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B737 800 WITH CFM 56-7B ENGTASK CARD FOR LIVERY PAINTING

TASK CARD NO: JBNG-51-PAINT-001-02

(APPROVED BY …..)

REF :AMM

A/C REGN.:VT-

SIGNATURE NAME DATEPREPARED BYVERIFIED BYAPPROVED BY

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ADDITIONAL WORKORDERS BY PLANNING

NUMBER OF WORKORDER ATTACHED BY MAINTENANCE /AUTHORISED PERSON

WORK ORDER NO. SIGNATURE

DETAILS OF AUTHORISED PERSON

NAME CAT AUTH/LIC.NO. FULL SIGN INITIAL

DETAILS OF TECHICINAS

NAME DESIGNATION SIGNATURE INITIAL

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Aircraft registration Station AICL TASK CARD NUMBER

TitleLivery painting

Date Task

Painting

Threshold Repeat AR FH AR FHAR FC AR FCAR DAYS AR DAYS

RELATED TASK CARD NUMBER

APPLICABILITYB737-800

WORKPACKAGE NO.

SKILL A

MAN HOURS MANDATING DOCUMENT ELAPSED TIME(HRS)USED MANHOURS

ZONE ACCESS WORK ORDER NO. RAISED

TASK CODE

TASK DESCRIPTION TECH AME/AUTH PERSON

A) CONSUMABLES/TOOLS/EQUIPMENTS REQUIRED:1. PAINT DETAILS:

S/N PART NUMBER DESCRIPTION QTY

1 . 4360-3031 Primer Base PAC 33CF AR

2 . 0763-9000 PAC 33CF Primer Activator A R

3 . 0433-9000 PAC 33CF Primer Thinner AR

P99. Wash Primer AR4 . CA8000B707 BAC707 Gray Paint AR5 . CA8000B0022

7 BAC227 Orange Paint AR6 . CA8000B2586 BAC2586 Orange

Paint Gloss AR7 . CA8000B0043

0 BAC 430 Green Paint AR8 . CA8000B0502

1 BAC 5021 Blue Paint AR

9 . CA8000B70846

BAC 70846 White Glass Paint AR

1 0 . BMS 10- 72TY8BAC121

Red Gloss AR

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8

1 1 . No SpecificStripper - Paint - Turco 5351 / Turco 4338 or Equivalent AR

NOTE: Paint details provided above is for PPG High Solids paints only.

2. CLEANING AGENTS:SIN PART

NUMBER DESCRIPTION QTY

1 . Magnus 169X Cleaning Solvent AR

2 . No Specific White Spirit A R3 . No Specific Dinitrol or Equivalent AR4 . TECHNICLE

ANAS58 Cleaning Agent AR

5 . No Specific Degreasing Agent, MIL-PRF-680

AR

6 .No specific

Solvent - Final Clning Of All Organic Ctgs Before Non-Structural Bonding (AMM20-30-89/201) — Series89

AR

7 . No Specific Acid - Technical Grade, Nitric. (61%-68.2% Purity), A-A-59105

AR

8 . No SpecificAlcohol - Ethyl (Denatured) AMS 3002F (MIL-E-51454, Type II)

AR

9 . No Specific Solvent - Aliphatic Naphtha (For Acrylic Plastics) TT-N-95 Type II, ASTM D-3735 Type Ill

AR

1 0 . No Specific Alcohol - Isopropyl TT-I-735

AR

1 1 . No SpecificSolvent - Methyl Ethyl Ketone (MEK) ASTM D740

AR

1 2 . No Specific Solvent - Methyl Isobutyl Ketone ASTM D1153

AR

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1 3 . No SpecificSolvent - Toluene, Nitration JAN-T- 171, Grade A

AR

1 4 . No Specific Alcohol - N-Butyl (Butanol) ASTM D304

AR

1 5 . No SpecificSolvent - Xylene, Nitration Grade ASTM D843

AR

1 6 . No SpecificSolvent - General Cleaning Of Composites (AMM 20-30-831201) - Series 83

