Training Manual: EASA Part-66 57 Level 3

ATR 72-500
Training Manual
Copyright © BinterTechnic
ATA 57 Mantenimiento e Ingeniería Aeronáutica
del Atlántico Sur S.L hereinafter
BINTERTECHNIC, with registered
offices at the Airport of Gran Canaria,
Telde, and with tax registration
EASA Part-66 number(CIF) B-35980937,and entered
in the Las Palmas'Business Register on

57 Level 3 folio 45,tome1882, section 8, sheet GC-
40094.
http://www.bintertechnic.com
AEROPUERTO DE GRAN CANARIA

Parcela 9 del ZIMA
35230-Telde Las Palmas ESPAÑA
Revision: 19July2012 Tel. 24h.+34 682 776 908
Author:CB/AO
FOR TRAINING PURPOSES ONLY!
Commercial Dpt. +34 682 776 880

For Training Purposes Only. Fax. +34 928 579 605
Copyright © 2012 BinterTechnic. [email protected]
All Rights Reserved. [email protected]
July 19,2012 LEVEL 3 0

57-00 ATR 72-500
WINGS
WING GENERAL
WINGS - GENERAL
The ATR is equipped with a high wing composed of three

main elements :
- rectangular center wing box

- two trapezoidal outer wing boxes with a dihedral of
2.5°.
The surface area of the wing is 61 m square (656.4 sq.ft) and

its span is 27 m (88 ft 7 inches).
The following secondary structures are attached to the main

elements :
- Wing tips
- Leading edges
- Trailing edges
- Ailerons
- Spoilers
- Fairings

57-00 ATR 72-500
WINGS
WINGS GENERAL
WINGS - GENERAL

57-10 ATR 72-500
WINGS
CENTER BOX
CENTER WING BOX
- Center Wing Box
The center wing box structure is made of light alloy and

includes :
- Front spar
- Rear spar
- 13 sheet metal ribs
- 14 machined ribs
- Single-piece lower skin
- Four-element upper skin

57-10 ATR 72-500
WINGS
CENTER BOX
CENTER WING BOX
The center wing box includes two fuel zones located between The center wing box includes three hoist points on the upper
ribs 4 and 13 on LH and RH sides. surface :
Fuel feeder tanks are located between ribs 4 and 5 on LH
and RH sides. - 2 hoist points on the front spar at ribs 4 LH and RH sides,
General access inside the center wing box is provided by - 1 hoist point on the rear spar at rib 0 making it possible to
removable upper surface panels. hoist the wing assembly.
Inspection doors on the removable panels between :
The center wing box includes two jacking points on the lower
- Ribs 1 and 2 LH side, surface directly below the rear spar, at ribs 10 LH and RH,
- Ribs 4 and 5 LH and RH sides, allowing the whole aircraft to be jacked using a third jacking
provide access to the fuel tank crossfeed valve and feeder point located on the forward part of the aircraft.
tank fuel equipment.
The center wing box is attached to the fuselage by 8 lower

surface fittings at ribs 2 and 4 at the front and rear spars. The
attachment is complemented by two shear webs picking up
longitudinal loads.
The engine nacelle pick-up fittings are located at ribs 10, 11

and 12.

57-12 ATR 72-500
WINGS
SPARS
CENTER WING BOX - FRONT AND REAR SPAR
The front spar is composed of a semi-machined sheet metal The rear spar is composed of a semi-machined sheet metal
web stiffened by added vertical stiffeners, a lower flange web stiffened by added vertical stiffeners, a lower flange
(extrusion) made of 2024 alloy and an upper flange (extrusion) made of 2024 alloy and an upper flange
(extrusion) made of 7075 alloy. The web/flange (extrusion) made of 7075 alloy. The web/flange
attachment is made by "lock-bolt" type titanium fasteners attachment is made by "lock-bolt" type titanium fasteners
installed with high interference. installed with high interference.
The front spar accommodates : The rear spar accommodates :
- Pick-up back fittings of the wing/fuselage lower junction - Pick-up back fittings of the wing/fuselage lower junction
fittings fittings
- Junction fittings with the outer boxes - Junction fittings with the outer boxes
-Engine nacelle pick-up fittings - Underwing box pick-up fittings
- Flap hinge arm pick-up fittings
The upper and lower flange extrusions pick up the leading - Flap interconnection device hinge fitting pick-up fittings
edge fasteners.

