GENERAL A320

SINGLE AISLE

TECHNICAL TRAINING MANUAL

MAINTENANCE COURSE - T1

GENERAL

This document must be used for training purposes only

Under no circumstances should this document be used as a reference

It will not be updated.

All rights reserved

No part of this manual may be reproduced in any form, by photostat, microfilm, retrieval system, or any other means, without the prior written permission of AIRBUS S.A.S.

GENERAL

Structure General (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Structural Breakdown and Zoning (3) . . . . . . . . . . . . . . . . . . . . . . . . 18

Ground Handling (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Electrostatic Discharge (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Computer Removal and Installation (3) . . . . . . . . . . . . . . . . . . . . . . 56

Maintenance External Visit (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

SINGLE AISLE TECHNICAL TRAINING MANUAL

MAINTENANCE COURSE - T1

01 - GENERAL

TABLE OF CONTENTS

Oct 17, 2005

Page 1

STRUCTURE GENERAL (1)

AIRCRAFT MATERIALS

METALLIC MATERIALS

The basic A/C structure is made of aluminum alloys with stainless steel and titanium alloys in specific areas.

COMPOSITE MATERIALS

Composite materials are used for primary and secondary structure.

Composite materials represent about 15% of the A/C structural weight.

Carbon Fiber Reinforced Plastic (CFRP) is mainly used for primary structures, whilst Aramid Fiber Reinforced Plastic (AFRP) and Glass

Fiber Reinforced Plastic (GFRP) are only used for secondary structures.



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01 - GENERAL

AIRCRAFT MATERIALS / COMPOSITE MATERIALS


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STRUCTURE PROTECTION

AIRCRAFT DRAINAGE

Wings and fuselage have different types of drains. Holes and gaps are meant to be used for a natural drainage of the fluid collection points.

Drain holes are drilled before application of pretreatments. Remote drains are used when natural drainage is not possible.

SURFACE PRETREATMENT

The protection of the structure against corrosion is achieved by means of appropriate surface pretreatment of the metallic parts.

Aluminum alloys: the primary protection is generally a pure aluminum cladding. The main pretreatment used is the unsealed chromic acid anodizing.

Titanium alloys: surface interfaying with aluminum alloy parts are zinc sprayed. The other titanium alloy surfaces are left bare. Titanium fasteners are either sulphuric acid anodized or aluminum coated.

Composite materials are left bare.



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01 - GENERAL

STRUCTURE PROTECTION / SURFACE PRETREATMENT


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STRUCTURE PROTECTION (continued)

PAINT SYSTEM

Before the final paint system, all aluminum parts are primed. The paint system used includes polyurethane primers and paint on the external surfaces, and epoxy primers and polyurethane paint on the internal surfaces. Anti-slip paint is the overwing escape zones.



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01 - GENERAL

STRUCTURE PROTECTION / PAINT SYSTEM


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STRUCTURE PROTECTION (continued)

NO STEP AREAS

Protective mats are required on the horizontal stabilizer as it is a carbon fiber structure.

JACKING POINTS

Three jacking points are provided, one below each wing outboard of the pylon and one in front of the NLG bay.



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01 - GENERAL

JACKING POINTS


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A318 STRUCTURE DIFFERENCES

The Main structure differences between the A319/A320/A321 and the

A318 are due to the reduced length of the fuselage. There are several general structure changes, laser beam welded structures and the vertical stabilizer fin tip extension.

GENERAL STRUCTURE CHANGES

The main general structure changes are:

- on section 17, due to reduced length of the fuselage, the longitudinal beams, the seat rails and the Z-profiles are replaced by new ones. The crossbeams at FRame 52, FR53 and FR54 are removed. New crossbeams are installed between FR55 to FR64,

- due to its location in the non-cylindrical part of the fuselage, a new cargo sill box replaces the A319/A320/A321 one's, in section 17,

- on section 15, the A319/A320/A321 skin panels have been modified.

For weight reduction the A318 skin panels are thinner than the

A319/A320/A321 one's,

- the aft part of the belly fairing is modified due to an overlap with non-cylindrical part of the fuselage. To avoid interference with cargo compartment door, the A318 belly fairing is two panels shorter than the A319/A320/A321 one's.



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01 - GENERAL

A318 STRUCTURE DIFFERENCES / GENERAL STRUCTURE CHANGES


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A318 STRUCTURE DIFFERENCES (continued)

VERTICAL STABILIZER

Compared with A319/A320/A321 A/Cs, the A318 vertical stabilizer fin tip is 750 mm (29,5 in.) longer.

The new developed tip is completely made of GFRP. There is an additional fin leading edge panel. There is a new spar and a new CFRP adaptor box, between the fin base and the fin tip.

