56-10-00 - Air Cargo Carriers 56/56-10-00.pdf · EFFECTIVITY: All 56-10-00 Page 4 z SD3-60 STRUCTURAL REPAIR MANUAL A. Materials and General Instructions (1) Sealant SMS49 (Qualifying

Jun 30/0156-10-00 Page 1EFFECTIVITY: All

zSD3-60 STRUCTURAL REPAIR MANUAL

SRM56-10-00 2.0.0.0FLIGHT COMPARTMENT WINDOWS - STRUCTURAL IDENTIFICATION

1. General

This section identifies the structural installation, components, and location of the various windows in the SD360 aircraft Flight Compartment. Details are also given of the materials, limits of allowable damage, approved minor repairs, and procedures for removal and installation.

2. Construction

A. Windshields

Refer to Figure 1.

Each windshield comprises of a thin outer toughened glass ply (which provides good general resistance to scratching by airborne abrasive particles); an electrical heating element; two load bearing inner acrylic plies; and a thin acrylic ply (for spall protection in the case of external impact e.g. bird strike etc. The edges of the windshield are protected from moisture ingress by an edge moulding, and weather seal of polysulphide rubber.

B. Side and Corner Windows

Refer to Figure 2.

There are ten unheated side and corner windows in the flight compartment. With the exception of the pilots opening window, these are comprised of two acrylic plies, laminated together with a plastic (P.V.B.) interlayer, and are attached by bolting through rubber sleeved light alloy bushes around the panel edges.

The pilots opening side window comprises a single element acrylic ply, contained as a sub-assy within a light alloy frame. The complete frame assembly is attached by threaded fasteners to the hinges and latches.

3. Replacement of Windows and Windshields

CAUTION: AVOID THE USE OF TRICHLOROETHYLENE OR OTHER ETHYLENE COMPOUNDS FOR DEGREASING OR CLEANING. ETHYLENES WILL MELT AND DESTORY PERSPEX AND ACRYLIC OR PLEXIGLASS COMPOUNDS.

When windshields or windows are replaced, careful attention should be given to bedding and sealing, and the use of correct sealing compound is important. The illustrations show the type of sealing compound required, and the correct structural position and usage.



WindshieldFigure 1


zSD3-60 STRUCTURAL REPAIR MANUALSD3-60 STRUCTURAL REPAIR MANUAL

Corner and Upper side windowsFigure 2

56-10-00 Page 4EFFECTIVITY: All


A. Materials and General Instructions

(1) Sealant SMS49 (Qualifying material Sikaflex 11FC manufactured by Sika Ltd, Watchmead, Welwyn Garden City, Herts, AL1BQ, England).

This is a one part sealant extruded from a cartridge by means of an applicator gun. Cut back end of cartridge nozzle until a suitable bead is obtained, the cut may be tapered for ease of application.

Refer to Figure 6. The most suitable bead dia. for laying up bedding, filleting etc., will be established by experience. Initially when bedding glazing, ensure that sufficient sealant is applied to produce a continuous and level gasket. Remove all surplus sealant before curing time elapses. White spirit may be used to aid cleaning process, provided sealant at joints is not saturated.

(2) Release tape 3M-Y2010

This is a self adhesive tape which provides a surface that prevents adherence of Silkaflex 11FC sealant. Tape will require to be jointed at corners etc., joints are to be closely butted, overlapping at joints is not acceptable. Where necessary extend release tape beyond mating surfaces in order to prevent adherence of any excess sealant.

(3) Tepol (Liquid detergent undiluted)

Use to accelerate curing of sealant and aid release of form templates.

(4) 3M Aluminium foil tape (3M Y434)

Use to seal gaps between glazing panels, prior to outer straps being fitted.

(5) Sealex (Klinger)

Use to fill gap at centreline of windscreen.

(6) 3M Pressure sensitive tape (1 mm thick) - 3M9528

Use to line the inside of straps to protect glazing panels and seal round edges of bolt holes.

B. Front Windscreen Panels

(1) Removal

Refer to Figure 3 (Sheet 1).

(a) Refer to AMM, 30-41-00, pb1.

1 Isolate power supply to windscreen.

2 Disconnect windscreen heating cables from terminal block

Jan 31/11



3 Remove the windscreen wiper drive arm assemblies.

(b) Remove windscreen upper and lower outer cover straps by removing all countersunk screws.

(c) Remove 'T' shaped tie plates and centre pillar cover strap.