57-12 ATR 72-500
WINGS
SPARS
CENTER WING BOX - FRONT AND REAR SPAR


57-13 ATR 72-500
WINGS
RIBS
CENTER WING BOX - RIBS
The center wing box framework is made of 27 ribs.

Sheet Metal Ribs13 ribs are made of sheet metal (stamped
core and added stiffeners) :
- Ribs 0, 3, 6, 7, 8, 9
Some of them are reinforced by added machined fittings or

flanges :
- Rib 0 (splicing of upper surface removable panels)

- Ribs 1 (fuselage pressurization load pick-up)
- Ribs 8 (flap hinge arm pick-up)
Machined Ribs14 ribs are machined :
- Ribs 2 (wing/fuselage junction)

- Ribs 4 (wing/fuselage junction, tank bottom and flap
hinge arm pick-up)
- Ribs 5 (fuel feeder tank bulkhead)
- Ribs 10 (wing/engine nacelle junction and jacking point)

- Ribs 11 and 12 (wing/engine nacelle junction)
- Ribs 13 (anti-ballast and flap hinge arm pick-up rib).

57-14 ATR 72-500
WINGS
SKINS
CENTER WING BOX – SKIN PANELS
-Lower Surface Skin - Upper Surface Skin
The center wing box skin is spliced on the front and rear The upper surface skin consists of 4 machined panels :
spars and on the ribs. It is composed of 5 panels :
- 1 Front panel extending from left rib 13 to right rib 13,
- 4 Upper surface panels (2 are removable) - 2 Removable panels extending from left rib 13 to rib 0 and
-1 Lower surface panel. from rib 0 to right rib 13 respectively,
- 1 Rear panel extending from left rib 13 to right rib 13.
- Lower Surface Skin
These panels are made of 7010 alloy and shaped step by
The lower surface skin is composed of a single-piece step on press after machining. Panel machining integrates
machined panel which extends from left rib 13 to right rib 13. the various doublers required at inspection door and indicator
It is made of 2024 alloy and shaped after machining by shot holes and the center box/outer box piano junction holes. The
peening. The machining of the panel integrates the various front and rear upper panels are attached to the spars and
doublers required at the fuel pump holes, water drains, ribs by "lock-bolt" type titanium fasteners installed with high
manual indicators and the center box/outer box junction interference. The two removable panels are attached to the
piano holes. front and rear panels and to the inter-spliced ribs at rib "0" by
countersunk head titanium screws and floating recessed
The lower panel is attached to the spars and ribsby "lock- anchor nuts on gang channels.
bolt" type titanium fasteners installed with high interference.

57-15 ATR 72-500
WINGS
FITTINGS
CENTER WING BOX - FITTINGS
The center wing box includes : -2 Longitudinal shear webs. Each of these webs is bolted to
two sections, one attached to the lower panel in the vicinity of
- Wing/fuselage junction fittings, rib 2, the other to the fuselage longitudinal beam.
- Engine attachment fittings,
- Center wing box/outer wing box junction fittings, A seal retainer section attached to the box lower surface
- Flap hinge arms. along the front and rear spars and along ribs 2 compresses a
rubber seal installed in the channel section bordering on the
- Wing/Fuselage Juntion Fittings fuselage upper opening to ensure pressure sealing between
fuselage and wing lower surface.
The wing is attached to the fuselage by :
- 4 Titanium fittings located at the intersection of ribs 2 and

the front and rear spars. These fittings equipped with ball
joints pick up the tops of the fuselage bulkheads by means of
expansion bolts. They are
each attached to the center wing box by four tension bolts
through cold worked holes.
-4 Steel fittings located at the intersection of ribs 4 and the

front and rear spars. These clevis-type fittings pick up the

titanium die forged wing/fuselage junction rods (equipped
with ball joints at their upper ends) by means of plain bolts.
They are each attached to the center box by four tension

bolts through cold worked holes.

