Installation of the Closing Panel

TASK 57-27-11-400-007-A
Installation of the Closing Panel

WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.

WARNING: PUT THE SAFETY DEVICES AND THE WARNING NOTICES IN POSITION BEFORE YOU START A TASK ON OR NEAR:

THE FLIGHT CONTROLS
THE FLIGHT CONTROL SURFACES
THE LANDING GEAR AND THE RELATED DOORS
COMPONENTS THAT MOVE.

MOVEMENT OF COMPONENTS CAN KILL OR CAUSE INJURY TO PERSONS AND/OR CAN CAUSE DAMAGE TO THE EQUIPMENT.

ZONE: 540
ZONE: 640

1. Reason for the Job
Self explanatory
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	1	ACCESS PLATFORM 5M (16 FT)- ADJUSTABLE
No specific	1	BRUSH - BRISTLED
No specific	1	SAFETY BARRIER(S)
No specific	1	WARNING NOTICE(S)
No specific	Torque wrench: range to between 9 and 8 m.N (79.65 and 70.80 lbf.in )
No specific	Torque wrench: range to between 0.9 and 0.8 m.daN (79.65 and 70.80 lbf.in )
98D27803500001	1	LOCKING TOOL ZERO POS

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.06ABA1)	Polysulfide Sealant-Fuel Tank Brushable -
(Material No.06ABB1)	Polysulfide Sealant-Fuel Tank Fillet -
(Material No.06AEA1)	Polysulfide Sealant-Low Adhesion Brushable -
(Material No.06AEB2)	Polysulfide Sealant-Low Adhesion Fillet Structure
(Material No.08BAA9)	Non Aqueous Cleaner-General - -
(Material No.14SBA1)	Textile-Lint free Cotton -

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
540	FUEL TANK
640	FUEL TANK
521AZ, 521BZ, 521CZ, 540BB, 540CZ, 540DZ, 621AZ, 621BZ, 621CZ, 640BB, 640CZ, 640DZ

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
2	CLOSING PANEL	AIPC 57-27-85-05-240
2	CLOSING PANEL	AIPC 57-27-85-05-250
2	CLOSING PANEL	AIPC 57-27-85-05-260
2	CLOSING PANEL	AIPC 57-27-85-05-270

E. Referenced Information

REFERENCE	DESIGNATION
TASK 12-11-28-650-003-A	Pressure Refuel with Automatic Control
TASK 20-28-00-912-802-A	Electrical Bonding - General Maintenance Procedure
TASK 20-28-00-912-803-A	Bonding Surface Preparation
TASK 24-41-00-861-002-A	Energize the Aircraft Electrical Circuits from the External Power
TASK 24-41-00-861-002-A-01	Energize the Aircraft Electrical Circuits from the APU
TASK 24-41-00-861-002-A-02	Energize the Aircraft Electrical Circuits from Engine 1(2)
TASK 24-41-00-862-002-A	De-energize the Aircraft Electrical Circuits Supplied from the External Power
TASK 24-41-00-862-002-A-01	De-energize the Aircraft Electrical Circuits Supplied from the APU
TASK 24-41-00-862-002-A-02	De-energize the Aircraft Electrical Circuits Supplied from the Engine 1(2)
TASK 28-10-00-910-001-A	Safety Procedures When You Do Work in a Fuel Tank
TASK 28-25-00-650-001-A	Pressure Defuel
TASK 28-25-00-650-003-A	To Drain Remaining Fuel from the Wing Tanks and the Center Tank
TASK 28-25-00-650-003-A-01	To Drain Remaining Fuel from the Wing Tanks and the Center Tank
TASK 28-42-00-740-001-A	Status Report (BITE)
TASK 28-46-00-740-001-A	Functional (BITE) Test
TASK 57-27-11-000-001-A	Removal of the Access Panel
TASK 57-27-11-000-005-A	Removal of the Access Panel
TASK 57-27-11-400-001-A	Installation of the Access Panel
TASK 57-27-11-400-005-A	Installation of the Access Panel
TASK 57-27-11-400-005-C	Installation of the Access Panel
TASK 57-27-11-400-005-D	Installation of the Access Panel
TASK 57-27-11-400-005-E	Installation of the Access Panel
Closing Panels 540CZ(640CZ)/540DZ(640DZ) ** ON A/C NOT FOR ALL
Closing Panels 540CZ(640CZ) and 540DZ(640DZ) ** ON A/C NOT FOR ALL
Typical Tightening Sequence for One Row of Bolts ** ON A/C NOT FOR ALL