(d) Remove left and right hand pillar cover straps from pillars.

(e) Carefully lift out unserviceable panels (approx. weight 25 lb each).

(2) Preparation prior to installing windows.

New sealant bedding.

(a) Remove all existing sealant (Thiokol)

(b) Remove grease and dirt from all surfaces to which Sikaflex 11FC sealant is applied.

(c) Ensure internal sealing plates are fitted.

(d) Refer to Figure 8. Refer to Figure 9. All voids, gaps etc., in basic structure must be filled with Sikaflex sealant before bedding gaskets are formed. Areas to which particular attention should be paid are:-

1 at skin joint along top of corner and side windows.

2 skin joint at frame 54, adjacent to side window.

3 at corners of windscreen posts

4 skin joggles

(3) Formation of Bedding Gaskets

(a) Prepare dummy windscreen, corner and side window form templates, with release tape as shown. Refer to Figure 3 (Sheet 1). Refer to Figure 4.

(b) Apply Sikaflex 11FC sealant to the windscreen structure. Refer to Figure 6. Leave sealant to air cure for approx. 30 minutes (optimum time to be determined from experience).

(c) Use locating bolts (not tightened) to position dummy windscreen former(s) on the extruded sealant. Apply light hand pressure to settle windscreen to its correct profile with the structure. The gasket thickness formed should be 0.02/0.06 in.

(d) Allow 8 hours to cure (not applicable if modified windscreen former template is used. Refer to Figure 7.).

Jan 31/11



(e) Apply Sikaflex 11FC sealant to structure at corner and side windows. Refer to Figure 4.

(f) Position corner and side windows using locating bolts (not tightened) and with hand pressure only, align firstly the corner window(s) to profile with windscreen and adjacent aircraft structure. Align the side windows to profile with corner windows.

NOTE: Any profile discrepancy at frame 54 to be accommodated within buttstrap. Refer to Figure 3 (Sheet 1). Refer to Figure 10. These give further clarification of respective procedures (c) and (f).

IMPORTANT: After glazings have been profile aligned they must not be disturbed for 8 hours. Locating bolts must not be tightened or used to distort natural profile of glazing panels.

(g) Leave assembly for an 8-12 hour period.

(h) Carefully remove dummy windscreen, corner and side window form templates. At this stage the sealant should be of firm consistency, however, it may not be fully cured throughout and should be treated carefully for a further period of 24 hours until fully air cured.

(i) After curing, trim off surplus sealant using a sharp knife. All remaining holes through sealant may be drilled out at this stage or at final assembly.

(j) Check finished gasket for any deformities. Repair by cleansing area with white spirit and apply Sikaflex 11FC sealant, smoothed to gasket profile using a flat blade.

(k) In lieu of gap fillers (SD3-17-0081) voids at top corners of windscreens may be filled with Sikaflex 11FC sealant as shown. Refer to Figure 9. Gap fillers, if used, must not protrude above level of windscreen and are to be set in Sikaflex 11FC sealant.

(4) Windscreen and window installations

NOTE: It is important to ensure that the bedding gaskets formed on the structure, match the natural profiles of the corner/side window.

(a) Place windows in position and check that complete contact with gasket is made without window deformation. If necessary rectify low areas by building up profile with additional layer of Sikaflex 11FC sealant (clean surfaces to be repaired with white spirit). When bedding is satisfactory proceed as follows:-

1 Position windscreen and windows using locating bolts only.

2 Seal joints between glazing panels with aluminium tape. Refer to Figure 3 (Sheet 1). Remove locating bolts to apply tape at each joint. Progressively remove and replace bolts during taping operation.

Jan 31/11



3 Ensure contact faces of outer straps and joint straps are smooth, remove any high spots and re-prime as necessary.

4 Cover contact faces of outer straps and joint straps with pressure sensitive tape as shown. Refer to Figure 3 (Sheet 1). Ensure entire contact area is covered.

NOTE: If double sided pressure sensitive tape is used, the exposed side must be faced with polythene film.

5 Remove locating bolts in way of strap to be assembled, fit strap and insert bolts (piercing aluminium foil) and apply Sikaflex 11FC sealant under bolt heads as shown. Refer to Figure 8. Complete each strap, tightening bolts sufficiently to bed glazing. Do not over torque. Approx. torque values, which should not damage glazing panels are:-

6 Before fitting joint straps, fill gaps between outer straps with Sikaflex 11FC. Level sealant with face of straps as shown. Refer to Figure 8. Remove surplus sealant from face of outer straps.

