AIRCRAFT MAINTENANCE MANUAL - Job Instruction Cards

REPAIR OF FUEL LEAK

1. General
This chapter provides the necessary information to perform a temporary and/or
permanent repair to stop a fuel leak.
The causes of fuel leaks are :
- damage of the structure,
- loose fasteners,
- incorrect installation of components,
- incorrect sealant application.
2. Leak category definition

In order to evaluate the appropriate action to be taken, it is very important

to exactly define the kind of leakage in accordance with the following
categories :

A. Seepage

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Is a permanent fuel presence without drops formation.

(1) Slight seepage (oozing)
A measurement not exceeding 50 mm (2 in.) in any directions.
(2) Heavy seepage (dripping)
A measurement greater than 50 mm (2 in.) but not exceeding 100 mm
(4 in.) in any direction.
B. Running leak
A leak greater than a seepage. Fuel reappears after the surface has been
wiped and falls in drops. Leak rate is classified in one of the following
sub-categories to determine actions to be taken :
- up to 10 drops per minute,
- over 10 and up to 20 drops per minute,
- over 20 and up to 30 drops per minute,
- over 30 drops per minute.

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3. Fuel leakage - Action to be taken
A. General
Specific consideration as :
- position of leak,
- equipment near leakage area, etc...

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Can change the general guidelines given herein.

Before starting the repair action, check at para. 4 the validity of action
to be choseen
B. Action
(1) Slight seepage : none.
(2) Heavy seepage :
No repair action is required in shortest term.
Periodic check for insuring that the leakage is not worsening.
(3) Running leak :
CAUTION: THE HEREIN MENTIONED DELAYS FOR THE CORRECTIVE ACTION DO NOT
CONSTITUTE APPROVAL FOR OPERATORS TO DEFER THE REPAIR.
SUCH DELAYS ONLY RELATE TO THE WING BOX STRUCTURE INTEGRITY.
OTHER SAFETY CONSIDERATIONS, SUCH AS GROUND FIRE RISK, MAY
IMPOSE TO PERFORM AT ONCE THE REPAIR ACTION.

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(a) Between 0 and 10 drops/minute :

No immediate repair action required but weekly inspections are
necessary to ensure that the leak is not worsening.
Repair has to be carried out at next "C" check or one year,
whichever comes first.

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(b) Between 10 and 20 drops/minute :

No immediate repair action required but weekly inspections are
necessary to ensure that the leak is not worsening.
The leak must be repaired at next scheduled "A" check inspection
or three mnoths whichever comes first.

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(c) Between 20 and 30 drops/minute :

Repair has to be carried out within 100 flights or a week
whichever comes first.
Daily inspection.
(d) Over up 30 drops/minute :
Immediate repair action before next flight can be required.
Return to main base possible. Contact manufacturer for action.
4. Fuel leak location (Ref. Fig. 1)
Five different fuel leak locations can be defined :
- Zone A
Center wing box between Ribs 4 LH and RH.
- Zone B
Center wing box between Rib 4 and Rib 10.

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- Zone C
Center wing box between Rib 10 and Rib 12 (including also jacking point at
Rib 10).

- Zone D
Wing box between Rib 12 and 14 (Center wing box/Outer wing box junction).

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- Zone E (ST1, ST4, ST5)

Outer wing box between Rib 14 and Rib 23.

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- Zone E (ST2, ST3)

Outer wing box between Rib 14 and Rib 24.
5. Leakage origin
A. Zone A
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leakage could be evidenced in this area caused by :

an incorrect junction of cross valve (intercom valve),
refueling valve,
application of insufficient amount of sealant at removable panel
installation (at Rib 4 left or right).

B. Zone B
On the wing upper skin an incorrect sealant application at removable panel
installation could be the origin of a leakage.
At spar areas, leak may come from loose fasteners, components installation,
or spar to skin junction.
C. Zone C
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CAUTION: IN THIS AREA NO LEAK IS ALLOWED. AN IMMEDIATE ACTION IS

REQUIRED. INSPECT FOR LEAK ORIGIN AND APPLY PERMANENT REPAIR
ACTION.
D. Zone D
The cause of the leakage could be an incorrect fasteners installation,
failed or damaged sealant and improperly installed components.
Fuel leak could be located at :
- set of recesses,
- center wing box Rib 13/fitting outer wing box junction fitting,
- injection holes of groves at Rib 13,
- junction between piano fitting/spar junction fitting/spar/stiffener
(front and rear spar at Rib 14).