57-15 ATR 72-500
WINGS
FITTINGS
- Engine Attachment Fitting. - Center wing box/outer wing box juntion fitting
Three attachment fittings at ribs 10, 11 and 12 pick-up the aft The outer box/center box junction is achieved by :
engine mount.
- 20 tension bolts for the lower panels installed in piano
junction holes integrated into the panel for the center box and
in added piano fittings for the outer box.
- 20 tension bolts for the upper panels installed in piano

junction holes integrated into the panel for the center box and
in added piano fittings for the outer box.
- 4 tension bolts (2 on lower surface, 2 on upper surface) and

6 shear bolts for the front spar,
- 4 tension bolts (2 on lower surface, 2 on upper surface) and

4 shear bolts for the rear spar.
July 19,2012 LEVEL 3 10

57-15 ATR 72-500
WINGS
FITTINGS
- Flap Hinge Arms. o
The flap hinge arms are located at ribs 4, 8 and 13. They
accommodate the flap hinge bearings and consist of
machined fittings made of aluminum
alloy and attached to the fittings, themselves attached to the
rear spar or directly to rib 13.
The arm at rib 4 is a double fitting which also accommodates

the left and right flap interconnection tube hinge bearing.
The fitting at rib 8 accommodates the flap control actuator

anchoring point.
July 19,2012 LEVEL 3 11

57-20 ATR 72-500
WINGS
OUTER BOX
OUTER BOX - GENERAL
- Outer Wing Box
The outer wing box includes :
- Front spar
- Rear spar
- 18 ribs
- Single-piece lower skin
- Three-element upper skin
Each outer box includes a fuel zone between ribs 13 and 23

making up a continuous tank with the adjacent fuel zone in
the center box.
The vent surge tank is located between ribs 23 and 24.
General access to the inside of the box is provided by a

removable upper surface panel.
July 19,2012 LEVEL 3 12

57-22 ATR 72-500
WINGS
SPARS
OUTER WING BOX - FRONT AND REAR SPAR
- Front Spar. - Rear Spar.
The web/flange junction is achieved by "lock-bolt" type The web/flange junction is achieved by "lock-bolt" type
titanium fasteners installed with high interference. titanium fasteners installed with high interference.
The front spar accommodates, on R13 side, a light alloy The rear spar accommodates, on R13 side, a light alloy fitting
fitting providing the junction with the center box spar. providing the junction with the center box spar. This fitting
This fitting has an access door to the inside of the box for has an access door to the inside of the box for connecting
connecting the fuel system when assembling the the fuel system when assembling the
outer wing and the center wing box. outer wing and the center wing box.
The spar web has access holes spaced between ribs 24 and The spar web has access holes spaced between ribs 25 and
31 31
The right front spar includes a refuel coupling at R20 The rear spar includes :
The front spar also includes leading edge attach lugs. - Flap arm pick-up fittings at ribs 18 and 23
- Spoiler hinge fittings, between R21 and R24
- Aileron hinge fittings at ribs 25, 28 and 31
- R18 and 23 flap hinge arm and fixed trailing edge panel
strut pick-up fittings.
July 19,2012 LEVEL 3 13

57-23 ATR 72-500
WINGS
RIBS
OUTER WING BOX - RIBS
Each outer wing box is composed of 18 ribs numbered 14 to u

31.
-Sheet Metal Ribs.
14 ribs are made of sheet metal (stamped core and added

stiffeners) :
- Ribs 15 to 21 and 25 to 31
Some of them are reinforced by added machined fittings or

flanges :
- Ribs 18 and 23 (flap hinge arm pick-up)

- Ribs 25, 28 and 31 (aileron bearing bracket pick-up)
-Machined Ribs.
- 4 Ribs are machined from 7075 alloy :

- Ribs 23 and 24 (fuel tank and vent surge tank ends)

- Ribs 14 and 22
July 19,2012 LEVEL 3 14

57-24 ATR 72-500
WINGS
SKIN AND STIFFENERS
OUTER WING BOX – SKIN PANELS
The outer box skin is composed 4 panels : - Upper Surface Skin.
- 1 Lower surface panel The outer wing upper surface skin is composed of 3 panels :
- 3 Upper surface panels.
- 2 Panels closing the box section between ribs 13 and 24.
- Lower Surface Skin.
The rear panel is removable and is attached to the forward
One single panel with integral stiffeners forms the lower panel by bolts.
surface section
of the outer box from rib13 to rib31. - 1 Panel closing the box section between ribs 24 and
31.It is attached to the other two panels by a splice bolted to
This panel has a carbon monolithic composite structure rib 24. This panel is fitted with vortex generators between rib
covered with bronze mesh. 24 and rib 28.
It is attached by light alloy rivets and HI-LITE bolts. The panels have a carbon monolithic composite structure,
covered with
bronze mesh.
July 19,2012 LEVEL 3 15

