TO: Recipients of the CF6-80E1 Fan Reverser Component Maintenance

Manual, MR 99440

SUBJECT: CF6-80E1 Fan Reverser Component Maintenance Manual (CMM),

MR 99440, Revision No. 38, dated 1 December 2016.

The subject revision follows this letter of transmittal. This publication is distributed in CD-ROM
format only.

This CMM is accepted by GE for the following engine models: CF6-80E1. GE has traceability to
FAA Engineering for acceptance of this CMM as complying with 14CFR Part 33 through
Amendment 12 Sec. 33.4.

Questions or comments concerning the technical content of this publication should be directed to
Middle River Aircraft Systems Technical Support, e-mail technical_support@mras-usa.com. For
questions of comments concerning Middle River Aircraft Systems Technical Publications and
Distribution, please e-mail MRAS@GE.com.

ALL TECHNICAL DOCUMENTATION AND INFORMATION CONTAINED HEREIN, WITH RESPECT TO ASSEMBLY AND
DISASSEMBLY, CLEANING, INSPECTION METHODS AND LIMITS, REPAIR METHODS AND LIMITS, OPERATIONAL LIMITS,
LIFE LIMITS, AND THE LIKE, HAVE BEEN DEVELOPED AND APPROVED FOR USE WITH NACELLES AND PARTS THAT HAVE
BEEN MANUFACTURED AND/OR APPROVED BY GE/MRAS, AND THAT HAVE BEEN MAINTAINED IN ACCORDANCE WITH
GE/MRAS TECHNICAL DOCUMENTATION AND RECOMMENDATIONS. MRAS HAS NO CONTRACTUAL OR LEGAL
OBLIGATION FOR, NOR KNOWLEDGE OF, NON-GE/MRAS-APPROVED PARTS AND REPAIRS. ACCORDINGLY, THIS
DOCUMENT IS NOT INTENDED TO APPLY TO NON-GE/MRAS-APPROVED PARTS AND REPAIRS.

THE INFORMATION CONTAINED IN THIS DOCUMENT IS MRAS PROPRIETARY INFORMATION AND IS DISCLOSED IN
CONFIDENCE. IT IS THE PROPERTY OF MRAS AND SHALL NOT BE USED, DISCLOSED TO OTHERS, OR REPRODUCED
WITHOUT THE EXPRESS WRITTEN CONSENT OF MRAS, INCLUDING, BUT WITHOUT LIMITATION, IT IS NOT TO BE USED IN
THE CREATION, MANUFACTURE, DEVELOPMENT, OR DERIVATION OF ANY REPAIRS, MODIFICATIONS, SPARE PARTS,
DESIGNS, OR CONFIGURATION CHANGES OR TO OBTAIN FAA OR ANY OTHER GOVERNMENT OR REGULATORY
APPROVAL TO DO SO. IF CONSENT IS GIVEN FOR REPRODUCTION IN WHOLE OR IN PART, THIS NOTICE AND THE NOTICE
SET FORTH ON EACH PAGE OF THIS DOCUMENT SHALL APPEAR IN ANY SUCH REPRODUCTION IN WHOLE OR IN PART.

THIS TECHNICAL DATA IS CONSIDERED E. A. R. WITH AN EXPORT CONTROL CLASSIFICATION NUMBER (ECCN) OF 9E991,
AND IS CONTROLLED PURSUANT TO 15 CFR PARTS 730-774 RESPECTIVELY. TRANSFER OF THIS DATA BY ANY MEANS
TO A NON-U. S. PERSON, WHETHER IN THE UNITED STATES OR ABROAD, WITHOUT THE PROPER U. S. GOVERNMENT
AUTHORIZATION (E.G., LICENSE, EXEMPTION, N. L. R., ETC.), IS STRICTLY PROHIBITED.

MIDDLE RIVER AIRCRAFT SYSTEMS

CF6 Technical Publications
 FAN REVERSER
CF6-80E1 CMM

THIS PAGE INTENTIONALLY BLANK

 MR 99440

TURBOFAN ENGINE
FAN REVERSER
COMPONENT MAINTENANCE MANUAL
WITHOUT
ILLUSTRATED PARTS LIST

PART NUMBERS
683L269G01 683L270G01
683L269G02 683L270G02
683L269G03 683L270G03
683L269G04 683L270G04

ALL TECHNICAL DOCUMENTATION AND INFORMATION CONTAINED HEREIN, WITH RESPECT TO ASSEMBLY AND DISASSEMBLY, CLEANING,
INSPECTION METHODS AND LIMITS, REPAIR METHODS AND LIMITS, OPERATIONAL LIMITS, LIFE LIMITS, AND THE LIKE, HAVE BEEN
DEVELOPED AND APPROVED FOR USE WITH NACELLES AND PARTS THAT HAVE BEEN MANUFACTURED AND/OR APPROVED BY GE/MRAS,
AND THAT HAVE BEEN MAINTAINED IN ACCORDANCE WITH GE/MRAS TECHNICAL DOCUMENTATION AND RECOMMENDATIONS. MRAS HAS
NO CONTRACTUAL OR LEGAL OBLIGATION FOR, NOR KNOWLEDGE OF, NON-GE/MRAS-APPROVED PARTS AND REPAIRS. ACCORDINGLY,
THIS DOCUMENT IS NOT INTENDED TO APPLY TO NON-GE/MRAS-APPROVED PARTS AND REPAIRS.

THE INFORMATION CONTAINED IN THIS DOCUMENT IS MRAS PROPRIETARY INFORMATION AND IS DISCLOSED IN CONFIDENCE. IT IS THE
PROPERTY OF MRAS AND SHALL NOT BE USED, DISCLOSED TO OTHERS, OR REPRODUCED WITHOUT THE EXPRESS WRITTEN CONSENT OF
MRAS, INCLUDING, BUT WITHOUT LIMITATION, IT IS NOT TO BE USED IN THE CREATION, MANUFACTURE, DEVELOPMENT, OR DERIVATION OF
ANY REPAIRS, MODIFICATIONS, SPARE PARTS, DESIGNS, OR CONFIGURATION CHANGES OR TO OBTAIN FAA OR ANY OTHER GOVERNMENT
OR REGULATORY APPROVAL TO DO SO. IF CONSENT IS GIVEN FOR REPRODUCTION IN WHOLE OR IN PART, THIS NOTICE AND THE NOTICE
SET FORTH ON EACH PAGE OF THIS DOCUMENT SHALL APPEAR IN ANY SUCH REPRODUCTION IN WHOLE OR IN PART. THE INFORMATION
CONTAINED IN THIS DOCUMENT MAY ALSO BE CONTROLLED BY U. S. EXPORT CONTROL LAWS. UNAUTHORIZED EXPORT OR RE-EXPORT IS
PROHIBITED. ECCN 9E991, NO LICENSE REQUIRED (NLR).

ISSUED: APR 01/94

REVISED: DEC 01/16
 FAN REVERSER
CF6-80E1 CMM

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 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

RECORD OF REVISIONS

REV. ISSUE DATE REV ISSUE DATE

NO. DATE INSERTED BY NO. DATE INSERTED BY

Basic APR 01/94 16 JUN 01/04

01 JUN 01/95 17 DEC 01/04

02 DEC 01/95 18 DEC 01/05

03 JUN 01/97 19 JUN 01/06

04 DEC 01/97 20 DEC 01/06

05 JUN 01/98 21 JUN 01/07

06 DEC 01/98 22 JUN 01/08

07 JUN 01/99 23 JUN 01/09

08 DEC 01/99 24 DEC 01/09

09 JUN 01/00 25 JUN 01/10

10 DEC 01/00 26 DEC 01/10

11 JUN 01/01 27 JUN 01/11

12 DEC 01/01 28 DEC 01/11

13 JUN 01/02 29 JUN 01/12

14 DEC 01/02 30 DEC 01/12

15 DEC 01/03 31 JUN 01/13

Retain this record in the front of manual. On receipt of revisions, insert revised sections in the manual, and
enter revision number, date inserted and name.

PAGE 1
RR JUN 01/13
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MAINTENANCE
MANUAL

683L SERIES

RECORD OF REVISIONS (Cont’d)

REV. ISSUE DATE REV ISSUE DATE

NO. DATE INSERTED BY NO. DATE INSERTED BY

32 DEC 01/13

33 JUN 01/14

34 DEC 01/14

35 JUN 01/15

36 DEC 01/15

37 JUN 01/16

R 38 DEC 01/16

Retain this record in the front of manual. On receipt of revisions, insert revised sections in the manual, and
enter revision number, date inserted and name.

PAGE 2
RR DEC 01/16
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MAINTENANCE
MANUAL

683L SERIES

RECORD OF TEMPORARY REVISIONS

TEMPORARY SECTION ISSUE DATE

REV. NO. PAGE NUMBER DATE BY REMOVED BY
78-001 Front Matter OCT 03/94 NOV 14/94
Time Limits
78-002 Front Matter NOV 14/94 JUN 01/95
Time Limits
78-003 78-32-10 JUN 15/12 DEC 01/12
Repair 001
78-004 78-32-10 JUN 15/12 DEC 01/12
Inspection
78-005 78-32-02 JUN 15/12 DEC 01/12
Repair 010
78-006 78-32-02 JUN 15/12 DEC 01/12
Inspection
78-007 78-32-09 FEB 28/14 JUN 01/14
Repair 006
78-008 78-32-09 FEB 28/14 JUN 01/14
Inspection
78-009 78-32-31 MAR 14/14 JUN 01/14
Repair 019

PAGE 1
RTR JUN 01/14
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CF6-80E1 CMM

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 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

SERVICE BULLETIN LIST

Service Bulletin Incorporated

Number in Revision Description

78-0001 No Effect Fan Reverser - Retrofit of CF6-80E1 Flight Test

Fan Reversers

78-0002 Rev. 01 Fan Reverser - Precooler Inlet Flow Diverter -

Introduction

78-0003 No Effect Fan Reverser - Power Door Opening Fitting -

(REV 01) No Effect Rework
(REV 02) No Effect

78-0004 No Effect Spare Parts Release

R (REV 01) No Effect

78-1001 Rev. 01 Fan Reverser - Actuation System Lock - Life

Limit

78-1002 No Effect Fan Reverser - Upper Duct Sidewall Fireseal -

(REV 01) No Effect Rework

78-5003 No Effect Exhaust – Fan Reverser – Directional Pilot

(REV 01) No Effect Solenoid Valve – Rework (Ref: AlliedSignal S/B
78-1521)

78-5004 No Effect Engine Exhaust - Lock Brake Assembly -

(REV 01) No Effect Rework Lock Brake Assembly

78-5005 No Effect Spare Parts Release

78-5006 No Effect Fan Reverser - Improved Actuation System

(REV 01) No Effect Lock - Introduction

78-5007 No Effect Exhaust – Fan Reverser – Actuator Feedback

Subsystem – Rework (Ref: AlliedSignal S/B 78-
1532)

78-5008 Rev. 02 Fan Reverser - Tee Track Wear Strip -

Replacement

78-5009 No Effect Fan Reverser - Improved Hold Open Rod

Bracket and Clamp - Introduction

78-5010 No Effect Spare Parts Release

PAGE 1
SB LIST DEC 01/16
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

Service Bulletin Incorporated

Number in Revision Description

78-5011 No Effect Exhaust – Fan Reverser – Autonomous Air

(REV 01) No Effect Supply Valve – Rework (Ref: AlliedSignal S/B
78-1570)

78-5012 No Effect Spare Parts Release

78-5013 No Effect Fan Reverser - Blocker Door Face Sheet -

(REV 01) No Effect Introduction

78-5014 No Effect Spare Parts Release

78-5015 No Effect Spare Parts Release

78-5016 No Effect Spare Parts Release

78-5018 No Effect Spare Parts Release

78-5019 No Effect Spare Parts Release

78-5020 No Effect Spare Parts Release

78-5021 No Effect Exhaust – Fan Reverser – Autonomous Air

(REV 01) No Effect Supply Valve – Rework (Ref: AlliedSignal S/B
78-1573)

78-5022 No Effect Exhaust – Fan Reverser – Core Cowl Interlock

(REV 01) No Effect Valve - Deactivation

78-5023 No Effect Spare Parts Release

78-5024 No Effect Spare Parts Release

78-5025 No Effect Spare Parts Release

78-5026 Rev. 06 Spare Parts Release

(REV 01) No Effect

78-5027 No Effect Exhaust - Fan Reverser - Rotary Variable

Displacement Transducer - Replacement

78-5028 No Effect Exhaust - Fan Reverser - Fastener Change at

(REV 01) No Effect Interface of Torque Box Ring and Forward Edge
R (REV 02) No Effect of Center Flow Web

78-5029 No Effect Spare Parts Release

78-5030 No Effect Spare Parts Release

PAGE 2
SB LIST DEC 01/16
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

Service Bulletin Incorporated

Number in Revision Description

78-5031 No Effect Exhaust - Fan Reverser - Refurbish IDG Access

Door Latch

78-5032 No Effect Exhaust - Fan Reverser - One Piece Wear Strip

for CF6-80E Torque Box - Introduction

78-5033 No Effect Exhaust - Fan Reverser - Forward Latch

R (REV 01) No Effect Assembly - Field Modification of Forward Latch
Assembly

78-5035 No Effect Spare Parts Release

78-5036 No Effect Exhaust - Fan Reverser - Forward Latch

Assembly - Field Installation of Caution Decal

78-5037 TBD Exhaust - Fan Reverser - Translating Cowl

R (REV 01) TBD P-Seals - Introduction

78-5038 No Effect Exhaust - Fan Reverser - Forward Latch

Assembly Improvements - Improved Bottom
Latch

78-5039 No Effect Exhaust - Fan Reverser - Forward Latch

Assembly Improvements - Improved Cable
Brackets
78-5040 No Effect Exhaust - Fan Reverser - Forward Latch
Assembly Improvements - Improved Cam

78-5041 No Effect Exhaust - Fan Reverser - Aft Cascade Support

R (REV 01) No Effect Ring - Improved Brackets at Latch and Hinge
Beam
78-5042 No Effect Spare Parts Release

78A5043 Rev. 012 Exhaust - Fan Reverser - Retention Service

R (REV 01) No Effect Checks
R (ADDENDUM 01) No Effect

78-5044 No Effect Spare Parts Release

78-5045 No Effect Exhaust - Fan Reverser - Alternate Flexible

Shaft Assemblies - Introduction

78-5046 No Effect Exhaust - Fan Reverser - Rework the Center

(REV 01) No Effect Drive Unit Actuator
(REV 02) No Effect

PAGE 3
SB LIST DEC 01/14
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

Service Bulletin Incorporated

Number in Revision Description

78-5047 Rev. 014 Exhaust - Fan Reverser - Forward Latch

(REV 01) No Effect Assembly Improvements

78-5048 No Effect Exhaust - Fan Reverser - Provide Additional

(REV 01) No Effect Clearance Between the Aft Cascade Support
Ring and the Translating Cowl Longeron Studs

78-5049 No Effect Exhaust - Fan Reverser - Rework the Actuator

(REV 01) No Effect Feedback Subsystem

78-5050 No Effect Exhaust - Fan Reverser - Alternate Flex Shaft

Assemblies - Introduction

78-5051 Rev. 09 Exhaust - Fan Reverser - Removal of Unused

Cover Plate from Auxiliary Drive Pad of Actuator
Feedback Subsystem

78-5052 No Effect Exhaust - Fan Reverser - Directional Pilot

(REV 01) No Effect Solenoid Valve - Service Evaluation

78A5053 No Effect Exhaust - Fan Reverser - DPV Leak Check

(REV 01) No Effect
R (REV 02)

78-5054 No Effect Exhaust - Fan Reverser - One-Piece Aft Fairing

Channel - Introduction

78-5055 No Effect Exhaust - Fan Reverser - Rework Autonomous

(REV 01) No Effect Air Supply Valve
(REV 02) No Effect

78-5056 No Effect Spare Parts Release

78-5057 No Effect Exhaust - Fan Reverser - Rework Center Drive

(REV 01) No Effect Unit Actuator

78-5058 No Effect Exhaust - Fan Reverser - Rework Actuator

Feedback Subsystem

78-5059 No Effect Exhaust - Fan Reverser - Rework Ballscrew

(REV 01) No Effect Gearbox Assembly

78-5060 No Effect Exhaust - Fan Reverser - Provide Additional

(REV 01) No Effect Clearance Between the Aft Cascade Support
(REV 02) No Effect Ring Bumper Attaching Rivets and the
Translating Cowl Longeron Studs

PAGE 4
SB LIST DEC 01/16
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

Service Bulletin Incorporated

Number in Revision Description

78-5061 No Effect Exhaust - Fan Reverser - Relocation of Drainage

R (REV 01) No Effect Holes in Pneumatic Signal Air Tubes
R (REV 02) No Effect

78-5062 No Effect Spare Parts Release

78-5063 No Effect Exhaust - Fan Reverser - Introduction of Steel

R (REV 01) No Effect Wearstrips to Reduce Blowout Door and Access
Door Latch Wear on Lower Closeout Tee

78-5064 No Effect Spare Parts Release

78-5065 No Effect Spare Parts Release

78-5066 No Effect Engine – Fan Module – Upper Latch Assembly –

Improved Adapter (U-bolt) Assemblies

78-5067 No Effect Spare Parts Release

78-5068 No Effect Spare Parts Release

78-5069 No Effect Spare Parts Release

78-5070 No Effect Spare Parts Release

78-5071 No Effect Spare Parts Release

78-5072 No Effect Spare Parts Release

78-5073 Rev. 31 Exhaust – Fan Reverser – Torque Box Field

Rework

78-5074 No Effect Spare Parts Release

78-5075 No Effect Exhaust – Fan Reverser – Translating Cowl –

Inner Bondment Void Condition - Inspection

R 78-5076 No Effect Exhaust – Fan Reverser – Conversion of an

R (REV 01) No Effect Airbus A330 Position 1 Configured Fan Reverser
R to an Airbus A330 Position 2 Configured Fan
R Reverser and Vice Versa

78-5077 Rev. 15 Exhaust – Fan Reverser – Torque Box Outer

R (REV 01) No Effect Ring Inspection and Repair – Shimming of
R (REV 02) No Effect Translating Cowl Bumpers