The metallic rudder tip is longer by 100 mm in vertical direction. The rudder trailing edge is increased in width by 50 mm.



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01 - GENERAL

A318 STRUCTURE DIFFERENCES / VERTICAL STABILIZER


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LASER BEAM WELDING

The technology used for the A319/A320/A321 A/Cs is riveted skin/stringer. On the A318, the skin/stringer connections are welded.

The new laser beam welded skin panels are installed in:

- the sections 13/14, FR24 to FR35, stringers 18 to 32,

- the sections 16/17, FR47/54 to FR64, stringers 32 to 41.

The skin panels are made thicker where the stringers are welded onto them.



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01 - GENERAL

A318 STRUCTURE DIFFERENCES / LASER BEAM WELDING


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CARGO DOORS

The A318 forward and aft cargo doors are smaller. The new cargo door width is reduced from 1.82 m (71.5 in) to 1.28 m (50.5 in). The under-floor cargo offers a usable volume of 21.21 m

3

. There is no containerized cargo system option.



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01 - GENERAL

A318 STRUCTURE DIFFERENCES / CARGO DOORS


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STRUCTURAL BREAKDOWN AND ZONING (3)

REFERENCE AXES

The structure elements are installed according to the following reference axes. The X axis in the longitudinal direction of the fuselage, the Y axis in the direction of the wing span and the Z axis in the vertical direction.

The cross section P presents a typical fuselage section at frame 47.

NOTE: Note: The reference (station 0) for all structural measurements for the X axis is set at 100 in (254 cm) forward of the A/C nose.



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01 - GENERAL

REFERENCE AXES


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ATA CHAPTERS

The A/C structure is divided according to the ATA 100 specifications.

SECTION NUMBERS

Each major part of the A/C receives a section number. The fuselage section base number is 10. The fuselage is divided into various sections for manufacturing reasons.



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01 - GENERAL

SECTION NUMBERS


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SECTION NUMBERS (continued)

WING AND TAIL PLANE

The general wing section base number is 20. The general tail plane section base number is 30.



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SECTION NUMBERS / WING AND TAIL PLANE


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SECTION NUMBERS (continued)

ENGINE, LANDING GEAR AND BELLY FAIRING

The engine section base number is 40. The L/G section base number is 50. The general belly fairing section base number is 60.



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SECTION NUMBERS / ENGINE, LANDING GEAR AND BELLY FAIRING


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STATION NUMBERS

FUSELAGE

The STAtion number is the distance in centimeters of a cross-section from a reference point. The station/frame numbers shown agree with the section boundaries.



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01 - GENERAL

STATION NUMBERS / FUSELAGE


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STATION NUMBERS (continued)

VERTICAL STABILIZER

For the vertical stabilizer the reference station is Z=0 at the vertical

Z-axis. Due to the fin tip extension, the A318 station numbers have changed. The new additional rib 12N is on the STA597.



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01 - GENERAL

STATION NUMBERS / VERTICAL STABILIZER


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STATION NUMBERS (continued)

HORIZONTAL STABILIZER, ENGINE AND WING

For the horizontal stabilizer the reference station is y=0 at the A/C Y axis. For the wings, the reference station is the wing reference axis

(WY). WY is located at 1868 mm (73.54 in) from the A/C X axis.

For the engines, station numbers are different depending on the version.



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01 - GENERAL

STATION NUMBERS / HORIZONTAL STABILIZER, ENGINE AND WING


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ZONES NUMBERS

There are 8 major zones for the A/C. Each major zone is identified by the first digit of a three digits number. The even numbers identify the zones on the RH side of the A/C, while odd numbers identify the zones on the LH side of the A/C. The sub-zone 320 identifies the vertical stabilizer.



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01 - GENERAL

ZONES NUMBERS


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ZONES NUMBERS (continued)

WING (UPPER SURFACE) AND HORIZONTAL

STABILIZER

The 500 numbers identify the LH wing zones, while the 600 numbers identify the RH wing zones. The sub-zones 330 and 340 identify the

LH and RH side of the horizontal stabilizer.



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ZONES NUMBERS / WING (UPPER SURFACE) AND HORIZONTAL STABILIZER


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WING (LOWER SURFACE), BELLY FAIRING AND

LANDING GEAR

The sub-zone 710 identifies the NLG. The sub-zones 730 and 740 identify the LH and RH MLG.

The sub-zone 190 indicates the belly fairing. 734 and 744 are the

MLG door zone numbers.