57-25 ATR 72-500
WINGS
FITTINGS AND SPLICES
OUTER WING BOX - FITTINGS
- Flap Hinge Arms. - Spoiler Bearing Fittings
The outboard flap hinge arms are located at ribs 18 and 23. The spoiler is hinged on three bearings, the bearing center
They accommodate the flap hinge bearings and consist of fitting consists of two machined flanges attached to the lower
machined fittings attached to the machined fittings and upper spar flanges and anchors the spoiler actuator.
themselves attached to the rear spar. The spoiler outer bearings are clevis-type fittings attached to
the rear spar upper flange.
The arm at rib 18 also accommodates the flap actuator
anchor. These arms are made of aluminum alloy.
- Aileron Bearing Fittings
The three aileron bearing fittings are located at ribs 25, 28

and 31.
These fittings are machined from aluminum thick plate and
are attached to the wing rear spar at the web and flanges.
These fittings are terminated by clevises and are embedded
laterally.
The center fitting picks up the aileron axial loads and includes
the aileron travel stops.
July 19,2012 LEVEL 3 16

57-30 ATR 72-500
WINGS
WING TIPS
WING TIPS
- Wing Tips
The wing tips are located at the end of the outer wing boxes.
They provide aerodynamic continuity between the wing and

the aileron horn.
The wing tips accommodate the navigation lights at the front

end.
They are made of a monolithic kevlar structure and are

protected against lightning by Alumesh fabric and metallic
strips.
July 19,2012 LEVEL 3 17

57-40 ATR 72-500
WINGS
LEADING EDGES
LEADING EDGE
- Leading Edges
Each wing includes six leading edge elements :
-Two leading edges on the center wing,

-Four leading edges on the outer wing.
The inner wing leading edges are attached to the spar

flanges.
Except for the two intermediate elements of the outer wing

leading edge which are metallic, the leading edges are of
composite structure.
The outer wing leading edges (metallic leading edges

and composite leading edges) and the leading edge of center
wing have integrated pneumatic de icers.
July 19,2012 LEVEL 3 18

57-50 ATR 72-500
WINGS
TRAILING EDGES
TRAILING EDGEDS
- Trailing Edges
The trailing edges include :
- Inboard flaps
- Outboard flaps
- Lower moving panels
- Upper fixed trailing edge panels
Each flap is hinged on three bearings, a center bearing and a

bearing at each end.
Each flap is controlled by a hydraulic actuator located at the

center bearing.
Inboard and outboard flaps on a same side are
interconnected by a junction rod.
- The upper fixed trailing edge panels are composed of one

element for the center wing and one element for the outer
wing.
- The lower moving panels are split to allow passage for the
flap hinge arms.
In the aileron zone, the extremely small trailing edge is
composed of a slight overlapping of the lower surface and
upper surface panels.
July 19,2012 LEVEL 3 19

57-52 ATR 72-500
WINGS
INBOARD FLAP
INBOARD FLAPS
- Inboard Flaps.
The inboard flap is composed of a main flap and lower

moving panel cam guides.
The structure of the main flap is composed of :
- Light alloy framework including :

. Spar
. Complete ribs (one at each bearing)
. Leading edge ribs (forward of the spar) which accommodate

the lower moving panel cam guides trailing edge strip.
- Upper surface and lower surface skin panels made of

sandwich type composite. These skin panels include lightning
protection bronze mesh on their outer surface.
Hinge arms made of machined parts, attached to the ribs

and accommodating the hinge bearings (ball joint roller
bearings).
Cam guides guide the movement of the lower moving panels.
July 19,2012 LEVEL 3 20

57-52 ATR 72-500
WINGS
INBOARD FLAP
INBOARD FLAPS
July 19,2012 LEVEL 3 21

57-53 ATR 72-500
WINGS
OUTBOARD FLAP
OUTBOARD FLAPS
Each outer wing accommodates an outboard flap. These

outboard flaps are hinged at wing ribs 13, 18 and 23.
The outboard flap design is similar to the one of the inboard
flap.
July 19,2012 LEVEL 3 22

57-53 ATR 72-500
WINGS
OUTBOARD FLAP
LOWER MOVING PANELS
The moving panels are sandwich type composite panels.

