the same clamp only if sufficient ties
stay on the individual groups to keep group identity.
(i) When cable groups go across each other, they must be tied together where they touch.
(10) The minimum bend radius of a cable other than coaxial cable is 10 times the outside diameter of the cable.
(a) At terminals where the cable is sufficiently supported, the minimum radius can be five times the outside
diameter.
(b) When it is not possible to get the correct radius, shorter bend radii are permitted if the bend is in insulated
tubing.
1 For electrical equipment and accessories, the minimum bend radius can be three times the diameter of the
wire.
(c) For coaxial cables, the minimum bend radius must be six times the outside diameter of the cable.
(11) Alternating current (AC) cables must be grouped and their routing not connected when possible except when AC and
direct current (DC) are both fastened to the same connector plug on a piece of equipment.
(12) When possible, the routing of wiring must be in open areas where it is visible for maintenance.
(13) Do not use adhesive tapes that will dry out in-service, cause a chemical reaction with the wire insulation, or absorb
moisture.
(14) Support wiring at intervals of not more than 24 inches (609.60 mm) except when contained in ducts or conduits.
(a) Tie wraps must be used on wiring bundles as necessary, but must not be at intervals of more than 6 inches
(152.40 mm) apart.
(b) Wire support devices must be the correct size to hold the wires correctly in position and not cause damage to
the insulation.
(c) Wiring support clamps must be installed on cabinet panels as shown in Figure 203.
1 You can use stick on anchors to contain the wires, but not to hold them.
(d) Do not use hot glue to hold the wires.
(15) Give protection to all wiring against factors that would stop the correct operation such as shorts, grounding, parting,
corrosion, or environmental exposure.
(16) When you connect wires to the terminals on the interturbine temperature (ITT) transmitter, do the routing of the wires
with a maximum of 3 to 4 inches (76.20 to 101.60 mm) of wire between the terminals and the first clamp or string tie.
Refer to Figure 205.
(17) All environmentally sealed-type connectors will have all empty cavities filled with unwired contacts (pins or sockets)
and sealing plugs.
8. Terminal Board Installation
A. All screws that attach the terminal board to the structure must be installed with the head toward the terminal side of the
board, if possible. All screws installed with the thread end toward the terminal side must have a maximum of 2 1/2 threads
through the nut.
B. A maximum of four terminals must be attached to one terminal lug.
C. The terminal must be attached to the terminal block so that no part of the wire touches the terminal stud.
D. When you tighten the nut on the stud, be careful that you do not break loose or break the molded-in stud or break the
frame.
E. All terminals must be installed on the terminal strip stud so that a possible movement of the terminal tightens the top stud
nut. When more than one terminal is attached to a terminal post, only the top terminal must be installed as described.
F. Refer to Figure 206 and start at the terminal block and assemble the washers, wire terminals and/or bus bars, and terminal
stud nuts on the terminal studs in the sequence that follows:

20-30-15-2 (Rev 1)
1. Plain washers
2. Lock washers
3. First stud nut
4. Terminal(s) and/or bus bar(s)
5. Plain washer
6. Lock washer
7. Last stud nut.
(1) When a terminal is attached to an equipment item with a screw, the screw must install through a lock washer, plain
washer, and terminal(s) in sequence with the wire terminal against the attachment point on the equipment.
9. Wire Repairs
A. General Instructions
CAUTION: Do not splice, solder, or tape a damaged wire unless it will not have an effect on the system
integrity. Do not use a smaller size wire. If you use a smaller size wire, burned wiring or
malfunctioning equipment can occur.
(1) Replace a broken, frayed, cracked, or damaged wire with a new wire.
(a) The full wire segment must be replaced.
(b) The replacement wire segment must be the size and type shown on the applicable wiring diagram.
(c) If wire or cable damage is only at the outer covering, the wire or cable can be repaired as given in this section.
B. Braided Nylon Insulated Wires
(1) Clean the repair area with aliphatic naphtha.
(2) Put loose nylon strands an equal distance over the damaged area.
(3) Use a spiral wrap, double layer of vinyl tape over the damaged area.
(a) Make an overlap of 1/2 width of the tape.
(b) Make sure that the tape extends at least 1 inch (25.40 mm) more than the two ends of the damaged area.
(4) Attach the two ends of the tape with nylon cord.
(a) Apply clear lacquer to the knots.
(5) You can wind adhesive vinyl tape around small gage wires.
C. Chromel/Alumel Thermocouple Wire
(1) Clean the damaged area with solvent.
(2) Put loose fiberglass an equal distance over the damaged area.
(3) Use a spiral wrap, double layer of glass fabric tape over the damaged area.
(a) Make an overlap of 1/2 width of the tape.
(b) Make sure that the tape extends at least 1 inch (25.40 mm) more than the two ends of the damaged area.
(c) The maximum length of the taped area must not be more than 3.5 inches (88.90 mm).
(4) Use a heat gun or a lamp to cure the tape in its position to approximately 320°F (160°C) for 30 minutes.
(a) Cover the adjacent wires with a heat resistant material to prevent damage.
(5) The ends of the outer insulation which have been removed and cut on the thermocouple leads must be served from
the ends of the insulation back to approximately 1/2-inch (12.70 mm).
(a) Wrap cord around the leads as shown in Figure 207.
D. Splicing Electrical Wires
NOTE: The splicing of wires is not recommended, but it can be necessary in some conditions.
(1) Refer to Splices, Terminals and Heat Shrinkable Tubing - Maintenance Practices for splices and tools.
(2) Cover all splices with an insulating sleeve.
(a) If the splice is fully covered, you do not need to cover the pre-insulated splices with a second sleeve.
(b) The splice crimping tool for pre-insulated splices has an insulation crimping adjustment set to 1, 2, 3, or 4 that
depends on the thickness of insulation.

20-30-15-2 (Rev 1)
(c) The splice must have a tight crimp on the insulation without damage.
(3) Splices in the same wire group or bundle must be staggered to prevent too much enlargement of the group or the
bundle.
(4) Do not splice aluminum cables.
(5) To splice high voltage wires used on indirect (fluorescent) lights, use environmental resistant splices covered with
heat shrinkable tubing. Refer to Figure 208.
(a) Splices on high voltage wires must be staggered a minimum of 1.5 inches (38.10 mm) to reduce the possibility
of arcing.
(b) Install splices where the wire is straight for the length of the heat shrinkable tubing.
NOTE: When the heat shrinkable tubing is bent after it is shrunk, small cracks can let high
voltage arcing.
(6) Splicing Shielded Wires. Refer to Figure 209.
(a) Refer to Splices, Terminals and Heat Shrinkable Tubing - Maintenance Practices for splices and tools.
(b) Splices in the same wire group or bundle must be staggered to prevent too much enlargement of the group or
the bundle.
(c) Do not install splices below a clamp or in a position where the wire bundle is flexed, for example at a wire bundle
breakout to an instrument.
(d) Inner conductor splices must be staggered as shown in Figure 209.
(e) After you install the braided solder sleeve, the solder must be fully melted and environmental seal bands must
touch the outer jacket of the wire.
(f) After you install the braided solder sleeve, the braided solder sleeve must not be cut or split. The shield strands
must not extend through the braided solder sleeve.
E. Splicing Coaxial Cables
NOTE: The splicing of coaxial cables is not recommended, but it can be necessary in some conditions.
(1) Do not install a splice on coaxial cables that are installed in a system where a specified length of cable is necessary
for correct operation.
(a) Examples of systems that use specified coaxial cable lengths are the radio altimeter and the emergency locator
transmitter (ELT).
(2) Do not install splices on triax cables.
(3) Only install coaxial cable splices to navigation, communication, and distance measuring equipment (DME) systems.
(a) Cut the coaxial cable at the location of the damage.
(b) Install TNC style (threaded) coaxial plugs and jacks on the ends of the coaxial cable or install TNC style coaxial
plugs on the two ends of the coaxial cable and connect to a bulkhead feed-thru connector.
(c) Cover the connectors with heat shrinkable tubing per MIL-I-23053. Refer to Splices, Terminals and Heat
Shrinkable Tubing - Maintenance Practices.
F. Terminal Installation
(1) Refer to Splices, Terminals and Heat Shrinkable Tubing - Maintenance Practices for terminals.
G. Heat Shrinkable Tubing Installation
(1) Refer to Splices, Terminals and Heat Shrinkable Tubing - Maintenance Practices for heat shrinkable tubing.
H. Wire Stripping
(1) Strip all wires with wire stripping tools. Do not use hand knives except when it is necessary for large cables.
(2) Strip sufficient insulation from the wire so no insulation will touch the conductor barrel.
(3) Be careful that you do not damage the wire or the remaining insulation.
(4) Refer to Table 204 for the minimum requirements that are permitted for nicked or cut wire strands.
Table 204. Maximum Nicked or Cut Strands for Stripped Wire
AWG Maximum Permitted Nicked or Cut Wire Strands

20-30-15-2 (Rev 1)
22 thru 14 3
12 thru 10 5
8 thru 2 6
I. Soldering
(1) Refer to Soldering - Maintenance Practices for soldering.
J. Backshell
(1) All non self-locking backshell coupling nuts must have RTV 157 applied to the nut and the backshell body after you
tighten it.
10. Resistors
A. When a resistor becomes unserviceable, the cause frequently will be a problem in a different part of the circuit. Do a check
for short circuits or other problems that could cause too much current.
B. Refer to Figure 210 for the color codes and the part numbers for resistors.
C. Part Number Value Guide
(1) CM3527 is 0.5 watt. CM3526 is 1 watt. These are Cessna engineering standards which are followed by a dash
number for the complete part number.
(a) The first number after the dash is the first digit.
(b) The second number after the dash is the second digit.
(c) The third number after the dash is the number of zeros.
(d) The fourth letter is the tolerance: G = +5 or -5% S = +10 or -10%.
Example: CM3527-430G is 43 ohms, 0.5 watt, +5 or -5%.
(e) For values less than 10 ohms, R is used in place of the second number and represents a decimal for the value.
Example: CM3527- 2R7G is 2.7 ohms, 0.5 watt, +5 or -5%.

20-30-15-2 (Rev 1)
Figure 201 : Sheet 1 : Wire Categories

A99882
Wire, Single-Conductor Unshielded

HJF162-96PF15(22)
High-temperature Wire, Unshielded (Wire Number is Underlined)

3S183-SP227(20)
Twisted Pair of Wires, Unshielded

23PF119-CPF41(22)WHITE
8PF119-EPF41(22)BLACK
Shielded Single Conductor

9PT52-9PT54(22)
Shielded Two Conductor

NOTE: Can be Shown with or without
"Twisted Wire" Symbol.
EJF28-MPF143(20)WHITE
FJF28-KPF143(20)BLACK
EJF28-MPF143(20)WHITE
FJF28-KPF143(20)BLACK
6238T407

20-30-15-2 (Rev 1)
Figure 202 : Sheet 1 : Wire Part Numbers

20-30-15-2 (Rev 1)
Figure 203 : Sheet 1 : Typical Cabinet Wire Bundle Routing

A99950
Bend radius of wire bundle Wire Bundle

to be 10 times the wire Diameter
bundle diameter
(Minimum).
Typical Wire Bundle Routing Bend

Edges of cabinet
must be rounded to accept
phenolic sheet.
Wire Bundle
(0.015 Inch (0.381 mm)
Phenolic Sheet Installed
with EC1300L Adhesive
Typical Wire Bundle Around Cabinet Corner

Varglas Tubing
(Slit, Wrap, and Tubing to
Attach with Install MS3420-4 or MS3420-6 Extend 0.050 Inch
Sta-Straps) tubing through panel (1.270 mm) Past
and secure with EC1300L Edge of Panel
adhesive.
Sta-Strap
Wire bundle routed Cabinet Panel

Typical Wire Bundle Routing through panel must
Over Edge of Panel have a bend radius
of 10 times the bundle
Increase cabinet cutout if diameter.
necessary to prevent wire Typical Wire Bundle
bundle from protruding beyond Routing Through a Panel
the back of the cabinet. 6518T2152

20-30-15-2 (Rev 1)

20-30-15-2 (Rev 1)

20-30-15-2 (Rev 1)
Figure 204 : Sheet 1 : Binding Tie

20-30-15-2 (Rev 1)
Figure 205 : Sheet 1 : Interturbine Temperature Transmitter (ITT) Wire Installation

20-30-15-2 (Rev 1)
Figure 206 : Sheet 1 : Terminal Board Installation

20-30-15-2 (Rev 1)
Figure 207 : Sheet 1 : Serving Thermocouple Leads

A99956
End Of Chord Must Not Be Exposed

More Than 0.125 Inch (3.175 mm)
At Either End Of Serve Approximately
0.50 Inch (12.70 mm)
Draw Crossed Twist

In Cord Under Wraps Thermocouple Leads
Outer Insulation
5598T2008

20-30-15-2 (Rev 1)
Figure 208 : Sheet 1 : Splicing High Voltage Electrical Wires

A99957
Centerline
M23053/5-105-0 Of Splice
Heat Shrinkable Tubing
Minimum 5.0 Inches (127.0 mm) 1.50 Inches
Long Centered On Splice (38.10 mm)
Centerline M81824/1-2
Splice High
Of Splice Voltage
Wire
XXXXTXXXX

20-30-15-2 (Rev 1)
Figure 209 : Sheet 1 : Shielded Wire Splices

20-30-15-2 (Rev 1)
Figure 210 : Sheet 1 : Resistor Part Numbers

20-30-15-2 (Rev 1)
Figure 210 : Sheet 2 : Resistor Part Numbers

ELECTRICAL AND COAXIAL CABLE CONNECTORS - MAINTENANCE PRACTICES

1. General
A. This section gives the maintenance practices for electrical and coaxial cable connectors.
B. Use the applicable safety equipment and procedures when you do the maintenance on electrical and coaxial cable
connectors to prevent damage to the equipment. Refer to Electrostatic Discharge Sensitive Components - Maintenance
Practices.
C. Electrical Connectors
(1) This section includes the procedures to assemble electrical connectors. It also gives electrical connector data for the
pin contacts and the insertion/extraction tools used with the electrical connectors.
(2) Electrical connectors are used to connect the airplane wire bundles and electrical wiring. Electrical connectors may
use solder-type or crimp-type contacts.
(3) All environmentally-sealed type connectors must have all empty cavities filled with unwired contacts (pins and
sockets) and sealing plugs.
D. Coaxial Cable Connectors
(1) This section includes the procedures to replace coaxial cable connectors.
(2) The two types of coaxial cable connectors included in this section are the threaded-type braid clamp and the swaged-
type braid clamp.
2. Electrical Connector Data
A. Refer to Table 201 for the different electrical connectors and the related data.
Table 201. Electrical Connector Data
Connector Manufacturer Wire Size Pin Socket Insertion Tool Extraction
American Wire Tool
Gage (AWG)
03-06-XXXX Molex Inc. 18-24 (Gold 02-06-6103 02-06-5103 11-01-0001 11-03-0009
(Refer to Figure 2222 Wellington Plate)
201) Ct. 18-24 (Tin) 02-06-2103 02-06-1103 11-02-0001 11-03-0009
Lisle, IL 60532-
1613
1-640507-0, 1- Tyco 18-26 640545-2 641300-2 455830-1 455822-2
640517-0 Electronics
(Refer to Figure Corp.
202) 2800 Fulling Mill
Middletown, PA
17057
205555-2 Tyco 20-24 205089-1 205090-1 91067-2 91067-2
(Refer to Figure Electronics
203) Corp.
207359-1, Tyco 16-18 66099-1 66101-1 91002-1 305183
207360-1, Electronics 20-24 66103-1 66105-1 91002-1 305183
207376-1, Corp.
207377-1,
207439-1,
207440-1
(Refer to Figure
204)
6-203736-0 Tyco 14 201570-1 201568-1 200893-2 305183
(Refer to Figure Electronics 16-18 66099-1 66101-1 91002-1 305183
205) Corp.
20-24 66103-1 66105-1 91002-1 305183

65003 (Refer to The Deutsch 20 Duetsch CTS-S20/20 - M15570-20 M15570-20

Figure 206) Co. 20-24 Military M39029/22-192 - M83723-31-20 M83723-31-20
Engineered
Connecting 22 Duetsch CTS-S22/22 - M15570-22 M15570-22
Devices
36033 Whittier
Ave.
Hemet, CA
92545
CTJ620E The Deutsch 20 Duetsch CTS-S20/20 - M15570-20 M15570-20
(Refer to Figure Co. 20-24 Military M39029/22-192 - M83723-31-20 M83723-31-20
206)
22 Duetsch CTS-S22/22 - M15570-22 M15570-22
D38999/XX - 12 M39029/58-365 M39029/56-353 M81969/14-04 M81969/14-04
(Refer to Figure 16 M39029/58-364 M39029/56-352 M81969/14-03 M81969/14-03
207)
20 M39029/58-363 M39029/56-351 M81969/14-02 M81969/14-02
DS04, DS07 The Deutsch 16 2841-7-9016 2803-5-0016 M15570-16 M15570-16
Series Co. 20 800-20/32-1 800-20/30-1 M15570-20 M15570-20
Connectors
(Refer to Figure 22 2841-5-9000 2803-4-9000 M15570-22-1 M15570-22-1
208)
FKDRS60- Incon, Inc. 22 201570-1 201568-1 200893-2 305183
PG35K00 F Series Div.
(Refer to Figure 5 Flagstone
209) Drive
Lewiston, ME
04243-7300
LMD4001X Amphenol 22 LMD-4022- LMD-4122- MIL-I-81969/14- MIL-I-81969/14-
(Refer to Figure Corp. 36LJ 96LD 02 02
210) Amphenol
Aerospace
Pyle-National
Connectors
40-60 Delaware
Ave.
Sidney, NY
13838-1395
LMD4003X Amphenol 20 LMD-4020- LMD-4120- MIL-I-81969/14- MIL-I-81969/14-
(Refer to Figure Corp. 96LD 96LD 01 01
210) Amphenol
Aerospace
Pyle-National
Connectors
M24308/2-X, - 18-20 330-5291-001 031-1007-001 None Required CET-20-15
M24308/4-X 20-24 030-5291-000 031-1007-000 None Required CET20-11 EXT-
(Refer to Figure 20HD
211)
M83723/77X - 12 M39029/4-113 M39029/5-118 M83723/31-20 M83723/31-20
212)
20 M39029/4-110 M39029/5-115 M83723/31-20 M83723/31-20

M83723/86X - 12 M39029/4-113 M39029/5-118 M83723/31-20 M83723/31-20

212)
20 M39029/4-110 M39029/5-115 M83723/31-20 M83723/31-20
MS24266 - 12 M39029/31-235 M39029/32-254 MIL-L- MS24256-R-12
Series (Refer to 81969/17-5
Figure 213) 16 M39029/31-229 M39029/32-248 MIL-L- MS24256-R-16
81969/17-4
20 M39029/31-241 M39029/32-260 MIL-L- MS24256-R-20
81969/17-9
MS27467, - 20 M39029/58-363 M39029/57-357 MS27534-20 MS27534-20
MS2747X, 22 M39029/58-360 M39029/57-354 MS27534-22D MS27534-22D
MS27484,
MS27497
(Refer to Figure
214)
MS311X, - 16-18 M39029/31-228 M39029/32-247 MS24256A16 MS24256R16
MS312X (Refer 20-24 M39029/31-240 M39029/32-259 MS24256A20 MS24256R20
to Figure 215)
MS345X (Refer - 12 M39029/29-213 M39029/30-219 MS27534-12 M83723-31-12
to Figure 216) 16-20 M39029/29-212 M39029/30-217 MS27534-16 MS83723-31-
16
16-20 with S M39029/29-212 M39029/30-218 MS27534-16 MS83723-31-
shell size (8S, 16
10S)
8 MS39029/29- MS39029/30- MS3165-8 M83723-32-8
214 220
MS347X Series - 12 M39029/4-113 M39029/5-118 MS3447-12 MS3447-12
(Refer to Figure 16 M39029/4-111 M39029/5-116 MS3447-16 MS3447-16
217)
20 M39029/4-110 M39029/5-115 MS3447-20 MS3447-20
S2800-39 - 14 - FC114N2 9099 9081
(Refer to Figure 16-18 - FC116N2 9099 9081
218)
20-24 - FC120N2 9099 9081
3. Crimp Tools and Positioner
A. Refer to Table 202 for the different crimp tools and positioners used with a contact.
Table 202. Crimp Tools and Positioner
Contact Crimp Tool Positioner
02-06-1103 11-01-0008 -
02-06-2103 11-01-0008 -
02-06-5103 11-01-0008 -
02-06-6103 11-01-0008 -
030-5291-000 M22520/2-01 M22520/2-08
030-5291-000 MS3191-A P20-3191-1
031-1007-000 M22520/2-01 M22520/2-08
031-1007-000 MS3191-A P20-3191-1

031-1007-001 M22520/1-01 TH25

031-1007-001 MS3191-1 P20-3191-17
201568-1 45098 -
201570-1 45098 -
205089-1 M22520/2-01 M2250/2-08
205090-1 M22520/2-01 M2250/2-08
2803-4-9000 MH800-K127 Daniels Mfg Co. Pontiac, -
Michigan
2803-5-0016 M15500-16-7 -
2803-5-0016 MS3191-1 -
2841-5-9000 MH800-K127 Daniels Mfg Co. Pontiac, -
Michigan
2841-7-9016 M15500-16-7 -
2841-7-9016 MS3191-1 -
330-5291-001 M22520/1-01 TH25
330-5291-001 MS3191-1 P20-3191-17
640545-2 90325-1 -
641300-2 90325-1 -
66099-1 90067 -
66099-1 90277-1 -
66101-1 90067 -
66101-1 90277-1 -
66103-1 90067 -
66103-1 90277-1 -
66105-1 90067 -
66105-1 90277-1 -
800-20/30-1 M15500-20 -
800-20/32-1 M15500-20 -
CTS-S20/20 M22520/7-01 M22520/7-12
CTS-S22/22 M22520/7-01 M22520/7-11
FC114N2 9100 9101-4
FC114N2 9501 9502-1
FC116N2 9100 9101-4
FC116N2 9501 9502-1
FC120N2 9100 9101-4
FC120N2 9501 9502-1
LMD-4020-96LD M22520/1-01 M22520/1-02
LMD-4022-36LJ M22520/2-01 -
LMD-4120-96LD M22520/1-01 M22520/1-02
LMD-4122-96LD M22520/2-01 M22520/2-07
M39029/22-192 M22520/7-01 M22520/7-12

M39029/29-213 CBT600B CCH-8-1 Crimp Head, CCHP8-6

Locator
M39029/31-228 M22520/1-01 M22520/1-02
M39029/31-229 M22520/1-01 -
M39029/31-235 M22520/1-01 -
M39029/31-240 M22520/1-01 M22520/1-02
M39029/31-241 M22520/1-01 -
M39029/32-247 M22520/1-01 M22520/1-02
M39029/32-248 M22520/1-01 -
M39029/32-254 M22520/1-01 -
M39029/32-259 M22520/1-01 M22520/1-02
M39029/32-260 M22520/1-01 -
M39029/4-110 M22520/1-01 M22520/1-02
M39029/4-111 M22520/1-01 M22520/1-02
M39029/4-113 M22520/1-01 M22520/1-02
M39029/5-115 M22520/1-01 M22520/1-02
M39029/5-116 M22520/1-01 M22520/1-02
M39029/5-118 M22520/1-01 M22520/1-02
M39029/57-354 M22520/2-01 M22520/2-06
M39029/57-357 M22520/1-01 M22520/1-04
M39029/58-360 M22520/2-01 M22520/2-08
M39029/58-360 MS3191-A P20-3191-1
M39029/58-363 M22520/1-01 M22520/1-04
M39029/58-365 M22520/1-01 M22520/1-04
B. Refer to Figure 219 for some typical tools used with crimp-type connectors.
C. Refer to Figure 220 for the typical removal/installation of front-release contact pins.
4. Wire Stripping Requirements
A. Obey the wire stripping requirements that follow:
(1) Use the approved wire stripping tools to do the wire stripping.
(2) Do not use hand knives to strip wire except when required for large cables.
(3) Sufficient insulation must be stripped from the wire so that no insulation will touch the conductor barrel.
(4) Be careful to prevent nicking or damaging the wire or remaining insulation.
(5) Refer to Table 203 for the maximum allowable nicked or broken wire strands.
Table 203. Wire Stripping Requirements
Wire Size American Wire Gage (AWG) Maximum Allowable Nicked or Broken Wire Strands
22 3
20 3
18 3
16 3
14 3
12 5
10 5

8 6
6 6
4 6
2 6
5. Backshell Installation Torque
A. Threaded backshells for circular connectors should be torqued to the values shown in Table 204. If the connector type is
not listed, follow the connector manufacturer's torque specification for that particular connector type.
Table 204. Backshell Installation Torque
Backshell Size Group 1, Light and Medium Duty: Group 2, Heavy Duty
MIL-C-5015 (MS3100 Series) MIL-C-5015 (MS3400 Series)
MIL-C-26482 Series I MIL-C-22992
MIL-C-26500 MIL-C-26482 Series II
MIL-C-27599 MIL-C-28840
MIL-C-38999 Series I and II MIL-C-38999 Series III, IV
MIL-C-81511 Series I, II, III, IV MIL-C-81703 Series III
MIL-C-81703 Series I MIL-C-83723 Series I, II, III
8, 9, A 40 Inch Pounds (4.5 N-m) 56 Inch Pounds (6.3 N-m)
3, 10, 10SL, 11, B 40 Inch Pounds (4.5 N-m) 76 Inch Pounds (8.5 N-m)
7, 12, 12S, 13, C 40 Inch Pounds (4.5 N-m) 108 Inch Pounds (12.2 N-m)
14, 14S, 15, D 40 Inch Pounds (4.5 N-m) 116 Inch Pounds (13.1 N-m)
16, 16S, 17, E 40 Inch Pounds (4.5 N-m) 116 Inch Pounds (13.1 N-m)
18, 19, 27, F 40 Inch Pounds (4.5 N-m) 116 Inch Pounds (13.1 N-m)
20, 21, 37, G 80 Inch Pounds (9.0 N-m) 136 Inch Pounds (15.3 N-m)
22, 23, H 80 Inch Pounds (9.0 N-m) 136 Inch Pounds (15.3 N-m)
24, 25, 61, J 80 Inch Pounds (9.0 N-m) 136 Inch Pounds (15.3 N-m)
28, 29 120 Inch Pounds (13.5 N-m) 148 Inch Pounds (9.0 N-m)
NOTE 1: All torque values have an allowable tolerance of +5 or -5 inch pounds (+0.5 or -0.5 N-m).
NOTE 2: Use Group 1 values for all composite backshells.
6. MS3106 Series Electrical Connector Assembly
A. Assemble the MS3106 Series Electrical Connector (Refer to Figure 221).
(1) Disassemble the electrical connector.
(2) Install the clamping nut with packing and the compression sleeve on to the wire bundle.
(3) Install the wires through the sealing grommet, coupling nut, and rear insert.
(4) Lock the ceramic retaining ring into its correct position by moving the silicone bushing toward the receptacle or pin
end of the contact pin.
NOTE: Locking the retaining ring can be done after crimping has been completed.
(5) Strip the insulation from the wire ends.
(6) Crimp the contact pins on to the wires.
(7) Install the contact pins in the front insert.
(a) Make sure that the keyway in the front insert is aligned with the rear insert.
(8) After all contact pins have been correctly positioned in the front insert, slide the rear insert over the rear of the contact
pins until the rear insert touches the front insert.

(9) Install the assembled inserts into the connector shell.

(a) Make sure that the packing is installed correctly on the connector shell.
(10) Install the coupling nut onto the connector shell.
(11) Slide the sealing grommet forward until it touches the rear insert.
(12) Slide the compression sleeve and clamping nut forward until the clamping nut engages the threads on the connector
shell.
(a) Make sure that the compression sleeve is aligned with the keyway.
(b) Make sure that the packing is installed correctly in the clamping nut.
(13) Tighten the clamping nut finger tight plus one-quarter turn.
NOTE:
A strap wrench or a padded wrench may be used to tighten the clamping nut the additional
one-quarter turn.
7. DBA-Type Electrical Connector Removal/Installation
NOTE: The removal and the installation of contact pins and contact sockets is typical.
A. Remove the Contact Pin (Refer to Figure 222 and Figure 223).
NOTE: For all crimp-type connectors, all unused wire cavities must be filled with a plastic wire hole filler
designed for the specific type of connector.
(1) With the rear pin insert toward you, use the correct size insertion/removal tool and snap the white end of it over the
wire of the related contact pin.
(2) Slowly slide the insertion/removal tool along the wire into the cavity until it engages the contact pin shoulder and you
feel a positive resistance.
NOTE: This will put the contact pin retaining clip in the unlock position.
(3) Press the wire against the serrations of the insertion/removal tool and pull the tool with the wire and the contact pin
from the shell receptacle.
B. Install the Contact Pin (Refer to Figure 222 and Figure 223).
(1) Strip the insulation from the wire ends.
(a) For number 12 thru number 20 contacts pins, strip between 0.25 to 0.31 inch (6.35 to 7.87 mm) of insulation.
(b) For number 20 contacts pins, strip between 0.15 to 0.21 inch (3.81 to 5.33 mm) of insulation.
(2) Put the wire into the contact pin until you can see the wire strands in the inspection hole.
(3) Crimp the contact pin with the correct crimping tool.
(4) Snap the wire into the correct insertion/removal tool.
(5) Pull the wire back through the insertion/removal tool until the tip of the tool seats against the back of the contact pin.
(6) Hold the connector with the backshell removed and slowly push the contact pin straight into the shell receptacle until it
stops firmly.
NOTE: The contact pin is correctly installed.
(7) Release the wire and remove the insertion/removal tool.
8. Coaxial Cable Connector Installation (Threaded Type)
A. Install the Coaxial Cable Connector (Threaded Type) (Refer to Figure 224).
(1) Cut the coaxial cable to length.
(2) Trim the jacket approximately 0.31 inch (7.87 mm) from the end of the cable.
(3) Slip the clamp nut, washer, gasket, and braid clamp onto the coaxial cable.
(4) Flare the cable braid over the braid clamp.
(5) Strip the insulation from the center conductor to the depth of contact solder pot.
(6) Install and solder the contact to the center conductor.
NOTE: The captivated nut, washer, and insulator are assembled before the contacts are soldered.
(7) Install the complete assembly into the connector body so that the contact enters the hold in insulator correctly.
9. Coaxial Cable Connector with K-Grip Installation (Swaged Type)

A. Install the Coaxial Cable Connector with K-Grip (Swaged Type) (Refer to Figure 225).
(1) Remove the nut, gasket, and braid clamp from the coaxial cable connector body.
(2) Remove the K-Grip barrel and the K-Grip sleeve from the individual package.
(3) Install the K-Grip sleeve and the nut onto the coaxial cable.
(4) Trim the jacket to Dimension A as shown in Table 205.
Table 205. Coaxial Cable Connector with K-Grip
Coaxial Cable Dimension A in Dimension B in Dimension C in K-Grip Tool
Connector Inches (mm) Inch (mm) Inch (mm)
UG-913A/U 1.18 0.3 0.111 KS-89-05 683-51470-1
UG-88C/U 1.18 0.3 0.111 KS89-05 683-51470-1
CAUTION: Do not nick or cut the cable braid.
(5) Use a small scissors or a fingernail clippers to trim the cable braid to Dimension B as shown in Table 205.
(6) Slide the grooved, slotted end of the K-Grip barrel over the dielectric and under the cable braid until the braid touches
the step of the barrel.
(7) Slide the nut in place so that the nut touches the collar of the K-Grip barrel.
NOTE: The nut must be in the correct position before you crimp the K-Grip sleeve.
(8) Hold the K-Grip barrel in its position and slide the K-Grip sleeve until the forward edge of the sleeve is even with the
step of the K-Grip barrel and the cable braid is visible between the sleeve and the step.
(9) Crimp the K-Grip sleeve with the specified tool as shown in Table 205.
(a) If an alternate tool is used, crimp the K-Grip sleeve twice to use the full length of the sleeve while a flare is left at
each end.
CAUTION: Do not nick or cut the center conductor.
(10) Trim the dielectric to Dimension C as shown in Table 205.
(11) Trim the center conductor to the depth of contact solder pot so that the contact is flush with the dielectric.
(12) Use a soldering iron to lightly tin the center conductor.
(13) Install and solder the solder contact on the center conductor.
(14) Install the gasket and the braid clamp.
(15) Insert the complete assembly into the connector body so that the contact enters the hole in the insulator and the braid
clamp installs correctly.
(16) Push the assembly into the connector body as far as possible.
(17) Install the connector nut by hand, then tighten it with a wrench.
10. MIL-C-25516 (M25516/20-XX-XX) Coaxial Cable Connector Assembly
A. Assemble the MIL-C-25516 (M25516/20-XX-XX) Coaxial Cable Connector (Refer to Figure 226).
NOTE: These instructions also include Ted Manufacturing Corporation Series 59 and 69 connectors for
shielded cables.
11. 2755-2-9 King K-Grip Coaxial Cable Connector Assembly
A. Assemble the 2755-2-9 King K-Grip Coaxial Cable Connector (Refer to Figure 227).

Figure 201 : Sheet 1 : 03-06 and 06-06 Series Molex Connectors

Figure 202 : Sheet 1 : MR II 2 Position Housing Connectors

Figure 203 : Sheet 1 : Amp Subminiature D Connectors

A100155
205208-1 Plug (25 Pin Contacts)

205212-1 Plug (50 Pin Contacts)
205555-2 Receptacle (9 Socket Contacts)

205817-1
Screw Lock
(Optional)
205980-1
Screw and Retainer
(Optional)
65181008

Figure 203 : Sheet 2 : Amp Subminiature D Connectors

Figure 204 : Sheet 1 : Amp Metrimate In-Line Series Connectors

Figure 205 : Sheet 1 : Amp M Series Connector Kit

A100158
201224-1 A B
Strain Relief C D
E F
H J
K L
M N
P R
S T
U V
W X
A Y B Z
A C B D
E C F D
E H F J
K H L J
K M L N
M N
200838-2
Block
Face View Pin Insert
201357-1

Figure 206 : Sheet 1 : CTJ Series Deutsch Connectors

A100159
CTJ-R06 Module Extraction

Tool to Disengage
Plug and Receptacle
CTJ-R01
Receptacle
65003-06N (CTJ920E06N)
65003-12N (CTJ920E12N)
Plug
CTJ620E06N
CTJ620E12N
Strain Relief
1629-01-06117
1629-01-12117
Strain Relief
1629-01-06117
1629-01-12117
62181044
62181043
62802012

Figure 207 : Sheet 1 : D38999 Series Connectors

A100160

Figure 207 : Sheet 2 : D38999 Series Connectors

A100161

Figure 208 : Sheet 1 : DS04, DS07, RTK06, and RTK07 Series Connectors

Figure 208 : Sheet 2 : DS04, DS07, RTK06, and RTK07 Series Connectors
A100163
Face View Pin Insert
2
1 3 7 3
1
2
6 5 4
3P 7P
1
3 2
33 7
6
4
5 8
1
10 9 11
16-33 19-2P
DS04-3P
DS07-7P
RTK06-16-33
RTK07-19-2P

Figure 209 : Sheet 1 : FKDRS60PG35K00 Texas Instruments Connectors

A100164

Figure 210 : Sheet 1 : LMD4000 Series Connectors

A100165
LMD-4001-S
S3070-09
LMS-01T-TL
Splice Connector
LMD-4001-P
S3070-10
LMD-4001-S
S3070-11
LMS-01T-TL
Splice Connector
LMD-4001-P
S3070-12
LMS Module
Removal Tool
4 3 2 1
Part Number TP-201399
3 2 1
8 7 6 5
6 5 4
12 11 10 9
Face Views
9 8 7
16 15 14 13
LMD-4003-S LMD-4001-S
S3070-09 S3070-11
1 2 3 4
1 2 3
5 6 7 8
4 5 6
12 11 10 9
7 8 9
16 15 14 13
LMD-4001-P LMD-4001-P
S3070-10 S3070-12
LMD-4001-S-S3070-11
LMD-4001-P-S3070-12
LMD-4003-S-S3070-09
LMD-4003-P-S3070-10

Figure 211 : Sheet 1 : M24308 Series Connectors



A100168

Figure 212 : Sheet 1 : M83723 Series 3 Connectors

Figure 212 : Sheet 2 : M83723 Series 3 Connectors

A100170
Face View Socket Insert
6 5
4
5 7
1
1 4
8 2 3 12
1 3 2 3
9 11
2 10
8-98 10-5 12-12
21 20
22 9 8 19 31
6 5 23 10 2 7 8 30
7 11 3 1 6 7
1 4
24 12 4 5 6 28
8 2 3 12
25 13 14 5 28
9 11
10 26 27
14-12 18-31
15 22
23 21
16 14 24 39
17 8 25 9 8
10 20
25 38
9 2 7 13 2 7
26 11 19 37
18 3 1 6 24 1
12 3 6 18
27 36
10 4 5 12
13 4 5 17
28 35
19 11 23 14 16
20 22 29 15 34
30 33
21 31 32
M83723-8-98
M83723-10-5
20-25 20-39 M83723-12-12
M83723-14-12
M83723-18-31
M83723-20-25
M83723-20-39

Figure 213 : Sheet 1 : MIL-C-26500 Series Connectors

Figure 214 : Sheet 1 : MIL-C-38999 Series 1 and Series 2 Connectors

A100172
Receptacle
MS27472
MS27497
MS27474
MS27484
Plug
MS27473


A100173


A100174

Figure 215 : Sheet 1 : MIL-C-26482 Series 1 Connectors

A100175
MS3121EXX-XXX
MS3471
Receptacle
PT000SE-XX-XXX
Receptacle PT01SE-XX-XXX
PT07SE-XX-XXX ** MS3120F-XX-XXX
** MS3124F16-26P MS3470
MS3474
NOTE: PT06AXX
PT06E-XX
*MS3116A-XX
*MS3116E-XX
*MS3116F-XX
Conncectors do not have
removable contacts.
Plug
PT06CE-XX-XXS(SR)(Bendix)
PT06SE-XX-XXS(SR)(Bendix)
**MS3126E-XX-XXS **MIL-C-26482(Series 1)
**MS3126F-XX-XXS **MIL-C-26482(Series 2)
MS3476
A D A C A
C A
B C C B B
Face View B
Pin Insert
8-3 8-4 8-33 8-98
G A
H A B
A A A
F B C K J
E F B F H B
E C B G C
D D C E C
F E D
D
10-6 10-98 12-3 12-8 12-10 Mil-C-26482-8-3

Mil-C-26482-8-4
Mil-C-26482-8-33
L A M A B Mil-C-26482-8-98
A H A K M B Mil-C-26482-10-6
L N P C
G J B
R N
Mil-C-26482-10-98
J C K U V R D Mil-C-26482-12-3
D B M K
L H P D J T S E Mil-C-26482-12-8
F C Mil-C-26482-12-10
C G E H G F
E D F Mil-C-26482-14-4
Mil-C-26482-14-12
Mil-C-26482-14-15
14-19 Mil-C-26482-14-19
14-4 14-12 14-15


A100176
R A
G J A
P S T B F A K
N a b U C
H B
M Z c V D H B L
E G C
L Y X W E
K F D C F D
J H G E
16-26 18-8 18-11
W A
A V B
T j X Y C
S U V B U i
e Z
Rd f W C T r a D
j h k m
P c g S g E
X D
h q n b
p
N b
Z
Y E R
f c F
M a F P e d G
L J N L K H
K H G M J
18-32 20-39
U A
Y A T V B
X Z B S n W C
W C m p X
k a k AA q Y
V m D R BB r D
j b z GG CC Z
U s n E j HH s
P y a E
i t c FF DD
T F i EE t
r p N x F
S G w u b
h q d v c
g h d
R e H g
P f J M G
f
N M K L e H
L K J
22-41 22-55 MIL-C-26482-16-26

MIL-C-26482-18-8
MIL-C-26482-81-11
MIL-C-26482-18-32
MIL-C-26482-20-39
MIL-C-26482-22-41
MIL-C-26482-22-55



A100178
FACE VIEW PIN INSERT
C A D A
C A B A
A B C B
B B
10SL-3 10SL-4 12S-3 14S-1 14S-2
H A A
A A F A G I B
F B
E B
E G B C B
F J C
D C E C
D D C E D
14S-5 14S-6 16S-1 18-1 18-5
A A
J A M B
I K B L N C
G E B
F C T P
F A H N L C K D
E G B
H G M D S R
E B J E D C
D A
F E H F
D C G
18-8 18-9 20-27 20-29 22-12
A B C D
E F G H J
A A B C D
K L M N P R
E E F G H J
S T U V W X Z
B K L M N P Q a b c d e
MIL-C-5015-10SL-3
f
MIL-C-5015-10SL-4
D R S T U V g h j k m MIL-C-5015-12S-3
C n p r s MIL-C-5015-14S-1
W X Y Z MIL-C-5015-14S-2
MIL-C-5015-14S-5
MIL-C-5015-14S-6
MIL-C-5015-16S-1
MIL-C-5015-18-1
MIL-C-5015-18-5
MIL-C-5015-18-8
24-12 24-28 28-21 MIL-C-5015-18-9
MIL-C-5015-20-27
MIL-C-5015-20-29
MIL-C-5015-22-12
MIL-C-5015-24-12
MIL-C-5015-24-28
MIL-C-5015-28-21



A100180


A100181

Figure 218 : Sheet 1 : Positronic GMCT Series Connectors

A100182
Face View Sockets
GMCT14F0

Figure 219 : Sheet 1 : Typical Tools Used with Crimp-Type Connectors

A100183
Deutsch Deutsch
M15500-x-7 M15515-20
Contact Crimping Tool Extraction Tool
Deutsch Deutsch
M15513-20 M15570-20
Insertion Tool Insertion / Removal Tool
MS3191-3
MS3191-4
With MS3191-3T
55981015
55801010
55801010
55981014
55802009


A100184
MS3191-1 MS3198-1
MS27495A20 MS27495R20
Insertion Tool Extraction Tool
Cannon MS24256A20
CIT-20-18
Cannon MS24256R20
CET-20-4 55802009
55802009
55802009
55802009
55802009
55802009
55802009
55802009


A100185
Bendix Bendix
11-3697 11-8794-20
11-3698 Insertion Tool
11-6783
11-6784
Extraction Tools
Amp
90066
Daniels
MH800-K127
55801010
55801010
55801010
55801011
55802009

Figure 220 : Sheet 1 : Typical Removal/Installation of Front-Release Contact Pins

A100186
Crimping Contacts
1. Strip wires according to the table,

taking care not to cut or nick strands.
2. Insert stripped wire into contact crimp

pot. Wire must be visible through
inspection hole.
Right
Wrong
3. Using correct crimp tool and locator,

cycle the tool once to be sure the
indentors are open. Insert contact and
wire into locator. Squeeze tool handles
firmly and completely to ensure a
proper crimp. The tool will not release
unless the crimp indentors in the tool
head have been fully actuated.
4. Release crimped contact and wire

from tool. Be certain the wire is visible
through inspection hole in contact.
55801008
55801009


A100187
Contact Insertion
5. Remove hardware from plug and

receptacle. Slide hardware over wire Endbell
bundle in proper order for reassembly.
Ferrule
Coupling Nut
Barrel
6. Use the proper contact insertion tool, Number 16 Contacts

and slide the tool over the terminal
end of the contact. The size 16 contact
lies in the tool and the tool tip butts
against the contact shoulder. The rear, Tool Tip Insertion
or insulation support of the size 20 Shoulder
contact butts against an internal
shoulder in the tool tip.
Number 20 Contacts
7. Beginning from center cavity and working

outward, insert wired contacts into rear
of connector by hand until the front of the
contact shoulder is no more than 0.12 inch
from the grommet. Holding the connector
securely, position tool behind contact.
Push tool straight into contact cavity until
contact snaps into position. A light pull on
the wire will assure that contact is locked
securely. Repeat for remaining contacts.
8. Use wire hole fillers or grommet sealing

plugs to fill any empty cavities and
assemble hardware to rear of plug or
receptacle.
55801008
55801009
55801008


Figure 221 : Sheet 1 : Solder-Type Connectors

Figure 222 : Sheet 1 : Crimp-Type Connector Assembly

Figure 223 : Sheet 1 : Typical Removal/Installation of Rear-Release Contact Pins



Figure 224 : Sheet 1 : Coaxial Cable Connector Installation (Threaded Type)

Figure 225 : Sheet 1 : Coaxial Cable Connector with K-Grip Installation (Swaged Type)

Figure 226 : Sheet 1 : MIL-C-25516 (M25516/20-XX-XX) Coaxial Cable Connector Assembly

A100196
Braid
Bushing Washer Clamp Gasket
Female
Contact
Assembly
Plug Body
Cable Cable V-Groove Braid Male
Nut Clamp Gasket Retainer Contact
Assembly
Cut cable off square and remove outer jacket to

dimension shown. Slip cable nut, bushing, cable
clamp, washer and gasket (V-groove as shown
for 69 series; flat gasket on 59 series) over outer
jacket of cable. Position braid clamp with inside
shoulder against shoulder of outer jacket.
21/64 Inch
Comb out braid and fold back over braid clamp

and trim off excess braid as shown. Trim die-
lectric from center conductor to dimension shown.
7/64 Inch
Position braid retainer and small gasket as shown.

Push both tightly against the braid clamp and
solder contact assembly to center conductor.
Solder
6018T1030
6018T1030
6018T1030
6018T1030

Figure 227 : Sheet 1 : 2755-2-9 King K-Grip Coaxial Cable Connector Assembly





20-30-25-2 (Rev 1)
SPLICES, TERMINALS AND HEAT SHRINKABLE TUBING - MAINTENANCE PRACTICES

1. General
A. This section contains information for the replacement of splices, terminals, and heat shrinkable tubing. All wire sizes
referenced are American Wire Gauge (AWG).
B. The splices are either a permanent crimp-type splice that must be destroyed to separate the wires or a quick-disconnect
type that can be connected and disconnected repeatedly.
C. The terminals are crimp-type in either straight or flag type.
D. Heat shrink tubing is used to cover the splices and terminals and short sections of wire where the insulation has been
damaged. Some types of heat shrink tubing are coated inside with sealant which melts when the tube shrinks. This
provides a moisture resistant seal to prevent corrosion. End caps are also used to dead end wires.
3. Splices
A. General
(1) Do not splice coaxial and aluminum cable.
(2) Do not position splices in cable clamps.
(3) Stagger splices in the same wire group or bundle to prevent excessive cable enlargement.
(4) Each end of the splice must be sized separately. If the splice selected for two wires in one end will not accept the third
wire in the other end, you can use the doubling back method. Refer to Figure 201.
Figure 201
(5) To prevent tearing the connecting strap of the splice, insert the splice into the crimping tool with the flat portion facing
one of the jaws.
(6) Single, double, and triple conductor crimped terminals and splices must be able to withstand the tension loads in
Table 201.
Table 201. Crimped Terminal and Splice Tension Loads
Wire Size
22 20 18 16 14 12 10 8 6 4 2
(AWG)
Load
(Pounds) 15 19 38 50 70 110 150 225 300 400 550
Load
(kg) 6.8 8.6 17.2 22.7 31.8 49.9 68.0 102.1 136.1 181.4 249
B. Quick Disconnect Non-Environmentally Resistant Splices

(1) A complete splice requires two S341-X disconnects. These splices are also called "wrist-lock" splices because they
connect to one another similar to a handshake.
(2) S341-1 splices are for AWG wire sizes 14 and 16 and have a maximum inside diameter where the wire will be

20-30-25-2 (Rev 1)
crimped in of 0.187 inch (4.75 mm).

(3) S341-2 splices are for AWG wire sizes 18 thru 22 and have a maximum inside diameter where the wire will be
crimped in of 0.150 inch (3.81 mm).
(4) A S341-1 disconnect will connect to a S341-2 disconnect.
(5) The wire to be spliced is first inserted through a larger diameter section and then into a smaller diameter section. The
smaller diameter section is the section that is to be crimped.
(6) Strip the insulation off of all of the wires that you are going to splice enough to where when they are inserted all of the
way into the splice, no insulation is in the barrel. If you strip too much of the wire, the insulation sleeve that goes over
the splice will not be able to cover all of the stripped wire.
(7) Insert the wires into either side of the splice and crimp the wires into the barrel with crimping tool WT110M.
(8) Do the same for the other half of the splice.
(9) All quick-disconnect splices (S341) must be covered with an insulating sleeve and secured.
C. Quick Disconnect Environmentally Resistant Splices
(1) Quick-disconnected splices that are environmentally resistant can accept 1 or 2 wires on each side.
(2) These splices accept AWG 22, 20, 16, and 12.
(3) Table 202 contains all of the approved quick-disconnect environmentally resistant splices.
Table 202. Quick-Disconnect Environmentally Resistant Splices
Insertion Tool Contacts Plugs
Configuration Splice P/N AWG Contact P/N
P/N Supplied Supplied
M81714/65-
Single 3 0
12-1 M39029/22-
12 M81969/16-03
M81714/65- 605
Double 4 1
12-2
M81714/65-
Single 2 0
16-1 M39029/22-
16 M81969/14-03
M81714/65- 193
Double 5 1
16-2
M81714/65-
Single 2 0
20-1 M39029/22-
20 M81969/14-11
M81714/65- 192
Double 5 1
20-2
M81714/65-
Single 2 0
22-1 M39029/22-
22 M81969/16-04
M81714/65- 191
Double 5 1
22-2
D. Permanent Non-Environmentally Resistant Splices
way into the splice barrel with no insulation in the barrel. If you strip too much of the wire, the insulation sleeve that
goes over the splice will not be able to cover all of the stripped wire.
(2) Select the correct splice for your application. Refer to Table 203 for the correct splice to use for the wire size and
number combination that you need to go into either side of the splice.
Table 203. Permanent Non-Environmentally Resistant Splices
Number of Wire Size in Side Number of Wires Wire Size in Side
Splice P/N Splice Color
Wires in Side 1 1 in Side 2 2
22
3 2 20
22

20-30-25-2 (Rev 1)
2 S1370-1 Red
1 22
1
2 2
20 20
1 1
3 20 18
2
20
1, 1 20, 18
1, 1 20, 18
3 20 3 20
2 18 2 18
1, 1 18, 20 1, 1 18, 20 S1370-2 Blue
1, 2 18, 20 2 20
2 2 18
16
1
16
1 2
14 1 14
2 2 12
1, 1 14, 12 1, 1 14, 12
2 14 14
S1370-3 Yellow
10
12 1
1 12
10 10
(3) Insert all of your wires into one side of the barrel of the splice.
(a) Make sure that all of the wires touch the center divider of the barrel.
(b) Make sure that no insulation of any wires is in the barrel.
(4) Use crimping tool 59239-4 to crimp -3 splices and use crimping tool 59250 to crimp all other dash number splices.
(a) The splice crimping tool has an insulation crimping adjustment set to 1, 2, 3, or 4 depending on the thickness of
insulation. The splice must have a firm crimp on the insulation without damage.
(5) Crimp the wires into the splice.
(6) Insert the wires into the other side of the barrel.
(7) Crimp the wires into the other side of the splice.
E. Permanent Environmentally Resistant Splices
(1) Permanent environmentally resistant splices may be used with wires that have tin plated and silver plated conductors
in locations where the temperature of the wire insulation will not be more than 302°F (150°C).
way into the splice barrel with no insulation in the barrel. If you strip too much of the wire, the insulation sleeve that
goes over the splice will not be able to cover all of the stripped wire.
(3) Select the correct splice for your application. Refer to Table 204 for the correct splice to use for the wire size and
number combination that you need to go into either side of the splice.
Table 204. Permanent Environmentally Resistant Splices
Number of Wire Size in Side Number of Wires Wire Size in Side
Splice P/N Splice Color
Wires in Side 1 1 in Side 2 2
24 24
22 22 M81824/1-1 D-
Red
436-36

20-30-25-2 (Rev 1)
20 20
1 18 1 18 M81824/1-2 D-
Blue
16 16 436-37
14 14 M81824/1-3 D-
Yellow
12 12 436-38
1 22
24
2 24
M81824/1-1 D-
22 Red
1 436-36
22 30
2
2 33
20
1 M81824/1-2 D-
20 18 Blue
436-37
2 22
1, 1 18, 20 1, 1 18, 20
1 16
18 2 20 M81824/1-3 D-
Yellow
2 1 18 436-38
2 16
16
1 14
1 24
24 D-436-0110 Red
2 22
1, 1 22, 20
3 22 20 D-436-52 Blue
22
2 20
20
18
2, 1 20, 18 20 D-436-53 Yellow
1
3 18 18
2
(4) If you have a combination of number of wires and sizes that are not listed in Table 204, you can calculate the circular
mil area (CMA) of the wires. Refer to the example below and Table 205 to find the CMA of common conductors. Then
make sure that they fit into the range in Table 206..
EXAMPLE: You want to splice two AWG 22 wires into side 1 and one AWG 14 into side 2.
Side 1 Side 2
CMA = 2 x 754 = 1508 CMA = 1 x 3831 = 3831
Table 205. CMA of Common Conductors
Wire Size (AWG) 24 22 20 18 16 14 12
CMA 475 754 1216 1900 2426 3831 5874
Table 206. Maximum and Minimum CMA by Part Number
Splice Part CMA Max # of Wires Max # of Wires
Color
Number Minimum Maximum in Side 1 in Side 2

20-30-25-2 (Rev 1)
D-436-36 2
Red 304 1510
D-436-0110 6
D-436-37 2
Blue 779 2680 2
D-436-52 6 (2 per Hole)
D-436-38 2
Yellow 1900 6755
D-436-53 6 (2 per Hole)
(5) After you select the appropriate splice for your application, slide the insulation sleeve that came with the splice over
all of the wires that will go into one side of the splice.
(6) If the wire that goes into one end of the barrel is to small for that selected barrel, you can strip more insulation off of
that wire and double back the conductor on itself. Refer to Figure 201.
(a) You can also strip one end of a 3.0 inch (76.2 mm) piece of wire and insert it in the barrel with the wire that is too
small. The open end of the 3.0 inch (76.2 mm) piece of wire must be dead-ended and secured to the bundle.
(7) Additional sleeves are not necessary as long as the splice is completely covered.
(8) Insert all of your wires into one side of the barrel of the splice.
(a) Make sure that all of the wires touch the center divider of the barrel.
(b) Make sure that no insulation of any wires is in the barrel.
(9) Use an AD-1377 (or equivalent) crimping tool to crimp the wires into the barrel.
(10) Insert the wires into the other side of the barrel.
(11) Crimp the wires into the other side of the barrel.
(12) Slide the insulation sleeve over the barrel and align the center of the insulation sleeve with the center of the barrel.
(13) Use a heat gun to heat the insulation sleeve until it shrinks and seals the barrel.
F. Environmentally Resistant Splices for Shielded Cable
(1) Select the appropriate splice for your application. Refer to Table 207 for environmentally resistant splices for shielded
cables with up to 3 shielded conductors. These splices are only for 1:1 cable splices.
Table 207. Environmentally Resistant Splices for Shielded Cable
Number of Conductors Conductor AWG Size Part Number
D-150-0168
26 - 20
S2963-1-1
18 - 16 D-150-0169
1
20 - 16 S2963-1-2
14 - 12 D-150-0170
16 - 12 S2963-1-3
D-150-0174
26 - 20
S2963-2-1
D-150-0175
18 - 16
S2963-2-2
2
D-150-0176
14
S2963-2-3
D-150-0177
12
S2963-2-4
D-150-0178
26 - 24
S2963-3-1
D-150-0179
22 - 20

20-30-25-2 (Rev 1)
22 - 20
S2963-3-2
3
D-150-0180
18 - 16
S2963-3-3
D-150-0181
14 - 12
S2963-3-4
(2) Cut the shielded cable at the location to be spliced. Make sure that if there was any damage to the cable, it is
removed.
(3) Insert the shield splice sleeve onto one end of the shielded cable.
(4) Remove the cable jacket and shield.
(a) For shielded cables with 1 conductor, remove 0.700 inch (18.00 mm) from each end of the shielded cable.
(b) For shielded cables with 2 conductors, remove 1.825 inches (46.50 mm) from each end of the shielded cable.
(c) For shielded cables with 3 conductors, remove 1.825 inches (46.50 mm) from each end of the shielded cable.
(5) Strip the conductor(s) as follows:
(a) For shielded cables with 1 conductor, strip 0.275 inch (7.00 mm) from each end of the conductor.
(b) For shielded cables with 2 conductors, from one end of the shielded cable, cut one conductor 0.675 inch (17
mm) from the cable jacket and strip 0.275 inch (7.00 mm) from both conductors of that end of the shielded cable.
For the other end of the shielded cable, cut the conductor that will connect to the long conductor of the already
stripped end 0.675 inch (17 mm) from the cable jacket and strip 0.275 inch (7.00 mm) from both conductors of
that end of the shielded cable.
(c) For shielded cables with 3 conductors, from one end of the shielded cable, cut two conductors 0.675 inch (17
mm) from the cable jacket and strip 0.275 inch (7.00 mm) from all conductors of that end of the shielded cable.
For the other end of the shielded cable, cut the conductor that will connect to the long conductor of the already
stripped end 0.675 inch (17 mm) from the cable jacket and strip 0.275 inch (7.00 mm) from both conductors of
that end of the shielded cable.
(6) Remove 0.375 inch (9.50 mm) of the jacket from each end of the shielded cable.
(7) Splice the conductor(s). Refer to Permanent Environmentally Resistant Splices. For shielded cables with 2 or 3
conductors, splice the short conductor from one end of the shielded cable to the long conductor on the other end of
the shielded cable.
(8) Position the shield splice sleeve to where the exposed shield from both ends of the cable are covered by it.
(9) Heat the sleeve as follows:
(a) Heat the middle of the sleeve until the solder melts and the shield and tube shrink.
(b) Move the heat toward one end of the shield slowly enough to keep the sleeve shrinking as you move. Do this for
both ends.
(c) Apply heat to the ends of the sleeve until the rings melt and flow along the cable jacket.
4. Terminals
A. General
(1) Properly installed terminals cannot have more resistance across them than an equivalent length of wire of the same
gage to which the terminal is attached.
(2) Only one wire per terminal is permitted unless there will be more than four terminals on the lug to which the terminals
will attach, in which case two per terminal is permitted.
NOTE: This does not apply to the Model 750.
(3) The crimped impression must be centered on the portion of the barrel intended to grip the conductor.
(4) The conductor(s) must not extend more than 0.050 inch (1.27 mm) past the end of the barrel and must not make any
contact with the installation of washers, nuts, or screws.
B. Standard Insulated Terminals
(1) Select the proper standard insulated terminal for your application. Refer to Table 208 for the part numbers for
standard insulated terminals.