PAGE 5
SB LIST DEC 01/14
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

Service Bulletin Incorporated

Number in Revision Description

78-5078 No Effect Exhaust – Fan Reverser – TRAS Lock Holding

Torque Check – One-time Inspection

78-5079 No Effect Exhaust – Fan Reverser – Improved Lockout

Plate Fasteners

78-5080 No Effect Spare Parts Release

78-5081 No Effect Exhaust – Fan Reverser – Additional Clamp for

R (REV 01) Forward Latch Cables

78-5082 No Effect Exhaust – Fan Reverser – Blocker Door

Inspection

78-5083 No Effect Exhaust – Fan Reverser – Translating Cowl -

Longeron Attach Bolts - Potted Hard Point
Mislocation - Inspection and Repair

78-5084 No Effect Spare Parts Release

78-5085 No Effect Exhaust – Fan Reverser – Identification Plate for

Recording Service Bulletin Accomplishment

78-5086 No Effect Exhaust – Fan Reverser – Precooler Duct

(REV 01) No Effect Assembly (SPD)

78-5087 No Effect Spare Parts Release

78-5088 No Effect Exhaust – Fan Reverser – Directional Pilot

(REV 01) No Effect Valve – Improved Pressure Switch
(ADDENDUM 01) No Effect

78-5089 No Effect Exhaust – Fan Reverser – Replace Flexible

Shaft Assembly Part No. 3278500-5 with
Flexible Shaft Assembly Part No. 3278500-7

78-5090 No Effect Exhaust – Fan Reverser – Fixed Structure

Assembly – Unisink Head Rivets for Sidewall
Fairings

78-5091 No Effect Exhaust – Fan Reverser – Blocker Door Trim

and Cascade Bolt Change – Elimination of
Interference with Aft Cascade Support Ring

PAGE 6
SB LIST DEC 01/16
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

Service Bulletin Incorporated

Number in Revision Description

78-5092 No Effect Exhaust – Fan Reverser – Improved Precooler

R (REV 01) No Effect Duct Flexible Seal Assembly
R (REV 02) No Effect

78-5095 No Effect Spare Parts Release

78-5096 No Effect Exhaust – Fan Reverser – Removal of Washer

R (REV 01) No Effect from Under Head of Each Hinge Bolt

78A5097 No Effect Exhaust – Fan Reverser – Check of the TRAS

Lock Flexible Shaft Assemblies after an Aborted
Take-off

78-5098 No Effect Spare Parts Release

78-5100 No Effect Exhaust – Fan Reverser – Clean and Inspect the

Pinion Bevel Gear Set of Ballscrew Gearboxes
Suspected of Having a Corrosion Condition

78-5101 No Effect Spare Parts Release

78-5102 No Effect Spare Parts Release

78-5104 No Effect Spare Parts Release

78-5106 No Effect Spare Parts Release

R 78-5107 No Effect Exhaust – Fan Reverser – Forward Latch

R Assembly - Replacement

78-5108 No Effect Exhaust – Fan Reverser – Translating Cowl –

Improved Clevis/Longeron Fasteners

R 78-5110 No Effect Exhaust – Fan Reverser – Power Opening

R (REV 01) No Effect Device Support Structure - Replacement

78-5111 No Effect Spare Parts Release

78-5112 No Effect Exhaust – Fan Reverser – Autonomous Air

Supply System – One-time Inspection

78-5113 No Effect Exhaust – Fan Reverser – Fastener Changes to

R (REV 01) No Effect Prevent Interference between Fasteners and
Wire Harnesses

PAGE 7
SB LIST DEC 01/14
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

Service Bulletin Incorporated

Number in Revision Description

78-5114 Rev. 028 Exhaust – Fan Reverser – Hold-open Rod

(REV 01) No Effect Inspection and One-time Weld Repair
(ADDENDUM 01) No Effect

78-5115 No Effect Spare Parts Release

78-5117 No Effect Spare Parts Release

78-5118 Rev. 027 Exhaust – Fan Reverser – Aft Cascade Support

Ring – Shop Inspection

78-5119 No Effect Exhaust – Fan Reverser – Improved Precooler

Inlet Fairing Assembly and Cover Assembly

78-5120 No Effect Exhaust – Fan Reverser – Improved Precooler

Inlet Fairing Assembly and Cover Assembly

78-5123 No Effect Exhaust – Fan Reverser – Stowage Lockout

(REV 01) No Effect Indicator Bracket Assembly – Replacement of
Non-Conductive Electrical Connector with
Conductive Electrical Connector

78-5124 No Effect Exhaust – Fan Reverser – Translating Cowl –

(REV 01) No Effect Fairings – Inspection and Temporary Repairs

78-5125 No Effect Exhaust – Fan Reverser – Autonomous Air

(REV 01) No Effect Supply System – Repetitive Inspections
R (REV 02)

78-5126 Rev. 033 Exhaust – Fan Reverser – Acoustic

(REV 01) No Effect Configuration for Increased Gross Weight

78-5127 No Effect Exhaust – Fan Reverser – Hinge Beam – Tee

R (REV 01) Track Cracks – Once-through-the-Fleet
Inspection – Repair and Repair Inspection

78-5128 No Effect Exhaust – Fan Reverser – Hinge Beam – Mid

R (REV 01) Lug Cracks – Once-through-the-Fleet Inspection
– Repair and Repair Inspection

78-5129 No Effect Exhaust – Fan Reverser – Translating Cowl –

(REV 01) No Effect Improved Blocker Door Fairings – Introduction
(REV 02) No Effect

78-5130 No Effect Exhaust – Fan Reverser – CDU Cone Brake

Improvements – Rework Center Drive Unit.

PAGE 8
SB LIST DEC 01/16
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

Service Bulletin Incorporated

Number in Revision Description

78-5131 No Effect Exhaust – Fan Reverser – CDU Cone Brake

Improvements – Rework Actuator Feedback
Subsystem.

78-5132 No Effect Spare Parts Release

78-5133 Rev. 33 EXHAUST - Fan Reverser – Forward Upper

(REV 01) No Effect Latch Assembly Part No. 491B1213081-001 –
Introduction

78-5134 No Effect Exhaust – Fan Reverser – Upper PIP Fairing

Bolt Correction

78-5135 No Effect EXHAUST - Fan Reverser – Translating Cowl –

Actuator Pin Access Covers – Length Reduction
of Attaching Bolts

78-5136 No Effect Spare Parts Release

78-5137 No Effect EXHAUST – Fan Reverser – Fixed Structure

Assembly – New Core Cowl Link Hinge Fittings
for Improved Blocker Door Preload

78-5138 No Effect EXHAUST – Fan Reverser – Center Drive Unit –

R (REV 01) No Effect Directional Control Valve Improvements –
Rework
Reference: Honeywell Service Bulletin
126784-78-1692

78-5139 No Effect EXHAUST – Fan Reverser – Actuator Feedback

R (REV 01) No Effect Subsystem – Directional Control Valve
Improvements – Rework Actuator Feedback
Subsystem Part Numbers 3269086-35/-36 to
Part Numbers 3269086-39/-40
Reference: Honeywell Service Bulletin
3269086-78-1694

78-5140 No Effect EXHAUST – Fan Reverser – Torque Box –

Improved Rub Strips

78-5143 No Effect EXHAUST – Fan Reverser – Conversion of a

Spare Actuator Feedback Subsystem
Configured for Use on a Left-Hand Fan Reverser
Half to the Configuration for Use on a Right-
Hand Fan Reverser Half and Vice Versa

PAGE 9
SB LIST DEC 01/16
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

Service Bulletin Incorporated

Number in Revision Description

R 78-5144 No Effect EXHAUST – Fan Reverser – Troubleshooting

R Thrust Reverser Faults – Thrust Reverser
R Actuation System (TRAS) Lock – Running
R Torque Inspection

R 78-5146 No Effect EXHAUST – Fan Reverser – Autonomous Air

R Supply System – Repetitive Inspection
R [LIMITED DISTRIBUTION]

PAGE 10
SB LIST JUN 01/16
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

HIGHLIGHTS - REVISION NO. 38 DATED DEC 01/16

CHAPTER/SECTION/PAGE DESCRIPTION OF CHANGE

SB List Updated SB List to reflect addition of new SB issue

LEP Revised to reflect this revision

78-32-02 Change step A.(10) to make the repair bushing and

Repair 018 washer for the aft bushing hole.
Page 610

78-32-02 Added Brolite (C04-024) to list of Consumable

Repair 022 Materials. Added (C01-015) to step D. Added step
Pages 603, 607-608, 622 J.(4).

78-32-02 Added note to omit primer on surface common to

Repair 027 electrical connector interface.
Page 613

78-32-09 Added latch release requirements to Table 501. Added

Inspection Fig. 502. Added IDG door hinge requirements to Table
Pages 504-505, 509-510 501. Added Fig. 503

78-32-31 Added Refer to Figure 605 to step 2.A.(3). Added step

Repair 016 (f) to 5.G. Added new figure 605 sheet 1 and figure
Pages 601, 615-617 605 sheet 2.

PAGE 1
HIGHLIGHTS DEC 01/16
 FAN REVERSER
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 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

LIST OF EFFECTIVE PAGES

CHAPTER/SECTION PAGE DATE CHAPTER/SECTION PAGE DATE

R TITLE 1 DEC 01/16 78-32-00 101 DEC 01/98
RIGGING 102 DEC 01/98
ROR 1 JUN 01/13 103 DEC 01/98
R 2 DEC 01/16 104 DEC 01/98
105 DEC 01/98
RTR 1 JUN 01/14 106 DEC 01/00
107 DEC 01/98
R SB-LIST 1 DEC 01/16 108 JUN 01/15
R 2 DEC 01/16 109 DEC 01/98
3 DEC 01/14 110 DEC 01/03
R 4 DEC 01/16 111 DEC 01/03
5 DEC 01/14 112 DEC 01/03
R 6 DEC 01/16 113 DEC 01/98
7 DEC 01/14 114 DEC 01/98
R 8 DEC 01/16
R 9 DEC 01/16 78-32-00 101 DEC 01/98
10 JUN 01/16 TESTING 102 DEC 01/98
103 DEC 01/98
R LEP 1 DEC 01/16 104 DEC 01/98
R 2 DEC 01/16 105 DEC 01/05
R 3 DEC 01/16
R 4 DEC 01/16 78-32-00 301 DEC 01/13
R 5 DEC 01/16 DISASSEMBLY 302 DEC 01/98
R 6 DEC 01/16 303 DEC 01/98
R 7 DEC 01/16 304 DEC 01/98
R 8 DEC 01/16 305 JUN 01/14
R 9 DEC 01/16 306 DEC 01/98
R 10 DEC 01/16 307 DEC 01/98
R 11 DEC 01/16 308 JUN 01/14
R 12 DEC 01/16 309 DEC 01/10
310 JUN 01/14
R CONTENTS 1 DEC 01/16 311 JUN 01/14
2 JUN 01/16 312 JUN 01/14
R 3 DEC 01/16 313 JUN 01/14
R 4 DEC 01/16 314 JUN 01/14
315 JUN 01/14
INTRO 1 JUN 01/14 316 JUN 01/14
2 DEC 01/98 317 JUN 01/14
318 JUN 01/14
TIME LIMITS 1 DEC 01/01 319 JUN 01/15
320 JUN 01/15
78-32-00 1 DEC 01/98 321 JUN 01/15
DESC & OPER 2 DEC 01/98
3 DEC 01/98
4 DEC 01/98

A = ADDITION; D = DELETION; R = REVISION

PAGE 1
LEP DEC 01/16
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MANUAL

683L SERIES

LIST OF EFFECTIVE PAGES

CHAPTER/SECTION PAGE DATE CHAPTER/SECTION PAGE DATE

78-32-00 322 JUN 01/15 78-32-00 726 JUN 01/15
DISASSEMBLY 323 JUN 01/15 ASSEMBLY 727 JUN 01/15
(Cont'd) 324 JUN 01/15 (Cont’d) 728 JUN 01/15
325 JUN 01/15 729 JUN 01/15
326 JUN 01/15 730 JUN 01/15
327 JUN 01/15 731 JUN 01/15
328 JUN 01/15 732 JUN 01/15
329 JUN 01/15 733 JUN 01/15
330 JUN 01/15 734 JUN 01/15
331 JUN 01/15 735 JUN 01/15
332 JUN 01/15 736 JUN 01/15
333 JUN 01/15 737 JUN 01/15
334 JUN 01/15 738 DEC 01/15
335 JUN 01/15 739 JUN 01/15
336 JUN 01/15 740 JUN 01/15
337 JUN 01/15 741 JUN 01/15
338 JUN 01/15 742 JUN 01/15
339 JUN 01/15 743 JUN 01/15
744 JUN 01/15
78-32-00 401 JUN 01/11 745 JUN 01/15
CLEANING 402 JUN 01/11 746 JUN 01/15
403 JUN 01/11 747 JUN 01/15
404 JUN 01/11 748 JUN 01/15
749 JUN 01/15
78-32-00 701 DEC 01/13 750 JUN 01/15
ASSEMBLY 702 JUN 01/14 751 JUN 01/15
703 JUN 01/15 752 JUN 01/15
704 JUN 01/15 753 JUN 01/15
705 JUN 01/15 754 JUN 01/15
706 JUN 01/15 755 JUN 01/15
707 JUN 01/15 756 JUN 01/15
708 JUN 01/15 757 JUN 01/15
709 JUN 01/15 758 JUN 01/15
710 JUN 01/15 759 JUN 01/15
711 JUN 01/15 760 JUN 01/15
712 JUN 01/15
713 JUN 01/15 78-32-01 501 DEC 01/98
714 JUN 01/15 INSPECTION
715 JUN 01/15
716 JUN 01/15 78-32-02 301 DEC 01/10
717 JUN 01/15 DISASSEMBLY 302 DEC 01/10
718 JUN 01/15 303 DEC 01/10
719 JUN 01/15 304 DEC 01/10
720 JUN 01/15 305 DEC 01/10
721 JUN 01/15 306 DEC 01/10
722 JUN 01/15 307 DEC 01/10
723 JUN 01/15 308 DEC 01/10
724 JUN 01/15 309 DEC 01/10
725 JUN 01/15 310 DEC 01/10

A = ADDITION; D = DELETION; R = REVISION

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DISASSEMBLY 312 DEC 01/10 DISASSEMBLY 357 DEC 01/10
(Cont’d) 313 DEC 01/10 (Cont’d) 358 DEC 01/10
314 DEC 01/10 359 DEC 01/10
315 DEC 01/10 360 DEC 01/10
316 DEC 01/10 361 DEC 01/10
317 DEC 01/10 362 DEC 01/10
318 DEC 01/10 363 DEC 01/10
319 DEC 01/10
320 DEC 01/10 78-32-02 501 DEC 01/13
321 DEC 01/11 INSPECTION 502 DEC 01/14
322 DEC 01/10 503 DEC 01/15
323 DEC 01/10 504 JUN 01/14
324 DEC 01/10 505 JUN 01/14
325 DEC 01/10 506 DEC 01/15
326 DEC 01/10 507 DEC 01/15
327 DEC 01/10 508 DEC 01/14
328 DEC 01/10 509 DEC 01/13
329 DEC 01/10 510 DEC 01/13
330 DEC 01/10 511 DEC 01/13
331 DEC 01/10 512 DEC 01/13
332 DEC 01/10 513 JUN 01/16
333 DEC 01/10 514 DEC 01/15
334 DEC 01/10 515 DEC 01/15
335 DEC 01/10 516 DEC 01/15
336 DEC 01/10 517 DEC 01/15
337 DEC 01/10 518 DEC 01/15
338 DEC 01/10 519 DEC 01/15
339 DEC 01/10 520 DEC 01/15
340 DEC 01/10 521 DEC 01/15
341 DEC 01/10 522 DEC 01/15
342 DEC 01/10 523 DEC 01/15
343 DEC 01/10 524 DEC 01/15
344 DEC 01/10 525 DEC 01/15
345 DEC 01/10 526 DEC 01/15
346 DEC 01/10 527 DEC 01/15
347 DEC 01/10 528 JUN 01/16
348 DEC 01/10
349 DEC 01/10 78-32-02 601 JUN 01/01
350 DEC 01/10 REPAIR 002 602 JUN 01/01
351 DEC 01/10 603 JUN 01/01
352 DEC 01/10
353 DEC 01/10
354 DEC 01/10
355 DEC 01/10

A = ADDITION; D = DELETION; R = REVISION

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REPAIR 004 602 JUN 01/13 REPAIR 009 607 JUN 01/13
603 JUN 01/13 (Cont’d) 608 JUN 01/13
604 JUN 01/13 609 JUN 01/13
605 JUN 01/13 610 JUN 01/13
606 JUN 01/13 611 JUN 01/13
607 JUN 01/13 612 JUN 01/13
608 JUN 01/13 613 JUN 01/13
609 JUN 01/13
610 JUN 01/13 78-32-02 601 DEC 01/12
611 JUN 01/13 REPAIR 010 602 DEC 01/12
612 JUN 01/13 603 DEC 01/12
613 JUN 01/13 604 DEC 01/12
605 DEC 01/12
78-32-02 601 DEC 01/00 606 DEC 01/12
REPAIR 005 602 DEC 01/00 607 DEC 01/12
608 DEC 01/12
78-32-02 601 JUN 01/14 609 DEC 01/12
REPAIR 006 602 JUN 01/14 610 DEC 01/12
603 JUN 01/14 611 DEC 01/12
604 JUN 01/14 612 DEC 01/12
605 JUN 01/14 613 DEC 01/12
606 JUN 01/14 614 JUN 01/15
607 JUN 01/14 615 DEC 01/12
608 JUN 01/14 616 DEC 01/12
609 JUN 01/14 617 DEC 01/12
610 JUN 01/14 618 DEC 01/12
619 DEC 01/12
78-32-02 601 DEC 01/15 620 DEC 01/12
REPAIR 007 602 DEC 01/15 621 DEC 01/12
603 DEC 01/15 622 DEC 01/12
604 DEC 01/15 623 DEC 01/12
605 DEC 01/15
606 DEC 01/15 78-32-02 601 DEC 01/98
607 DEC 01/15 REPAIR 013 602 DEC 01/98
608 DEC 01/15 603 DEC 01/98
609 DEC 01/15
78-32-02 601 DEC 01/13
78-32-02 601 DEC 01/98 REPAIR 014 602 JUN 01/02
REPAIR 008 602 DEC 01/98 603 JUN 01/02
603 DEC 01/98 604 JUN 01/02
604 DEC 01/98 605 JUN 01/02
606 JUN 01/02
78-32-02 601 JUN 01/13 607 JUN 01/07
REPAIR 009 602 JUN 01/13 608 JUN 01/02
603 JUN 01/13 609 JUN 01/02
604 JUN 01/13 610 JUN 01/02
605 JUN 01/13 611 JUN 01/02
612 JUN 01/02