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E. Zone E
In this area leakage origin could be :
- an incorrect fasteners installation,
- failed or damaged sealant.
6. Fuel leak source detection
A. This is the mont important step in fuel leak repair. It is requested to pay
attention in fuel leak source detection in order to exactly determine the
true origin of the leakage.
It shall be emphasized that,
fasteners) can be found, the
appropriate inspection shall
determined on a case by case

if no evident leakage origin (such as

presence of a crack can be suspected. An
then be applied for crack detection (to be
basis.

It is recommended to detect the leak issue with the tank full of fuel for
12 hours minimum.
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B. Operations
(1) On external wing surface :
(a) Degrease the leak area using a cleaning solvent
(Mat. No. 11-003/11-004) (Ref. 20-24-06).
(b) Perform a first leakage issue detection (hole, damaged sealant
loose fastener).
(c) Determine the fuel leak issue following the leakage path step by
step (wetting subsequently leak issue).
(2) On internal wing surface :
(a) Defuel tank (JIC 121100-DFG-10000) and make inerting
(JIC 281200-DAR-10000).
(3) Apply liquid soap (or equivalent) on internal leak area and use
filtered compressed air at external leak issue to determine leak
origin.
With this criteria will be possible to determine exactly the leakage
path in order to define the repair action.

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R 7. Repair of fuel leak (Ref. Fig. 1, 2 and 3)

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WARNING: BEFORE PROCEEDING WITH REPAIR WORK MAKE CERTAIN THAT GROUND SAFETIES
AND/OR WARNING NOTICES ARE IN CORRECT POSITION TO PREVENT
INADVERTENT OPERATION OF CONTROLS.
BEFORE UNDERTAKING REPAIR WORK ON THE FUEL SYSTEM, THE PRESCRIBED
SAFETY PRECAUTIONS MUST BE REGOROUSLY OBSERVED.
BEFORE UNDERTAKING ANY OPERATION ON THE FUEL SYSTEM, MAKE SURE THAT
FIRE FIGHTING EQUIPMENT IS READLY AVAILABLE AND IN PROXIMITY TO THE
WORK AREA.
BEFORE UNDERTAKING ANY REPAIR ACTION MAKE SURE THAT THE LEAK AREA IS
PERFECTLY DEGREASED.
A. Temporary repair
(1) General
A temporary repair does not require wing panel removal.
It is allowable whenever possible to reduce the fuel leakage to a
minimum with respect of permissible leak rates. This repair does not
permit to determine the origin of the leak ; this will be done during
permanent repair.

In this case, a leakage check (Daily Inspection) is required to ensure

that the rate is not increased.
(2) Equipment and materials
ITEM

NOMENCLATURE

QTY

MATERIAL/REMARK

Cleaning solvent

Mat. No. 11-003/11-004

(Ref. 20-31-00)

Temporary stopper

Mat. No. 05-093 (Ref. 20-31-00)

Mat. No. 05-094 (Ref. 20-31-00)

Adhesive tape

Vinyl

(3) Repair
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(a) Clean the leak area thoroughly, using a cleaning solvent

(Mat. No. 11-003/11-004) (Ref. 20-24-06)

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(b) Immediately apply the temporary stopper (Mat. No. 05-093 or 05-094)
to crevices and fasteners (manufacturer's instructions).

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(c) Apply an adhesive tape to extend the life of the repair.

NOTE: To prevent defueling when it is possible, the fuel can be
repelled from the leak area by the continuous use of the
filtered compressed air.
B. Permanent repair
(1) General
When fuel tank sealant is being repaired, the safety precautions
detailed in the following topics must be observed. In addition,
appropriate protective clothing and equipment must be used.
Fuel leak may be caused by structural damage. In this case, reference
should be made to the appropriate chapter of SRM and a full
investigation must be carried out, followed by all necessary
rectification actions, before sealant repairs are performed.
(2) Equipment and materials
ITEM

NOMENCLATURE

QTY

MATERIAL/REMARK

Adhesive primer

Mat. No. 08-021 (Ref. 20-31-00)

Polysulfide sealant

Mat. No. 09-002A (Ref. 20-31-00)

Polysulfide sealant

Mat. No. 09-001A (Ref. 20-31-00)

Cleaning solvent

Mat. No. 11-003/11-004

(Ref. 20-31-00)

Abrasive pad

SCOTCHBRITE fine grade

Sealant hand tools

See Fig. 2

(3) Preparation
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(a) Remove the removable wing panel for center wing box or outer wing
box (JIC 571412-RAI-10000 or JIC 572412-RAI-10000).
CAUTION: OBSERVE ALL RELEVANT SAFETY PRECAUTIONS AND PROCEDURES
BEFORE OPENING THE TANK.
(b) Using the sealant cutting and removal tools, carefully remove the
defective section of bead, working along the bead in both
directions until undamaged areas are reached.
NOTE: Remove also the sealant around the leakage issue area with an
extension greater than leak are detected.