20-30-25-2 (Rev 1)
NOTE: The S1367 series insulated terminal is a permitted substitution for the MS25036 insulated
terminal.
Table 208. Standard Insulated Terminals
Wire Strip Length in
AWG Color Stud Size Part Number
Inch (mm)
#4 MS25036-148
#6 MS25036-102
#8 MS25036-149
22 - 18 Red #10 MS25036-103
1/4 MS25036-150
5/16 MS25036-104
3/8 MS25036-105
0.203 - 0.234 (5.16 -
#4 MS25036-152
5.94)
#6 MS25036-106
#6 MS25036-107
#8 MS25036-153
16 - 14 Blue
#10 MS25036-108
1/4 MS25036-154
5/16 MS25036-109
3/8 MS25036-110
#6 MS25036-111
#8 MS25036-156
#10 MS25036-112 0.312 - 0.343 (7.93 -
12 - 10 Yellow
1/4 MS25036-157 8.71)
5/16 MS25036-123
3/8 MS25036-114
#10 MS25036-115
1/4 MS25036-116
8 Red 0.4375 (11.11)
5/16 MS25036-117
3/8 MS25036-118
#10 MS25036-119
1/4 MS25036-120
6 Blue
5/16 MS25036-121
3/8 MS25036-122
0.5 (12.7)
#10 322052
1/4 MS25036-123
4 Yellow
5/16 MS25036-124
3/8 MS25036-125
1/4 MS25036-126
2 Red 5/16 2-328942-1 0.625 (15.88)
3/8 MS25036-127

20-30-25-2 (Rev 1)
(2) Strip the wire(s) to the correct length as shown in Table 208.
(3) Insert the wire(s) into the barrel of the terminal until the end of the conductor(s) is flush with the end of the barrel.
(4) Crimp the wire(s) into the barrel.
(a) For AWG 22 thru 10 terminals, use AMT4001 (or equivalent) crimping tool.
(b) For AWG 8 thru 2 terminals, use the TBHD1M (or equivalent) tool head with HH80C (or equivalent) crimping
tool.
C. Insulated Insulation-Restricting Terminals
(1) Insulation-restricting terminals are a standard closed circular terminal that fits onto up to 7 different stud sizes.
(2) They are insulation restricting because when you insert a wire into the barrel a groove at about the midpoint of the
barrel stops the wire from further insertion.
(3) These terminals have colored transparent sleeves with a stripe on them. Each color combination represents a wire
size that the terminal is designed to accept.
(4) You may crimp multiple wires into one terminal as long as the circular mil area (CMA) is smaller than the maximum
CMA for that terminal and the sleeve on the terminal does not have to be modified or damaged. Refer to Permanently
Environmentally Resistant Splices for an example of how to calculate CMA of multiple wires.
(a) For backshell grounding, refer to Table 210 and Table 211.
(5) Select the proper terminal for your application. Refer to Table 209 for the insulation restricting terminal part numbers.
Table 209. Insulation Restricting Terminals
Sleeve Color/Stripe
AWG Maximum CMA Stud Size Part Number
Color
#4 52273
#6 51863-2
#8 1-320551-2
22 1089 Red/Green #10 2-36153-3
1/4 2-320571-3
5/16 2-320572-2
3/8 2-320573-1
#4 52273-1
#6 51863-3
#8 1-320551-3
20 1681 Red/Red #10 2-36153-4
1/4 2-320571-4
5/16 2-320572-3
3/8 2-320573-2
#4 52273-2
#6 51863-4
#8 1-320551-4
18 2601 Red/White #10 2-36153-5
1/4 2-320571-5
5/16 2-320572-4
3/8 2-320573-3
#6 51864-6
#8 1-51864-0

20-30-25-2 (Rev 1)
16 3364 Blue/Blue #10 51864-7

1/4 2-320563-3
5/16 2-320575-2
3/8 2-320564-1
#6 51864-8
#8 1-51864-1
#10 51864-9
14 5329 Blue/Green
1/4 2-320563-4
5/16 2-320575-3
3/8 2-320564-2
#6 2-36161-5
#8 2-320568-2
#10 2-36161-3
12 8100 Yellow/Yellow
1/4 2-320569-5
5/16 2-320576-2
3/8 2-320577-1
#6 2-36161-6
#8 2-320568-3
#10 2-36161-4
10 12996 Yellow/Brown
1/4 2-320569-6
5/16 2-320576-3
3/8 2-320577-2
Table 210. Backshell Grounding, Standard Insulated Terminals
MS25036 Terminals
AWG Color Stud Size Part Number
#4 MS25036-148
#6 MS25036-102
#8 MS25036-149
22 - 18 Red #10 MS25036-103
1/4 MS25036-150
5/16 MS25036-104
3/8 MS25036-105
#4 MS25036-152
#6 MS25036-106
#6 MS25036-107
#8 MS25036-153
16 - 14 Blue
#10 MS25036-108
1/4 MS25036-154
5/16 MS25036-109
3/8 MS25036-110
#6 MS25036-111

20-30-25-2 (Rev 1)
#8 MS25036-156
#10 MS25036-112
12 - 10 Yellow
1/4 MS25036-157
5/16 MS25036-123
3/8 MS25036-114
#10 MS25036-115
1/4 MS25036-116
8 Red
5/16 MS25036-117
3/8 MS25036-118
#10 MS25036-119
1/4 MS25036-120
6 Blue
5/16 MS25036-121
3/8 MS25036-122
#10 322052
1/4 MS25036-123
4 Yellow
5/16 MS25036-124
3/8 MS25036-125
1/4 MS25036-126
2 Red 5/16 2-328942-1
3/8 MS25036-127
Silver Terminals MS20659 (No Insulation)
22-16 Silver #10 MS20659-102
18-14 Silver #10 MS20659-104
8 Silver 1/4 MS20659-141
12-10 Silver #6 MS20659-165
Table 211. Backshell Grounding, Standard Insulated Terminals
Maximum Allowance of Wire and Braid to be used per Terminal Type
Wire 1 Wire 2 Color
22 - Red
22 22 Red
20 - Red
18 - Red
1 Braid - Red
20 20 Blue
20 22 Blue
22 16 Blue
20 18 Blue
20 16 Blue
16 - Blue
18 18 Blue
14 - Blue

20-30-25-2 (Rev 1)
2 Braids - Blue
3 Braids - Blue
16 16 Yellow
14 14 Yellow
14 12 Yellow
12 - Yellow
10 - Yellow
Maximum Allowance for High Temperature Wires to be used per Terminal Type
Wire 1 Wire 2 Color
22 - Red
20 - Red
18 - Red
20 20 Blue
20 22 Blue
16 - Blue
14 - Blue
16 16 Yellow
12 - Yellow
10 - Yellow
(6) Strip the insulation off of all of the wires that you are going to crimp into the terminal.
(a) For wire sizes 22 thru 14, strip 0.266 to 0.282 inch (6.8 to 7.1 mm) of insulation from each wire.
(b) For wire sizes 12 and 10, strip 0.391 to 0.407 inch (9.9 to 10.3 mm) of insulation from each wire.
(7) Insert the wire(s) into the barrel of the terminal until the wire insulation makes contact with the barrel groove that is
about halfway through the barrel. No conductors should extend more than 0.050 inch (1.27 mm) beyond the end of the
barrel.
(8) Crimp in the middle of the terminal sleeve with a 59824-1 (or equivalent) crimping tool.
D. Flag Terminals
(1) Flag terminals use is intended to be limited to where space does not allow for the use of a standard terminal.
(2) Select the proper terminal for your application. Refer to Table 212 for the flag terminal part numbers.
Table 212. Flag Terminals
AWG Stud Size Part Number
#8 MS25189-1
#10 MS25189-2
1/4 MS25189-3
8
5/16 MS25189-4
3/8 MS25189-5
1/2 MS25189-6
#10 MS25189-7
1/4 MS25189-8
6 5/16 MS25189-9
3/8 MS25189-10
1/2 MS25189-11

20-30-25-2 (Rev 1)
#10 MS25189-12
1/4 MS25189-13
4 5/16 MS25189-14
3/8 MS25189-15
1/2 MS25189-16
#10 MS25189-17
1/4 MS25189-18
5/16 MS25189-19
2
3/8 MS25189-20
7/16 MS25189-21
1/2 MS25189-22
(3) Strip the length of the selected terminal barrel off of the wire.
(4) Crimp the wire into the barrel with an AN3427 crimp tool (or equivalent). Make sure to not crimp any wire insulation in
the barrel of the terminal.
5. Heat Shrinkable Tubing
A. General
(1) Heat shrinkable tubing shrinks when it is exposed to 275°F (135°C) air temperature for a short time. The amount that
the tubing shrinks is dependent on the part number.
(2) Some types of shrink tubing are coated inside with adhesive, which melts when the tube shrinks. This provides a
moisture resistant seal to prevent corrosion.
B. Heat Shrinkable Tubing Use
(1) Select the correct heat shrinkable tubing for the application. Refer to Cessna Heat Shrinkable Tubing.
(2) Make sure that you put the heat shrinkable tubing on the wire before you install the splice or terminal.
(3) After you install the electrical component, center the sleeve over the exposed wire as required.
CAUTION: Protect adjacent areas from heat as the heat gun produces in excess of 275°F (135°C) air
temperature.
(4) Heat the heat shrinkable tubing with a heat gun to approximately 275°F (135°C).
(5) Stop heating the heat shrinkable tubing when it is fully shrunken.
C. Cessna Heat Shrinkable Tubing
(1) 2:1 Shrink Ratio
(a) The part number format for this heat shrinkable tubing is S3410-X-X.
1 The first X ranges from 2 to 64. If you divide this number by 16, it will give you the inside diameter (inch) of
the heat shrinkable tubing before it has shrunk. If you divide this number by 32, it will give you the inside
diameter (inch) of the heat shrinkable tubing after it has shrunk.
2 The second X is however long you want the heat shrinkable tubing (inch).
EXAMPLE: S3410-32-10 has a starting diameter of 2 inches, a final diameter of 1 inch, and comes in a
piece 10 inches long.
(b) S3410 heat shrinkable tubing only comes in black.
(c) This tubing is rated for an continuous operating temperature of -67 to 275°F (-55 to 135°C).
(2) 3:1 Shrink Ratio
(a) The part number format for this heat shrinkable tubing is S3409XX-X.
1 The first X represents the color of the heat shrinkable tubing. Refer to Table 213 for the color designators of
heat shrink tubing.

20-30-25-2 (Rev 1)
Table 213. Cessna Heat Shrinkable Tubing Color Designators

Color Black Red Yellow Green Blue White
Designator B R Y G BU W
2 The second X ranges from 2 to 32. If you divide this number by 16, it will give you the inside diameter (inch)
of the heat shrinkable tubing before it has shrunk. If you divide this number by 48, it will give you the
approximate inside diameter (inch) of the heat shrinkable tubing after it has shrunk.
3 The second X is however long you want the heat shrinkable tubing (inch).
EXAMPLE: S34109BU24-10 is blue and has a starting diameter of 1.5 inch, an approximate final
diameter of 0.5 inch, and comes in a piece 10 inches long.
(b) This tubing is rated for an continuous operating temperature of -40 to 230°F (-40 to 110°C).
(c) This tubing has an inner adhesive liner.
D. Heat Shrinkable End Caps
(1) If the Cessna part numbers for heat shrinkable tubing do not meet your needs, you may use heat shrinkable tubing
from MIL-I-23053 or SAE-AMS-DTL-23053.
(2) End caps are used to terminate or dead end a wire or coax cable when not in use. Refer to Table 214 for the part
numbers of end caps.
Table 214. End Caps
Length (inches [mm]) Part Number
0.75 (19.1) TC4001
1.0 (25.4) TC4003
1.125 (28.6) TC4005

SOLDERING - MAINTENANCE PRACTICES

1. General
A. This section gives the procedures for making solder joints with a filler metal having a flow temperature below 800°F
(426°C).
B. Electrical wiring and connections must be soldered with a tin-lead solder using a non-corrosive flux.
2. Soldering Materials
A. Table 201 gives a list of the solder and flux requirements.
Table 201. Solder and Flux Requirements
Solder Per QQ-S-571 Flux Flux Solvent
Use Rosin Core or Granular Rosin (O- Aliphatic Naphtha per TT-N-95 or
SN 50 WS
F-506, QQ-S-571, or MIL-F-14256) Isopropyl Alcohol per TT-I-735
Flux not Necessary - Use Rosin Core Aliphatic Naphtha per TT-N-95 or
SN 60 WRMAP2
Solder Isopropyl Alcohol per TT-I-735
Flux not Necessary - Use Rosin Core Aliphatic Naphtha per TT-N-95 or
SN 63 WRMAP2
Solder Isopropyl Alcohol per TT-I-735
No. 123 Liquid Flux Shanda Labs, S-39 Neutralizer - Mix Three Parts
SN 95 WS
Closter, NJ Water to One Part Neutralizer
Type RA or AC Zinc Chloride Base per Water and Organic Solvents
AG 1.5 WS
QQ-S-571E
Type RA or AC Zinc Chloride Base per Water and Organic Solvents
AG 5.5 WS
QQ-S-571E
Solder Alloy per J-STD 006 Flux per J-STD 004 Flux Solvent
ORM0 or for repair use ORH1 Deionized Water or an Approved
Sn63Pb37
Aqueous Cleaner
B. Table 202 gives a list of the solder details.
Table 202. Solder Details
Solder per IPC J-STD 006 Temperature Usage
Solidus °F (°C) Liquidus °F (°C)
General purpose solder for electrical
connectors, plain tinned or galvanized
Sn50Pb50 (SN 50) 361 (182) 421 (216)
iron, steel, and copper below 250°F
(121°C) applications.
Preferred for electrical and electronic
Sn60Pb40 (SN 60) 361 (182) 374 (190) connections below 250°F
(121°C)applications.
Preferred for printed circuit boards and
special purpose electrical wiring where
Sn63Pb37 (SN 63) 361 (182) 361 (182) temperature limitations are critical and
in applications where extremely short
melting range is desired.
Good wetting characteristics and
Sn95Pb05 (SN 95) 430 (221) 473 (245) superior joint strength for fine
instrumentation work.

Good tensile, creep, and shear

strengths up to 350°F (176°C). Fatigue
properties are better than those alloys
Sn1Pb97.5Ag1.5 (AG 1.5) 588 (308) 588 (308) which do not contain silver. Use for
joining steel, copper, and brass. Typical
application for low temperature
thermocouples.
This alloy develops a shearing strength
of about 1500 psi at 350°F (176°C).
Typical application is on thermocouples
for aircraft engines where relatively high
Ag5.5Pb94.5 (AG 5.5) 579 (303) 689 (365) operating temperatures will not affect
strength of solder. Poor flow
characteristics and susceptible to
corrosion under humid environmental
conditions.
C. General Tools
(1) Only use holding tools, bending tools, and clinching tools that will not damage wires, wire insulation, terminals, or
components.
(2) If toothed clips are used, the clip jaws must be plastic covered.
(3) Needle nose pliers must have rounded jaws.
D. Cutting Tools
(1) Cutting pliers, dies, and roller-type cutters, must cut squarely without burrs, excessive ridges, or sharp points. They
must be maintained to make sure there are consistent, clean, and smooth cuts.
E. Insulation Strippers
(1) The different insulation stripper types that follow are authorized:
(a) Mechanical Strippers - Mechanical strippers are used to remove insulation covers from stranded or solid
conductor wires. They can be the hand operated or automatic, high-volume, machine type. Hand operated
strippers must be of a fixed-die configuration. Automatic high-volume machine strippers must be of a type that
uses either fixed dies or dies adjustable to calibrated stops. Dies, whether adjustable or fixed, must be
maintained to make sure there are consistently sharp and even cuts without damage to the wires or unstripped
insulation.
(b) Thermal Strippers - Thermal strippers that are used to remove insulation covering from stranded and solid
conductor wires must be of a type that can be regulated to supply the necessary temperature. Temperature
controls must be sufficient to prevent damage to the wire or insulation that is not stripped from the wire.
(c) Chemical Strippers - Chemical solutions, pastes, and creams that are used to strip hookup and magnet wires
must be suitable for the removal of the insulating coating (i.e., enamel, shellac, etc.) to be stripped and must be
limited to those that:
1 Do not cause degradation of the base metal of the wire.
2 Clean and neutralize the wires or conductors of both ionic and non-ionic contaminants.
F. Soldering Irons
(1) The size and shape of the soldering iron and tip must permit soldering with maximum ease and control without
causing damage to adjacent areas or connections. The soldering iron or resistance heating electrode must heat the
joint area rapidly and maintain the correct soldering temperature at the joint throughout the soldering operation.
Soldering equipment must not produce detrimental magnetic fields or introduce electrical energy detrimental to items
soldered. Three-wire cords and positive tip grounding must be used when voltage-sensitive components are
soldered to prevent potential greater than two millivolts. Transformer-type solder guns must not be used.
Temperature-controlled soldering guns are acceptable, if the sensing of the temperature is at the soldering tip.
Soldering tips must be made of commercially pure copper, tellurium copper, or lead copper, and must be
plated/coated with another metal that prevents solution of the copper tip in molten solder.

G. Soldering Iron Holder

(1) Soldering iron holders must be the type that can support the iron body without tip contact to any part of the structure
and must protect personnel from burns.
H. Thermal Shunts
(1) Thermal shunts or heat sinks must be preferably be made of copper for good heat conductivity and must be of such
size and shape that gives sufficient thermal protection and minimum mechanical interference to the parts during the
soldering operation. Refer to Figure 201 for a view of the different thermal shunts.
I. Cleaning Pad (Cellulose Sponge)
(1) Cellulose sponge pads for cleaning the soldering tip must be a fine-textured, low-sulphur, synthetic sponge, and must
be kept clean and moistened with water.
J. Anti-Wicking Tools
(1) Anti-wicking tools must correspond to conductor gage sizes. The size must be marked on the tool.
3. Work Area
A. Cleanliness
(1) Soldering work areas and tools shall be maintained in a clean and orderly condition. All dirt, grease, flux, solder
spatter, chips, and other contaminating foreign material shall be promptly removed. Eating, smoking, and drinking
shall not be permitted in soldering area, and precautions shall be taken to preclude contamination of the work station
by products of such activities.
B. Airborne Contaminants
(1) Soldering must be done in a well ventilated area that is free from airborne contaminants. Manufacturing operations or
other activities that produce airborne contaminants must not be permitted in or near the soldering work area.
C. Lighting
(1) Lighting fixtures must supply sufficient shadow-less illumination on work surfaces.
4. Soldering
A. Conductor Preparation
(1) Length - It is necessary to cut the wires and leads to the correct length before their attachment.
(2) Stress Relief - All wires and leads terminated as a solder connection must have sufficient slack in the form of a
gradual bend. In applications where multiple wires are routed from a common cable trunk to equally spaced terminals,
the stress relief must be uniform to prevent stress on any one wire. Soldered components must not impinge on
adjacent circuitry.
(3) Mechanical Support - Solder joints must not be subjected to mechanical loads. Mechanical support must be
provided, when a component weight is more than 1/4 ounce per load, for components or wire bundles by clamping,
potting, embedding, or other means to prevent stresses on the solder joints.
B. Insulation Removal
(1) Insulation must be removed from conductors using insulation strippers. Refer to Insulation Strippers in this section for
the types of insulation strippers. After stripping, the wire must be examined for insulation damage. Wires with
damaged insulation must not be used. Charred, frayed, split, or pinched insulators, or insulators exposing the wires
must be considered damaged insulation. Slight discoloration must not be a cause for rejection. Refer to Figure 202.
(2) Damage to Wire - Care must be taken to keep the wire strands straight after stripping and to avoid damage to the
wire covering or severance of the wire strands. Damaged or severed wire strands shown in Figure 202 must not
exceed the limits shown in Table 203.
Table 203. Limitations of Damaged Wire Strands
Strands Maximum Permitted Nicked or Broken Strands
Less Than 7 0
7 - 15 1
16 - 18 2
19 - 25 3

26 - 36 4
37 - 40 5
41 or More 6
(3) Strip sufficient insulation from the wire or component leads so that no insulation will touch the solder connection. The
insulation clearance is that gap between the insulation and the edge of the terminal or solder cup. Refer to Figure 203
and Table 204 for the insulation clearance.
Table 204. Insulation Clearance
Wire Size - American Wire Gauge
Minimum Clearance Maximum Clearance
(AWG)
Smaller Than 20 Visible Clearance 0.06 Inch (1.5 mm)
20 Thru 10 0.031 Inch (0.80 mm) 2 Times Diameter of Insulation
8 Thru 2 0.031 Inch (0.80 mm) 0.37 Inch (9.5 mm)
1 and Larger 0.031 Inch (0.80 mm) 0.50 Inch (12.7 mm)
C. Tinning
(1) All parts of stranded wires that come in contact with the area to be soldered can be tinned by dipping the fluxed wire
in a solder pot or by using a soldering iron. The solder must penetrate to the inner strands of the conductors.
(2) The distance between the end of the wire insulation and the beginning of the tinned part must not be less than 1/2 the
outside diameter of the wire insulation. Refer to Figure 203.
(3) Part leads or terminals that are pre-tinned by the part manufacturer will not need more tinning unless corrosion has
occurred during storage. Corrosion products must be removed by cleaning, then tinning the lead or terminal again.
Refer to Cleaning Pretreatment in this section for different cleaning procedures.
(4) Parts that are dip-tinned must be held in the solder container (Pot) until a bright, continuous, tightly adhering coat of
solder is formed. The solder pot must operate at a temperature that is 20 to 50°F (11 to 27°C) above the liquidus of
the solder alloy used. The molten solder must be of such volume that the temperature will not be reduced more than
10°F (5.5°C) when parts are dipped.
(5) To make sure that you can do an inspection for nicks or cuts at the point of insulation termination, solder and wicking
must not conceal the individual outer wire strands. A thermal shunt can be used to prevent this occurrence.
D. Mechanical Fasteners
(1) Conductors must be connected to the terminals with wrap angle limits shown in Figure 204. The conductor must be
tangent to the terminal for the full curvature of the wrap or hook. Insulation must not extend through or around any part
of the guide configuration on a terminal.
(2) Wire connections to a terminal must not overlap. Each wire must be placed adjacent to the surface of the terminal.
The wraps around a turret terminal can be clockwise or counterclockwise, but all wraps must be in the same direction.
Refer to Figure 204.
(3) The bend of a wire around a turret terminal must not be less than 90 degrees or more than 270 degrees. The wires or
leads must be snugly attached to the base in the lower guide slot or to the top shoulder in the upper guide slot. The
end of the wire must follow the radius and must not protrude beyond the guide shoulders, depending on design
considerations. The side route must be used on all solid post turret-type terminals. Insulation clearance must be
referenced from the base of the top shoulder, as applicable. Refer to Figure 204.
(4) Solder Cup Terminals
(a) The tinned wire or lead must not be bent or formed for a solder cup termination.
(b) All conductors terminating in a solder cup must bottom in the cup. Refer to Figure 203.
(c) Insulation clearance must be referenced from the point of entry into the cup. Refer to Figure 203.
E. Sleeving of Terminals with Insulation Tubing (Refer to Figure 205)
(1) Insulation tubing must be used to give mechanical and electrical protection to soldered joints, wires, and leads, and to
protect wire harnesses and conductors against abrasion.
(a) Insulation tubing must be installed over wires, leads, and harnesses before they are attached to terminals of

relays, connectors, and similar items that are not protected by insulating grommets or potting.
(b) Insulation tubing must be pushed back far enough from the terminal so as not to interfere with the securing and
soldering operations.
(c) After the solder has solidified and cooled, and the joint is cleaned, the insulation tubing must be slipped back
over the wires and terminals. Heat shrink can be installed if applicable.
(d) After installation, the tubing must extend above the stripped part of the attached conductor; a distance equal to
or greater than the tubing diameter.
F. Cleaning Pretreatment
(1) Surfaces to be joined by soldering must have greases, oils, oxides, dust, or other loose matter removed.
(2) Vapor degreasing, solvent cleaning, wire brushing, vapor blasting, or ultrasonic cleaning can be used for cleaning.
(3) Sand blasting or steel wool must not be used for cleaning.
(4) If parts and assemblies can be totally submerged in the cleaning fluid without damage, it is the preferred method for
cleaning.
(5) When only brushing with a liquid cleaner is permitted, use only non-activated or mildly activated rosin core solder,
where flux residues can be left in place.
(a) All flux residue must be removed using the applicable flux solvent listed in Table 201.
G. Fluxing
(1) Flux application per Table 201 can be part of the solder or separate from the solder.
(2) The application of a separate flux can be necessary for some soldering alloys and can be either powder, paste, or
liquid.
(a) When liquid flux is used, it must be applied in small amounts, but in sufficient quantities to make sure that the
fluxing action is effective.
(b) When cored fluxes are used, liquid or paste fluxes must not be added except during rework or touch-up.
(3) A thin even coating of flux must be placed over the surface to be joined before heating to the soldering temperature,
except when using rosin core solder.
(4) Corrosive flux must not be permitted to come in contact with textile material, insulation, lead, or wire strands.
(5) Leads and wires can be coated with flux or dipped into a container of flux immediately before dip tinning.
H. Heating
(1) A soldering iron, torch, induction, or resistance are authorized heat sources.
(2) The soldering iron tip must be kept clean, smooth, and brightly tinned. The preferred method is to use a cellulose
sponge.
(3) Soldering tips plated by the manufacturer must not be filed.
(4) Thermal shunts (heat sinks) can be used as necessary to prevent excess heat flow to adjacent pre-soldered joints or
heat-sensitive parts.
(5) The soldering iron tip must be applied to the connection in such a manner that the soldering temperature of the
surfaces to be soldered will be reached in a minimum time.
I. Soldering (Refer to Figure 206)
(1) Wires and leads must be held tightly and rigidly to terminals in such a manner that there will be no motion relative to
each other during the soldering operation and during cooling and solidification of the solder.
(2) The soldering iron tip must be grounded when soldering voltage sensitive components.
(3) Except for cup terminals and for printed circuit boards, solder must be applied as follows:
(a) Solder must be applied to the joint when the temperature of the joint will let the solder melt quickly.
(b) Solder must be applied at the junction of the soldering iron tip and the parts to be joined.
(c) Solder must not be melted on the soldering iron tip and permitted to flow over the parts to be joined.
(4) Soldered Joint
(a) Sufficient solder must be applied to form a slight concave fillet between the terminal and each side of the wire.
(b) The contour of the wire must be visible after soldering.

(c) Exposed copper ends on the conductors must be completely covered with solder.
(d) Too much solder, that completely obscures the wire and terminals, is not permitted.
(e) Use caution to prevent relative movement in the soldered joint during solidification. Forced cooling of the solder
before the solidification is not permitted.
(f) There must not be visible wicking under the insulation (strands must not be distorted to examine the wicking).
When excessive wicking is suspected, a stiffness greater than the normal two diameters from the trimmed end
of the insulation will be cause for rejection.
J. Soldering Cup or Hollow Cylindrical Terminals (Refer to Figure 207)
(1) The solder cup must have a sufficient amount of precut solder to completely fill the cup when the solder is melted and
the tinned wire is inserted into the bottom of the cup.
(2) Sufficient heat must be applied after the cup is filled with solder to make sure that the flux has boiled up and out of the
bottom of the cup. For the best result, continuous soldering iron contact must be maintained throughout the soldering
operation.
(3) The solder must follow the contour of the cup entry slot and must not spill over or adhere to the sides of the cup.
(4) Connection can be made with either a resistance or conduction type soldering iron.
(a) When a conducting type soldering iron is used, the slight tinned effect occurring at the point where the tip
touches the base of the cup is normal and is acceptable if there are no peaks, globules, or excessive buildup of
solder.
(5) Too much buildup or overflow on a hollow terminal must not cause a short circuit between the pins of either conductor.
Excess solder must not interfere with the mechanical function of the terminals.
K. Soldering for Printed Circuit Boards
(1) Printed circuits must be soldered with a tin-lead solder with an extremely short melting range. No flux is necessary.
(2) Circuit areas and component leads must be cleaned as necessary before tinning the leads.
(3) Component leads on the opposite side of a printed circuit board can be clinched or extend straight through
approximately 0.03 inch (0.76 mm). Refer to Figure 208.
(4) Horizontally mounted ceramic components must touch the board at least at one point. The maximum clearance of
ceramic components is 0.015 inch (0.38 mm). Glass components must not rattle against the board during vibration
and must not touch the board. A maximum clearance of 0.03 inch (0.76 mm) between glass components and the
board must be observed. Refer to Figure 209.
(5) For clearance requirements on circuit boards with plated through holes, refer to Figure 210.
(a) Plated through holes must show signs of good wetting and sufficient solder on both sides of the printed circuit
board. Refer to Figure 210. Nominal spring back of clinched wire is permitted. Refer to Figure 209.
(6) The distance between the body of the part of a weld and the bent section of a lead must be at least twice the
diameter of the lead but not less than 0.03 inch (0.76 mm). Refer to Figure 209 for the correct bend radius.
(7) Solder joints must not be subjected to mechanical loads. Mechanical support must be supplied to components or
wire bundles by clamping, potting, embedding, or other means to prevent stresses on the solder joints when the
component's weight exceeds 1/4 ounce per lead. Refer to Figure 211.

Figure 211
(8) Solder joints must be free of cracks, fractures, and projections. Porosity, voids, and foreign materials in the solder
joint must not be more than 25% of the total area between the lead and the wall of the plated-thru-hole. Solder wetting
of the component lead and of the hole wall to the pad must be evident. Refer to Figure 208.
L. Resoldering
(1) When resoldering is necessary, the quality standards for the resoldered connections must be the same as for the
initial connections.
(2) It is only necessary to heat and flow the solder again for a cold-solder, excessive-solder, or a disturbed joint.
M. Flux Removal
(1) Rosin-base flux residue can be removed by mechanical means or by applying appropriate organic solvents when
necessary.
(2) The residue of non-rosin-base flux must be completely removed or neutralized by an approved procedure, after the
connection has cooled, to prevent corrosion.
(3) The solder must be clean, smooth, and bright in appearance. The degree of brightness will vary with the solder alloy.
N. Solder Joint Examination (Refer to Figure 212)
(1) The quality of soldered joints must be examined for the unsatisfactory conditions that follow:
(a) Signs of charring, burning, or other heat damage to the insulation cover.
(b) Loose joint.
(c) Flux splatter or solder on adjacent connections of parts.
(d) Solder points.
(e) Rosin joints, that look chalky and rough.
(f) Cold joints that look dull and frosted.
(g) Pitted joints that show scars or holes.
(h) Too much solder.
(i) Loose parts caused by too much heat.

Figure 201 : Sheet 1 : Typical Thermal Shunts

Figure 202 : Sheet 1 : Unacceptable Wire and Insulation Damage

Figure 203 : Sheet 1 : Soldering Solder Cup Terminals

A99988
Insulation
Clearance Pretinned Wire
Refer to Table 204
The distance between the

Point of Entry insulation and the solder
must not be less than 1/2
the outside diameter of the
wire insulation.
The wire must

bottom in the cup.
6518T1254

Figure 204 : Sheet 1 : Terminal Wire Connection

Figure 205 : Sheet 1 : Soldering and Sleeving of Insulated Terminals

Figure 206 : Sheet 1 : Soldering Turret Terminals

A99991
Conductor
Soldering Iron Tip

Apply the Solder Opposite of
the Soldering Iron Tip
Soldering Iron Position
Wicking Does Not Extend

to the Insulation
The Wire Contour is Visible
Completed Solder Joint
5680T1023

Figure 207 : Sheet 1 : Soldering Solder Cup Terminals

Figure 208 : Sheet 1 : Soldering Printed Circuit Boards

A99993
Lead
Solder Lead Component
Component Conductive Path
Printed Solder
Circuit
Board
Printed
Solder Circuit
Approximately Solder
0.03 Inch Board
A. Clinched B. Straight Through
Top View Top View

Solder Piled
Smooth Fillet On Connection
VOIDS
Bottom View Bottom View

Acceptable Not Acceptable
62801087

Figure 209 : Sheet 1 : Printed Circuit Board Component Installation

Figure 209 : Sheet 2 : Printed Circuit Board Component Installation

Figure 210 : Sheet 1 : Soldering Printed Circuit Boards with Plated-Thru Holes
A99996
0.160 Inch (4.06 mm) 0.060 Inch (1.52 mm)
0.030 Inch (0.76 mm) Maximum Radius Minimum
Minimum Straight
Maximum 0.030 to 0.060 Inch Maximum 0.030 to 0.060 Inch

0.060 Inch (0.76 to 1.52 mm) 0.030 Inch (0.76 to 1.52 mm)
(1.52 mm) (0.76 mm)
Maximum
0.030 Inch
(0.76 mm)
Maximum Maximum 0.100 to 0.187 Inch

0.060 Inch The Durez On The Leads Stand-Off 0.030 Inch (2.54 to 4.75 mm)
(1.52 mm) Must Not Enter The Hole (0.76 mm)
NOTE: The components shown above must be mounted

perpendicular to the board within 15 degrees.
METAL
PLASTIC
0.030 to 0.187 Inch Mount Parallel To The Board Seating Plane Maximum
(0.76 to 4.75 mm) Less Than 0.050 Inch (1.27 mm) 0.030 Inch
From The Offset. (0.76 mm)
Metal Or Plastic Can Dips

Transistors And IC's
6318T1252

Figure 210 : Sheet 2 : Soldering Printed Circuit Boards with Plated-Thru Holes
A99997
Lead
Plated-Through Hole
Solder Foil
Acceptable
Lead Plated-Through Hole
Solder Foil
Minimum Acceptable
One Lead Diameter Lead Plated-Through Hole

Clearance
Solder Foil
Acceptable
One Lead Diameter Lead Plated-Through Hole

Clearance
Solder Foil
Minimum Acceptable
6518T1253

Figure 212 : Sheet 1 : Unsatisfactory Solder Joint

ELECTROSTATIC DISCHARGE SENSITIVE COMPONENTS - MAINTENANCE PRACTICES

1. General
A. The procedures in this section apply to all Cessna Operated Service Centers and other facilities that come into contact
with electrostatic discharge sensitive (ESDS) devices used on Cessna manufactured or installed components, directly or
indirectly.
B. Personnel that work with electronic components must know the methods for electrostatic discharge (ESD) protection given
in this section.
C. Anyone that touches ESDS devices are required to protect it while they have it, and to make sure that the correct package,
label, and ESDS information stay with the part.
D. All personnel that work with ESDS electronic parts are to be ESDS awareness trained and certified as necessary.
E. An assembly or equipment that is labeled as ESDS, which can be threatened by discharge into receptacle pins or
terminals, must have a conductive cap, cover, or remain in a protective container until the unit is correctly installed into the
system.
F. ESDS devices, assemblies, equipment, or packages must have a similar label with one of the three ESDS symbols as
shown in Figure 201. The ESDS label must be in a visible location. The symbol must be located on equipment in a
position readily visible to personnel. In addition, the symbol must be located in a position readily visible when an ESDS
assembly is incorporated into its next higher assembly. These symbols show that an assembly includes devices that are
ESDS and must be handled as such
NOTE: Some devices, assemblies, equipment, or packages can come from a supplier without an ESDS
label. If you do not know if it is ESDS, refer to the applicable section in the maintenance manual
before you touch it.
2. Related Documents
A. Unless otherwise specified, you must use the latest revision of the documents shown in Table 201.
Table 201. ESD Specifications
Specification Title
ANSI/ESD S20.20 ESD Association Standard for the Development of an Electrostatic Discharge Control Program
for – Protection of Electrical and Electronic Parts, Assemblies and Equipment (Not including
Electrically Initiated Explosive Devices)
ASTM-D257 D-C Resistance or Conductance of Insulating Materials
DOD-HDBK-263 Electrostatic Discharge Control Handbook for Protection of Electrical and Electronic Parts,
Assemblies and Equipment
EIA Std. RS-471 Symbol and Label for Electrostatic Sensitive Devices
MIL-B-81705 Barrier Materials, Flexible, Electrostatic-Free, Heat Sealable
MIL-B-82647 Bags, Conductive Plastic, Heat Sealable, Flexible
MIL-P-81997 Pouches, Cushioned, Flexible, Electrostatic-Free, Recloseable, Transparent
MIL-P-82646 Plastic Film, Conductive Heat Sealable, Flexible
MIL-STD-129 Marking for Shipment and Storage
MIL-STD-701 Lists of Standard Semiconductor Devices
MIL-STD-1686A Electrostatic Discharge Control Program for Protection of Electrical and Electronic Parts,
Assemblies and Equivalent
section.
NOTE: You can use equivalent tools and equipment.

Bag checker Model 705 3M Bag checker (not necessary if

Static Control Systems Model 711 is used).
P.O. Box 2968
Austin, TX 78769
Charge Analyzer Model 711 3M Static Control Systems To do a variety of test
procedures for static control
equipment and materials.
Connector Covers Model 4270 and 3M Static Control Systems To cover electrical connectors
4720 on ESDS components.
Electrically Conductive Model 4018 3M Static Control Systems To use as ESDS workstation
Plastic Assembly Rack equipment.
Electrically Conductive Type 4415, 4425 3M Static Control Systems To use as ESDS workstation
Tote Boxes and 4428 equipment.
Floor Mat Model 8200 3M Static Control Systems To use as ESDS workstation
equipment.
Ionized Air Blower Model 963 3M Static Control Systems To use as ESDS workstation
equipment.
Monitor Model 724 3M Static Control Systems To check wrist straps and work
surfaces.
Static Shielding Bag Type 2100R 3M Static Control Systems To use as ESDS workstation
equipment.
Table Mat Model 8210-15 3M Static Control Systems To use as ESDS workstation
equipment.
Wrist Strap Model 2214 3M Static Control Systems To use as ESDS workstation
equipment.
Wrist Strap Tester Model 746 3M Static Control Systems To do a test of the wrist straps.
4. Quality Assurance
A. A scheduled inspection must be done to make sure that all of the necessary technical precautions and instructions of this
standard are used by all personnel. Some applicable procedures are:
(1) Use of the correct package
(2) Certified work stations and equipment
(3) Correct ways to touch and send equipment
(4) Make sure that all ESDS work is done in a certified area.
B. DOD-HDBK-263 and MIL-STD-1686A can be used as references for more correct procedures and recommendations to
obey this standard.
5. Definitions
A. Electrostatic Discharge Sensitivity (ESDS) General Description
(1) A component, assembly, or device whose electrical and/or physical function can be changed because it touches an
electrostatic discharge or field is to be thought of as electrostatic discharge sensitive. Electrostatic discharge
sensitivity is the maximum possible electrostatic discharge (in terms of magnitude and duration) to which the
component, assembly, or device may have when it is touched and stored and not be damaged.
B. Electrostatic Discharge Sensitivity (ESDS) Detailed Description
(1) Any component, assembly, or device whose electrical and/or physical characteristics can be changed by an
electrostatic discharge from a 100 pF capacitor charged to 15 kv (15,000V) or less through a 1.5 kohm resistor,
through the part, assembly or device to ground. These conditions typically supply the maximum possible electrostatic
discharge which may be found in a handling and storage environment that is not controlled.
C. Electrostatic Discharge (ESD)

(1) A movement of electrostatic charge between objects at different electrostatic potentials caused by direct contact or
induced by an electrostatic field.
D. Electrical and Electronic Part
(1) A part such as a microcircuit, discrete semiconductor, resistor, capacitor, thick or thin film device, or piezoelectric
crystal.
E. ESD Protective Material
(1) Material capable of one or more of the following: Limits the generation of static electricity, dissipates electrostatic
charges, or gives shielding from electrostatic fields. ESD protective materials are classified in accordance with their
surface resistivity (or alternate conductivity) as conductive, static dissipative, or anti-static.
F. Anti-Static Material
(1) ESD protective material having the property of reduction of triboelectric charge generation. Anti-static materials
minimize the generation of static charges.
G. Conductive Material
(1) Surface Conductive Type: Materials with a surface resistivity less than 10^5 ohms per square.
(2) Volume Conductive Type: Materials with a volume resistivity less than 10^4 ohm-cm.
H. Insulative Material
(1) Material that is not conductive or dissipative.
I. Protected Area
(1) An area that is constructed and equipped with the necessary ESD protective materials and equipment to limit ESD
voltage below the sensitivity level of ESDS items handled therein.
J. Static Dissipative Materials
(1) Surface Conductive Type: Materials with a surface resistivity equal to or less than 10^5 ohms per square.
(2) Volume Conductive Type: Materials with a volume resistivity equal to or less than 10^4 ohm-cm.
K. Soft Ground
(1) A connection to ground through a resistance sufficiently high to limit current flow to safe levels for personnel. The
impedance needed for a soft ground is dependent upon the voltage levels that could be contacted by personnel near
the ground. Normally, a 1-megohm resistor is in series with the ground strap.
L. Hard Ground
(1) A connection to ground either directly or through a low impedance.
M. Electrostatic Detectors
(1) Types of electrostatic detectors include electrometer amplifiers, electrostatic voltmeters, electrostatic field meters,
and leaf deflection electroscopes. Commonly used detectors include electrostatic field meters which are battery
operated and portable. Field meters give readings of the electrostatic fields produced by charged bodies using a
non-contact probe or sensor, and give readings in electrostatic field strength or electrostatic voltage at a calibrated
distance from a charged body. Some electrostatic field meters use radioactive sources similar to those of
radioactive ionizers.
N. Ionizers
(1) Ionizers dissipate electrostatic charges by ionizing air molecules, forming both positive and negative ions. The
positive ions are attracted to negatively charged bodies and negative ions to positively charged bodies, resulting in
charge neutralization. Ionized air can be used where effective grounding cannot be accomplished to bleed-off static
charges, or to dissipate charges on insulators where grounding would not be effective.
O. Topical Antistats
CAUTION: Do not apply topical antistats to electrical circuit boards, parts, or assemblies since they can
increase conductivity or possibly affect solderability.
(1) Topical antistats are chemical agents which when applied to surfaces of insulative materials will reduce their ability to
generate static.
(2) Topical antistats are generally liquids consisting of a carrier and an antistat. The carrier is the vehicle used to
transport the antistat to a material. It acts as a solvent and can be water, alcohol, or mineral spirits, or other

compatible material.
(3) The antistat is the material which remains deposited on the material surface after the carrier evaporates and provides
the static control function.
(4) Topical antistats can be brushed, sprayed, rolled, dipped, mopped, wiped, or otherwise applied to floors, carpets,
work bench tops, parts trays, parts carriers, chairs, walls, ceilings, tools, paper, plastics, and clothing to render them
ESD protective to varying degrees.
(5) Some antistats are also good cleaners and can be mixed with water to clean surfaces such as floors and bench tops
and at the same time render them anti-static.
(6) Topical antistats can be removed during cleaning operations involving solvents and the cleaned work and tool surface
may require retreatment.
(7) Topical antistats can provide protection for an extended period of time depending upon factors such as application
rate and the amount of handling. Their effectiveness should be periodically checked by measuring the surface
resistivity of a sample of the material using appropriate test equipment.
P. ESD Container
(1) A receptacle with rigid bottom and sides used for ESD and physical protection.
Q. ESD Protective Packaging
(1) Packaging with ESD protective materials to prevent ESD damage to ESDS items.
R. ESD Sensitive (ESDS) Items
(1) Electrical and electronic parts, assemblies and equipment that are sensitive to ESD voltages of 15,000 volts or less
as determined by the original equipment manufacturer of item. The list that follows gives some examples of known
sensitive devices:
(a) Metal Oxide Semiconductor (MOS) devices including C, D, N, P, V, and other MOS technology without
protective circuitry, or protective circuitry having Class 1 sensitivity.
(b) Surface Acoustic Wave (SAW) devices.
(c) Operational Amplifiers (OP AMP) with unprotected MOS capacitors.
(d) Junction Field Effect Transistors (JFETs) Ref: Similarity to MIL-STD-701: Junction field effect transistors and
junction field effect transistors, dual utilized.
(e) Silicon Controlled Rectifiers (SCRs) with Io <0.175 amperes at 212°F (100°C) ambient temperature - Ref:
Similarity to MIL-STD-701: Thyristors (silicon controlled rectifiers).
(f) Precision Voltage Regulator Microcircuits: Line or Load Voltage Regulation <0.5 percent.
(g) Microwave and Ultra-High Frequency Semiconductors and Microcircuits: Frequency >1 GigaHertz.
(h) Thin Film Resistors (Type RN) with tolerance of ?0.1 percent; power >0.05 watt.
(i) Thin Film Resistors (Type RN) with tolerance of >0.1 percent; power ?0.05 watt.
(j) Large Scale Integrated (LSI) Microcircuits including microprocessors and memories without protective circuitry,
or protective circuitry having sensitivity devices - Note: LSI devices usually have two to three layers of circuitry
with metallization crossovers and small geometry active elements.
(k) Hybrids utilizing ESDS parts.
(l) MOS devices or devices containing MOS constituents including C, D, N, P, V, or other MOS technology with
protective circuitry having sensitivity devices.
(m) Schottky diodes - Ref: Similarity to MIL-STD-701: Silicon switching diodes (listed in order of increasing trr).
(n) Precision Resistor Networks (Type RZ).
(o) High Speed Emitter Couple Logic (ECL) Microcircuits with propagation delay ?1 nanosecond.
(p) Transistor-Transistor Logic (TTL) Microcircuits - Schottky, low-power, high-speed, and standard.
(q) Operational Amplifiers (OP AMP) with MOS capacitors with protective circuitry having sensitivity parts.
(r) LSI with input protection using ESD sensitivity.
(s) Lower Power Chopper Resistors - Ref: Similarity to MIL-STD-701 Power Chopper Transistors.
(t) Resistor Chips.

(u) Small Signal Diodes with power ?1 watt excluding Zeners - Ref: Similarity to MIL-STD-701: Silicon Switching
Diodes (listed in order of increasing trr).
(v) General Purpose Silicon Rectifier Diodes and Fast Recovery Diodes - Ref: Similarity to MIL-STD-701: Silicon
Axial Lead Power Rectifiers, Silicon Power Diodes (listed in order of maximum DC output current), Fast
Recovery Diodes (listed in order of trr).
(w) Low Power Silicon Transistors with power ?5 watts at 77°F (25°C), - Ref: Similarity to MIL-STD-701: Silicon
Switching Diodes (listed in order of increasing trr), Thyristors (bi-directional triodes), Silicon PNP Low-Power
Transistors (Pc ?5 watts @ TA -25°C (-13°F), Silicon RF Transistors).
(x) Piezoelectric Crystals.
6. Requirements
A. Individual component containers containing ESDS devices as received from suppliers must only be opened by soft
grounded personnel at ESD protected stations or static safe areas for electrical inspection, repackaging, or for installation
into higher assemblies. At the time of opening of containers and removal of devices, all applicable requirements of this
standard must be followed.
B. The following detailed requirements are defined to give control measures for the protection of electrostatic discharge
sensitive electronic components and assemblies until installed into the final assembly end product.
NOTE: The theory of electrostatic discharge protection is simply to keep all nonoperating ESDS
components and assemblies at the same electrical potential. If the personnel, components
facilities, and tools are all at the same potential, no extraneous charge can be transmitted to the
ESDS device(s).
C. Facility: Unprotected ESDS devices and assemblies must only be handled by correctly grounded personnel at ESD
protective stations or areas meeting or exceeding the following requirements.
D. Environmental Conditions
(1) The environment of work areas involved in the handling, assembly and room ambient testing of electrostatic
discharge sensitive devices and assemblies must be conditioned and maintained at 75°F, +10 or -10°F (24°C +5.5
or -5.5°C) and the relative humidity must not be between 40 and 60 percent.
(2) When humidity levels decrease below 40 percent, air ionizer equipment should supplement ESDS protected stations
and/or portable humidifiers must be operated to bring levels of humidity up to minimum limits so that area work may
continue.
(3) Precautions must be taken to make sure that adverse amounts of room ambient air laden moisture will not produce
detrimental effects on units being worked on.
(4) Areas where ESDS equipment are in electrostatic protective packaging, barrier materials, enclosures, or containers
do not require humidity controls.
E. Test Equipment
(1) Test equipment must have all exposed metallic surfaces electrically connected to the test equipment power system
ground (200 ohms or less) when measured with a Simpson Ohmmeter Model 260, equivalent or better, R×10 scale.
F. Carpeting
(1) Carpeting is prohibited in ESDS protected areas unless it is conductive or dissipative carpeting.
G. Storage And Transportation Equipment
(1) Trays, carriers, tote boxes, cushioning material, and bags used to transport, store, or hold components or assemblies
must have a surface. Resistivity of less than 10^5 ohms per square when measured per ASTM Test Method D257 or
equivalent or better.
H. Grounding
(1) Each protected area must have all grounds connected to a common point, with that point wired to earth ground. The
third wire (green), AC equipment ground, is the preferred choice for ground.
I. Temperature Chambers
(1) Temperature chambers, when used, must be equipped with grounded baffles or alternately ionized air or shields to
divert direct air flow over electronic components and subassemblies present in the temperature chamber. Electronic
ESDS components that have not been assembled must be placed in containers with a surface resistivity of 10^9

ohms/square or less when measured per ASTM Test Method D257 or equivalent, and suitable to withstand the test
temperature ranges.
J. Electrical Equipment, Tools, Soldering Irons, Solder Pots, Flow Soldering Equipment
(1) Soldering irons, solder pots, or flow soldering equipment must be transformer isolated to the power line and be
grounded. The resistance reading from the tip of a hot soldering iron to the workstation ground must not be more than
5 ohms and the potential voltage difference between workstation ground and the tip of the hot soldering iron must not
exceed 2 mV RMS (Simpson Model 260 meter or equivalent R×1 Scale).
(2) Low voltage (less than 15 volts) soldering equipment need not be grounded if the isolation transformer contains a
grounded electrostatic shield between its primary and secondary windings.
(3) Other electronic equipment or tools which come into contact with electrical components or assemblies must be
grounded (200 ohms or less) when measured with a Simpson Model 260 meter, equivalent or better, R×10 scale.
(4) ESD protective "solder suckers" such as metallized or protective types must be used.
(5) Insulated handles on hand tools are to be avoided unless periodically treated with staticide materials. Refer to
Topical Antistats in this section.
K. Static Safe Work Station
(1) A protected area can be a single safe workstation as shown in Figure 202 or a room, building, or any other area with
pre-designated boundaries that contains materials and equipment designed to limit electrical potential.
(2) Handling and testing of electronic components and assemblies must be performed at a static safe work station as
shown in Figure 202. Avoid nonconductive material coming into the area with ESDS equipment (i.e., styrofoam cups,
nonconductive tapes, plastic solder removers, plastic spooled solder, polyethylene materials, sheet protectors,
notebook folders, combs, etc.).