A = ADDITION; D = DELETION; R = REVISION

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REPAIR 015 602 DEC 01/99 REPAIR 022 611 DEC 01/04
603 DEC 01/99 (Cont’d) 612 DEC 01/04
604 DEC 01/99 613 DEC 01/04
614 DEC 01/04
78-32-02 601 JUN 01/01 615 DEC 01/04
REPAIR 016 602 JUN 01/01 616 DEC 01/04
603 JUN 01/01 617 DEC 01/04
604 JUN 01/01 618 DEC 01/04
605 JUN 01/01 619 DEC 01/02
606 JUN 01/01 620 DEC 01/02
621 DEC 01/02
78-32-02 601 JUN 01/06 R 622 DEC 01/16
REPAIR 018 602 JUN 01/06 623 DEC 01/02
603 JUN 01/06 624 DEC 01/02
604 JUN 01/06
605 JUN 01/06 78-32-02 601 DEC 01/15
606 JUN 01/06 REPAIR 023 602 DEC 01/15
607 JUN 01/06 603 JUN 01/12
608 JUN 01/06 604 JUN 01/12
609 JUN 01/06 605 DEC 01/15
R 610 DEC 01/16 606 DEC 01/15
611 JUN 01/06 607 DEC 01/15
612 JUN 01/06 608 DEC 01/15
613 JUN 01/06 609 DEC 01/15
610 DEC 01/15
78-32-02 601 JUN 01/99 611 DEC 01/15
REPAIR 019 602 JUN 01/99 612 DEC 01/15
603 JUN 01/99 613 DEC 01/15
604 JUN 01/99 614 DEC 01/15
605 JUN 01/99 615 DEC 01/15
606 JUN 01/99 616 DEC 01/15
607 JUN 01/99 617 DEC 01/15
608 JUN 01/99 618 DEC 01/15
609 JUN 01/99 619 DEC 01/15
610 JUN 01/99 620 DEC 01/15
621 DEC 01/15
78-32-02 601 DEC 01/02 622 DEC 01/15
REPAIR 022 602 DEC 01/02 623 DEC 01/15
R 603 DEC 01/16 624 DEC 01/15
604 DEC 01/02
605 DEC 01/02 78-32-02 601 DEC 01/10
606 DEC 01/02 REPAIR 024 602 DEC 01/10
R 607 DEC 01/16 603 DEC 01/10
R 608 DEC 01/16 604 DEC 01/10
609 DEC 01/02 605 JUN 01/16

A = ADDITION; D = DELETION; R = REVISION

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78-32-02 601 JUN 01/12 78-32-02 618 DEC 01/14
REPAIR 025 602 DEC 01/10 REPAIR 027 619 DEC 01/14
603 DEC 01/10 (Cont’d) 620 DEC 01/14
604 DEC 01/10 621 DEC 01/14
605 DEC 01/10 622 DEC 01/14
606 DEC 01/10 623 DEC 01/14
624 DEC 01/14
78-32-02 601 DEC 01/14 625 DEC 01/14
REPAIR 026 602 DEC 01/15 626 DEC 01/14
603 DEC 01/14 627 DEC 01/14
604 DEC 01/15
605 DEC 01/14 78-32-02 601 JUN 01/15
606 DEC 01/14 REPAIR 028 602 JUN 01/15
607 DEC 01/14 603 JUN 01/15
608 DEC 01/15 604 DEC 01/14
609 DEC 01/14 605 DEC 01/14
610 DEC 01/14 606 DEC 01/14
611 DEC 01/14 607 DEC 01/14
612 DEC 01/15 608 JUN 01/15
613 DEC 01/14 609 JUN 01/15
614 DEC 01/14 610 JUN 01/15
615 DEC 01/14 611 JUN 01/15
616 DEC 01/14 612 JUN 01/15
617 DEC 01/14 613 JUN 01/15
618 DEC 01/14 614 JUN 01/15
619 DEC 01/14 615 JUN 01/15
620 DEC 01/14 616 JUN 01/15
621 DEC 01/14 617 JUN 01/15
622 DEC 01/15 618 DEC 01/14
619 DEC 01/14
78-32-02 601 DEC 01/14 620 DEC 01/14
REPAIR 027 602 DEC 01/14 621 JUN 01/15
603 DEC 01/14 622 DEC 01/14
604 DEC 01/14
605 DEC 01/14 78-32-02 701 DEC 01/11
606 DEC 01/15 ASSEMBLY 702 DEC 01/11
607 DEC 01/15 703 DEC 01/11
608 DEC 01/15 704 DEC 01/11
609 DEC 01/15 705 DEC 01/11
610 DEC 01/15 706 DEC 01/11
611 DEC 01/14 707 DEC 01/11
612 DEC 01/14 708 DEC 01/11
R 613 DEC 01/16 709 DEC 01/11
614 DEC 01/15 710 DEC 01/11
615 DEC 01/15 711 DEC 01/11
616 DEC 01/15 712 DEC 01/11
617 DEC 01/14 713 DEC 01/11
714 DEC 01/11

A = ADDITION; D = DELETION; R = REVISION

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78-32-02 715 DEC 01/11 78-32-03 503 JUN 01/06
ASSEMBLY 716 DEC 01/11 INSPECTION 504 JUN 01/06
(Cont’d) 717 DEC 01/11 (Cont’d) 505 DEC 01/13
718 DEC 01/11 506 JUN 01/06
719 DEC 01/11 507 JUN 01/06
720 DEC 01/11 508 JUN 01/06
721 DEC 01/11 509 JUN 01/06
722 DEC 01/11 510 DEC 01/13
723 DEC 01/11 511 DEC 01/13
724 DEC 01/11 512 DEC 01/13
725 DEC 01/11 513 DEC 01/13
726 DEC 01/11
727 DEC 01/11 78-32-03 601 DEC 01/98
728 DEC 01/11 REPAIR 001 602 DEC 01/12
729 DEC 01/11 603 JUN 01/08
730 DEC 01/11 604 DEC 01/98
731 DEC 01/11 605 DEC 01/98
732 DEC 01/11 606 DEC 01/98
733 DEC 01/11 607 JUN 01/02
734 DEC 01/11 608 JUN 01/08
735 DEC 01/11 609 DEC 01/98
736 DEC 01/11 610 DEC 01/98
737 DEC 01/11 611 DEC 01/98
738 DEC 01/11 612 DEC 01/98
739 DEC 01/11 613 DEC 01/98
740 DEC 01/11 614 DEC 01/98
741 DEC 01/11 615 DEC 01/98
742 DEC 01/11 616 DEC 01/98
743 DEC 01/11 617 DEC 01/98
744 DEC 01/11 618 DEC 01/98
745 DEC 01/11 619 DEC 01/98
746 DEC 01/10 620 DEC 01/98
747 DEC 01/10 621 DEC 01/12
748 DEC 01/10 622 DEC 01/98
749 DEC 01/10 623 DEC 01/98
750 DEC 01/10 624 DEC 01/98
751 DEC 01/10 625 JUN 01/08
752 DEC 01/10 626 DEC 01/98
753 DEC 01/10 627 DEC 01/05
754 DEC 01/10
755 DEC 01/10 78-32-03 601 JUN 01/01
756 DEC 01/10 REPAIR 003 602 JUN 01/15
757 DEC 01/10 603 JUN 01/15
758 DEC 01/10 604 DEC 01/98
759 DEC 01/10 605 DEC 01/98
606 JUN 01/01
78-32-03 501 DEC 01/98 607 JUN 01/01
INSPECTION 502 DEC 01/13 608 DEC 01/98

A = ADDITION; D = DELETION; R = REVISION

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REPAIR 003 610 JUN 01/01 REPAIR 009 607 JUN 01/15
(Cont’d) 611 JUN 01/01 (Cont’d) 608 JUN 01/06
612 JUN 01/01
613 JUN 01/01 78-32-03 601 DEC 01/13
614 JUN 01/01 REPAIR 010 602 JUN 01/06
615 JUN 01/01 603 JUN 01/06
604 JUN 01/06
78-32-03 601 DEC 01/06 605 JUN 01/06
REPAIR 004 602 DEC 01/06 606 JUN 01/06
603 DEC 01/06 607 JUN 01/06
604 DEC 01/06 608 JUN 01/06
605 DEC 01/06 609 JUN 01/11

78-32-03 601 DEC 01/98 78-32-03 601 DEC 01/98

REPAIR 005 602 DEC 01/98 REPAIR 011 602 DEC 01/12
603 DEC 01/98 603 DEC 01/10
604 DEC 01/98 604 DEC 01/98
605 DEC 01/98
78-32-03 601 DEC 01/98 606 DEC 01/98
REPAIR 006 602 DEC 01/98 607 DEC 01/98
603 DEC 01/98 608 DEC 01/98
604 DEC 01/98 609 DEC 01/98
605 DEC 01/98 610 DEC 01/98
611 DEC 01/98
78-32-03 601 JUN 01/02 612 DEC 01/98
REPAIR 007 602 JUN 01/02 613 DEC 01/98
603 JUN 01/02 614 DEC 01/98
604 JUN 01/02 615 DEC 01/98
605 JUN 01/02 616 DEC 01/98
617 DEC 01/98
78-32-03 601 JUN 01/02 618 DEC 01/98
REPAIR 008 602 JUN 01/02 619 DEC 01/98
603 DEC 01/09
604 JUN 01/02 78-32-03 601 DEC 01/15
605 JUN 01/02 REPAIR 014 602 DEC 01/15
606 JUN 01/02 603 DEC 01/15
607 JUN 01/02 604 DEC 01/15
608 JUN 01/02 605 DEC 01/15
609 DEC 01/98 606 DEC 01/15
610 DEC 01/98 607 DEC 01/15
611 DEC 01/98 608 DEC 01/15
609 DEC 01/15
78-32-03 601 JUN 01/06 610 DEC 01/15
REPAIR 009 602 JUN 01/15 610 DEC 01/15
603 JUN 01/15 611 DEC 01/15
604 JUN 01/06 612 DEC 01/15
605 JUN 01/06

A = ADDITION; D = DELETION; R = REVISION

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REPAIR 014 614 DEC 01/15 REPAIR 002 602 JUN 01/02
(Cont’d) 615 DEC 01/15 603 JUN 01/02
616 DEC 01/15 604 JUN 01/02
617 DEC 01/15 605 JUN 01/02
618 DEC 01/15 606 JUN 01/02
619 DEC 01/15 607 JUN 01/02
620 DEC 01/15 608 JUN 01/02
621 DEC 01/15
622 DEC 01/15 78-32-09 501 DEC 01/98
623 DEC 01/15 INSPECTION 502 DEC 01/06
624 DEC 01/15 503 DEC 01/06
R 504 DEC 01/16
78-32-04 501 JUN 01/00 R 505 DEC 01/16
INSPECTION 502 JUN 01/00 506 DEC 01/13
503 JUN 01/00 507 DEC 01/13
504 JUN 01/00 508 DEC 01/13
A 509 DEC 01/16
78-32-05 501 DEC 01/98 A 510 DEC 01/16
INSPECTION 502 DEC 01/98
78-32-09 601 DEC 01/13
78-32-06 501 JUN 01/01 REPAIR 001 602 DEC 01/13
INSPECTION 502 DEC 01/98 603 DEC 01/13

78-32-06 601 JUN 01/01 78-32-09 601 DEC 01/00

REPAIR 001 602 JUN 01/01 REPAIR 002 602 DEC 01/00
603 JUN 01/01
604 JUN 01/01 78-32-09 601 JUN 01/01
REPAIR 003 602 JUN 01/01
78-32-07 501 DEC 01/14 603 JUN 01/01
INSPECTION 502 JUN 01/14 604 JUN 01/01
503 JUN 01/14 605 JUN 01/01
504 DEC 01/14 606 JUN 01/01
505 DEC 01/14 607 JUN 01/01
506 DEC 01/14
507 DEC 01/14 78-32-09 601 DEC 01/98
REPAIR 004 602 JUN 01/01
78-32-08 501 DEC 01/98 603 JUN 01/01
INSPECTION 502 DEC 01/98
503 JUN 01/02 78-32-09 601 DEC 01/13
504 DEC 01/98 REPAIR 005 602 DEC 01/13
603 DEC 01/13
78-32-08 601 JUN 01/01 604 DEC 01/13
REPAIR 001 602 JUN 01/01 605 DEC 01/13
603 JUN 01/01 606 DEC 01/13
604 JUN 01/01 607 DEC 01/13
605 JUN 01/01 608 DEC 01/13
609 DEC 01/13

A = ADDITION; D = DELETION; R = REVISION

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REPAIR 006 602 JUN 01/14 INSPECTION 502 DEC 01/98
603 JUN 01/14 503 DEC 01/98
604 JUN 01/14 504 DEC 01/13
605 JUN 01/14 505 DEC 01/14
606 JUN 01/14 506 JUN 01/10
607 JUN 01/14 507 JUN 01/16
608 JUN 01/14 508 DEC 01/14
609 JUN 01/14 509 DEC 01/15
610 JUN 01/14 510 DEC 01/13
611 JUN 01/14 511 DEC 01/13
512 DEC 01/14
78-32-10 501 DEC 01/12 513 DEC 01/13
INSPECTION 502 DEC 01/12 514 DEC 01/14
503 DEC 01/12 515 DEC 01/13
504 DEC 01/12 516 DEC 01/14
505 DEC 01/12 517 DEC 01/14
518 JUN 01/16
78-32-10 601 DEC 01/12
REPAIR 001 602 DEC 01/12 78-32-31 601 DEC 01/00
603 DEC 01/12 REPAIR 001 602 DEC 01/00
604 DEC 01/12 603 DEC 01/01
605 DEC 01/12 604 DEC 01/00
606 DEC 01/12
607 DEC 01/12 78-32-31 601 JUN 01/00
608 JUN 01/14 REPAIR 002 602 JUN 01/16
609 JUN 01/14 603 JUN 01/16
610 JUN 01/14 604 DEC 01/98
611 JUN 01/14 605 JUN 01/16
612 JUN 01/14 606 JUN 01/00
613 JUN 01/14 607 JUN 01/16
614 JUN 01/14 608 JUN 01/16
615 DEC 01/12 609 JUN 01/16
610 JUN 01/16
78-32-11 501 DEC 01/98 611 JUN 01/16
INSPECTION/ 502 DEC 01/98 612 JUN 01/16
CHECK 503 DEC 01/11 613 JUN 01/16
504 DEC 01/11 614 JUN 01/16
505 DEC 01/11 615 JUN 01/16
616 JUN 01/16
78-32-11 601 JUN 01/01 617 JUN 01/16
REPAIR 001 602 JUN 01/01 618 JUN 01/16
603 JUN 01/01 619 JUN 01/16
604 JUN 01/01 620 JUN 01/16
605 JUN 01/01 621 JUN 01/16
606 JUN 01/01 622 DEC 01/98
623 JUN 01/16

A = ADDITION; D = DELETION; R = REVISION

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REPAIR 002 625 JUN 01/16 REPAIR 012 609 JUN 01/08
(Cont’d) 626 JUN 01/16 (Cont’d) 610 JUN 01/08
627 JUN 01/16
628 DEC 01/13 78-32-31 601 JUN 01/07
629 JUN 01/16 REPAIR 013 602 JUN 01/07
630 DEC 01/98 603 JUN 01/07
604 JUN 01/07
78-32-31 601 DEC 01/01 605 JUN 01/07
REPAIR 003 602 DEC 01/01 606 JUN 01/07
603 DEC 01/01 607 JUN 01/07
604 JUN 01/01 608 JUN 01/07
605 DEC 01/01
606 DEC 01/01 78-32-31 601 JUN 01/10
607 DEC 01/01 REPAIR 014 602 DEC 01/14
608 DEC 01/01 603 JUN 01/10
609 DEC 01/01 604 DEC 01/14
610 DEC 01/01 605 JUN 01/10
606 JUN 01/10
78-32-31 601 JUN 01/11 607 DEC 01/14
REPAIR 006 602 DEC 01/05 608 JUN 01/10
603 DEC 01/05 609 JUN 01/13
604 JUN 01/02 610 JUN 01/10
605 JUN 01/02 611 JUN 01/10
606 JUN 01/02 612 JUN 01/10
607 JUN 01/99 613 JUN 01/10
608 JUN 01/02 614 JUN 01/10
615 JUN 01/10
78-32-31 601 DEC 01/98 616 JUN 01/10
REPAIR 008 602 DEC 01/10 617 JUN 01/10
603 DEC 01/98 618 JUN 01/10
619 JUN 01/10
78-32-31 601 DEC 01/98 620 JUN 01/10
REPAIR 011 602 DEC 01/14 621 JUN 01/10
603 DEC 01/98 622 JUN 01/10
604 DEC 01/98 623 DEC 01/14
605 DEC 01/14 624 DEC 01/14
606 DEC 01/98 625 JUN 01/10
607 DEC 01/98
78-32-31 601 DEC 01/06
78-32-31 601 JUN 01/08 REPAIR 015 602 DEC 01/06
REPAIR 012 602 JUN 01/08 603 DEC 01/06
603 JUN 01/01 604 DEC 01/06
604 JUN 01/08 605 DEC 01/06
605 JUN 01/08 606 DEC 01/06
606 JUN 01/08 607 DEC 01/06
607 JUN 01/08 608 DEC 01/06

A = ADDITION; D = DELETION; R = REVISION

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CHAPTER/SECTION PAGE DATE 610 JUN 01/14

78-32-31 609 DEC 01/06 CHAPTER/SECTION PAGE DATE
REPAIR 015 610 DEC 01/06 78-32-31 601 DEC 01/14
(Cont’d) 611 DEC 01/06 REPAIR 020 602 DEC 01/14
612 DEC 01/06 603 DEC 01/14
613 DEC 01/06 604 DEC 01/14
614 DEC 01/06 605 DEC 01/14
606 DEC 01/14
R 78-32-31 601 DEC 01/16 607 DEC 01/14
REPAIR 016 602 DEC 01/10 608 DEC 01/14
603 JUN 01/10 609 DEC 01/14
604 JUN 01/10 610 DEC 01/14
605 JUN 01/10 611 DEC 01/14
606 JUN 01/10 612 DEC 01/14
607 JUN 01/10
608 JUN 01/10
609 JUN 01/10
610 JUN 01/10
611 JUN 01/10
612 JUN 01/10
613 JUN 01/10
614 JUN 01/10
R 615 DEC 01/16
A 616 DEC 01/16
A 617 DEC 01/16