3. Job Set-up
Subtask 57-27-11-941-066-A ** ON A/C NOT FOR ALL

A. Safety Precautions

WARNING: BEFORE YOU DO WORK IN OR NEAR A FUEL TANK, MAKE SURE THAT YOU OBEY ALL THE SAFETY PROCEDURES. THIS WILL PREVENT INJURY TO PERSONS AND/OR DAMAGE TO THE AIRCRAFT.

(1) Obey the fuel safety procedures when you do the work in a fuel tank (Ref. AMM TASK 28-10-00-910-001).
(2) Make sure that the 98D27803500001 LOCKING TOOL ZERO POS is correctly installed on the flap/slat control lever.
(3) Make sure that the SAFETY BARRIER(S) is(are) in position.
(4) Make sure that the WARNING NOTICE(S) is(are) in position in the cockpit to tell persons not to operate the flaps or slats.
(5) Make sure that the ACCESS PLATFORM 5M (16 FT)- ADJUSTABLE is in position below the wing fuel tank at zone 540(640).

Subtask 57-27-11-860-069-A ** ON A/C NOT FOR ALL

B. Aircraft Maintenance Configuration
(1) Make sure that the aircraft is defueled (Ref. AMM TASK 28-25-00-650-001).
(2) Make sure that the applicable fuel tank(s) is(are) drained (Ref. AMM TASK 28-25-00-650-003).
(3) Make sure that access panel 540BB( 640BB) is removed (Ref. AMM TASK 57-27-11-000-001).
(4) Make sure that access panels 521AZ( 621AZ), 521BZ( 621BZ) and 521CZ( 621CZ) are removed (Ref. AMM TASK 57-27-11-000-005).

4. Procedure
Subtask 57-27-11-110-054-B ** ON A/C NOT FOR ALL

A. Preparation for Installation
(1) Use a Textile-Lint free Cotton - (Material No.14SBA1) , made moist with Non Aqueous Cleaner-General - - (Material No.08BAA9) to clean the interfaces of:

the closing panel (2)
the dry bay structure (1).

(2) Examine for damage the interfaces of:

the closing panel (2)
the dry bay structure (1).

(3) On a pre modification 26839 (composite) closing panel (2):
(a) Examine the aluminium foil layer on the fuel-tank side of each panel (2) for damage.
(b) The closing panel (2) must be replaced if there is:

damage to the foil around any of the electrical-bonding positions
any splits in the foil.

NOTE: Straight horizontal splits of less than 50 mm (1.97 in.) in length are permitted if no loss of foil has occured.

any area where the foil is not correctly bonded to the panel.

NOTE: Separation is permitted if it is less than 6 mm (0.24 in.) from the panel outer edge (and not at an electrical-bonding position).

Subtask 57-27-11-420-055-B ** ON A/C NOT FOR ALL

B. Installation of the Closing Panel

NOTE: There are two different types of closing panel available which are interchangeable. If a replacement closing panel of a different type is to be installed, then the removed fasteners must also be replaced. Discard the used fasteners and get the applicable fasteners for the new type of closing panel.

(1) Install a pre modification 26839 (composite) closing panel as follows:
(a) Make sure that the work area is clean and clear of tools and equipment.
(b) Make sure that there are no unwanted objects and materials, tools or other equipment in the wing.
(c) Apply Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) or Polysulfide Sealant-Low Adhesion Fillet Structure (Material No.06AEB2) to the interfaces of:

the closing panel (2)
the dry bay structure (1).

NOTE: At each electrical bonding position keep a 15 mm (0.59 in.) diameter area around the bolt hole clear of sealant.