Figure 202
(3) Static safe workstations must be certified yearly per instructions given in DOD-HDBK-263.
(4) The purpose of the static safe work station is to provide a path for static charge which would otherwise damage
sensitive components. Such work stations have a conductive or anti static work surface which is connected to both a
common ground and the worker's skin, preferability with a wrist strap, having a minimum 500K ohm resistance to
eliminate shock hazard, should the worker contact live circuitry. When deemed necessary, an ionized air blower may
be required for more sensitive applications. All process essential insulators that have electrostatic fields that exceed
2,000 volts must be kept at a minimum distance of 12 inches (304.80 mm) from ESDS items.
(5) Refer to Table 203 for the static-free workstation resistance values.
Table 203. Static Free Workstation Resistance Values
Reading from Operator Through Maximum Tolerable Resistance Acceptable Discharge Rate
(NOTE 1)
Floor Mat to Ground 1000 Megohms Less than 1 Second
Table Mat to Ground 1000 Megohms Less than 1 Second
Wrist Strap to Ground 100 Megohms Less than 0.1 Second
NOTE 1: The minimum resistance to ground for each is 500 kilohms.
(6) Refer to Table 204 for the typical static-free workstation required equipment.
Table 204. Static-Free Workstation Required Equipment
Item Number Description

1 Floor Mat
2 Table Mat
3 Wrist Strap
4 Ionized Air Blower
5 Electrically Conductive Plastic Assembly Rack
6 Electrically Conductive Tote Boxes
7 Static Shielding Bag
NOTE 1: Refer to Tools and Materials for part numbers and manufacturer.
L. Ionized Air Blowers
(1) Ionized air blowers can be used as environmental control devices to neutralize static buildup in the work area or in/on
equipment using unbaffled high velocity flow of dry air or gasses when grounding techniques cannot be used. The
ionized air blowers capable of neutralizing voltages to 10,000 volts from an exposure distance of 3.0 feet (0.91 m) in
a period of 15 seconds or less, must be placed at a maximum distance of 4.0 feet (1.21 m) from the electronic
component or assembly being tested or handled.
(2) Ionizers must not stand alone as a means of protection against ESD, unless the safety of the individual prevents use
of ground straps or ground strapping becomes impractical.
M. Personnel Wearing Apparel
(1) Personnel should not put on or remove shop coats in the area where unpacked ESDS devices are present.
(2) Personnel handling ESDS items can wear ESD protective smocks or clothing. Additional protection is necessary for
some working situations. Finger cots or gloves, where used, must also be of ESD protective materials. Protective
apparel must be frequently checked, especially after cleaning to make sure it has correct performance.
N. Personnel Grounding Provisions
(1) Personnel handling ESDS items must wear skin contact wrist straps meeting the resistance requirements of Tools
and Equipment to dissipate personnel static charges safely to ground and equalize personnel static levels with that of
the grounded work station.
(2) Alternate grounding methods can be used to supplement wrist straps consisting of conductive shoes, shoe or heel
ground straps or covers, in conjunction with ESD protective floors or mats.
(3) When not at grounded workstations, personnel may use alternate grounding methods consisting of conductive shoes,
shoe or heel ground straps or covers, in conjunction with ESD protective floors or mats. Refer to Ionized Air Blowers
when personnel grounding becomes impractical.
(4) Avoid unnecessary physical activities near ESDS devices which tend to be friction producing, which includes wiping
of feet, rubbing of hands, etc.
O. Handling
(1) Components and assemblies must be unpackaged, packaged, handled, and worked on only at static safe work
stations or other ESD protected areas.
P. Printed Circuit Board Assembly Handling
(1) Personnel removing or installing printed circuit board assemblies which are clearly identified with the ESDS marking
must be grounded to the airplane before they touch the printed circuit board assembly. Airplane grounding must be
accomplished through an approved wrist strap. Removed assemblies must be packaged in ESD protective
packaging before the removal of personnel grounding.
Q. Black Box Assembly Handling
(1) Assemblies and or black boxes clearly identified with an ESDS marking must be handled with caution. ESDS
connector protective covers must be installed immediately after disconnecting the airplane wire harness from the unit.
(2) Only connector covers having the ESDS marking are approved for this use.
(3) Assemblies must be further protected by protective covering.
R. Component Handling
(1) ESDS components and devices, where size permits, are to be handled by their body (case). Avoid handling by their

leads.
S. Protective Coverings
(1) ESDS components and assemblies must be covered, wrapped, bagged or placed in tote trays, barrier materials, or
containers made of appropriate ESD protective materials whether conductive, static dissipative, or anti-static
whenever the items are not being worked on. Such protective materials must have a maximum surface resistivity as
defined in the definitions paragraph.
(2) ESDS components must not be removed from their ESD protective coverings or have the caps on external
equipment terminals, interconnecting cables, and connector assemblies removed until just before their installation.
ESDS components must be enclosed in static shielding bags and/or lidded/capped containers during transport or
storage to keep foreign material out and maintain applicable shielding effectiveness.
(3) Protect sensitive components and assemblies when not being actively worked on with anti-static bags, boxes, wraps,
or shunts such as bars, clips, or conductive foam.
(4) If counting is required by receiving inspection, parts must not be removed from the supplier packing under any
circumstances.
T. Power Applied to Leads
(1) No power must be applied to the component or assembly test socket(s) while being inserted or otherwise connected.
U. External Leads
(1) Components and assemblies received, shipped, or stored must be packed in such a manner that external leads are
electrically connected to each other through ESDS materials not exceeding 10^5 ohms per square when measured
per ASTM Test Method D257 or equivalent or better method. ESD protective materials, whether conductive, static
dissipative, or anti static, may be in the form of bags, DIP tubes or vials, rigid shorting bars and clips, foam shapes
used for shorting part leads, assembly connectors, or as a cushioning for packaging.
V. Marking of Containers
(1) Components and assemblies received or to be shipped or stored must have their associated container(s) marked or
taped with a legend of an attention attracting color which is easily readable to normal or corrected vision at a distance
of three feet. The following legend or equivalent must be used: ELECTROSTATIC SENSITIVE DEVICE: DO NOT
REMOVE ANTI-STATIC PROTECTION EXCEPT WHEN APPLYING TEST VOLTAGE OR FOR FINAL ASSEMBLY.
W. Packing Material
(1) Components and assemblies must be wrapped in static shielding packaging. Materials include topically treated
polyethylene sheets and film, specially coated corrugated cartons, carbon-loaded plastics, metalized plastic film and
various foils. The objective of ESD protective packaging is to prevent a direct electrostatic discharge to the ESDS
item contained within and allow for dissipation of charge from the exterior surface. In addition the packaging must
minimize charging of the ESDS item in response to an external electrostatic field and triboelectrification. Users must
be aware that some packaging materials can be humidity dependent and can have limited shelf life. They may also
lose static shielding properties by crumpling, puncturing, and folding.
(2) Make sure that any warning or precaution marking stays on the packaging as it is received from the supplier.
7. Typical Prime Charge Sources That Must Be Avoided
A. Work Surfaces
(1) Waxed, painted, or varnished surfaces, common vinyl or plastics.
B. Floors
(1) Sealed concrete, waxed, finished wood, common vinyl tile or sheeting.
C. Clothes
(1) Common clean room smocks, common synthetic personnel garments, non-conductive shoes, and virgin cotton.
NOTE: Virgin cotton can be a static source at low relative humidities such as below 30 percent.
D. Chairs
(1) Finished wood, vinyl, and fiberglass.
E. Packaging and Handling
(1) Common plastic bags, wraps, envelopes, common bubble pack, foam, common plastic trays, plastic tote boxes,
vials, and parts bins.

F. Assembly, Cleaning, Test and Repair Areas

(1) Spray cleaners, common plastic solder suckers, solder irons with ungrounded tips, solvent brushes (synthetic
bristles), temperature chambers, cryogenic sprays, heat guns and blowers, sand blasting, electrostatic copiers, and
cathode ray tubes.

Figure 201 : Sheet 1 : ESDS Labels

20-30-45-2 (Rev 1)
HIRF, EMI AND EMC - MAINTENANCE PRACTICES

1. General
A. HIRF (High Intensity Radiated Fields) and EMI (Electromagnetic Interference) can be described as unwanted energy
coupled in aircraft electronics that causes a disruption of normal operation. Coupling can occur through the airplane wiring
or directly into the equipment itself. This unwanted energy can be in the form of a lightning strike or interference from other
transmitters.
(1) The HIRF inspection/checks in this section were developed to detect any protection degradation so protection can be
restored to its initial condition.
(2) The HIRF inspection/checks can be performed any time system protection is suspected to be compromised.
B. EMC (Electromagnetic Compatibility) is a condition when a signal transmitted by an onboard transmitter or other
electrical/electronic component affects other system(s) in the airplane.
(1) EMC caused by onboard transmitters occurs due to incorrect bonding of an access panel or other element common
to the skin of the airplane. The transmitted signal creates skin currents and is radiated again at the point of the
incorrect bonding and can bleed back into other system(s).
(2) EMC caused by electrical/electronic equipment is a condition when the equipment case or the wire shields
connected to the equipment is incorrectly bonded. Without correct bonding, the signal is radiated into other
equipment or wiring.
C. Protection against HIRF, EMI, and EMC is accomplished through specific wire routing, correct grounding of equipment,
and the use of shielded wires (with the shield grounded at both ends of each wire segment).
3. Maintenance Considerations
A. An electrical bonding check must be completed when equipment racks, support structure, instrument panels, or flight
control surfaces are removed and installed. Refer to Electrical Bonding and Grounding - Maintenance Practices for
bonding information.
B. When maintenance is performed on airplane wiring, an electrical bonding check must be completed between the shield
terminations and the termination ground point. Electrical bonding between the affected connectors and the airplane ground
must also be completed. Refer to Electrical Bonding and Grounding - Maintenance Practices for resistance values.
C. Electrical conductors, such as hydraulic lines, fuel lines, and pitot static lines, are bonded at bulkheads and other points of
entry into structure. When removal and installation is necessary, a clean metal surface-to-surface contact is necessary to
make sure that the bonding is satisfactory.
D. Most shielded wires have the shield grounded at both ends of each wire segment. An open shield at one end of a wire
segment will cause the loss of HIRF, EMI, and EMC protection of the wire, and can affect other systems in the airplane.
Refer to Electrical Bonding and Grounding - Maintenance Practices for shield terminations.
(1) Shield grounding can be at a connector backshell or an equipment rack. Sometimes a band clamp is used to bond
the shields to a backshell or an equipment rack. Refer to Electrical Bonding and Grounding - Maintenance Practices
for the band clamp installation procedures.
(2) Some wire bundles are enclosed in a shield overbraid to give more HIRF/EMI protection. The shield overbraid is
grounded at both ends with the installation of a band clamp. Refer to Electrical Bonding and Grounding - Maintenance
Practices for the band clamp installation procedures.
(3) A braided solder sleeve type splice must be used to splice shielded wires. Refer to Wiring and Resistors -
Maintenance Practices and Splices, Terminals, and Heat Shrinkable Tubing - Maintenance Practices.
CAUTION: The wire bundle routing must not be changed if the change will cause the relative distance between the
airplane skin or the structure and the wire bundle to change.
E. HIRF, EMI, and EMC protection is designed to give the best routing for wire bundles. Relocation of a wire bundle can
cause a change in the common mode impedance between wire conductors and the airplane fuselage.
4. Airplane Modifications
A. The installation or removal of equipment for an airplane modification must obey bonding specifications and shield
terminations for HIRF, EMI, and EMC protection. Modification design must make sure there is HIRF, EMI, and EMC
protection both for the modification and the other airplane systems.

20-30-45-2 (Rev 1)
5. Access Panels and Doors Bonding

A. Know the maximum allowable resistance value in ohms for the particular access panel or door. For resistance listings,
refer to Electrical Bonding and Grounding - Maintenance Practices, Table 202.
B. Use an approved bonding meter to measure the resistance value of the electrical bond for the access panel or door.
(1) If the resistance value of the electrical bond for the access panel or door is not in limits, repair the electrical bond.
Refer to Electrical Bonding and Grounding - Maintenance Practices.
6. Equipment Bonding
A. Know the maximum allowable resistance value in ohms for the applicable equipment. For resistance listings, refer to
Electrical Bonding and Grounding - Maintenance Practices, Table 202.
B. Use an approved bonding meter to measure the resistance value of the electrical bond for the equipment.
(1) If the resistance value of the electrical bond for the equipment is not in limits, repair the electrical bond. Refer to
Electrical Bonding and Grounding - Maintenance Practices.
7. Wire Bundle Protection
A. Before a wire bundle shield bonding check is performed, make sure that the shield terminations are installed correctly and
serviceable. Refer to Electrical Bonding and Grounding - Maintenance Practices, Termination of Shielded Electrical
Cables.
B. Know the maximum allowable resistance value in ohms for the applicable wire bundle shield. For resistance listings, refer
to Electrical Bonding and Grounding - Maintenance Practices, Table 202.
C. Use an approved bonding meter to measure the resistance value of the electrical bond for the wire bundle shielding.
(1) If the resistance value of the electrical bond for the wire bundle shielding is not in limits, repair the electrical bond.
8. Visual Check
A. General
(1) In this section, a visual check of an affected system or area will be performed. Considerations are general condition,
corrosion, environmental concerns, correct installation, and wire routing.
B. Visual Check
(1) This inspection is completed after maintenance is performed that temporarily or permanently moves wiring. The
extent of maintenance determines what needs to be inspected. This includes moving, removing, or replacing wire
bundles, wire ties, clamps, brackets, and wiring feed-thru parts. Mounting trays, mount holders, mounting brackets,
and shock mounted components are also inspected.
C. Wire Bundles Visual Inspection
(1) In the area where maintenance was performed, do an inspection of the installation of wiring for corrosion,
environmental damage, and general condition.
(2) Do an inspection of all wire bundles within the general area for mounting security.
(3) Do an inspection of the wire routing to make sure that the routing has not changed from its initial routing.
(4) Make sure that no unnecessary strains are put on wire segments between clamps and wire holders.
(5) Do an inspection of the external shielding and coverings as necessary to make sure that the shielding is not
interrupted and the coverings are in good condition.
(6) Do an inspection of the adjacent access panels and doors for necessary bonding jumpers and/or local grounding
studs. Perform bonding and grounding checks as necessary.
NOTE: Installation of the grounding studs after maintenance will need an electrical check.
D. Data Bus Wiring Visual Inspection
(1) Data bus wiring can be identified by markings or by looking at the reference designators for the connectors. Data bus
wiring is critical for input/output signals to operate correctly.
(2) Do an inspection of the end terminations where shielded and twisted shielded wiring has been disconnected for
maintenance. Do an inspection for corrosion on the pins.
(3) Do an inspection of the connector shells for corrosion and the connector threads to make sure that they are in good
condition.

20-30-45-2 (Rev 1)
(4) Do an inspection of the backshell for corrosion. If the backshell has a ground terminal, do an inspection for a loose
terminal and the condition of the wire to the terminal.
(5) After maintenance, make sure that the installation of the data bus wire is the same as it was before the maintenance.
(6) Do an inspection of the exterior of the wiring for damage and shielding continuation. Breaks in the shielding must be
repaired.
(7) Do an inspection of the clamps, standoffs, and cable guides for correct installation position, correct hardware, and
security of installation.
E. Rack Mounted Components Visual Inspection
(1) If an electrical component that is mounted on a tray or rack is removed for maintenance, do an inspection of the
component to the rack interface to make sure that the connections are correct.
(2) Do an inspection of the rack or mounting tray for correct grounding. If a screw is used, make sure that it is tight and
bonded correctly.
(3) If a bond jumper is installed, make sure that the jumper is in good condition and mounted correctly.
9. Electrical Wire Bundle Assembly Inspection
CAUTION: Coaxial cable assemblies identified as impedance matching units must be of a specified length. Do not
shorten the cable to remove too much slack.
NOTE: Electrical wire bundle assemblies are examined when the individual component or system is examined.
When working in an applicable zone on the airplane, and access panels or floorboards are removed,
wire bundle assemblies must be inspected at the same time.
NOTE: If maintenance on a component has an effect on the electrical bond to the primary structure, the
electrical bond check must be completed again. Refer to Electrical Bonding and Grounding -
A. Wire Bundle Assembly Inspection
(1) Do an inspection of the wire bundle for correct routing and clamp installation.
(2) Do an inspection of the wire bundle for signs of chafing or other damage.
(3) Make sure that the electrical connectors and the wiring show no signs of overheating or arcing.
(4) Do an inspection of the wire bundle connector backshells for the conditions that follow:
(a) Security and signs of corrosion.
(b) Application of silicone sealant (RTV-157).
(c) If sealant is not applied:
1 Make sure that the backshell is tight.
2 Clean the outside of the backshell.
3 Apply a bead of RTV-157 sealant approximately 1/4 inch long on outside of connector, between connector
and backshell. Sealant must not interfere with the connection of the connector. Refer to Fuel, Weather,
Pressure and High-Temperature Sealing - Maintenance Practices.
(5) Do an inspection for any crossovers, twists, sharp bends, or kinks.
(6) Make sure that the wiring is not attached to or supported by plumbing lines that contain flammable liquids or oxygen.
(a) Wiring installed less than six inches from lines with flammable liquids or oxygen must be tightly supported and if
possible, installed above the lines.
(7) Cables installed in locations where fluid can be trapped must be protected against contamination by the fluid.
(8) Where possible, wires must be kept away from high temperature equipment.
(9) Make sure that a nylon grommet is installed where wiring passes through cutouts or holes in the airplane structure.
(10) Make sure that wire bundles have enough free play to:
(a) Correctly stake the terminals.
(b) Remove, install, or move the wire bundles for maintenance.
(c) Make sure there is free movement of the shock mounted equipment.
(d) Prevent tension and strain on the wires and supports.

20-30-45-2 (Rev 1)
(e) Give sufficient drip and service loops.

NOTE: Make sure that the drip loops are routed so that a drip from a loop does not have a
negative effect if it falls on equipment.
NOTE: On moisture resistant connectors, it is not necessary for drip loops where space is
limited.
(11) Do an inspection of the wires for any sharp bends.
(a) The minimum bend radius for wires is 10 times the outside diameter of the wire.
(b) At terminal strips where the wire is sufficiently supported, the minimum bend radius is 3 times the outside
diameter of the wire.
(12) Make sure that the wire groups or bundles are tied at intervals that are not more than 12 inches.
(a) Make sure that the ties are not pulled so tightly that it can cause a cut or penetration of the insulation.
(b) Make sure that twist ties are not used to support a wire or wire bundle.
(c) Make sure that when wires or bundles cross, they are tied together at the area where they cross.
(d) In areas where the operating temperature is 200°F (93°C) or less, ties can be made from waxed twine.
(e) In areas where the operating temperature is more than 200°F (93°C), ties must be made from fiberglass cord.
(f) Wire bundle assemblies outside of the engine compartment that have QUIK-TY connector clamps can be
secured with ties and lacing cords or plastic tie wraps.
(13) To prevent the wires from shorting to ground, especially in the engine compartment, make sure that the wiring is not
tied to the plumbing and that the wires are secured correctly with standoff clamps.
(14) The cable assembly that routes through the cabin floor must be visually examined for the conditions that follow:
(a) The cable assembly is secured with tie wraps, anchors, and clamps.
(b) The cable assembly must be supported and clamped to make sure that it does not rub the structure or touch the
bleed air ducts.
(c) Grommets must installed where the cables are routed through a bulkhead.
(d) Shield terminations must be carefully visually examined for damage or corrosion.
B. Internal Zonal Visual Inspection of Lightning and High Intensity Radiated Fields
(1) General
(a) In this section, a visual inspection of an affected system or area will be performed. Considerations are signs of a
lightning strike, general condition, corrosion, environmental concerns, correct installation, and wire routing.
NOTE: This inspection includes wire bundles, wire ties, back shells, bonding straps, clamps,
brackets, and wiring feed-thru parts. Mounting trays, mount holders, mounting brackets,
and shock mounted components are also examined.
(b) Do an inspection for corrosion, environmental damage, and general condition.
(c) Do an inspection for any signs of chafing or other damage.
(d) Do an inspection of all wire bundles in the general area for mounting security.
(e) Do an inspection of the external shielding and coverings as necessary to make sure that the shielding is not
(f) Do an inspection of the clamps, standoffs, and cable guides for correct installation, correct hardware, and
(g) If a bond jumper is installed, make sure that the jumper is in good condition and is installed correctly.
(h) Do an inspection of adjacent access panels and doors for necessary bonding jumpers and/or local grounding
studs.
(i) Do an inspection of the backshell for corrosion. If the backshell has a ground terminal, examine it for a loose
(j) Do an inspection of the rack or mounting tray for correct grounding. If a screw is used, make sure that it is tight
and bonded correctly.
(k) Do an inspection of the wire ties for security.

20-30-45-2 (Rev 1)
(l)
Do an inspection for signs of a lightning strike. Look for burnt wires, discolored structure, and exit holes in
structure and/or skin.
C. External Zonal Visual Inspection of Lightning and High Intensity Radiated Fields
(1) General
(a) In this section, a visual inspection of an affected system or area will be performed. Considerations are signs of a
lightning strike, general condition, corrosion, environmental concerns, correct installation, and wire routing.
NOTE: If applicable, this includes wire bundles, wire ties, back shells, bonding straps, clamps,
brackets, and wiring feed-thru parts.
(b) Do an inspection for corrosion, environmental damage, and general condition.
(c) Do an inspection of all wire bundles in the general area for mounting security.
(d) Do an inspection of the external shielding and coverings as necessary to make sure that the shielding is not
(e) Do an inspection of the clamps, standoffs, and cable guides for correct positioning, correct hardware, and
(f) If a bond jumper is installed, make sure that the jumper is in good condition and is installed correctly.
(g) Do an inspection of the adjacent access panels and doors for necessary bonding jumpers and/or local
grounding studs.
(h) Do an inspection of the backshell for corrosion. If the backshell has a ground terminal, examine it for a loose
(i) Do an inspection of the wire ties for security.
(j) Do an inspection for signs of a lightning strike. Look for burnt wires, discolored structure, and exit holes in
structure and/or skin.

SOLVENTS, SEALANTS AND ADHESIVES - DESCRIPTION AND OPERATION

1. General
A. Solvents, sealants, and adhesives are a group of chemicals that often are poisonous. Anyone who does maintenance,
repair, and operation of the airplane and airplane accessories may be exposed to these chemicals.
B. Work only in a clean, well-lit, and well-ventilated area to help avoid touching, breathing, or ingestion of these poisons. Wear
rubber gloves and protective clothes and avoid breathes of spray fumes because they are very poisonous.
C. When work is done with these substances, always know the symptoms of poisoning. If symptoms are seen, it is most
important to immediately remove all personnel from the area that has the contamination.
2. Description
A. To help maintenance personnel know about solvents, sealants, and adhesives the information about them are given in
individual paragraphs.
(1) Solvents
(a) Solvents are made of chemicals which can dissolve other materials. Their primary function is to be used as a
cleaning agent. Clean parts with solvents when they are not easily cleaned by vapor degreasing or immersion in
chemical cleaners.
(2) Sealants
(a) Sealants are made of chemical compounds and are used much of the time as a seal against the flow of air and
liquids. The classes sealants are put in is given by the way they are used.
(3) Adhesives
(a) Adhesives are made of a mixture of chemicals which becomes composite that is used much of the time to bond
materials. The classes adhesives are put in is given by the way they are used.

GENERAL SOLVENTS/CLEANERS - MAINTENANCE PRACTICES

1. General
A. Solvents are used to clean parts with a large number of different procedures. Some solvents can be used to remove oil, grease, and dirt from objects
and will not damage metal, plastics, or elastomeric parts. This section will give the general requirements for different methods of general solvents and
cleaners for specific materials.
2.Manual Cleaning
WARNING: Read the manufacturers material safety data sheet (MSDS) before you use any solvent cleaner.
A. Liquid Cleaner Classification
(1) Type I, Noncritical Cleaning - Surface preparation (cleaning) for non-special processes (surfaces for handling and/or temporary storage of
parts/assemblies).
(a) Class 1 - Solvent Base
(b) Class 2 - Water Base.
(2) Type II, Critical Cleaning - Surface preparation before special processes such as finishes (finishing, sealing, erosion boots, application, decal
application, etc.) bonding, and joining (welding, etc.).
(a) Class 1 - Solvent Base
(b) Class 2 - Water Base (none approved).
B. Wiper Classification
(1) Type I, Noncritical Cleaning - Minimal cleaning of surfaces for handling.
(2) Type II, Critical Cleaning - Maximum cleaning of surfaces for special processes such as finishing, sealing, bonding, erosion boots application, decal
application, and all other processes requiring critical cleaning.
(3) Class 1 - Virgin cloth, composed of 100% cotton fibers, with or without added binders.
(4) Class 2 - Virgin cloth, composed of 100% synthetic or blended synthetic, cotton, or cellulose materials, with or without added binders, which remain
stable up to 400°F (204°C).
(5) Class 3 - Not used.
(6) Class 4 - 100% synthetic (polyester, rayon, polypropylene, etc.) knit with or without binders.
(7) Form 1 - Dry cloth (in individual wipes or rolls).
(8) Form 2 - Cloths contained in a pre-saturated wiping system, except that binders, surfactants, or other chemical treatments must not be included.
C.Materials
(1)Liquid Cleaners
(a) Type I, Noncritical Liquid Cleaners. Refer to Table 201 for the approved liquid cleaners.
Table 201. Approved Liquid Cleaners
Liquid Cleaner Type and Class Manufacturer
Dry Cleaning Solvent MIL-PRF-680, Type I Type I, Class 1 Commercially Available
Dry Cleaning Solvent MIL-PRF-680, Type II Type I, Class 1 Commercially Available
Isopropyl Alcohol TT-I-735 Type I, Class 1 Commercially Available
Denatured Alcohol Type I, Class 1 Commercially Available
Citra-Safe (Deodorized) Type I, Class 1 Inland Technology Inc.
Acetone (99.5% Pure) ASTM D329 Type I, Class 1 Commercially Available
Liquid Dish Washing Detergent Type I, Class 2 Commercially Available
Windex with Vinegar (Ammonia-Free) Type I, Class 2 S.C. Johnson & Son Inc.
Type II, Class 2
DeSoclean 110 - 020K019 Type II, Class 1 PPG Aerospace
DS 108 Type II, Class 1 Dynamold Inc.
Buckeye Shop Master RC Type II, Class 1 Buckeye Intl, Inc.
Aircraft Degreaser MX-412 Type II, Class 1 Misco International Chemicals

Methyl n-Propyl Ketone Type II, Class 1 Eastman Chemicals
Barton Solvent A-2904 Type II, Class 1 Barton Solvents
Isopropyl Alcohol TT-I-735 Type II, Class 1 Commercially Available
Aliphatic Naphtha TT-N-95 Type II, Class 1 Barton Solvents
Water/Isopropyl Alcohol - 50/50 Reverse Type II, Class 1 Commercially Available
Osmosis, Deionized Water
Barsol A-4497 Type II, Class 1 Barton Solvents
MEK ASTM D740 (Vapor Pressur70 mmHg) Type II, Class 1 Barton Solvents

Ethyl Acetate TT-E-751 (Vapor Pressure Type II, Class 1 Barton Solvents
82mmHg)
DeSoclean 45 Type II, Class 1 PPG Aerospace
Barsol A-3736 Type II, Class 1 Barton Solvents
(b) Refer to Table 202 for the Type I noncritical cleaning applications.
Table 202. Type I Noncritical Cleaning Applications
Classification Type I, Class 1 Type I, Class 2
Liquid Cleaner Dry Cleaning Isopropyl Denatured Citra-Safe Acetone (99.5% Liquid Dish Windex with
Solvent MIL- Alcohol TT-I- Alcohol (Deodorized) Pure) ASTM Washing Vinegar
PRF-680, Type 735 D329 Detergent (Ammonia-Free)
I, Type II
Metal Materials X X X X X X X
(NOTE 1)
Plastic Materials X
Before Painting
Plastic Materials: X X
ABS,
Cellulose
Acetate,
Cellulose-
Acetate-Butyrate
(CAB),
Polyphenyl-ene
Oxide (PPO),
Poly-styrenes,
Poly-urethanes,
Silicones,
Vinyls
Acetal (Polyoxy-
methylene),
Acrylics,
Composites,
Epoxies,
Melamines,
Nylons,
Phenolics,
Polycarbon-ates
Polyesters,
Polyethyl-enes,
Polymides,
Polypropyl-enes
Plastic Materials: X
Fluoro-plastics
(TFE, FEP, KEL-
F)
Rubber X
Materials:
Buna N,
Buna S,
Butyl,
Ethylene
Propylene,
Natural,
Neoprene,
Silicones,
Thiokol
NOTE 1: The choice of cleaner depends on how much the surface needs to be cleaned.
NOTE 2: A 50:50 solution of IPA/DI or RO water is also an approved liquid cleaner for all plastic materials.

(c) Type II, Critical Liquid Cleaners. Refer to Table 201 for the approved liquid cleaners.
(d)Refer to Table 203 for the Type II critical cleaning applications.
Table 203. Type II Critical Cleaning Applications
Liquid Metal Plastic Mold Composite Materials Before Before Before Before Before
Cleaner Materials Materials: Release Materials Before the Adhesive Adhesive Application Application Application
(NOTE 1) Polyesters, Agents for Application Bonding Bonding of Sealants of Sealants of Sealants
Polyethylenes, Composite of Primer, for Metal for to Cast to for
Polymides, Materials Primer Materials Nonmetallic Acrylic Stretched Adhesive
Polypropylenes, (NOTE 3) Surfacer, Materials Materials ( Acrylic Primer,
Fluoroplastics Sanding Cessna Materials Primer
Surfacer, Windows) (Cessna Surfacer,
and Windows) Sanding
Topcoat Surfacer,
and
Topcoat
DeSoclean X X
110 - 020K019
DS 108 X X
Buckeye Shop X X
Master RC
Aircraft X X
Degreaser MX-
412
Methyl n-Propyl X X X X X X X
Ketone (90%
Pure)
Barton Solvent X X X X
A-2904
Isopropyl X X X X X
Alcohol TT-I-
735
Aliphatic X X X X
Naphtha TT-N-
95 Type II
Water/Isopropyl X X X X (NOTE 2) X
Alcohol - 50/50
Reverse
Osmosis,
Deionized
Water
Barsol A-4497 X X X
MEK ASTM X X X X X X X
D740 (Vapor
Pressur70
mmHg)
Ethyl Acetate X X
TT-E-751
(Vapor
Pressure
82mmHg)
DeSoclean 45 X X X X
Barsol A-3736 X X
Windex with X X X
Vinegar
NOTE 1: The choice of cleaner depends on how much the surface needs to be cleaned.
NOTE 2: Use when an airplane is exposed to water/rain before topcoat. Metalbond assemblies are first cleaned using the blend of 50 (DI
or RO) water:50 IPA or SATWipes followed by solvent cleaning using Methyl n-Propyl Ketone before the application of fuel
primer or corrosion protection primer.
NOTE 3: For cleaning water based release agents, use 50 water (DI or RO):50 (Kindex Dawn Dishsoap detergent solution) or other
approved cleaning agents. For cleaning solvent based release agents, use MEK, MPK, IPA, or other approved cleaning agents.

NOTE 4: All liquid cleaners are Type II, Class 1 except for Windex with Vinegar which is Type II, Class 2.
(2) Wiping Cloths
(a) Type I Wiping Cloths. Refer to Table 204 for the approved wiping cloths.
NOTE: Any Type II (Class and Form) wiping cloth can be used for Type I, Noncritical cleaning for that class and form.
Table 204. Approved Wiping Cloths
Wiping Cloth Type, Class Form Manufacturer
Kamen 41-25 Type I, Class 1 Form 1 Kamen
Kimwipe Delicate Task Wipes Type I, Class 1 Form 1 Kimberly-Clark Corporation
#34721
Wypall L40-05701 Type I, Class 2 Form 1 Kimberly-Clark Corporation
Kimtex 33560 Blue Type I, Class 2 Form 1 Kimberly-Clark Corporation
Synthetic Wipes JW420003 Type I, Class 4 Form 1 Contec
Synthetic Wipes JW420004 Type I, Class 4 Form 1 Contec
KimTech Prep 07644000 Type I, Class 4 Form 1 Kimberly-Clark Corporation
KimTech Prep 07622000 Type I, Class 4 Form 1 Kimberly-Clark Corporation
Rymplecloth Type II, Class 1 Form 1 American Fiber & Finishing
Sponges 582556 Type II, Class 1 Form 1 American Fiber & Finishing
Aerotex - 210 Type II, Class 1 Form 1 American Fiber & Finishing
Aerotex - 204 Type II, Class 1 Form 1 American Fiber & Finishing
Hermitex 300 Type II, Class 1 Form 1 DeRoyal Textiles
Hermitex 301 Type II, Class 1 Form 1 DeRoyal Textiles
DuPont Sontara 8642 Type II, Class 2 Form 1 DuPont/Axalta
DuPont Sontara K802 Type II, Class 2 Form 1 DuPont/Axalta
Veraclean Type II, Class 2 Form 1 Fiberweb
Veraclean Plus Type II, Class 2 Form 1 Fiberweb
Kimtech Scottpure Type II, Class 1 Form 1 Kimberly-Clark Corporation
Kamen Veraclean 561692 Type II, Class 4 Form 1 Kamen
SATWIPES 6X9 IPA SWCN0195 Type II Form 2 Contec
SATWIPES 9X11 IPA SWCN0082 Type II Form 2 Contec
SATWIPES 6X9 MPK SWCN0001 Type II Form 2 Contec
SATWIPES 9X11 MPK Type II Form 2 Contec
SWCN0013
SATWIPES 6X9 A2904 Type II Form 2 Contec
SWCN0253
SATWIPES 9X11 A2904 - Type II Form 2 Contec
SATWIPES 6X9 IPA SW420195 Type II, Class 4 Form 2 Contec
SATWIPES 9X11 IPA SW420138 Type II, Class 4 Form 2 Contec
SATWIPES 6X9 MPK SW420166 Type II, Class 4 Form 2 Contec
SATWIPES 9X11 MPK SW420050 Type II, Class 4 Form 2 Contec
SATWIPES 6X9 A2904 Type II, Class 4 Form 2 Contec
SW420028
SATWIPES 9X11 A2904 Type II, Class 4 Form 2 Contec
SW420012
SATWIPES 4X4 70 IPA: 30 DI Type II, Class 4 Form 2 Contec
Water SW420951
SkyWipe Elixair - 602 Type II, Class 2 Form 2 3M
(b) Type II Wiping Cloths. Refer to Table 204 for the approved wiping cloths.
(3) Gloves
(a) Refer to Table 205 for the approved glove materials for use in the surface preparation of organic coatings (metallic and nonmetallic surfaces) and
other applications.
Table 205. Approved Glove Materials
Glove Manufacturer

Sol-Vex 37-175 Nitrile Ansell

Value Master Natural Best VMS Showa-Best
Best Nitrile 7500PF Showa-Best
Technicians #390 Natural Latex/Neoprene Solvent Resistant Ansell
Nitrile N-Dex Showa-Best
Conform XT Glove #69-318 Ansell

Ansell Accutech 91-104 Ansell
FL Latex Glove #FL-100 Ansell
PIP 97-500 Disposable White Cotton Glove Protective Industrial Products
Superior LL40 Disposable White Cotton/Poly Glove Superior
Superior ML40 Disposable White Cotton/Poly Glove Superior
Magid 660, 671, and 651J White Cotton Glove Magid Glove and Safety Manufacturing
Crime Scene 3-5221-1 White Cotton Glove Crime Scene
NOTE 1: All gloves in this table are resistant to Type I and Type II liquid cleaners.
D. Facilities and Equipment
(1) Take all necessary safety precautions including safety glasses, gloves, masks, etc. while using liquid solvents.
(2) Sufficient ventilation must be provided and/or respirators are required for all closed areas.
(3) All solvents must be considered flammable and must not be exposed to flame or sparks under any circumstances.
(4) Solvent/liquid cleaners must be stored in spill proof containers.
(5) Solvent/liquid cleaners must be poured from safety cans or other approved containers.
E. General Requirements
(1) Solvent cleaners that are applied by hand are to be used when it is not practical to vapor degrease or to immerse the part in chemical cleaners.
(2) The solvents and materials used for final cleaning operations must be clean.
(3) Do not apply the solvent directly to the surface. Always apply the solvent to the wiping material.
(4) The surface that is to be cleaned must be dry and free of visible solids. An iridescent surface means that the surface needs to be cleaned more.
(5) The surface that is cleaned should be processed as soon as possible after it has been cleaned and dried.
(6) Make sure that the airplane is grounded before cleaning the outside of the airplane with a solvent.
(7) Remove all dust, lint, chips, shavings, etc., with a vacuum cleaner where necessary.
(8) Clean the surface after you fit, file, drill, dimple, deburr, or do any other pre-assembly operation.
(9) Wear the applicable gloves when wiping using a liquid cleaner is necessary. Refer to Table 205.
(10) Make sure that you are in a well ventilated area when you use solvents.
F. General Manual Cleaning Procedure
(1) Wipe any oil, grease, or dirt from the surface that is to be cleaned with dry clean wiping material.
(2) Apply liquid cleaner to clean wiping material. Do not wet the wiping material so much that solvent drips off of it. You can also use pre-saturated wipe
dispensers. Refer to Table 204 for the approved wiping cloths.
(3) Wipe the surface with the wet wiping material as required to dissolve or loosen soil. Work on a small enough area so that the surface remains wet.
(4) While the surface is still wet, wipe it with a clean dry wiping material.
(a) If the surface dries before being wiped dry, reapply the liquid cleaner and clean again.
(5) Reclean the surface until there is no discoloration on the drying cloth.
G. Manual Cleaning Procedure for Specific Surfaces
(1) Metal Surfaces
(a) Metal surface cleaning can be done using any Type I or Type II liquid cleaner depending on the soil level of the surface.
(2) Primed or Painted Surfaces
(a) Bonding surfaces with adhesive primer must be solvent cleaned with Type II solvent. Refer to Type II, Critical Liquid Cleaners in this section.
(b) Surfaces with the corrosion protection epoxy primer must be lightly abraded with Scotch-Brite or 240 grit (or finer) aluminum oxide sandpaper
then solvent cleaned with Type II solvent before painting or non-critical adhesive bonding.
(c) Surfaces with a urethane paint finish must be lightly abraded with Scotch-Brite or 240 grit (or finer) aluminum oxide sandpaper then solvent
cleaned with Type II solvent before secondary bonding.
(3) Plastic or Rubber (Nonmetallic) Surfaces
(a) Remove heavy soil from plastic and rubber surfaces with a mild solution of water and liquid dishwashing detergent before liquid cleaning.

(a) Remove heavy soil from plastic and rubber surfaces with a mild solution of water and liquid dishwashing detergent before liquid cleaning.
(b) Before you bond a plastic or rubber surface, lightly abrade the surface with 150 to 240 grit aluminum oxide sandpaper followed by solvent
cleaning.
(c) For plastic or rubber surfaces, solvent clean with the correct solvent. Refer to Liquid Cleaners in this section.
(4) Composite Surfaces
(a) Composite surfaces with release agents must first be cleaned per the General Manual Cleaning Procedure in this section with the correct Liquid
Cleaners in this section. Then solvent clean again using the correct Liquid Cleaners in this section.
(5) Polycarbonate Cabin Window Frost Panes with Anti-Fog Coating
(a) Non-critical cleaning of the anti-fog surface is only to be cleaned using Windex with vinegar and Kamen VeraClean Wipers.
(b) For spot cleaning, spray the VeraClean Wipe until it is moist. Remove all smudges and spots using with light pressure until all smudges and spots
are removed.
(c) To clean the entire pane, spray the surface of the pane using Windex with vinegar and immediately wipe with a VeraClean wipe until the solvent is
gone. Do not allow the liquid cleaner to dry on the surface of the pane.
NOTE: The anti-fog coating is applied to only one surface of the frost pane. If the pane is removed from the airplane, the anti-fog
surface can be identified by exhaling on each side of the pane. The side that does not form a fog when breathed upon
has the anti-fog coated surface.
(6) Airplane Exterior Surfaces
(a) This section applies to the liquid cleaning of airplane exterior surfaces before the application of corrosion primer, sanding surfacer,
surfacer/primer, and urethane topcoat paint.
(b) For the applicable surfaces, use Type II, Class 1 liquid cleaner.
(c) Use one of the gloves that follow:
1 Ansell 6L0106 37-175 Glove
2 Ansell 6L0112 37-145 Glove.
(d) It is recommended to use 12 X 16.5 inch Sontara Aircraft wipers, to do the liquid cleaning.
(e) Clean the airplane exterior surfaces per the General Manual Cleaning Procedure in this section.
H. Additions or Exceptions
(1) Metals
(a) Before non-structural bonding, lightly abrade the surface with a Scotch-Brite pad or 320 grit (or finer) sandpaper followed by liquid cleaning.
(b) Before applying a second coat of primer or topcoat to primed details, lightly abrade the surface with a Scotch-Brite pad or 180 grit (or finer)
sandpaper followed by Type II liquid cleaning.
(2) Sealant
(a) Initial Cleaning
1 All surfaces to which sealant is to be applied must be cleaned with liquid cleaners with the correct Liquid Cleaners in this section. This
includes the nut plates and all fasteners and their related nuts, collars, spacers, washers, etc.
2 Pipe cleaners, acid brushes, and nylon bristle brushes can be used to clean corners, gaps, channels, joggles, etc.
3 Epoxy primed surfaces must be scuffed with Scotch-Brite. Care must be taken not to abrade through the primer. Any exposed metal must be
repaired and primer reapplied. Final cleaning with liquid cleaners must be done per Final Cleaning with Solvent or Final Cleaning with
SkyWipe - Confined Bay Area in this section.
4 Adhesive primed surfaces must only be solvent cleaned per Final Cleaning with Solvent or Final Cleaning with SkyWipe - Confined Bay
Area in this section, before sealant application.
5 Composites must be cleaned per Composite Surfaces in this section.
(b) Final Cleaning with Solvent
1 Final cleaning must be done before sealant application by the person who is going to apply the sealant.
2 Wipe the abraded surface using the wetted wiping material as required with the correct liquid cleaner. Immediately wipe the wet surface with
dry, clean wiping material. If the surface dries before being wiped dry, reapply the liquid cleaner and then clean again.
3
Always clean an area larger than the area where the sealant is to be applied. Never clean an area larger than 30 inches (0.76 m) in length
when practical.
4 Continue cleaning until there is no discoloration on the clean drying cloth. A slight yellow stain from the integral fuel tank primer or green stain
from corrosion resistant primer is acceptable. Wax or grease pencil marks must be removed from parts before sealing.
5 Allow all cleaned (wet wipe-dry wipe) surfaces to dry a minimum of 5 minutes before the application of sealant materials.
(c) Post Cleaning
1 Sealant must be applied as soon as possible after cleaning and drying the surfaces.
2 Do not allow handling of any parts between the cleaning and sealing operations unless it is unavoidable, in which case, personnel handling
cleaned surfaces must wear clean white gloves to prevent surface contamination.
3 In the event that contamination does occur, the surfaces must be cleaned again.
(3) Windows
(a) Windows must be cleaned per the General Manual Cleaning Procedure in this section with the correct Liquid Cleaners in this section.
(4) Post-Fay Seal Work

(4) Post-Fay Seal Work
(a) Immediately after the assembly is completed and all permanent fasteners have been installed, remove the excess uncured sealant using a clean
cloth moistened with liquid cleaner. The cloth should not be saturated to the point where dripping will occur. Too much liquid cleaner can damage
the integrity of the seal.
(5) Final Cleaning with SkyWipe - Confined Bay Area
(a) The surfaces cleaned per Initial Cleaning in this section must be solvent wiped with the following method for final cleaning. This 3-step cleaning
process is limited to the confined bay area, before the application of sealant on primed parts.
1 Wipe with SkyWipe and follow with a clean dry cloth.
2 Wipe with X071368 SATWipes and follow with a clean dry cloth.
3 Wipe with X071368 SATWipes and follow with a clean dry cloth.
(6) Cleanup of Skydrol Spills and Leaks
(a) Citra-Safe (Deodorized) can be used per the General Manual Cleaning Procedure in this section to cleanup Skydrol spills and leaks.
(b) Citra-Safe (Deodorized) can affect some plastic and rubber compounds. Do not use on windows.
(7) Carpet Cleaning
(a) Any material to be used for cleaning interior carpet for the removal of spots, stains, etc. must require flammability approval. Cleaning materials
must be applied to a small scrap sample of carpet to determine color fastness before applying the cleaner to carpet installed in the airplane. The
following materials are approved for use:
• Resolve cleaner from Reckitt Benckiser
• Corn Starch.
3. Vapor Degrease
WARNING: Read the manufacturers MSDS before you use any solvent cleaner.
A. Materials
(1) The solvent in Cessna vapor degreasers must be trichloroethylene (79-01-6).
(2) Inhibitors are used to control the acid acceptance of the solvent. The approved inhibitors and their manufacturers are as follows:
(a) MAXISTAB Alk Stabilizer - Dow Chemical Company
(b) MAXISTAB AA Stabilizer - Dow Chemical Company
(c) NA-86 Stabilizer - Detrex Chemical Industries.
B. General Requirements
(1) The degreaser must be in a place that does not have drafts.
(2) The degreaser must be covered when not in use. The unit should have a split cover so that it can be covered while in use.
(3) The baskets and racks used in the degreaser must be made of solid round rod and mesh to reduce solvent dragout.
(4) The water separator must be on continuously while the degreaser is on.
(5) Do not put bearings, oiled phosphated steel, or plastics in the degreaser because they may get damaged.
(6) Only oil and grease will be removed by the degreaser. Soil, paint, tape residue, etc. will need to be cleaned off before the surface is degreased.
Refer to Manual Cleaning in this section.
(7) Chem filmed parts should not be vapor degreased when possible.
(8) The vapor safety thermostat should operate at 160°F (71°C).
(9) The sump thermostat should operate between 185 and 195°F (85 and 91°C).
NOTE: The mixture in the sump or boiling chamber must have a liquid solvent purity such that the boiling temperature is 195°F
(91°C) or less.
(10) Adjustments to steam input and cooling water flow must be made slowly.
(11) The liquid solvent level must never fall below 2.0 inches (50.8 mm) above the heating coils.
(12) The solvent vapor level must be between the lower and middle coils of the condenser.
(13) When the degreaser is shut off, the cooling water must stay on until the unit cools completely.
(14) The pH in the water separator must be above 7. You can add sodium bicarbonate to the water compartment if the pH is below 7.
C. Vapor Degreasing Procedures
(1) Make sure that all parts to be degreased do not have any water on them.
(2) Place all parts to be degreased on the rack to where all parts drain rapidly and completely.
(3) If the area of the rack is less than half of the area of the opening of the vapor zone, lower the rack into the vapor zone at a maximum speed of 2.2
inches per second (55.8 mm per second). If the area of the rack is greater than half of the area of the opening of the vapor zone, the maximum
speed that the rack can be lowered into the vapor zone is 0.6 inches (15.2 mm) per second.
(4) Suspend the rack in the solvent vapors until condensation stops. If you need to transfer work within the vapor zone, keep it below the vapor zone.
(5) If liquid solvent gets trapped inside, you can tilt or shake the rack below the vapor zone to drain the trapped solvent.
(6) Check and record the two temperatures that follow three times (at least two hours apart) for each shift that the degreaser operates:
(a) The incoming steam pressure, if the steam is used as the heat source. This is not applicable for electric vapor degreasers.
(b) The boiling temperature of the solvent mixture in the sump or boiling chamber.

(7) The recorded temperatures are to be checked by Quality Control.

(8) Raise the rack out of the vapor zone at the same rate that it was lowered down.
(9) If the parts are not completely clean, you can wait for the parts to cool to room temperature then return them to the vapor zone. If the parts are still
not clean, you can spray them with a stream of clean solvent from the reservior. Make sure that you keep the nozzle 6.0 inches (152.4 mm) below
the vapor zone and do not spray any solvent out of the degreaser.
D. Quality Control
(1) Use the Dow Acid Acceptance and Alkalinity Test Kit to determine the solvents acid acceptance value.
(2) The acid acceptance value for the trichloroethylene should be between 0.15 and 0.25. An acid acceptance value of 0.08 is marginal and 0.04 is
unacceptable.
(3) If the acid acceptance value is 0.15 or higher, the solvent should be checked at least once a week to make sure that it does not fall below 0.15.
(4) If the acid acceptance value is not between 0.15 and 0.25, you will need to stabilize the solvent with an inhibitor as follows, depending on the
inhibitor that you have available:
(a) Do NA-86 stabilization.
1 Refer to Table 206 to determine how many gallons of inhibitor need to go into the solvent reservoir.
Table 206. NA-86 Inhibitor Calculation
Variable NA-86 Inhibitor Calculation
A = The acid acceptance value that you want.
B = The acid acceptance value that the solvent is currently at. Gallons = (A+B)*C/5
C = The reservoir volume, in gallons.
NOTE 1: Round the result to the nearest gallon.
2 Pour the NA-86 inhibitor into the reservoir.
(b) Do the MAXISTAB stabilization.
1 Follow the instructions that are in the Dow Acid Acceptance and Alkalinity Test Kit to determine how much MAXISTAB Alk and
MAXISTAB AA to add to the reservoir.
(5) If you stabilized the solvent from between 0.08 and 0.15, check the acid acceptance value twice a week until it stabilizes greater than 0.15.
(6) If you stabilized the solvent from between 0.04 and 0.08, check the acid acceptance value daily until it stabilizes greater than 0.15.
E. Maintenance
(1) Check the acidity of the solvent.
(a) Take a sample of approximately 0.85 fluid ounces (25 ml) of solvent from the reservoir.
(b) Mix the sample with 2.54 fluid ounces (75 ml) of 7 pH water.
(c) Test the pH of the mixture.
(d) If the pH is less than 6.5, do the clean out procedure.
(2) Do the clean out procedure.
(a) Empty the solvent from the vapor degreaser.
(b) Air out the degreaser with a fan, compressed air, or a blower until all of the solvent is gone.
(c) Scrape or brush off corrosion products and other residue on all of the equipment.
(d) Flush all equipment with a mixture of sodium carbonate and water. The mixture should have 8 ounces (227 g) of sodium carbonate for every
1.0 gallon (3.78 l) of water.
(e) Completely dry out all equipment.
(f) Refill the reservoir with solvent.
(g) You need to check the acid acceptance value of the solvent daily until it stabilizes above 0.15. If the acid acceptance value drops below 0.08
in the first three days, take 20 to 25 percent of the solvent out and replace it with new solvent.
4. Ultrasonic Solvent Clean
WARNING: Read the manufacturers MSDS before you use any solvent cleaner.
A. Types
(1) Type I - Alkaline Cleaners should be used on all nonmetallic parts.
(a) Amberclean L-12
(b) Turco 3878
(c) Turco 3878 LF-NC.
(2) Type II - Solvent Cleaners should be used on metallic parts.
(a) Isopropyl Alcohol - TT-I-735
(b) Trichloroethylene - O-T-634.
(1) This cleaning method is for when impacted solids, such as buffing compounds, must be removed from small and/or expensive, such as precision-
type parts or instrument parts, and when removal of solid particles is mandatory, such as in electronic parts.

(2) When flammable cleaning solutions are used, tank covers must be used when the tank is not in operation.
(3) Holding tanks should have a fume hood for volatile liquids and for heated water solutions.
(4) Baskets must be of as large a mesh as possible so the basket does not interfere with the cleaning process.
(5) An air heater and blower or and oven that can hold a minimum temperature of 200°F (93°C) is recommended to dry parts.
(6) Follow the installation, operation, and maintenance of all equipment as provided by the manufacturer.
(7) There must be at least 2.0 inches (50.8 mm) of liquid above the top of the transducers while the equipment is in use.
(8) Parts, racks, or baskets must not touch the surface of the transducers while in use.
(9) The cleaning solution and water rinse must be kept clean by periodic or continuous filtration or replacement.
C. Procedures
(1) To make sure that the ultrasonic cleaner operates as efficiently as possible, do the Manual Cleaning and/or Vapor Degrease the parts.
(2) For Type I cleaners, dilute the mixture in the tank as recommended on the cleaner label. Do not dilute Type II cleaners.
(3) Turn on the ultrasonic cleaner and let it run for 5 minutes before you put any parts in.
(4) Place the parts in the basket such that no air pockets will form when the basket is lowered into the cleaning solution.
(5) Fully immerse the parts into the cleaning solution.
(6) Let the parts clean for a minimum of 3 minutes.
(7) Remove the basket from the cleaning solution.
(8) Let the parts fully drain.
(9) For Type I solutions, rinse the parts with warm tap water.
(10) Flush parts, except those cleaned with Amberclean L-12, with isopropyl alcohol.
(11) Fully dry parts with an air heater and blower or and oven that can hold a minimum temperature of 200°F (93°C).

FUEL, WEATHER, PRESSURE AND HIGH-TEMPERATURE SEALING - MAINTENANCE PRACTICES

1. General
A. This section describes fuel, weather, pressure, and high-temperature sealant type and class designations, and what each
type/class combination is to be used for. This section also contains definitions, safety precautions, application instructions,
and lists of approved sealants.
A. For the tools and equipment, that are not sealants or sealant aids, that are used in this section, refer to Standard Practices
- General.
3. Definitions
A. The definitions that follow give basic information about terms used when sealants are used. This list does not include all
terms related to sealants, only some key terms.
(1) Absolute Sealing - There can be no leakage permitted. All openings of any type through the seal plane are correctly
sealed. This is the first level of sealing. All holes, slots, joggles, fasteners, and seams must be sealed.
(2) Accelerator (Activator) - An agent which makes the sealant cure faster.
(3) Application Time - The length of time sealant stays flexible or useful for application to structure by brush, extrusion
gun, spatula, or roller.
(4) Base Compound - The primary component of a two-part sealing compound. It is mixed with the accelerator before
application to make a fuel, temperature, pressure, weather, and/or firewall sealing material.
(5) Brush Coat - Apply a protective coating or continuous film of sealing compound by use of a brush.
(6) Electrical Seal Fitting - A device used for sealing electrical wires which pass through bulkheads, etc. Not to be used
through the integral fuel tank wall.
(7) Fay Seal or Faying Surface Seal - A seal to stop leakage made when sealant is put between mating surfaces of
structure. Precaution must be used to prevent metal chips or dirt at the faying surface.
(8) Fillet Seal - Sealant material applied at the seam, joint, or fastener after the assembly has all of the permanent
fasteners installed and must agree with the dimension in the applicable figure.
(9) Hole - An opening that has no depth, such as a tool hole. Holes that are through the seal plane must be metal filled
with a fastener, gusset, or patch.
(10) Injection Seal - When sealant is put into a void or cavity after assembly to fill channels.
(11) Integral Tank - When structure and sealant material are put together which makes a tank that can contain fuel without
a bladder.
(12) Intermediate Seal - The second level of sealing. All holes, slots, joggles, and seams in the seal plane must be sealed.
A minor amount of leakage is permitted and it is not necessary that permanent fasteners be sealed.
(13) Post-Assembly Seal - A seal that is applied after the structure is assembled (fillet and injection seals).
(14) Preassembly Seal - Sealant material that must be applied during or before the assembly of the structure (faying
surface and pre-pack seals).
(15) Pre-pack Seal - An assembly seal made before installation, used to fill voids and cavities. It can be a primary seal
used to supply seal continuity when used with a fillet seal. It can be used as a backup seal to hold a fillet across a
void. Fill all of the space to be pre-packed. Its use as a primary seal must be kept to a minimum.
(16) Primary Seal - Sealant material that prevents leakage and becomes a continuous seal plane. This seal directly
touches the fuel, fumes, air, acid, etc. A fillet seal usually is used as a primary seal.
(17) Sealant - A compound applied to make a seal to prevent leakage.
(18) Seal Plane - A surface made of structure, sealant, and fasteners on which the continuity of seal is made sure of.
(19) Shank Sealing - Sealant compound must be applied to the hole or to both the shank and the under-head area of the
fastener in sufficient quantity that the entire shank has a layer. A small continuous bead of sealant is extruded out
around the complete circumference of each end of the fastener when installed. The fastener must be installed within
the time necessary for the sealing compound used.
(20) Squeeze-Out Life - The length of time sealant stays applicable for structure assembly in faying surface seal
application.