78-32-31 601 JUN 01/14

REPAIR 018 602 JUN 01/14
603 JUN 01/14
604 JUN 01/14
605 JUN 01/14
606 JUN 01/14
607 JUN 01/14
608 JUN 01/14
609 JUN 01/14
610 JUN 01/14
611 JUN 01/14
612 JUN 01/14
613 JUN 01/14
614 JUN 01/14

78-32-31 601 JUN 01/14

REPAIR 019 602 JUN 01/14
603 JUN 01/14
604 JUN 01/14
605 JUN 01/14
606 JUN 01/14
607 JUN 01/14
608 JUN 01/14
609 JUN 01/14

A = ADDITION; D = DELETION; R = REVISION

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TABLE OF CONTENTS

CHAPTER SECTION PAGE

Title Page ........................................................................................................... 1

Record of Revisions ........................................................................................... 1
Record of Temporary Revisions ......................................................................... 1
Service Bulletin List ............................................................................................ 1
Highlights ............................................................................................................. 1
List of Effective Pages ........................................................................................ 1
Table of Contents ............................................................................................... 1
Introduction ......................................................................................................... 1
Time Limits ......................................................................................................... 1

78-32-00 Fan Reverser Assembly

Description and Operation ................................................................................. 1

Rigging ...............................................................................................................101
Testing ................................................................................................................101
Disassembly .......................................................................................................301
Cleaning .............................................................................................................401
Assembly ............................................................................................................701

78-32-01 Fan Reverser Translating Cowl

Inspection/Check ................................................................................................501

78-32-02 Fan Reverser Support Assembly

Disassembly .......................................................................................................301
Inspection/Check ................................................................................................501
Repair 001 Deleted ............................................................................................601
Repair 002 Replacement of the Tee Track Wear Strip ......................................601
Repair 003 Deleted ............................................................................................601
Repair 004 Repair of Unbonded Areas in the Upper Duct Sidewall ..................601
Repair 005 Replacement of Rivets .....................................................................601
Repair 006 Honeycomb Dent Repair ..................................................................601
Repair 007 Lower Duct Sidewall Dent Repair……………………… ....................601
Repair 008 Replacement of Core Cowl Assembly Aft Closeout Wear Strips .....601
Repair 009 Repair of a Disbonded or Damaged Lower Duct Sidewall
Inner Skin ........................................................................................................601
Repair 010 Repair/Replacement of Sidewall Fairings ........................................601
Repair 013 Repair of Blistered Paint on Aft Core Cowl Surfaces .......................601
Repair 014 Repair of the Core Cowl Wire Mesh .................................................601
Repair 015 Replacement of Support Assembly Rubber Bumper .......................601
Repair 016 Support Assembly Damaged Lockout Bolthole Repair ....................601
R Repair 018 Repair of Worn or Damaged Power Opening Device (POD)
Support Bushing Holes ...................................................................................601
Repair 019 Fireseal Repair .................................................................................601
R Repair 022 Repair of Damaged MA-25S Insulation Coating ..............................601

PAGE 1
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TABLE OF CONTENTS (Continued)

CHAPTER SECTION PAGE

78-32-02 Fan Reverser Support Assembly (Continued)

Repair 023 Replacement of Delaminated Upper and Lower Duct

Sidewall Outer (Flowpath) Skins.....................................................................601
R Repair 024 Repair of Minor Damage to the Core Cowl Zee Rib.........................601
Repair 025 Doubler Repair of the Upper Torque Box Retainer
(491B1330011) ...............................................................................................601
Repair 026 Replacement of the Core Cowl Skin and Doublers……………… ....601
Repair 027 Fan Thrust Reverser Fixed Structure
Re-Finishing………………………………………………………………. ............601
Repair 028 Fan Thrust Reverser Fixed Structure
Re-Sealing………………………………………………….. ...............................601
Assembly ............................................................................................................701

78-32-03 Fan Reverser Blocker Doors and Associated Hardware

Inspection/Check ................................................................................................501
Repair 001 Blocker Door Hinge Replacement ...................................................601
Repair 002 Deleted ............................................................................................601
Repair 003 Blocker Door Hinge - Clevis Sleeve and/or Flanged
Sleeve Replacement ......................................................................................601
Repair 004 Blocker Door Teflon Wear Strip Replacement ................................601
Repair 005 Blocker Door Link Support Wear Strip Replacement ......................601
Repair 006 Repair of Damage to Blocker Door Edges ......................................601
Repair 007 Repair of Tears and Cuts in the Blocker Door Screen ....................601
Repair 008 Blocker Door Screen Replacement .................................................601
Repair 009 Repair of Blocker Door Back Plate Damage ...................................601
Repair 010 Repair of Blocker Door Face Sheet Damage in the Acoustic Area..601
Repair 011 Blocker Door Edge Repair ...............................................................601
Repair 014 Blocker Door Face Sheet Replacement………………………. .........601

78-32-04 Fan Reverser Vaned Deflectors

Inspection/Check ................................................................................................501

78-32-05 Fan Reverser Deflector Gang Channels

Inspection/Check ................................................................................................501

78-32-06 Fan Reverser Angle Gearbox Housing

Inspection/Check ................................................................................................501
Repair 001 Replacement of Bushings ...............................................................601

PAGE 2
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TABLE OF CONTENTS (Continued)

CHAPTER SECTION PAGE

78-32-07 Fan Reverser Mounting Ring Latch Assembly

Inspection/Check ................................................................................................501

78-32-08 Fan Reverser Link and Support

Inspection/Check ................................................................................................501
Repair 001 Replacement of Link Sleeve Bearings ............................................601
Repair 002 Link Block Flame Spray Repair .......................................................601

78-32-09 Fan Reverser Blowout and Access Doors

R Inspection/Check ................................................................................................501
Repair 001 Epoxy Resin (Green) Touchup Repair ............................................601
Repair 002 Replacement of Rivets ....................................................................601
Repair 003 Blowout, Access, and IDG Access Doors Hinge Replacement ......601
Repair 004 Blowout Door Cable Attach Angles (Clips) Replacement ...............601
Repair 005 Repair of a Worn Forward Edge on the Blowout Door .....................601
Repair 006 Repair of a Worn Aft Edge on the Blowout Door..............................601

78-32-10 Fan Reverser Hinge Cover

Inspection/Check ................................................................................................501
Repair 001 Repair of Cracks in the Thrust Reverser Hinge Cover Panel .........601

78-32-11 Fan Reverser Hardware

Inspection/Check ................................................................................................501
Repair 001 Repair of the Hold Open Rod ..........................................................601

78-32-31 Fan Reverser Translating Cowl

Inspection/Check ................................................................................................501
Repair 001 Replacement of Rivets ....................................................................601
Repair 002 Repair of Penetration Type Damage ...............................................601
Repair 003 Repair of the Filler Material Joint .....................................................601
Repair 006 Remove and Replace the Blocker Door Hinge Bearing ..................601
Repair 008 Remove and Replace the Worn or Damaged Bumpers
on the Translating Cowl ..................................................................................601
Repair 011 Locally Manufactured Bushings ......................................................601
Repair 012 Translating Cowl Inner Flow Path Fiberglass Closure
Ply Repair........................................................................................................601
Repair 013 Translating Cowl Main Air Seal Repair.............................................601
Repair 014 Fan Thrust Reverser Translating Cowl Screen Replacement..........601
Repair 015 Replace the Damaged or Worn Wear Strips on the Cowl ...............601
Guide Hook Fitting ..........................................................................................601

PAGE 3
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TABLE OF CONTENTS (Continued)

CHAPTER SECTION PAGE

78-32-31 Fan Reverser Translating Cowl (Continued)

R Repair 016 Replacement of the Tee Hinge Wear Strip ......................................601

Repair 018 Replacement of Translating Cowl Clevis/Longeron Assembly
Fasteners .......................................................................................................601
Repair 019 Translating Cowl Screen Patch On-Wing/Under-Wing Repair.........601
Repair 020 Fan Thrust Reverser Translating Cowl Re-Finishing……… ............601

PAGE 4
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INTRODUCTION

1. General.

This component maintenance manual covers the detail maintenance or overhaul instructions for the Fan
Reverser Assembly. This includes the disassembly, inspection, repair, rigging, and assembly.

U.S. EXPORT REGULATIONS

The following disclosure notice is to inform you of your obligations as a recipient of technical information
under U.S. Export laws.

THE INFORMATION (INCLUDING TECHNICAL DATA) CONTAINED IN THIS DOCUMENT IS THE

PROPERTY OF MIDDLE RIVER AIRCRAFT SYSTEMS. IT IS DISCLOSED IN CONFIDENCE AND
THE TECHNICAL DATA THEREIN IS EXPORTED UNDER A U.S. GOVERNMENT LICENSE.
THEREFORE, NONE OF THE INFORMATION MAY BE DISCLOSED TO OTHER THAN THE
RECIPIENT, OR USED FOR PURPOSES OTHER THAN TO RENDER SERVICES TO MIDDLE
RIVER AIRCRAFT SYSTEMS, WITHOUT THE EXPRESS PRIOR WRITTEN AUTHORIZATION OF
MIDDLE RIVER AIRCRAFT SYSTEMS. IN ADDITION, THE TECHNICAL DATA THEREIN, AND
THE DIRECT PRODUCT OF THE DATA, MAY NOT BE TRANSFERRED, RE-EXPORTED, OR
DISCLOSED IN ANY MANNER NOT PROVIDED FOR BY THE LICENSE WITHOUT THE PRIOR
WRITTEN APPROVAL OF THE U.S. GOVERNMENT.

R A. The part numbers for Fan Reversers used on the Airbus A330 are 683L269G01, 683L269G02,
R 683L269G03, 683L269G04, 683L270G01, 683L270G02, 683L270G03 and 683L270G04.

B. Use safety precautions and approved standard shop practices at all times to prevent damage to
equipment and/or injury to personnel.

C. This manual refers to standard GE processes or procedures that are used many times and can
be found in a separate manual, the Commercial Engine Standard Practices Manual
(GEK 9250).

D. To help with part identification, several page blocks (Disassembly, Assembly, Inspection, and
Repair) will refer to a number known as a Catalog Sequence Number (CSN) from the Fan
Reverser Illustrated Parts Catalog (MM 99379). The CSN can be identified as follows:

(1) The CSN will follow the part it refers to and will be contained in parentheses.

(2) The CSN will contain the figure and item number of the part it refers to followed by the
Chapter/Section/Subject number of the figure and index number. Example: Feedback
Gearbox 5-220, 78-32-11.

PAGE 1
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E. Dimensions are given in US Standard Units with the equivalent values of the International
System of Units (SI Units) in parentheses. The equivalent SI units will follow or be below the
US units. Conversions and abbreviations used are as follows:

US Standard Metric
Unit Abbreviation Equivalent Abbreviation

Degrees Fahrenheit F Degrees Celsius C

Inch in. Millimeter mm
Pound-inches lb in. Newton-meters N·m
Pound (mass) lb Kilogram kg

F. Information applicable to life limits of specific fan reverser parts can be found in the Time Limits
section of this manual.

PAGE 2
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LIFE LIMITS

1. General.

This section contains the FAA approved life limits for the fan reverser parts. Part life is expressed in
terms of flight cycles.

2. Requirements.

An accurate history must be kept for the total operation of each fan reverser, with the governing factor
being accumulated cycles. It is the operator's responsibility to ensure adequate records are maintained
and cyclic life limits are not exceeded.

A. The maximum life limits for all fan reverser parts, regardless of part condition, are defined in the
following sections. An accurate history of cycles must be kept, on all fan reverser parts, in two
forms:

(1) The total number of cycles operated.

(2) The number of cycles remaining.

B. One cycle consists of start, takeoff, landing, and shutdown.

C. Unless specifically stated otherwise, the life limits contained in this chapter are cumulative total
cycles which must be counted progressively for each part from its first entry into service.

3. Life limits.

Figure Part
Index No. Nomenclature Part Number Cycles

78-36-10-02-10 Actuation System 3283086-30 2,000

Lock (GE 1806M46P02)

R NOTE: The 2,000-cycle life limit does not apply to P/Ns 1806M46P06 and higher.

PAGE 1
TIME LIMITS DEC 01/01
 FAN REVERSER
CF6-80E1 CMM

THIS PAGE INTENTIONALLY BLANK

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FAN REVERSER ASSEMBLY - DESCRIPTION AND OPERATION

1. General.

The fan reverser assembly, located directly aft of the fan frame, forms a bifurcated duct and fan nozzle in
the stowed (forward thrust) position (see figure 1). In the deployed (reverse thrust) position (see
figure 2), the translating cowl moves aft and pulls the hinged blocker doors into place to divert the fan
discharge air outboard and forward through vaned deflectors that are exposed when the translating cowl
moves aft. The reverser assembly has two halves that are hinged to the pylon at the top, clamped to the
fan frame at the forward end and latched together at the bottom split line. The translating cowl is moved
by pneumatically/mechanically driven ball screw actuators.

2. Operation.

Reverse thrust is initiated by pilot command. The reverser actuation system moves the translating cowl aft
to uncover vaned deflectors and rotates the blocker doors into the fan flow path to divert the air outboard
through the deflectors. The reverser is stowed by pilot command which moves the translating cowl back to
its forward position.

A. Fan Reverser Components:

Component Function/Description Location

Support Assembly Provides inner fan flow path (core Directly aft of engine fan
(Fixed Structure) cowl) and supports for T-hinge frame.
guides for the translating cowl. The
fixed structure also provides support
for top hinges, bottom latches, and
a clamp ring at the forward end.
The flow path is acoustically
treated.

DESC & OPER

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Component Function/Description Location

Translating Cowl Provides outer nacelle surface and Outer surface of fan
outer wall for fan duct/nozzle. reverser.
Covers vaned deflectors in the
forward thrust position. Blocker
doors are hinged to its inner wall
and are rotated into the fan flow
path as the cowl is moved by the
three pneumatically/mechanically
driven ball screw actuators. Flow
path walls are acoustically treated.

Blocker Doors Divert fan air flow outboard through Inner wall of translating
vaned deflectors in reverse thrust cowl.
position. Form part of outer fan flow
path wall in forward thrust position.
Hinged to translating cowl at
forward end. Attached to the fixed
structure by linkages. Flow path
surface is acoustically treated.
Blocker doors are spring loaded in
the stowed (forward thrust) position
to prevent flutter and wear.

DESC & OPER

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CF8-6640-01-A
Fan Reverser Stowed Position
Figure 1

DESC & OPER

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CF8-6641-00-A
Fan Reverser Deployed Position
Figure 2

DESC & OPER

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78-32-00 DEC 01/98
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FAN REVERSER ASSEMBLY - RIGGING

1. General.

A correctly rigged/adjusted fan reverser is necessary not only to reverser performance, but also to
engine performance in the forward thrust range. Correct adjustment of the reverser actuation system
keeps dynamic friction (parts wear) to a minimum by alignment of the translating cowls to the fixed
structure guide tracks and makes sure of minimum deploy/stow actuation times. Alignment of the
translating cowls also sets the fan exit nozzle area and makes sure of correct seal engagement to
provide optimum engine performance in forward thrust. Also, correct adjustment more evenly
distributes loads between the actuation components which increases their service life and prevents
lockup of the feedback actuator assembly (CDU).

Anytime an end gearbox, end actuator, flexible shaft, or CDU is removed/replaced, the reverser should
be adjusted before any operation.

2. Fan Reverser Rigging/Adjustment Procedure.

CAUTION: DURING ADJUSTMENT, THE REVERSER HALVES MUST BE CLOSED AND

LATCHED.

CAUTION: IF A PNEUMATIC WRENCH IS USED TO DEPLOY OR STOW THE TRANSLATING

COWL, OBSERVE THE FEEDBACK STOP ROD FOR MOTION WHEN
APPROACHING FULL DEPLOY/STOW. WHEN MOTION IS DETECTED, REMOVE
THE PNEUMATIC WRENCH AND COMPLETE THE CYCLE WITH A MANUAL
SPEED WRENCH. THIS PREVENTS LOCKUP OF THE CDU FROM TOO MUCH
TORQUE WHEN STOPS ARE ENGAGED.

CAUTION: NEVER OPERATE THE REVERSER WITH APU OR GROUND CART AIR UNTIL ALL
ADJUSTMENT HAS BEEN SATISFACTORILY COMPLETED.

The adjustment procedure consists of various subtasks that all tie together to ensure a correctly rigged
actuation system. The text will only address adjustment of one reverser half because the procedure is
the same for the other half and either half can be adjusted independently of the other. However, if an
actuation component is removed/replaced on both halves, the adjustment procedure must be
accomplished on both sides.

A. Stow the CDU.

(1) Manually release the thrust reverser electro-mechanical disk brake. Move the brake
lever from the locked position to the up position. See figure 101.

(2) Manually release the CDU brake. Position the manual brake release lever at the detent
angle of approximately 60 degrees (until a flat is felt) with the body of the CDU. In any
other position the brake will be applied. See figure 102.

(3) Remove the two bolts that attach the lockout cover to the CDU and remove the lockout
cover.

RIGGING
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(4) Install a 0.25 in. (6.4 mm) square drive speed handle into the manual drive pad and
hand crank the CDU to move the translating cowl to the near stow position which is
when the feedback stop rod begins to move forward and stop. Do not apply more than
10 lb in. (1.13 N·m) of running torque to turn the CDU. If the running torque is more
than 10 lb in. (1.13 N·m), refer to Paragraph 4. and correct the condition before you
continue.

(5) Open the quick release clamps that hold the flexible shafts. Remove the flexible shafts
from the clamps. See figure 103.

(6) At the CDU, remove the four bolts that attach the flexible shafts to the CDU and
disengage the flexible shafts from the CDU.

NOTE: Make sure the core of the upper flexible shaft does not slide out of the
housing.

(7) Apply and hold finger pressure on the stow position indicator rig indicator button.
See figure 102.

CAUTION: DO NOT APPLY MORE THAN 15 LB IN. (1.68 N·M) OF TORQUE.

(8) Slowly turn the CDU toward the stow position. If the torque at or near the stow position
is more than 15 lb in. (1.70 N·m), check the translating cowl stow gap. See figure 104.
Refer to Paragraph 3, and correct the condition before you continue.

(9) Stop turning the CDU when the rig indicator button moves farther in and then starts to
move back out. Reverse the direction with the speed handle to slowly turn the CDU
back toward the deploy position to locate the bottom motion of the rig indicator button.
This locates the stow rig position. Check the stow rig position. Use the inspection
window in the CDU housing to make sure that the rig indicator plunger is physically
seated in the round stow position indicator detent on the extension tube flange as
shown in figure 102.