Access doors and panels are identified by the number of the zone in which the panel is installed followed by a two letter suffix. These two letters are used to indicate the doors and panels. The first letter indicates which access door or panel it is, starting from the reference axis (A=first, B=second, ..., G=seventh, etc...). The second letter indicates the access door or panel location:

- T=top (upper) surface,

- B=bottom (lower) surface,

- R=right side,

- L=left side,

- Z=internal,

- F=floor panel,

- W=sidewall panel,

- C=ceiling panel.

Here is an example of access panels on the left wing lower surface.



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ZONES NUMBERS / WING (LOWER SURFACE), BELLY FAIRING AND LANDING GEAR


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NACELLE, PYLON, ENGINE AND DOOR

The difference between the LH and RH pylon and nacelle is made with the ten digits of the zone number 400. The difference between the LH side and RH side is identified by the last digit (Tens digit: odd for he left and even for the right). Within one engine, an odd zone number indicates the LH side and an even zone number indicates the

RH side of the engine. The major zone 800 identifies the doors.



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01 - GENERAL

ZONES NUMBERS / NACELLE, PYLON, ENGINE AND DOOR


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GROUND HANDLING (1)

SERVICING POINTS

The ground service connections layout is the same on the AIRBUS A318 and A319.The main difference between A320 and A321 servicing point is a second potable water draining panel in the center of the A/C on the

A320.



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GROUND HANDLING (1)

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01 - GENERAL

SERVICING POINTS

GROUND HANDLING (1)

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GROUND HANDLING (1)

A/C SERVICING ARRANGEMENT

On the A318, note that special care must be taken during manual cargo loading and unloading of the forward cargo compartment, because of the close proximity of the engine air intake to the cargo loading vehicles

(conveyor belt).

NOTE: Note: The use of a self-propelled conveyor belt is not recommended by Airbus Industrie.

The main difference between the A318/A319 and the A320/A321 servicing arrangement is that the A320 and A321 can have a bulk loader on the bulk cargo door.



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GROUND HANDLING (1)

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01 - GENERAL

A/C SERVICING ARRANGEMENT

GROUND HANDLING (1)

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GROUND HANDLING (1)

TURNING RADII

The different turning radii are shown on a steering diagram. "Y" is the distance between the centerline of the A/C longitudinal axis (X-axis) and the theoretical center of turn for turning radius. "A" matches the minimum turning width for a 180° turn. "Y, A" and the radii "R3, R4, R5 and R6" values depend on two parameters: effective turn angle and steering angle.



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GROUND HANDLING (1)

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01 - GENERAL

TURNING RADII

GROUND HANDLING (1)

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ELECTROSTATIC DISCHARGE (3)

ELECTROSTATIC DISCHARGE PROBLEMS

Electro Static Discharge (ESD) is generated by rubbing materials with each other. By moving over plastic materials (synthetic fibers), wearing synthetic fiber clothing, electrical charges build up on the body. Thus voltages of 12000 to 35000 volts can develop on a person. Touching connector pins of computer units, a discharge path is formed through wiring and components. Integrated Circuit (IC) chips can be partly damaged or totally destroyed. Rubbing materials from the "tribo-electris" series against each other and then separating them from each other causes a build-up of electrostatic charges. If the materials are far apart in the series, there will be a higher electric charge.



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01 - GENERAL

ELECTROSTATIC DISCHARGE PROBLEMS


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ELECTROSTATIC DISCHARGE PROTECTION

Here are some precautions to avoid damage of electronic equipment by

ESD. Line Replaceable Units (LRUs) that are sensitive to ESD are identified by a black and yellow label on equipment face.



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ELECTROSTATIC DISCHARGE PROTECTION


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LRU REMOVAL

Replacing an LRU bearing the black and yellow label requires these precautions.



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01 - GENERAL

LRU REMOVAL


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LRU TEST

Testing of installed LRUs requires the following precautions.



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01 - GENERAL

LRU TEST


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WORK STATION

The removal and testing of printed-circuit boards from an LRU bearing the black and yellow label, is carried out as follows.



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01 - GENERAL

WORK STATION


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COMPUTER REMOVAL AND INSTALLATION (3)

COMPUTER REMOVAL/INSTALLATION

Before starting a computer removal/installation procedure, the A/C has to be set-up for maintenance. The first task is to make sure that the ground service network is energized and the access door is open and accessible.

Then make sure that the C/Bs listed in the removal of the computer procedure of Aircraft Maintenance Manual (AMM) is open. The first action is to loosen the nut and then to lower the nut. When the nut is lowered, pull the computer on its rack to disconnect the electrical connectors and remove the computer from its rack. Before starting a computer installation procedure, clean and do a visual inspection of the component interface and of the adjacent area. First remove the blanking caps from the electrical connectors and make sure that the electrical connectors are clean and in the correct condition. Then install the computer on its rack and push it on its rack to connect the electrical connectors. Now you can engage the nuts on the studs and tighten them.