(21) Tack-Free Time - Tack-free time is a step, during the cure of the sealant compound, after which the sealant
compound is no longer tacky. When the sealant compound is pushed tightly with the knuckles, but no longer bonds to
the knuckles, the sealant compound is tack-free.
4. Safety
A. The safety precautions that follow are to be obeyed to prevent personal injury or damage to the airplane or parts.
WARNING: Read the manufacturers material safety data sheet (MSDS) before you use any sealant or solvent.
(1) Cleaning solvents and sealants must be used in a well ventilated area that is away from excessive heat, open flames,
and sparks. Smoking is prohibited in all areas where cleaning solvents and sealants are to be used.
(2) Cleaning solvents must be dispensed from approved containers. Solvent-wetted cloths and used solvents must be
disposed of in a special container that is provided solely for that purpose.
(3) Make sure that you use all personal protective equipment (PPE) that the manufacturer MSDS call out when cleaning
solvents and sealants are used.
(4) Never use a metal knife or razor blade to trim, remove, scrape, or otherwise conduct any other cleaning or sealant
operation.
(5) Make sure that you fully wash your hands before you eat or smoke after you have handled cleaning solvents or
sealants.
(6) Food must never be stored, cooked, or consumed near cleaning solvents or sealants. Never use a microwave to thaw
frozen sealant.
A. When work is done with sealants, obey the requirements that follow:
(1) Unmixed sealants in storage at temperatures above 80°F (27°C) must be used within five weeks.
(2) Frozen sealants must be allowed to thaw to room temperature in ambient air or warm, clean water before use.
(3) Mixed, frozen sealants which have been returned to the correct temperature are not to be refrozen.
(4) Complete fit, file, drill, countersink, dimple, and deburr preassembly operations before cleaning and sealant
application.
(5) Surfaces must be clean and dry, free from dust, lint, grease, chips, oil, condensation, or other moisture and all other
substances that cause contamination before sealant is applied. For instructions on how to clean many material types,
refer to General Solvents/Cleaners - Maintenance Practices.
(6) Sealant materials may be applied to unprimed or primed surfaces. Primers must have good adhesion to the
substrate material and must cure at least 48 hours before the sealant is applied. Adhesive bonding primer must be
scuffed and cleaned before the sealant is applied.
(7) Type 1, Class B (AMS-S-8802) and Type XII sealants are the only sealants which may be used on plastic
transparencies.
(8) Sealant applied by the fillet or brush coat methods must always be applied to the pressure side of a joint if possible.
(9) After application, sealants must be free of air bubbles and must not have poor adhesion. All fillets must be smooth
and pushed into the seam or joint with a filleting tool before the sealant application time has expired.
(10) Where sealant has been applied to the shank or under the head of fasteners:
(a) Extruded sealant must be found around the complete periphery of the fastener to show correct sealing.
(b) Sealant extruded through a hole by a rivet must be wiped from the end of the rivet before it is attached.
(c) Threaded fasteners which have had sealant applied to their shank or under the head must not be torqued after
the application time of the sealant has expired.
(d) Sealant must be removed from the threads before to torque is applied. Turn the nut rather than the bolt when
torque is applied, if possible.
(11) Do not do a pressure test until the sealant is fully cured.
(12) Sealant must not be applied over ink, pencil, or wax pencil marks. If these materials are in the sealing area, they must
be removed.
(13) If sealing is to be done over primer and the primer is removed during the cleaning process, it is allowed to seal
directly over the cleaned area and then touch up the exposed areas after the sealant has been applied and is tack

free.
(14) Do not touch or move a sealed structure until the sealant is tack free (sealant may be dislodged or have the adhesion
damaged). Too much vibration of the structure, such as riveting, engine run up, etc., is not permitted.
(15) Drilling holes and installing fasteners through a fay sealed area must be done during the working life of the faying
sealant or the entire shank and area under fastener head must be fay sealed.
6. Material Classification and Use
A. Type of Sealants - Sealants are in different categories by type of use. Class designation are used to separate sealants
with different properties within the same type. The dash number that follows the class (i.e. A-2, B-1/2, C-20, ect.) is used to
tell you the minimum application time in hours for class A and B and the assembly time in hours for class C. The different
classes, grades, and types are as follows:
(1) Classes
(a) Class A - Sealant which can be applied with a brush.
(b) Class B - Sealant which can be applied with an extrusion gun, spatula, etc.
(c) Class C - Sealant which can be applied on a faying surface.
(2) Grades
(a) Grade 1 - Sealant is a polythioether polymer (Type XII) or has a specific gravity between 1.20 and 1.35 (Type
XIII).
(b) Grade 2 - Sealant is a polysulfide polymer (Type XII) or has a specific gravity between 1.06 and 1.19 (Type XIII).
(c) Grade 3 - Sealant has a specific gravity between 1.05 or less (Type XIII).
(3) Types
(a) Type I - Fuel, Pressure, and Weather sealant.
(b) Type IV - Firewall Sealant. This material is for use when it does not touch fuel regularly and for intermittent
temperature uses up to 500°F (260°C), but is not applicable for pressure sealing.
(c) Type V - Extreme High-Temperature Sealant. This material is for use when it does not touch fuel regularly and
for intermittent uses up to 600°F (316°C) and is also applicable for pressure sealing. They are for fillet sealing
only. They are not for pressure sealing.
(d) Type VI - Water-Tight and Weather-Tight Sealant. These materials are for use where there is no fuel, high
temperature, or pressure.
(e) Type VIII - Low Adhesion Access Door Sealant. This Class B sealant is for sealing faying surfaces where easy
separation of the joined surfaces is required. The sealant has low adhesion and makes a gasket that shapes
itself to fill all defects between two surfaces. The sealant is unusually resistant to fuels, greases, water, most
solvents, and hydraulic oil as well as other oils.
(f) Type IX - Fluorosilicone RTV Sealant. This sealant is a room temperature sealant that will vulcanize and
withstand the touch of fuel.
CAUTION: Type X sealant must not be used in any application where it will contact fuel.
(g) Type X - Corrosion Inhibitive Sealant. These materials are two-part, synthetic rubber compounds, that cure at
room temperature. They are used to seal and coat metal components for protection against corrosion.
(h) Type XI - Sealant Tape. These materials are permanently flexible and can be used to set windshields before
they are sealed or to seal covers.
(i) Type XII - Windshield and Window Sealant. These materials are two-part, synthetic rubber compounds that cure
at room temperature. They are used to seal glass, polycarbonate, or acrylic transparencies.
(j) Type XIII - Low-Density (1.35 specific gravity maximum) Fuel Tank Sealant. This material is manganese dioxide
cured, for applications at service temperatures of -65° to 250°F (-54° to 121°C).
(k) Type XIV - Fast Cure, Intermediate Density (1.45 specific gravity maximum), Fuel Tank and Fuselage Sealant.
This material is manganese dioxide cured, for applications at service temperatures of -65° to 250°F (-54° to
121°C) with intermittent excursions to 360°F (182°C).
NOTE: No manufacturing substitutions are permitted for Type XIV sealant.
(l) Type XV - Electrically Conductive Sealant. These materials are synthetic rubber base materials that cure by the
addition of a separate manganese curing compound and do not depend on solvent evaporation for cure. These

materials are room temperature curing and are used in the sealing and coating of metal components for
electrical conductivity.
NOTE: Electrically conductive sealant is not permitted in fuel immersion applications.
B. Approved Sealants
(1) All approved types, classes, and grades of sealants can be found in Table 201.
Table 201. Approved Sealants
Designation Type Class Manufacturer Use
A-2 To use for weather
B-1/2, B-2, B-4 and pressure sealing
P/S 890
C-8/20, C-8/48, C- and integral fuel tank
8/80 PRC-DeSoto sealant.
Valencia, CA 91355 To use for weather
A-1/2, A-2
and pressure sealing
PR-1440 B-2, B-4
and integral fuel tank
C-8/20
sealant.
To use for weather
A-1/2, A-2
CS 3204 B-2, B-4
Flamemaster and integral fuel tank
C-8/48
Corporation sealant.
Pacoima, CA 91331- To use for weather
2315 and pressure sealing
CS 3204R I B-1/2
sealant.
To use for weather
AC-236 B-1/2, B-2, B-4
3M Company sealant.
3M Center
St. Paul, MN 55144 To use for weather
AC-240 B-1/2
sealant.
Royal Adhesives & To use for weather
Sealants and pressure sealing
WS-8020 B-1/2, B-1, B-2, B-4
Wilmington, CA and integral fuel tank
90744 sealant.
D. Aircraft, Inc. To be used as a
DAPCO 2100 IV B
Anaheim, CA 92807 firewall sealant.
Momentive
RTV-102
Performance
RTV-103 To be used as a
Materials Inc.
RTV-108 A Waterford, NY 12188 general purpose
adhesive sealant.
732 RTV Dow Corning
734 RTV Midland, MI 48686
To be used as a
moderate
SS-69A B temperature, up to
500°F (260°C),
Silicone Solutions adhesive/sealant.
Cuyahoga Falls, OH
V 44224

AS-157 To be used as a high-

AS-159 C strength, high-peel
adhesive/sealant.
To be used as a non-
General Electric
corrosive, high-
RTV 162 E Huntersville, NC
strength
28078
adhesive/sealant.
To be used as a high-
temperature, fuel, oil
Silastic 730 F Dow Corning
and solvent resistant
adhesive/sealant.
H.B. Fuller Company
FA-0606-770
St. Paul, MN 55116 To be used as a
VI water and weather
Schnee-Moorehead tight sealant.
SM8500
Irving, TX 75017
PR-1773 PRC-DeSoto
To be used to seal
VIII B-1/2, B-2 Flamemaster
CS3330 access doors.
Corporation
A-2
P/S 870 B-1/2, B-2 PRC-DeSoto
C-12, C-24, C-48 To be used as a
X corrosion inhibitive
3M sealant.
AC-665 B-1/2, B-2 Garden Grove, CA
92841
EP-7191T-0877 Fiber Resin Corp.
(0.062 in. x 0.5 in.) Burbank, CA 91502 To be used as a
XI weather tight window
PF5422 (0.125 in. x 3M Company sealant tape.
0.5 in.) 3M Center
To be used as a
windshield and
window sealant. PR-
PR-1829 (Grade 1)
142 adhesion
XII PRC-DeSoto promoter is
necessary.
To be used as a
PR-1425 (Grade 2) windshield and
window sealant.
PPG Aerospace
PR-1776B
PRC-DeSoto Int'l Inc. To be used as a low
PR-2007
XIII B-2 Mojave, CA 91209 density fuel tank
Royal Adhesives & sealant.
WS-8032
Sealants
B-1/2, B-2, B-4, B-6, To be used as a fast
AC-350 3M
B-12 cure, intermediate
XIV
Royal Adhesives & density fuel tank and
WS-8020RC B-1/2, B-2 fuselage sealant.
Sealants
To be used as an
Flamemaster
Chem Seal 3209 XV B-2 electrically conductive
Corporation
sealant.

C. Approved Chemical Sealant Aids

(1) Some sealant applications require other chemical aids for proper use. These sealant aids are shown in Table 202.
Table 202. Other Chemical Sealant Aids
Petrolatum, Parting
VV-P-236 Commercially Available To prevent sealant sticking.
Agent
To decrease time until sealant
Tack Accelerator P/S 815 PPG Industries, PRC-Desoto
is tack free.
Adhesion Promoter PR-142 PPG Industries, PRC-Desoto To promote bond between
Adhesion Promoter AC-137 3M sealant and airplane.
7. Cleaning
A. Surfaces to be sealed must be free from dust, lint, grease, oil, condensation or other moisture, and all other contamination.
For instructions on how to clean many material types, refer to General Solvents/Cleaners - Maintenance Practices.
8. Mixing
A. Requirements
WARNING: Read the manufacturers MSDS before you use any sealant or solvent.
(1) Sealants must be mixed or made thinner the way the manufacturer recommends and fully mixed before it is applied.
All mixed sealant must be as void free as possible.
(2) Before it is mixed, the sealing compound base and its curing agent must be brought to a temperature between 75
and 90°F (26 and 32°C) in their original unopened containers. The required mixing equipment must also be brought
to a temperature between 75 and 90°F (26 and 32°C).
B. Hand Mixing of Sealant
(1) Weigh and put the correct amount of base and curing agent, per the manufacturer's instructions, into clean, wax-free
containers immediately before they are mixed. An alternate method is to mix the sealant on a flat plate with a spatula.
The scales and weighing process must be controlled within +2 or -2 percent to make sure the quality is good.
(2) Do not let the accelerator touch the sides of the container.
(3) Materials must be accurately weighed on scales that are calibrated and maintenance done on for required accuracy.
(4) Mix the components until the color is constant and make sure not to trap air in the sealant.
(5) Move the sealant to another clean container and complete the mix.
C. Sem-Kit Mixing (Refer to Figure 201)
WARNING: Hold the cartridge firmly, but do not squeeze, because the dasher blades may go through the
cartridge and cause injury to the hand.
(1) Pull the dasher rod to the FULL OUT position so that the dasher is at the nozzle end of the cartridge.
(2) Put a ramrod in the center of the dasher rod, against the piston and push the piston in approximately 1.0 inch (25
mm).
NOTE: More force will be needed on the ramrod at the start of accelerator injection into the base
material.
(3) Move the dasher rod in approximately 1.0 inch (25 mm), then push the piston in another 1.0 inch (25 mm). Do this
action again until accelerator is supplied along the entire length of the cartridge.
NOTE: The accelerator has been fully injected into the cartridge when the ramrod is fully put into the
dasher rod.
(4) Remove and correctly discard the ramrod.
(5) Do the manual mixing as follows:
(a) Turn the dasher rod in a clockwise direction and slowly move it to the FULL OUT position to start the mixing
operation.
NOTE: Do not turn the dasher rod counterclockwise because the four-blade dasher inside the
cartridge will loosen and disconnect from the dasher rod.

(b) Continue to turn the dasher rod clockwise and slowly move it to the FULL IN position.
1 Rotate the dasher rod 90 degrees for each full-out stroke and for each full-in stroke of the dasher rod.
Approximately 50 strokes are necessary for a complete mix.
NOTE: If streaks are present in the sealant (look through the side of the cartridge), the
sealant is not completely mixed.
(c) Stop the mixing operation with the four-blade dasher at the bottom of the cartridge.
(d) Hold the cartridge vertical at the four blade dasher and turn the dasher rod counterclockwise to remove the
dasher rod.
(e) Remove the dasher rod.
(f) Turn the correct nozzle into the cartridge. If a sealant gun is to be used, install the cartridge in gun.
9. Application
A. General
(1) Use the type of sealing material required for the area being sealed when new sealant is applied. Use the same type
of sealing material as that the repair is for when sealant repairs are done.
(2) The application time of the sealing compound must be obeyed. Material which does not move easily and is difficult to
work or which does not wet the surface correctly must be discarded even though the application time has not expired.
(3) Before sealant is applied, all surfaces to be sealed must be cleaned. Refer to General Solvents/Cleaners -
(4) Premixed frozen sealants must be thawed to a temperature between 60 and 80°F (16 and 27°C) immediately before
they are applied.
(5) Sealants must not be applied when the structure or surface to be sealed is below 50°F (10°C).
B. Fay Seal - A faying surface seal must be applied only when new structure is added to the airplane and requires a faying
surface seal or when the structure and/or parts have been disassembled for causes other than an unsatisfactory seal. Fay
sealed joints must be closed and attached before the work life has expired. Sealant must push out of a fay sealed joint
when attachment is made. You can countersink and ream holes through a fay sealed joint when every other hole is held
firm by temporary or permanent fasteners. Spring-loaded, plunger-type clecos will not make sufficient pressure for the
sealant to push out. Fabrication and changes done after sealing are not recommended and must be done a minimum
quantity of times. Fasteners installed after the sealant has cured to replace temporary fasteners must be installed wet with
sealing compound.
NOTE: Fit, file, drill, dimple, and deburr pre-assembly operations must be done before clean and seal
applications are done.
(1) Immediately before the joint is closed, sealant must be applied to one mating surface of the joint with a sealant gun,
spatula, roller, or other applicable tool. Sufficient sealant must be applied so that the space between the assembled
faying surfaces is fully filled with sealant and a small quantity is pushed out in a continuous bead around the periphery
of the joint when the joint is attached. Refer to Figure 202.
(2) Put the parts in assembly position and install the fasteners in the application time or less of the faying surface sealant.
When an assembly is made where permanent-type fasteners are not possible, temporary fasteners (clecos or bolts)
can be used. When the temporary fasteners are used, they must be replaced by permanent-type fasteners before the
expiration of the work life of the faying surface sealant. The permanent fastener must be installed immediately after
each individual temporary fastener is removed.
(3) When a fillet seal is required around the periphery of a fay sealed joint, it is not necessary to remove the sealant
pushed out where the fillet is if:
(a) The material which was pushed out has been made into a small fillet configuration shape before the expiration of
the application time.
(b) When the pushed out sealant has been made into a shape, a final or full bodied seal can be applied over that
shape before the pushed out sealant cures.
(c) If the pushed out material was not made into the shape before its application time expires, it must be removed
from locations where a fillet is to be applied with a plastic tool after it is in a tack-free condition.
(4) Immediately after the assembly is completed and all of the permanent-type fasteners have been installed, use clean
rags moist with Methyl n-Propyl Ketone to remove sealant which has not cured and extrudes onto the exterior of the

airplane.
C. Fay Seal with One Surface Not Bonded - When it is required that an access panel or close out panel be able to be
removed without the seal being damaged or replaced, the fay seal must be bonded to one surface only. The sealant is
usually applied to the access panel or close out panel, unless otherwise stated. Use Type VIII sealant, unless otherwise
stated.
(1) Use cheesecloth to apply parting agent on to one of the faying surfaces. The sealant will be applied to the other faying
surface.
NOTE: Make sure that the cheesecloth with parting agent does not touch any other panels.
(2) The panel must be positioned and secured in the normal manner, within the application time of the sealant used.
(3) Do not loosen or remove the panel until the sealant has fully cured.
(4) Use a non-metallic scraper or tongue depressor to trim the cured sealant squeeze out from the exterior surfaces.
(5) Once the sealant has fully cured, remove all fasteners and open the panel carefully.
(6) Use a non-metallic scraper or tongue depressor to trim excess sealant from the interior edge of the seal to where it is
flush with the edge of the faying surfaces.
(7) Use clean rags moist with Methyl n-Propyl Ketone to remove the parting agent from the seal, structure, and panel.
(8) Remove cured sealant from fasteners and fastener holes.
D. Fay Seal Access Doors - When access doors are fay sealed, Type VIII Class B sealant is used without any parting agent.
Unless otherwise specified, the fay surface of the access door must be the chemical filmed and not primed. Type VII Class
B sealant will bond to corrosion protection epoxy primer.
(1) The access door must be installed within the application time of the sealant.
(2) Tighten fasteners to get as close as possible to metal-to-metal contact.
(3) Use a non-metallic scraper or tongue depressor to trim the cured sealant squeeze out from the exterior surfaces.
(4) For cosmetic reasons, it is permitted to brushcoat the red Type VIII sealant once it has cured.
E. Injection Seal - Sealant is forced from a pneumatic sealant gun into cavities between two or more assembled parts until
the sealant extrudes from all other openings and the cavity is full.
(1) Sealant must be put into the channel, joggle, void, or cavity from one point only. A sealant gun must be used so that no
air is caught and the channel, joggle, void, or cavity is completely filled and sealant can be seen pushed out from the
opening. Refer to Figure 203. Do not stop while the void is filled with sealant, if there is more than one exit or channel.
Make a blockage on each channel exit when it is filled, so that sealant extrudes into all of the necessary channels.
(2) Remove any sealant that was more than necessary before its application time expires and use an applicable tool to
make it smooth and flush with the surface.
F. Fillet Seal
(1) Fastener considerations:
(a) Do not fillet seal any parts until they are held completely together by permanent fasteners.
(b) Before fillet sealing the periphery of structure and fittings attached with bolts, it is necessary that they be correctly
torqued.
(2) A sealant gun or spatula must be used to apply the sealant.
(3) When a sealant gun is used for fillet sealing, the nozzle tip must be pointed into the seam or joint and must be kept
almost perpendicular to the line of travel. A continuous bead of sealant is put ahead of the tip and the tip size, shape,
and rate of travel must let sufficient sealant be applied to make the required fillet.
(4) Fillets must be in a shape or form that give the size and shape necessary that are shown in the applicable figures.
(a) Use the nozzle tip and/or fairing tools to push against the sealant while it is moved parallel to the bead.
(b) Use caution to prevent folds and caught air when the sealant is applied. Make the shape of the fillet and remove
any visible air bubbles.
(c) The fillet must be made so that the highest part of the fillet is put over the center of the edge of the structure or
fitting.
(d) Do not use any type of lubrication to make fillets smooth.
(e) The size of the fillet must always be kept as near minimum as possible.

(5) Where it is easier or the fillet has fallen, the fillet can be applied in two steps.
(a) A small first fillet is applied which is let to cure to a tack-free condition.
(b) Sufficient sealant is then applied a second time to make the final fillet agree to the specified dimensions for a
fillet seal. If the first fillet has cured, it must be cleaned before the second application of sealant is made. If the
fillet has only cured to a tack-free condition, it must be cleaned lightly with a gauze pad or cheesecloth pad damp
with cleaning solvent.
(6) Let the sealant cure to a tack-free condition before the airplane is moved, touched, and/or worked on.
(7) In conditions where a fillet seal connects to an injection seal, the full body of the fillet must extend past the end of the
injection and then have a gradual decrease in thickness.
(8) Lap joint and seam fillets must be as shown in Figure 204.
(9) Butt joint fillets must be as shown in Figure 205.
(10) Bolts must be fillet sealed as shown in Figure 206. The area for sealing must have the area of the surround structure,
the bottom of the fastener end, and all of the exposed area of the fastener. An optional procedure of sealing threaded
fasteners is to apply a brush coat of Type I, Class A sealant. When a brush coat is used as the procedure of sealing
threaded fasteners, the sealant must be carefully put around each fastener with a stiff brush to be good. Make sure
the area is brushed with sufficient sealant to make a good seal.
(11) Dome-type nutplates must be fillet sealed as shown in Figure 207. The area for sealing must have the structure that
surrounds the bottom of the fastener and from there up and over the rivets to the dome.
(12) Hole filling and slot fillets must be as shown in Figure 208.
NOTE: A hole or slot through the wall which is part of a fuel tank must not be sealed by this
procedure.
(a) Large holes or slots may have masking tape used as backing to prevent too much extrusion of sealant through
the holes or slots. The masking tape must be removed after the sealant has cured to a tack-free condition.
(b) Tooling holes must be shank sealed with a soft rivet as a plug and then do brush coat sealing with Type I, Class
A sealant.
G. Firewall Seal - Firewalls must be sealed to a middle level of sealing with the use of Type IV sealant.
(1) Clean the areas to be sealed. Refer to General Solvents/Cleaners - Maintenance Practices.
(2) Only Type IV sealants must be used for flame penetration prevention.
(3) Fillet and brush coat seals must be applied to the hot side of the firewall. All excess sealant that is squeezed out
through the mating parts or small voids must be wiped clean.
(4) Applied sealant must be smoothed and pressed into seams or joints with a fairing tool or your finger with a rubber
glove before application time expires. Small amounts of a 50/50 mixture of isopropyl alcohol and water are permitted
to smooth the seal. For best results clean the tool or glove after each swipe.
H. Shank Sealing Fasteners (Refer to Figure 209)
(1) Shank sealing is the application of sealant either to the hole or to both the shank and under the head area of a
fastener or to the outer surface of a bearing or bushing.
(2) The junction of the part and the fastener, bearing, or bushing is to have a complete layer over it.
(3) Class B sealant must be applied to the hole or to both the shank and under the head of the fastener.
(4) The entire shank must have a layer of sealant and there is to be a small quantity of sealant pushed out around the
complete periphery of each end of the fastener when installed.
(5) Fasteners must be installed within the application time of the shank sealant.
(a) Do not torque threaded fasteners again, after the application time of the sealant has expired.
(b) If the fastener is not torqued correctly before the application time has expired, it must be removed, sealed
correctly, and torqued again.
(c) Unwanted sealant at the fastener ends can be removed. However, to make sure the seal is correct, a small,
continuous quantity of sealant must stay at the periphery of the fastener ends.
I. Shank Seal Bearings, Bushings, and Miscellaneous Parts (Refer to Figure 209)
(1) If the outer surface of a bearing, bushing, or miscellaneous part is a dissimilar material from the part in which it is

installed, it must be shank sealed.

(a) Apply Class A or B sealant to the installation hole or to the outer surface of the bearing, bushing, or other
installed part.
(b) Carefully install the bearing, bushing, or other miscellaneous part.
(c) Carefully remove any unwanted sealant.
(d) To make sure that the seal is correct, a small, continuous quantity of sealant must stay around the complete
periphery of the ends of the material joint.
(e) Do not get sealant on the inner surfaces of bearings or bushings.
(f) Do not get sealant in the ball bearings of bearing assemblies.
J. Brush Coat and Daub Seal - A brush coat seal involves the application of a film of sealant with an acid brush. A daub seal
involves the application of a small amount of sealant by use of sealant gun with the appropriate tip. Type I, Class A and
Type IV (firewall only) sealant are used for brush coat seals. Type I, X, XIII, XIV, XV, and IV (firewall only) all Class B
sealants are used for daub seals. The difference between a brush coat and daub seal is the thickness. A daub seal should
be between 2 and 10 times thicker than a brush coat seal.
(1) Brush coat seals are applied with an acid brush. All brushes must be clean and dry before use. Brush coats of sealant
must be approximately 0.01 to 0.03 inch (0.25 to 0.76 mm) thick.
(2) Daub seals are applied with a sealant gun. A minimum amount of sealant must be used to make a seal that is
approximately 0.06 to 0.10 inch (1.52 to 2.54 mm) thick.
K. Wire Bundle and Connector Sealing
(1) Wire Bundle Sealing
(a) When wire bundles are continuous, pass through a bulkhead, inlet, or other obstruction, they must be sealed with
the correct type of sealant and method. The different methods for sealing wire bundles and connectors are given
here.
(b) General Procedure
1 Pass the wire bundle through the bulkhead cutout.
NOTE: Bundle ties must not be placed within 6 inches (152 mm) of a location that is to be
sealed. This is to allow better sealant penetration around wires.
2 Pull each single wire away from the rest of the wire bundle and individually coat each wire with sealant over
the length that passes through the bulkhead plus 0.25 to 0.50 inch (12.7 to 25.4 mm) on each side.
3 When the wire bundle is fully coated, pull the bundle through the bulkhead until the midpoint of where
sealant was applied is flush with the midpoint of the bulkhead.
4 Fillet seal around the between and around wires bundles, between wire bundles and the conduit, between
wire bundles and the bulkhead, and between the conduit and the bulkhead. All cavities must be filled and
the fillet of sealant must be applied so that it overlaps the edge of the bulkhead at all points on both sides of
the bulkhead, if both sides are accessible.
5 Smooth and feather back the fillet from the wire group to the edge of the bulkhead within the application
time of the sealant.
(c) Seal Fitting - If a seal fitting is used to pass the wires through the bulkhead, instead of just the bulkhead, do one
of the procedures that follow:
1 Pre-pack Method
a Pass the wire bundle through the bulkhead cutout.
NOTE: Bundle ties must not be placed within 6 inches (152 mm) of location that is to be
sealed. This is to allow better sealant penetration around wires.
b Place the seal fitting halves around the wire bundle on both sides of the bulkheads, unless otherwise
specified.
c If necessary, place polyethylene filler rods in the fitting around the outside of the wire bundle. Center
the filler rods lengthwise in the seal fitting.
NOTE: The filler rods are used so that future additions of wires do not require
disassembly of the sealed fitting.

d Wrap several turns of masking tape around the wire bundle and over the cylindrical end of the fitting.
The masking tape is to hold the wires in place and hold the sealant in when it is injected.
e Hold the seal assembly as vertical as possible with the open base end up.
f Inject sealant in the fitting around the wires. Place the sealant gun nozzle at multiple locations in and
around the bundle to be sure that you fill all openings between and around wires and the seal
assembly.
g Put a heavy bead of sealant on the inner surface of the flange of the seal fitting so that when it is place
against the bulkhead sealant will extrude between the flange and the bulkhead.
h Attach the seal assembly to the bulkhead.
i Wipe excess sealant that extruded out from in between the bulkhead and the seal assembly.
j If filler rods were used, tie them to the rest of the wire bundle within 1 inch (50.8 mm) of the base of the
seal fitting and 1 inch (50.8 mm) away from the end of the filler rod.
k After the sealant fully cures, remove the masking tape.
2 Injection Method
a Pass the wire bundle through the bulkhead cutout.
NOTE: Bundle ties must not be placed within 6 inches (152 mm) of a location that is to
be sealed. This is to allow better sealant penetration around wires.
b Place the seal fitting halves around the wire bundle on both sides of the bulkheads, unless otherwise
specified.
c If necessary, place polyethylene filler rods in the fitting around the outside of the wire bundle. Center
the filler rods lengthwise in the seal fitting.
NOTE: The filler rods are used so that future additions of wires do not require
disassembly of the sealed fitting.
d
Wrap several turns of masking tape around the wire bundle and over the cylindrical end of the fitting.
The masking tape is to hold the wires in place and hold the sealant in when it is injected.
e Attach the seal assembly to the bulkhead.
f Puncture a hole in the masking tape that is just large enough to fit the nozzle of the sealant gun into. Be
careful not to damage the wire bundle.
g Inject sealant into the hole until sealant comes out of both notches in the outer edge of the seal fitting
base.
h Wipe away all excess sealant.
i If filler rods were used, tie them to the rest of the wire bundle within 1 inch (50.8 mm) of the base of the
seal fitting and 1 inch (50.8 mm) away from the end of the filler rod.
j After the sealant fully cures, remove the masking tape.
(2) Electrical Connector Sealing - The procedures that follow are for sealing electrical connectors where protection from
moisture is required:
(a) All areas of insulation materials which contain fluorine, such as, Teflon or Kevlar, to which sealant is to adhere,
should be cleaned before they are etched. Refer to General Solvents/Cleaners - Maintenance Practices.
(b) Etch the insulation materials which contain fluorine in accordance with manufacturers instructions.
(c) Before application of sealant, check all wires to make sure they are properly attached and in the correct
position.
(d) Carefully insert the nozzle into the center of the wires. Inject the sealant keeping the nozzle slightly below the
surface of the sealant.
1 The injection shall be done slowly to allow the sealant to flow between the wires as it rises. Entrapped air
may be released by vibration or lightly tapping the receptacle on a firm surface.
2 Do not damage connector contacts.
(e) When the nozzle cannot be inserted between the wires because of spacing, insert the nozzle to one side of the
wires and as near to the center as possible without forcing.

(f)
Application continues until the mold is filled.
1 Backshells should be filled to a minimum height of 0.25 inch (6.35 mm) above the top of the longest contact
or the highest shield termination.
2 Complete filling of backshell is preferred.
(g) Trapped air within sealants must be avoided in all cases. Air bubbles act as reservoirs for moisture buildup
which may lead to short circuits.
L. Window Sealant
(1) Requirements
(a) No voids, pinholes, or bubbles are allowed in the applied sealant.
(b) Ripples or depressions are acceptable if they are gradual and a less than 0.25 inch (6.35 mm) in length and no
more than:
1 Three along the side of the window.
2 Two along the top of the window.
3 Two along the bottom of the window.
4 A total of six per window.
(c) Steps or ridges in the sealant that are greater than 0.25 inch (6.35 mm) are not acceptable.
(d) Contaminants larger than 0.06 inch (1.52 mm) in diameter are not acceptable.
(e) The width of the sealant must be constant and between 0.25 and 0.375 inch (6.35 and 9.53 mm). The width of
the sealant may not change more than 0.0625 inch (1.59 mm) in a 6 inch (152.4 mm) length.
(f) The sealant color and texture must match all other windows.
(g) No paint is allowed on the sealant area.
(h) Do not use adhesion promoter on transparencies.
(2) Type I Window Sealant - All Type I polysulfide sealants must be applied to acrylic, polycarbonate, or glass windows in
accordance with the requirements that follow:
(a) Only Class B-2 or B-4 sealant can be used.
(b) Type XI sealant tape may be used to set the window.
(c) The surface must be prepared as follows:
1 Solvent clean the window before application of sealant.
2 For glass transparencies, do not use adhesion promoter and apply the sealant immediately after the
window is cleaned.
3 For acrylic and polycarbonate transparencies, apply AC-137 adhesion promoter with and acid brush. If any
adhesion promoter touches the transparency, wipe it off immediately with cheesecloth and solvent. Allow
the adhesion promoter to dry for 15 to 30 minutes.
4 Polysulfide sealant must be applied within 4 hours after adhesion promoter dries. However if the surface
becomes contaminated, it must be cleaned and adhesion promoter must be reapplied.
(3) Type XII Window Sealant - PR-142 adhesion promoter must be used with this type of sealant, except for glass
transparencies. When using Type XII sealant on glass transparencies, you must apply the sealant immediately after
you solvent clean the surface.
M. Integral Fuel Tank Sealant
NOTE: Integral fuel tank sealing or leak repair must be done with Type I sealant only.
NOTE: Integral wing fuel tank sealing is related to the fuel sealing process. With an integral fuel tank, the
fuel is kept only in a sealed cavity in the wing structure.
(1) Integral Fuel Tank Sealing With Type I Sealant
(a) All damaged or areas with leakage must be fully and carefully repaired.
(b) Clean areas with a clean cheesecloth damp with solvent. Brushes or pipe cleaners can be used to clean
corners, gaps, joggles, and channels.
(c) After application, the sealant must be free of air bubbles caught in the sealant.

(d) All fillets are to be made smooth and pushed into the seam or joint with a filleting tool.
(e) The sealant must be tack-free and 50 percent more time than necessary for normal cure time must be given
before refueling.
(f) The sealant must be cured before pressure testing is done.
N. Aerodynamic Smoothing Compound
(1) Application of aerodynamic smoothing compound applies to filling of joints only. For other applications, refer to the
applicable Structural Repair Manual.
(2) Cleaning of Joints
(a) Clean the joint with a small brush and Methyl n-propyl Ketone.
(3) Application of Aerodynamic Smoothing Compound
(a) Apply aerodynamic smoothing compound directly into the joint so that the compound extrudes ahead of the
nozzle tip and sealant fills the bottom of the joint. Refer to Figure 210.
(b) It is recommended that masking tape be applied to each side of the joint before to sealant application. This will
help clean up.
(c) The aerodynamic smoothing compound has a two-hour application time and will be tack-free within 24 hours.
Sanding may be done within 72 hours at room temperature.
(d) After the tack-free time is complete, remove the masking tape, if used.
(e) Sand the seal smooth after it has cured.
10. Sealant Curing
A. Room Temperature
(1) Room temperature curing properties are based on a temperature of 77°F, +5 or -5°F (25°C, +3 or -3°C) and a
relative humidity of 50 percent unless otherwise shown. An increase in temperature or relative humidity may shorten
application time, work life, tack-free time, and curing time. The curing properties for each Type of sealant is as
follows:
(a) Type I
1 Room temperature curing properties of Type I sealants are given in Table 203.
Table 203. Curing Properties of Type I Sealant
Class Minimum Minimum Work Maximum Tack- Maximum Curing
Application Life (Hours) Free Time (Hours) Time (Hours)
Time (Hours)
A-1/2 0.5 - 10 40
A-2 2 - 40 72
B-1/2 0.5 - 4 6
B-2 2 - 40 72
B-4 4 - 48 90
C-20 8 20 96 168 (7 days)
C-48 12 48 120 (5 days) 336 (14 days)
C-80 8 80 120 (5 days) 504 (21 days)
(b) Type IV
1 Room temperature curing properties of Type IV sealants are given in Table 204.
Table 204. Curing Properties of Type IV Sealant
Class Maximum Tack-Free Time Maximum Curing Time (Hours)
(Minutes)
B 15 48
(c) Type V

1 Room temperature curing properties of Type V sealants are given in Table 205.
Table 205. Curing Properties of Type V Sealant
Maximum Tack-Free Maximum Curing Time
Class Material
Time (Minutes) (Hours)
RTV-102
RTV-103 60
A RTV-108
732 RTV 25
734 RTV 20 72 (3 days)
B SS-69A 30
AS-157
C 120
AS-159
E RTV-162 360
F Silastic 730 30 168 (7 days)
(d) Type VI
1 Room temperature curing properties of Type VI sealant are: Tack-Free Time 2 Hours (Maximum), Curing
Rate 16 Hours (Maximum).
(e) Type VIII
1 Room temperature curing properties of Type VIII sealants are given in Table 206.
Table 206. Curing Properties of Type VIII Sealant
Class Minimum Application Maximum Tack-Free Maximum Curing Time
Time (Hours) Time (Hours) (Hours)
B-1/2 15 10 24
B-2 15 24 72
(f) Type X
1 Room temperature curing properties of Type X sealants are given in Table 207.
Table 207. Curing Properties of Type X Sealant
Time (Hours) NOTE Time (Hours) (Hours)
1
B-1/2 15 18 24
B-2 20 24 48
C-12 20 120 (5 days) 336 (14 days)
C-24 20 180 (7.5 days) 504 (21 days)
C-48 20 360 (15 days) 1344 (56 days)
NOTE 1: Not less than 20 grams per minute (15 grams per minute for B-1/2) will be extruded.
(g) Type XI sealant tape is a moldable solid and does not need to cure.
(h) Type XIII
1 Room temperature curing properties of Type XIII sealants are given in Table 208.
Table 208. Curing Properties of Type XIII Sealant

Class Grade Material Minimum Maximum Tack- Maximum

Application Free Time Curing Time
Time (Hours) (Hours)
(Hours)
B-2 1 PR-1776M 50 16 24
2 PR-2007 9 10
WS-8032
(i) Type XIV
1 Room temperature curing properties of Type XIV sealants are given in Table 209.
Table 209. Curing Properties of Type XIV Sealant
Class Material Minimum Maximum Tack- Minimum Maximum
Application Free Time Extrusion Rate Curing Time
Time (Hours) (Hours)
(Hours)
AC-350 30 5 5 g/min at 1 hour 5
B-1/2
WS-8020RC 40 5 5 g/min at 1 hour 5
AC-350 35 9 5 g/min at 3 10
hours
B-2
WS-8020RC 35 9 5 g/min at 3 10
hours
B-4 AC-350 30 32 5 g/min at 6 32
hours
B-6 AC-350 45 36 5 g/min at 10 36
hours
B-12 AC-350 35 96 5 g/min at 18 96
hours
(j) Type XV
1 Room temperature curing properties of Type XV sealants are given in Table 210.
Table 210. Curing Properties of Type XV Sealant
Time (Hours) Time (Hours) (Hours)
B-2 20 40 72
B. Accelerated Curing
(1) Accelerated curing of sealant can be done in several ways. The procedures for accelerated cure of each type and
class is as follows:
(a) Type I, Classes A-1/2 and B 1/2 - Let stand at room temperature for 1 hour, then heat at 120 to 130°F (49 to
54°C) for 5 to 6 hours. Higher humidity will accelerate the cure time.
(b) Type I, Classes A-1 to A-4 and B-1 to B-4 - Let stand at room temperature for 1 hour, then heat at 120 to 130°F
(49 to 54°C) for 8 hours. Higher humidity will accelerate the cure time.
(c) Type I, Class C - Let stand at room temperature for 1 hour, then heat at 120 to 130°F (49 to 54°C) for 8 hours.
Higher humidity will accelerate the cure time.
(d) Type IV - Cure the material at 75°F (26°C) for 72 hours, then heat at 120 to 130°F (49 to 54°C) for 6 hours.
(e) Type VIII - Let stand at room temperature for 48 hours, then cure at 140°F for 24 hours. Higher humidity will
accelerate the cure time.
(f) Type X, Class B - Let stand at room temperature for 1 hour, then heat at 120 to 130°F (49 to 54°C) for 8 hours.
Higher humidity will accelerate the cure time.

(g) Type XII, Grade 1, PR-1829 - Heat up to 130°F (54°C). The cure time will be half for every 18°F (10°C) above or
doubled for every 18°F (10°C) below. Humidity has no effect on cure time.
(h) Type XII, Grade 2, PR-1425 - Heat up to 130°F (54°C). The cure time will be half for every 10 to 15°F (6 to 8°C)
above or doubled for every 10 to 15°F (6 to 8°C) below. Lower humidity will increase cure time.
(i) Type XIII - Let stand at room temperature for 1 hour, then heat at 120 to 130°F (49 to 54°C) for 8 hours. Higher
humidity will accelerate the cure time.
(2) Type V, VI, IX, X, Class C, XI, XIV, and XV sealants do not have procedures for accelerated cure.
11. Sealant Repair
A. Repairs usually must be done with the same type of material as that of the repair.
NOTE: Type I, Class B-1/2 is recommended for use during cold weather to get a faster cure.
B. Fillet and Fastener Sealant Repairs
(1) Repair of damaged or defective sealant applications must be done as follows:
(a) Remove all damaged or defective sealant to make sure that solid material remains.
(b) Sealant must be cut so it makes a smooth continuous scarfed face. Refer to Figure 211. The sealant must be
completely removed in those areas. The cutting tools must be made from nonmetallic materials that are softer
than aluminum.
(c) Examine repair areas for clean and smooth cuts. Loose sealant on the cut areas must be removed.
(d) Clean the area to be sealed with the scarfed face of the old seal. Refer to General Solvents/Cleaners -
(e) Apply new fillet seals. Refer to Sealing Application, Fillet Sealing in this section. A small overlap of the new
material over the fillet already there is required. Do not let large buildup of sealant occur. Type VI sealant may be
used over Type I, II, and III sealant, but not for the integral fuel tank sealing. Type VI will cure faster for weather
and pressurization repairs.
(f) When a fillet which has been oversprayed or brushed with primer is done again, it must use a scarfed joint and
the fillet that has primer on it removed in the area of the repair. The primer must not be put between the old and
new sealants.
(g) If the primer is removed during the cleaning operation, it is permitted to apply the new fillet seal directly over the
clean bare metal and then use the correct primer on all of the areas of bare metal after the sealant has been
applied.
C. Faying Surface Sealant Repair - It is only permitted to apply a fillet seal along the perimeter of a fay seal that leaks or is
damaged if either of the two fay surfaces will be damaged if the two parts are separated. If the two parts can be operated
with out any damage to either, the parts must be separated, the old seal must be removed and a new seal applied.
D. Brush Coat Sealant Repair - Clean the area where the sealant is to be applied and the surrounding structure. Refer to
General Solvents/Cleaners - Maintenance Practices. Apply a new brush coat of sealant within the sealant application time.
E. Daub Sealant Repair - Daub seal repair is done by removing the leaking or damaged daub seal with a non-metallic
scraper. Clean the area where the sealant is to be applied and the surrounding structure. Apply a new daub seal within the
sealant application time. It is also permitted to clean the damaged daub seal and apply another daub or brush coat seal
over it as long as the seal is properly applied to where there is no air trapped between the old and new seal.

Figure 201 : Sheet 1 : Two-Part Sealant Cartridge

A100347
Cartridge
Four-Blade Dasher
Dasher Rod
Base Material
Accelerator
Piston
Dasher Handle
Ramrod
NOTE: Cartridge is disposable after use.
5580T1044

Figure 202 : Sheet 1 : Fay Sealing

A100348
Faying Surface Seal
Sealant Sealant
(NOTE 1) (NOTE 1)
Sealant Sealant
(NOTE 1) VIEWA-A (NOTE 1)
NOTE 1: The sealant must be extruded continuously.

6998T1001
AA6998T1002

Figure 202 : Sheet 2 : Fay Sealing

A100349
Faying Surface Seal

(NOTE)
Prepack and Faying Surface Seal Application on a Joggle
Fay Seal Squeeze-Out
Fay Seal Squeeze-Out
Prepack and Faying Surface Seal Assembly with Proper Squeeze-Out
NOTE: A prepack seal can be applied to either surface.

6998T1003

Figure 203 : Sheet 1 : Injection Sealing

A100350
Injection is complete
when sealant emerges
from this side.

Figure 204 : Sheet 1 : Lap Joints and Seam Fillets

A100351
A
T B
W
DETAIL A
Lap Joint Fillet
H W B
DETAIL B
Seam Fillet
DETAIL B T A W H
0.149 Inch 0.020- 0.125- 0.250-

A (3.78 mm) 0.040 Inch 0.250 Inch 0.375 Inch -
Maximum (0.51-1.01 mm) (3.2 - 6.4 mm) (6.4 - 9.5 mm)
0.150 Inch 0.250- Approximately

(3.81 mm) - - 0.375 Inch Dimension B. 0.375
B Inch (9.5 mm)
Minimum (6.4 - 9.5 mm) Maximum
NOTE: All fillets must be kept to the minimum dimensions if possible.
6998T1004

Figure 205 : Sheet 1 : Butt Joint Fillets

A100354
A
F T
E B
DETAILA
F
B H
DETAILB
DETAIL B A F E
0.149 Inch 0.149 Inch
(3.78 mm) 0.125 - 0.250 Inch 0.125 - 0.250 Inch
A (3.2 - 6.4 mm) (3.78 mm) (3.2 - 6.4 mm)
Maximum Maximum
0.150 Inch 0.150 Inch
B (3.81 mm) - (3.81 mm) -
Minimum Minimum
DETAIL T C H
0.50 Inch
A 0.020 - 0.040 Inch (12.7 mm)
(0.5 - 1.0 mm) -
Maximum
0.50 Inch Approximately Dimension
B - (12.7 mm) B. 0.250 Inch (6.35 mm)
Maximum Maximum
NOTE: In all cases, minimum fillet dimensions are shown.

Fillet size must be kept to the minimum dimensions if possible.
6280T1003

Figure 206 : Sheet 1 : Bolt Head, Nut and Thread Sealing

A100355
0.15 - 0.18 Inch 0.06 - 0.08 Inch

0.06 - 0.08 Inch (3.8 - 4.6 mm) (1.5 - 2.0 mm)
(1.5 - 2.0 mm)
Bolt Head
0.15 - 0.18 Inch

(3.8 - 4.6 mm)
0.06 - 0.08 Inch

(1.5 - 2.0 mm) 0.06 - 0.08 Inch
(1.5 - 2.0 mm)
Nut and Thread
6280T1003

Figure 207 : Sheet 1 : Dome Type Fillets

A100356
0.06 Inch
(1.5 mm)
Minimum
0.06 Inch
(1.5 mm)
Minimum
0.15 - 0.18 Inch
(3.8 - 4.6 mm) Packing
Rivet
NOTE: In all cases, minimum fillet dimensions are shown.

Fillet size must be the minimum dimensions, if possible.
6280T1003

Figure 208 : Sheet 1 : Slot, Hole, and Mismatch Sealing

A100357
0.25 Inch 3W
Pressure (6.4 mm)
Side Maximum
Pressure
3W Side
0.25 Inch 0.25 Inch

(6.4 mm) W (6.4 mm)
W Maximum Maximum
Hole
3W
Slot 0.25 Inch

3W (6.4 mm)
Maximum
Pressure
Side W
W 0.25 Inch
(6.4 mm) Maximum
Mismatch
5598T2006

Figure 209 : Sheet 1 : Shank Sealing

A100358
Sealant
Fastener
Bushing Outer Surface

(With Sealant Applied)
Bushing
Bearing Outer Surface

(With Sealant Applied)
Bearing
6998T1005

Figure 210 : Sheet 1 : Aerodynamic Joint Compound

A100359
Aerodynamic Joint
Compound
6591T1009

Figure 211 : Sheet 1 : Fillet Seal Repair

A100360
30º
30º
Complete Removal
Notched Cleanly

Figure 211 : Sheet 2 : Fillet Seal Repair

A100361
< 90º
Incorrect Fillet Edge - Reentrant Edge
> 90º
Correct Fillet Edge - Non-Reentrant Edge
6998T1007

ADHESIVE AND SOLVENT BONDING - MAINTENANCE PRACTICES

1. General
A. This section describes adhesive type and class designations, and what each type/class combination is to be used for.
This section also contains definitions, safety precautions, application instructions, and lists of approved adhesives.
A. For the tools and equipment, that are not adhesives or bonding solvents, that are used for this section, refer to Standard
Practices - General.
3. Definitions
A. The definitions that follow give basic information about terms used when adhesives are used. This list does not include all
terms related to adhesives, only some key terms.
(1) Adherends - Materials that are adhesively bonded.
(2) Adhesive - A substance that can hold materials together by surface attachment. Adhesive is a general term that
includes cement, glue, mucilage, and paste.
(3) Batch - A quantity of material that was formed by the same procedure or in one continuous procedure and has the
same properties everywhere. A discrete quantity of material with a total commonality of raw materials and process
history.
(4) Contact Adhesive - An adhesive which is applied to both adherends, allowed to dry to a tacky condition, and when
the adherends are brought together without constant pressure, a bond is made.
(5) Curing Agent/Catalyst/Hardener - A material or mixture of materials that are added to the adhesive base to promote
the curing reaction. The curing agent is the material that goes into the reaction, the catalyst does not.
(6) Handling/Fixture Time - The period of time after which support tooling or pressure used during cure may be removed.
Load application should be small until full cure is achieved.
(7) Hot Melt Adhesive - An adhesive that is applied in a molten state and forms a bond when it cools to a solid state.
(8) Lot - A specified quantity of material made at one time by the same procedure at the same conditions and sold as a
unit quantity.
(9) Mix Ratio - The parts by weight or volume of base to catalyst.
(10) Pot/Work Life - The period of time when an adhesive stays usable after it has been mixed with the catalyst.
(11) Mechanical Life - The amount of time, for a 1 part adhesive, that it takes for a adhesive to start to cure after it has
been removed from storage.
(12) Pressure Sensitive Adhesive - An adhesive that immediately bonds to adherend surfaces with the application of
pressure.
(13) Shelf Life - The length of time that material can be kept at a specific temperature and still meet design requirements.
(14) Solvent Bonding/Cementing/Welding - The procedure of bonding thermoplastics with the application of a solvent that
is able to soften the surfaces to be joined when the softened surface are pushed together.
(15) Tack - The property of an adhesive which allows it to form a bond of measurable strength immediately after the
adhesive and adherend make contact under low pressure.
(16) Toughened Adhesive - An adhesive that was designed to be more elastic, less brittle.
4. Safety
A. The safety precautions that follow must be obeyed to prevent personal injury or damage to the airplane or parts.
WARNING: Read the manufacturers material safety data sheet (MSDS) before you use any adhesive or solvent.
(1) Solvents and adhesives must be used in a well ventilated area that is away from excessive heat, open flames, and
sparks. Smoking is prohibited in all areas where solvents and adhesives are to be used.
(2) Solvents must be dispensed from approved containers. Solvent-wetted cloths and used solvents must be disposed of
in a special container that is provided solely for that purpose.
(3) Make sure that you use all personal protective equipment (PPE) that the manufacturer MSDS call out when solvents
and adhesives are used.
(4) Make sure that you fully wash your hands before you eat or smoke after you have handled solvents and adhesives.
(5) Food must never be stored, cooked, or consumed near solvents and adhesives. Never use a microwave to thaw

frozen adhesive.
A. When work is done with adhesives and solvents, obey the requirements that follow:
(1) For all storage and shelf life requirements, refer to Adhesives, Cements and Sealants Shelf Life and Storage -
Description and Operation.
(2) Tightly close all containers when not in use.
(3) Surfaces to be bonded must be free from dust, lint, grease, oil, condensation or other moisture, and all other
contamination. For instructions on how to clean many material types, refer to General Solvents/Cleaners -
(4) Bonding strength will be improved for composite, plastic, and rubber if you first clean the surface with a mild
detergent, then lightly abrade it to remove surface glass, and finally solvent clean.
(5) Frozen adhesives must be allowed to thaw to room temperature in ambient air or warm, clean water before use.
(6) Bonds must be free of wrinkles and entrapped air bubbles. They must not be loose at the edges or show poor
adhesion.
(7) Adhesives must not be applied when the temperature of either the adhesive or the surfaces to be bonded is below
65°F (18°C).
6. Material Classification and Use
A. Types of Adhesives - Adhesives are in different categories by type of use. Class designation are used to separate
adhesives with different properties within the same type. The different classes and types are as follows:
(1) Type I, Epoxy
(a) High strength bonding of metals, composites, honeycomb core, most plastics, and wood.
(b) Class A - A one-part, thermosetting, non-volatile, epoxy-paste adhesive used for structural bonding of composite
or metal surfaces.
(c) Class B - A two-part, room temperature curing paste adhesive that is primarily for use in structural bonding
applications.
(d) Class C - A two-part, room temperature curing adhesive with high-temperature (350°F or 177°C) shear
properties intended for use in structural bonding applications.
(e) Class D - An initial high-tack adhesive.
(f) Class E - A two-part fast-cure adhesive.
(g) Class F - A two-part filler.
(h) Class G - A two-part conductive paste adhesive.
(i) Class H - A two-part elastomeric paste adhesive.
(j) Class I - A two-part paste for low-temperature interior applications.
(k) Class J - A two-part paste for high-temperature interior applications.
(2) Type II, Neoprene Rubber
(a) Bonds synthetic rubber, cork, leather, or fabric to metal, wood, and some plastics.
(b) Class A - Solvent-base petroleum oil resistant adhesive to bond neoprene rubber to a metallic surface.
(c) Class B - Water-base petroleum oil resistant adhesive to bond neoprene rubber to a nonmetallic surface.
(3) Type III, Nitrile Rubber
(a) Bonding synthetic rubber, cork, leather, or fabric to themselves, metal, wood, and some plastics where fuel and
petroleum resistance is required.
(b) Class A - A fuel and petroleum oil resistant rubber cement adhesive.
(c) Class B - A fuel and petroleum oil resistant rubber cement coating.
(4) Type IV, Synthetic Resin
(a) Bonding metals and many thermoplastics.
(5) Type V, Silicone Rubber
(a) High-temperature (400 to 500°F or 205 to 260°C) bonding or sealing applications. These adhesives are the

only type suitable for bonding cured silicone parts.

(b) Class A - General Purpose
(c) Class B - High-Temperature.
(d) Class C - High-Strength/Peel.
(e) Class E - Noncorrosive, High-Strength.
(f) Class F - High-Temperature, Fuel, Oil, and Solvent Resistant.
(6) Type VI, Solvent Cementing
(a) Used for cementing thermoplastics to themselves.
(7) Type VII, Cyanoacrylate Adhesive
(a) Part fixturing and other fast-cure bonding of most metals, plastic, and rubber.
(b) Class A - General Purpose Instant Adhesive.
(c) Class B - Toughened Instant Adhesive.
(8) Type VIII, Pressure Sensitive Adhesive
(a) Bonding interior trim panels, placards, and other interior parts.
(9) Type IX, Polyurethane Adhesive
(a) Bonding polyurethane to metals and other plastics.
(b) Class A - One-Part.
(c) Class B - Two-Part.
(10) Type X, Acrylic Plastic Adhesive
(a) Bonding metals, glass, and some thermoplastics.
(11) Type XI, Hot Melt
(a) Bonding polyolefin plastics to metals, other plastics, wood, and hardboard.
(12) Type XII, Duco/Velcro
(a) General purpose, low strength bonding.
(b) Class A - Duco Cement.
(c) Class B - Velcro.
B. Approved Adhesives
(1) All approved types and classes of adhesives can be found in Table 201. All solvents that are approved for solvent
cementing applications can be found in Table 202.
Table 201. Approved Adhesives
Designation Type Class Manufacturer Full Cure Time Use
3M Company
EC-2214 40 Minutes at
3M Center To be used for
EC-3445 250°F (121°C)
St. Paul, MN 55144 structural bonding of
I A
Henkel Corporation composite or metal
EA-9304.1 60 Minutes at surfaces.
Bay Point, CA
EA-9346.5 350°F (177°C)
94565-0031
EA-9309.3 NA
3-5 Days To be used for
EA-9314 NA
I B Henkel Corporation structural bonding
EA-9330.3 applications.
5-7 days
EA-9339
To be used for high-
temperature (350°F
EA-9394
I C Henkel Corporation 3-5 Days or 177°C) structural
EA-9396
bonding
applications.