7 Fit joint straps as described for outer straps.

8 Clean edges of all straps and adjacent surfaces of aircraft. Fillet edges of straps with Sikaflex 11FC sealant. Refer to Figure 8.

NOTE: Cut nozzle of sealant tube so that the bead extruded allows just sufficient sealant to form an aerodynamic fillet when smoothed with wetted finger. Refer to Figure 8. Apply masking tape as shown so that surplus sealant is easily removed and a controlled fillet edge is produced.

9 Leave assembly to cure for a minimum of 8 hours before water test, and 24 hours before painting.

(5) With reference to Maintenance Manual, chapter 30:-(a) Install the windscreen wiper drive arm assemblies (30-42-00, pb201).(b) Perform a function test of the windscreen wipers (para. 2.B.).(c) Connect windscreen heating cables to terminal block (30-41-00, pb201).

NOTE: Make sure that terminal P2 is connected to the terminal block as detailed in Figure 3 (sheet 2) of this procedure, to prevent a foul condition.

(d) Perform a function check of the windscreen heating (para. 2.A.).

1/4 in. dia. - 15 lbf/in.10.32 dia. - 10 lbf/in.

Jan 31/11



(6) Water Test

(a) Hose exterior of windscreen and windows with water using a sweeping motion for a period of five minutes.

(b) Check flight compartment interior for absence of water ingress.

C. Opening side window - left side

(1) Removal of window assembly

(a) Refer to Figure 10. Remove the complete window assembly by detaching at the hinge points on the side pillar and repair damaged window as follows;

(2) Removal of damaged window

(a) Remove the hi-shear collared rivets from the frame.

(b) Remove the reinforcing strips from the damaged window and discard, if damaged or partially defective.

(c) Remove the damaged window from the inner frame casting.

(d) Clean off the remains of the TENSOL No.3 adhesive from the window frame attachment face.

(e) Examine the O-ring seal around the frame for damage, or ageing or surface cracks.

(f) If the seal is defective remove and clean the seal groove of adhesive residue. See para D. for method of seal replacement.

(3) Installation of new window

(a) Apply TENSOL No.3 adhesive to the window frame attachment face.

(b) Locate the windshield on the frame by means of location pins in rivet holes.

(c) Apply new reinforcing strips over the location pins and clamp securely together.

(d) Rivet the complete assembly together using high shear CSK rivets (spec. HS235-14) and collars (spec. HS24-5).

(e) Allow the adhesive in the rivetted assembly to cure for 24 hours before installing the new window assembly on the aircraft. (See also para. D.).

(4) Installation of window assembly

Install the new assembly by attaching the frame at the hinge points on the side pillar. Refer to Figure 10.

Jan 31/11



D. O-Ring seal replacement

(1) If the O-ring seal has been removed replace as follows

(a) Ensure that the annular groove for the seal is clear, dry, and free from grease or foreign matter.

(b) Apply evostic No.528 adhesive evenly around the groove on the frame.

(c) Carefully place the seal in position, avoiding unnecessary twisting of the seal.

(d) Press firmly all around the seal to aid the bedding in of the seal in the groove.

(e) Allow the adhesive to cure for 24 hours before installing the window frame assembly.

Jan 31/11



Windshield - Removal/InstallationFigure 3 (Sheet 1)

Jan 31/11



Windshield - Removal/InstallationFigure 3 (Sheet 2)

Jan 31/11



Side Window - Removal/InstallationFigure 4

Jan 31/11



Curved Windows - Removal/InstallationFigure 5

Jan 31/11



Typical Application of Sealent for Deddong WindshieldsFigure 6

Jan 31/11



Windshield Bedding Former TemplateFigure 7

Jan 31/11



Voids & GapsFigure 8

Jan 31/11



Voids at Top Edge of WindshieldFigure 9

Jan 31/11



Voids at Top Edge of WindshieldFigure 10

Jan 31/11

Apr 24/0356-10-00 Page 101EFFECTIVITY: All


SRM56-10-00 3.0.0.0FLIGHT COMPARTMENT WINDOWS - ALLOWABLE DAMAGE

1. General

A. Triplex type Windshield

Refer to the Triplex CMM. The Triplex CMM can be procured from:

Pilkington Aerospace Ltd Eckersall Rd Kings Norton Birmingham West Midlands B38 8SS