The installation is finished. You can close the C/B. The last actions of the computer installation are to do a test through the MCDU and to close the access. Make sure that the work area is clean and clear of tools and other items, close the access door and remove the access platform.



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01 - GENERAL

COMPUTER REMOVAL/INSTALLATION


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MAINTENANCE EXTERNAL VISIT (3)

PRESENTATION

This film presents the A321 outside safety inspection and cockpit

Check-List (CL) to be performed before powering the A/C for maintenance purposes. Various main stations have been defined. The inspection starts with the nose station. First verify that the NLG chocks are in place. Then, observe that the NLG doors are closed. Make sure that the NLG safety pin is installed. The NLG steering pin must be as required. Finally, verify that the A/C is electrically grounded. The second step consists of inspecting the right MLG. Start by checking that the

MLG door is closed. Then, verify that the MLG safety sleeve is installed.

Lastly, observe that the MLG chocks are in place. Let us continue with the right engine station, the first thing to do is to make sure that the engine right side access doors are secured. The same must be done for the left side. Check that the engine fan cowls and thrust reverser cowls are secured. The right wing is the 4 th

station. Observe the position of the slats and then, the flaps. The spoilers must be retracted. Then move to the left wing station. Here again observe the position of the flaps and then, the slats. Although make sure that the spoilers are retracted. The next step is the left engine station. Check that the engine right side access doors are secured. Then pass around the engine to verify that the left side access doors are secured. Make sure that the engine fan cowls and thrust reverser cowls are secured. Proceed with the left MLG station. The Ram Air

Turbine (RAT) safety device must be in the stowed position. Continue by checking that the MLG door is closed and that the MLG safety sleeve is installed. Before moving on, observe that the MLG chocks are in place.

In the A/C area station you have to make sure that the A/C area is clean and clear of tools and any other items. Now you have to check the 9 th station: the external power receptacle. Verify that the external power is connected and available. Finally enter the cockpit for the last station.

Start by checking the rear and the overhead circuit breaker, then have a look to the emergency equipment. This consists in: verifying that the escape ropes are present, observing that the fire extinguisher is in position, making sure that the cockpit is equipped with smoke hoods, checking that the fire protective gloves are present, ensuring the crash axe is in position, checking that the cockpit is equipped with life vest, verifying that the oxygen masks are present, observing that the flash lights are in position. You must then make sure that the wipers are off. BATtery 1 and 2 P/BSW must be off and their voltage should be about 25 volts.

Proceed by setting the BAT1 P/BSW to AUTO. Then, set the BAT2

P/BSW to AUTO, check that the right hand dome light is on. Verify that the speed brake handle is in the RETract disarm position. If the speed brake handle disagrees with the surface position maintenance action is due. On the center pedestal make sure that the thrust levers are in the idle position. Engine master switches 1 and 2 must be in the OFF position and the engine ignition mode selector in the NORMal position. Observe that the flap handle is set according to surface position. If engine reverse cowls have to be opened for maintenance action, the slats must to be retracted. Still on the center pedestal, check that the radar is off, also verify that the ATC transponder is off. Make sure that the gravity gear extension crank handle is in the reset stowed position. On the instrument panel observe that the three green triangles on the LanDinG GEAR panel are on. The control safety check list should now have been accomplished.

On the overhead panel set the EXTernal PoWeR P/BSW to ON, also set the GENerator 1 P/BSW to on and the GEN2 P/SW to ON. Scan and check that no amber lights are on except GEN1 and 2 FAULT light on panel 44VU. The GALY & CAB P/BSW should be as required. Finally verify that there is no light on the VENTilation panel. The A/C is now ready for maintenance.

NOTE: This film shows an A321 but the procedure is also valid for

A318, A319 and A320 aircrafts.


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01 - GENERAL

PRESENTATION


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STEP BY STEP

The following topics develop step by step the previous film presentation.

NOSE STATION AND EXTERNAL POWER RECEPTACLE

To the station 1, in first, verify that the NLG chocks are in place. Then, observe that the NLG doors are closed. Make sure that the NLG safety pin is installed. The steering pin must be as required. Finally, verify that the A/C is electrically grounded.

NOTE: Note: The A/C can also be grounded from the MLG.

For the station 9, verify that the external power is connected and available.



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NOSE STATION AND EXTERNAL POWER RECEPTACLE


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RIGHT AND LEFT MLG STATION

The station 2 and 7 consist of inspecting the Right (R) and Left (L) MLG.