To be used for
SIA Adhesives, Inc.
applications when
A-1186-B I D Akron, OH 44311- 8 Hours
an initial high tack is
1081
required.
Ciba-Geigy
Corporation
Fastweld 10 4 Hours To be used for
Miami, FL 33142-
3926 applications that
I E
require a fast cure
608 Epoxy Patch Henkel Corporation 24 Hours
time.
Polystrate 5-Minute Devcon
16 Hours
Epoxy Corporation
Danvers, MA To be used to fill a
Aluminum Putty 01923-3786 7 Days
surface that has
I F
voids or is uneven
EA-960F Henkel Corporation 24 Hours
in some way.
Dayton-Granger To be used in
16307 Fort Lauderdale, FL 24 Hours applications where
33335 the surfaces that
I G are to be adhered
Dexter-Hysol need to be
KE4238/HD3475 24 Hours electrically
Olean, NY 14760
conductive.
To be used in
applications where
15348 I H Dayton-Granger 48 Hours
an elastomeric
paste is required.
Magnobond 6162 To be used in
interior applications
that require
intermediate
I I viscosity and up to
Magnolia 6166 160°F (71°C)
maximum
continuous service
life.
To be used in
Magnolia Plastics that require
Inc. intermediate
Magnolia 6398-5 Chamblee, GA viscosity and up to
30341 200°F (93°C)
maximum
continuous service
7 Days life.
To be used in
that require low
I J viscosity and up to
Magnolia 6167
200°F (93°C)
maximum
continuous service
life.

To be used in
that require low
3M Company viscosity and up to
EC-3531 B/A FR
3M Center 160°F (71°C)
maximum
continuous service
life.
Midwest Industrial To be used in
See Manufacturer
Vangrip 14-30 Chemical applications where
Information
St. Lous, MO 63110 neoprene is to be
Scotch-Grip 1357 A 15 Minute Dry Time joined to a metal
Neutral per Coat surface and a
petroleum oil
Scotch-Grip 1300L resistant is needed.
II
Fastbond 30-NF To be used in
3M Company
applications where
3M Center See Manufacturer neoprene is to be
B Information joined to a
Fastbond 2000-NF nonmetallic surface
and a petroleum oil
resistant is needed.
To be used as a
10 Minute Dry Time
Scotch-Weld 847 A fuel and petroleum
3M Company per Coat
resistant adhesive.
3M Center
EC-776
24 Hours
EC-776SR III To be used as a
Flamemaster fuel and petroleum
B
Corporation resistant
CS-3600 10 Minute Dry Time adhesive/coating.
Pacoima, CA
91331-2315
Scotch-Grip 2262
7 Days To be used to bond
Plastic Adhesive 3M Company
IV metals and many
Scotch-Grip 4693 3M Center
24 Hours thermoplastics.
Plastic Adhesive
Momentive
RTV-102 Performance
RTV-103 Materials Inc. To be used as a
RTV-108 A Waterford, NY general purpose
12188 adhesive sealant.
732 RTV Dow Corning
734 RTV Midland, MI 48686
To be used as a
3 Days
moderate
SS-69A B temperature (up to
Silicone Solutions 500°F or 260°C)
Cuyahoga Falls, OH adhesive/sealant.
V 44224 To be used as a
AS-157 high-strength, high-
AS-159 C
peel
adhesive/sealant.

To be used as a
General Electric
non-corrosive, high-
RTV 162 E Huntersville, NC
strength
28078
adhesive/sealant.
7 Days To be used as a
high-temperature,
Silastic 730 F Dow Corning fuel, oil and solvent
resistant
adhesive/sealant.
To be used as a
general purpose
Loctite 495 A 24 Hours
Loctite Corp. quick-cure
VII Newington, CT adhesive.
06111 To be used as a
Black Max 380 B 5 Days high-strength quick-
cure adhesive.
950 Transfer Tape
4930 VBH Tape 3M Company
Tape 4945 VBH 3M Center
4962 Scotch-Mount
To be used to bond
1191 UHA Avery Dennison
interior trim panels,
FasTape Corp.
VIII - Not Applicable placards, and other
3099 UHA St. Painesville, OH
interior
FasTape 44077
applications.
American National
Rubber Co.
4111N Foam Tape
Huntington, WV
25776-7338
Thixon 405 A Dow Corning 30-50 Minutes
Hartel Enterprises
Inc.
HE17017 7-10 Days To be used to bond
La Canada
polyurethanes to
IX Flintrige, CA 91011
B metals and other
Uralane 8089 A/B Advanced Materials 16-24 Hours plastics.
(Huntsman)
Uralane 5774 A/B The Woodlands, TX 7 Days
77380
PS-18 A,B,C Cadillac Plastic and To be used to bond
PS-30 A, B Chemical Co. metal, glass, and
X Southfield, MI 24 Hours some
325/707 48033 thermoplastics to
Loctite Corp. each other.
To be used to bond
Bostik Inc. polyolefin plastics to
Hot Melt 6363 XI Middleton, MA When Cool metal, other plastic,
01949 wood, and
hardwood.

Devcon Inc. To be used for

Duco Cement A 16 Hours
Danvers, MA 01923 general, low-
XII
Velcro Industries strength
Velcro #40 B 24 Hours applications.
Boulder, CO 80302
Table 202. Approved Solvents for Solvent Cementing
Solvent Approved for Use On Thermoplastic Trade Name
Acrylic/PVC Kydex
Acetone
Cellulose-Acetate-Butyrate (CAB) Tenite Butyrate
Acrylic/PVC Kydex
Cyclohexane
CAB Tenite Butyrate
Acrylonitrile-Butadiene Styrene (ABS) Cycolac, Lustran, Royalite
Ethylene Chloride
CAB Tenite Butyrate
Acrylic Acrylite, Plexiglass, Poly II, Poly 84
Acrylic/PVC Kydex
Methylene Chloride
CAB Tenite Butyrate
Polycarbonate Lexan, Merlon, Tuffak
ABS Cycolac, Lustran, Royalite
Acrylic/PVC Kydex
Methyl Propyl Ketone (MPK)
CAB Tenite Butyrate
Polyester Hytrel, Kodar PETG
Tetrahydrofuran Acrylic/PVC Kydex
7. Cleaning
A. Surfaces to be bonded must be free from dust, lint, grease, oil, condensation or other moisture, and all other
contamination. For instructions on how to clean many material types, refer to General Solvents/Cleaners - Maintenance
Practices.
8. Mixing
A. Requirements
WARNING: Read the manufacturers MSDS before you use any adhesive or solvent.
(1) For two-part adhesives, you must get both parts of the adhesive in the correct ratio provided by the manufacturer. You
can use a scale when ratios are required by weight and a volume measuring tool, such as a measuring cup, when the
ratio is required by volume.
(2) Make sure that you know what the pot life of the adhesive is before you mix it. Do not use the adhesive after the pot
life provided by the manufacturer.
(3) Thoroughly mix both components together until the adhesive is a uniform color. No streaks are allowed.
(4) If you mix a smaller batch or use a shallow container for the adhesive, the pot life will be longer.
(5) All Type V, Type VII, XI, and XII are one-part adhesives that do not need to be stirred before use. All other one-part
adhesives should be stirred before use.
9. Application
A. The consistency of the adhesive must be such that it can be applied with a spatula, knife coat, notched trowel, or extrusion
tool.
B. Type I, Class B
(1) Uniformly apply the adhesive to both surfaces to be bonded to a thickness of approximately 0.01 to 0.02 inch (0.25 to
0.51 mm) with a spatula, roller, or brush.
(2) Tightly clamp or fix the two bonding surfaces together for the entire work life of the adhesive.

(3) Wipe excess adhesive away with a clean, dry cloth.

(4) Do not remove any adhesive from under the edge of the faying surfaces.
C. Type I, Class D, Type II, Type III, Type IV, and Type XII, Class B
(1) Apply a thin, even coat of adhesive to both surfaces to be bonded with an application tool such as a spatula, knife
coat, notched trowel, or extrusion tool.
(2) Let the adhesive dry until it is still tacky, but will not transfer to your finger if you touch it. You can let Type II and Type III
fully dry and reactivated with a cloth that is dampened with MPK.
(3) Place the two surfaces together then push or roll tightly to make sure the surfaces fully contact each other.
NOTE: You may need to apply another coat of adhesive if one or both of the surfaces based on
material and geometry. If this is the case, allow the first coat to fully dry before you apply the
second coat.
D. Type I, Class F - Epoxy Filler
(1) Apply the epoxy filler with a spatula or similar tool.
(2) Allow the epoxy filler to fully cure for at least 4 hours.
(3) Sand down the cured epoxy filler to the desired size, shape, and finish.
E. Type I, Class I and J
(1) If the adhesive is packaged in a side by side cartridge to be extruded by an EPX Applicator Gun or pneumatic
extrusion system, extrude some adhesive until both sides are uniform.
(2) Make sure that there are no air bubbles present when you mix the adhesive.
(3) Attach a 21 Element Static Mixing Nozzle to the end of the cartridge.
(4) Apply mixed adhesive directly to the bonding surfaces within the manufacturers work life.
(5) For fast cure adhesives, the 21 Element Static Mixing Nozzle must be changed for every 3 minutes of continuous
extrusion of adhesive and when there is interruption of extrusion in one single application.
(6) With a spatula, or similar tool, spread the adhesive to a thickness of approximately 0.01 to 0.02 inch (0.25 to 0.51
mm).
(7) You must maintain pressure within the work life of the adhesive.
(8) Remove excess adhesive with a clean dry cloth.
(9) Do not remove any adhesive from under the edge of the faying surface.
(10) If there is adhesive left in the cartridge, leave the last 21 Element Static Mixing Nozzle on the cartridge as a way to
seal off the adhesive that remains.
F. Type VI - Solvent Cementing
(1) Apply the solvent to the surfaces to be bonded with a brush, clean cloth, felt pad, or spray bottle. Refer to Table 202
for what type of solvent should be used to solvent bond different plastic types.
(2) Push the softened surfaces together until the solvent fully evaporates and the plastic hardens. If necessary, you can
place the surfaces in a fixture while you wait for the plastic to harden.
NOTE: You can thicken the solvent by adding small particles of the plastic to be bonded to it.
G. Type VII - Cyanoacrylates
(1) Apply the adhesive to one surface. Use the smallest amount of adhesive needed to fill the joint. One drop will spread
2
approximately 1.0 square inch (645.16 mm ) when the surfaces are pushed together.
(2) Tightly push the two surfaces to be bonded together.
(3) Hold pressure until the adhesive sets. The set time could be from a few seconds up to 5 minutes, depending on the
bonding surfaces.
H. Type VIII - Pressure Sensitive Tapes
(1) Lay tape on the bonding surface, sticky side down.
NOTE: Do not apply this adhesive at temperatures below 50°F (10°C).
(2) Tightly push or roll the tape in place.
(3) Remove the backing from the tape. Only do this right before you are to adhere the other bonding surface to the tape.

(4) Tightly push or roll the other bonding surface.

I. Type XI - Hot Melt Glue
(1) Load the Hot Melt Gun with stick adhesive.
(2) Plug the Hot Melt Gun into a 110 V AC outlet.
CAUTION: Do not touch the nozzle of the hot melt gun or melted adhesive, they can be up to 410°F
(210°C).
(3) Let the Hot Melt Gun warm up until adhesive comes out of the nozzle when you squeeze the trigger.
(4) Pull the trigger to apply adhesive to the hardest bonding surface with the nozzle in contact with the surface.
(5) When you are done, release the trigger and wipe the nozzle against the surface to prevent the adhesive from stringing
off of the surface.
(6) Close the prefitted joint as quickly as possible.
J. All other Types/Classes
(1) Apply the adhesive to bonding surfaces.
(2) Tightly squeeze the bonding surfaces together to squeeze out excess adhesive.
(3) Wipe off excess adhesive with a clean, dry cloth.
(4) Fixture or clamp bonding surfaces together until the adhesive reaches its handling time.
10. Adhesive Curing
A. Type I, Class A
(1) These adhesives are a one-part thermosetting adhesive. They require the application of heat to cure. Table 201
contains how long and at what temperature that the bonding surfaces need to be in an oven for the bond to be fully
cured.
B. All other Types/Classes
(1) All other adhesives listed in Table 201 can be cured at room temperature. The time until full cure at room temperature
is given in Table 201. In most cases, the application of heat will accelerate the cure process. Heat can be applied by
heat gun, or oven. Accelerated curing instructions for any adhesive can be found from the manufacturer.
(2) Some Type II and Type III adhesives need to be applied, allowed to dry, then bonded. Once the bonding surfaces
touch, the bond is complete, there is no cure time. Make sure that you carefully read all manufacturer instructions.

ANAEROBIC ADHESIVES - MAINTENANCE PRACTICES

1. General
A. This section describes anaerobic adhesive and primer groups, classes, and grades, and what each group, class, and
grade is used for. This section also contains definitions, safety precautions, application instructions, and lists of approved
anaerobic adhesives and primers.
A. For the tools and equipment, that are not anaerobic adhesives or primers, that are used for this section, refer to Standard
Practices - General.
3. Definitions
A. The definitions that follow give basic information about terms used when anaerobic adhesives and primers are used. This
list does not include all terms related to anaerobic adhesives and primers, only some key terms.
(1) Adhesive - A substance that can hold materials together by surface attachment. Adhesive is a general term that
includes cement, glue, mucilage, and paste.
(2) Anaerobic Adhesive - An adhesive that cures in the absence of oxygen.
(3) Handling/Fixture Time - The period of time after which support tooling or pressure used during cure may be removed.
Load application should be small until full cure is achieved.
(4) Lot - A specified quantity of material made at one time by the same procedure at the same conditions and sold as a
unit quantity.
(5) Shelf Life - The length of time that material can be kept at a specific temperature and still meet design requirements.
4. Safety
A. The safety precautions that follow must be obeyed to prevent personal injury or damage to the airplane or parts.
WARNING: Read the manufacturers material safety data sheet (MSDS) before you use any adhesive, primer, or
cleaning solvent.
(1) Anaerobic adhesives contain methacrylate ester, which may irritate sensitive skin. If any comes into contact with your
skin, wash immediately.
(2) Anaerobic adhesives, primers, and cleaning solvents must be used in a well ventilated area that is away from
excessive heat, open flames, and sparks. Smoking is prohibited in all areas where anaerobic adhesives, primers,
and cleaning solvents are to be used.
(3) Solvents must be dispensed from approved containers. Solvent-wetted cloths and used solvents must be disposed of
in a special container that is provided solely for that purpose.
(4) Make sure that you use all personal protective equipment (PPE) that the manufacturer MSDS call out when anaerobic
adhesives, primers, and cleaning solvents are used.
(5) Make sure that you fully wash your hands before you eat or smoke after you have handled anaerobic adhesives,
primers, and cleaning solvents.
A. When work is done with anaerobic adhesives, primers, and cleaning solvents, obey the requirements that follow:
(1) For all storage and shelf life requirements, refer to Adhesives, Cements and Sealants Shelf Life and Storage -
(2) Tightly close all containers when not in use.
(3) All surfaces that are to be bonded and/or sealed must be free of paints and corrosion preventive organic coatings.
(4) Surfaces, including hardware, to be bonded must be free from dust, lint, grease, oil, condensation or other moisture,
and all other contamination. For instructions on how to clean many material types, refer to General Solvents/Cleaners
(5) Anaerobic adhesives and primers must not be applied when the temperature of either the adhesive, primer, or the
surfaces to be bonded are below 60°F (16°C).
(6) Enough anaerobic adhesive must be used so that a small excess will squeeze out when all of the associated parts
are tightened and secure.
(7) Primers are used to increase cure speed and fill the gaps better.

6. Approved Materials
A. Approved Anaerobic Adhesives and Primers
(1) All approved anaerobic adhesives and primers are Loctite brand, made by the Henkel Corporation. The Henkel
Corporation is located in Rocky Hill, CT 06067. Each adhesive is in a series based on its use, those series are as
follows:
(a) 200 Series materials are threadlocking materials that are used to seal threaded fasteners.
(b) 500 Series materials are thread sealing materials that are used to seal metal tubes to prevent leaks.
(c) 600 Series materials are retaining compounds used to seal non-threaded gaps.
(d) 7000 Series materials are primers.
(2) All approved anaerobic adhesives and primers can be found in Table 201.
Table 201. Adhesives and Applications
Loctite Product Color Recommended Application
Number Primer
Low-strength adhesive to lock and seal threaded fasteners
222MS Purple T or N that are 0.25 inch (6.3 mm) and smaller. Removable with
hand tools.
Medium-strength adhesive to lock and seal threaded
242 Blue T or N fasteners that are 0.25 inch (6.3 mm) diameter or larger.
Removable with hand tools.
Medium-strength adhesive to lock and seal threaded
fasteners that are 0.25 to 0.75 inch (6.3 to 19.1 mm) in
243 Blue T or N
diameter. Removable with hand tools. Oil resistant version of
242.
High-strength adhesive to lock and seal threaded fasteners
(removable). Good for fasteners subjected to heavy shock,
262 Red T or N
vibration, and stress levels. Removable with heat and hand
tools.
High-strength adhesive to lock and seal threaded fasteners
271 Red T or N
up to 1.0 inch (25.4 mm) diameter.
High-viscosity, high-strength adhesive to lock and seal
277 Red T or N threaded fasteners up to 1.0 inch (25.4 mm) diameter and
larger.
Adhesive to lock and seal pre-assembled threaded fasteners
290 Green T or N
that works by capillary action. Also used to seal welds.
Medium-strength adhesive to seal threaded hydraulic and
pneumatic fittings up to 2.0 inches (50.8 mm) in diameter.
569 Brown T
Resists high pressures and vibration. Not recommended for
use on plastic tubing.
Adhesive to immediately seal pipe threads and threaded
592 White NF fittings. Has lubricant and is resistant to continuous
temperatures up to 400°F (204°C).
Low-viscosity, adhesive that cures fast to assemble press
609 Green T or N and slip-fit parts. Can be used on slip-fits up to 0.005 inch
(0.1 mm) diametral clearance.
High-temperature, high viscosity adhesive to lock
620 Green T
components at temperatures up to 450°F (230°C).
660 Silver T or N For repair of worn machinery parts.

Medium-viscosity, high-strength adhesive to lock components

680 Green T
and cure quickly.
736 Primer NF Brown - A primer that acts very fast.
7471 Primer T Yellow - A primer that acts fast.
7649 Primer N Green - A general purpose primer.
7. Cleaning
A. Surfaces to be primed and bonded must be free from dust, lint, grease, oil, condensation or other moisture, and all other
contamination. For instructions on how to clean many material types, refer to General Solvents/Cleaners - Maintenance
Practices.
8. Application
WARNING: Read the manufacturers MSDS before you use any adhesive, primer or cleaning solvent.
A. Primer Application
(1) Make sure that you use the correct primer for the anaerobic adhesive that you need to use. Refer to Table 201,
Recommended Primer.
(2) Spray a thin, uniform layer of primer on the surfaces that you are going to bond and/or seal. Do not use too much
primer.
(3) Let all primed parts fully drain and air dry.
B. Adhesive Application
(1) If it is possible, apply the adhesive to bonding surfaces.
(2) Apply enough adhesive so that a small excess will be squeezed out when the joint is fully tightened.
(3) Fully tighten the joint immediately.
(4) Remove the excess adhesive with a solvent dampened cloth. Refer to General Solvents/Cleaners - Maintenance
Practices.
9. Anaerobic Adhesive Curing
A. The factors that follow affect the cure time of anaerobic adhesives:
(1) Activity of surfaces
(2) Clearance in joint fit
(3) Adhesive used
(4) Primer used
(5) Temperature.
B. All anaerobic adhesives will be fully cured after 24 hours at room temperature 77°F (25°C).
C. Heat can be applied to the joint to reduce cure time.
D. Read the manufacturers label for more information on cure times.

ADHESIVES, CEMENTS AND SEALANTS SHELF LIFE AND STORAGE - DESCRIPTION AND OPERATION
1. General
A. This section provides information which defines the proper storage and usable life (shelf life) of adhesives, cements, and
sealants which are used for maintenance and/or repair of the airplane. Also included in this section are the criteria used for
testing these materials after the normal shelf life has expired to determine if an extension to the shelf life is possible.
B. Shelf life refers to a specified period of time that starts on the date of manufacture and ends on the expiration date. The
date of manufacture is normally stamped or printed on the product container. The expiration date is found using the limits
specified in Table 1, or if applicable, the manufacturer's expiration date printed or stamped on the product container. The
specified shelf life is dependent on proper storage in accordance with the limits specified in this section and/or the
manufacturer's instructions. When the age of the material is calculated, the month that the product was shipped or
manufactured is not counted.
2. Storage Criteria
A. Storage of Adhesives and Cements
(1) All adhesives and cements must be stored under controlled temperature conditions. If open shop storage becomes
necessary, these products must in no case be stored in an area which will subject them to temperatures in excess of
95°F (35°C). Containers must be tightly closed before placing them in the proper storage environment. For the
definition of the proper storage environment, refer to Table 1 and the following paragraphs. For identification of
adhesive and cement classifications, refer to Adhesive and Solvent Bonding - Maintenance Practices.
(a) Class I - These are epoxy base materials and have 1 year storage at room temperature. 0°F (-18°C) storage
temperature will extend the storage life. Refer to the product container instructions for storage temperature and
life.
(b) Class II, III, and IV - These are rubber and resin base materials and have 6 months storage at room temperature.
40°F (4°C) storage temperature will extend the storage life. Refer to the product container instructions for
storage temperature and life.
(c) Class V - These are silicone rubber base materials and have 1 year storage at temperatures below 80°F
(27°C). Refer to the product container instructions for storage temperature and life.
(d) Class VI - These are solvent bonding solvent materials and must be stored at 40°F (4°C) in their initial
containers. Refer to the product container instructions for storage temperature and life.
(e) Class VII - These are Cyanoacrylate base materials and must be stored at 40°F (4°C) in their initial containers.
Refer to the product container instructions for storage temperature and life.
(f) Class VIII - These are pressure sensitive materials and have 2 years storage at 75°F (24°C) and 50 percent
relative humidity. Refer to the product container instructions for storage temperature and life.
(g) Class IX - These are polyurethane materials and must be stored between 70 and 100°F (21 and 38°C) in their
initial containers. Urethanes are moisture sensitive and precautions should be taken to prevent moisture
contamination. Refer to the product container instructions for storage temperature and life.
(h) Class X - These are acrylic base materials and must be stored at 40°F (4°C). Refer to the product container
instructions for storage temperature and life.
B. Storage of Sealants
(1) All sealants must be stored in controlled temperature conditions. If open shop storage becomes necessary, these
products must in no case be stored in an area which will subject them to temperatures more than 95°F (35°C) or less
than 40°F (4°C). Containers must be tightly closed before placing them in the proper storage environment. For the
proper storage environment, refer to Table 1, and the following paragraphs. For identification of sealant classification,
refer to Fuel, Weather, Pressure and High-Temperature Sealing - Maintenance Practices.
(a) Premixed and frozen sealants must be stored as follows:
1 The materials stored at temperatures of -40°F (-40°C) or colder must not be used more than 6 weeks after
the date of mixing.
2 The materials stored at temperatures between -40°F (-40°C) and -30°F (-34°C) may be stored for a
maximum of 2 weeks at temperatures more than -40°F (-40°C), in addition to the time at -40°F (-40°C) or
colder for a combined total storage time not to exceed 5 weeks beyond the date of mixing.
3 The materials stored at temperatures between -40°F (-40°C) and -20°F (-28°C) may be stored for a

maximum of 1 week at temperatures more than -30°F (-34°C) in addition to the time at -40°F (-40°C) or
colder for a combined total storage time not to exceed 4 weeks beyond the date of mixing.
(b) Unmixed sealants must be stored at a controlled temperature range between 40 and 80°F (4 and 27°C).
Unmixed sealants usually have a shelf life of 6 to 12 months when stored within this temperature range. Unmixed
sealants stored at temperatures more than 80°F (27°C) must be used within 5 weeks
C. All materials must be used within their shelf life, extended shelf life, or expiration date. The adhesives, cements, and
sealants should be rotated so this requirement can be accomplished. All material containers should be clearly marked with
a "use by" date, consisting of the year and month. All materials not used by this date must be tested before use. Refer to
Testing Criteria and Table 1.
3. Testing Criteria
A. Any material (adhesive, cement, or sealant) not opened or used within its shelf life will be tested and the results reviewed
to determine if the material is usable. If there is doubt about the material being usable, it must be properly discarded.
Material that has exceeded its initial shelf life may be retested to determine if the material meets its requirements.
Materials meeting their requirements will have their shelf life extended as specified in Table 1.
B. Testing Overage of Adhesives and Cements
NOTE: Overage adhesives and cements are those that have exceeded their initial shelf life and must be
tested before use and/or given extended shelf life.
(1) For identification of adhesive and cement classification, refer to Adhesive and Solvent Bonding - Maintenance
Practices.
(a) Class I Epoxy Adhesive - Examine both components to ensure that they are still workable. Check for gelling
and/or contamination. Stir components and mix a small amount of adhesive. Verify that adhesive sets up and
hardens.
(b) Class II, III, and IV Rubber and Resin Base Adhesive - Open containers and check for gelling and/or
contamination. Check for spreading and drying.
(c) Class V Silicone Rubber Adhesive - Examine adhesive for hardness. If adhesive is still soft and can be spread,
it is acceptable. Verify that adhesive will harden.
(d) Class VI Solvent Bonding Solvent - Check for signs of apparent contamination. Solvents should be clean and
clear with no signs of cloudiness.
(e) Class VII Cyanoacrylic Base Adhesive - Verify that product is still liquid with no visible signs of contamination.
(f) Class VIII Pressure Sensitive Material - Open containers and inspect for hardening, gelling, and contamination.
Stir components and mix a small amount of adhesive. Verify that adhesive sets up properly.
(g) Class X Acrylic Adhesive - Inspect base material to ensure that it is still liquid. Mix a small amount of the
components and verify that it sets up properly.
(2) In general, if these materials exhibit normal physical properties, with no signs of hardening, gelling, or contamination
and set up and/or harden properly as applicable, the shelf life may be extended as specified in Table 1.
C. Testing Overage of Sealants
NOTE: Overage sealants are those that have exceeded their initial shelf life and must be tested before use
and/or given extended shelf life.
(1) For identification of sealant classification, refer to Fuel, Weather, Pressure and High-Temperature Sealing -
(2) Overage sealants to be tested for possible shelf life extension must be properly mixed using the correct materials,
procedures, and equipment.
(3) Overage premixed frozen sealants, along with unmixed sealants should be visually inspected. Sealant appearance
which shows conclusive signs of separation, discoloration, and/or gelling before the addition of a thinner or curing
agent must be discarded. When in doubt of the sealant quality, the overage sealant should be compared with the
same type of sealant, under six months old, which is known to be satisfactory.
(4) The mixed sealants may be tested by placing a small amount of sealant (sample buttons) on a sheet of paper. After
the sample buttons have cured, they should be cut in half and examined. The sealant should show no signs of spots or
streaks of unmixed base compound or curing agent. However, sample buttons containing spots, streaks,
discoloration, and/or variations in uniformity of color are acceptable if these spots, streaks, etc., are tack free upon

inspection. All mixed sealant should be as void free as possible.

(5) Contaminated sealant and premixed sealant that have been thawed and refrozen must be discarded.
(6) In order for a sealant to have its shelf life extended, it must meet specific requirements based on type.
(a) Type I sealant must meet requirements for appearance and application time.
(b) Type IV sealant must meet requirements for appearance, application time, tack-free time, and cure time.
(c) Type V sealant must meet requirements for cure time and hardness. These materials may only have their shelf
life extended once.
(d) Type VI sealant must meet requirements for cure time.
(e) Type VIII sealant must meet requirements for appearance, application time, tack-free time, cure time, and
adhesion.
(f) Type X sealant must meet requirements for appearance and application time.
(g) Type XI sealant must meet requirements for pliablility and tack.
(h) Type XIII sealant must meet requirements for appearance and application time.
(i) Type XIV sealant must meet requirements for appearance, application time, tack-free time, extrusion rate, and
cure time.
(j) Type XV sealant must meet requirements for appearance and application time.
Table 1. Storage and Shelf Life of Adhesives, Cements, and Sealants
Product Storage Condition Shelf Life Extend Shelf Life Retest In
(Temperature)
Adhesives And Cements
AF-126-2 Less than 10°F (-12°C) 6 Months 3 Months 3 Months
CS-3600 35 to 85°F (2 to 29°C) 12 Months 6 Months 6 Months
Devcon F 40 to 80°F (4 to 27°C) 12 Months 6 Months 6 Months
DP-820 35 to 85°F (2 to 29°C) 12 Months 6 Months 6 Months
EA-9304.1 Less than 10°F (-12°C) 6 Months 3 Months 3 Months
EA-9309.3 NA 35 to 85°F (2 to 29°C) 12 Months 6 Months 6 Months
EA-9314 NA 35 to 85°F (2 to 29°C) 12 Months 6 Months 6 Months
EA-9330.3 35 to 85°F (2 to 29°C) 12 Months 6 Months 6 Months
EA-9339 35 to 85°F (2 to 29°C) 12 Months 6 Months 6 Months
EA-9628 Less than 10°F (-12°C) 6 Months 3 Months 3 Months
EA-9690 Less than 10°F (-12°C) 12 Months 6 Months 6 Months
EC-3531 B/A FR 35 to 85°F (2 to 29°C) 12 Months 6 Months 6 Months
EC 776 35° to 85°F (2 to 29°C) 12 Months 6 Months 6 Months
EC 776R 35 to 85°F (2 to 29°C) 6 Months 3 Months 3 Months
EC-847 35 to 85°F (2 to 29°C) 17 Months 7.5 Months 7.5 Months
EC-2214 Less than 0°F (-18°C) 12 Months 6 Months 6 Months
EC-2262 35 to 85°F (2 to 29°C) 15 Months 7.5 Months 7.5 Months
EC-3445 Less than 10°F (-12°C) 6 Months 3 Months 3 Months
EC-9346.5 Less than 0°F (-18°C) 6 Months 3 Months 3 Months
Fastbond 20000-
35 to 85°F (2 to 29°C) 15 Months 7.5 Months 7.5 Months
NF

Fastbond 30-NF 35 to 85°F (2 to 29°C) 12 Months 6 Months 6 Months

Fastweld 10 40 to 80°F (4 to 27°C) 12 Months 6 Months 6 Months
FM-300 Less than 10°F (-12°C) 6 Months 3 Months 3 Months
FM-73C Less than 10°F (-12°C) 6 Months 3 Months 3 Months
FM-73C-OST Less than 10°F (-12°C) 6 Months 3 Months 3 Months
Loctite 222MS 35 to 85°F (2 to 29°C) 24 Months Not Applicable Not Applicable
Loctite 242 35 to 85°F (2 to 29°C) 24 Months Not Applicable Not Applicable
Loctite 736 Primer
35 to 85°F (2 to 29°C) 24 Months Not Applicable Not Applicable
NF
Loctite 7471 Primer
T
Loctite 7649 Primer
N
L303-XL Less than 0°F (-18°C) 6 Months 3 Months 3 Months
Magnabond 6162 35 to 85°F (2 to 29°C) 12 Months Not Applicable Not Applicable
Magnabond 6166 35 to 85°F (2 to 29°C) 12 Months Not Applicable Not Applicable
Magnolia 6167 35 to 85°F (2 to 29°C) 12 Months Not Applicable Not Applicable
Magnolia 6398-5 35 to 85°F (2 to 29°C) 12 Months Not Applicable Not Applicable
Pliogrip 7779 35 to 85°F (2 to 29°C) 12 Months Not Applicable Not Applicable
PS-18 40 to 80°F (4 to 27°C) 12 Months 6 Months 6 Months
PS-30 40 to 80°F (4 to 27°C) 12 Months 6 Months 6 Months
Scotch-Grip 1300L 60 to 80°F (16 to 27°C) 15 Months 7.5 Months 7.5 Months
Scotch-Grip 1357 35 to 85°F (2 to 29°C) 15 Months 7.5 Months 7.5 Months
Scotch-Weld 847 35 to 85°F (2 to 29°C) 15 Months 7.5 Months 7.5 Months
Vangrip 14-30 35 to 85°F (2 to 29°C) 12 Months 6 Months 6 Months
608 Quickset 40 to 80°F (4 to 27°C) 12 Months 6 Months 6 Months
732 RTV 35 to 85°F (2 to 29°C) 15 Months 7.5 Months Not Applicable
734 RTV 35 to 85°F (2 to 29°C) 12 Months 6 Months Not Applicable
Sealants
AC-236 40 to 80°F (4 to 27°C) 9 Months 4.5 Months 4.5 Months
AC-240 40 to 80°F (4 to 27°C) 12 Months 6 Months 6 Months

AC-350 Less than -40F (-40C) 6 Weeks 3 Weeks 3 Weeks

AC-665 B 35 to 85°F (2 to 29°C) 6 Months 3 Months 3 Months
AS-157 35 to 85°F (2 to 29°C) 12 Months 6 Months Not Applicable
AS-159 35 to 85°F (2 to 29°C) 12 Months 6 Months Not Applicable
CS 3204 40 to 80°F (4 to 27°C) 9 Months 4.5 Months 4.5 Months
CS 3204R 40 to 80°F (4 to 27°C) 9 Months 4.5 Months 4.5 Months
CS-3209 40 to 80°F (4 to 27°C) 9 Months 4.5 Months 4.5 Months
CS 3330 35 to 85°F (2 to 29°C) 9 Months 4.5 Months 4.5 Months
CS3100 40 to 80°F (4 to 27°C 9 Months 4.5 Months 4.5 Months
Dapco 2100 35 to 85°F (2 to 29°C) 6 Months 3 Months 3 Months
EP-7191T-0877 35 to 85°F (2 to 29°C) 3 Months 1.5 Months 1.5 Months
FA-0606-770 40 to 85°F (4 to 29°C) 12 Months 6 Months 6 Months
PF5422 35 to 85°F (2 to 29°C) 24 Months 12 Months 12 Months
PR-1440 35 to 85°F (2 to 29°C) 9 Months 4.5 Months 4.5 Months
PR-1776M Less than -40°F (-40°C) 6 Weeks 3 Weeks 3 Weeks
PR-2007 Less than -40°F (-40°C) 6 Weeks 3 Weeks 3 Weeks
Pro-Seal 815 40 to 80°F (4 to 27°C) 6 Months 2 Months 2 Months
Pro-Seal 870 35 to 85°F (2 to 29°C) 6 Months 3 Months 3 Months
Pro-Seal 890 40 to 80°F (4 to 27°C) 9 Months 4.5 Months 4.5 Months
RTV-730 40 to 80°F (4 to 27°C) 6 Months 2 Months 2 Months
RTV-102 35 to 85°F (2 to 29°C) 12 Months 6 Months Not Applicable
Silastic 730 35 to 85°F (2 to 29°C) 12 Months 6 Months Not Applicable
SS-69A 35 to 85°F (2 to 29°C) 12 Months 6 Months Not Applicable
WS-8020 40 to 80°F (4 to 27°C) 9 Months 4.5 Months 4.5 Months
WS-8020RC Less than -40°F (-40°C) 6 Weeks 3 Weeks 3 Weeks
WS-8032 Less than -40°F (-40°C) 6 Weeks 3 Weeks 3 Weeks

20-40-60-2 (Rev 1)
POLYURETHANE ANTENNA GASKET SEALING - MAINTENANCE PRACTICES

1. General
A. This section supplies sealing material and accomplishment instructions when antennas are to be removed and installed
using a conductive polyurethane gasket.
B. Sealant and/or gaskets are used for the correct installation/functionality and protection from weather. For additional
information on antennas, refer to the maintenance practices section for the desired antenna.
A. For a list of all required tools and equipment, refer to Chapter 20, Fuel, Weather, Pressure and High Temperature Sealing
Part Number Description Use
HT3326-5 Av-Dec Self-Leveling Green Sealant Fast setting sealant. (5 minute working
life, 10 Minute Gel time) NOTE
EN110589 and AD89513 Av-Dec Hi-TAK Polyurethane Tape Sealant used to prevent moisture
StretchSeal ingress
TG3212 Av-Dec Thixoflex Black Sealant Polyurethane Sealant for fast setting
fillet seals (4 minute working life, 8
Minute Gel time, 2 hour full cure)
3. Antenna Sealing Instructions
A. Seal the antenna with the conductive polyurethane gasket.
(1) Make sure the antenna and airplane are prepared for electrical bonding. Refer to Chapter 20, Electrical Bonding and
Grounding - Maintenance Practices.
CAUTION: If switching from a fay/fillet seal combination, installation hardware may change. This could cause
damage to airplane equipment and affect antenna functionality. Refer to the attached parts list for
the correct installation hardware.
(2) Make sure to use the correct screws and polyurethane gasket for desired antenna. Refer to the Illustrated Parts
Catalog.
(3) Remove cap(s) or cover(s) from electrical connector(s).
(4) Make sure the antenna, connector cutout and fuselage surfaces are free of dust, oil, grease, fingerprints, and all
previously applied sealants or adhesives.
(5) Put the polyurethane gasket in position on the antenna.
NOTE: Some antennas may use a spacer or adapter, make sure to use the correct hardware for the
desired antenna. Refer to the Illustrated Parts Catalog.
CAUTION: Do not fold or bend the polyurethane gasket. Replace the polyurethane gasket if it has been
damaged or previously installed. Damaged or reinstalled gaskets may allow moisture to
collect under the antenna.
CAUTION: Make sure to leave the release film in place on the "aircraft side" of the polyurethane gasket
until you are ready to install the antenna. This will reduce the chances of dirt and debris
sticking to the polyurethane gasket.
(6) If required, connect the electrical connector(s).
NOTE: Some antennas may be installed before connecting the electrical connector(s). Make sure to
choose the correct method for desired antenna. It is recommended, when practical, to install
the coaxial connector(s) prior to installation to aid in sealing procedures.
(a) It is recommended to apply a fillet seal around connector mounting area(s) with Av-Dec HT3326-5 Self-Leveling
Green sealant for corrosion protection. If used, allow the sealant to cure for 30 minutes before mounting antenna
to aircraft. Refer to Figure 201, Av-Dec Antenna Sealing.
(b) It is recommended to apply Av-Dec Hi-TAK Polyurethane Stretch Seal (EN110589 or AD89513) tape over the
connector for corrosion protection. Refer to Figure 201, Av-Dec Antenna Sealing.
(7) Remove the release film from the "aircraft side" of the polyurethane gasket.

20-40-60-2 (Rev 1)
(8) Put the antenna in position on the fuselage skin.

(9) Install and torque the screws that attach the antenna to the fuselage skin. Refer to Chapter 20, Torque Data -
Maintenance Practices for correct torque.
(a) Make sure to wait a minimum of 15 minutes, then torque the screws a second time.
(10) If connecting the coaxial connector(s) after the antenna is mounted, it is recommended to apply a fillet seal around
connector mounting area(s) with Av-Dec HT3326-5 Self-Leveling Green sealant for corrosion protection. Refer to
Figure 201, Av-Dec Antenna Sealing.
(11) Use Type I Class B sealant or Av-Dec Thixoflex Black Sealant (TG3212) to apply a fillet seal around the perimeter of
antenna for complete corrosion protection. Refer to Chapter 20, Fuel, Weather, Pressure and High Temperature
Sealing - Maintenance Practices, Fillet Sealing.
NOTE: Type I, Class B sealant is the preferred sealant for the fillet seal. AvDec Thixoflex Black is an
acceptable alternative.
(12) Make note of applicable cure times. Refer to Chapter 20, Fuel, Weather, Pressure and High Temperature Sealing -
Maintenance Practices, Sealant Curing.
(13) Refer to the applicable antenna installation procedures for any additional installation, bonding or return-to-service
checks.

20-40-60-2 (Rev 1)
Figure 201 : Sheet 1 : Av-Dec Antenna Sealing

20-50-00-7 (Rev 1)
EXTERIOR FINISH - CLEANING/PAINTING

1. General
A. The airplane's exterior finish is polyurethane paint or a mechanical finish. Polyurethane paint is applied over most of the
airplane's external surface. It has a chemical film application, a corrosion protection primer application, and a topcoat and
stripe application. The airplane's mechanical finish is the unpainted aluminum surface that is usually polished and buffed
with a compound to a mirror finish.
2. Exterior Finish Requirements
A. General
CAUTION: Do the RVSM Skin Waviness Inspection if the area around the static ports is repainted. This will
help to keep reduced vertical separation minimum (RVSM) airplanes certified. Refer to the
CAUTION: Give protection to airplane openings and sensitive components during the surface preparation and
painting processes. Some airplane systems and components are sensitive to paint debris.
(1) Do not paint the polished surfaces or the antennas.
(2) The angle-of-attack probes and the static ports must remain unpolished as received from the supplier.
(3) All of the external latches must be left as supplied by the supplier.
(4) The cabin and the emergency exit doors must have a 2.00 inch (51.00 mm) border along the edge of the doors.
(5) Some airplanes have erosion boots installed on the nose radome and the vertical stabilizer.
(6) Cabin door handles are polished and not painted.
(7) The visual fairing, panel cavity areas and inside the door entrance surfaces have paint to match the overall paint.
(8) All areas of the flight control surfaces have paint according to the paint definition except where paint will interfere with
the operation of the flight control surfaces.
(9) Do not apply paint to polished surfaces such as pylons, engine inlets, wing leading edges, and vertical/horizontal
stabilizer leading edges.
(10) Do not apply paint on the rub strips installed on the bottom aft surfaces of the speed brakes or the roll spoilers.
(11) The inside of the landing gear doors and wheel well areas have paint to match the color definition.
(12) Do not apply paint to the nose gear door retract mechanism.
(13) Do not apply paint to the latches, hinges, drain masts, locks, or the quick-release fasteners.
(14) Do not apply paint to the sight glasses on the cabin or the baggage door.
(15) The inside surfaces of the left and right battery and the auxiliary power unit (APU) panels have beige color paint.
(16) The inside surfaces of the toilet waste line door, hydraulic access door, external electrical power receptacle panel,
and the fuel servicing access door have beige color paint.
(17) The inside surfaces of the tailcone jack-stand door, maintenance access door, and all visual airplane structures within
the doors have beige color paint.
(18) Areas on the speed brake and spoiler panels (trailing edge) that are near flap panels use Teflon paint approximately
1.0 inch (25.40 mm) wide near the structure.
(19) Do not apply paint to the fairing attach screws.
(20) The registration characters must be 12 inches (304.80 mm) in height and must have a color contrast that obeys 14
CFR Part 45.29(b).
(21) The wing surface is a laminar flow structure and must be prepared and have paint applied to maintain this laminar air
flow. The loss of natural laminar air flow can result in a loss of up to 15 knots true airspeed.
3. Paint Touch-Up Kit
A. An optional paint touch-up kit is available for touching up the airplane's exterior painted areas that are chipped, worn, or
damaged during maintenance, insect acidity pitting, or deterioration. The touch-up kit contents are listed on the kit, which
contains the primary color, top/bottom stripe color, accent stripe color, catalyst, and gray bottom (belly) color if applicable.
The airplane's serial number and manufacturing date are also shown on the kit.
NOTE: The shelf life for paint touch-up kits is 6 months and starts at the date of packaging (DOP). An
extension to the shelf life of touch up kits is not authorized.

20-50-00-7 (Rev 1)
4. Paint Stripping
NOTE: This includes the procedures for the removal of cured paint from the exterior of the airplane. It includes
mechanical paint stripping, chemical paint stripping, and localized paint stripping.
• Abrasive Blasting Tool
• Mop
• Plastic Squeegee
• Polypropylene Bristle Brush
• Portable Sprayer
• Soft Bristle Brush.
• Alkaline Cleaner
• Blast Cleaning Materials
• Chemical Paint Stripper
• Scotchbrite Pad.
B. Prepare the Airplane for the Paint Stripping.
(1) Move the airplane to a paint stripping facility.
(2) If necessary, solvent clean the airplane or the applicable area. Refer to General Solvents/Cleaners - Maintenance
Practices.
C. Mechanical Paint Stripping
(1) General
WARNING: Wear goggles, rubber gloves, apron, boots, and other protective clothing when you do the
mechanical paint stripping. Paint stripping must be done in a well-ventilated area.
(a) Use adequate protective equipment, clothing, and breathing air or respirators during the paint stripping.
(b) Use ladders or other lift equipment as necessary to allow access to all of the airplane surfaces for the paint
stripping.
(c) Mechanical removal of paint is recommended for areas where chemical strippers would be impractical because
of structural complexities, rinsing difficulties, or composition of the substrate, such as fiberglass, composite, or
plastic.
(d) Grit and glass bead blasting equipment must be equipped with blast intensity controls and must be provided
with clean dry air.
(e) Grit blasting is not recommended for general use on aluminum sheet, springs, close tolerance dimensioned
parts, and threads.
(f) Use 180 grit or finer abrasive cloth and/or brush where a significant loss of metal cannot be tolerated and/or a
smooth finish is required. When heavy layers of scale or oxides are to be removed and the surface finished by
subsequent operations or processes, a 150 grit or coarser metallic brush can be used.
(g) Parts fabricated from different material types as shown in Table 701 must not be grit blasted with the same grit,
wire brushed with the same brush, or cleaned with the same abrasive cloth or paper.
Table 701. Blast Cleaning Materials and Procedure
Nozzle Air
Material Type Abrasive Type Abrasive Material Notes
Pressure in psi

20-50-00-7 (Rev 1)
Aluminum Oxide Grit,

Commercial Grade,
Aluminum Oxide, High-Purity, Size #60 60-70
thru #120
Carbon and Low Steel Grit,
Alloy Steels Steel (NOTE 1) Commercial Grade, 60-70
Size #50 thru #120
Glass Beads, MIL-G-
Glass Beads 9954, Size 13 or 50 Maximum
Size 10
Aluminum Oxide Commercial Grade, #120 Grit
50 or Less
(NOTE 1) High-Purity, Size #60 Recommended
Aluminum Alloys thru #120
Glass Beads, MIL-G- Blast Cleaning of
Glass Beads 9954, Size 13 or 50 Maximum Sheet Materials not
Size 10 Recommended
Aluminum Oxide Commercial Grade,
60-90
Corrosion Resistant (NOTE 1) High-Purity, Size #60
Steels and Nickel thru #120
Base Alloys Glass Beads, MIL-G-
Glass Beads 9954, Size 13 or 50 Maximum
Size 10
Aluminum Oxide Commercial Grade,
70 or Less
(NOTE 1) High-Purity, Size #60
Copper and Copper thru #120
Base Alloys
Glass Beads, MIL-G-
Glass Beads 9954, Size 13 or 50 or Less
Size 10
Not Applicable Due
Magnesium Alloy - - -
to Fire Hazard
Glass Beads, MIL-G- Recommended for
Brazing Joints Glass Beads 9954, Size 13 or 50 or Less Uniform Flow of
Size 10 Braze Alloy
Aluminum Oxide Commercial Grade, #120 Grit
70 or Less
(NOTE 1) High-Purity, Size #60 Recommended
Titanium thru #120
Glass Beads, MIL-G-
Glass Beads 9954, Size 13 or 50 or Less
Size 10
NOTE 1: This is the preferred abrasive.
(h) Parts and assemblies must be cleaned after abrasive cleaning to make sure that all abrasive media is removed.
(2) Blast Cleaning
(a) Blast cleaning abrasive material must be used in accordance with Table 701.
(b) Oily parts must be solvent cleaned before blast cleaning. Refer to General Solvents/Cleaners - Maintenance
Practices.

20-50-00-7 (Rev 1)
(c) Parts must be within original permissible tolerances after blast cleaning and must shown no significant signs of
warping or distortion. Thin sections require care to prevent warping. Blast cleaning of section thickness less than
0.050 inch (1.27 mm) is not recommended.
(d) All loose particles must be removed from blast cleaned surfaces with air jet blast immediately after blast
cleaning. Subsequent specified surface treatments shall be applied as soon as possible after blast cleaning.
(e) Suitable masking material must be used for holes, surfaces, or other portions of parts that could be damaged by
blast cleaning.
(f) Blast cleaning of high erosion prone metallic areas on the exterior of the airplane as part of the pretreatment
before painting must be accomplished using glass beads (MIL-G-9954, Size 10 or 13) and an abrasive blasting
tool.
1 For this application, the recommended pressure at the blasting tool is 50 to 60 psi and this pressure must
not exceed 65 psi.
CAUTION: It is not recommended to hold the blast nozzle perpendicular or too close to the blast
surface. Surface damage can occur if the nozzle is not in the correct position.
2
An adapter boot must be used to maintain the blast nozzle at an appropriate angle to the blast surface and
at a constant distance of 5 inches (127 mm).
3 The blasting tool must be moved across the surface at a velocity of not less than 0.5 inch (12.70 mm) per
second.
4 Blasting must be limited to local high-erosion prone areas only, e.g., 1.0 to 1.5 inches (25.40 to 38.10 mm)
widths along the edges of wing and nacelle skins just aft of the polished leading edges.
5 Blast cleaned surfaces must have a uniform satin finish.
(3) Abrasive Cleaning with Cloths, Papers, and Pads
(a) Abrasive cleaning of small surface areas and the surfaces of parts on which blast cleaning is prohibited must be
accomplished by one of the applicable abrasives shown in Table 702.
Table 702. Abrasives Use
Carbon and
Resistant Aluminum Magnesium Copper
Abrasives Low Alloy Titanium
Steels Alloys Alloys Alloys
Steels
Emery
Paper or
Recommended Acceptable Prohibited Acceptable Acceptable Acceptable
Cloth (Silica
Carbide)
Aluminum
Oxide
Paper, Acceptable Recommended Recommended Acceptable Recommended Recommended
Cloth, or
Pads
Steel Wool Acceptable Prohibited Prohibited Prohibited Prohibited Prohibited
Aluminum
Prohibited Prohibited Acceptable Prohibited Prohibited Prohibited
Wool
Stainless
Prohibited
Steel, Wool, Acceptable Recommended Prohibited Prohibited Acceptable
(NOTE 1)
or Brush
Carbon
Recommended Prohibited Prohibited Prohibited Prohibited Prohibited
Steel Brush
NOTE 1: Stainless steel wire brushes can be used on titanium if they have never been used on any
material other than titanium.
(b) For fiberglass, composites, Kevlar, or plastic, use medium to fine grit sandpaper or Scotchbrite pads to carefully
remove the finish. Be careful that you do not damage the fibers under the finish.

20-50-00-7 (Rev 1)
(c) All abrasives can be used with either power or hand tools.
(d) All loose particles must be removed from parts by a jet of air immediately and cloth wiped upon completion of
abrasive cleaning.
(e) Care must be exercised that surfaces adjoining the surface to be abrasively cleaned are not impaired by any
phase of the cleaning process.
(4) Wire Brushing
CAUTION: Do not use low carbon steel brushes on aluminum, magnesium, copper, stainless steel, or
titanium surfaces. Steel particles may become embedded in the surfaces and later rust or
cause galvanic corrosion of the metal surfaces.
(a) Wire brush parts for a period of time no longer than necessary to produce a clean surface.
(b) Wire brushing materials must be in accordance with Table 702.
(c) Wire brush speeds and pressure must be such that obvious surface smearing and excessive heating of the part
surface are eliminated.
D. Chemical Paint Stripping
(1) General
WARNING: Wear goggles, rubber gloves, apron, boots, and other protective clothing when you use the
chemical paint stripper. The chemical paint stripper will damage the eyes and skin. If it gets on
your skin, wash with water. If it gets in your eyes, flush with water and immediately refer the
injured person to a physician. Paint stripping must be done in a well-ventilated area.
(b) A pressurized delivery system must be used to spray the stripper on the surfaces of the airplane with sufficient
thickness to strip the coatings.
(c) Use ladders or other lift equipment as necessary to allow access to all of the airplane surfaces for the spraying
operation.
(d) Polypropylene bristle brushes, acrylic scrapers, or equivalents must be used to scrape the lifted paint from the
airplane surfaces.
(e) All chemical paint strippers must be stored in an area with a temperature range of 35 to 90°F (2 to 32°C). The
paint stripper should be used within six months from the date of manufacture.
(f) The seams, joints, skin laps, repairs, inspection holes, or any other position on the honeycomb or bonded
assemblies where the paint stripper can touch adhesives must be masked.
(g) When you remove paint from the full external skin of a airplane, all of the assembly openings, Plexiglas, rubber,
and other nonmetals must be protected from the paint stripper by masking. Be careful to prevent Plexiglas and
plastics to touch the paint stripper. If it is touched, it must be immediately flushed with water from the Plexiglas
material. Paint stripper must be kept out of the interior areas of assemblies.
CAUTION: Do not let the paint stripper touch high-heat-treated steel pins, such as the pins that attach the
landing gear components. Paint stripper can cause hydrogen embrittlement in high-heat-
treated steel.
(h) Before you apply the paint stripper, fully mask or remove high heat treated steel pins, such as pins that attach the
landing gear components.
CAUTION: Do not use masking tape.
(2) Use plastic tape with plastic sheeting or waxed paper to mask all of the airplane surfaces that follow: Refer to
Masking in this section.
NOTE: Overlap the strips of tape so as to make at least a 0.50 inch (12.70 mm) safety margin between
the protected surface and the surface to be stripped.
(a) Mask all transparencies such as windows.
(b) Mask or remove all composite surfaces.
(c) Mask all rubber and other nonmetals.
(d) Mask all faying surfaces and access doors.

20-50-00-7 (Rev 1)
(e) Mask all seams, joints, skin laps, inspection holes, drain holes, or any opening that will allow the paint stripper to
enter the airplane.
(f) Mask all edges and fasteners on all honeycomb panels.
(g) Mask all pivots, bearings, and landing gears.
(h) Mask all titanium that is exposed to the paint stripper.
WARNING: Know and obey all safety precautions when you use flammable materials for the clean and paint
procedures.
chemical stripping solution. The chemical stripping solution will damage the eyes and skin. If it
gets on your skin, wash with water. If the solution gets in your eyes, flush with water and
immediately refer the injured person to a physician. Paint stripping must be done in a well-
ventilated area.
CAUTION: Do not use a heater with an open flame in an area where methylene chloride-type solution is used.
This will help to prevent the formation of hydrochloric acid fumes. The acid fumes will get on the
airplane and will corrode all surfaces.
CAUTION: Do not use chemical paint stripper on zinc, fiberglass, kevlar, or graphite composite material. It will
damage the material.
CAUTION: Chemical paint stripper will remove epoxies, urethanes, and other organic material from ferrous
and nonferrous metals. Do not let this material touch zinc, glass, ceramics, concrete, or dissimilar
metals.
CAUTION: Acrylic windows will become soft or damaged by solvent, paint, and paint stripper.
CAUTION: Do not let the paint stripper touch high-heat-treated steel pins, such as pins that attach the landing
gear components. Paint stripper can cause hydrogen embrittlement in high-heat-treated steel.
(3) Apply Type II, Class 2 chemical paint stripper by spray or brush coating sufficiently thick to all paint surfaces to be
removed. Refer to Table 703 for chemical paint strippers.
Table 703. Chemical Paint Stripper
Type, Class Number Manufacturer Use
PRC-DeSoto International,
Spray or brush on
Inc.
Type II, Class 2 PR-4028 aluminum, cadmium, steel,
and titanium.
Symar, CA 91342
Henkel Corp. Spray or brush on
Type II, Class 2 Turco 6017 2850 Willow Pass Road aluminum, cadmium, steel,
Bay Point, CA 94565 and titanium.
Savagran Spray or brush on
Type IV, Class 2 (NOTE 1) Strypeeze P.O. Box 130 aluminum, cadmium, and
Norwood, MA 02062 steel.
Spray or brush on
aluminum, cadmium,
Type IV, Class 2 (NOTE 1) Turco 5873 NC Henkel Corp.
magnesium, steel, and
titanium.
Sea to Sky Innovations
6741 Cariboo RD, Unit 204
SPC-909 Burnaby, British Columbia Spray or brush
V3B4A3
Canada
Type VI (SEE NOTE 2 AND
CAUTION BELOW)

20-50-00-7 (Rev 1)
PPG
PR-5044 Spray or brush
Sylmar, California 91342
Phone: 818-362-6711
NOTE 1: Type IV, Class 2 may only be used for localized stripping.
NOTE 2: You can heat Type VI strippers to a maximum temperature of 110°F (43.3°C). Temperatures
below 77°F (25°C) significantly decrease rate of removal. Make sure that the Type VI stripper
does not dry on the surface.
(a) For the spray method, first, apply a light coat to the surface and after the paint starts to lift, apply a second heavy
coat.
NOTE: If the temperature is more than 85°F (29°C), apply a single, even, wet coat of paint stripper
on only a section of the airplane.
(b) For the brush method, brush across the surface only in one direction.
(4) After the paint starts to lift, use a polypropylene bristle brush to agitate the paint stripper to allow further penetration of
it to the unaffected painted area.
(5) Remove the lifted paint with a plastic squeegee. Dispose of the material in accordance with local regulations.
(6) Examine all surfaces for incomplete paint removal.
(7) Do this procedure again as necessary to remove all of the paint.
(8) After all of the paint is removed, use high-pressure, hot water to remove the chemical paint stripper residue.
(9) Wash the airplane with an alkaline cleaner as follows:
(a) Mix one part of Eldorado ED-500 alkaline cleaner with 8 to 12 parts reverse osmosis (RO) or deionization (DI)
water.
(b) Apply the alkaline cleaner solution with a portable sprayer or mop from the bottom to the top to minimize drying
on the surface.
(c) Agitate the solution with a soft bristle brush or a Scotchbrite pad after or during application.
(d) Make sure that the surfaces stay wet and allow the solution stand for approximately 10 to 15 minutes.
(e) Follow immediately with an RO or DI water rinse.
(10) Dry the airplane.
(11) Remove the masking materials.
(12) Hand sand or mechanical sand the remaining paint around windows, seams, door handles, drains, and on composite
surfaces.
NOTE: Metal surfaces only need to be scuffed if fasteners are cadmium plated.
(13) Remove the dust with dry shop air.
(14) Solvent clean the airplane or the applicable area. Refer to General Solvents/Cleaners - Maintenance Practices.
E. Localized Paint Stripping
(1) General
chemical paint stripper. The chemical paint stripper will damage the eyes and skin. If it gets on
your skin, wash with water. If it gets in your eyes, flush with water and immediately refer the
injured person to a physician. Paint stripping must be done in a well-ventilated area.
(b) Use ladders or other lift equipment as necessary to allow access to all of the airplane surfaces for the stripping
operation.
(c) Polypropylene bristle brushes, acrylic scrapers, or equivalents must be used to scrape the lifted paint from the
airplane surfaces.
(d) All chemical paint strippers must be stored in an area with a temperature range of 35 to 90°F (2 to 32°C). The
paint stripper should be used within six months from the date of manufacture.