AR

1 7 . No SpecificCleaner - Oakite Isoprep 177 C00167 Acid, Chromic (Chromium Trioxide) A-A-55827

AR

1 8 . No SpecificCompound - Polysulfide, Polyurethane, And Epoxy Paint Remover BAC5725

AR

1 9 . No SpecificSolvent - Presealing, Cleaning Solvent BMS11-7

AR

2 0 . No SpecificCompound - Aircraft Surface Cleaning MIL-C-43616

AR

2 1 . No SpecificCleaner - Aerospace Equipment MIL-PRF-87937

AR

2 2 . No SpecificSolvent - Cleaning Compound, Mixtures A-A-59281

AR

2 3 . No SpecificSolvent - Final Cleaning Of Metal Prior To Painting (AMM 20-30- 84/201) - Series 84

AR

2 4 . No Specific

Solvent - Final Cleaning Of All Organic Coatings Prior To Painting (AMM 20-30-85/201) - Series 85 C00175 Primer — Urethane Compatible, Corrosion Resistant (Less Than 1% Aromatic Amines) BMS1O-79, Type III

AR

3.GENERAL PARTS REQUIREMENTS

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S / N PART NUMBER DESCRIPTION QTY

1 . 3M 600/ 3M250 Masking Tape AR

2 . No Specific Wrapping Paper AR

3 . No Specific

Cotton Wiper - Process Cleaning Absorbent Wiper (Cheesecloth,Gauze) BMS15-5

AR

4 . No Specific Clothes AR5 . No specific Scotch Brite 3M AR6 . No specific Aluminised Pa per AR

7 . 3M471-2

Vinyl Tape, 2" AR

8 .BMS 13-54 TY3 CL1 .Lacing

Chord AR

9 . RTV102 Sealant AR

1 0 .No specific

Tape - Yellow Vinyl Adhesive, Scotch Brand No.471, 1.5 Inches (38.1 mm)Wide

AR

1 1 . No specific

Adhesive - Silicone Rubber, 2 Part, RN BAC5010, Type 68

AR

1 2 .

FP001-1 / or P/N as per effectivity

Boot, Radome01

1 3 . No specific Compound - Antiseize

BMS3-28AR

1 4 . No Specific

Abrasive - Aluminum Oxide CoatedCloth AR

1 5 . No Specific

Sponge - Synthetic AR

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1 6 . No Specific Paper

AR

1 7 . No Specific

Tape - Aluminum Foil BMS8-289

AR

1 8 . No Specific

Abrasive - Aluminum Oxide Paper, 150 grit A-A-1048

AR

1 9 . No Specific

Abrasive - Aluminum Oxide Paper, 240 grit or finer

AR

2 0 . No Specific Sand Paper, Grades

100 to 400 AR

4.CONTROL SURFACE BALANCING

S / N PART NUMBER

DESCRIPTION QTY

1 . 113A7183-6

Aileron balance adjust weight AR

2 . 183A0210-1

Elevator Balance adjust weight

AR

3 . 173A5300-1

Rudder Balance Adjust weight

AR

5.GENERAL TOOLS REQUIREMENT

S / N PART NUMBER

DESCRIPTION QTY

1 . No Specific Scraper — Non metallic AR2 . No Specific Heat Gun 013 . No specific Nylon Brushes AR4 . No specific Brush - Stiff Bristle,

Non-metallicAR

5 . No Specific Water Pressure source, 0-70 psi

01

6 . No specific Gun, Pressure sprayer AR7 . No specific Brush — Paint AR8 . 04181 Ohm meter AR

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9 .015292

Bonding Meters - Approved, Intrinsically Safe (Approved for use in Class I, Divisions I & II hazardous (classified) locations. Outside these hazardous locations, COM-614 can be used in lieu of COM-1550).