Start by checking that the MLG door is closed. Then, verify that the MLG safety sleeve is installed. Finally, observe that the MLG chocks are in place.

To the left station, the Ram Air Turbine (RAT) stowed position safety device must be installed.



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01 - GENERAL

RIGHT AND LEFT MLG STATION


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RIGHT AND LEFT ENGINE STATION

RIGHT AND LEFT ENGINE SIDE ACCESS DOORS

On station 3, the first thing to do is to make sure that the engine right and left side access doors are secured. The same must be done on station 6.



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RIGHT AND LEFT ENGINE STATION / RIGHT AND LEFT ENGINE SIDE ACCESS DOORS


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RIGHT AND LEFT ENGINE STATION (continued)

ENGINE FAN COWLS AND THRUST REVERSER

COWLS

Check that the engine fan cowls and thrust reverser cowls are secured.



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RIGHT AND LEFT ENGINE STATION / ENGINE FAN COWLS AND THRUST REVERSER COWLS


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RIGHT AND LEFT WING STATION

The R and L wing are the 4 and 5 stations. Confirm the position of the slats and then, the flaps. The spoilers must be retracted.



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RIGHT AND LEFT WING STATION


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AIRCRAFT AREA

In the A/C area station 8, you have to make sure that the A/C area is clean and clear of tools, other items and FOD.



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AIRCRAFT AREA


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COCKPIT STATION

REAR AND OVERHEAD C/B PANELS

Start by checking that the rear C/Bs and the overhead C/Bs are in closed position.



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COCKPIT STATION / REAR AND OVERHEAD C/B PANELS


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COCKPIT STATION (continued)

EMERGENCY EQUIPMENT

Then, have a look the emergency equipment. This consists in verifying that the escape ropes are present, observing that the fire extinguisher is in position, making sure that the cockpit is equipped with smoke hoods, checking that the fire protective gloves are present, ensuring that the crash axe is in position, checking that the cockpit is equipped with life vests, verifying that the oxygen masks are present and observing that the flash lights are in position.



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COCKPIT STATION / EMERGENCY EQUIPMENT


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PEDESTAL PANEL CHECK LIST

On the center pedestal, verify that the speed brake handle is in the retract/disarm position. If the speed brake handle disagrees with the surface position, maintenance action is due. Make sure that the thrust levers are in the IDLE position.

ENG MASTER SWs 1 and 2 must be in the OFF position and the engine ignition mode selector in the NORMal position.

Observe that the flap handle is set according to surface position.

If engine reverser cowls have to be opened for maintenance action, the slats must be retracted.

Check that the radar is off. Also, verify that the Air Traffic Control

(ATC) transponder is off.

Make sure that the gravity gear extension handle is in the reset and stowed position.



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COCKPIT STATION / PEDESTAL PANEL CHECK LIST


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OVERHEAD PANEL CHECK LIST AND A/C POWER

SUPPLY

You must then make sure that the wipers are off. BATteries 1 & 2

P/BSWs must be OFF and the voltage should be about 25 volts.

Proceed by setting the BAT 1 P/BSW to AUTO position. Then, set the BAT 2 P/BSW to AUTO position.

NOTE: Note: if BAT voltage is below 25V, a charging cycle of 20 minutes is required.

Check that the right hand dome light is on.

A/C power supply procedure:

On the overhead panel, set the EXTernal PoWeR P/BSW to ON. Also, set the GEN 1 P/BSW to ON and the GEN 2 P/BSW to ON.

Scan and check that no amber lights are on except GENerator (GEN)

1 and GEN 2 FAULT lights on panel 35VU.

The GALY & CAB P/BSW should be as required. Finally, verify there is no light on the ventilation panel.

The A/C is now ready to maintenance.



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COCKPIT STATION / OVERHEAD PANEL CHECK LIST AND A/C POWER SUPPLY


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MAIN INSTRUMENT PANEL CHECK LIST AND

CONTROLS SAFETY CHECK LIST COMPLETED

On the instrument panel, make sure that the L/G lever is in the down position and confirm that the three green arrows on the L/G panel are on. The control safety CL should now have been accomplished.



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COCKPIT STATION / MAIN INSTRUMENT PANEL CHECK LIST AND CONTROLS SAFETY CHECK LIST COMPLETED


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AIRBUS S.A.S.

31707 BLAGNAC cedex, FRANCE

STM

REFERENCE U2C05411

OCTOBER 2005

PRINTED IN FRANCE

AIRBUS S.A.S. 2005

ALL RIGHTS RESERVED

AN EADS JOINT COMPANY

WITH BAE SYSTEMS