20-50-00-7 (Rev 1)
(e) The seams, joints, skin laps, repairs, inspection holes, or any other position on the honeycomb or bonded
assemblies where the paint stripper can touch adhesives must be masked.
(f) When you remove paint from the full external skin of a airplane, all of the assembly openings, Plexiglas, rubber,
and other nonmetals must be protected from the paint stripper by masking. Be careful to prevent Plexiglas and
plastics to touch the paint stripper. If it is touched, it must be immediately flushed with water from the Plexiglas
material. Paint stripper must be kept out of the interior areas of assemblies.
CAUTION: Do not let the paint stripper touch high-heat-treated steel pins, such as the pins that attach the
landing gear components. Paint stripper can cause hydrogen embrittlement in high-heat-
treated steel.
(g) Before you apply the paint stripper, fully mask or remove high heat treated steel pins, such as pins that attach the
landing gear components.
(2) Make sure that the ambient temperature is between 50 and 100°F (10 and 37°C) and the airplane surface
temperature is between 50 and 90°F (10 and 32°C).
(3) Apply the applicable chemical paint stripper to the paint surface to be removed. Refer to Table 703 for chemical paint
strippers and application methods and cleanup.
(4) Scrub lightly with a soft bristle brush to help remove the paint.
(5) Make sure that you keep a wet film of paint stripper on the paint surface for approximately 30 to 60 minutes.
(6) Remove the lifted paint with a plastic squeegee. Dispose of the material in accordance with local regulations.
(7) Examine all surfaces for incomplete paint removal.
(8) Do this procedure again as necessary to remove all of the paint.
(9) After all of the paint is removed, use high-pressure, hot water to remove the chemical paint stripper residue.
5. Masking
• None.
• Masking Materials.
• None.
B. Refer to Table 704 for the masking materials.
Table 704. Masking Materials
MATERIAL PART NUMBER MANUFACTURER CESSNA PART USE
DESCRIPTION (Note NUMBER (Note 4)
1)
Latex Impregnated
To cover windows and
Paper with Liner (10 Protex 10V X450548
windshields
mils) (Elephant Hide)
Mask-Off Company,
Latex Impregnated Inc. To cover windows and
Paper with Liner (10 Protex 20V 345 West Maple X450708
windshields.
mils) (Elephant Hide) Avenue
White Adhesive Back Monrovia, CA 91016- To cover windows and
Protex 343 X570938
Paper 1148 windshields.

20-50-00-7 (Rev 1)
A840014, A840015
Aluminum Foil Tape To protect the areas
(Do not use on electro-
(Aluminum Masking where paint and
No. 425 thermo windshields),
Material) 1/4", 1/2", 1", chemicals are not
A840013 and
2" wanted.
A840010
To mask around outer
X570801 thru edges of composite,
Green Plastic Tape,
No. 218 3M X570804 and bright work, leading
1/4", 1/2", 3/4", 1", 2"
Industrial Adhesives X570814 edges, and de-ice
and Tapes Division boots.
Black Plastic Tape, 1", St Paul, MN 55144- X570316 and To mask Cockpit
No. 226, LHD
1 1/2" 1000 X570378 windows.
To protect the areas
where paint and
Protective Tape, 18" No. 346 X001445
chemicals are not
wanted.
Black, Polyethylene To cover windows and
film, Masking Tape, 2" No. 483 X570643 windshields.
window
Gray Cloth Duct Tape To protect sensitive
No. 3939 F480022
2" aircraft parts.
White Vinyl Duct Tape To protect sensitive
No. 3903 X664042
2" aircraft parts.
3M
P840282 (Blue tape, To protect sensitive
Vinyl Tape (All colors Industrial Adhesives
No. 471 1/2") and P840284 aircraft parts.
and widths) (Note 2) and Tapes Division
Blue tape, 1")
St Paul, MN 55144-
Vinyl Tape (All colors 1000 P840188 (Red tape, To protect sensitive
No. 471
and widths) (Note 2) 1/4") aircraft parts.
X664043 (Indigo, To protect sensitive
Vinyl Tape (Note 2) No. 471+ 1/4"), and X664044 aircraft parts.
(Indigo, 3/4")
Masking Tape 1", 1 X570982, 570984 and To protect sensitive
No. 2380
1/2", 2"., 3" 570980 aircraft parts.
X571000 and To protect sensitive
Scotch tape 1", and 2" No. 231 / 231A
X571001 aircraft parts.
3M To protect sensitive
Masking Tape 1.18" No. 232 Industrial Adhesives X664040
aircraft parts.
and Tapes Division
St Paul, MN 55144- To protect sensitive
Masking Tape 0.94" No. 234 X664041
1000 aircraft parts.
X571002 thru To protect sensitive
Masking Tape No. 301+
X571008 thru To protect sensitive
Masking Tape No. 501+
Aluminum Protective Compac Industries To use over Protex
120-6U/L X011001
Tape, 18" wide 20V (elephant Hide)
Waxed Kraft Paper, Commercially To cover windows and
Class A, Type I X450549, X450510
12" Available windshields.

20-50-00-7 (Rev 1)

Polyethylene Plastics Commercially where paint and
---- X464101
4'x100', 0.004 Inch Available chemicals are not
wanted.
Polyethylene Plastics, Commercially where paint and
---- X570643
2' X 36 yds Available chemicals are not
wanted.
Permacel
Division of Avery
Company
Vinyl Masking Tape, P840288, P840289, where paint and
P-34 US Highway 1
3/4", 1" P840281 chemicals are not
PO Box 671
wanted.
New Brunswick, New
Jersey 08903
Caplugs
Kwiki Dots- Crepe 2150 Elmwood Avenue To protect the areas
X098006, X098012
Masking Discs Buffalo, New York where paint and
---- thru X098020,
(Various, off-white 14207 chemicals are not
X570013, X570638
sizes) (Note 3) Email: wanted.
sales@caplugs.com
Viadon, LLC
26200 South Whiting
Way
Green Polyester Tape X570996, X570997, where paint and
VGT215 Monee, Illinois 60449
(Note 3) and X570998 chemicals are not
Phone: 866-534-3900
wanted.
Email:
info@viadon.com
NOTE 1: The tape, as received, must be of constant quality, and normal in appearance and condition. If the
tape leaves a residue, Contact Customer Service at: Email Address Email: TMDC@txtav.com,
Telephone: 316-517-5800, to obtain instructions for manually cleaning the surface and obtaining a
new roll of tape before proceeding. Contact Customer Service if nonconforming tape rolls are
found in inventory.
NOTE 2: Not to be used with Ketone based solvents.
NOTE 3: This Material is approved for use to mask for electrical bonding, and may be used to mask and
protect parts in other painting operations.
NOTE 4: It is permissable to use any widths of approved masking tapes as applicable.
C. Masking Requirements
(1) The following areas must be masked:
• Cockpit Windows
• Cabin Windows
• Foul Weather Windows
• Composite Areas
• Nose Radome
• Plastic Areas
• Wing Leading Edges
• Vertical Stabilizer Leading Edges
• Engine Inlets and Exhausts
• De-Ice Boots
• Horizontal Stabilizer Trailing Edges
• Vertical Stabilizer Trailing Edges
• Landing Gear Wheel Wells (Nose and Main)

20-50-00-7 (Rev 1)
• Landing Gear
• Inboard Wing Trailing Edge
• Outboard Wing Trailing Edge
• Belly Vent(s)
• Speed Brakes
• Pylon Trailing Edges (Airplane Models 550 and 560)
WARNING: Airplane Models 550 and 560 pylon trailing edges are made of Magnesium. Failure to
follow proper procedures could result in fire due to chemical reaction with the chemical
stripper.
• Wing Outboard Trailing Edges (Airplane Models 550 and 560)
WARNING: Airplane Models 550 and 560 wing trailing edges are made of Magnesium. Failure to
follow proper procedures could result in fire due to chemical reaction with the chemical
stripper.
• Pitot Tubes
• Main Door Hinge
WARNING: The main door hinge is made of Magnesium. Failure to follow proper procedures could
result in fire due to chemical reaction with the chemical stripper.
• Main Door Latch
• Fuel Port(s)
• Avionics and Baggage Door Latches
• Locks
• Plastic Lenses
• Antennas
• Static Wick Bases
• Seams and Other areas
(2) Because the treatment solutions will attack bare metals and plastics, there are areas in which the solutions must not
be allowed to touch. These areas must be masked with waxed paper and/or polyethylene sheeting using plastic
tapes. Masking tapes cannot be used since solutions can penetrate paper.
(3) Mask all rubber surfaces.
(4) Mask all magnesium, anodized aluminum, and cadmium plated surfaces. Deoxidizing solution will attack these
surfaces.
(5) Mask all high-strength steel parts, such as landing gears, flap brackets, and propeller components. High-strength
steels can be embrittled by deoxidizing solution.
(6) All exposed titanium parts must be masked to prevent embrittlement such as engine attach points and flap hinges.
(7) All exposed magnesium must be masked during chemical film coating and then demasked and brush protective
treated.
(8) Mask lights, drain holes, locks, and identification plates with aluminum tape or plastic tape.
(9) Mask all transparent plastic or glass surfaces, such as windows and windshields as follows:
(a) Wash all windows with a 50/50 alcohol and water solution. Wash all glass windshields with water and a clean,
soft cloth.
(b) Use the two-inch 3M No. 483 black masking tape to mask the window/windshield from the bottom to the top with
a 0.25 inch lap of each strip. Squeegee the tape to remove air bubbles and maximize adhesion. For airplanes
with polished windshield retainers, cover these surfaces with 3M No. 226 black plastic tape.
(c) On top of the window and windshield maskings, center the precut Protex 10V latex impregnated paper and
squeegee.
(d) Place the plastic insert behind the bleed air duct on the windshield and mask edges with 3M No. 226 tape.
(e) Place the precut plastic film on top of the Protex paper and mask edges using 3M No. 226 tape. If necessary,
apply additional 3M No. 226 tape on the perimeter for abrasion protection when sanding.
(f) After a chemical film coating process, remove the plastic film and the tape holding it on the airplane.
(g) Starting with the primer application, cover the Protex paper with waxed Kraft paper and mask the edges with 3M

20-50-00-7 (Rev 1)
No. 226 tape.

(h) For the process of priming, painting, and stripping, the Protex paper and the 3M No. 483 tape under it must
remain on the windows and windshield until the finish process is completed.
(i) After each application of primers and paints, remove the Kraft paper and the tape holding it in place.
(j) Wipe the 3M No. 483 tape holding the Protex paper with 50/50 alcohol and water solution. If the Protex paper
becomes wet, it must be completely dried before you continue.
(k) After the masking of the Protex paper has been wiped and dried, replace the Kraft paper and tape with 3M No.
483 tape just before each primer and paint application.
6. Nonmetallic Surface Preparation
• Fine and Medium Grit Sandpaper
• Multimeter
• Scotchbrite Pad
• Spray Equipment.
• Anti-Static Coating
• Conductive Coating
• Filler Putty
• Sanding Surfacer
• 3M Conductive Electrical Tape.
• Maintenance Manual.
B. General
(1) The objective of using filler putty and sanding surfacer on nonmetallic surfaces is to fill local depressions, pits, pin
holes, and other small surface defects to make a smooth surface for painting.
(2) The total thickness of sanding surfacer must not exceed 0.002 inch (0.050 mm) after sanding on radomes and must
not exceed 0.005 inch (0.127 mm) after sanding on non-radome parts.
(3) Sanding surfacer must be applied as thin as possible. After it cures, the sanding surfacer will be brittle, making the
painted finish more susceptible to cracking in service.
(4) The surface preparation includes the steps that follow:
(a) Cleaning
(b) Filler Putty Application
(c) Sanding Surfacer Coating
(d) Nose Radome Anti-Static Coating
(e) Fuel Access Door Anti-Static Coating
(f) Composite Assembly Conductive Coating
(g) Final Preparation.
C. Cleaning
CAUTION: Do not use chemical paint stripper on fiberglass, Kevlar, and graphite composite assemblies. Paint
stripper will damage these assemblies. External composite assemblies include the inner surfaces
of the nose access doors, nose landing gear doors, wing tips, aileron tips, maintenance access
door, tailcone stinger cap, pylon ram air scoop, and vertical stabilizer bullet.

20-50-00-7 (Rev 1)
CAUTION: Do not sand into the fibers of the nonmetallic parts. This will cause damage and decrease the
strength.
(1) Make sure that the paint is removed from the surface. Refer to Paint Stripping in this section.
(2) Solvent clean the nonmetallic surfaces to remove debris and surface deposits. Refer to General Solvents/Cleaners -
(3) Use Scotchbrite pads or fine sandpaper to sand all exterior surfaces of the nonmetallic components (fiberglass,
Kevlar, or graphite) which are to receive the sanding surfacer.
NOTE: Sanding removes the surface glaze to promote adhesion.
(a) Acrylonitrile-butadiene-styrene (ABS) only needs to be solvent wiped with alcohol or cleaned by immersion with
a mild alkaline cleaner. Refer to General Solvents/Cleaners - Maintenance Practices.
(4) Solvent clean the nonmetallic surfaces to remove the sanding residue. Refer to General Solvents/Cleaners -
D. Filler Putty Application
(1) Requirements
(a) Use an enclosed facility with a filtered air system to provide clean, dust and dirt free air.
(b) The air system must have a filtered exhaust system to remove evaporated solvent and as much overspray as
practical.
(c) Use respirators, face shields or goggles, rubber aprons, gloves, and other protective clothing.
(2) Make sure that the nonmetallic surfaces are clean. Refer to General Solvents/Cleaners - Maintenance Practices.
(3) Mix one of the filler puttys that follow per the manufacturer's instructions.
• AKZO 467-9 Epoxy, CA-41B Catalyst
• Shell Epon 815 Epoxy
• AKZO 28-C-1 Epoxy.
• Mankiewicz 369-11 Water-based filler.
(4) Use a plastic squeegee to apply the filler putty to the surface of the part to fill local depressions, pin holes, and other
surface defects.
(a) Use the plastic squeegee to force the filler putty into holes by displacing the air.
NOTE: A soft cotton cloth can also be used.
(b) You can thin the filler putty a slight amount to allow smoother applications.
NOTE: For Mankiewicz 369-11 water is used as the thinner.
(c) Do not apply too much filler putty to the part before smoothing with the plastic squeegee. The action of the
plastic squeegee will pull the filler and leave a rough surface.
(5) Let the filler putty dry. Refer to the manufacturer's instructions for drying times.
(6) Use medium to fine grit sandpaper or Scotchbrite pads to sand the surfaces.
(a) The final sanding must be done by hand.
(b) Do not sand into the fibers.
(c) Touch up low areas, depressions, and pin holes that were not filled with the first application with filler putty.
(d) Let the filler putty dry. Refer to the manufacturer's instructions for drying times.
(e) Re-sand the surfaces with medium to fine grit sandpaper or Scotchbrite pads.
E. Nose Radome Anti-Static Coating
(1) Requirements
practical.
(d) Make sure that the ambient temperature is above 40°F (4°C).

20-50-00-7 (Rev 1)
(e) Make sure that the spray equipment is sufficiently grounded and is set to 30 to 45 psi atomization pressure.
(3) Apply masking to the surface as necessary. Refer to Masking in this section.
(4) Mix the Type II anti-static coating (PPG Aerospace/PRC-DeSoto CA7870 Base, 910x464 Activator) per the
manufacturer's instructions.
(5) Let the mixture stand a minimum of 30 minutes before application.
(a) After 30 minutes stir only enough to lift any sediments off the bottom of the container every 10 to 15 minutes. Be
careful to not stir this material too much.
(6) Put a metallic test panel adjacent to the radome surface as a witness panel.
(7) Use standard spray equipment or a cup gun to apply a medium wet coat of the anti-static coating to the radome
surface and the metallic test panel in a crisscross pattern.
(8) Let the anti-static coating dry at room temperature for 8 to 12 hours, then force cure from 135 to 155°F (57 to 68°C)
for one hour.
(9) Make sure that the dry film thickness is 0.5 to 1.0 mil on the metallic test panel.
NOTE: The dry film thickness on the metallic test panel should be considered as the same thickness
as on the nose radome.
(10) Measure the resistance of the anti-static coating as follows:
(a) Put five sets of two strips of 3M copper conductive electrical tape 1.5 inches (38.10 mm) long, 1.5 inches (38.10
mm) apart and parallel to each other on the anti-static radome coating.
(b) Make sure that the conductive electrical tape is pressed firmly in place.
(c) Connect a multimeter to each of the five sets of conductive electrical tape and record the megohms.
(d) Add the five readings together and divide by five to get an average reading.
(e) Make sure that the average resistance is between 1.0 and 100 megohms.
1 If the average resistance is less than 1.0 megohm, reject it and refinish the nose radome again.
2 If the average resistance is more than 100 megohms, force cure it a second time for one hour and do this
check again.
a If the average resistance is still more than 100 megohms, reject it and refinish the nose radome again.
F. Sanding Surfacer Coating
(1) Requirements
practical.
(d) Use a high-volume low-pressure (HVLP) sprayer to apply the sanding surfacer.
(2) For the nose radome, use only one of the following sanding surfacers at a thickness of 1 to 2 mils dry on top of the
anti-static coating:
• Sherwin Williams 482-300 Blue Base, 487-600 Tan Base, 120-900 Curing Agent
• Mankiewicz Seevenax Sprayfiller 314-11
• PPG 09W015 White High-Build Sanding Surfacer
(3) Make sure that the nonmetallic surfaces are clean. Refer to General Solvents/Cleaners - Maintenance Practices.
(4) Mix one of the sanding surfacers that follow per the manufacturer's instructions.
• AKZO 464-3-1 Base, CA-142 Catalyst
• Sherwin Williams 482-300 Blue Base, 487-600 Tan Base, 120-900 Curing Agent
• Sterling U-1761 Base, U-1762 Curing Agent
• Diamond Vogel Paints VLX15350-02-100 (Base, VLX14590-01-025 Curing agent (Previously Hyperthane
82X03 Base, 81C1 Curing Agent).

20-50-00-7 (Rev 1)

(5) Use a sprayer to apply a medium coat of the sanding surfacer to the surface of the part 1 to 2 mils thick.
(6) Let the sanding surfacer dry. Refer to the manufacturer's instructions for drying times.
(7) Use fine grit sandpaper or Scotchbrite pads to sand the surface coat until it is smooth.
(a) The final sanding must be done by hand.
(b) Do not sand into the fibers.
(c) Make sure that the surface is free of defects and pin holes.
(d) Apply a second coat of sanding surfacer if the surface is not smooth.
NOTE: The surface can have some small pin holes.
G. Fuel Access Door Anti-Static Coating
(1) Requirements
practical.
(d) Make sure that the ambient temperature is above 40°F (4°C).
(e) Make sure that the spray equipment is sufficiently grounded and is set to 30 to 45 psi atomization pressure.
(4) Mix the Type IV anti-static coating that follows per the manufacturer's instructions.
• PPG Aerospace/PRC-DeSoto CA7850A Base, CA7850B Activator.
(5) Put a metallic test panel adjacent to the fuel access door as a witness panel.
(6) Use standard spray equipment or a cup gun to apply a medium wet coat of the anti-static coating to the fuel access
door and the metallic test panel in a crisscross pattern.
(7) Let the anti-static coating dry at room temperature for 24 hours before you apply the overcoat.
NOTE: The dry film thickness on the metallic test panel should be considered as the same thickness
as on the fuel access door.
(9) Measure the resistance of the anti-static coating as follows:
(a) Put two strips of 3M copper conductive electrical tape 1.5 inches (38.10 mm) long, 1.5 inches (38.10 mm) apart
and parallel to each other on the anti-static fuel access door coating.
(c) Connect a multimeter to the two strips of conductive electrical tape and record the megohms.
(d) Make sure that the resistance is between 0.1 and 1.0 megohms.
H. Composite Assembly Conductive Coating
CAUTION: Do not apply conductive coating to the nose radome.
(1) Requirements
(a) Do not apply the conductive coating on the nose radome.
(b) Use an enclosed facility with a filtered air system to provide clean, dust and dirt free air.
(c) The air system must have a filtered exhaust system to remove evaporated solvent and as much overspray as
practical.
(d) Use respirators, face shields or goggles, rubber aprons, gloves, and other protective clothing.
(e) Make sure that the ambient temperature is above 40°F (4°C).

20-50-00-7 (Rev 1)
(f) Make sure that the spray equipment is sufficiently grounded and is set to 30 to 45 psi atomization pressure.
(2) Use Scotchbrite pads to sand the surface coat until it is smooth.
(3) Solvent clean the surfaces to remove the sanding residue. Refer to General Solvents/Cleaners - Maintenance
Practices.
(5) Mix the Type III conductive coating that follows per the manufacturer's instructions.
• PPG Aerospace/PRC-DeSoto 528x310 Base, 910x464 Activator.
(6) Let the mixture stand a minimum of 30 minutes before application.
(a) After 30 minutes stir only enough to lift any sediments off the bottom of the container. Be careful to not stir this
material too much.
(7) Put a metallic test panel adjacent to the composite assembly.
(8) Use standard spray equipment or a cup gun to apply a medium wet coat of the conductive coating to the composite
assembly and the metallic test panel in a crisscross pattern.
(9) Let the conductive coating dry at room temperature for 4 to 24 hours before you apply the overcoat.
NOTE: The dry film thickness on the metallic test (witness) panel should be considered as the same
thickness as on the composite assembly.
(11) Measure the resistance of the conductive coating as follows:
(a) Put five sets of two strips of 3M copper conductive electrical tape 1.5 inches (38.10 mm) long, 1.5 inches (38.10
mm) apart and parallel to each other on the conductive coating.
(c) Connect a multimeter to each of the five sets of conductive electrical tape and record the megohms.
(d) Add the five readings together and divide by five to get an average reading.
(e) Make sure that the average resistance is between 0.0 and 0.1 megohms.
1 If the average resistance is less than 0.0 megohm, reject it and refinish the composite assembly again.
2 If the average resistance is more than 0.1 megohms, force cure it at 135 to 155°F (57 to 68°C) for one hour
and do this check again.
a If the average resistance is still more than 0.1 megohms, reject it and refinish the composite assembly
again.
I. Final Preparation
NOTE: This procedure is done before the topcoat application.
(1) Scuff sand the surface with fine sand paper or Scotchbrite pads.
(2) Apply a thin coat of one of sanding surfacer to cover the previous coating. Refer to Sanding Surfacer Coating in this
section.
CAUTION: Do not sand through the anti-static coating.
(3) Sand the surface smooth with fine sandpaper. All pinholes and defects must be covered up.
(4) Apply the topcoat. Refer to Topcoat and Stripe Application in this section.
(5) For the nose radome, do the steps that follow:
(a) Install the lightning diverter strips. Refer to the applicable Maintenance Manual.
(b) Install the nose radome erosion boot. Refer to the applicable Maintenance Manual.
7. Finish Painting

20-50-00-7 (Rev 1)
• Portable Sprayer or Mop

• Scotchbrite Pad
• Small Paddle-Shaped Tool
• Soft Bristle Brush
• Spray Equipment
• V-Shaped Rod.
• Aerodynamic Fairing Compound
• Aerodynamic Smoothing Compound
• Alkaline Cleaner
• Chem Film Solution
• Clean Cloths
• Corrosion Protection Primer (Refer to Table 705)
• Deoxidizer
• Methyl n-Propyl Ketone
• Mylar Tape
• Sanding/Sealer Primer
• Sanding Surfacer
• Sandpaper - 80, 150, and 220 Grit
• Scotchbrite Pad
• Topcoat/Stripe Paint.
• Structural Repair Manual.
B. Aerodynamic Surfaces
(1) Check the allowable deviations for local contour, mismatch and gap, and roughness limits, and flushness
requirements. Refer to the applicable Structural Repair Manual, Chapter 51.
C. Masking
(1) Apply masking to the applicable areas on the airplane. Refer to Masking in this section.
D. Scotchbrite Wet with Methyl n-Propyl Ketone
(1) Scuff sand all primed surfaces with a Scotchbrite pad wet with Methyl n-Propyl Ketone. Add Methyl n-Propyl Ketone
as necessary to keep the pad wet. Work on a small area so that the surface being abraded stays wet.
(2) Immediately wipe the surface dry with a clean, dry cloth. Do not let the surface evaporate dry.
NOTE: Details on the airplane that are not primed or have been paint stripped can start finishing at
this point with only a solvent wipe if needed. Refer to Corrosion Protection Primer Application.
E. Chemical (Chem) Film Application
(1) Requirements
(a) This process is done on pre-primed surfaces to chem film rivet heads, unprimed metal edges of skins and
bonded assemblies, and metal exposed.
(b) Spraying equipment must be used to wash the airplane with alkaline cleaner. This equipment should be
adequate to spray deoxidizer, chem film solution, and rinse water. The spraying equipment must be rinsed and
flushed with reverse osmosis (RO) or deionization (DI) water between applications of alkaline cleaner,
deoxidizer, and chemical film solutions. A high-pressure washer, with or without hot water, is recommended.
(c) Use an enclosed facility with a filtered air system to provide clean, dust and dirt free air.
(d) The air system must have a filtered exhaust system to remove evaporated solvent and as much overspray as
practical.
(e) Use respirators, face shields or goggles, rubber aprons, gloves, and other protective clothing.
(f) The RO or DI water pressure should be sufficient to provide a spray rinse application of water to the surface of

20-50-00-7 (Rev 1)
the airplane to keep the entire surface wet for proper review of a water-break free condition.
(g) After you clean the external surfaces, visually examine after the final rinse with RO or DI water for a smooth water
break-free film.
(h) Each time there is a pause in the painting sequence of overnight or longer, it is necessary to solvent clean the
surface by hand immediately before finishing the painting sequence.
(i) All properly cleaned and pretreated surfaces shall be examined to assure that the surfaces are free from dirt,
dust, finger marks, and other contaminants of any kind.
(j) It is recommended that all of the materials used to pretreat the airplane be from the same supplier for alkaline
cleaning, deoxidizing, and chem filming.
(k) All surfaces must remain wet and not be allowed to dry during all phases of the chemical film process, including
the rinsing process.
(l) The final paint system or primer must be applied only on a fully dry chem film coating after a water break-free film
was formed.
(2) Alkaline Clean
(a) Mix one part of Eldorado ED-500 alkaline cleaner with 8 to 12 parts RO or DI water.
(b) Apply the alkaline cleaner solution with a portable sprayer or mop from the bottom to the top to minimize drying
on the surface.
(c) Agitate the solution with a soft bristle brush or a Scotchbrite pad after or during application.
(d) Make sure that the surfaces stay wet and allow the solution stand for approximately 10 to 15 minutes.
(e) Follow immediately with an RO or DI water rinse as follows:
1 Begin at the bottom of the airplane and work upwards then back down again. Continue rinsing until the
water sheets from the airplane in a smooth bead, droplet-free film. Pay particular attention to door
openings, windshield retainers, and other areas that could trap alkaline cleaner, deoxidizer, and chemical
film residue.
2 Continue rinsing with RO or DI water until the airplane surface is completely water-break free. A water-
break free surface indicates the surface is clean and is defined by unheated water remaining in a thin,
continuous film over the area. A contaminated surface will cause the water to bead up or go around a
contaminant in a discontinuous film.
3 Any area showing a water break indicates contamination and must be alkaline cleaned again followed with
the RO or DI water rinse.
(f) For local cleaning such as gear walls, flaps, nacelles, or thrust reverser, do as follows:
1 Mix one part of Ardrox 1900-BD alkaline cleaner with 5 to 10 parts RO or DI water.
2 Apply the alkaline cleaner solution with a portable sprayer or mop.
3 Agitate the solution with a soft bristle brush and allow it to stand for approximately 5 to 10 minutes.
4 Follow immediately with an RO or DI water rinse as follows:
a Begin at the bottom of the airplane and work upwards then back down again. Continue rinsing until the
openings, windshield retainers, and other areas that could trap alkaline cleaner, deoxidizer, and
chemical film residue.
b Continue rinsing with RO or DI water until the airplane surface is completely water-break free. A water-
c Any area showing a water break indicates contamination and must be alkaline cleaned again followed
with the RO or DI water rinse.
(3) Deoxidize
(a) Mix 1.0 to 1.5 parts of Eldorado AC-12 deoxidizer with 4 to 5 parts RO or DI water.
(b) Apply the deoxidizer solution with a portable sprayer or brush from the bottom to the top to minimize drying on
the surface.

20-50-00-7 (Rev 1)
(c) Make sure that the surfaces stay wet and allow the solution stand for approximately 2.5 to 5 minutes.
(d) Follow immediately with an RO or DI water rinse as follows:
1 Begin at the bottom of the airplane and work upwards then back down again. Continue rinsing until the
openings, windshield retainers, and other areas that could trap alkaline cleaner, deoxidizer, and chemical
film residue.
2 Continue rinsing with RO or DI water until the airplane surface is completely water-break free. A water-
3 Any area showing a water break indicates contamination and must be alkaline cleaned again followed with
the RO or DI water rinse.
(4) Chem Film
(a) Mix 1.5 to 2.0 ounces of Eldorado Dorado Kote #1 chem film solution per gallon of RO or DI water.
(b) Make sure that the airplane is still wet from rinsing after deoxidizing. Check for water break-free surfaces. If the
water breaks or the surfaces have been allowed to dry after deoxidizing, the procedure must be done again
starting with Alkaline Clean.
(c) On a water break-free surface, apply the chem film solution liberally with a portable sprayer, mop, or brush from
the bottom to the top in an even coating.
(d) Make sure that the surfaces stay wet and allow the solution to stay on the surface until the color changes from
golden brown to light brown. Do not allow the solution to dry on the surfaces. If the room temperature is more
than 90°F (32°C), the dwell time for the chem film solution will be shortened.
(e) Follow immediately with a one-step RO or DI water rinse as follows:
1 Begin at the bottom of the airplane and work upwards then back down again. Pay particular attention to
door openings, windshield retainers, and other areas that could trap alkaline cleaner, deoxidizer, and
chemical film residue.
2 During rinsing, check for water break-free surfaces and areas that did not take the chem film coating. Make
sure that there is a uniform color of yellow to dark gold.
3 Large areas that do not have the uniform color or very little color must be chem filmed again, if the surface
has not dried, followed with the RO or DI water rinse until the desired color is obtained.
a If the inadequate chem film coating has dried or there are water-breaks on the surface, the areas or
the whole airplane must be cleaned, deoxidized, and chem filmed again.
F. Dry the Airplane
(1) Let the airplane dry completely before continuing this procedure.
(2) You can shorten the drying time by blowing the water off and out of seams with dry, filtered, compressed air, then,
heat the airplane to 120 to 130°F (48 to 54°C) for 4 to 8 hours.
G. Solvent Clean
NOTE: If it has been 48 hours or more since the chem film application, it is necessary to solvent clean the
airplane before you continue.
(1) Solvent clean the airplane. Refer to General Solvents/Cleaners - Maintenance Practices.
H. Corrosion Protection Primer Application
(1) Requirements
practical.
(c) Use the appropriate tips, air caps, fluid pressures, and atomization pressures. All application devices used to
apply primers or topcoats must be operated according to local environmental compliance requirements.
(d) Use respirators, face shields or goggles, rubber aprons, gloves, and other protective clothing.

20-50-00-7 (Rev 1)
(e) Make sure that the ambient temperature is above 50°F (10°C).
(f) The surfaces must be clean and dry at the time of primer application.
(g) A slight orange peel is characteristic of an epoxy primer coating.
(2) If it has been 24 hours or more since the solvent wipe, it is necessary to solvent wipe the surface again before you
apply the primer.
(3) If it has been 48 hours or more since the solvent wipe, do the steps that follow before you apply the primer:
(a) Scuff sand all primed surfaces with a Scotchbrite pad wet with Methyl n-Propyl Ketone. Add Methyl n-Propyl
Ketone as necessary to keep the pad wet. Work on a small area so that the surface being abraded stays wet.
(b) Immediately wipe the surface dry with a clean, dry cloth. Do not let the surface evaporate dry.
(4) Mix one of the primers shown in Table 705 per the manufacturer's instructions.
Table 705. Primers
Name Manufacturer Use
PPG Aerospace
PRC-DeSoto International
513x419 (Base)
5430 San Fernando Rd Corrosion Protection Primer
910x492 (Catalyst)
P.O. Box 1800
Glendale, CA
PPG Aerospace
PRC-DeSoto International
02-Y-40 or 02-Y-40 CATA 5430 San Fernando Rd Corrosion Protection Primer
P.O. Box 1800
Glendale, CA
Sterling Lacquer Manufacturing Co.
U-1201F or U-1202F 3150 Brannon Ave. Corrosion Protection Primer
St. Louis, MO 63139
International Paint LLC
DBA Akzo Nobel Coatings
10-P20-13 Base, EC-213 Catalyst Corrosion Protection Primer
1 East Water Street
Waukegan, IL 60085
Akzo Coatings Inc
10P8-11 Base, EC-286 Catalyst 1 East Water Street Corrosion Protection Primer
Waukegan, IL 60085
(5) Put a metallic test panel adjacent to the painting surface.
(6) Apply the primer with one wet spray coat 0.6 to 0.9 mil thick. The primer coat should be smooth and continuous, free
of sags, blisters, and surface irregularities such as dirt, lint, and other foreign debris.
(7) Let the primer cure per the manufacturer's instructions.
(8) Make sure that the primer thickness is 0.6 to 0.9 mil on the metallic test panel.
NOTE: The primer thickness on the metallic test panel should be considered as the same thickness
as on the airplane surface.
I. Aerodynamic Fairing Compound Application (If Necessary)
(1) Requirements
(a) If necessary, aerodynamic fairing compound should be applied to correct contour, roughness, and dimensional
deviations.
(b) Make sure that the surfaces are free of dust, grease, shop oils, cutting fluids, identification marking, metal filings,
moisture, solvents, and other foreign particles before you apply aerodynamic fairing compound.
(c) The primer must be dry enough to shown no fingerprints before aerodynamic fairing compound application.
(d) Keep the aerodynamic fairing compound thickness as thin as possible.
(e) Do not mix the different types of aerodynamic fairing compounds.

20-50-00-7 (Rev 1)
(f)
Do not apply the aerodynamic fairing compound over the heads of screws, bolts, or fasteners that have to be
removed at regular service intervals for routine maintenance.
(g) Use Type I and Type III aerodynamic fairing compound to fill on fiberglass or composite if the depth is too much
for sanding surfacers.
(h) Use Type II aerodynamic fairing compound to fill on exterior surfaces that are not subject to flexing, bending, or
other modes of deformation. Do not use on or over surfaces of radomes or radio altimeters due to interferences
effects from the metal powder or metal flake filler contained in the material.
(2) Mix the applicable aerodynamic fairing compound shown in Table 706 per the manufacturer's instructions.
Table 706. Aerodynamic Fairing Compounds
Type Name Manufacturer
Bondtite Premium 80 Light Body
Bondtite Products
Filler
White Diamond Body Filler Bondtite Products
Loctite EA960F Aero Henkel Corporation
Type I, Polyester Resin and Styrene
Dynalite #494, #496 Dynatron
Monomer
Rage Xtreme #122 ITW Evercoat
Techniglaze DF-715 PPG Industries, Inc.
Metal Glaze, Finishing and Blending
ITW Evercoat
Putty #100416
Type II, Polyester Resin with
Aluminum Putty (F) - 10610 - 1 gallon ITW Devcon
Aluminum Powder
Epoxy Filler Putty 467-9 AKZO Coatings
Loctite EA 9394 PT Aero Henkel Corporation
Quantum1 Large Repair #497 - 3
Gallon Pail
Catalyst #457 and #455 ITW Evercoat
Use with #171 Putty Pusher -
X530004
Quantum1 Large Repair #490 - 0.5
Gallon Pail ITW Evercoat
Catalyst #457 and #455
Type III, Epoxy Resin
10:1 BPO Catalyst Fast #457 - 2.8
oz. ITW Evercoat
Use with Quantum1 #490 and #497
10:1 BPO Catalyst Very Fast #455 -
2.8 oz. ITW Evercoat
Use with Quantum1 #490 and #497
Quantum1 Fast #492 - 825 mL
Cartridge ITW Evercoat
Use with #835 Dispenser - X530003
369-11 Mankiewicz
(3) Use a plastic squeegee to apply the aerodynamic fairing compound to the airplane surface.
(4) Force the aerodynamic fairing compound into the indentations or unlevel areas in the surface by making a passing
motion while applying a firm downward pressure at the same time.
(5) Apply a thin layer initially, for maximum adhesion and then apply the desired thickness and contour.
(6) While building the thickness above the metal surface, smooth in several directions.
(7) The aerodynamic fairing compound can be built up to any desired thickness by repeating this procedure.

20-50-00-7 (Rev 1)
(8) Let the aerodynamic fairing compound cure per the manufacturer's instructions.
(9) Sand the aerodynamic fairing compound with 80 grit or finer sandpaper until the surfaces conform closely to the
contour of the surrounding surfaces and are flush with the surrounding edges. You can use a power sander or sand by
hand.
(10) The sanded surfaces with aerodynamic fairing compound must not vary in contour by more than 0.060 inch per linear
distance across the faired area when checked with a spline in the direction parallel to and/or perpendicular to the
direction of the airstream.
(11) All faired surfaces that were sanded must be sanded with 150 grit or finer sandpaper until the faired surfaces are
smooth and the 80 grit striations are sanded away. You can use a power sander or sand by hand.
(12) After sanding, all exposed metal must be brush or spray chem filmed, then epoxy primed. Refer to Chem Film and
Corrosion Protection Primer Application in this section.
J. Aerodynamic Smoothing Application (If Necessary)
(1) Requirements
(a) If necessary, this process fills and seals gaps and seams between the skins of the airplane exterior to get a
smooth aerodynamic surface.
(b) The aerodynamic smoother should be applied as soon as possible after cleaning and drying of seams.
(2) If it has been 12 hours or more since the primer application, it is necessary to solvent wipe the exposed edges again
before you apply the aerodynamic smoother.
(3) Fill the seams with PPG Aerospace P/S 870, 6 oz. Frozen B-2 aerodynamic smoothing compound.
(4) Strike off the excess material with a plastic squeegee. Freshly applied fillets of aerodynamic smoothing compound
may be shaped or smoothed with a small paddle-shaped tool.
(5) If the seams must be visible, use a V-shaped rod to score a depression in the newly applied material and remove
excess material.
(6) Let the aerodynamic smoothing compound cure per the manufacturer's instructions.
(7) Polyurethane paint or sanding surfacer may be applied after 10 to 12 hours or when the surface of the aerodynamic
smoother is tack-free.
(8) The cured aerodynamic smoothing compound may be shaped or smoothed by wet-sanding with a suitable abrasive
or with a sharp cutting tool. Mylar tape can be applied to both sides of the seams to protect the primed surfaces. Do
not sand or cut through the Mylar tape.
K. Sanding Surfacer Application (If Necessary)
(1) Requirements
(a) Sanding surfacer must be applied to all metal exterior surfaces that have been epoxy primed, faired, and
smoothed.
(b) Sanding surfacer may be applied to all plastic, fiberglass, and composite exterior surfaces if necessary.
(c) The thickness of the sanding surfacer should be sufficient to cover scratches, orange peel in metal and primer,
and all other imperfections. The maximum thickness permitted is 5 mils.
(2) If it has been 48 hours or more since the epoxy primer application, do the steps that follow before you apply the
sanding surfacer:
(a) Scuff sand all primed surfaces with a Scotchbrite pad wet with Methyl n-Propyl Ketone. Add Methyl n-Propyl
Ketone as necessary to keep the pad wet. Work on a small area so that the surface being abraded stays wet.
(b) Immediately wipe the surface dry with a clean, dry cloth. Do not let the surface evaporate dry.
(3) Mix one of the sanding surfacers that follow per the manufacturer's instructions.
• Sterling U-4750 Base, U-4752 Catalyst
• Akzo 10P30-8 Base, EC-284 Catalyst
• Akzo K8032 Base, K3002 Catalyst
• Akzo 20P20-3 Base, PC-232 Catalyst

20-50-00-7 (Rev 1)
(4) Apply sanding surfacer by conventional spray technique (wet cross-coat method). Apply three medium coats for a
total thickness of 3 to 5 mils.
NOTE: It is permitted to use one of the recommended sanding surfacers as a base coat and use a
second of a different color to build thickness. This provides a color line to help you determine
when to stop sanding.
(5) Let the sanding surfacer cure for 10 to 12 hours.
(6) Use 150 grit sandpaper to sand the sanding surfacer until the surfaces are smooth and most of the sanding surfacer
to be removed has been sanded away. You can use a power sander or sand by hand.
(7) All surfaces that were sanded must be sanded with 220 grit or finer sandpaper until the surfaces are smooth and the
150 grit striations are sanded away. You can use a power sander or sand by hand.
(8) The sanding surfacer should be 1.0 mil thick maximum. The sanding surfacer can be sanded thinner, even to the
epoxy primer but do not sand into the epoxy primer more than 0.5 mil. Local areas of the sanding surfacer can
exceed 1.0 mil thickness for aerodynamic reasons.
(9) If metal is exposed during sanding, the area must be primed again. Refer to Corrosion Protection Primer Application
in this section.
L. Sanding/Sealer Primer Application (If Necessary)
(1) Requirements
(a) Sanding/sealer primer application may be done within two to three hours of the sanding surfacer application or
after the sanding of the surfacer.
(b) Small areas of the sanding surfacer may require filling with a urethane sanding/sealer primer.
(c) Apply the sanding/sealer primer only to the surfaces with sanding surfacer.
(2) Solvent wipe the surface. Refer to General Solvents/Cleaners - Maintenance Practices.
(3) Mix Akzo Nobel 467-9 sanding/sealer primer per the manufacturer's instructions.
(4) Apply the sanding/sealer primer by conventional spray technique, brush, or plastic squeegee.
(a) You can recoat in 20 minutes.
(b) Do not exceed 3 to 5 mils thickness.
(5) Let the sanding/sealer primer dry for one hour.
(6) Use 150 grit sandpaper to sand the sanding/sealer primer. You can use a power sander or sand by hand.
(7) All surfaces that were sanded must be sanded with 220 grit or finer sandpaper until the surfaces are smooth and the
150 grit striations are sanded away. You can use a power sander or sand by hand.
(8) The sanding/sealer primer should be 1.0 to 1.5 mils thick maximum.
(9) If metal is exposed during sanding, the area must be primed again. Refer to Corrosion Protection Primer Application
in this section.
M. De-Mask the Airplane
(1) Remove the masking material from the airplane.
(2) Use dry, filtered, shop air to blow off the dust and debris from the airplane.
(3) Move the airplane to an applicable painting facility.
(4) Solvent wipe the surface of the airplane. Refer to General Solvents/Cleaners - Maintenance Practices.
N. Masking
(1) Apply masking to the applicable areas on the airplane. Refer to Masking in this section.
O. Topcoat and Stripe Application
(1) Solar Heat Reflective (SHR) Topcoat Standards
(a) The choice of paint colors offered to customers on upward facing surfaces (30° down from the horizontal plane
of composite and metalbond structures must have a reflectance value of 26 or more. Typically, paints darker
than light gray (blue, black, etc...) fall into this category. Refer to the following figures for the applicable airplane
model:
• Model 510

20-50-00-7 (Rev 1)
• Model 525
• Model 525A
• Model 525B
• Model 525C
• Model 560
• Model 560XL
• Model 560XLS
• Model 680
• Model 680A
• Model 700
• Model 750
• Typical Model 500 Series / 650 Airplanes
NOTE: The diagram in each figure shows how to determine the upper facing composite or
metalbond surfaces that need SHR topcoats for dark colors..
(b) The paint manufacturer will supply the color standards.
(c) Composites and metalbond upper facing surfaces that must have Solar Heat Reflective (SHR) topcoats for dark
colors are shaded gray in each of the airplane model illustrations. Refer to Table 707 for upper facing parts that
do not have SHR requirements per airplane model.
Table 707. SHR Location Requirements
Alrn Vert Elvtr
Nose Spd Tail- Horz
Mdl Fuslage Wing Flap Alrn Trim Pyln Lead Elvtr Trim
Fuselage Brks cone Stab
Tabs Edge Tabs
500 / No No No No No No No No
No SHR SHR SHR SHR SHR
501 SHR SHR SHR SHR SHR SHR SHR SHR
510 No No No No No No No No No No
No SHR SHR SHR
SHR SHR SHR SHR SHR SHR SHR SHR SHR SHR
525 M2 No No No No No No No No No No
No SHR SHR SHR
No SHR SHR SHR
525A No No No No No No No No No No
No SHR SHR SHR
525B No No No No No No No No No No
No SHR SHR SHR
525C No No No No No No No No
SHR SHR SHR SHR SHR
SHR SHR SHR SHR SHR SHR SHR SHR
550 / No No No No No No No
No SHR SHR SHR SHR SHR SHR
551 SHR SHR SHR SHR SHR SHR SHR
550 No No No No No No No
Bravo SHR SHR SHR SHR SHR SHR SHR
S550 No No No No No No No
SHR SHR SHR SHR SHR SHR SHR
No SHR SHR SHR
560XL / No No No No No No
560XLS SHR SHR SHR SHR SHR SHR
650 No No No No No No No

20-50-00-7 (Rev 1)
680 No No No No No
SHR SHR SHR SHR SHR
680A No No No No No No No
SHR SHR SHR SHR SHR SHR
700 No No No No No No
SHR SHR SHR SHR SHR SHR
750 No No No No No
SHR SHR SHR SHR SHR
NOTE 1: Solar Heat Reflective (SHR) Coatings are NOT required on the Radome, Bullet/Vertical
Caps, Nacelles, Stingers and Winglets on all Citation Models.
NOTE 2: The nose fuselage is the part of the fuselage aft of the radome and forward of the
windshield.
(2) Upper Facing Stripes and Registration Numbers that do not have SHR Requirements.
(a) The maximum acceptable stripe width for dark colors going over the top of a metalbond fuselage or wing for
symmetrical appearance is 18 Inches (457.2 mm).
(b) Any stripe widths greater than 18 Inches (457.2 mm) must have SHR topcoats for dark colors.
(c) Registration numbers that are on the upper facing surfaces of wings and are dark colors, do not need to have
SHR topcoats.
NOTE: The stripe width and registration numbers are fully separate from the composites and
metalbond upper facing surfaces that must have Solar Heat Reflective (SHR) topcoats for
dark colors (mentioned in Table 707 and Figures 701 through 716).
(3) Facility and Equipment Requirements
practical. It is recommended that the enclosure be under positive pressure.
(d) The air system used for spraying must deliver air free from oil and moisture.
(e) Conventional air spray equipment is recommended for the application of topcoats.
(f) The recommended pot pressure for polyurethane paint is 10 to 13 psi. The flow rate through a tip size of FX and
air cap No. 735 should be 12 to 16 fluid ounces per minute at 75 to 85°F (23 to 29°C) when the paint is thinned.
The pot pressure may be increased from 19 to 24 psi if the height of the gun above the pot and/or the length of
the hose is increased.
(g) The recommended atomizing air pressure is 50 to 60 psi.
(h) Use the appropriate tips, air caps, fluid pressures, and atomization pressures. All application devices used to
apply primers or topcoats must be operated according to local environmental compliance requirements.
(4) Pre-Paint Requirements
(a) The airplane must be pretreated, primed, faired, surfaced, and sanded before the topcoat application.
(b) The airplane must be electrically grounded during the finishing operations.
(c) The exterior surfaces must be solvent wiped before the topcoat application.
(d) The exterior surfaces must be clean, dry, and free from dirt, grease, and other foreign contaminants.
(e) The applicable areas of the airplane must have masking applied.
(5) Material Requirements
(a) All materials must be qualified and approved for topcoat use.
(b) All materials must be thoroughly mixed before application.
(c) Topcoats and their respective curing solutions must be a product of the same manufacturer.
(d) All materials must be stored in sealed containers in a clean, dry area.
(e) After mixing, the materials must be homogeneous and free from lumps, seeding, or signs of resin kick out.

20-50-00-7 (Rev 1)
(6) Application Requirements

(a) The dried film must be free of runs, sags, streaks, blisters, lifting, and blushing. A slight orange peel is
characteristic of a topcoat finish.
(b) The total dry film thickness of the paint system should be between 5.5 to 9.0 mils and not to exceed 10.0 mils
except for aerodynamic reasons. This includes corrosion primers, sanding surfacer, and topcoat. It does not
include fairing or striping.
(c) To improve rain erosion resistance, it is permissible to add a flex agent to the topcoat for the windshield retainer
ring. After the primer application, mask the windshield retainer ring. After airplane is painted, then masking for
the stripes can begin. De-mask the retainer ring and mask off the painted areas around the ring. Topcoat the
retainer ring using a flex agent.
(d) Spray equipment must be cleaned with Methyl n-Propyl Ketone or toluene immediately after spraying.
(e) When mixing tints for stripes, stir the containers for at least 20 minutes before weighing out the required quantity.
(f) Do not apply paint at temperatures more than 105°F (40°C).
(7) If it has been 24 hours or more since the surface was sanded, it must be lightly sanded and then solvent wiped again
before you apply the topcoat.
(8) Mix one of the topcoats shown in Table 708 per the manufacturer's instructions.
Table 708. Topcoat and Stripe Products
TOPCOAT AND STRIPE PRODUCT (See Notes 1, 2, MANUFACTURER
3)
Alumigrip 4200 Base Akzo Nobel Aerospace Coatings Inc.
Alumigrip PC-242 Hardener East Water Street
Alumigrip 4950 Activator Waukegan, Illinois 60085
Alumigrip 4951 Activator
Alumigrip 4952 Activator
Imron Aviation AF-3500 Activator: 13110S/194S
Accelerator 13803S/13808S
Pot Life Extender 13895S
Thinner 13775S/13785S
Silica Reducer 13821S
Imron AF-700 Base Axalta Coating Systems
Activator 13100S DeNemours and Company, Inc.
Accelerator 13803S 1007 Market Street
Reducer 13765S (or 13775S) (max 15% pbv) Wilmington, Delaware 19898
AF740 Clear
Catalyst 13110S
Accelerator 13803S or 13808S (for repair)
Reducer 13765S, 13775S, or 13930S (max. 15% pbv)
Blenders 19301S or 13982S
Desothane HS CA8800 Buffable Topcoat
CA8800Z Activator
CA8800CT Thinner
CA8800 CT-1 Thinner
CA8800 CT-2 Thinner
CA8800 CT-4 Thinner
PPG Aerospace
PRC- DeSoto Coatings
Glendale, California 91209

20-50-00-7 (Rev 1)
9008B0900D Clearcoat
9008B Activator
9008CSR Clearcoat Reducer (50/50 blend by vol. of
9008CS and 9008CTR)
9008CR Reducer
9008CS Reducer
Used with Desothane HD 9008 Basecoat
Jet Glo 570 Series Base (Conventional)

Acry Glo 571 Series Base (Conventional)
Jet Glo Express 840 Series
CM840081 Hardener
CM840A01 Activator
CM840A02 Activator
CM840A03 Activator Sherwin Williams
CM840A05 Activator 101 Prospect Ave N W
CM840A07 Activator Cleveland, Ohio 44115-1042
Low VOC Acrylic Polyurethane 830 Series Base
CMO 830-081 Catalyst
CMO 830-H18 Accelerator
F63 Series Base
V66V55 Catalyst
R6K30 Reducer (up to 12% pbv)
Sterling 76-U Base
Sterling 78-U Color
97U-5000 Series Base (Gloss)
97U-5000 Hardener Sterling Laquer Manufacturing Company.
97U-5106 Activator 3150 Brannon Avenue
97U-5107 Activator St. Louis, Missouri 63139
97U-5108 Activator
97U-6001 Base (Flat)
97U-6000 Hardener
NOTE 1: It is not required to use the same manufacturer's product for both the topcoats and stripes but
it is required to use the same manufacturer for the base-coat/clear-coat application.
NOTE 2: These products are approved for use as both topcoat and stripe applications.
NOTE 3: Imron AF3000 and Akzo K series are not available
(9) Apply the topcoat to the airplane surface per the manufacturer's instructions.
(10) Let the topcoat cure per the manufacturer's instructions.
(12) Apply masking as applicable for stripes, windshield retainer ring, letters, and/or numbers on the airplane. Refer to
Masking in this section.
(13) Scuff sand the topcoat in the area to be painted with 220 grit sandpaper or finer.
(14) Solvent wipe the surface as applicable. Refer to General Solvents/Cleaners - Maintenance Practices.
(15) Mix one of the stripe paints as shown in Table 708 per the manufacturer's instructions.
(16) Apply the paint as applicable for the stripes, windshield retainer ring, letters, and/or numbers per the manufacturer's
instructions.
(17) Let the paint cure per the manufacturer's instructions.
(19) Do the necessary cleaning and detailing.