(d) Make sure that there is no sealant applied to:

the threads of the bolts (4)
the structure (1) captive-nuts.

(e) Put the closing panel (2) in position and install the bolts (4) and the washers (3).
(f) TORQUE the bolts (4) in a diagonally opposite sequence to between 0.9 and 0.8 m.daN (79.65 and 70.80 lbf.in )

.
(g) Check all the bolts (4) are correctly tightened to between 0.9 and 0.8 m.daN (79.65 and 70.80 lbf.in )

.
(h) Make sure that the closing panel (2) is correctly bonded to dry bay structure (1):
1 Do a bonding test between the closing panel (2) and the dry bay structure (1). (Ref. AMM TASK 20-28-00-912-802). Make sure that the electrical resistance is less than 10 milliohms.
(i) Apply a continuous bead of Polysulfide Sealant-Fuel Tank Fillet - (Material No.06ABB1) and make a fillet seal between the closing panel (2) and structure (1):

at the joint on the fuel-tank side of the closing panel (2)
at the joint on the dry bay side of the closing panel (2).

(j) Use a BRUSH - BRISTLED to apply an overcoat layer of Polysulfide Sealant-Fuel Tank Brushable - (Material No.06ABA1) or Polysulfide Sealant-Fuel Tank Fillet - (Material No.06ABB1) on the fuel-tank side to:

the bolts (4)
the washers (3)
the joint between the closing panel (2) and the structure (1).

(2) Install a post modification 26839 (solid alloy) closing panel as follows:
(a) Make sure that the work area is clean and clear of tools and equipment.
(b) Make sure that there are no unwanted objects and materials, tools or other equipment in the wing.
(c) Apply Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) or Polysulfide Sealant-Low Adhesion Fillet Structure (Material No.06AEB2) to:

the interface of the closing panel (2)
the interface of the dry bay structure (1)
to the shank and the bottom of the head of each bolt (4).

NOTE: At each electrical bonding position keep a 15 mm (0.59 in.) diameter area around the bolt hole clear of sealant.

(d) Make sure that there is no sealant applied to:

the threads of the bolts (4)
the structure (1) captive-nuts.

(e) Put the closing panel (2) in position and install the bolts (4).

NOTE: It is necessary to install the closing panel (2) with the WET SIDE identification mark on the fuel tank side.

(f) TORQUE the bolts (4) in a diagonally-opposite sequence to between 0.9 and 0.8 m.daN (79.65 and 70.80 lbf.in )

.
(g) Check all the bolts (4) are correctly tightened to between 0.9 and 0.8 m.daN (79.65 and 70.80 lbf.in )

.
(h) Make sure that the closing panel (2) is correctly bonded to the dry bay structure (1):
1 Do a bonding test between the closing panel (2) and the dry bay structure (1) (Ref. AMM TASK 20-28-00-912-802). Make sure that the electrical resistance is less than 10 milliohms.
(i) Apply a continuous bead of Polysulfide Sealant-Fuel Tank Fillet - (Material No.06ABB1) and make a fillet seal between the closing panel (2) and structure (1):

at the joint on the fuel-tank side of the closing panel (2)
at the joint on the dry bay side of the closing panel (2).

the bolts (4)
the joint between the closing panel (2) and the structure (1).

Subtask 57-27-11-110-054-D ** ON A/C NOT FOR ALL

C. Preparation for Installation
(1) Clean the interfaces that follow with the Textile-Lint free Cotton - (Material No.14SBA1) made moist with Non Aqueous Cleaner-General - - (Material No.08BAA9) :

The closing panel (2)
The dry bay structure (1).

(2) Examine for damage the interfaces of:

The closing panel (2)
The dry bay structure (1).

(3) If you find damage, replace the AIPC 57-27-85-05-240 CLOSING PANEL (2) or AIPC 57-27-85-05-250 CLOSING PANEL (2) or AIPC 57-27-85-05-260 CLOSING PANEL (2) or AIPC 57-27-85-05-270 CLOSING PANEL (2).