Tel: 0121 606 4100Fax: 0121 606 4191e-mail: [email protected]

B. Lucas type Windshield

Refer to the Lucas CMM 56-10-11. The Lucas CMM can be procured from:

Aerospace Composite Technologies Ltd Percival Way London Luton Airport Luton Bedfordshire LU2 9PQ

Tel: 01582 731441Fax: 01582 452049e-mail: [email protected]



THIS PAGE LEFT BLANK INTENTIONALLY



SRM56-10-00 3.0.0.0FLIGHT COMPARTMENT WINDOWS - ALLOWABLE DAMAGE

1. General

A. Triplex type Windshield

Refer to the Triplex CMM. The Triplex CMM can be procured from:

Pilkington Aerospace Ltd Eckersall Rd Kings Norton Birmingham West Midlands B38 8SS

Tel: 0121 606 4100Fax: 0121 606 4191e-mail: [email protected]

B. Lucas type Windshield

Refer to the Lucas CMM 56-10-11. The Lucas CMM can be procured from:

Aerospace Composite Technologies Ltd Percival Way London Luton Airport Luton Bedfordshire LU2 9PQ

Tel: 01582 731441Fax: 01582 452049e-mail: [email protected]



SRM56-10-00 4.0.0.0FLIGHT COMPARTMENT WINDOWS - REPAIRS

1. Windshield

For detailed procedures covering repair and/or replacement of (a) heater terminal sockets, (see Fig. 1), and (b), moulded rubber weather seals, (see Fig. 2), a manufacturers repair kit is available. This can be requested from Bombardier Aerospace (Belfast) upon completion of an "APPLICATION FOR REPAIR SCHEME/DAMAGE REPORT", document as explained in the INTRODUCTION to this manual (paragraph 3).

NOTE: Damage to windshields, other than that described above is not repairable, and the complete windshield should be replaced.

2. Side and Corner Windows - Scratch Removal

A. General

CAUTION: DO NOT USE THESE SCRATCH REMOVAL PROCEDURES ON HEATED PILOT AND COPILOT GLASS WINDSHIELD.

Plastic windows and windshields with scratches should not be replaced if the scratches do not interfere with vision. This is not to be mistaken for crazing. Crazing is the presence of fine cracks which may extend in a network over or under the surface or through the plastic. These fine cracks are often difficult to detect because they run perpendicular to the surface, are very narrow in width, and usually are not over 0.001 inch deep. They can be seen by reflecting light from their surfaces, and they appear as bright lines when the specimen is viewed at varying angles to the source of the light. In contrast, scratches are caused by physical abuse of the surface of the plastic and generally are detectable by the naked eye. Plastic windows can be reworked to remove scratches, but crazing cannot be reworked. There are three types of scratches that can be reworked: 1. Hairline scratches that are very light scratches or hazing, usually caused by improper cleaning procedures. 2. Minor scratches, that can be detected with a fingernail. 3. Deep scratches, that are easily felt with the fingertip.

B. Removal of Scratches

(1) For removal of hairline scratches, scratches, nicks, dents, or discolouration, the use of a Micro-mesh cushioned cleaning kit No. KR 70 is recommended.

Manufacturer: Microsurface Finishing Products Inc.,1213 W. Third St.,Box 818, Wilton, Iowa, 52778, U.S.A.

U.K. Supplier: Micro-mesh, P.W. Products Ltd.,Rowlandson House,289/293 Ballards Lane,London N12 8MP



(2) Abrading methods and procedures are to be carried out in accordance with the manufacturers instructions. Particular attention being given to the following notes:-

NOTE: (1) Scratches, nicks, and dents may be repaired by abrading, as noted above, if the removal of plastic material in this operation is limited to 10% of the original thickness of the plastic material. Rework causing removal of more than 10% is cause for replacement.

(2) All scratch removal should be done with surfaces wet with water.

(3) Do not use too much pressure during scratch removal. This could overheat the surface and cause local distortion or crazing.

(3) Other equipment and materials may be used in lieu of those listed above, provided that their quality and performance is not inferior, and that they comply with the relevant specifications and have been approved by Bombardier Aerospace (Belfast) Quality and Materials Technology Departments.

Documents

56-10-00 - Air Cargo Carriers 56/56-10-00.pdf · EFFECTIVITY: All 56-10-00 Page 4 z SD3-60 STRUCTURAL REPAIR MANUAL A. Materials and General Instructions (1) Sealant SMS49 (Qualifying