(10) Return the manual brake release lever, on the CDU, to the locked position. This
applies the CDU brake to hold the CDU at the stow rig position. See figure 102.

(11) Remove the three bolts that attach the electro-mechanical disk brake to the mounting
bracket. Remove the two bolts that attach the disk brake interconnecting flexshaft to
the upper angle gearbox. Slowly remove the disk brake and interconnecting flexshaft
as a unit. See figure 103.

NOTE: Make sure the core of the flex shaft does not slide out of the housing.

(12) Remove the two bolts that attach the cover to the unused drive pad of the lower angle
gearboxes and remove the covers.

(13) Turn the upper and lower angle gearboxes to their stow stops with a 0.02 in. (5.1 mm)
square drive and hold them against the stow stop. Make sure that the CDU is in stow
rig position.

RIGGING
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MM50029-00-A
Electro-Mechanical Disk Brake
Figure 101

RIGGING
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1120693-00-A
CDU Adjustment
Figure 102

RIGGING
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78-32-00 DEC 01/98
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MM60008-00-A
Removal of the Electro-Mechanical Disk Brake
Figure 103

RIGGING
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1118702-02-C
Translating Cowl Stowed Gap Measurement
Figure 104

(14) Insert the upper flexshaft into the CDU. If the spline will not engage in the drive socket,
slowly move the end actuator slightly off the stow stop, but do not move more than 30
R degrees. Attach the flexshaft to the CDU with two bolts (25-020, 78-32-11). Tighten
the bolts to 24-27 lb in. (2.7-3.1 N·m) of torque.

(15) Install the flexshaft into the quick-release clamps and secure.

(16) Do step (14) again for the lower angle gearbox.

B. Measure the translating cowl stowed gap. See figure 104.

(1) Measure and record the gap between the fixed structure and the translating cowl at the
centerline of the CDU and the upper and lower angle gearboxes.

(2) No adjustment is necessary if the gap measurement is between 0.060-0.150 in. (1.52-
3.81 mm). If the gap is not within the limits, refer to Paragraph 2.C.

NOTE: The end actuators must be within 0.030 in. (0.76 mm) of the CDU gap.

RIGGING
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78-32-00 DEC 01/00
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MM60004-00-A
CDU Shim Installation
Figure 105

RIGGING
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(3) Do a check of the translating cowl bumpers and adjust if necessary. Refer to
paragraphs 3.B.(4) through 3.B.(11).

C. Adjust the CDU and the upper and lower end actuators.

CAUTION: DO NOT USE MORE THAN A TOTAL OF FOUR SHIMS AT THE CDU,
REGARDLESS OF THE COMBINATION USED. THIS INCLUDES THE
STOWED POSITION.

(1) If the gap is less than 0.060 in. (1.52 mm) at the CDU, remove the CDU shims (5-160,
78-32-11) and install four shims in the stored position (5-160, 78-32-11). Tighten the
mount bolts to 55-70 lb in. (6.2-7.9 N·m) of torque. See figure 105.

CAUTION: DO NOT USE MORE THAN A TOTAL OF FOUR SHIMS AT THE CDU
REGARDLESS OF THE COMBINATION USED. THIS INCLUDES THE
STOWED POSITION.

(2) If the gap is more than 0.150 in. (3.81 mm) at the CDU, add the shims (5-160, 78-32-
11) from the stored position to the shims (5-160, 78-32-11) already installed between
the CDU and the support assembly. Tighten the mount bolts to 55-70 lb in. (6.2-7.9
N·m) of torque. See figure 105.

NOTE: Extra end actuator shims have been installed on the torque box

NOTE: If you cannot get the correct gap with the shims, use an alternative shim
5-160A, 78-32-11) which is one-half the thickness of the shims that are
supplied.

(3) If the gap is less than 0.060 in. (1.52 mm) at the end actuators, adjust the shims
R (15-065, 78-32-11) to get approximately the same gap ±0.031 in. (0.79 mm) as the
CDU.

(4) If the gap is more than 0.150 in. (3.81 mm) at the end actuators, adjust the shims
R (15-065, 78-32-11) to get approximately the same gap ±0.031 in. (0.79 mm) as the
CDU.

(5) Measure and record the gap between the fixed structure and the translating cowl at the
centerline of the CDU and the upper and lower angle gearboxes. No adjustment is
necessary if the gap measurement is between 0.060-0.150 in. (1.52-3.81 mm). If the
gap is not within the limits, do steps 2.C.(1) through (5) again until the gap is within
limits. See figure 104.

(6) Fully deploy and stow the translating cowl. At several points between each position,
check the torque necessary to move the translating cowl. The torque should not be
more than 10 lb in. (1.1 N·m).

NOTE: In the last 0.005 in. (0.13 mm) of the stow/rig position, the torque necessary
to move the translating cowl may reach, but not be more than 50 lb in. (5.6
N·m).

RIGGING
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(7) Place the brake lever on the electro-mechanical disk brake, in the up position. See
figure 101.

(a) Insert the open spline of the flexshaft into the upper end actuator gearbox and
attach with the bolts that were removed. Tighten the bolts to 24-27 lb in. (2.7-
3.1 N·m) of torque.

(b) Attach the brake to the bracket with the bolts and washers that were removed.
Tighten the bolts to 55-70 lb in. (6.2-7.9 N·m) of torque.

(c) Put the brake lever back to the locked position.

(8) Install the dust covers on the lower end actuators and attach with the bolts that were
removed. Tighten the bolts to 24-27 lb in. (2.7-3.1 N·m) of torque.

3. Excessive Stow Torque at or Near the Stow Stops.

If the torque required to stow the reverser is more than 15 lb in. (1.70 N·m) at the CDU or 30 lb in.
(3.39 N·m) at the upper/lower angle gearboxes, continue as follows:

A. For torque limits and translating cowl stow gaps not within limits.

(1) Adjust the translating cowl stow gap as necessary. Refer to Paragraph 2.

(2) Adjust the actuation system. Refer to Paragraph 2.

(3) If the stow torque is not in the limits, continue as follows:

B. For torques not in the limits, and translating cowl stow gaps that are in the limits.

(1) Manually release the CDU brake and the electro-mechanical disk brake. Refer to
Paragraphs 2.A.(1) and (2).

(2) Temporarily insert the flexible shafts into the CDU drive pads.

(3) Install a 0.25 in. (6.4 mm) square drive speed handle at the CDU manual drive pad and
hand-crank the CDU to move the translating cowl toward the deploy position
approximately 6.0-8.0 in. (152.4-203.2 mm).

(4) Measure the bumper extension of all eight bumpers on the translating cowl to be
rigged. See figure 106.

RIGGING
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R MM60005-01-C
Bumper Extension and Radial Position
Figure 106

RIGGING
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Figure 107
(Deleted)

RIGGING
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R (5) If the bumpers measure 0.70 in. (17.8 mm) or less, no adjustment is necessary.
R Replace any bumpers that measure more than 0.70 in. (17.8 mm) or trim the forward
R edge of the bumper(s) to get the 0.66-0.70 in. (16.8-17.8 mm) extension.

(6) Manually turn the CDU to position the leading edge of the translating cowl
approximately 0.5 in. (12.7 mm) from the aft edge of the fixed structure.

(7) Place a straight edge (i.e., a steel rule) against the translating cowl outer surface and
allow the straight edge to overlap the aft edge of the fixed structure. See figure 106.

(8) Measure the distance from the inner surface of the straight edge to the outer surface of
the fixed structure (dimension D). If dimension D is greater than 0.045 in. (1.14 mm),
then the bumper(s) must be shimmed to make sure of correct bumper to fixed structure
engagement.

(9) If dimension D is greater than 0.045 in. (1.14 mm), calculate the necessary shim
thickness. Subtract the measured dimension D from the maximum dimension D of
0.045 in. (1.14 mm).

CAUTION: DO NOT USE ALUMINUM SHIMS ON THE TRANSLATING COWL AS

CORROSION (DISSIMILAR MATERIAL, GALVANIC ACTION) MAY RESULT.

(10) Make shim(s) of the necessary thickness from stainless steel, or use shim P/N
491B1200075-001 (1-254, 78-32-31). Remove the three nuts that attach the bumper to
the translating cowl. Remove the bumper from the translating cowl. Install the shim
between the translating cowl and the bumper and attach with the nuts. Tighten the nuts
to 24-27 lb in. (2.7-3.1 N·m) of torque.

(11) If dimension D is less than 0.045 in. (1.14 mm), no shims are necessary. This includes
situations where dimension D is less than zero (fixed structure outer surface is farther
out radially than the translating cowl outer surface).

(12) Adjust the actuation system. Refer to Paragraph 2.

4. Too Much Torque is Necessary to Move the Reverser in Transit Away from the Stow Stop.

A. Isolate the defective component.

(1) Manually release the electro-mechanical disk brake and the CDU brake. Refer to
Paragraphs 2.A.(1) and (2).

(2) Temporarily insert the flexible shafts into the CDU drive pads.

(3) Measure the torque necessary to deploy and stow the translating cowl. Use a 0.25 in.
(6.4 mm) square drive to turn the CDU through the manual drive pad. See figure 102.

NOTE: Do not take torque readings at or near stow stops. Contact of translating
cowl bumpers to the fixed structure causes increases in the torque
necessary to turn the CDU.

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(4) If the torque is more than 10 lb in. (1.13 N·m), deploy the translating cowl approximately
6.0 in. (152.4 mm). Disconnect both the upper and lower flexible shafts from the CDU.
Remove the screws that attach the cover plate on the translating cowl to get access to
the CDU ballscrew actuator attachment clevis. Use pusher/puller 2C6367 to remove
the clevis pin from the translating cowl. See figure 108.

(5) Measure the running torque necessary to turn the CDU through the manual drive pad
toward the stow and deploy position. Hold the CDU ballscrew actuator housing to
prevent interference with the reverser structure. If the torque is more than 6.0 lb in.
(0.68 N·m), replace the CDU.

(6) Remove the bolts that attach the upper and lower flexible shafts to the angle
gearboxes. Remove the flexible shafts.

(7) Remove the screws that attach the cover plates on the translating cowl to get access to
the upper and lower ballscrew actuator clevises. Use the pusher/puller, 2C6367, to
remove the clevis pins from the translating cowl. See figure 108.

(8) Measure the running torque necessary to turn the upper or lower gearboxes. Use a
0.20 in. (5.1 mm) square drive through the unused manual drive pad while you hold the
respective ballscrew actuator housing to prevent interference with the reverser
structure. If either gearbox needs more than 3.0 lb in. (0.34 N·m) of torque to move it
toward the stow and deploy positions, replace the defective gearbox.

(9) Open the quick disconnect clamps that attach the upper and lower flexible shafts to the
fixed structure and remove the flexible shafts from the reverser. Measure the torque
necessary to turn each flexible shaft and replace either if the torque is more than 1.0 lb
in. (0.1 N·m).

(9) Manually turn the CDU and end actuators so that you can reconnect the respective
ballscrew actuator rod ends to the translating cowl clevises. Hold the ballscrew
actuator housings to guide the rod ends into the translating cowl clevises. Use the
pusher/puller, 2C6367, to install the clevis pins.

(10) Install the upper and lower flexible shafts.

(11) Adjust the actuation system. Refer to Paragraph 2.

5. To Release a Locked Up (Jammed) CDU.

A. Do the procedure that follows if a CDU locks up (jams) in the stow position. You can try to
release the unit and continue it in service.

(1) Manually release the electro-mechanical disk brake and the CDU brake. Refer to
Paragraphs 2.A.(1) and (2).

(2) Apply a maximum of 130 lb in. (14.7 N·m) of torque in the deploy direction through the
0.25 in. (6.4 mm) square drive of the CDU manual drive pad. If the CDU will not
release and turn freely, replace the CDU.

RIGGING
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1119539-02-A
Removal of the Ballscrew Actuator Clevis Pins
Figure 108

RIGGING
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FAN REVERSER ASSEMBLY - TESTING

1. General.

This procedure gives the instructions to functionally test the fan reverser assembly for electrical
continuity.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools.

Tool No. Description

2C14748G03 Stand, Assembly/Disassembly and Test - Fan

Reverser Assembly

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment.

Description Use

Voltmeter Checking continuity

B. Consumable Materials. None required.

C. Expendable Parts. None required.

D. Referenced Procedures. None required.

3. Procedure.

A. Attach the fan reverser to the test stand, 2C14748. Use a minimum of every other bolt to attach
the forward J-ring and forward latch ring.

TESTING
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1088258-00-A
Fan Reverser Electrical Schematic
Figure 501 (Sheet 1)

TESTING
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1088259-00-A
Fan Reverser Electrical Schematic
Figure 501 (Sheet 2)

TESTING
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B. Rig the fan reverser. Refer to 78-32-00, Rigging.

C. Check the electrical continuity of the stow and deploy switches on the feedback actuator
assembly (CDU) as follows: See figure 501.

(1) Install a 0.25 in. (6.4 mm) square-drive wrench into the CDU auxiliary drive pad.

(2) Turn the wrench to deploy the translating cowl 0.1 in. (2.5 mm) from the CDU stow rig
position.

NOTE: One full turn of the wrench is equal to 0.0606 in. (1.539 mm) movement of
the translating cowl.

(3) Make sure all electrical continuity conditions meet the stowed position listed in table
501.

(4) Deploy the translating cowl until the stow switch trips. The trip point limits are 0.11-0.30
in. (2.8-7.6 mm) from the stow rig position.

(5) Make a record of the Left Hand (LH) and Right Hand (RH) stow switch trip points.

(6) Make sure all electrical continuity conditions meet the in-transit position listed in table
501.

(7) Deploy the translating cowl until the deploy switch trips on the CDU. The trip point
limits are 21.230-21.550 in. (539.24-547.37 mm) from the stow rig position.

(8) Make a record of the LH and RH deploy switch trip points.

(9) Make sure all electrical continuity conditions meet the deployed position listed in table
501.

(10) Stow the translating cowl until the stow switch trips on the CDU. The trip point limits
are 0.3 -0.1 in. (7.6 - 2.5 mm) from the stow rig position.

(11) Make a record of the LH and RH stow switch trip points.

D. Check the electrical continuity of pins 1 and 8 of the pressure switch directional valve on the LH
reverser.

E. Check the electrical continuity of pins 9 and 10 of the Directional Pilot Valve (DPV) solenoid.

TESTING
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Table 501. Continuity Conditions Compared to Stroke Position Limits

Deploy Stroke Limits from the Stow Rig Position

NAME PIN NO. STOWED IN-TRANSIT DEPLOYED

0-0.1 IN. 0.3-21.30 IN. 21.55-22.13 IN.

R
(0-2.5 MM) (7.6-541.0 MM) (547.4-562.1 MM)

RH Stow
CDU 2-3 Open Closed Closed
4-5 Open Closed Closed
RH Deploy
CDU 11-12 Closed Closed Open
13-14 Closed Closed Open
8-11 Open Open Closed
6-13 Open Open Closed
LH Stow
CDU 2-3 Open Closed Closed
4-5 Open Closed Closed
LH Deploy
CDU 11-12 Closed Closed Open
13-14 Closed Closed Open
6-13 Open Open Closed
DPV
9-10 Closed (LH
reverser only)
Pressure
Switch 1-8 Closed (LH
reverser only)

TESTING
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CF6-80E1 CMM

THIS PAGE INTENTIONALLY BLANK

 COMPONENT
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683L SERIES

FAN REVERSER ASSEMBLY - DISASSEMBLY

1. General.

The fan reverser has two halves. The halves are mirror images of each other, except for several
components. This disassembly procedure applies to both halves. Components which are mounted on
only one half are denoted as such in the procedure.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools.

Tool No. Description

2C14748 Stand, Assembly/Disassembly and Test - Fan

Reverser Assembly

R 2C14750G02 Sling, Lift - Fan Reverser

2C6367G01 Tool, Install/Remove Pin - Fan Reverser Actuator

Rod

MSE-43 Spanner Wrench

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment. None required.

B. Consumable Materials.

Code No. Description

C03-005 Primer, Epoxy Resin

C05-003 Carter's Marks-A-Lot (Black or Blue), or equivalent

C. Referenced Procedures. None required.

DISASSEMBLY
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3. Procedure.

A. Install the fan reverser half into the stand, 2C14748, with the sling, 2C14750, and the hoist.

B. Remove the electrical harnesses.

(1) Remove the electrical harness from the left reverser half. See figure 301.

(a) Disconnect the connectors on the harness from the directional pilot valve,
pressure switch, and two places on the feedback actuator assembly (CDU).

(b) Open the hinged loop clamps that attaches the harness to the latch ring
brackets at two places.

(c) Loosen the bolts on the tabs of the bulkhead bracket that attach the harness.

(d) Remove the harness from the spring clips on the latch ring brackets. Install
protective caps on the connectors on the harness.

(2) Remove the electrical harness from the right reverser half. See figure 302.

(a) Disconnect the connectors on the harness from the CDU.

(b) Open the hinged loop clamps that attach the harness to the latch ring brackets.

(c) Loosen the bolts on the tabs of the bulkhead bracket that attach the harness.

(d) Remove the harness from the spring clips on the latch ring brackets. Cap the
connectors on the harness.

C. Remove the upper and lower flexible shafts (25-120, -125, 78-32-11). See figure 303.

(1) Loosen the bolts that attach the flexible shafts to the CDU and the upper and lower end
actuators.

(2) Open the hinged loop clamps that attach the flexible shafts to the fixed structure.
Remove the flexible shafts.

(3) Remove the bolts, washers, and nuts that attach the hinged loop clamps to the
brackets. Remove the hinged loop clamps.

(4) Remove the bolts, washers, and nuts that attach the hinged loop clamp brackets (25-
110, -115, -220, and -230, 78-32-11) to the support assembly.

DISASSEMBLY
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1121150-01-A
Removal of the Left Reverser Half Electrical Harness
Figure 301

DISASSEMBLY
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1121151-01-A
Removal of the Right Reverser Half Electrical Harness
Figure 302

DISASSEMBLY
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R D. Remove the center drive unit (CDU) (5-170, 78-32-11). See figure 303.

(1) Remove the CDU position feedback transducer (5-240, 78-32-11). See figure 303A.

(a) Remove the bolts (5-250, 78-32-11 ) that attach the CDU position
feedback transducer (5-240, 78-32-11) to the auxiliary pad on the center drive
unit.