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(c) Taper the undamaged fillet at both ends of the defective area to
make a scarf joint 25 mm (1 in.) for the repair.

(d) Clean the exposed surface of the leak area using cleaning solvent
(Mat. No. 11-003/11-004) applied with lint-free cleaning fabric.
(e) Lightly abrade the painted surface with abrasive pad (5) wetted
with cleaning solvent. Wait 1 hour.
(4) Repair

(a) Apply adhesive primer (Mat. No. 08-021). Wait 30 mn.

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(b) Apply sealant (Mat. No. 09-002A) and then sealant

(Mat. No. 09-001A).
NOTE: The success of the sealing operation depends on strict adherence
to drying and (curing) times in fuel free environment.
Curing time (in hours) with humidity between 20 % and 70 %.

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15C
20C
25C
30C
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CURING TIME (HOURS)

Mat. No. 09-001A
Mat. No. 09-002A

TEMPERATURE
(59F)
(68F)
(77F)
(86F)

160
80
48
24

156
72
36
18

NOTE: Sealant (Mat. No. 09-001A) is more flowing than sealant

(Mat. No. 09-002A) is well used in injection at recesses, hole
injection (ZONE D).
The thick coat of fillet sealant over the repair area must be
applied respecting the same thickness as the nest of the fillet
(Ref. Fig. 3).
(c) Smooth out the applied sealant, using the fillet fairing tool to
give the repair area the same profile as the rest of the fillet.
NOTE: Make sure that a smooth fillet, free from air bubbles is
formed.
(d) Reinstall any structure or equipment removed to carry out the
repair.
(e) Remove all tools, equipment and cleaning materials from the tank.

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(f) Install removable panel (JIC 571412-RAI-10000 or

JIC 572412-RAI-10000).

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CAUTION: MAKE CERTAIN THAT THE FUEL TANK IS CLEAN AND CLEAR OF TOOLS
AND MISCELLANEOUS ITEMS OF EQUIPMENT.
(g) Perform leak test by refueling.
C. Leak at sets of recesses
(1) Dry sets for leak detection.
(2) Localize discrepant sets.
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NOTE: If a crack or other damage on structure is evidenced contact

manufacturer.
(3) Invertigate for leak origin.

(4) Defuel tank (JIC 121100-DFG-10000).

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(5) Improve sealing at Rib 13 on lower wing (Ref. SB 57-0003, embodiment

for wing lower surface).

NOTE: Where it is necessary to inject sealant (Mat. No. 09-001A).

D. Leak at piano junction
(1) Dry leakage area and localize leak origin.

(2) Defuel tank (JIC 121100-DFG-10000).

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(3) Using a 2.5 mm (3/32 in.) drill open up, max 6.5 mm (0.256 in.) deep
injection grooves at Rib 13 (Ref. SB 57-0003).

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(4) Inject solvent (Mat. No. 11-003/11-004), wait 1 hour, and then adhesive
(Mat. No. 08-021). Wait 30 mn.

(5) Inject sealant (Mat. No. 09-001A) into injection holes in Rib 13 grooves.
(6) Wait 24 hours for sealant curing.

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(7) Restore surfaces : clean, degrease and paint (Ref. 20-24-12).

E. Fuel leak on carbon wing structure (ST2, ST3).

Refer to para. B.

NOTE: For structure damage evaluation and repair Refer to SRM 57-24-00,
Pages Block 300 and 400.

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Fuel Leak Location

Figure 1 (Sheet 1)

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Fuel Leak Location

Figure 1 (Sheet 2)

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EFFECTIVITY : ST1, ST4, ST5

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Fuel Leak Location

Figure 1 (Sheet 2)

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EFFECTIVITY : ST2, ST3

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Fuel Leak Location

Figure 1 (Sheet 3)

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Fuel Leak Location

Figure 1 (Sheet 3)
EFFECTIVITY : ST2, ST3
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Sealant Hand Tools

Figure 2

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Fillet Application Method

Figure 3

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