Subtask 57-27-11-420-055-D ** ON A/C NOT FOR ALL

D. Installation of the Closing Panel
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Make sure that there are no unwanted objects and materials, tools or other equipment in the wing.
(3) Apply Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) or Polysulfide Sealant-Low Adhesion Fillet Structure (Material No.06AEB2) on the interface of:

The closing panel (2)
The dry bay structure (1).

(4) At each electrical bonding, keep a 15 mm (0.59 in.) diameter area without sealant around the bolt hole.
(5) Make sure that there is no sealant on:

The threads of the bolts (4)
The captive nuts of the dry bay structure (1).

(6) Prepare the surface of the bonding point(s)
(Ref. AMM TASK 20-28-00-912-803).
(7) Put the closing panel (2) in the correct position (with the WET SIDE identification mark on the fuel tank side) and install the washers (3) and the bolts (4).
(8) TORQUE the bolts (4) in a diagonally-opposite sequence to between 9 and 8 m.N (79.65 and 70.80 lbf.in )

. Do the tightening of the bolts (4) first for the inner row, then for the outer row.

Typical Tightening Sequence for One Row of Bolts ** ON A/C NOT FOR ALL

(9) Make sure that the bolts (4) are correctly tightened to between 9 and 8 m.N (79.65 and 70.80 lbf.in )

NOTE: The bolts can get loose during the initial torque step because of the possible joint play.

(10) Do the electrical resistance measurement and the final protection of the bonding point(s)
(Ref. AMM TASK 20-28-00-912-802).
(11) Apply a continuous bead of Polysulfide Sealant-Fuel Tank Fillet - (Material No.06ABB1) and make a fillet seal between the closing panel (2) and the dry bay structure (1) at the joint, on:

The fuel tank side of the closing panel (2)
The dry bay side of the closing panel (2).

(12) Apply a layer of Polysulfide Sealant-Fuel Tank Brushable - (Material No.06ABA1) or Polysulfide Sealant-Fuel Tank Fillet - (Material No.06ABB1) with the BRUSH - BRISTLED on the fuel tank side, on:

The bolts (4)
The joint between the closing panel (2) and the dry bay structure (1).

Subtask 57-27-11-410-056-A ** ON A/C NOT FOR ALL

E. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Install access panel 540BB( 640BB) (Ref. AMM TASK 57-27-11-400-001).

Subtask 57-27-11-860-067-A ** ON A/C NOT FOR ALL

F. Aircraft Maintenance Configuration
(1) Energize the aircraft electrical circuits
(Ref. AMM TASK 24-41-00-861-002).
(2) Refuel the wing tank to the high-level cut-off condition (Ref. AMM TASK 12-11-28-650-003).

Subtask 57-27-11-790-054-A ** ON A/C NOT FOR ALL

G. Test
(1) Do a status report (BITE) of the fuel quantity indicating-system (Ref. AMM TASK 28-42-00-740-001).
(2) Do a functional (BITE) test of the fuel quantity sensors (Ref. AMM TASK 28-46-00-740-001).
(3) Examine panels 540CZ( 640CZ) and 540DZ( 640DZ) for leaks in the dry bay.

5. Close-up
Subtask 57-27-11-860-068-A ** ON A/C NOT FOR ALL

A. Aircraft Maintenance Configuration
(1) De-energize the aircraft electrical circuits
(Ref. AMM TASK 24-41-00-862-002).

Subtask 57-27-11-410-057-A ** ON A/C NOT FOR ALL

B. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Install access panels 521AZ( 621AZ), 521BZ( 621BZ) and 521CZ( 621CZ) (Ref. AMM TASK 57-27-11-400-005).

Subtask 57-27-11-942-057-A ** ON A/C NOT FOR ALL

C. Removal of Equipment
(1) Remove the SAFETY BARRIERS.
(2) Remove the access platform(s).
(3) Remove the 98D27803500001 LOCKING TOOL ZERO POS from the flap/slat control lever.
(4) Remove the WARNING NOTICE(S).
(5) Remove the ground support and maintenance equipment, the special and standard tools and all other items.

[Rev.10 from 2021] 2026.04.01 02:12:02 UTC