(b) Lift the CDU position feedback transducer off of the auxiliary pad of the center
drive unit. Examine the preformed packing (P/N 299-4557-207A, FSCM
19710) for cracks and missing material. If you see a defect, discard the
preformed packing. If there are no defects, keep it for use at installation.

(2) Loosen the B-nut on the flexible air hose (1-410, 78-32-11 and 1-260, 78-32-12)
attached to the CDU, and disconnect.

(3) Loosen the B-nut on the signal air tubes (1-240, 78-32-11 and 1-270, 78-32-12)
attached to the feedback unit on the CDU, and disconnect.

(4) Remove the bolts, washers, nuts, and shims that attach the shock pins (5-090, -100,
78-32-11) to the support assembly. Remove the shock pins from the CDU.

(5) Remove the bolts, washers, nuts, and shims that attach the CDU to the support
assembly.

R (6) Remove the screws that attach the actuator pin cover (1-10, 78-32-31) to the translating
cowl. Remove the cover.

R (7) Loosen the bolt on the clip (5-286, 78-32-31) and rotate the clip out of the way of the
R actuator pin (1-760, 78-32-01).

(8) Remove the actuator pin that attaches the CDU to the translating cowl. Use fixture
2C6367. Remove the CDU.

NOTE: If necessary, release the brake on the CDU and hand-crank the CDU in
both directions to ease the tension on the actuator pin.

R (9) OPTIONAL: To gain access to the actuator pin from the inside of the translating cowl,
R do the following. See figure 303B.

R (a) Cut the sealant around the outside edge of the inner actuator pin access cap
R assembly (5-299, 78-32-31).

R (b) Remove the screw from the center of the inner actuator pin access cap
R assembly.

R (c) The cap assembly is sealed to the inner cup. Put a threaded T-handle (thread
R size 0.190-32) into the center of the cap assembly. Turn to engage the anchor
R nut. Pull the T-handle to break the sealant bond. Remove the cap assembly.

R (d) Remove the inner actuator pin retainer (5-288, 78-32-31) to access the actuator
R pin.

DISASSEMBLY
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1119537-01-A
Removal of the Feedback Actuator Assembly (CDU)
Figure 303 (Sheet 1 of 3)

DISASSEMBLY
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1121149-00-A
Removal of the Feedback Actuator Assembly (CDU)
Figure 303 (Sheet 2 of 3)

DISASSEMBLY
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1121177-00-C
Removal of the Feedback Actuator Assembly (CDU)
Figure 303 (Sheet 3 of 3)

E. Remove the right side retractable support assembly (1-545, 78-32-01). See figure 304.

(1) Remove the bolts, washers, and nuts that attach the clamp support bracket (5-570,
78-32-02) to the support assembly.

NOTE: It is not necessary to remove the clamp support bracket from the
retractable support assembly.

(2) Remove the retractable support assembly from the clevis support bracket (5-500,
78-32-02) by removing the bolt, washers, and nut.

F. Remove left and right side electro-mechanical brake assembly (2-010 or -013, 78-36-10). See
figure 305.

(1) Remove the bolts that attach the interconnecting flex shaft (2-115, 78-36-10) to the
upper end actuators (10-090, 78-32-11).

(2) Remove the bolts and washers that attach the electro-mechanical brake to the
mounting bracket (2-025 or -030, 78-36-10). Remove the electro-mechanical brake
and the interconnecting flex shaft as a unit. Remove the interconnecting flex shaft from
the electro-mechanical brake.

R DISASSEMBLY
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MM50006-00-A
CDU Position Feedback Transducer
Figure 303A

R DISASSEMBLY
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R MR60043-00-A
R Installation of the Inner Actuator Pin Retainer and Inner Actuator Pin Access Cap Assembly
R Figure 303B

DISASSEMBLY
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1121148-01-A
Removal of the Retractable Support Assembly and Latch Ring Brackets
Figure 304

R DISASSEMBLY
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MM60006-02-A
Removal of the Electro-Mechanical Disk Brake
Figure 305

R DISASSEMBLY
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1119538-02-A
Removal of the Right Reverser Half Forward Latch Assembly
Figure 306 (Sheet 1 of 2)

R DISASSEMBLY
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MM60022-00-A
Removal of the Right Reverser Half Forward Latch Assembly
Figure 306 (Sheet 2 of 2)

R DISASSEMBLY
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G. Remove the right reverser half latch ring brackets. See figure 304.

(1) Remove the loop clamps that attach the forward latch cable to the inside of the clevis
support bracket (5-500, 78-32-02).

(2) Remove the bolts, washers, and nuts that attach the eight brackets along the latch ring.
Remove the brackets.

H. Remove the right reverser half forward latch assembly (1-005, 78-32-41). See figure 306.

(1) Remove the loop clamps that attach the forward latch cable, at four places, to the
support brackets and thrust reverser latch ring.

(2) Remove the screws, washers, and nuts that attach the four support brackets (1-015,
78-32-41) to the thrust reverser latch ring.

(3) Remove the bolt, washer, and nut that attaches the rod-end feedback cable to the
upper latch link mechanism.

(4) Remove the self-locking nut that attaches the cable to the electro-mechanical brake
mounting bracket (2-030, 78-36-10).

(5) Remove the bolts, washers, and nuts that attach the electro-mechanical brake
mounting bracket to the latch ring. Remove the bracket.

(6) Remove the bolts, washers, and nuts that attach the upper latch assembly to the thrust
reverser latch ring.

(7) Remove the bolt, screws, washers, and nuts that attach the lower cable bracket
(1-115, 78-32-41) to the thrust reverser latch ring.

(8) Remove the bolts, washers, and nuts that attach the lower latch assembly to the thrust
reverser latch ring. Remove the latch assembly.

I. Remove the left reverser half retractable support assembly and latch ring brackets. See figure
307.

(1) Remove the bolts, washers, and nuts that attach the clamp support bracket (5-670,
78-32-01) to the support assembly.

NOTE: It is not necessary to remove the clamp support bracket from the
retractable support assembly.

(2) Remove the bolt, washers, and nut that attach the retractable support assembly to the
clevis support bracket (5-600, 78-32-01).

(3) Remove the two loop clamps that attach the forward latch cable to the inside of the
clevis support bracket (5-600, 78-32-01).

R DISASSEMBLY
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1121146-01-A
Removal of the Left Reverser Half Retractable Support Assembly and Latch Ring Brackets
Figure 307

R DISASSEMBLY
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1121170-00-A
Removal of the Left Reverser Half Forward Latch Assembly
Figure 308 (Sheet 1 of 2)

R DISASSEMBLY
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1121171-00-A
Removal of the Left Reverser Half Forward Latch Assembly
Figure 308 (Sheet 2 of 2)

R DISASSEMBLY
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(4) Remove the bolts, screws, washers, and nuts that attach the 11 brackets to the latch
ring. Remove the brackets.

R Pre SB 78-5061 * * * (RELOCATION OF DRAINAGE HOLES IN PNEUMATIC SIGNAL AIR TUBES)

R (5) Remove signal air tube bracket (5-865) from the latch ring by removing two bolts (5-
R 870, 78-32-01), washers (5-875, 78-32-01), and nuts (5-880, 78-32-01).

R End Pre SB 78-5061 * * *

R Post SB 78-5061 * * * (RELOCATION OF DRAINAGE HOLES IN PNEUMATIC SIGNAL AIR

TUBES)

R (5) Remove two bolts (5-870, 78-32-01), washers (5-875, 78-32-01), and nuts (5-880, 78-
R 32-01) from the latch ring.

R End Post SB 78-5061 * * *

J. Remove the left reverser half forward latch assembly (5-040, 78-32-01). See figure 308.

(1) Remove the four loop clamps that attach the forward latch assembly to the four support
brackets (1-015, 78-32-41).

(2) Remove the bolt, washer, and nut that attaches the rod-end feedback (1-140, 78-32-41)
cable to the upper latch link mechanism.

(3) Remove the self-locking nut that attaches the cable to the electro-mechanical brake
mounting bracket (2-025, 78-36-10).

(4) Remove the bolts, washers, and nuts that attach the electro-mechanical brake mounting
bracket to the latch ring. Remove the bracket.

(5) Remove the bolts, washers, and nuts that attach the upper latch mechanism to the latch
ring.

(6) Remove the bolt, screws, washers, and nuts that attach the lower cable bracket (1-110,
78-32-41) to the latch ring.

(7) Remove the bolts, washers, and nuts that attach the lower latch assembly to the latch
ring. Remove the latch assembly.

(8) Remove the bolts, washers, and nuts that attach the brackets (1-015, 78-32-41) to the
latch ring.

DISASSEMBLY
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K. Remove the translating cowl assembly from the support assembly.

(1) Disconnect the upper and lower end actuators (10-090, -250, 78-32-11) from the
translating cowl. See figure 309.

(a) Remove the screws, at two locations, from the translating cowl and remove
the actuator pin covers (1-010, 78-32-31).

CAUTION: DO NOT REMOVE THE BOLT FROM THE CLIP. LOOSEN THE
BOLT ENOUGH TO PERMIT YOU TO ROTATE THE CLIP.
REMOVAL OF THE BOLT WILL DAMAGE THE NUT PLATE.

(b) Loosen the bolts that attach the retaining clips (5-308, 78-32-31) and
rotate the retaining clips 90 degrees.

(c) Remove the upper and lower actuator pins that attach the actuators to the
translating cowl. Use fixture 2C6367.

R DISASSEMBLY
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1119539-02-A
Removal of the Upper and Lower End Actuator Pins
Figure 309

R DISASSEMBLY
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1120740-00-A
Removal of the Blocker Door Assembly Hardware
Figure 310

R DISASSEMBLY
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(2) OPTIONAL: To gain access to the actuator pin from the inside of the translating cowl,
do the following. See figure 303B.

(a) Cut the sealant around the outside edge of the inner actuator pin access cap
assembly (5-299, 78-32-31).

(b) Remove the screw from the center of the inner actuator pin access cap
assembly.

(c) The cap assembly is sealed to the inner cup. Put a threaded T-handle (thread
size 0.190-32) into the center of the cap assembly. Turn to engage the anchor
nut. Pull the T-handle to break the sealant bond. Remove the cap assembly.

(d) Remove the inner actuator pin retainer (5-288, 78-32-31) to access the actuator
pin.

(3) Disconnect the blocker door link arm assembly (20-510, 78-32-21) from each of the six
blocker door assemblies (1-185, 78-32-31). See figure 310.

(a) Remove the screws and washers that attach the spring retainer cap assembly
(1-805, 78-32-01) and springs (1-762, 78-32-01) to the blocker door link
support.

(b) Remove the cotter pin, nut, and bolt that attaches the link block (1-765, 78-32-
01) to the link arm assembly.

NOTE: After the links arms are disconnected, attach the links arms to the
inner support structure with tape to prevent interference with the
translating cowl assembly during removal or installation.

(4) Lift the translating cowl assembly until the T-hinges disengage from the guides.

(5) Align the translating cowl assembly in a vertical position with the leading edge down.

L. Remove the items that follow from the translating cowl assembly. See figure 311.

(1) Remove the screws, washers, and nuts that attach the eight wear bumpers (1-253, 78-
32-31) to the translating cowl.

(2) Remove the screws, washers, and nuts that attach the three lockout plates (1-270, 78-
32-31) to the translating cowl. Remove the lockout plates and shims.

(3) Remove the nuts, washers, and bolts from each blocker door hinge assembly (5-050,
78-32-31). Remove the blocker doors (1-185, 78-32-31).

(4) Remove the blocker door hinge assemblies (5-050, -055, 78-32-31).

(a) Remove the bolts, washers, and nuts from the forward leg of the blocker door
hinges.

(b) Remove the bolts, washers, and nuts from the aft leg of blocker door hinges.

R DISASSEMBLY
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1119540-00-A
Removal of Translating Cowl Hardware
Figure 311

R DISASSEMBLY
PAGE 324
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1120741-01-A
Removal of the Left Reverser Half Air Tubes and Flexible Hose
Figure 312

R DISASSEMBLY
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CAUTION: DO NOT LOSE OR DISCARD THE BLOCKER DOOR HINGE SHIMS;

THE SHIMS MUST BE REINSTALLED IN THE SAME LOCATION
FROM WHICH THEY ARE REMOVED. MARK, AND/OR TAG
IDENTIFY, THE LOCATION OF THE SHIMS AS YOU REMOVE
THEM.

(c) Remove the blocker door hinge shims. Use a marker (C05-003) to make a
mark at the location of the shims.

M. On the left reverser half, remove the directional signal air tubes (1-080 and -240, 78-32-11).
See figure 312.

(1) Remove the bolt, washer, spacer, and clamp (1-400, 78-32-11) from the lower signal air
tube (1-240, 78-32-11).

(2) Disconnect the B-nut on the lower signal air tube from the bulkhead tee fitting (1-270,
78-32-11) on the directional pilot valve (35-010, 78-32-11). Remove the lower signal air
tube.

(3) Remove the nut, spacer, washer, bolt, and clamps (1-170, -180, 78-32-11) that
attaches the upper signal air tube (1-080, 78-32-11) and the air tube (1-010, 78-32-11)
to the support assembly.

(4) Disconnect the B-nut on the upper signal air tube (1-080, 78-32-11) from the bulkhead
fitting located at the 1 o'clock position on the support assembly bulkhead bracket and
from the bulkhead tee fitting in the directional pilot valve (35-010, 78-32-11). Remove
the upper signal air tube.

N. On the left reverser half (aft looking forward), remove the air tubes and the flexible hose (1-010,
-200, and -410, 78-32-11). See figure 312.

(1) Remove the nuts, washers, bolts, and clamps (1-320, -360, 78-32-11) that attach the air
tube (1-010, 78-32-11), at two places, to the support assembly.

(2) Disconnect the B-nut on the flexible hose (1-410, 78-32-11) from the air tube and
remove the flexible hose.

(3) Disconnect the B-nut on the air tube (1-200, 78-32-11) from the saddle fitting on the air
tube (1-010, 78-32-11) and from the directional pilot valve. Remove the air tube.

(4) Disconnect the B-nut on air tube (1-010, 78-32-11) from the bulkhead fitting at 1 o'clock
position on the support assembly bulkhead bracket. Remove the air tube.

O. On the right reverser half, remove directional signal air tubes (1-070 and -270, 78-32-12). See
figure 313.

(1) Remove the bolt, washer, and clamp (1-320, 78-32-12) that attaches the lower signal
air tube to the support assembly.

(2) Remove the bolt, washer, spacer, and clamp (1-250, 78-32-12) that attaches the upper
signal air tube to the support assembly at the flexible shaft clamp.

R DISASSEMBLY
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1120742-01-A
Removal of the Right Reverser Half Air Tubes and Flexible Hose
Figure 313

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(3) Remove the bolts, washers, spacers, and loop clamps (1-160, -170, 78-32-12) that
attaches the signal air tube and the air tube (1-010, 78-32-12), at two locations, below
the upper end actuator housing.

(4) Disconnect the B-nut on the lower signal air tube (1-270, 78-32-12) from the upper
signal air tube. Remove the lower signal air tube.

(5) Disconnect the B-nut on the upper signal air tube (1-070, 78-32-12) from the bulkhead
fitting at the 11 o'clock position on the support assembly bulkhead bracket. Remove
the upper signal air tube.

P. On the right reverser half (aft looking forward), remove the air tube and the flexible hose (1-010
and -260, 78-32-12). See figure 313.

(1) Remove the nut, washer, bolt, and clamp (1-210, 78-32-12) that attaches the air tube to
the support assembly at the flexible shaft hinge clamp.

(2) Disconnect the B-nut on the flexible hose (1-260, 78-32-12) from the air tube. Remove
the flexible hose.

(3) Disconnect the B-nut on the air tube (1-010, 78-32-12) from the bulkhead fitting at the
11 o'clock position on the support assembly.

Q. On the left reverser half, remove bolts, washers, and nuts that attach the directional pilot valve
(35-010, 78-32-11) to the mount bracket on the support assembly. See figure 314.

R. Remove the upper and lower end actuators (10-090 and -250, 78-32-11). See figure 315.

(1) Remove the bolts, washers, and nuts that attach the actuator clips (10-050, -060, -210,
and -220, 78-32-11) to the gearbox housings.

(2) Remove the actuator pins (10-070, -080, -230, and -240, 78-32-11) that attach each
end actuator to the gearbox housing.

(3) Pull the end actuators out of the upper and lower gearbox housings.

S. Remove the upper and lower gearbox housings (15-010, 78-32-11). See figure 315.

(1) Remove the bolts, washers, and nuts that attach the seal retainers (10-130, -150, -290,
and -310, 78-32-11), seals (10-140 and -300, 78-32-11), and feedback support
brackets (10-160, 78-32-11 upper housing only) from the gearbox housings.

(2) Remove the bolts, washers, and nuts that attach the gearbox housings to the thrust
reverser support assembly. Remove the gearbox housings.

T. Install the support assembly into the stand, 2C14748, with the sling, 2C14750, and hoist.

R DISASSEMBLY
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1120943-00-A
Removal of the Directional Pilot Valve
Figure 314

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1119542-00-A
Removal of the End Actuators and Gearbox Housings
Figure 315

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1119543-00-A
Removal of the Vaned Deflectors
Figure 316

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U. Remove all of the vaned deflectors from the left and right side support assemblies. See figure
316.

(1) Remove the bolts, washers, screws, and nuts that attach the deflectors to the support
assembly.

NOTE: Illustrated Parts Catalog reference numbers for deflector attachment

hardware are located in figures 25, 30, 35 and 40, 78-32-00.

V. Remove the support assembly from the stand, 2C14748 with the sling, 2C14750, and hoist.
Putt the support assembly in the vertical position with the leading edge down.

W. Remove the pins, washers, and nuts that attach the blocker door link fitting hinges (20-150, 78-
32-21) (with the link arms attached) to the support assembly.

X. On the left reverser half, remove the precooler duct (20-300, 78-32-21). See figure 317.

(1) Remove the screws that attach the precooler inlet fairing assembly (30-140, 78-32-21)
to the thrust reverser inner cowl.

(2) Remove the screws that attach the precooler inlet cover (30-120, 78-32-21) to the
thrust reverser inner cowl.

(3) Remove the pins, washers, and nuts that attach the precooler duct to the thrust
reverser inner cowl. Hold the shaft of the pins with an allen wrench while you remove
the nuts.

(4) Remove the bolts and washers that attach the precooler duct to the precooler inlet
(30-090, 78-32-21) and the support assembly.

(5) Remove the precooler duct and gasket.