01

No Specific Coating Thickness Gauge (0 to 2000 microns with 0.1 micron accuracy)

01

B.REFERENCE DOCUMENTS

1 . AMM 05-51-91 EXCESSIVE CABIN PRESSURE LEAKAGE

2 . AMM 07-11-01 A/C JACKING3 . AMM 12-14-01 POTABLE WATER

TANK DRAINING4 . AMM 12-40-11 A/C CLEANING &

POLISHING5 . AMM 20-40-11 A/C GROUNDING

6 .AMM 24-31-11 MAIN / EMERGENCY

BATTERY REMOVAL / INSTALLATION

7 . AMM 27-11-11 AILERON REMOVAL / INSTALLATION

8 . AMM 27-21-11 RUDDER REMOVAL / INSTALLATION

9 .AMM 27-31-11 ELEVATOR

REMOVAL / INSTALLATION

1 0 . AMM 51-21-XX INTERIOR & EXTERIOR FINISHES

1 1 . SRM 51-60-XX CONTROL SURFACE BALANCING

1 2 . TASKCARD JBNGCL-12-

EXTERIOR CLEANING

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CLN-001-XX

1 3 .TASKCARD JBNG-PREDOCK-001-

PRE-DOCKING CHECKS

1 4 .BOEING 737NG-FTD-27-08007

FOLLOW ALL CAUTIONS & WARNINGS AS GIVEN IN REF AMM.

DO NOT ALLOW PAINT STRIPPER TO CONTACT SKIN

ALL WORK TO BE CARRIED OUT IN ADEQUATELY VENTILATED AREAS.

DO NOT USE SHARP KNIVES OR ANY OTHER METAL TOOLS THAT CAN DAMAGE THE FUSELAGE SKIN PANEL TO REMOVE SEALANT OR TRIM DECALS AND THAT EXTREME CAUTION BE EXCERCISED DURING THE PROCESS.

C) ACCOMPLISHMENT INSTRUCTIONS1.TASK PREPARATION (PREDOCKING & AIRCRAFT WASHING

a) Prior to aircraft docking into hangar, carryout a/c cleaning per latest revision of Exterior Cleaning task card or as per AMM 12-40-00.

b) Drain Potable Water Tank per AMM 12-14-01.c) Position aircraft in the hangar & electrically ground

aircraft as per AMM 20-40-11.d) Dock the aircraft.e) Carryout Jacking of the aircraft per AMM 07-11-01,

if required.NOTE: COVER ALL WINDOW SURFACES USING

ALUMINISED PAPER & ALUMINIUM FOIL TAPE. ENSURE GAPS BETWEEN FUSELAGE SKIN & WINDOW FRAME ARE MASKED WITH ALUMINIUM FOIL TAPE.

NOTE: ENSURE THE ALUMINISED PAPER COVER AT LEAST TWO INCHES ALL AROUND THE SURROUNDING OF THE WINDOWS.

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NOTE: Use caution when painting near Leading Edge Flap/Slat Actuators to avoid incidental painting of the working surface of the rods. Do not paint on Piston rods.

Paint over-spray on the piston rods can be detrimental to the seals during actuation and can result in varying degrees of leakage. Once the seals are damaged, the actuator can continue to leak even during periods when the flight controls have not been actuated for an extended period.

f) Put the covers / masks on the following components: Decoupied static dischargers or retainers on the

wing and empennage.Rain repellent nozzles that are forward of the

windshields.Rubber mohair seals, rub strips made of stainless steel,

anodized handles and door handle pans, or silicone rubber sealant.

Pressure relief valves or outflow valves.Circular bands, one inch in width, around or on the

pressure relief valve doors, or outflow valves.

Door operating mechanisms, hinge assemblies, and equivalent surfaces.

Flight deck and main cabin windows.Pitot probes and static ports.Angle-of-attack sensors.Exterior light lensesEngine inlet, fan exhaust, and turbine exhaust.Brakes. Tires.

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g) Remove main and emergency batteries as per AMM 24-31-11. Retain the batteries for re-installation after painting.

h) Remove & discard the currently installed Radome Boot per AMM 53-5200.