They are hinged on a piano hinge screwed to a section
attached to the box lower flange. By means of rollers and
springs, they bear on the cam guides attached to the flap
leading edges.
When the flaps are deflected, the moving panels are

retracted inside the profile thus improving the flap
aerodynamic flow. These moving panels allow access to the
rear spar equipment.
July 19,2012 LEVEL 3 23

57-54 ATR 72-500
WINGS
TRAILING EDGE
UPPER FIXED TRAILING EDGE PANELS
The fixed trailing edge panels are sandwich composite

panels. A Tedlar film ensures the sealing of the sandwich by
virtue of a small number of fabric plies.
They are screwed to the upper flanges of the boxes and are
cross-braced by struts picked up on the lower flanges.
July 19,2012 LEVEL 3 24

57-60 ATR 72-500
WINGS
AILERON
AILERON - GENERAL
The aileron includes : - Overlapping leading edge providing part of the aerodynamic
balance and composed of skin, ribs and a small metallic spar.
- Load carrying box composed of skin panels and ribs made This small spar receives part of the aileron balance weights.
of unidirectional carbon tapes, light alloy spar and strip.
- End horn providing part of the aerodynamic balance. It
- Bronze mesh on the surface of the skin panels and metallic receives, at the front, the rest of the balance weights and an
strips which connect the strip to the spar, providing lightning electrical anti-icing system. It is composed of composite skin
protection. panel, lightning protection being provided by bronze mesh
and metallic strips.
- Aileron bearings attached to the front spar, the center
bearing accommodates the control bellcrank and picks up the - A gust lock enabling locking of ailerons when aircraft is on
axial loads, the outer bearings in shackle form axial freedom. ground.
- Tab composed of skin, ribs and spar, made of unidirectional

carbon tapes and a metallic strip. It is controlled by the
aileron control bellcranck and is hinged on four ball joints.
Tab balancing is ensured by a balance weight.
July 19,2012 LEVEL 3 25

57-60 ATR 72-500
WINGS
AILERON
AILERON - GENERAL
- Lower Surface.
July 19,2012 LEVEL 3 26

57-70 ATR 72-500
WINGS
SPOILERS
SPOILER - GENERAL
The spoiler is made of a metallic honeycomb/light alloy skin

sandwich structure and includes a metallic strip connected to
the hinge fittings by electrical bonding strips. It is hinged on
three bearings (gooseneck fittings and ball joint bearings)
and controlled by a hydraulic actuator at its center bearing.
- Fittings
The spoiler is hinged on three bearings, the bearing center

fitting is composed of two machined flanges attached to the
lower and upper spar flanges and anchors the spoiler
actuator.
The spoiler outer bearings are clevis-type fittings attached to

the rear spar upper flange.
July 19,2012 LEVEL 3 27

57-90 ATR 72-500
WINGS
WING FAIRINGS
FLAP HINGED ARM FAIRING
The wing is equipped with fairings to protect the flap hinge

arms.
- Flap Hinge Arm Fairings
The flap arm fairings are made of sandwich type composite.
They are composed of three elements :
-Front fairing attached to the wing box
- Two-element rear fairing attached to the flap