20-50-00-7 (Rev 1)
(20) Install the applicable erosion boots and or de-ice boots as applicable. Refer to the applicable Maintenance Manual.
8. Mechanical Finish Polishing/Buffing
A. General
(1) This section includes the requirements and procedures for mechanical finish polishing and buffing.
• Pneumatic Polishing/Buffing Tool.
• Buffing Compound
• Polishing Compound.
C. Requirements
(1) The parts must be free of nicks, gouges, scratches, and other defects before the polishing and buffing. Minor defects
that do not penetrate the cladding and will be removed during the polishing and buffing are permitted.
(2) All parts must be solvent cleaned before polishing and/or buffing.
(3) Be careful during polishing and buffing to prevent penetration and removal of the clad. Use light contact pressure with
the wheels of the sanding discs.
(4) The polishing and buffing wheels must be kept clean by raking to prevent caking of compounds which might cause
scratching.
(5) Polished and buffed parts must have a uniform finish.
(6) Polished and buffed parts must be solvent cleaned immediately to remove excess polishing/buffing compounds.
(7) The perimeter of some polished parts such as the wing leading edges have a gap that is filled with sealer. The
condition and integrity of the gap sealer must be inspected and the sealer replaced if the polishing steps have
damaged, degraded or pulled the sealer loose.
D. Prepare the airplane for the Mechanical Finish Polishing/Buffing.
(1) Clean the surface with solvent. Refer to General Solvents/Cleaners - Maintenance Practices.
(2) Apply masking as applicable to prevent damage to the paint. Refer to Masking in this section.
E. Do the Polishing.
(1) This mechanical finishing process removes surface imperfections on metal parts, such as extrusion lines and rolling
marks, in addition to increasing the luster of the metal surface.
(2) Polish the surface with a muslin polishing wheel and one of the polishing compounds that follow:
• Nushine II, Grade C
• Nushine II, Grade S.
(3) Gradually abrade the metal surface to an extremely smooth surface by using a progressively finer abrasive.
(4) The required contact pressure between the part and the polishing wheel is determined by the surface condition of the
metal. Greater pressure increases both the amount of metal removed and the surface brightness.
(5) The polishing wheel must revolve at approximately 6500 surface feet-per-minute (fpm) for satisfactory results.
F. Do the Buffing.
(1) After parts have been polished, an additional operation called buffing must be performed. Buffing will impart a high
degree of luster to the aluminum surfaces.
(2) Buff the surface with a very soft buffing wheel and one of the buffing compounds that follow:
• Buffing Compound, Formula No. 1187

20-50-00-7 (Rev 1)
• Buffing Compound, SS-17

• Buffing Compound, SS-47.
(3) Use a light contact pressure between the part and the buffing wheel.
(4) The buffing wheel must revolve at approximately 8000 surface fpm.
G. Put the airplane back to its initial condition.
(1) Clean the surface with solvent to remove any excess polishing and buffing compounds. Refer to General
(2) Remove the masking materials from the airplane.
(3) For any wing leading edge panels that have a perimeter gap sealer installed; inspect the sealer condition and
integrity. Replace the sealer if found damaged, degraded or pulled loose from skin gap.
9. Missing Paint
A. Missing paint can be considered cosmetic in most cases (Refer to Table 709). It is acceptable to operate the aircraft with
missing paint in the following areas:
Table 709. Missing Paint Locations
Location
Aircraft Fuselage (Nose, Cabin, Tailcone and Empennage) (NOTE 1)
Wing
Doors (Main Cabin, Escape Hatch, Baggage and Service)
Flight Control Surfaces (Flaps, Ailerons, Rudder, Elevators, Speed Brakes and Tabs) (NOTE 2)
Landing Gear (Nose/Main/Doors)
Vertical Stabilizer Assembly
Horizontal Stabilizer Assembly
Strakes
Fairing Assemblies
Engine Nacelle, Cowling, Exhaust, Pylons and Inlet
Radome (NOTE 3)
NOTE 1: This guidance does not apply to RVSM-related areas. Refer to the appropriate maintenance manual
for RVSM-related information. The RVSM static areas must be maintained in accordance with
instructions in this section.
NOTE 2: After a flight control surface, including tab if applicable, is found to be within the weight and static
balance specifications per the appropriate structural repair manual, and is installed on an aircraft,
cosmetic damage to the paint coat up to and including the loss of paint over 20 percent of the
surface area of the control surface and tab is allowed without rechecking the weight or static
balance of the control surface and tab. For composite flight control surfaces and fairings/panels,
an appropriate inspection of the area and its component assembly should be completed to
determine cause for the paint loss. Refer to the appropriate maintenance manual and/or structural
repair manual sections for lightning strike and/or mechanical damage procedures, if suspected.
Due to potential long term environmental effects on the exposed areas, continued operation of the
aircraft should not exceed 10 calendar days, or 40 operations hours, whichever occurs first.
NOTE 3: Composite radomes have specific p-static requirements. It is acceptable for paint to be missing
from the radome, provided the underlying finish (primer/surfacer) remains intact. In this case, it is
acceptable for continued operations for up to 10 calendar days. Refer to the appropriate
Maintenance Manual and/or Structural Repair Manual sections for information on events where the
paint and primer are missing from the radome.
B. Visual inspections (during the normal preflight inspection) either by a pilot or a qualified aircraft technician are acceptable
in determining the amount of paint loss.
C. Paint topcoat is a form of corrosion protection and prevention. It is recommended that retreating the exposed surfaces be

20-50-00-7 (Rev 1)
completed as soon as practical. Refer to the appropriate structural repair manual for information on protective treatment of
metal and corrosion protection procedures.
D. Composite radomes have specific p-static requirements. It is acceptable for paint to be missing from the radome,
provided the underlying blue primer remains intact. Refer to the appropriate maintenance manual for information on
radomes.
NOTE: Continuous operations for composite radomes with missing paint should not exceed 10 calendar
days. Refer to the appropriate maintenance manual and /or structural repair manual sections for
published guidance regarding events where the paint and primer are missing from the radome.

20-50-00-7 (Rev 1)
Figure 701 : Sheet 1 : Model 510

A104059
32 Inches Vertical Plane 32 Inches
Arc Length Arc Length
Horizontal Plane
30° 30°
Fuselage
Circumference
189 Inches
VIEW A-A
A A
Metal Bond Composite Solar Heat

Reflective
Coating

20-50-00-7 (Rev 1)

A104060
Horizontal Plane
30° 30°
Fuselage
Circumference
201 Inches
VIEW A-A
A A

Reflective
Coating

20-50-00-7 (Rev 1)
Figure 703 : Sheet 1 : Model 525A

A104063
Horizontal Plane
30° 30°
Fuselage
Circumference
201 Inches
VIEW A-A
A A

Reflective
Coating

20-50-00-7 (Rev 1)
Figure 704 : Sheet 1 : Model 525B

A104065
Horizontal Plane
30° 30°
Fuselage
Circumference
201 Inches
VIEW A-A
A A

Reflective
Coating

20-50-00-7 (Rev 1)
Figure 705 : Sheet 1 : Model 525C

A104067
Horizontal Plane
30° 30°
Fuselage
Circumference
A A 201 Inches
VIEW A-A

Reflective
Coating

20-50-00-7 (Rev 1)

A104068
Horizontal Plane
30° 30°
Fuselage
Circumference
228 Inches
A A
VIEW A-A

Reflective
Coating

20-50-00-7 (Rev 1)
Figure 707 : Sheet 1 : Model 560XL

A104069
Horizontal Plane
30° 30°
Fuselage
Circumference
228 Inches
A A
VIEW A-A

Reflective
Coating

20-50-00-7 (Rev 1)
Figure 708 : Sheet 1 : Model 560XLS

A104070
Horizontal Plane
30° 30°
Fuselage
Circumference
228 Inches
A A
VIEW A-A

Reflective
Coating

20-50-00-7 (Rev 1)

A104071
Horizontal Plane
30° 30°
A A
Fuselage
Circumference
228 Inches
VIEW A-A
38.00
Inches
11.00
VIEW B-B Inches

Reflective
Coating

20-50-00-7 (Rev 1)
Figure 710 : Sheet 1 : Model 680A

A104072
Horizontal Plane
30° 30°
Fuselage
Circumference
263 Inches
VIEW A-A
A A

Reflective
Coating

20-50-00-7 (Rev 1)

A104075
Horizontal Plane
30° 30°
A A Fuselage
Circumference
228 Inches
VIEW A-A
Airplanes without
winglets are similar.
7.00
Inches
28.00
Inches
67.00 Inches
Pylon
VIEW B-B

ReflectiveCoating

20-50-00-7 (Rev 1)
Figure 712 : Sheet 1 : Typical Model 500 Series / 650 Airplanes

A106199
Horizontal Plane
NOTE 1: Image shows typical areas
with Solar Hear Reflective 30° 30°
Coating requirements on
Model 500 Series/650 Airplanes.
Refer to the "SHR Location
Requirements" table for
specific locations.
Fuselage
NOTE 2: Composite and Metal Bond Circumference
areas not shown. 228 Inches
VIEW A-A
A A
Solar Heat
Reflective
Coating

20-50-00-7 (Rev 1)

A105533

Horizontal Plane
30° 30°
Fuselage
Circumference
A A 263 Inches
VIEW A-A

Reflective
Coating

EXTERIOR FINISH PAINT THICKNESS - CLEANING/PAINTING

1. General
A. This section gives the lightning strike zones and the maximum paint thickness for composite surfaces.
B. Lightning can cause extensive damage as a result of the energy in the lightning strike. A low impedance (resistance) path
to the airframe structure is required to let the metal parts of the airplane to conduct the electric current without a large
voltage buildup. It is very important that the resistance between the different structures of the airplane be kept to a
minimum to prevent high voltage buildup during a lightning strike.
2. Lightning Strike Zones
A. Definitions
NOTE: Refer to SAE ARP 5412 and SAE ARP 5414 for more information about lightning strikes and
airplane zones.
• Attachment Point - A point of contact of the lightning flash with the airplane.
• Breakdown - The production of a conductive ionized channel in a dielectric medium resulting in the collapse of a
high electric field.
• Dwell Point - A lightning attachment point.
• Dwell Time - The time that the lightning channel remains attached to a single spot on the aircraft.
• External Environment - Characterization of the natural lightning environment for design and certification purposes.
• First Return Stroke - The high current surge that occurs when the leader completes the connection between the two
charge centers. The current surge has a high peak current, high rate of change of current with respect to time
(di/dt), and a high action integral.
• Flashover - This term is used when the arc produced by a gap breakdown passes over or close to a dielectric
surface without puncture.
• Leader - The low luminosity, low current precursor of a lightning return stroke, accompanied by an intense electric
field.
• Lightning Channel - The ionized path through the air along which the lightning current pulse passes.
• Lightning Flash - The total lightning event. It may occur within a cloud, between clouds, or between a cloud and
ground. It can consist of one or more return strokes, plus intermediate, or continuing currents.
• Lightning Strike - Any attachment of lightning flash to the airplane.
• Lightning Strike Zones - Airplane surface areas and structures classified according to the possibility of lightning
attachment, dwell time, and current conduction.
• Reattachment - The establishment of new attachment points on the surface of an airplane due to the sweeping of
the flash across the surface of the airplane by the motion of the airplane.
• Restrike - A subsequent high current surge attachment, which has a lower peak current, a lower action integral, but
a higher di/dt than the first return stroke. This normally follows the same path as the first return stroke, but may
reattach to a new location further aft on the airplane.
• Swept Leader - A lightning leader that has moved its position relative to an airplane, subsequent to initial leader
attachment, and prior to the first return stroke arrival, by virtue of airplane movement during leader propagation.
• Swept Channel - The lightning channel relative to the airplane, which results in a series of successive attachments
due to sweeping of the flash across the airplane, by the motion of the airplane.
• Zoning - The process, or the end result of the process, of determining the location on an airplane to which the
components of the external environment are applied.
B. The surface of an airplane is divided into a set of regions called lightning strike zones. These zones represent the areas
likely to experience the various types of lightning currents. The three major zones are as follows:
(1) Zone 1 includes the regions likely to experience initial lightning attachment and first strokes.
• Zone 1A First Return Stroke Zone - Includes all the areas of the airplane's surfaces where a first return stroke
is likely during lightning channel attachment with a low expectation of flash hang on.
• Zone 1B First Return Stroke Zone with Long Hang On - Includes all the areas of the airplane's surfaces where
a first return stroke is likely during lightning channel attachment with a high expectation of flash hang on.
• Zone 1C Transition Zone for First Return Stroke - Includes all the areas of the airplane's surfaces where a first
return stroke of reduced amplitude is likely during lightning channel attachment with a low expectation of flash
hang on.
(2) Zone 2 includes the regions which are unlikely to experience first return strokes but which are likely to experience

subsequent return strokes. This will happen where the airplane is in motion relative to a lighting channel causing
sweeping of the channel backwards from a forward initial attachment point.
• Zone 2A Swept Stroke Zone - Includes all the areas of the airplanes's surfaces where a subsequent return
stroke is likely to be swept with a low expectation of flash hang on.
• Zone 2B Swept Stroke Zone with Long Hang On - Includes all the areas of the airplanes's surfaces into which
a lightning channel carrying a subsequent return stroke is likely to be swept with a high expectation of flash
hang on.
(3) Zone 3 includes the regions which are unlikely to experience any arc attachment but which will have to conduct
lightning current between attachment points. This includes all the other airplane's surfaces not in Zones 1A, 1B, 1C,
2A, or 2B where any attachment of the lightning channel is unlikely, and those portions of the airplane that lie beneath
or between the other zones and/or conduct substantial amounts of electrical current between the direct or swept
stroke attachment points.
C. Refer to Figure 701 for the Model 510 lightning strike zones.
D. Refer to Figure 702 for the Model 525 lightning strike zones.
E. Refer to Figure 703 for the Model 525 (M2) lightning strike zones.
F. Refer to Figure 704 for the Model 525A lightning strike zones.
G. Refer to Figure 705 for the Model 525B lightning strike zones.
H. Refer to Figure 706 for the Model 525C lightning strike zones.
I. Refer to Figure 707 for the Model S550 lightning strike zones.
J. Refer to Figure 708 for the Model 560 lightning strike zones.
K. Refer to Figure 709 for the Model 560XL lightning strike zones.
L. Refer to Figure 710 for the Model 650 lightning strike zones.
M. Refer to Figure 711 for the Model 680 lightning strike zones.
N. Refer to Figure 712 for the Model 680A lightning strike zones.
O. Refer to Figure 742 for the Model 700 lightning strike zones.
P. Refer to Figure 713 for the Model 750 lightning strike zones.
Q. Refer to Figure 714 for the Model 750+ lightning strike zones.
3. Paint Thickness
A. Paint thickness includes all materials applied to the composite surfaces of the airplane including but not limited to filler,
sanding primer, primer, finish paint, and anti-static paint.
B. Radome paint thickness is determined by transmission requirements and not lightning protection. Lightning protection for
the radome is provided by lightning diverter strips. All airplane radomes are required to have no more than 12 mils of paint
thickness. This satisfies the performance standard and transmission requirements associated with all radomes. Paint
thickness includes all materials applied to the composite surfaces of the airplane including but not limited to filler, sanding
primer, primer, finish paint and anti-static paint. Any filler applied to the radome surface must comply with these
requirements.
C. If the paint is too thick on the exterior surface of the airplane, especially on composite structures, the voltage on the outer
surface can become so high that it can burn large holes in the structure.
D. Ultrasonic inspections of paint thicknesses are required to keep continued safe operations when or if the airplane’s
outside finish is removed and refinished. Refer to the applicable Nondestructive Testing Manual, Part 4, Exterior Paint
Thickness Measurement Procedure.
E. Refer to Figure 715 for the Model 510 maximum paint thickness.
F. Refer to Figure 716 for the Model 525 (M2) maximum paint thickness.
G. Refer to Figure 717 for the Model 525A maximum paint thickness.
H. Refer to Figure 718 for the Model 525B maximum paint thickness.
I. Refer to Figure 719 for the Model 525C maximum paint thickness.
J. Refer to Figure 720 for the Model 560XL maximum paint thickness.
K. Refer to Figure 721 for the Model 680 maximum paint thickness.

L. Refer to Figure 722 for the Model 680A maximum paint thickness.
M. Refer to Figure 743 for the Model 700 maximum paint thickness.
N. Refer to Figure 723 for the Model 750 maximum paint thickness.
O. Refer to Figure 724 for the Model 750+ maximum paint thickness.
4. Radome Exterior Paint Inspection
A. Do the Radome Exterior Paint Inspection.
NOTE: The radome exterior paint inspection is done to determine why the paint came off of the radome.
This could be the result of lightning damage, precipitation static (P-static) damage, or mechanical
damage. Refer to the applicable Nondestructive Testing Manual, Part 4, Exterior Paint Thickness
Measurement Procedure for paint and damage criteria.
NOTE: The area applicable for the paint touch-up is in the radar window area. The area outside the radar
window does not need to comply with the requirements in this inspection or be monitored.
NOTE: Cessna Aircraft Company cannot guarantee the transmissivity performance of a radome with
multiple paint touch-ups and therefore it should be scheduled for complete repaint at a convenient
maintenance opportunity.
NOTE: The radome exterior paint is critical because the paint thickness directly affects the radar
transmissivity and the paint protects the radome from moisture intrusion. If the radome has been
struck by lightning or weakened by P-Static effects, this inspection is critical to make sure that the
damage is correctly detected and repaired. This will make sure that the lightning protection is
maintained.
(1) Remove the nose radome. Refer to the applicable Maintenance Manual.
(2) Visually examine for missing paint and other damage on the inside and the outside surfaces of the radar window
area on the nose radome.
(a) Refer to Figure 725 for the Model 500 radar window area.
(b) Refer to Figure 726 for the Model 510 radar window area.
(c) Refer to Figure 727 for the Model 525 radar window area.
(d) Refer to Figure 728 for the Model 525 (M2) radar window area.
(e) Refer to Figure 729 for the Model 525A radar window area.
(f) Refer to Figure 730 for the Model 525B radar window area.
(g) Refer to Figure 731 for the Model 525C radar window area.
(h) Refer to Figure 732 for the Model 550 radar window area.
(i) Refer to Figure 733 for the Model S550 radar window area.
(j) Refer to Figure 734 for the Model 550B radar window area.
(k) Refer to Figure 735 for the Model 560 radar window area.
(l) Refer to Figure 736 for the Model 560XL radar window area.
(m) Refer to Figure 737 for the Model 650 radar window area.
(n) Refer to Figure 738 for the Model 680 radar window area.
(o) Refer to Figure 739 for the Model 680A radar window area.
(p) Refer to Figure 744 for the Model 700 radar window area.
(q) Refer to Figure 740 for the Model 750 radar window area.
(r) Refer to Figure 741 for the Model 750+ radar window area.
(3) Paint touch-up is permitted in the radar window area on the radome with the requirements that follow:
(a) The diameter of the area that requires paint touch-up is not more than 0.5 inch (12.7 mm).
(b) The number of areas that require paint touch-up is not more than 6 per event.
(c) The areas that require paint touch-up are 2.0 inches (50.8 mm) apart minimum.
(d) The applied paint thickness is not more than the surrounding paint thickness and/or 12 mils (0.30 mm).

(e) The nose radome is visually inspected internally and externally for signs of damage.
(4) If it is necessary to fully repaint the nose radome, refer to Exterior Finish - Cleaning/Painting and the applicable
Nondestructive Testing Manual, Part 4, Exterior Paint Thickness Measurement Procedure.
(5) Make a record of the date when the touch-up paint or repainting was applied to the radome.

Figure 701 : Sheet 1 : Model 510 Lightning Strike Zones

A100017
20 Inches
(0.5 m) 20 Inches
(0.5 m)
20 Inches
(0.5 m)
20 Inches
(0.5 m)
51 Inches
(1.3 m)
51 Inches
(1.3 m)
20 Inches
(0.5 m)
20 Inches
(0.5 m)
Legend
Zone 1A Zone 2A Zone 3
Zone 1B Zone 2B
Zone 1C


Figure 703 : Sheet 1 : Model 525 (M2) Lightning Strike Zones

Figure 704 : Sheet 1 : Model 525A Lightning Strike Zones

A100020
20 Inches
(0.5 m) 20 Inches
(0.5 m)
20 Inches
(0.5 m)
20 Inches
(0.5 m)
51 Inches
(1.3 m) 20 Inches
(0.5 m)
51 Inches
(1.3 m)
20 Inches
(0.5 m)
Legend
Zone 1A Zone 2A Zone 3A
Zone 1B Zone 2B
Zone 1C

Figure 705 : Sheet 1 : Model 525B Lightning Strike Zones

A100021
20 Inches
(0.5 m) 20 Inches
(0.5 m)
20 Inches
(0.5 m)
20 Inches
51 Inches (0.5 m)
(1.3 m)
51 Inches
(1.3 m)
20 Inches
(0.5 m)
Legend

Zone 1B Zone 2B
Zone 1C

Figure 706 : Sheet 1 : Model 525C Lightning Strike Zones

A100022
20 Inches
(0.5 m) 20 Inches
(0.5 m) 20 Inches
(0.5 m)
20 Inches
(0.5 m)
51 Inches
(1.3 m)
51 Inches
(1.3 m)
20 Inches
(0.5 m)
Legend

Zone 1B Zone 2B
Zone 1C
7110T1006
7110T1006

Figure 707 : Sheet 1 : Model S550 Lightning Strike Zones

A100023 18 Inches
(0.45 m) 4 Inches
(0.1 m)
18 Inches
(0.45 m)
18 Inches
(0.45 m) 4 Inches
(0.1 m)
18 Inches
18 Inches (0.45 m)
(0.45 m)
18 Inches
(0.45 m)
Legend
Zone 1A Zone 2A Zone 3 4 Inches

(0.1 m)
Zone 1B Zone 2B
Zone 1C
18 Inches
(0.45 m)


Figure 709 : Sheet 1 : Model 560XL Lightning Strike Zones

A100025
18 Inches
(0.45 m) 18 Inches
(0.45 m)
18 Inches
(0.45 m)
18 Inches
(0.45 m)
18 Inches
18 Inches (0.45 m)
(0.45 m)
18 Inches
(0.45 m)
18 Inches
(0.45 m) 18 Inches
(0.45 m)
18 Inches
(0.45 m)
Legend
Zone 1B Zone 2B 6610T1054

6610T1055


A100026
4 Inches 18 Inches
(0.1 m) (0.45 m)
18 Inches
(0.45 m)
4 Inches 18 Inches
(0.1 m) (0.45 m)
18 Inches
(0.45 m)
18 Inches
(0.45 m)
18 Inches
(0.45 m)
4 Inches
(0.1 m)
Legend
Zone 1B Zone 2B


A100027
20 Inches
(0.5 m) 20 Inches
(0.5 m)
20 Inches
(0.5 m) 20 Inches
(0.5 m)
20 Inches (0.5 m)
20 Inches
(0.5 m)
20 Inches (0.5 m)
51 Inches (1.3 m)
51 Inches (1.3 m) Legend
Zone 1A Zone 2A
Zone 1B Zone 2B
Zone 1C Zone 3
6910T1003

Figure 712 : Sheet 1 : Model 680A Lightning Strike Zones

A100028
More Than 20.00 Inches (0.50 m)
20.00 Inches
(0.50 m)
20.00 Inches
20.00 Inches (0.50 m)
(0.50 m)
20.00 Inches (0.50 m)

20.00 Inches
(0.50 m)
Legend
Zone 1A Zone 2A
Zone 1B Zone 2B 20.00 Inches

(0.50 m)
Zone 1C Zone 3
51.00 Inches (1.30 m)

51.00 Inches (1.30 m)


A100034
18 Inches
(0.45 m)
18 Inches
(0.45 m)
18 Inches
Legend (0.45 m) (JAA Only)
Zone 1A Zone 1B 18 Inches
(Zones 2 and 3 also underlie Zone 1) (0.45 m)
Zone 2A Zone 2B 18 Inches
(Zone 3 also underlies Zone 2) (0.45 m) (JAA Only)
Zone 3 18 Inches (0.45 m)
18 Inches (0.45 m)
18 Inches
(0.45 m)
6710T1001

Figure 714 : Sheet 1 : Model 750+ Lightning Strike Zones

A100029
18 Inches
(0.45 m)
18 Inches
(0.45 m)
18 Inches
(0.45 m)
18 Inches
(0.45 m)
18 Inches
(0.45 m)
18 Inches
(0.45 m)
Legend
Zone 1A Zone 1B
(Zones 2 and 3 also underlie Zone 1)
Zone 2A Zone 2B
(Zone 3 also underlies Zone 2)
ZONE 3

Figure 715 : Sheet 1 : Model 510 Maximum Paint Thickness

A100030
Vertical Stabilizer Bullet Fairing

10 Mils
Middle Fuselage Escape Hatch Seal

10 Mils
Nose Radome
12 Mils
Aft Tailcone
Stinger Cap
15 Mils
Aft Tailcone Strake

15 Mils
Lower Fuselage Light Panel
Closeout
10 Mils
Center Lower Fuselage Fairing

10 Mils
NOTE: All paint thicknesses are the maximum permitted.

7010T1002

Figure 716 : Sheet 1 : Model 525 (M2) Maximum Paint Thickness

A100031
Aft Aileron Tip

Forward Aileron Tip 15 Mils
15 Mils
Elevator Tips
10 Mils
Bullet Composite Fairing

10 Mils
Rudder Cap
Winglet 15 Mils
Nose Radome 10 Mils
12 Mils Stinger Wedge
15 Mils
Stinger Cap
15 Mils
Main Landing Gear Door Fairing

15 Mils

Figure 717 : Sheet 1 : Model 525A Maximum Paint Thickness

A100032
Forward Aileron Tip

15 Mils
Aft Aileron Tip

15 Mils
Nacelle Drain Mast
15 Mils
Horizontal Stabilizer
Nose Tip
15 Mils
Elevator Tip Bullet Fairing

10 Mils 10 Mils Rudder Cap
15 Mils
Nose Radome Right Access Door

12 Mils 15 Mils
Stinger Cap
15 Mils
Lower Fuselage Fairing Stinger Wedge
15 Mils 15 Mils
6310T1097
NOTE: All paint thicknesses are the maximum permitted. 6310T1111

Figure 718 : Sheet 1 : Model 525B Maximum Paint Thickness

A100033
Forward Aileron Tip

15 Mils
Aft Aileron Tip

15 Mils
Nacelle Drain Mast

15 Mils
Forward Stabilizer Tip

15 Mils
Aft Elevator Tip Bullet Fairing

10 Mils 10 Mils
Rudder Cap
Nose Radome 15 Mils
12 Mils
Stinger Wedge
15 Mils
Stinger Cap
15 Mils
Lower Fuselage Fairing
15 Mils

6310T1089

Figure 719 : Sheet 1 : Model 525C Maximum Paint Thickness

A100035
Bullet Aft
Fairing Lower
10 Mils Bullet
12 Mils
Nose Radome
12 Mils
Rudder
Trim Tab
12 Mils
Stinger
Wedge
Stinger 15 Mils
Cap
Lower Lower 15 Mils
Fuselage Fuselage
Fairing Fairing
12 Mils 12 Mils
Right Aileron
Trim Tab
12 Mils
Ground Spoiler
12 Mils
Elevator
Trim
Tab
12 Mils
Pylon
12 Mils

Figure 720 : Sheet 1 : Model 560XL Maximum Paint Thickness

A100036 Rudder Tip
Vertical Fin Tip
Vertical Stabilizer
Upper/Lower Wiper
Nose Radome Vertical Stabilizer
12 Mils Forward Wiper
Shim
Stinger
Cap
Strake Aft Strake
Tip Closeout
Forward
Outboard Forward Forward
Fairing Access Access Aft Closeout Forward Strake
Inboard Fairing Tailcone
Fairing Panel Panel Closeout
Access
Door
Nacelle
Inboard/ Drain Upper/Lower
Outboard Mast Nacelle Skirt
Nacelle Skin Lower Pylon
Access Door
Elevator
Trim Tab
10 Mils
Nose Radome
12 Mils
Inboard Elevator
Flap Outboard Tip
Thrust Inboard Horizontal
Reverser Thrust Stabilizer
Reverser Tip
Outboard
Flap
NOTE: The maximum paint thickness is 15 mils except where shown. 6610T1006


A100037
Nose Radome
12 Mils
Spoilers
15 Mils
Wing End Cap

15 Mils
Engine Nacelle
12 Mils with Allowance of
15 Mils for Striping and Lettering
Pylon
15 Mils
Horizontal Stabilizer Tip Vertical Fin Tip

15 Mils 10 Mils
Elevator Trim Tab Vertical Fin Leading Edge

10 Mils 15 Mils Rudder
Trim Tab
Composite 10 Mils
"Sail"
Closeout
15 Mils
Fillet
15 Mils
Stinger
15 Mils

6910T1002


A100038
15 Mils Maximum
11 Mils Maximum
10 Mils Maximum
6910T1031


A100039
Nose Radome
12 Mils
Spoiler
15 Mils
Wing Tip
15 Mils
Engine Nacelle
15 Mils for Striping and Lettering
Pylon
15 Mils
Horizontal Stabilizer Tip

10 Mils
Elevator Trim Tab Vertical Fin
10 Mils Leading Edge
15 Mils Vertical Fin Tip
Rudder Trim Tab 10 Mils
10 Mils
Composite "Sail" Closeout

15 Mils
Dorsal Inlet
Nose Radome 15 Mils
12 Mils
Stinger Stinger
11 Mils 15 Mils
CSAM043


A100040
15 Mils Maximum
10 Mils Maximum
CSAM043


A100041
Aft Wing to Fuselage Closeout

10 Mils Nose Radome
Inboard Flap 12 Mils
15 Mils
Speed Brake
15 Mils
Center Flap
15 Mils
Spoiler
15 Mils Forward Wing to Fuselage Closeout
15 Mils
Outboard Flap
15 Mils
Aileron
15 Mils
Wing Tip
15 Mils
Forward Nacelle/Cowling
15 Mils
Engine Nacelle
15 Mils
Pylon
15 Mils
Elevator Tip
15 Mils Elevator
10 Mils
Bullet Nose Panel Bullet Radome

15 Mils (Airplanes -0001 Thru -0312) 15 Mils (Airplanes -0001 Thru -0312)
10 Mils (Airplanes -0313 and On) 12 Mils (Airplanes -0313 and On)
Vertical Stabilizer Leading Edge
15 Mils Upper Rudder
Lower Rudder 15 Mils
15 Mils
Fillet Closure
15 Mils
Dorsal Fin
15 Mils
Lower and Aft
Bullet Panels
15 Mils
Rudder Fairing Lower Stinger Panel
Nose Radome 15 Mils
12 Mils 15 Mils
6710T1002A


A100042
Aluminum Structure
Airplanes -0001 Thru -0234

The fairing panels shown are composite unless otherwise noted.
The maximum permitted paint thickness for all composite fairing
panels is 15 mils.
6710T1022
6710T1024


A100043
Fuselage to Wing Composite Fairing

10 Mils
11 Mils
12 Mils
Aluminum Structure
Airplanes -0235 and On

The fairing panels shown are composite unless otherwise noted.
All paint thicknesses are the maximum permitted.
6710T1022
6710T1024

Figure 724 : Sheet 1 : Model 750+ Maximum Paint Thickness

A100044
Nose Radome
Forward Wing to 12 Mils
Fuselage Closeouts
15 Mils
Aft Wing to
Fuselage Closeouts
10 Mils
Speed Brake Inboard Flap
15 Mils 15 Mils
Center Flap
15 Mils
Spoiler
15 Mils
Outboard Flap
15 Mils
Aileron
15 Mils
Winglet
10 Mils
Forward Nacelle/Cowling
15 Mils
Engine Nacelle
15 Mils
Pylon
15 Mils
Elevator Tip
15 Mils
Elevator
15 Mils
Vertical Fin Bullet Nose Panel
Leading Edge 10 Mils
15 Mils Upper Rudder
15 Mils
Fillet Closure Bullet Radome
15 Mils 12 Mils
Dorsal Fin
15 Mils Lower and Aft
Bullet Panels
15 Mils
Lower Rudder
Nose Radome Stinger Wedge 15 Mils
12 Mils 15 Mils
NOTE: All paint thicknesses are the maximum permitted. 67101002A
6700751-1

Figure 724 : Sheet 2 : Model 750+ Maximum Paint Thickness

A100045

10 Mils
11 Mils
12 Mils
Aluminum Structure
NOTE: The fairing panels shown are composite unless otherwise noted. All paint
thicknesses are the maximum permitted.
6710T1022
6710T1024

Figure 725 : Sheet 1 : Model 500 Radar Window Area

A100046
A
A
FS 21.70
FWD
VIEWA-A
NOTE: The radar window area
is forward of FS 21.70.
5510T3001
6314T1744


A100047
A
A
FS 73.79
FWD
VIEWA-A 7010T1001
7014T1146


A100048
A
A
FS 22.91
NOTE: The radar window area FWD

is forward of FS 22.91. VIEWA-A
6310T1001

Figure 728 : Sheet 1 : Model 525 (M2) Radar Window Area

A100049
A
A
FS 23.63

VIEWA-A
6310T1168

Figure 729 : Sheet 1 : Model 525A Radar Window Area

A100050
A
A
FS 22.91

VIEWA-A
6310T1036

Figure 730 : Sheet 1 : Model 525B Radar Window Area

A100051
A
A
FS 23.63

VIEWA-A
6310T1072

Figure 731 : Sheet 1 : Model 525C Radar Window Area

A100052
A
A
FS 22.75
FWD
VIEWA-A
7110T1001
A7118T1243


A100053
A
A
FS 22.79
FWD
NOTE: The radar window area VIEWA-A
6510T1024
AA6314T1744

Figure 733 : Sheet 1 : Model S550 Radar Window Area

A100054
A
A
FS 22.79
FWD
6510T2014
AA6314T1744

Figure 734 : Sheet 1 : Model 550B Radar Window Area

A100055
A
A
FS 22.84
FWD
6510T1024
AA6314T1744


A100056
A
A
FS 21.70
FWD
is forward of FS 21.70. VIEWA-A
5610T1001A
6314T1744

Figure 736 : Sheet 1 : Model 560XL Radar Window Area

A100057
A
A
FS 30.75
FWD
6610T1001
AA6314T1744


A100058
A
A
FS 35.60
FWD
VIEWA-A
6210T2003
A6211T1096


A100059
A
A
FS
27.30

VIEWA-A
6910T1001
AA6714T1332

Figure 739 : Sheet 1 : Model 680A Radar Window Area

A100060
A
A
FS
28.19
NOTE: The radar window area is forward of FWD

FS 28.19. VIEWA-A
7410T1002
6714T1332


A100061
A
A
FS
27.30
FWD
NOTE: The radar window area is forward of VIEWA-A
FS 27.30.
6710T1001
AA6714T1332

Figure 741 : Sheet 1 : Model 750+ Radar Window Area

A100062
A
A
FS
17.43
FWD
VIEWA-A
NOTE: The radar window area is forward of
6710T1103
FS 17.43. AA6714T1332


A102630
More Than 20.00 Inches
(0.50 m)
Legend
Zone 1A Zone 2A
Zone 1B Zone 2B
20.00 Inches
Zone 3 (0.50 m)
Zone 1C
20.00 Inches
(0.50 m)
20.00 Inches
(0.50 m)
58.23 Inches
(1.5 m)
15.47 Inches
(0.4 m)
7400T700-1


A102631
Nose Radome
12 Mils
Spoiler
15 Mils
Wing Tip
15 Mils
Engine Nacelle
15 Mils for Striping and
Lettering Pylon
15 Mils
Horizontal Stabilizer Tip

10 Mils Elevator Trim Tab
10 Mils
Vertical Fin
Leading Edge
15 Mils
Dorsal Inlet
Nose Radome 15 Mils
12 Mils
Rudder Trim Tab
10 Mils
Stinger
11 Mils
NOTE: All paint thicknesses are the maximum permitted. 74101011

7400700-1


A102632
15 Mils Maximum
10 Mils Maximum
74101011
7400700-1


A102633
A
A
FS
26.89
FWD
VIEWA-A
7410T1011
NOTE: The radar window area is forward of FS 26.89. AA7418T052--1

INTERIOR FINISH - CLEANING/PAINTING

1. General
A. This section is designed to assist the operator and recommend the different types of cleaning materials and cleaning
procedures for the interior of the aircraft.
B. The primary interior paint of the airplane is typically epoxy primers and polyurethane topcoats. For additional information
on how to remove the paint, refer to Exterior Finish - Cleaning/Painting, Paint Stripping.
NOTE: Equivalent substitutes can be used for the following:
NAME NUMBER MANUFACTURER USE
Yosemite Y999 Yosemite Chemical Co. For cleaning vinyl - coated
1248 Wholesale St. fabrics, Mylar, Scotchcal murals,
Los Angeles, CA Polyplaxtex, leathers, vinyl
flooring, Formica, linoleum,
finished Flexwood, or painted
surfaces.
Aliphatic Naphtha TT-N-95 Commercially Available For cleaning vinyl - coated
fabrics, Mylar, Scotchcal murals,
Polyplaxtex, leathers, vinyl
flooring, Formica, linoleum,
finished Flexwood, or painted
surfaces.
Flame Control Coating No. 173 Flame Control Coatings LLC Topcoat for locations requiring
4120 Hyde Park Blvd. flame control coating application.
Niagara Falls, New York 14305
Phone: 716-282-1399
Host Dry Cleaning Host of California For cleaning drapes, curtains,
Compound 2935 Coleridge Ave. upholstery, fabrics and carpet.
Pasadena, CA
Townsend Leather Townsend Leather Company, Inc. To clean and condition interior
Cleaner, Conditioner 4549 Townsend Avenue leather components.
and Protector P.O. Box 609
Johnstown, NY 12095
Townsend Leather Ink Townsend Leather Company, Inc. To remove ink and stains from
and Stain Remover leather components.
Wet Rug Shampoo Commercially Available Carpeting.
Perchloroethylene Commercially Available Spot clean carpet.
Stoddard Solevent Fed. Spec. Cleaning nylon safety belts.
Mild Soap Detergent Commercially Available Cleaning nylon safety belts.
Cleaning Noryl plastic.
Sponge Commercially Available Used to remove spill.
Shop Towels Commercially Available Used to remove spill.
Scotch Brite Pads Commercially Available Used to clean spill.
Soft Nylon Brush Commercially Available Cleaning Tool
Clean Water Commercially Available Fluid used to de-contaminate spill
(Deionized or Reverse area.
Osmosis)

WARNING: Cleaning operations using solvent should be performed in a well-ventilated atmosphere. Exercise
normal safety precautions during use.
WARNING: Read the manufacturers material safety data sheet (MSDS) before you use any solvent cleaner.
3. Coatings Application
• None.
• Polyurethane Topcoat
• Epoxy Primer.
• Exterior Finish - Cleaning/Painting
• Structural Repair Manual.
B. Requirements
(1) The surface to receive coatings must be pretreated.
(2) The surface must be clean and dry at the time of coating application. If necessary, solvent clean the applicable area.
(3) The time between cleaning and pretreatment must be as short as practical.
(4) All coatings must have the pigment homogeneously dispersed before thinning or application. Two component
materials must be mixed thoroughly in proper proportion and induction times must be observed.
(5) A slight orange peel is characteristic of an epoxy primer coating and is acceptable.
(6) Obey the manufacturer’s instructions to get the best results.
(7) You must clean the paint equipment with an approved solvent immediately after the spray application.
(8) The epoxy coatings, applied by spraying, should be smooth and continuous, free of sags, blisters, and surface
irregularities such as dirt, lint, and other foreign debris.
(9) The air system used for spraying must have the appropriate filters and separators to remove oil and water.
(10) Appropriate tips, air caps, fluid pressures, and atomization pressures must be used. All application devices used to
apply primers or topcoats must be operated according to the local environmental compliance requirements.
(11) Primers and paints must not be applied when the ambient temperature decreases below 50°F (10°C).
C. Pretreatment
(1) Aluminum surfaces must be chemical filmed or pretreatment (wash) primed before the application of epoxy primer.
(a) For the chemical film treatment, refer to Exterior Finish - Cleaning/Painting, Chem Film.
(b) For the pretreatment (wash) primer, refer to the applicable Structural Repair Manual, Chapter 51, Protective
Treatment of Metal, Pretreatment Priming.
(2) Fiberglass surfaces must be cleaned with sandpaper and an approved solvent before the application of epoxy
primer. Refer to General Solvents/Cleaners - Maintenance Practices.
(3) Non-corrosion resistant steel surfaces must be pretreatment (wash) primed before the application of epoxy primer.
Refer to the applicable Structural Repair Manual, Chapter 51, Protective Treatment of Metal, Pretreatment Priming.
(4) Corrosion resistant steel must be pickled, or abrasive blasted before the application of epoxy primer. Refer to the
applicable Structural Repair Manual, Chapter 51, Protective Treatment of Metal, Pretreatment Priming.
D. Epoxy Primer Application

(1) Epoxy primer can be applied to pretreated surfaces in accordance with Pretreatment in this section.
(2) Mix the Akzo Nobel epoxy primer base 10P8-11 with catalyst EC-286 per the manufacturer's instructions. Refer to
Corrosion Protection Primer Application.
(3) Apply the epoxy primer by spray to a dry film thickness of 0.5 to 1.0 mil. The epoxy primer coat should be smooth and
continuous, free of sags, blisters, and surface irregularities such as dirt, lint, and other foreign debris.
(4) Let the epoxy primer cure per the manufacturer's instructions.
E. Coating Application
NOTE: Topcoats must be applied to surfaces with epoxy primer. Refer to Epoxy Primer Application in this
section.
(1) Mix the topcoats per the manufacturer's instructions.
(2) Apply the topcoat by spray to a dry film thickness of 1.2 to 1.6 mils. The topcoat should be smooth and continuous,
free of sags, blisters, and surface irregularities such as dirt, lint, and other foreign debris.
(4) Refer to the applicable Interior Maintenance Manual and Illustrated Parts Catalog, Interior Trim Coordination Package
for information on the interior paint installed in the airplane.
4. Polycarbonate (Lexan) Components Painting
• None.
• Primer
• Topcoat.
B. Prepare the Airplane for the Polycarbonate (Lexan) Components Painting.
(1) Solvent wipe the components with isopropyl alcohol. Refer to General Solvents/Cleaners - Maintenance Practices.
C. Primer Application
(1) Mix the primer to be applied per the manufacturer's instructions.
(2) Apply the primer by spray to a dry film thickness of 0.5 to 1.0 mil. The primer coat should be smooth and continuous,
(3) Let the primer cure per the manufacturer's instructions.
D. Topcoat Application
(1) Mix the topcoat per the manufacturer's instructions.
(2) Apply the topcoat by spray to a dry film thickness of 1.4 to 2.0 mils. The topcoat should be smooth and continuous,
5. Flame Control Coating Application
• Brush.


• Flame Control Coating.
• Exterior Finish - Cleaning/Painting.
B. Requirements
(1) The applied flame control coating will have a fibrous appearance due to its composition. Therefore, do not strain the
material.
(2) The flame control coating can be topcoated with a polyurethane finish.
C. Prepare the Airplane for the Flame Control Coating Application.
(1) If necessary, solvent clean the applicable area. Refer to General Solvents/Cleaners - Maintenance Practices.
(2) Apply primer to the surface of the area if the primer has been removed. Refer to Exterior Finish - Cleaning/Painting,
Corrosion Protection Primer Application.
D. Apply the Flame Control Coating.
(1) Mix the Flame Control Coatings LLC, Flame Control No. 173 coating per the manufacturer's instructions. Refer to
Table
(2) Use a brush to apply one uniform cross coat of the flame control coating between 8 and 10 mils to the area.
(3) Let the coating air dry at room temperature for 30 minutes, then force dry at 175°F, +15 or -15°F (79°C, +8 or -8°C)
for a minimum of 1.5 hours.
(4) Do this procedure again until you get 30 mils, +5 or -5 mils flame control coating thickness.
(5) After the final coating, air dry at room temperature for 30 minutes, then force dry at 175°F, +15 or -15°F (79°C, +8 or -
8°C) for a minimum of 2 hours.
(6) Let it dry 24 hours before you apply some other paint as a topcoat.
(7) Apply the topcoat finish as necessary.

INTERIOR - CLEANING/WASHING/RINSE - SERVICING

1. General
A. This section gives the interior cleaning procedures for the airplane interior and a procedure for cleaning fluid spills to
protect the airplane structure. The cleaning of the airplane interior includes cleaning the interior decorative materials, rugs,
drapes, curtains, carpets, and upholstery.
B. For more airplane interior data, refer to the applicable Interior Maintenance Manual and Illustrated Parts Catalog.
2. Interior Cleaning
A. Table 301 gives a list of the interior cleaning tools and equipment.
Table 301. Interior Cleaning Tools and Equipment
Aliphatic Naphtha TT-N-95 Commercially Available To clean the interior
decorative materials.
Clean Water (Deionized Commercially Available Fluid used to de-
or Reverse Osmosis) contaminate spill area.
Cleaning Cloth (Non- Commercially Available To clean the interior
Synthetic Chamois Skin, decorative materials.
100 Percent Cotton Terry
Cloth, or Flannel)
Container Commercially Available To mix the cleaner
compounds.
Cornstarch Commercially Available To clean the nubuck and
the suede leather.
Final Inspection Meguiar's No. 34 Meguiar's Direct To clean and polish the
20 Constitution Blvd. polyurethane coated
South Shelton, CT 06484 wood surfaces.
Fine Abrasive Pad Commercially Available To clean the nubuck and
the suede leather.
Flight Wipes Townsend Leather Group To clean the interior
Townsend Avenue leather components.
P.O. Box 66945-49
Johnstown, NY 12095
Host Dry Cleaning Host of California To clean the drapes,
Compound 2935 Coleridge Ave. curtains, upholstery,
Pasadena, CA 91107 fabrics, and carpet.
Mild Soap Detergent Commercially Available To clean the nylon safety
belts and the plastic.
Nonmetallic Blade Commercially Available To clean the interior
(Scraper) decorative materials.
Perchloro-Ethylene Commercially Available To spot clean the carpet.
Carpet Cleaner
Scotch Brite Pads Commercially Available To do general interior
cleaning.
Shop Towels Commercially Available To remove spills.
Soft Bristle Fiber Brush Commercially Available To do general interior
cleaning.
Soft Nylon Brush Commercially Available To do general interior
cleaning.

Sponge Commercially Available To remove spills.

Spray Bottle Commercially Available To do general interior
cleaning.
Sprayon General S00880 Krylon Products Group To do general interior
Purpose Cleaner 101 W. Prospect Ave. cleaning.
Cleveland, OH 44115
Stoddard Solvent PS661 MIL-PRL- Commercially Available To clean the nylon safety
(Mineral Spirits or White 680 belts.
Spirits)
Surface Glow Brillianize Brillianize, Inc. To clean and polish
4952 Industrial Way mirrored surfaces,
P.O. Box 867 plexiglass, windows, and
Benicia, CA 94510 electronic flight instrument
system (EFIS).
Townsend Leather Townsend Leather Company, Inc. To clean and condition
Cleaner, Conditioner and 4549 Townsend Ave. the interior leather.
Protector Johnstown, NY 12095
Townsend Leather Ink Townsend Leather Company, Inc. To remove ink and stains
and Stain Remover from the leather.
Upholstery Hand Commercially Available To clean the upholstery.
Shampoo Device
Vacuum Cleaner Commercially Available To clean the interior and
exterior areas of the
airplane.
Wet Rug Shampoo Commercially Available To clean the carpet.
Yosemite Y-999 Yosemite Chemical Co. To clean the vinyl-coated
1248 Wholesale St. fabrics, mylar, scotchcal
Los Angeles, CA 90021 murals, polyplastex, vinyl
floor, formica, linoleum,
finished flexwood, and
painted surfaces.
B. Prepare the Airplane for the Interior Cleaning.
CAUTION: Before you start the interior cleaning, know and understand all supplier instructions and
recommendations. Refer to the Interior Maintenance Manual and Illustrated Parts Catalog, Vendor
List. This will help to prevent damage that can void supplier warranties.
(1) If possible, remove the materials, equipment, and items to be cleaned from the airplane. Refer to the applicable
Maintenance Manual, Chapter 25, Equipment/Furnishings and the applicable Interior Maintenance Manual and
Illustrated Parts Catalog.
C. Clean the Interior Decorative Materials (Refer to the applicable Interior Maintenance Manual and Illustrated Parts Catalog,
Interior Care Cleaning Instructions).
WARNING: Obey all safety precautions when you use solvents. Make sure that the area where you use the
solvents has good airflow. Refer to Chapter 20, General Solvents/Cleaners - Maintenance
Practices.
(1) Use Yosemite Y-999 cleaner or an approved alternative to clean the interior decorative materials.
(a) Use a spray bottle to apply the cleaner on the dirty surface.
(b) Rub the surface with a clean cotton cloth that is moist with water.
(2) Clean the surface with Aliphatic Naphtha.
(a) Rub the surface with a dry clean cotton cloth until it is dry.
(b) Rub the surface with a clean cotton cloth that is moist with aliphatic naphtha.

(c) To remove tar, asphalt, or chewing gum, carefully remove as much as possible with a nonmetallic blade
(scraper).
1 Put aliphatic naphtha on a clean cotton cloth and rub the surface to prevent possible stains from the
aliphatic naphtha.
D. Clean the Airplane Rugs, Drapes, Curtains, and Upholstery Fabrics (Refer to the applicable Interior Maintenance Manual
and Illustrated Parts Catalog, Interior Care Cleaning Instructions).
(1) If possible, dry clean the rugs, drapes, curtains, and the upholstery fabrics commercially.
(2) Use Host Dry Cleaning Compound to dry clean.
(a) Apply Host Dry Cleaning Compound, as necessary, to the dirty area.
(b) Rub the cleaning compound into the dirty area.
(c) Use a vacuum cleaner to remove the cleaning compound.
NOTE: The Host Dry Cleaning Compound is not flammable. You can use it on fueled airplanes.
(3) Spot-Clean the Carpet.
(a) If possible, spot-clean the carpet in the airplane.
(b) Soak a clean cotton cloth with perchloroethylene carpet cleaner.
CAUTION: Do not put perchloroethylene carpet cleaner directly on the carpet.
(c) Use the clean cotton cloth to rub the perchloroethylene carpet cleaner in a circular movement on the dirty area.
CAUTION: Do not use a mechanical shampoo device to clean carpet or upholstery. This will help to
prevent damage to the carpet and upholstery.
(d) Use an upholstery hand shampoo device for the areas that are difficult to clean.
(4) Wet Shampoo the Airplane Carpet or Upholstery.
(a) Remove the carpet or the upholstery from the airplane.
(b) Vacuum the carpet or upholstery to remove as much dirt and dust as possible.
(c) Put a tablespoon of wet rug shampoo in a container and add water to the shampoo to make a foam.
(d) Apply the foam equally on the surface to be cleaned.
(e) Remove the foam with a soft bristle fiber brush or a clean cotton cloth.
NOTE: There must be minimum moisture in the foam, so the fabric will not be too wet.
CAUTION: Do not use a mechanical shampoo device to clean the carpet or the upholstery. This will help
to prevent damage to the carpet and the upholstery.
E. Clean the Vanity and Toilet Area.
(1) Use deodorizer and disinfectant to clean the toilet area. If applicable, refer to the applicable Maintenance Manual,
Chapter 12, Externally Serviceable Flush Toilet - Servicing.
F. Clean the Leather (Refer to the applicable Interior Maintenance Manual and Illustrated Parts Catalog, Interior Care
Cleaning Instructions).
CAUTION: Do not use abrasives, solvents, saddle soap, dish detergent, household cleaners, and all other
soap to clean leather. Clean very dirty areas through the work of a trained professional.
(1) Remove the dirt with a material that sufficiently absorbs the cleaner.
(2) Clean the leather immediately after it gets dirty.
CAUTION: Do not rub the leather. This will help to prevent damage to the leather.
(3) Use a vacuum cleaner and a moist clean cotton cloth to clean the leather.
(4) Use approved cleaning products to clean very dirty finished leather.
CAUTION: Dry leather slowly and away from heat. This will help to prevent damage to the leather.
(5) Clean the Nubuck and the Suede Leather.
(a) Use a soft bristle fiber brush to clean the Nubuck or the Suede leather.
(b) Use a vacuum cleaner to remove the loose dirt.
(c) Use a very fine abrasive pad with minimum pressure to remove the stains.

(d) Apply cornstarch on the oil or grease spots and use a moist clean cotton cloth as a cover for between four and
six hours.
1 Remove the cornstarch from the Nubuck or the Suede leather.
2 Continue this procedure as necessary.
(e) Use a dry, clean cotton cloth to remove the food and the beverages from the Nubuck or the Suede leather.
(f) Use clean water to flush blood or urine from the Nubuck or the Suede leather.
1 Remove the water with a clean cotton cloth.
(6) Use a professional cleaner to clean ink marks from the Nubuck or the Suede leather.
G. Put the Airplane Back to its Initial Condition.
(1) Install the materials, equipment, and items that were removed from the airplane as applicable. Refer to the applicable
Maintenance Manual, Chapter 25, Equipment/Furnishings and the applicable Interior Maintenance Manual and
Illustrated Parts Catalog.
3. Internal Structure Cleaning
A. General
(1) The purpose of this section is to provide instructions for cleaning the internal tailcone and cabin structure.
(2) Its important that any area being inspected be properly clean and free from debris.
(3) If a fluid spill has been discovered inside the cabin it should be cleaned per "Fluid Spill Cleanup and Corrosion
Prevention Procedure" in this section.
B. Cleaning the Interior Structure
(1) Clean the internal structure in the cabin and tailcone using either the Dry Wash or Alternate Wash Procedure. Refer to
Chapter 20 Exterior Cleaning Wash Rinse-Servicing.
4. Fluid Spill Cleanup and Corrosion Prevention Procedure
A. General
(1) The purpose of this section is to describe a general procedure that is necessary to remove any fluid spills that can
happen in the cabin or baggage compartment.
(2) All fluid spills should be addressed as soon as practical to prevent any corrosion formation.
(3) Blue Water products used for the lavatory can be corrosive to the airplane structure.
(1) Refer to Table 301 for a list of the interior cleaning tools and equipment.
C. Cleaning Up after the Spill
(1) Gain Access
(a) Remove any interior items that would prevent access to the affected area (carpets, seats, floorboards). Refer to
the applicable Maintenance Manual, Chapter 25, Equipment/Furnishings and the applicable Interior
Maintenance Manual and Illustrated Parts Catalog.
(b) Remove and discard any bagged insulation or sound dampening material that may be contaminated from the
fluid spill.
(2) Remove all standing fluid and clean the structure.
WARNING: Remove electrical power from the airplane and disconnect the airplane battery before
attempting to remove fluids from the airplane.
WARNING: Be aware that some electrical devices continue to hold an electrical charge that may be life-
threatening, even after electrical power has been removed. Take appropriate precautions.
(3) Make sure to protect surrounding equipment and structures from further contamination, by visual inspection. If
necessary, use shop towels and sponges to keep the fluid from spreading.
(4) Absorb all of the standing fluid with a sponge or shop towel.
(5) Use soapy water and a stiff nylon brush to thoroughly clean the contaminated area. Make sure to clean all residual or
dried fluid from the structure, including external areas around belly drains and the upper surface of the center wing as
applicable.

(6) Flush all affected areas with clean water to remove all soap.
(7) Repeat this procedure as necessary to make sure the area has been completely cleaned and free of contaminants.
CAUTION: Do not use shop air to help with the evaporation of the water. The air pressure can damage
equipment and force any fluid or foreign objects further into the airplane.
(8) Use isopropyl alcohol to help complete evaporation of any residual water.
NOTE: The affected area must be completely dry before reassembling the interior. It may be
necessary to use an auxiliary fan/blower to help aid the drying process.
(9) Clean the removed carpeting as given in this section.
D. Inspect and Restore all Protective Finishes and/or Corrosion Inhibiting Compounds (CIC).
(1) Inspect all areas affected by the spill for any signs of corrosion. If corrosion is found, it must be addressed. Refer to
the applicable Structural Repair Manual, Chapter 51, Crack, Scratch, Gouge, and Corrosion.
(2) Restore all protective finishes and/or CICs. Refer to the applicable Structural Repair Manual, Chapter 51, Protective
Treatment of Metal and Chapter 51, Corrosion Inhibitor - Maintenance Practices in this manual.
NOTE: Corrosion Inhibiting Compounds (CIC's) are an effective way to prevent corrosion from
occurring on the structure. Refer to Chapter 51, Corrosion Inhibitor Compounds, Description
and Operation, in this manual.
E. Restore the interior
NOTE: Any insulation or sound dampening materials that were contaminated by the spill must be removed
and replaced.
(1) If cleaned and reusable, install all interior carpet, seats, and floorboards that were removed to clean the spill.