Y. On the left reverser half, remove the precooler inlet (30-090, 78-32-21).

(1) Remove the screws, washers, and nuts that attach the precooler inlet to the precooler
bridge on the support assembly.

Pre SB 78-002 * * * (PRECOOLER INLET DIVERTER)

(2) Remove the screws that attach the precooler inlet to the outside of the core cowl.

End Pre SB 78-002

SB 78-002 * * * (PRECOOLER INLET DIVERTER)

(2) Remove the screws that attach the precooler inlet and flow diverter (30-092, 78-32-21)
to the outside of the core cowl.

End SB 78-002

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1119544-01-A
Removal of the Precooler Duct
Figure 317

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1119545-00-A
Removal of the Deflection Limiters
Figure 318 (Sheet 1 of 2)

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1119546-00-A
Removal of the Deflection Limiters
Figure 318 (Sheet 2 of 2)

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(3) Keep the precooler inlet fillers (laminated shims) to use again. Use a marker (C05-003)
to make a mark of the position and reverser serial number on the inlet fillers.

Z. Remove the upper and lower deflection limiters (1-110 and -160, -200, -250, 78-32-01). See
figure 318.

(1) Remove the screws (1-210, 78-32-01) that attach the two forward upper deflection
limiters (1-200, 78-32-01). Remove the laminated shims (1-220, 78-32-01).

(2) Remove the screws (1-170, 78-32-01) and washers (1-180, 78-32-01) that attach the
two middle upper deflection limiters (1-160, 78-32-01). Remove the laminated shims
(1-190, 78-32-01).

(3) Remove the screws (1-255, 78-32-01), washers (1-260, 78-32-01), and nuts (1-265, 78-
32-01) that attach the two right half lower deflection limiters (1-250, 78-32-01). Remove
the laminated shims (1-270, 78-32-01).

(4) Remove the screws (1-120, 78-32-01), washers (1-130, 78-32-01), and nuts (1-140, 78-
32-01) that attach the aft upper deflection limiters (1-110, 78-32-01). Remove the
laminated shims (1-150, 78-32-01).

AA. On the right reverser half, remove the screws (60-015, 78-32-22), washers (60-020, 78-32-22),
and nuts (60-025, 78-32-22) that attach the access door assembly (1-540, 78-32-01). See
figure 319.

AB. Remove the blowout door assembly (1-525, 78-32-01) from the right reverser half. See figure
320.

(1) Open the blowout door and remove the bolts (55-005, 78-32-22), washers (55-010, 78-
32-22), and nuts (55-015, 78-32-22) that attach the blowout door cables (55-055, -060,
78-32-22) to the support assembly.

(2) Remove the screws and nuts that attach the blowout door hinge (15-683, 78-32-21) to
the support assembly lower closeout tee. Remove the nuts while you hold the shaft of
the screw with an allen wrench.

AC. Remove the three latch assemblies (1-370, -420, and -470, 78-32-01) from the left reverser
half. See figure 321.

(1) Remove the bolts (1-430, -480, 78-32-01), bushings (1-450, -500, 78-32-01), and nuts
(1-440, -490, 78-32-01) that attach the forward and middle toggle hook latch
assemblies (1-420, -470, 78-32-01). Remove the shims (1-460, -510, 78-32-01).

(2) Remove the bolt (1-380, 78-32-01), bushings, (1-400, 78-32-01) and nut (1-390, (78-
32-01) that attach the aft latch (1-370, 78-32-01). Remove the shim (1-410, 78-32-01).

AD. Remove the screws ( 1-230, 78-32-01), washers (1-235, 78-32-01), and nuts (1-240, 78-32-01)
that attach the wear pads (1-225, 78-32-01) to the support assembly on the left reverser half.
Remove the laminated shims (1-245, 78-32-01).

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1119547-00-A
Removal of the Access Door Assembly
Figure 319

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CF8-A6024-00-A
Removal of the Blowout Door Assembly
Figure 320

R DISASSEMBLY
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CF8-7210-01-C
Removal of the Latch Assemblies and Wear Pads
Figure 321

R DISASSEMBLY
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 FAN REVERSER
CF6-80E1 CMM

THIS PAGE INTENTIONALLY BLANK

 COMPONENT
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MANUAL

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FAN REVERSER ASSEMBLY - CLEANING

R 1. General.

R The table that follows gives information about the procedures used to clean the parts of the fan
R reverser assembly. The table includes the part name, the part material, the part finish, and a reference
R to the cleaning procedure for the part. The number or numbers in the “Cleaning Method” column
R refer to section 70-21-03 or 70-46-01 of the GE Standard Practices Manual (SPM) (GEK 9250).

R CAUTION: WHEN THE FAN REVERSER IS CLEANED AS AN ASSEMBLY, MAKE SURE TO PROTECT
R ALL SPACES WHERE LIQUID CAN COLLECT, OR DAMAGE TO THE EQUIPMENT CAN
R RESULT.

R CAUTION IF A COMPONENT, GEARBOX, SWITCH, OR BALLSCREW CAN BE TOUCHED BY A

R CLEANING VEHICLE, MAKE SURE YOU FULLY DRY THE COMPONENT, AND DO A
R VISUAL INSPECTION FOR MOISTURE OR DAMAGE.

R 2. Cleaning.

R Part Name Part Material Part Finish Cleaning Method

R A. Translating Cowl (Outer and Inner Bondment)

R Acoustic Skin Graphite/Epoxy None 70-46-01: Composite

R Cleaning Method No. 5;
R Water Break Test

R All other skins Graphite/Epoxy None 70-46-01: Composite

R Cleaning Method No. 5;
R Water Break Test

R Guide Bracket 7075-T73511 Anodize; 70-21-03, Cleaning Method

R (QQ-A-200/11) Epoxy Resin No. 3
R Primer

R Fwd Seal 2024-T62 (QQ-A- Anodize; 70-21-03, Cleaning Method

R Support 250/4) Epoxy Resin No. 3
R Primer

R Actuator Clevis 17-4 PH (AMS 5342) Passivate 70-21-03, Cleaning Method

R No. 3

CLEANING
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R Part Name Part Material Part Finish Cleaning Method

R B. Support Assembly

R Cowl Outer Skin AL-2024-T42 (QQ-A- Alodine 70-21-03, Cleaning Method

R 250/4) No. 3

R Cowl Inner Skin AL-2024-T42 (QQ-A- Alodine 70-21-03, Cleaning Method

R 250/5) No. 3

R Actuator Castings AL-ALY-A-356.0 Class Anodize; 70-21-03, Cleaning Method

R 2, Grade B Epoxy Resin No. 3
R Primer

R Inner Skin (Duct AL-2024-T3 Alodine; 70-21-03, Cleaning Method

R Sidewall) (QQ-A-250/4) Epoxy Resin No. 3
R Primer

R Outer Skin (Duct AL-2024-T3 Alodine 70-21-03, Cleaning Method

R Sidewall) (QQ-A-200/3) No. 3

R Deflection Limiter AL-2024-T3511 Anodize; 70-21-03, Cleaning Method

R Bracket (QQ-A-250/4) Epoxy Resin No. 3
R Primer

R Fairings AL-2024-T42 Epoxy Resin 70-21-03, Cleaning Method

R (QQ-A-250/5) Primer No. 3

R Core Cowl - AMS4144 AL-2219- Alodine 70-21-03, Cleaning Method

R Forward T852 1 Layer No. 3
R Bulkhead Polyurethane
R (Support Ring) (MIL-C-83286
R Type I, or MIL-
R C-85285 Type I)

R Core Cowl - Aft AL-7075-T76 Alodine 1500; 70-21-03, Cleaning Method

R Bulkhead Epoxy Resin No. 3
R (Support Ring) Primer

R Attach Angles AL-2224-T42 Anodize; 70-21-03, Cleaning Method

R (Core Cowl to (QQ-A-200/3) Epoxy Resin No. 3
R Upper/ Lower Primer
R Duct Sidewall)

CLEANING
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R Part Name Part Material Part Finish Cleaning Method

R C. Blocker Doors

R Face Sheet Fiberglass/Epoxy Epoxy Resin 70-46-01: Composite

R Primer; Cleaning Method No. 5;
R Black Urethane Water Break Test
R Elastomer

R Inner Skin Graphite/Epoxy None 70-46-01: Composite

R Cleaning Method No. 5;
R Water Break Test

R Hinge Assembly AMS 4260 AL 356 Alodine; 70-21-03, Cleaning Method

R Epoxy Resin No. 3
R Primer

R D. Hinge Cover AL-2024-T42 Alodine; 70-21-03, Cleaning Method

R Anodize No. 3

R E. Deflectors

R Aluminum AMS 4218 Anodize; 70-21-03, Cleaning Method

R Deflectors Epoxy Resin No. 3
R Primer

R Composite Graphite/Epoxy None 70-46-01: Composite

R Deflectors Cleaning Method No. 5;
R Water Break Test

R Blank Deflectors AL2024-T3 (QQ-A- Alodine 70-21-03, Cleaning Method

R 250/5) No. 3

R F. Deflector Beams AL-2024-T4 Anodize 70-21-03, Cleaning Method

R (AMS 4037) No. 3

R G. Link Arms AMS 4144 Anodize 70-21-03, Cleaning Method

R No. 3

R H. Core Cowl Link AL-A357 Anodize; 70-21-03, Cleaning Method

R Support Alodine 1500; No. 3
R Epoxy Resin
R Primer

CLEANING
PAGE 403
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R Part Name Part Material Part Finish Cleaning Method

R I. Mounting Ring Latch Assembly

R Fwd Latch Ring AL-7075-T73 Anodize 70-21-03, Cleaning Method

R No. 3

R Latch Hook Inconel 718 None 70-21-03, Cleaning Method

R (Forward Upper) No. 3

R J. Deflection Limiter

R Bracket A3570 Anodize; 70-21-03, Cleaning Method

R Epoxy Resin No. 3
R Primer

R Bumper AL-6061-T6 (AMS Anodize 70-21-03, Cleaning Method

R 4121) No. 3

CLEANING
PAGE 404
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MANUAL

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FAN REVERSER ASSEMBLY - ASSEMBLY

1. General.

A. The fan reverser has two halves. This procedure applies to both halves. Components which
are mounted on only one half are denoted as such in the procedure.

B. A properly rigged/adjusted fan reverser is necessary for reverser performance and engine
performance in the forward thrust range. Proper rigging of the reverser actuation system
minimizes dynamic friction (parts wear) by the alignment of the translating cowls to the fixed
structure guide tracks. This ensures minimum deploy/stow actuation times. Also with
alignment of the translating cowls, the fan exit nozzle area is set and proper seal engagement is
ensured to provide optimum engine performance in forward thrust. Further, proper rigging more
evenly distributes loads between the actuation components, which increases their service life
and prevents feedback actuator assembly (CDU) stock lockup.

C. Whenever an end gearbox, end actuator, flexible shaft, or CDU is removed and replaced, the
reverser should be adjusted before any operation.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools.

Tool No. Description

2C14748G03 Stand, Assembly/Disassembly and Test - Fan

Reverser Assembly

R 2C14750G02 Sling, Lift - Fan Reverser

2C6367G01 Tool, Install/Remove Pin - Fan Reverser Actuator Rod

MSE-43 Spanner Wrench

T7-032586 Cascade Installation Fixture

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment. None required.

ASSEMBLY
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B. Consumable Materials.

Code No. Description

C01-007 Compound, Silicone Rubber RTV 106

C01-008 Compound, Silicone Rubber RTV 560

R C01-073 Compound, Sealing, PR 1750 B-2

C01-145 Compound, Sealing, SQ32L

C02-004 Lubricant, Tiolube 70 (GE Spec. A50TF192 Class B)

C02-009 Lubricant, Molycote Type Z

C03-005 Primer, Epoxy Resin

C02-032 Anti-seize Compound, High Temp

R DELETED

C04-003 Solvent, Acetone (Fed. Spec. 0-A51)

C04-035 Isopropyl Alcohol

C10-071 Safety Wire

C10-182 Cotton Cloth, Lint-free

--- Grease, SEA MS-G-4343

C. Expendable Parts. None required.

D. Referenced Procedures.

71-50-08 Nacelle Wire Harness Component Maintenance Manual (Goodrich #RDN 922)

78-32-00 Rigging

78-32-00 Testing

3. Procedure.

A. Install the support assembly into the stand, 2C14748, with a sling, 2C14750, and a hoist.

B. Install the components on the support assembly: See figure 701.

(1) On the left reverser half, install the wear pads, (1-225, 78-32-01) and the laminated
shims (1-245, 78-32-01) with screws (1-230, 78-32-01), washers (1-235, 78-32-01), and
nuts (1-240, 78-32-01). Tighten the nuts to 33-37 lb in. (3.7-4.2 N·m) of torque.

ASSEMBLY
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MANUAL

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CF8-7210-01-C
R Left Reverser Half Wear Pads and Lower Latch Assemblies
Figure 701

(2) On the left reverser half, install the three latch assemblies (1-370, -420, -470,
78-32-01).

(a) Install the forward and middle toggle hook latch assemblies (1-490, 78-32-01)
with bolts (1-505, 78-32-01), bushings (1-500, 78-32-01), and nuts (1-510,
R 78-32-01). Tighten nuts to 300-360 lb in. (33.9-40.7 N·m) of torque.

(b) Install aft latch (1-465, 78-32-01) with a bolt (1-480, 78-32-01), bushings (1-
475, 78-32-01), and nut (1-485, 78-32-01). Tighten nut to 190-230 lb in. (21.5-
25.9 N·m) of torque.

WARNING: DO NOT USE LUBRICANT (C02-004) NEAR FLAMES OR HEAT. DO

NOT LET LUBRICANT TO GET ON YOUR SKIN OR IN YOUR EYES.
MAKE SURE YOU HAVE A GOOD FLOW OF CLEAN AIR. THIS
MATERIAL IS FLAMMABLE AND DANGEROUS TO YOUR SKIN,
EYES, AND LUNGS. PUT ON PROTECTIVE CLOTHING, GOGGLES,
AND A FACE MASK.

(c) Spray the latch hook contact areas with lubricant (C02-004).

ASSEMBLY
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MANUAL

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R
R Right Reverser Half Wear Pads and Lower Latch Bolts
R Figure 702

R (3) On the right reverser half, install three latch bolts, (1-480 and -505, 78-32-02)
R and nuts (1-485 and -510, 78-32-02) as follows. See Figure 702.

R (a) Install the forward and middle latch bolts (1-505, 78-32-02) and nuts (1-510, 78-
R 32-02). Tighten nuts to 250-300 lb in. (28.3-33.9 N m) of torque.

R (b) Install aft latch bolt (1-480, 78-32-02) and nut (1-485, 78-32-02). Tighten nut to
190-230 lb in. (21.5-25.9 N m) of torque

ASSEMBLY
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CF8-A6024-00-A
Blowout Door Assembly
R Figure 703

ASSEMBLY
PAGE 705
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MANUAL

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R (4) On the right reverser half, install the blowout door assembly (1-525, 78-32-01). See
R figure 703.

(a) Attach the door hinge (15-683, 78-32-21) to the support assembly lower
closeout tee with the screws and nuts. Hold the shaft of the screws with an
allen wrench and tighten the nuts to 8-10 lb in. (0.9-1.1 N·m) of torque.

(b) Connect the blowout door cables (55-055, -060, 78-32-22) to the support
assembly with the bolts (55-005, 78-32-22), washers (55-010, 78-32-22), and
nuts (55-015, 78-32-22). Tighten the nuts to 33-37 lb in. (3.7-4.2 N·m) of
torque.

R (5) On the right reverser half, install the access door assembly (1-540, 78-32-01) with
screws (60-015, 78-32-22), washers (60-020, 78-32-22), and nuts (60-025, 78-32-22).
R Tighten the nuts to 13-16 lb in. (1.5-1.8 N·m) of torque. See figure 704.

R (6) Install the upper and lower deflection limiters (1-110, -160, -200, -250, 78-32-01). See
R figure 705.

(a) Install the two deflection limiters (1-110, 78-32-01) and laminated shims (1-150,
78-32-01) to the aft upper locations on both halves with screws (1-120, 78-32-
01), washers (1-130, 78-32-01), and nuts (1-140, 78-32-01). Tighten the nuts
to 33-37 lb in. (3.7-4.2 N·m) of torque.

(b) Install the two deflection limiters (1-250, 78-32-01) and laminated shims (1-270,
78-32-01) to the right half lower locations with screws (1-255, 78-32-01),
washers (1-260, 78-32-01), and nuts (1-265, 78-32-01). Tighten the nuts to 33-
37 lb in. (3.7-4.2 N·m) of torque.

(c) Install the two deflection limiters (1-160, 78-32-01) and laminated shims (1-190,
78-32-01) to the middle upper locations on both halves with screws (1-170, 78-
32-01) and washers (1-180, 78-32-01). Tighten the screws to 33-37 lb in. (3.7-
4.2 N·m) of torque.

(d) Install two deflection limiters (1-200. 78-32-01) and laminated shims (1-220, 78-
32-01 and 78-32-02) to the forward upper locations on both halves with screws
(1-210. 78-32-01). Tighten the screws to 33-37 lb in. (3.7-4.2 N·m) of torque.

R (7) On the left reverser half, install the precooler inlet (30-090, 78-32-21). See figure 706.

ASSEMBLY
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1119547-00-A
Installation of the Access Door Assembly
R Figure 704

ASSEMBLY
PAGE 707
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1119545-00-A
Installation of the Deflection Limiters
R Figure 705 (Sheet 1 of 2)

ASSEMBLY
PAGE 708
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1119546-00-A
Installation of the Deflection Limiters
R Figure 705 (Sheet 2 of 2)

ASSEMBLY
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1119544-01-A
Installation of the Precooler Duct
R Figure 706

ASSEMBLY
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(a) Put the precooler inlet (30-090, 78-32-21) into the support assembly.

(b) Put the precooler inlet fillers (laminated shims) (30-110, -115, 78-32-21) into
position under the precooler inlet edges, in the same location, as marked, from
where they were removed during disassembly.

Pre SB 78-0002 * * * (PRECOOLER INLET DIVERTER)

(c) Install screws (30-095, 78-32-21) along the top, bottom, and forward edge of
the precooler inlet. Tighten the screws with your fingers.

(d) Install screws (30-295, 78-32-21), washers (30-300, 78-32-21), and nuts (30-
305, 78-32-21) to attach the precooler inlet to the precooler bridge on the
support assembly. Tighten the nuts to 33-37 lb-in. (3.7-4.2 N·m) of torque.