2) TASK DESCRIPTION:a) REMOVING EXTERNAL DECALS:`

I) Carryout removal of external decals using a non-metallic scraper.CAUTION: Under no circumstances any sharp objects / tools are to be used.II) non-metallic scraper may be used to help pull up

the edges so that the painter can grip the decal to remove it,

III) If required, use heat guns to remove decals. Soften the adhesive around the edges & peel off the decals with continual application of heat.

b) COATING THICKNESS MEASUREMENT:Carryout coating thickness measurement using the coating thickness measuring gauge. Note down the details on Appendix 1 of this Taskcard.

c) PAINT REMOVAL

WARNING: DO NOT USE PAINT STRIPPERS ON COMPOSITE STRUCTURAL PARTS.CAUTION: TAKE CARE NOT TO WASH DOWN THE RESIDUES INTO THE CREVICES OF AIRCRAFT STRUCTURES.1.PAINT REMOVAL - COMPOSITE PARTS

(MECHANICALLY): Rub-down the paint with 80-240 grit disc or grade

280 abrasive paper followed by finish with grade 400 abrasive paper or emery cloth & demineralised water.

Fibreglass surface are to be sanded down using grit 400 or finer abrasive paper or very fine scotch brite pads to remove paint coating.

Thoroughly rinse the rub-down area with pressurised water (20-40 psi maximum) & scrub.

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Use nylon brushes & scotch brite pads to remove residue if present

2.PAINT REMOVAL - METALLIC PARTS (MECHANICALLY): Rubdown the paint upto the primer with 80-240

grit disc or grade 100 abrasive paper followed by finish with grade 400 abrasive paper & demineralised water.

Rubdown one coat of primer with 80-240 grit disc or grade 280 abrasive paper followed by finish with grade 400 abrasive paper & demineralised water.

Thoroughly rinse the re-worked area with pressurised water (40-60 psi maximum) & scrub. Use nylon brushes & scotch brite pads to remove residues if present.

3. PAINT REMOVAL - METALLIC PARTS (CHEMICALLY): Fully mix the strippers per manufacturer's

instruction. Apply large quantities of stripper on the surface

using a natural bristle paint brush or by non-atomising spray.

Add more layers of the stripper if necessary. Keep the surface wet with the stripper a sufficient time (per paint stripper manufacturer instructions) for the finish to become soft & become wrinkled.

Remove thd loosened material with a bristle paint brush or with a sealant removal tool, before the stripper become dry.

Flush the area fully with clean water to remove the remaining stripper & loose finish. Flush the area again with high pressure (40-60 psi maximum), clean and warm water.

d) ALKALINE. CLEANING:

CAUTION: TAKE CARE NOT TO WASH DOWN THE RESIDUES INTO THE CREVICES OF AIRCRAFT STRUCTURES.

1. Spray wash rub-down / strip down surfaces using

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Magnus 169X cleaner or equivalent.2. Remove local stubborn residues & masking

adhesives with white spirit or equivalent.3. Dry the surface with a cotton wiper.

e) GENERAL CLEANING OF EXTERNAL SURFACES:

1. Clean all the external surfaces with solvent. Use cloths soaked in solvent to prevent trickling in seals. Clothes should be changed as required to prevent spreading greases. Solvent may be applied via wash bottles.

2.Carryout washing/cleaning/polishing of unpainted surfaces such as nose cowl, wing and stabilizer leading edges.

3. Carryout landing gear & wheel well area cleaning and apply DINITROL as necessary.

f) WATER BREAK-FREE TEST:

1. Carryout Water Break Free test on the surfaces where the paint has been removed. If the test fails, repeat Paint Removal, Alkaline Cleaning & General Cleaning as per steps provided above.

g) INSPECTION:

1. Carryout general visual inspection of external skin surfaces for cracks, corrosion, loose rivets, scribe marks and report any discrepancies to Technical Services department.

2. Carryout structural mapping & produce a dent and buckle chart, if required.

3. Check for the sealant conditions on the aircraft at butt joints & lap joints. Damaged sealants are to be removed and reapplied as required.

4. Check flight control surfaces for satisfactory condition.

h) SURFACE PREPARATION:

1. Carryout surface treatment of metallic parts as required.

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2. Mechanically reactivate all the surfaces to be painted with primer / antistatic paint as required.