20-52-20-3 (Rev 1)
EXTERIOR - CLEANING/WASHING/RINSE - SERVICING

1. General
A. This section gives the exterior cleaning (wash/rinse) procedures necessary to give maintenance personnel instructions to
clean (wet wash) the airplane exterior as a function of corrosion prevention. Alternative procedures are also included in this
section to help maintenance personnel when a wet wash is not possible.
B. Washing removes contamination from the exterior airplane surfaces to prevent corrosion from runway deicing fluids, salts,
oily fluids, foreign material, and surface dirt.
C. Exterior washing is a necessary part of a Corrosion Prevention and Control Program (CPCP). Refer to the applicable
Maintenance Manual, Chapter 51, Corrosion Prevention and Control Program - Description and Operation.
2. Exterior Cleaning (Wash/Rinse) Considerations
A. Read and know all of the Warnings, Cautions, Notes, instructions, and other data given in this section and in the section
that follows. Refer to Exterior Cleaning (Wash/Rinse) in this section.
B. Tools, Equipment, and Consumables
CAUTION: Read and obey all of the manufacturer's instructions, warnings, and cautions for the
cleaning/solvent compounds that you use.
NOTE: If general purpose (mild detergent) cleaning compounds given in Table 301 are not available, email
maintenanceengineering@txtav.com to find if you can use alternatives.
Table 301. General Purpose (Mild Detergent) Cleaning Compounds
Product Name Number Manufacturer/Web Address Use
To wash the exterior of
Aerowash 3000 Rhoba-Chemiewww. rhoba-chemie.com
the airplane (general
purpose cleaning).
Aircraft Cleaner II Zep Inc.www.zepodistribution.com the airplane (general
purpose cleaning).
Eco 2000 ZI-400 or ZI-400HD Eco 2000 www.eci2000.com.au/zi400air.s the airplane (general
purpose cleaning).
ZI-
ZI-400 or ZI-400HD ZI-400 or ZI-400HD the airplane (general
Chemicalhttps://zichemicals.com/aircraft.htm
purpose cleaning).
Super Bee 210 To wash the exterior of

Super Bee 210 McGean www.mcgean.com the airplane (general
Cleaner (NOTE 2)
purpose cleaning).
Cee-Bee A-882 To wash the exterior of
Cee-Bee A-882 Cleaner McGean www.mcgean.com the airplane (general
Cleaner (NOTE 2)
purpose cleaning).
A thickened general
purpose cleaner for use
Cee-Bee A-883 on vertical structures
Cee-Bee A-883 Cleaner McGean www.mcgean.com
Cleaner (NOTE 2) such as gear wells, flap
wells and vertical
stabilizers.
Eraser Extreme Clean Knipps the airplane (general
(NOTE 2) www.knipps.com purpose cleaning)
(NOTE: 2).

20-52-20-3 (Rev 1)
Mild Detergent (NOTE MIL-C-43616MIL-PRF- To wash the exterior of

1) Commercially Available the airplane (general
85570
purpose cleaning).
95111 (Diluted) To wash the exterior of
Cleaning System, Inc.www.cleaning-
Release Ultra 95110 (Concentrate: the airplane (general
systemsinc.com
Dulute 1:20 purpose cleaning).
Surtech 121 Surtecwww.surtec.com the airplane (general
purpose cleaning).
SOCO/MOREwww.socomore.com/sysnclair-
Synclair A/C the airplane (general
a-c/pr38.html
purpose cleaning).
NOTE 1: You can use equivalent alternatives. Cleaning compound performance characteristics must only
meet corrosion, total immersion corrosion, effects on plastics, and the pH requirements given in
MIL-PRF- 43616 or MIL-C-85570.
NOTE 2: Cleaners can leave an alkaline residue on the airplane that should be rinsed off with clean water
after use.
WARNING: Be careful when you use degreasers. Degreasers are toxic to your skin, eyes, and respiratory tract.
Make sure that your work area has a ventilation system that supplies sufficient fresh air.
CAUTION: Apply corrosion inhibiting compounds (CIC’s) again if they are removed or damaged. Use of heavy
degreasers can have an effect on CIC’s durability. Take precautions to preserve all CIC’s that
already were applied. Refer to the applicable Maintenance Manual, Chapter 51, Corrosion Inhibitor -
CAUTION: Use Extreme Simple Green Aircraft and Precision Cleaner only. Other Simple Green products have
been found to cause corrosion to the airplane structure.
NOTE: If heavy duty cleaners (degreasers) given in Table 302 are not available, email
Table 302. Heavy Duty Cleaners (Degreasers)
Name Number Manufacturer/Web Address Use
To remove grease and
Kent Automotivewww.kent- other heavy contamination
Acrysol
automotive.com from the exterior of the
airplane.
Arrow-Magnolia other heavy contamination
Carbon X
Internationalwww.arrowmagnolia.com from the exterior of the
airplane.
Extreme Simple Green
Sunshine Makers, Incwww.industrial- other heavy contamination
Aircraft and Precision
simplegreen.com from the exterior of the
Cleaner
airplane.
other heavy contamination
Naptha NOTE 1 MIL-PRF-680 Commercially Available
from the exterior of the
airplane.

20-52-20-3 (Rev 1)

Zep Power Degreaser other heavy contamination
NOTE 2 MIL-PRF-85570 Commercially Available
from the exterior of the
airplane.
NOTE 1: There are other commercially available cleaners that meet the requirements of MIL-PRF-680
applicable for removing contamination.
NOTE 2: There are other commercially available cleaners that meet the requirements of MIL-PRF-85570
applicable for removing contamination.
NOTE: If dry wash products given in Table 303 are not available, email
Table 303. Dry Wash Products
Name Number Manufacturer/Web Address Use
To dry wash the exterior
Rhoba-Air 3 Rhoba-Chemie www.Rhoba-chemie.com
of the airplane.
Whitmore Aviation Dry Whitmore, - CSW Industrials Company To dry wash the exterior
Wash www.whitmores.com/products/aviation.htm of the airplane.
To dry wash the exterior
No-H20 Wash & Wax No-H20 Ltd www.noh20.ie/about-us
of the airplane.
CAUTION: Read and obey all of the manufacturer's instructions, warnings, and cautions for the polishing
compounds that you use.
NOTE: If polishes given in Table 304 are not available, email maintenanceengineering@txtav.com to find if
you can use alternatives.
Table 304. Polishes and Cleaning Supplies
Name Number Manufacturer/Web Use
Address
Access Equipment (Ladder, To get access to all
Servicing Platform, Work Commercially Available contamination exposure
Stand, other) zones.
To clean, wash, and polish
Cheesecloth Commercially Available
the exterior of the airplane.
Clean Cotton Cloths Commercially Available
Clean Shop Towels Commercially Available
To wet wash the exterior of
Clean Water Commercially Available
the airplane.
To polish the exterior of the
DuPont Car Polish Commercially Available
airplane.
To remove sand, dirt, salts,
and other foreign object
Hydraulic Fluid Note 1 Commercially Available debris (FOD) from the
landing gear piston external
surface.
Low-Pressure Garden Hose Commercially Available
the airplane.

20-52-20-3 (Rev 1)

Non-Metal Cleaning Pad Commercially Available
the airplane.
To remove sand, dirt, salts,
Nonwoven Fabric Cleaning and other FOD from the
Commercially Available
Cloth landing gear piston external
surface.
Protective Covers (Nonstick
To give protection to the
Tape, Barrier Material, Cloth,
Commercially Available airplane during washing and
Plastic Cover, Waterproof
rinsing.
Nonadhesive Paper, other)
Soft Bristle Brush Commercially Available
the airplane.
To use for the alternative
Spray Bottle or Garden-Type
Commercially Available wash the exterior of the
Sprayer
airplane.
Telescopic Cleaning Tool Commercially Available
the airplane.
To polish the exterior of the
Tripoli T-41 Commercially Available
airplane.
NOTE 1: Make sure to use the correct hydraulic fluid for your airplane.
C. Types of Washing/Rinsing
NOTE: There are four types of washing/rinsing procedures. The procedures that you use depend on the
amount of contamination, area to be washed, and local environmental laws.
(1) Wet Wash
(a) The full wet wash (water-based wash) cleans the exterior areas of the airplane with a high volume of clean water,
cleaning solution, and soft bristle brush. This includes washing the landing gear, wheel wells, and trailing edge
coves (wing, horizontal, and vertical). Refer to Table 301, Table 302, and Table 305.
(2) Alternative Wash
(a) The alternative wash uses a spray bottle to apply an approved cleaner, soft bristle brush, a low volume rinse of
clean water from another spray bottle, and clean shop towels to dry the exterior of the airplane. Refer to Table
301, Table 302, and Table 305.
(3) Dry Wash
(a) The dry wash is an apply-and-remove (wipe on/wipe off) procedure that you can use during other maintenance
or as part of the alternative wash procedure. Dry washing is only approved for smooth surfaces. Refer to Table
303.
(4) Runway Deicing (RDI) Clean Water Rinsing
(a) If the airplane has deicing fluid contamination, Cessna recommends that you rinse (flush) the deicing fluid from
the airplane within three days of contamination. Deicing fluids can cause corrosion, which can quickly damage
the airplane structure. Clean water rinsing will flush the RDI contamination away from the high exposure areas -
Airplane Zone 1 on the airplane structure. Clean water rinsing is not an approved alternative to wet washing or
alternative washing. Refer to Table 305.
D. Corrosion Prevention Control Program (CPCP)
(1) Cessna recommends that you use the Baseline Exterior Wash Schedule for your CPCP wash schedule. Refer to the
NOTE: The Baseline Exterior Wash Schedule is progressive and designed so that each Airplane
Exposure Zone will be cleaned at the same time. When you do a 90-day Low Exposure -
Airplane Zone 3 wash, you will also do the 15-day High Exposure - Airplane Zone 1 wash and
the 45-day Medium Exposure - Airplane Zone 2 wash.
NOTE: The airplane exterior must be washed on a frequency which is applicable to the environment

20-52-20-3 (Rev 1)
in which it operates. The frequency of the washes must be made and adjusted to minimize the
development of corrosion on the airplane.
NOTE: A full wash will use one or more of the washing procedures to remove all contamination from
the exposure areas.
NOTE: The operator must make the decision as to which washing procedures, tools, equipment, and
materials to use for each occurrence.
NOTE: Some areas of the airplane will probably have more contamination than other areas. The
higher the level of exposure to contamination in these areas, the higher the possibility that
corrosion will occur.
Table 305. Baseline Exterior Wash Schedule
Task Title Description Airplane Zone
High Exposure Areas:
Airplane Zone 1
• Landing Gear Wheel Wells
• Landing Gear
NOTE: Refer to the applicable
15 Day High Exposure Areas Maintenance Manual,
• Wing Trailing Edge Structure
Airplane Zone 1 Wash Chapter 12, Exterior
(Aft Side of the Rear Spar) in
the inboard section of the Flap Cleaning
Bays directly behind the MLG (Wash/Rinse).
Medium Exposure Areas:

• Lower Fuselage Skins
• Lower Wing Skins
• Wing Trailing Edge Structure
(Aft Side of the Rear Spar) Airplane Zone 2
• Vertical Stabilizer Trailing NOTE: Refer to the applicable
45 Day Medium Exposure Areas Edge Structure (Aft Side of the Maintenance Manual,
Airplane Zone 2 Wash Rear spar) Chapter 12, Exterior
• Horizontal Stabilizer Trailing Cleaning
Edge/Leading Edge (Wash/Rinse).
• Vertical Stabilizer Trailing
Edge Structure (Aft Side of
Rear spar)
• APU Exhaust
Airplane Zone 3
Low Exposure Areas: NOTE: Refer to the applicable
90 Day Low Exposure Areas Maintenance Manual,
• All Remaining External
Airplane Zone 3 Wash Chapter 12, Exterior
Surfaces
Cleaning
(Wash/Rinse).
NOTE: These progressive wash intervals are a baseline aircraft wash schedule. If an aircraft flies into
any Severe Corrosion Areas during its operation route, it may be necessary to increase the
frequency of the wash schedule. Refer to the applicable Maintenance Manual, Chapter 51,
Corrosion Severity Maps - Description and Operation and Corrosion Prevention and Control
Program - Description and Operation.
NOTE: If the airplane flight schedule does not make it possible to align with the 15/45/90 day
recommended baseline wash schedule, the operator should use a wash schedule that follows
the 15/45/90 day recommended baseline wash schedule as close as possible and that
provides effective results at maintaining corrosion protection for the operational environment.
E. Locations for Washing and Rinsing
NOTE: Washing and rinsing is usually done at a washing rack or on the flight line.
(1) Do the full washing at a facility where all contamination and cleaning solutions are caught and disposed of in

20-52-20-3 (Rev 1)
accordance with local environmental laws.

(2) Do the clean water rinse where all contamination and cleaning solutions will have no effect on adjacent facilities,
personnel, and operations.
(3) The different procedures in the section that follows give the instructions to remove contamination that causes and
increases corrosion.
F. Water Quality
CAUTION: To prevent corrosion, do not let dissolved salts collect between faying surfaces or in joints, seams,
or other entrapment areas.
(1) The quality of water that you use to wash and rinse contaminates from the airplane is important. Much of the world's
water contains chlorides, sulfates, and other salts. In areas that you know contain these dissolved salts, Cessna
recommends that you use de-ionized, de-mineralized, or reverse osmosis water to wash and rinse the corrosion that
cause contaminates from the airplane.
3. Exterior Cleaning (Wash/Rinse)
A. Tools, Equipment, and Consumables
• Access Equipment (Refer to Table 305).
• Protective Covers (Refer to Table 305).
• As Necessary (Refer to Table 301, Table 302, Table 303 and Table 304).
• Applicable Maintenance Manual, Chapter 6, Access Plates and Panels Identification - Description and
Operation
• Applicable Maintenance Manual, Chapter 9, Towing - Maintenance Practices
• Applicable Maintenance Manual, Chapter 12, Windshield And Cockpit Side Window - Servicing
• Applicable Maintenance Manual, Chapter 20, Exterior Finish - Cleaning/Painting
• Applicable Maintenance Manual, Chapter 24, External Electrical Power - Maintenance Practices
• Applicable Maintenance Manual, Chapter 27, Control Lock System - Description and Operation
• Applicable Structural Repair Manual.
B. Prepare the Airplane for the Exterior Cleaning (Wash/Rinse)
(1) Read and know all of the Warnings, Cautions, Notes, instructions, and other data given in this section and in the
section before this. Refer to Exterior Cleaning (Wash/Rinse) Considerations in this section.
WARNING: If you will operate the washing rack, use only trained and authorized personnel. All personnel
must wear personal protective equipment (PPE), which includes protective clothing. This will
help to prevent injury to personnel.
(2) Move the airplane to a washing rack or other area. Refer to the applicable Maintenance Manual, Chapter 9, Towing -
(3) Fully extend the flaps.
(4) Keep all flight controls in their neutral positions. Refer to the applicable Maintenance Manual, Chapter 27, Control
Lock System - Description and Operation.
(5) Disconnect external electrical power from the airplane. Refer to the applicable Maintenance Manual, Chapter 24,
External Electrical Power - Maintenance Practices.
CAUTION: Do not let servicing platforms, work stands, ladders, and other equipment touch the pitot
probes, static ports, and other instrumentation devices. This will help to prevent damage to
those devices.
(6) Put access equipment in their positions adjacent to the airplane. Refer to Table 305.
(7) Make sure that all access plates and panels are installed and/or closed. Refer to the applicable Maintenance Manual,
Chapter 6, Access Plates and Panels Identification - Description and Operation.
CAUTION: Keep water and abrasive or aromatic cleaners off of and out of the components that use
lubricants and/or abrasive-resistant films. This will help to prevent corrosion.

20-52-20-3 (Rev 1)
CAUTION: Adhesive residue left on the airplane surfaces by protective covers must be removed.
(8) Use tape and other barrier material to give protection to the areas that follow:.
• Air Cycle Machine (ACM) Inlet
• ACM Outlet
• Battery Access Vents
• Fuel Vents (at the wing tips
• Hydraulic Brake Reservoir Overfill Drain
• Hydraulic Brake Reservoir Vent
• Radome Scupper
• Ram Air Inlet
• Static Ports
• Windows and Windshields.
CAUTION: Do not wash landing gear areas until you supply protection for the components. Use the
manufacturer's instructions to clean the wheels and the brake assemblies. Refer to the
applicable Maintenance Manual, Introduction, Supplier Publication List.
(9) Install protective covers to the areas that follow:
• Air Conditioning Intake Scoop and Exhaust Outlet
• APU Exhaust
• Brakes
• Engine Exhaust
• Engine Inlets
• Generator Inlets (on the engine cowls
• Pitot Tubes
• Wheel Assemblies.
(10) Before you install the protective covers, make sure that the surfaces are clean, with no oil, grease, dirt, or other
contamination on them.
WARNING: Be careful when you use degreasers. Degreasers are toxic to your skin, eyes, and respiratory
tract. Make sure that your work area has a ventilation system that supplies sufficient fresh air.
CAUTION: Take precautions to prevent entrapment of contamination. The quality of water that you use
for washing and rinsing the airplane is important. Much of the world's water contains
chlorides, sulfates, and other salts. If you let these salts collect between faying surfaces or in
joints, seams, or other entrapment areas, corrosion can result.
CAUTION: The use of heavy degreasers can affect CIC's durability. Use precautions for the preservation
of the CIC already applied. Apply the CIC again if they are damaged or removed. Refer to the
applicable Maintenance Manual, Chapter 51, Corrosion Inhibitor - Maintenance Practices.
NOTE: In areas that you know contain these dissolved salts, Cessna recommends that you use de-
ionized, de-mineralized, or reverse osmosis water to wash and rinse these contaminates from
the airplane.
(a) Remove contamination from the surfaces with an approved degreaser. Refer to Table 302.
(b) Clean the surfaces with cheesecloth and a cleaning compound. Refer to Table 301 and Table 305.
(c) Rinse the surfaces with clean water. Refer to Table 305.
(d) Dry the surfaces with clean shop towels. Refer to Table 305.
C. Airplane Wet Wash.
CAUTION: Do not use a pressure washer to clean the exterior of the airplane. High-pressure water can
remove grease and other lubricants and can damage sensitive components. All water pressure
that you use to clean the airplane must be applied at less than 100 psi (689.48 kPa).
CAUTION: Be careful that you keep water and cleaning compounds from wire bundles, electrical switches,
and connectors. This will help to prevent damage to them.
CAUTION: Do not remove the protective covers until you have completed all washing and rinsing.
CAUTION: Use cool, clean water to reduce the exterior surface temperatures to ambient. Cleaning

20-52-20-3 (Rev 1)
compounds applied to hot surfaces can damage the exterior finish.

NOTE: The airplane wet wash is an acceptable method to clean all external areas on the airplane.
NOTE: If necessary, you can use clean water and cleaning compounds to soak the surfaces.
NOTE: During the airplane wet wash, any surfaces with cleaners on them must not dry before they are
rinsed with clean water.
NOTE: For landing gear components cleaning instructions, refer to Airplane Special Area Cleaning in this
section.
(1) Spray the surfaces of the areas to be cleaned. Refer to Table 305.
CAUTION: Use only clean water to wash and rinse the contaminates from the airplane. Cessna
recommends that you use de-ionized, de-mineralized, or reverse osmosis water to wash and
rinse the contaminates from the airplane. Refer to Exterior Cleaning (Wash/Rinse)
Considerations in this section.
(2) Apply cleaner to areas to be cleaned. Refer to Table 301 for a list of approved cleaners.
CAUTION: Clean only a small area at one time. This will make sure that the cleaning compounds do not
dry on the surface.
NOTE: Follow cleaner manufacturer's recommended soak times.
(3) Clean the area using a soft cloth or soft bristle brush. Refer to Table 304.
(4) Rinse each area with clean water immediately after it is washed.
(5) Carefully clean and dry these areas with clean shop towels or clean cotton cloths.
(6) Apply lubricants and corrosion inhibiting compounds again if they were accidentally removed. Refer to the applicable
Maintenance Manual, Chapter 51, Corrosion Inhibitor - Maintenance Practices.
(7) Remove the protective covers as applicable.
(8) Clean the landing gear components. Refer to Airplane Special Area Cleaning in this section.
D. Airplane Alternative Wash
CAUTION: Use only clean water to wash and rinse the contaminates from the airplane. Cessna recommends
that you use de-ionized, de-mineralized, or reverse osmosis water to wash and rinse the
contaminates from the airplane. Refer to Exterior Cleaning (Wash/Rinse) Considerations in this
section.
CAUTION: Be careful that you keep water and cleaning compounds from wire bundles, electrical switches,
and connectors. This will help to prevent damage to them.
CAUTION: Do not let cleaning compounds and/or water collect in low areas. This will help to prevent
corrosion in those areas.
NOTE: The best procedure for washing the airplane is the full water-based washing procedure (wet wash).
Because of environmental laws at some locations, a full water-based washing is not permitted. The
alternative wash method is an satisfactory equivalent.
(1) To clean surfaces that are not smooth, do as follows
(a) Put clean shop towels below the area to be cleaned to collect cleaning compounds.
(b) Apply mild detergent cleaning compound. Allow to soak per the manufacturer's recommendations. Refer to
Table 301, and Table 305.
CAUTION: Clean only a small area at one time. This will make sure that cleaning compounds do not
dry on the surface.
NOTE: Some contamination is difficult to get access to, but it is important that you remove all of
it.
1 Make sure that you clean all fasteners, angles, crevices, stiffener assemblies, and extended structures.
(c) Use a soft bristle brush to fully clean the treated areas.
(d) Using a spray bottle or garden-type sprayer, rinse each area with clean water immediately after it is washed.
Refer to Table 304.
1 Carefully examine these areas and continue to clean them until you have removed all contamination.

20-52-20-3 (Rev 1)
(e) Dry each area with clean shop towels.

(f) Remove the collected water and cleaning compounds.
1 Dispose of the collected water and cleaning compounds in accordance with local environmental laws.
(g) Make sure that these areas have sufficient lubrication.
(h) Apply corrosion inhibiting compound again if it was accidentally removed. Refer to the applicable Maintenance
Manual, Chapter 51, Corrosion Inhibitor - Maintenance Practices.
E. Airplane Dry Wash
(1) To clean surfaces that are smooth (airplane skins), do as follows:
NOTE: This is the dry washing procedure and it is only approved to clean smooth surfaces on the
wing, fuselage, and empennage surfaces.
NOTE: This is an apply-and-remove (wipe on/wipe off) cleaning procedure.
(a) Apply the dry wash compound with clean shop towels, clean cotton cloths, or a clean nonmetal cleaning pad.
Refer to Table 303 and Table 305.
(b) Quickly remove the dry wash compound from the surface.
(c) Continue to apply and remove the dry wash compound until you have removed all contamination.
(d) Make sure that the surfaces are clean and dry, with no remaining residue.
(e) Dispose of the dry wash compound and shop towels, cotton cloths, or nonmetal cleaning pad in accordance with
local environmental laws.
F. Airplane Special Area Cleaning.
WARNING: Be careful when you use degreasers. Degreasers are toxic to your skin, eyes, and respiratory tract.
Make sure that your work area has a ventilation system that supplies sufficient fresh air.
CAUTION: The use of heavy degreasers can affect CIC's durability. Use precautions for the preservation of
the CIC already applied. Apply the CIC again if they are damaged or removed. Refer to the
applicable Maintenance Manual, Chapter 51, Corrosion Inhibitor - Maintenance Practices.
CAUTION: Do not use aerosol-type fluids on the landing gear hydraulic systems. The propellants in aerosols
can damage the packing and other internal components of the landing gear piston.
CAUTION: Be careful when you clean the landing gear piston surface. You must not cause scratches on the
piston surface. A scratch on the piston surface can cause leakage and failure of the cylinder.
CAUTION: Do not leave too much hydraulic fluid on the piston surface. This will help to keep hydraulic fluid
off other landing gear components.
CAUTION: Do not clean or rinse the brake assemblies. The carbon disks in the brake assemblies must be kept
dry. A change in the carbon properties and possible freezing of the brake assemblies can occur if
water gets on the disks. Use the manufacturer's instructions to clean the wheels and the brake
assemblies. Refer to the applicable Maintenance Manual, Introduction, Supplier Publication List.
CAUTION: Take precautions to prevent entrapment of contamination. The quality of water that you use for
washing and rinsing the airplane is important. Much of the world's water contains chlorides,
sulfates, and other salts. If you let these salts collect between faying surfaces or in joints, seams, or
other entrapment areas, corrosion can result.
NOTE: In areas that you know contain these dissolved salts, Cessna recommends that you use de-
ionized, de-mineralized, or reverse osmosis water to wash and rinse the contaminates from the
airplane.
NOTE: This procedure is used to clean the landing gear component (cylinder housing, door, piston,
trailing link, trunnion, and wheel) surfaces.
(1) To clean the landing gear piston surface (the external surface that you can see), do as follows:
(a) Carefully remove sand, dirt, salts, and other foreign object debris (FOD) with a nonwoven fabric cleaning cloth
and hydraulic fluid.

20-52-20-3 (Rev 1)
1 Remove the contamination away from the seals and the seal junctions.
2 Use your hands to make sure that the piston surface is fully clean.
3 Make sure that the piston surface is not dry.
NOTE: The piston surface must only have a sufficient layer of hydraulic fluid on it. There
must not be drops of unwanted hydraulic fluid on the cylinder housing.
(2) To clean the landing gear door, linkage, and cylinder housing surfaces, do as follows:
(a) Apply a mild detergent or degreaser and allow to soak per the manufacturer's recommendations.
(b) Using a soft bristle brush, clean cotton cloths, or clean shop towels, fully clean the exterior surfaces. Refer to
Table 301, Table 302, and Table 305.
1 Using a hose, spray bottle, or garden-type sprayer, rinse each area fully with clean water to make sure that
you have removed all of the cleaning residue.
CAUTION: Do not clean or rinse the brake assemblies. The carbon disks in the brake
assemblies must be kept dry. A change in the carbon properties and possible
freezing of the brake assemblies can occur if water gets on the disks. Use the
manufacturer's instructions to clean the wheels and the brake assemblies. Refer to
the applicable Maintenance Manual, Introduction, Supplier Publication List.
(3) To clean the landing gear trunnion and the trailing link surfaces, do as follows:
(a) Apply a mild detergent to a clean shop towel to clean the exterior surfaces. Refer to Table 301 and Table 305.
NOTE: Do not use a spray cleaner on the trunnion or the trailing link.
1 Using a spray bottle, rinse the trunnions and trailing links with clean water to remove all of the cleaning
residue.
CAUTION: Do not clean or rinse the brake assemblies. The carbon disks in the brake
assemblies must be kept dry. A change in the carbon properties and possible
freezing of the brake assemblies can occur if water gets on the disks. Use the
manufacturer's instructions to clean the wheels and the brake assemblies. Refer to
the applicable Maintenance Manual, Introduction, Supplier Publication List.
(4) To clean the wheels, do as follows:
(a) Apply a mild detergent or dry cleaning compound to a shop towel or nonmetal cleaning pad and wipe as
necessary to remove contaminates.
1 Make sure that you remove all of the cleaning residue.
(5) Polish the leading edge metal surfaces. Refer to the applicable Maintenance Manual, Chapter 20, Exterior Finish -
Cleaning/Painting.
(6) Clean the windshield and the windows. Refer to the applicable Maintenance Manual, Chapter 12, Windshield and
Cockpit Side Window - Servicing.
(7) To clean the engine compressor, do as follows:
(a) For data on how to wash the engine compressor, refer to the applicable engine manufacturer's maintenance
manual.
G. Airplane Runway Deicing (RDI) Clean Water Rinsing.
NOTE: The clean water rinsing procedure is to be done if the airplane has accidental RDI fluid
contamination. Cessna recommends that you do this rinsing procedure in the next three days after
the RDI fluid contamination has occurred. Deicing fluid can quickly cause corrosion on the
airplane exterior.
(1) Do the RDI clean water rinsing procedure only on the high exposure areas - Airplane Zone 1. Refer to Exterior
Cleaning (Wash/Rinse) Considerations in this section.
(2) Make sure that all of the necessary rinsing preparation is done. Refer to Prepare the Airplane for the Exterior
Cleaning (Wash/Rinse) in this section.
(3) Using a low-pressure garden hose, a garden-type sprayer or a spray bottle, rinse the high exposure areas with clean
water as follows:
CAUTION: Do not use a pressure washer. High-pressure water can remove grease and other lubricants,

20-52-20-3 (Rev 1)
and can damage sensitive components. All water pressure that you use to rinse the airplane
must be applied at less than 100 psi (689.48 kPa).
(a) Moving the sprayer in a side-to-side motion, rinse the landing gear.
CAUTION: Do not clean or rinse the brake assemblies. The carbon disks in the brake assemblies
must be kept dry. A change in the carbon properties and possible freezing of the brake
assemblies can occur if water gets on the disks. Use the manufacturer's instructions to
clean the wheels and the brake assemblies. Refer to the applicable Maintenance Manual,
Introduction, Supplier Publication List.
NOTE: Do not point the sprayer into openings and surfaces that are adjacent to the openings.
(b) Let the water drain from the surfaces. Use clean shop towels to absorb any residual water.
CAUTION: Do not try to open the small drain holes on the bottom of the fuselage from out of the
airplane. This can cause damage to the diaphragms on the inboard side of the fuselage
skin.
NOTE: Make sure that there is no water left in the wheel wells, flap coves, and other areas.
H. Put the Airplane Back to its Initial Condition.
(1) Remove all protective covers, tape, and other barrier materials from the airplane.
(2) Remove all access equipment from the area.
(3) Release all of the control locks. Refer to the applicable Maintenance Manual, Chapter 27, Control Lock System -
(4) Move the airplane back to its initial location. Refer to the applicable Maintenance Manual, Chapter 9, Towing -

PLACARDS, DECALS, AND WRAPS - MAINTENANCE PRACTICES

1. General
A. This section describes the procedures and the requirements for the fabrication, processing, and application of placards,
decals, wraps, and other signage or artwork applied to the airplane.
B. Placards, decals, wraps must only be installed by trained and qualified personnel.
2. Definitions
• Application - The placing and attaching of the prepared film or appliques to the airplane or airplane parts.
• Applique - Any placard, stripe, decal, or digitally printed film item that is applied to an airplane or airplane part.
• Clear Coat - A protective coating of clear paint applied to decals, placards, or wraps after installation.
• Color Foil - A thermal transfer ink ribbon, roll, or cartridge where ink is adhered to one surface of a foil or film. During
printing the back of the foil is heated, causing the ink to be transferred to the marking film.
• Decal - A marking film applique applied to an airplane or airplane part, which is made from colored marking film or can
be screen printed, and is applied to improve the appearance of the airplane.
• Engineering Order (EO) - A document used to describe the design of the exterior finishes of a particular airplane.
• Fabrication - The printing, coating, cutting, and other preparation of film or placard appliques.
• Ink Jet Print - Digital printing technique where a digital image is recreated on a marking film using an ink jet printer. Inks
can be solvent based, water based, ultraviolet (UV) curable, or other.
• Luster - The degree of specular reflectance exhibited by a film or ink. Usually described as Gloss, Flat, Satin or similar
terms.
• Marking Film - A plastic film, usually vinyl, that becomes the base of placards, decals, and wraps.
• Overlaminate - A clear protective film made of polyester or other solvent and chemical resistant material that is applied
over a marking film to protect the ink and vinyl of the applique.
• Pick-Off - The removal of very small grains of ink or film.
• Print Seal - A thin coating applied to printed film to provide a measure of protection against weather and UV damage.
This is always applied to the film at the fabricator before installation. This can be applied as a coating or by thermal
transfer foil.
• Placard - Small signage applique applied to an airplane or airplane part, which can be fabricated from aluminum,
plastic, or film and printed using an approved method.
• Screen Print - Printing technique where an image is applied to a marking film by pressing ink through a negative
masked screen.
• Stripe - A long, thin decal usually applied along the long axis of the fuselage.
• UV Ink - Printing ink that contains a cure catalyst which is activated when the ink is irradiated using UV light.
• Wrap - A large marking film applique that is digitally printed and applied to an airplane or airplane part. These can only
be applied to certain areas of an airplane or airplane part, and contribute to the exterior paint thickness limitations.
3. Marking Film Classification
A. Types
• Type I - Temporary Registration Numbers
• Type II - Exterior Signage Placards
• Type III - Interior Signage Placards
• Type IV - Stripe/Decal - Single Engine
• Type V - Stripe/Decal - Jets
• Type VI - Fuselage Digitally Printed Wraps - Single Engine
• Type VII - Fuselage Digitally Printed Wraps - Jets.
B. Classes
• Class A - Requires Overlaminate or Clear Coat
• Class B - Does Not Require Overlaminate or Clear Coat.
4. Storage and Handling
A. General
(1) Marking films and transfer adhesives must be stored according to the manufacturer’s requirements. Storage life
records must be maintained for each roll or individual container. This storage life information shall be indicated on the
fabricated product or on the packaging. End of life can be extended by mechanical testing as required. All rolls of

marking film must be handled and supported by the center core in a horizontal orientation. Do not lay rolls of marking
film on work surfaces or vertically on end.
TM
B. Metalphoto Placards (Photosensitive Anodized Aluminum)
(1) Unused photosensitive anodized aluminum must be stored away from light in lightproof packaging.
(2) The printer, photosensitive anodized aluminum, and negative surfaces shall be free of dust and dirt during exposure.
(3) The developer, in the developing tank, must be covered with a layer of tap water to prevent evaporation. This water
layer shall be periodically changed to prevent deposition of particles on exposed film.
(4) The developer and etchant must be used for the period of time recommended by the manufacturer or until they are no
longer useful.
(5) Photo placard materials should be used by the date specified by the manufacturer, however, the material may be
revalidated, for a 3 month period, (by exposing and developing) if the requirements of this specification are met.
TM
C. Polycolor Placards and Dyes
TM
(1) Polycolor dyed plates are not light sensitive and have a shelf life of two years.
TM
(2) Polycolor dyes and stripper should be stored below 80°F (26°C) and have a one year shelf life in the original
unopened container.
(3) Photo placard materials should be used by the date specified by the manufacturer, however, the material may be
revalidated, for a 3 month period, (by exposing and developing) if the requirements of this specification are met.
D. Marking Films and Overlaminates
(1) Vinyl material must be stored at environmental conditions of 40 to 100°F (4 to 37°C) temperature at 20 to 85%
humidity. They may be stored for up to 24 months.
(2) Non-Vinyl marking films and overlaminates must be stored at environmental conditions of 40 to 90°F (4 to 32°C)
temperature at 20 to 85% humidity. They may be stored for up to 24 months if kept under the climate conditions
specified.
E. Silk Screens and Ink
(1) Silk screens shall be cleaned with wash-up T-925 or cyclohexanone for catalyzed paints, toluol, or Methyl n-Propyl
Ketone for non-catalyzed paints or equivalent by brushing with a soft bristled brush and then carefully wiped dry.
(2) Do not use water to clean the silk screen, since the film in the silk screen is water soluble.
(3) Silk screens shall not be immersed or allowed to soak in solvent.
(4) After cleaning, screens shall be wiped with a cloth dampened with mineral spirits and stored in an upright position.
(5) Damaged screens shall be replaced.
(6) When the silk screening ink being used shows signs of setting up, gelling, or otherwise displays an unsatisfactory
quality, it shall be discarded.
F. Thermal Transfer Decals
(1) Transfer ribbon or color foils must be stored at 40 to 100°F (4 to 37°C) temperature and 40 to 60% humidity. They
can be stored for up to 24 months if kept under climate conditions specified.
(2) Transfer ribbons or color foils must be stored in the original containers or in printer cassettes when not in use.
(3) Printed polyester labels can be stored under climate conditions of 40 to 100°F (4 to 37°C) and a minimum 50%
humidity. They can be stored for up to 24 months.
(4) Vinyl material can be stored for up to 24 months if kept at 40 to 100°F (4 to 37°C) at 20 to 85% humidity.
5. Photo Placard Fabrication
• Heat Gun
• Photo Placards Exposure/Developer Equipment

• Plastic Squeegee.
• None.
• Interior Finish - Cleaning/Painting.
TM
B. Metalphoto Fabrication - Aluminum placards of different sizes and shapes can be manufactured using photosensitive
anodized aluminum plates, which are exposed to placard template images, developed, dyed if applicable and sealed. The
TM
Metalphoto system by Horizons Incorporated is an example of commercial products available for fabricating this kind of
TM
placard. Polycolor dyes, also from Horizons Incorporated, are available in a number of different colors when color
placards are required. Refer to Electrically Grounded Aluminum Placard Installation in this section for the procedures to
install aluminum placards.
(1) Fabricate in a dark room to give protection to the light sensitive material.
(2) Remove the aluminum from the light proof package.
(3) Make sure that the exposure unit, negatives or positives, and aluminum are free of dust and dirt.
(4) Expose the material to light for the recommended time (usually a setting of 2.5).
(5) Run the exposed sheet through the fixer and the developer tank.
(6) Thoroughly rinse the sheet with tap water.
(7) Let the sheet air dry or force it dry with a heat gun.
(8) If you find any spots or blemishes, a the deletion pen to remove them by using the treatment end followed by the
erasing edge.
TM
(9) If Engineering requires, a colored background can be achieved by applying a uniform coat of Polycolor with a lint-
free cloth. Let the sheet set for approximately one minute and then wipe away the excess. Let the sheet air dry or
force it dry with a heat gun.
(10) After the sealing tank has come to a rolling boil, clamp the sheet and put it in the tank for approximately fifteen
minutes.
(11) Hang the sheet to dry.
(12) Cut the sheet to size.
TM
C. Polycolor Fabrication
(1) Remove the photo resist coated panels from their package.
TM
NOTE: Polycolor material is not light sensitive.
(2) Remove the black filter from the exposure unit.
(3) Make sure that the exposure unit, positives or negatives, and material are free of dirt and dust.
(4) Put the aluminum sheet, with the resist layer face up, on the exposure unit and the negative on top of it.
NOTE: The resist layer has a blue tint.
(5) Expose the material for the necessary amount of time (usually a setting of 15).
(6) Thoroughly rinse the exposed material with water.
(7) Let the material air dry or force it dry with a heat gun. If dried with heat gun, let it cool to room temperature.
(8) If necessary, mask off the areas that are to have additional colors applied.
(9) Apply the first color over the exposed area in a uniform coat. Let it set for approximately one minute and wipe away
the excess. Allow this to dry.
(10) Demask and remask the part as necessary until all of the colors are applied. Masking over colored areas is not a
concern if the dye is dry.
(11) Demask the part completely.
(12) Make sure that the part is dry and put it in a bath of stripper.

(13) Gently wipe off the part while in the bath, removing the resist layer.
(14) Rinse the part thoroughly.
(15) Dry the part by gently dabbing and let it air dry or force dry with heat gun.
(16) After sealing tank has come to a rolling boil, clamp the sheet and put it in the tank for approximately fifteen minutes.
(17) Hang the sheet to dry.
(18) Cut the sheet to size.
TM TM
D. Pressure Sensitive Adhesive Application - All placards of Metalphoto or Polycolor may not require pressure sensitive
adhesive application. Refer to the engineering drawing for the specific requirements.
(1) After processing the photo placards, the sheet must be thoroughly dried.
(2) Turn the printed side down and lay it on a clean, non-scratching surface. Wipe the back side with a cloth dampened
with a Type II, Class 1 solvent to remove all of the dust and oil. Refer to General Solvents/Cleaners - Maintenance
Practices.
(3) Unroll the needed length of adhesive and put it on the back side of the photo placard sheet. Use a plastic squeegee
to push out all of the trapped air.
(4) Cut individual photo placards from the sheet at any time after the adhesive is applied.
TM
(5) If the exposed edges are a concern for the installed anodized Metalphoto placards, edge seal or overcoat with a
clear urethane. Refer to Interior Finish - Cleaning/Painting.
6. Marking Film Fabrication
• None.
• None.
• Interior Finish - Cleaning/Painting.
(1) Vinyl and polyester film decals must be silk screened with the correct silk screening inks.
(2) Color usage of films and silk screen inks must obey the applicable engineering drawings.
(3) Films can be applied over surfaces which have been lacquer top-coated, polyurethane top-coated, epoxy top-coated,
or epoxy primed. Films may also be applied to clean bare aluminum or clad aluminum which has been chemically
filmed.
(4) Transparent films must not be used as a background color for warning signs.
(5) Films are intended for exterior and interior use on surfaces not subjected to temperatures more than 225°F (107°C).
(6) For all printed, silkscreened, or thermal transfer imaged applique, one of the following conditions must apply:
(a) Applique intended for exterior use must have either a chemically resistant overlaminate and edge sealing, or a
urethane clear coat and edge seal.
(b) Applique intended for interior use must have either a print seal over the lettering, or an overlaminate. Edge
sealing is optional for interior use.
C. Silk Screening
(1) All of the surfaces to be silk screened must be free of dust, oil, and grease. Surfaces can be wiped with a cloth
dampened with naphtha. Refer to General Solvents/Cleaners - Maintenance Practices.
(2) The silk screen must be positioned on the surfaces so that it will produce the correct results.

(3) Thoroughly mix the silk screen inks per the manufacturer’s instructions.
(4) After the silk screen is positioned properly, the specified ink must be applied with a silk screen applicator in one
clean even stroke with constant pressure. The silk screen must be removed immediately after the ink application.
Clean the screen per the manufacturer’s instructions.
(5) The parts must be allowed to dry overnight without contact to the lettering or design. After drying, contact with the
stenciled lettering must be kept at a minimum.
(6) The design and lettering made by silk screen stencils must be the color specified and must be sharply legible and
free from smears with good adherence to the marked surfaces.
(7) All silkscreening done to primed surfaces must be over-coated with a clear urethane before the part is installed on the
airplane. Refer to Interior Finish - Cleaning/Painting.
D. Silk Screen Inks Drying
(1) Conventional silk screen inks must dry overnight at room temperature without contact with any materials. When
printing multicolor jobs, it is not necessary to fully cure each color. Partial cure must be allowed between colors until
tack-free. A final cure is necessary.
(2) Ultraviolet curable inks will not dry until exposed to a UV light source per the ink manufacturer’s specifications for
specific ink types and substrates. The distance from the substrate and exposure time is dependent upon the
substrate and ink type as specified by the cure parameters. Besides substrates, other variables that may influence
cure parameters can be ink color, ink chemistry, ink deposit/film weight, mesh used, and halftone or line color. The
fabricator should follow the ink and the equipment manufacturer’s requirements for UV light cure conditions.
E. Pressure Sensitive Adhesive Application
(1) If the application of pressure sensitive adhesive is required, refer to Pressure Sensitive Adhesive Application in this
section.
F. Thermal Transfer Decal Procedure
(1) The thermal transfer decal process can be used as an alternate to the silkscreen process when the color matches are
not critical.
(2) The thermal transfer labels must be designed and printed per the equipment and material manufacturer’s
specifications.
(3) The decals are suitable for use in environments up to 248°F (120°C).
G. Ink Jet Printing
(1) Only use the approved marking films for digital printing. Refer to Table 201.
Table 201. Approved Digital Printing Marking Films
Description Approved Materials Manufacturer Type, Class Cessna Material
Number
IJ180Cv3 White, Black, 3M Type II, Class A P840438
Transparent Commercial Graphics Type III, Class B P840440
Division Type IV, Class A P840441
3M Center, Building Type V, Class A
220-12E-04 Type VI, Class A
St. Paul, MN 55144- Type VII, Class A
3220
Oracal 3951 Only Available in Orafol Type II, Class A P840439
White Europe GmbH - Type III, Class B
OrafolstraBe 2 Type IV, Class A
D 16515 Type V, Class A
Oranienburg Type VI, Class A
Germany Type VII, Class A

A7322 Only Available in 3M Type II, Class B P840442

White Commercial Graphics Type III, Class B
Division Type IV, Class B
Type V, Class B
Type VI, Class B
Type VII, Class B
3M ControlTac All Colors 3M Type II, Class A Not Applicable
Graphic Film with Commercial Graphics Type III, Class B
Comply Adhesive Division Type IV, Class A
Series 180C Type V, Class A
IJ180C-10
(2) Only use the inks approved for digital printing. Refer to Table 202.
Table 202. Approved Digital Printing UV Ink Jet Inks
Description Approved Materials Manufacturer Class
Specialty Flexible Scitex 8-Color UVIJ Hewlett Packard Inc. Class A
UVIJ Ink 1501 Page Mill Road Class B
HP FB210 Palo Alto, CA 94304
(3) The fabricator must make sure that the film and inks are within the shelf life of the materials.
(4) Only suppliers approved by Cessna Aircraft Company Quality can fabricate digitally printed films.
(5) Interiors Engineering will provide the image to be printed in a file format compatible with the printing equipment to be
used by the supplier. The Engineering Order will give details about image placement and splice patterns.
H. Overlaminate Application
(1) If overlaminate film is necessary, it must be applied by the fabricator after all printing is completed. Overlaminate film
is necessary for Class A materials of all Types.
7. Placard Installation
• Rubber Roller.
• None.
B. Install the Placard.
(1) The surface that will receive the placard must be clean, dry, and lint free. This can be accomplished by wiping the
surface with solvent followed by wiping with a lint free cloth. Refer to General Solvents/Cleaners - Maintenance
Practices.
(2) Remove the protective backing and carefully set the placard in place, starting at one end and securing contact
progressively toward the other end avoiding wrinkling and air bubbles.
(3) Use a rubber roller or plastic spatula to press the placard firmly in place.
(4) Refer to the General Requirements for overlaminate or clear coat, and edge seal in this section.
8. Decal Installation

• Rivet Brush
• Rubber Roller.
• None.
B. Install the Decal.
(1) The surface that will receive the decal must be clean, dry, and lint free. This can be accomplished by wiping the
surface with solvent followed by wiping with a lint free cloth. Refer to General Solvents/Cleaners - Maintenance
Practices.
(2) Remove the protective backing and carefully set the decal in place, starting at one end and securing contact
progressively toward the other end avoiding wrinkling and air bubbles.
(3) Use a rubber roller or plastic spatula to press the decal firmly in place.
(4) Remove the pre-masking tape at a 180 degree angle.
(5) Work out all air bubbles by pushing the air out to the nearest edge or perforation.
(6) Work the film down into irregular areas with a rivet brush.
(7) Squeegee all edges and overlaps after the pre-mask is removed.
(8) Refer to the General Requirements for overlaminate or clear coat, and edge seal in this section.
9. Wrap Installation
• Low Friction Sleeve
• PA-1 Applicator
• Razor Blade
• Rivet Brush.
• None.
(1) Review the Engineering Order (EO) and application instructions before starting.
(2) Use the film within its shelf life.
(3) Apply the film when the air and surface temperatures are 50 to 100°F (10 to 38°C).
(4) Make sure that the surface is clean. Even newly finished surfaces must be cleaned before application. Refer to
General Solvents/Cleaners - Maintenance Practices.
(5) Use a sharp, nick free PA-1 applicator and a low friction sleeve.
(6) Use firm squeegee pressure with overlapping strokes.
(7) Overlap the adjacent film by a minimum of 0.25 inch (6.35 mm), but not more than 0.5 inch (12.70 mm).

(8) Remove the premasking tape at a 180 degree angle.

(9) Work out all air bubbles by pushing the air out to the nearest edge or perforation.
(10) Work the film down into irregular areas with a rivet brush.
(11) Squeegee all edges and overlaps after the premask is removed.
(12) Cut the film over all substrate seams and then edge seal.
(13) Edge seal is required on all edges.
C. Install the Wrap.
(1) Before applying the graphics to a freshly painted surface, the paint must be cured for the time recommended by the
paint manufacturer. Special attention must be given to two-part polyurethane paint systems and clear coats because
these outgas as they cure. The outgassing will cause bubbling of the graphic. A minimum of 5 days curing time at
70°F (21°C) or above is generally required before outgassing decreases to a point where bubbles are no longer
detectable.
(2) Freshly painted surfaces must be cleaned. Clean the surface with a solvent such as isopropyl alcohol and wipe dry
with clean lint free rags. Do not allow the solvent to evaporate before wiping. Refer to General Solvents/Cleaners -
(3) Film applied to surfaces that have a matte texture, such as those used on some military aircraft, may lift and erode
prematurely because of low adhesion to the matte paint or clear coat. Matte surfaces must be finished to a
smoothness comparable to glossy paint or clear coat, especially in areas where the film's leading edge and edge
sealer are applied.
(4) Position the graphic on the surface of the airplane according to the EO.
(5) Make registration marks on the surface to position the top or side edge of the graphic.
(6) Separate the liner and film by flicking the film edge away from the liner with the ball of your thumb or a fingernail. A
small bend at the corner or edge will also make the liner separate from the film.
(7) Lay the graphic face down against the side of the airplane or on a clean flat surface. Pull off the entire liner in a
continuous motion at a 180 degree angle. If the liner is scored, bend at the seam and remove. Always remove the
liner from the graphic, not the graphic from the liner.
(8) Tack the graphic in place with thumb pressure in the upper corners.
(9) Hold the rest of the graphic away from the surface to avoid pre-adhesion. Using firm, initial squeegee pressure, begin
at the center of the graphic and work outward in all directions.
(10) To avoid wrinkles, release the tack points before squeegeeing over them.
(11) Continue to remove the liner and work the film with a squeegee from the middle outward.
(12) Work the film around rivets using a squeegee. Heat may be applied if necessary, but warm air from the blowers shall
not exceed 160°F (71°C).
(13) Cut the graphic on all substrate seams with a razor blade (in a holder) or similar cutting tool. Squeegee the edges or
use a rivet brush.
(14) Look for bubbles in the flat areas. To remove a bubble, puncture it at one end with a pin or round pointed tool; never
use a razor blade. Move toward the hole with a finger and press out the trapped air.
(15) Work the film down into the irregular areas with a rivet brush.
(16) Apply edge seal or clear coat as required.
10. Electrically Grounded Aluminum Placard Installation
• None.
• None.


• Electrical Bonding and Grounding - Maintenance Practices
• Fuel, Weather, Pressure and High-Temperature Sealing - Maintenance Practices.
B. Install the Electrically Grounded Aluminum Placard.
(1) Mark the location of placard on the receiving part or assembly, aligning fastener holes.
(2) Inside the marked location, remove the organic finish from an area approximately 1.0 inch (25.40 mm) in diameter
using fine sandpaper until bare metal shows.
(3) Scuff sand the remaining area inside the marked location to promote adhesion, then solvent clean thoroughly. Refer
to General Solvents/Cleaners - Maintenance Practices.
(4) Use Type XV sealant to fay seal the placard. Refer to Fuel, Weather, Pressure and High-Temperature Sealing -
(5) Use Type XV sealant to fillet seal the outer edge of the placard. Refer to Fuel, Weather, Pressure and High-
(6) Do an electrical bonding check of the placard to make sure that it obeys the maximum allowable resistance value.
11. Placard, Decal, or Wrap Removal
• Spatula.
• None.
B. Remove the Placard, Decal, or Wrap.
(1) Appliques with removable adhesives can be removed by working a corner or edge loose and pulling the film quickly
at a small angle back on itself. If necessary, heat can be used up to 160°F (71°C).
(2) Appliques with permanent adhesives likely will require heat to soften the adhesive and should be pulled slowly at a
large angle.
(3) For particularly tenacious appliques, chemical strippers or solvents can be used to soften the adhesive. The film
should be loosened with a spatula while wet. Be cautious that the chemical strippers can affect the underlying coating.


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Citation Standard Practices Manual (Rev 1)

STANDARD PRACTICES AIRFRAME - GENERAL

Copyright © Textron Aviation Inc. Page 1 of 10

Metal Glaze, Finishing and Evercoat To correct the contour,

Copyright © Textron Aviation Inc. Page 2 of 10

Antiseize Compound TT-A-580 Commercially Available To install instant fittings.

Copyright © Textron Aviation Inc. Page 3 of 10

Turco 5873 NC Henkel Corp. Spray or brush on aluminum,

Copyright © Textron Aviation Inc. Page 4 of 10

Daniels DMC Series Tool Daniels Manufacturing To install safety cable.

Copyright © Textron Aviation Inc. Page 5 of 10

Copyright © Textron Aviation Inc. Page 6 of 10

Micro-Ohmmeter Model 580 or equivalent Keithley Instruments, Inc. To measure resistance.

Copyright © Textron Aviation Inc. Page 7 of 10

Copyright © Textron Aviation Inc. Page 8 of 10

Semco Hand-Operated Model 850 PPG Aerospace/PRC- To apply sealant.

Copyright © Textron Aviation Inc. Page 9 of 10

Torque Putty Commercially Available To inspect for movement of

Copyright © Textron Aviation Inc. Page 10 of 10

STANDARD PRACTICES AIRFRAME - MAINTENANCE PRACTICES

Copyright © Textron Aviation Inc. Page 1 of 2

Copyright © Textron Aviation Inc. Page 2 of 2

MATERIAL AND TOOL CAUTIONS - DESCRIPTION AND OPERATION

Copyright © Textron Aviation Inc. Page 1 of 3

Copyright © Textron Aviation Inc. Page 2 of 3

Copyright © Textron Aviation Inc. Page 3 of 3

AIRPLANE HARDWARE - DESCRIPTION AND OPERATION

Copyright © Textron Aviation Inc. Page 1 of 1

TUBING, HOSE AND FITTINGS - MAINTENANCE PRACTICES

Copyright © Textron Aviation Inc. Page 1 of 16

A. Tools and Equipment

Copyright © Textron Aviation Inc. Page 2 of 16

(e) Loosen the fitting at the end of the tubing.

Copyright © Textron Aviation Inc. Page 3 of 16

Copyright © Textron Aviation Inc. Page 4 of 16

(4) Put the hose assembly in its position in the airplane.

Copyright © Textron Aviation Inc. Page 5 of 16

Copyright © Textron Aviation Inc. Page 6 of 16

Copyright © Textron Aviation Inc. Page 7 of 16

(1) Obey the Standard Maintenance Practices in this section.

Copyright © Textron Aviation Inc. Page 8 of 16

• Emery Cloth - Fine Grade

Copyright © Textron Aviation Inc. Page 9 of 16

Copyright © Textron Aviation Inc. Page 10 of 16

(5) Examine hoses for twisting, weather cracks, or splitting.

Copyright © Textron Aviation Inc. Page 11 of 16

Figure 201 : Sheet 1 : Tube Installation Mismatch

Angular Mismatch Radial Mismatch

Copyright © Textron Aviation Inc. Page 12 of 16

Figure 202 : Sheet 1 : Universal Fitting Installation

Positioning Type Fitting Installation

Copyright © Textron Aviation Inc. Page 13 of 16

Figure 203 : Sheet 1 : Clamp-Type Coupling Installation

Copyright © Textron Aviation Inc. Page 14 of 16

Figure 204 : Sheet 1 : Tubing Clamp Installation

Tubing−to−Tubing with Spacer

Tubing−to−Tubing Multiple Tubing−to−Tubing

Copyright © Textron Aviation Inc. Page 15 of 16

Figure 204 : Sheet 2 : Tubing Clamp Installation