July 19,2012 LEVEL 3 28

57-90 ATR 72-500
WINGS
WING FAIRINGS
CPCICF
July 19,2012 LEVEL 3 29

57-90 ATR 72-500
WINGS
WING FAIRINGS
CPCICF
July 19,2012 LEVEL 3 30

57-90 ATR 72-500
WINGS
WING FAIRINGS
CPCICF
July 19,2012 LEVEL 3 31

57-90 ATR 72-500
WINGS
WING FAIRINGS
CPCICF
July 19,2012 LEVEL 3 32

57-00 ATR 72-500
WINGS
MAINTENANCE PROCEDURE CHECK OF WING ACCESS DOORS

CONDUCTIVITY
1. Connect a milliohmmeter tip to the engine mount reference
point.
2. Connect the other milliohmmeter tip (with 100 deg. Cone

adapter) to the door to be checked.
3. Energize the milliohmmeter.
Warning: the current value imperatively limited to 0.1a.
Note: energize the milliohmmeter, only after the

measurement tip is in contact with the access door to be
checked.
4. Perform the measurement between the Access door and

the engine mount.
Note : to obtain correct measurement, the Milliohmmeter tip

must pass through the door protective coating to be in
contact with the bare metal.
5. Make sure that the conductivity value is less than 12

milliohms. In the contrary case, make sure that the access
door was closed in accordance with the job
Instruction card and perform a new measurement.
Note: contact aircraft manufacturer if the value is still more

than 12 milliohms.
July 19,2012 LEVEL 3 33

57-00 ATR 72-500
WINGS
MAINTENANCE PROCEDURES
July 19,2012 LEVEL 3 34

57-00 ATR 72-500
WINGS
July 19,2012 LEVEL 3 35

57-00 ATR 72-500
WINGS
July 19,2012 LEVEL 3 36

57-00 ATR 72-500
WINGS
July 19,2012 LEVEL 3 37

57-00 ATR 72-500
WINGS
July 19,2012 LEVEL 3 38

57-00 ATR 72-500
WINGS
END OF MODULE
July 19,2012 LEVEL 3 39

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ATR 72-500

ATA 57 Mantenimiento e Ingeniería Aeronáutica

del Atlántico Sur S.L hereinafter

BINTERTECHNIC, with registered

offices at the Airport of Gran Canaria,

Telde, and with tax registration

EASA Part-66 number(CIF) B-35980937,and entered

in the Las Palmas'Business Register on

AEROPUERTO DE GRAN CANARIA

Commercial Dpt. +34 682 776 880

July 19,2012 LEVEL 3 0

The ATR is equipped with a high wing composed of three

- rectangular center wing box

The surface area of the wing is 61 m square (656.4 sq.ft) and

The following secondary structures are attached to the main

July 19,2012 LEVEL 3 1

July 19,2012 LEVEL 3 2

CENTER WING BOX

- Center Wing Box

The center wing box structure is made of light alloy and

July 19,2012 LEVEL 3 3

CENTER WING BOX

The center wing box is attached to the fuselage by 8 lower

The engine nacelle pick-up fittings are located at ribs 10, 11

July 19,2012 LEVEL 3 4

CENTER WING BOX - FRONT AND REAR SPAR

The front spar accommodates : The rear spar accommodates :

July 19,2012 LEVEL 3 5

CENTER WING BOX - FRONT AND REAR SPAR

July 19,2012 LEVEL 3 6

CENTER WING BOX - RIBS

The center wing box framework is made of 27 ribs.

Some of them are reinforced by added machined fittings or

- Rib 0 (splicing of upper surface removable panels)

Machined Ribs14 ribs are machined :

- Ribs 2 (wing/fuselage junction)

- Ribs 10 (wing/engine nacelle junction and jacking point)

July 19,2012 LEVEL 3 7

CENTER WING BOX – SKIN PANELS

-Lower Surface Skin - Upper Surface Skin

bolt" type titanium fasteners installed with high interference.

July 19,2012 LEVEL 3 8

CENTER WING BOX - FITTINGS

- 4 Titanium fittings located at the intersection of ribs 2 and

-4 Steel fittings located at the intersection of ribs 4 and the

front and rear spars. These clevis-type fittings pick up the

They are each attached to the center box by four tension

July 19,2012 LEVEL 3 9

CENTER WING BOX - FITTINGS

- 20 tension bolts for the upper panels installed in piano

- 4 tension bolts (2 on lower surface, 2 on upper surface) and

- 4 tension bolts (2 on lower surface, 2 on upper surface) and

July 19,2012 LEVEL 3 10

CENTER WING BOX - FITTINGS

- Flap Hinge Arms. o

The arm at rib 4 is a double fitting which also accommodates

The fitting at rib 8 accommodates the flap control actuator

July 19,2012 LEVEL 3 11

OUTER BOX - GENERAL