Wings: Using the 1000rpm drysanding machine with self

adhesive redoxal discs, grade 180 or 240. Fuselage: using the 300 rpm machine with solvent

supply with scotch brite. For all inaccessible areas and places where

machine can't be used, do the reactivation using scotch brite soaked in solvent manually.

i) PAINTING:

NOTE: PRIMER APPLICATION MUST BE .DONE WITHIN h .HOURS AFTER SURFACE TREATMENT.

1. ETCH PRIMER / WASH PRIMER — Apply Etch Primer / Wash Primer as required wherever paints removed to bare metal.

2. PRIMER - Apply one coat of primer on all the rub down / strip down surfaces.

3. TOP COAT - Apply two top coats on the surfaces as applicable and as per the applicable External Livery drawings.

4. DECORATIVE COAT - Apply one coat of decorative paint on the surfaces as applicable and as per the applicable External Livery drawings.

j) DECAL / STENCIL INSTALLATION:

1.Carryout exterior Decal / Stencil installation as per AMM 11-21-13 / 11- 23-01 / 11-25-03. Ensure the decals are installed without bubbling, tilting or folding.

2.Carryout the Painting / Stenciling of the following on the a/c:

Empty weight on aft LH lower fuselage. Max all up weight on aft LH lower fuselage.

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"CVR" on aft RH Center fuselage after aft cargo. "INFLATE WITH NITROGEN ONLY " on shock strut /

landing Tyre p ressure l im i t s on shock s t ru ts /

l and ing gear doors ( re fe r AMM 12-15-51) "HOT" on fo rward and a f t d ra in masts . "ETOPS" on the applicable a/c above the External

Power Receptacle.k) Install Flight Controls back (If removed during Task Preparation) per AMM provided below

Ailerons — AMM 27-11-11 Rudder — AMM 27-21-11 Elevators — AMM 27-31-11

I) Carryout duplicate inspection of flight control installations if required.m) CONTROL SURFACE BALANCING:Carryout static balancing of flight control surface's per SRM as applicable.

Rudder — SRM 51-60-07 Elevators — SRM 5I-60-04 Ailerons—SRM 51-60-01

3) A/C RESTORATION:a)Install main & emergency batteries as per AMM 24-

31-11, removed during Task Preparation.b)After painting re-install Radome as per AMM 53-52-

00, if removed during Task Preparation.c)Install Radome Boot per AMM 53-52-00. Carry out

post installation checks as required.d)Carryout lubrication of landing gear & flight

controls as per AMM chapter 12-21 & 12-22.e)Carryout General inspection of Painting and Decal

installation performed, rectify if any discrepancy

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found.

4) CLOSE-UP:a) Remove all the covering tapes / masking tapes

installed during the Task Preparation.b) Ensure all blanks of pitot probes, static holes,

engine inlets/exhaust, ACM inlets and outflow valve are removed.

c) Carryout coating thickness measurement using the coating thickness measuring gauge. Note down the details on Appendix 1 of this Taskcard.

d) Remove aircraft grounding cable as per AMM 20-40-11.

e) De-Jack the aircraft if Jacking was carried out per AMM 07-11-01.

f) Carryout weighing of aircraft if required. If weighing not carried out, Weight change will be accounted during annual weight growth. Record the total quantity & weight of the paint consumed during the Livery change.

Total paint qty used (in Litres) =______________________

Total weight of paint used (in Kgs) =__________________

g) Carryout pressurization leak check per AMM 05-51-91.

h) Carryout Pre-Departure Check part of Current Extended Transit Schedule.

i) Restore aircraft to normal configuration.

j) Review all paper work is complied & complete as necessary.

5)FLIGHT TEST (IF REQUIRED)a) Carry out test flight of aircraft if required as per

applicable procedures of the test flight

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schedule.

I HEREBY CERTIFY THAT THIS TASKCARD HAS BEEN COMPLETED IN ALL RESPECTS.

DATE :________ (UTC) SIGNATURE :____________

TIME:______(UTC) LICENCE / AUTH. NO._________

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