(e) Tighten the screws (30-095, 78-32-21) along the top, bottom, and forward edge
of the precooler inlet to 33-37 lb-in. (3.7-4.2 N·m) of torque.

End Pre SB 78-0002

SB 78-0002 * * * (PRECOOLER INLET DIVERTER)

(c) Install the flow diverter (30-092, 78-32-21) to the precooler inlet (30-090, 78-32-
21) with screws (30-097, 78-32-21). Install screws (30-095, 78-32-21) along
the top, bottom, and forward edge of the precooler inlet. Tighten the screws
with your fingers.

(d) Install the screws (30-295, 78-32-21), washers (30-300, 78-32-21), and nuts
(30-305, 78-32-21) that attach the precooler inlet to the to the precooler bridge
on the support assembly. Tighten the nuts to 33-37 lb-in. (3.7-4.2 N·m) of
torque.

(e) Tighten the screws (30-095, -097, 78-32-21) along the top, bottom, and forward
edge of the precooler inlet to 33-37 lb-in. (3.7-4.2 N·m) of torque.

End SB 78-0002

Pre SB 78-5086 * * * (PRECOOLER DUCT ASSEMBLY)

R (8) On the left reverser half, install the precooler duct (20-300, 78-32-21). See figure 706.

(a) Align the precooler duct (20-300, 78-32-21) flange and the precooler duct
gasket (20-310, 78-32-21) to the precooler inlet (30-090, 78-32-21) flange.
Install 16 bolts (20-320, 78-32-21), 32 washers (20-340, -350, 78-32-21),
and 16 nuts 20-360, 78-32-21). Do not tighten the fasteners at this time.

(b) Install 3 pins (20-370, 78-32-21) through the zee rib (30-475, 78-32-21) and
precooler duct (20-300, 78-32-21) brackets with 3 washers (20-380, 78-32-21)
and 3 nuts (20-390, 78-32-21). Do not tighten the fasteners at this time.

ASSEMBLY
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(c) Align the precooler inlet fairing (30-140, 78-32-21) to the precooler duct
(20-300, 78-32-21) with 6 bolts (20-320, 78-32-21), 12 washers (20-340, -350,
78-32-21), and 6 nuts (20-360, 78-32-21). Install 2 screws (30-095, 78-32-21)
to attach the precooler inlet fairing (30-195, 78-32-21) to the precooler inlet
(30-090, 78-32-21). Tighten the screws to 33-37 lb-in. (3.7-4.2 N·m) of torque.

(d) Tighten all 25 nuts to 33-37 lb-in. (3.7-4.2 N·m) of torque.

(e) Apply sealing compound (C01-073) to all joints and gaps in the
precooler inlet (30-090, 78-32-21), precooler inlet cover (30-120, 78-32-21),
and precooler inlet fairing (30-140, 78-32-21).

End Pre SB 78-5086

SB 78-5086 * * * (PRECOOLER DUCT ASSEMBLY (SPD))

R (8) On the left reverser half, install the precooler duct (20-300, 78-32-21). See figure 706.

(a) Align the precooler duct (20-300, 78-32-21) flange and the precooler duct
gasket (20-310, 78-32-21) to the precooler inlet (30-090, 78-32-21) flange.
Install 16 bolts (20-320, 78-32-21), 32 washers (20-340, -350, 78-32-21),
and 16 nuts 20-360, 78-32-21). Do not tighten the fasteners at this time.

(b) Install 5 pins (20-400, 78-32-21) through the zee rib (30-475, 78-32-21),
shim(s) (20-405, 78-32-21) (as necessary), and precooler duct (20-300,
78-32-21) brackets with 5 washers (20-410, 78-32-21) and 5 nuts (20-420,
78-32-21). Do not tighten the fasteners at this time.

(c) Align the precooler inlet fairing (30-140, 78-32-21) to the precooler duct
(20-300, 78-32-21) with 6 bolts (20-320, 78-32-21), 12 washers (20-340, -350,
78-32-21), and 6 nuts (20-360, 78-32-21). Install 2 screws (30-095, 78-32-21)
to attach the precooler inlet fairing (30-195, 78-32-21) to the precooler inlet (30-
090, 78-32-21. Tighten the screws to 33-37 lb-in. (3.7-4.2 N·m) of torque.

(d) Tighten all 27 nuts to 33-37 lb-in. (3.7-4.2 N·m) of torque.

(e) Apply sealing compound (C01-073) to all joints and gaps in the
precooler inlet (30-090, 78-32-21), precooler inlet cover (30-120, 78-32-21),
and precooler inlet fairing (30-140, 78-32-21).

End SB 78-5086

ASSEMBLY
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SB 78-002 * * * (PRECOOLER INLET DIVERTER)

R (9) Install the six blocker door link fitting hinges (20-150, 78-32-21), with the link arms
installed, with pins (20-175, 78-32-21), washers (20-180, 78-32-21), and nuts (20-185,
78-32-21). Hold the shaft of the pins with an allen wrench and tighten the nuts to 33-37
lb in. (3.7-4.2 N·m) of torque.

CAUTION: BEFORE YOU TO INSTALL THE DEFLECTORS, PUT THE SUPPORT

ASSEMBLY IN THE VERTICAL POSITION WITH THE LEADING EDGE
DOWN ON THE TORQUE BOX, TO ENSURE THE CASCADE AFT SUPPORT
RING IS IN THE PROPER POSITION.

R (10) Remove the support assembly from the stand, 2C14748, with the sling, 2C14750, and
hoist. Set the support assembly in the vertical position with the leading edge down.

CAUTION: TORQUE THE DEFLECTOR ATTACHMENT HARDWARE BEFORE YOU

TURN THE SUPPORT ASSEMBLY.

R (11) Install the vaned deflectors with the bolts, washers, screws, and nuts. See table 701
R and figure 707. If you install bolts NAS6403U4 into the aft ring, apply anti-seize
compound (C02-032) to the bolt threads before installation. If you install bolts
J793P005C into the aft ring, it is not necessary to apply anti-seize compound. Tighten
the bolts to 24-27 lb in. (2.7-3.1 N·m) of torque.

NOTE: Illustrated Parts Catalog reference numbers for deflector attachment

hardware are from figures 25, 30, 35, and 40, 78-32-00.

(a) Use the Cascade Installation Fixture (T7-032586) to hold the contour of the
cascade ring before you install the vaned deflectors (cascades).

NOTE: You can get the field drawing for the Cascade Installation Fixture
from http://www.mras-usa.com. Choose the Customer Resources
button on the main page. You can also contact MRAS Customer
Support to get the drawing.

ASSEMBLY
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Table 701. Vaned Deflector Installation

Position 1 (Left Wing) Position Number And Installation Hardware IPC Reference 78-32-00

Pos. Fig. Deflector Channel Screw Nut Bolts Washer

L1 25 - 010 -050 -060 -070 -020, -030 -040

L2 25 - 010 -050 -060 -070 -020, -030 -040
L3 25 - 010 -050 -060 -070 -020, -030 -040
L4 25 - 010 -050 -060 -070 -020, -030 -040
L5 25 - 080 -050 -060 -070 -090, -100 -110
L6 25 - 080 -120 -130 -140 -090, -100 -110
L7 25 - 010 -120 -130 -140 -020, -030 -040
L8 25 - 160 -050 -060 -070 -170, -180 -190
L9 25 - 200 -150 -240 -250 -260 -210, -220 -230
L10 25 - 010 -240 -250 -260 -020, -030 -040
L11 25 - 010 -050 -060 -070 -020, -030 -040
L12 25 - 010 -050 -060 -070 -020, -030 -040
L13 25 - 010 -050 -060 -070 -020, -030 -040
L14 25 - 080 -050 -060 -070 -090, -100 -110
L15 25 - 080 -120 -130 -140 -090, -100 -110
L16 25 - 270 -120 -310 -130 -140 -280, -290 -300

R1 30 - 010 -050 -060 -070 -020, -030 -040

R2 30 - 010 -050 -060 -070 -020, -030 -040
R3 30 - 010 -050 -060 -070 -020, -030 -040
R4 30 - 010 -050 -060 -070 -020, -030 -040
R5 30 - 010 -050 -060 -070 -020, -030 -040
R6 30 - 080 -050 -130 -140 -090, -100 -110
R7 30 - 200 -120 -250 -260 -210, -220 -230
R8 30 - 200 -240 -250 -260 -210, -220 -230
R9 30 - 160 -150 -240 -250 -260 -170, -180 -190
R10 30 - 080 -240 -060 -070 -020, -030 -040
R11 30 - 080 -050 -060 -070 -020, -030 -040
R12 30 - 080 -050 -060 -070 -020, -030 -040
R13 30 - 080 -050 -060 -070 -020, -030 -040
R14 30 - 010 -050 -130 -140 -090, -100 -110
R15 30 - 010 -120 -130 -140 -090, -100 -110
R16 30 - 270 -120 -310 -320 -330 -280, -290 -300

R ASSEMBLY
PAGE 714
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Table 701. Vaned Deflector Installation (Continued)

Position 2 (Right Wing) Position Number And Installation Hardware IPC Reference 78-32-00

Pos. Fig. Deflector Channel Screw Nut Bolts Washer

L1 35 - 010 -050 -060 -070 -020, -030 -040

L2 35 - 010 -050 -060 -070 -020, -030 -040
L3 35 - 010 -050 -060 -070 -020, -030 -040
L4 35 - 010 -050 -060 -070 -020, -030 -040
L5 35 - 010 -050 -060 -070 -020, -030 -040
L6 35 - 120 -050 -170 -180 -130, -140 -150
L7 35 - 080 -160 -170 -180 -090, -100 -110
L8 35 - 200 -160 -290 -300 -210, -220 -230
L9 35 - 240 -190 -280 -290 -300 -250, -260 -270
L10 35 - 240 -280 -290 -300 -250, -260 -270
L11 35 - 240 -280 -290 -300 -250, -260 -270
L12 35 - 240 -280 -290 -300 -250, -260 -270
L13 35 - 240 -280 -290 -300 -250, -260 -270
L14 35 - 010 -280 -290 -300 -020, -030 -040
L15 35 - 010 -050 -060 -070 -020, -030 -040
L16 35 - 310 -050 -350 -360 -370 -320, -330 -340

R1 40 - 010 -050 -060 -070 -020, -030 -040

R2 40 - 010 -050 -060 -070 -020, -030 -040
R3 40 - 010 -050 -060 -070 -020, -030 -040
R4 40 - 010 -050 -060 -070 -020, -030 -040
R5 40 - 080 -050 -060 -070 -090, -100 -110
R6 40 - 080 -120 -130 -140 -090, -100 -110
R7 40 - 010 -120 -130 -140 -020, -030 -040
R8 40 - 200 -050 -060 -070 -210, -220 -230
R9 40 - 160 -150 -240 -250 -260 -170, -180 -190
R10 40 - 010 -240 -250 -260 -020, -030 -040
R11 40 - 010 -050 -060 -070 -020, -030 -040
R12 40 - 010 -050 -060 -070 -020, -030 -040
R13 40 - 010 -050 -060 -070 -020, -030 -040
R14 40 - 080 -050 -060 -070 -090, -100 -110
R15 40 - 080 -120 -130 -140 -090, -100 -110
R16 40 - 270 -120 -310 -320 -330 -280, -290 -300

R ASSEMBLY
PAGE 715
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 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

MR60029-00-A
Installation of the Vaned Deflectors
R Figure 707

ASSEMBLY
PAGE 716
78-32-00 JUN 01/15
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MANUAL

683L SERIES

R (12) Install the support assembly into the stand 2C14748 with the sling, 2C14750, and hoist.

R (13) Install the upper and lower gearbox housings (15-010, 78-32-11). See figure 708.

(a) Align the gearbox housings and shims (15-065, 78-32-11) against the forward
side of the support assembly.

(b) Attach each gearbox housing with four bolts (15-020, 78-32-11), washers (15-
030, 78-32-11), and nuts (15-040, 78-32-11). Tighten the nuts to 55-70 lb in.
(6.2-7.9 N·m) of torque.

(c) Install the seal retainers (10-130, -150, -290, -310, 78-32-11), seals (10-140,
-300, 78-32-11), and feedback support brackets (10-160, 78-32-11 upper
housing only), onto the forward end of the gearbox housings with the bolts
(10-100, -260, 78-32-11), washers (10-110, -270, 78-32-11), and nuts (10-120,
-280, 78-32-11). Tighten the nuts to 33-37 lb in. (3.7-4.2 N·m) of torque.

R (14) Install the upper and lower end actuators (10-090, -250, 78-32-11).

(a) Put the long shaft of the end actuators through the upper and lower gearbox
housings.

(b) Attach the actuators to the gearbox housings with the actuator pins (10-070,
-080, -230, -240, 78-32-11).

(c) Safety the actuator pins to the gearbox housings with the actuator clips
(10-050, -060, -210, -220, 78-32-11), bolts (10-010, -170, 78-32-11), washers
(10-020, -030, -180, -190, 78-32-11), and nuts (10-040, -200, 78-32-11).
Tighten the bolts to 33-37 lb in. (3.7-4.2 N·m) of torque.

R (15) On the left reverser half, install the directional pilot valve (35-010, 78-32-11). See figure
R 709.

(a) Attach the pilot valve to the mount bracket, below the upper end actuator, with
bolts (35-020, 78-32-11), washers (35-030, 78-32-11), and nuts (35-040, 78-
32-11). Tighten the nuts to 33-37 lb in. (3.7-4.2 N·m) of torque.

(b) Place a preformed packing (1-290, 78-32-11) and a locknut (1-280, 78-32-11)
on the tee fitting (1-270, 78-32-11). Turn the tee fitting into the “OUT” port on
the pilot valve. Do not tighten the fitting.

(c) Install the elbow (1-230, 78-32-11) on the “IN” port on the valve. Do not tighten
the elbow.

ASSEMBLY
PAGE 717
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MANUAL

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1119542-00-A
Gearbox Housings and End Actuators
R Figure 708

ASSEMBLY
PAGE 718
78-32-00 JUN 01/15
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MAINTENANCE
MANUAL

683L SERIES

1120943-00-A
Installation of the Directional Pilot Valve
R Figure 709

ASSEMBLY
PAGE 719
78-32-00 JUN 01/15
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R (16) Install the upper and lower flexible shaft support brackets (25-115, -230, 78-32-11)
right-hand side and (25-110, -220, 78-32-11) left-hand side to the support assembly
with the bolts (25-080, -190, 78-32-11), washers (25-090, 200, 78-32-11), and nuts (25-
100, -210, 78-32-11). Tighten the nuts to 55-70 lb in. (6.2-7.9 N·m) of torque.

(a) Put a hinged loop clamp (25-070, -180, 78-32-11) on each support bracket with
bolts (25-040, -150, 78-32-11), washers (25-050, -160, 78-32-11), and nuts
(25-060, -170, 78-32-11). Align the clamp toward the outside of the support
assembly. Tighten the nuts to 33-37 lb in. (3.7-4.2 N·m) of torque.

R (17) Install the flexible shaft assemblies (25-015, -125, 78-32-11) right-hand side and (25-
010, -120, 78-32-11) left-hand side.

(a) Put the square end of the shafts into the end actuators and attach with bolts
(25-020, 130, 78-32-11) and washers (25-030, -140, 78-32-11). Before you
install the bolts, apply anti-seize compound (C02-032) to the bolt threads.
Tighten the bolts to 33-37 lb in. (3.7-4.2 N·m) of torque and safety wire (C10-
071).

(b) Open the hinged loop clamps and put the four shafts in the hinged loop clamps.
Close the hinged loop clamps.

R (18) On the right reverser half (aft looking forward), install the air tube and flexible hose
R (1-010, -260, 78-32-12). See figure 710.

(a) Apply grease SAE-AMS-G-4343) to all threaded connectors used in the

installation of the air tube. Apply grease between the connector and the air
tube. Apply grease to all o-rings before installation.

(b) Connect the air tube (1-010, 78-32-12) to the bulkhead fitting, located at the
1 o'clock position on the support assembly. Route the tube down and under
the flexible shaft.

(c) Attach the air tube to the support assembly, outboard of the flexible shaft
clamp, with a loop clamp (1-210, 78-32-12), bolt (1-200, 78-32-12), washer
(1-190, 78-32-12) and nut (1-180, 78-32-12). Tighten the nut to 33-37 lb in.
(3.7-4.2 N·m) of torque.

(d) Connect the flexible hose (1-260, 78-32-12) to the air tube (1-010, 78-32-12).
Tighten the B-nut to 112-128 lb ft (151.9-173.6 N·m) of torque and safety wire.

ASSEMBLY
PAGE 720
78-32-00 JUN 01/15
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1120742-01-A
Installation of the Right Side Air Tubes and Flexible hose.
R Figure 710

ASSEMBLY
PAGE 721
78-32-00 JUN 01/15
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R (19) On the right reverser half, install the directional pilot valve signal air tubes (1-070, -270,
78-32-12).

(a) Connect the upper signal air tube (1-070, 78-32-12) to the bulkhead fitting
located at the 1 o'clock position on the support assembly bulkhead bracket.
Route the upper signal air tube down and below the flexible shaft support
bracket.

(b) Connect the lower signal air tube (1-270, 78-32-12) to the upper signal air tube.
Route the lower signal air tube down. Hand-tighten the B-nut.

(c) Attach the upper air tube to the air tube (1-010, 78-32-12) at two locations on
the support assembly, below the upper end actuator housing, with loop clamps
(1-160, -170, 78-32-12), bolts (1-130, 78-32-12), washers (1-140, 78-32-12),
and spacers (1-150, 78-32-12). Tighten the bolts to 33-37 lb in. (3.7-4.2 N·m)
of torque.

(d) Attach the upper air tube to the support assembly, below the flexible shaft
clamp, with a loop clamp (1-250, 78-32-12), bolt (1-220, 78-32-12), washer
(1-230, 78-32-12), and spacer (1-240, 78-32-12). Tighten the bolt to 33-37 lb
in. (3.7-4.2 N·m) of torque.

(e) Attach the lower air tube to the support assembly at two locations, on both
sides of the CDU mount location, with loop clamps (1-320, 78-32-12), bolts
(1-300, 78-32-12), and washers (1-310, 78-32-12). Tighten the bolts to 33-37
lb in. (3.7-4.2 N·m) of torque.

(f) Tighten the B-nuts on the small air tubes to 135-150 lb in. (15.3-16.9 N·m) of
torque and safety wire (C10-071).

(g) Tighten the B-nuts on the large air tubes to 112-128 lb ft. (151.9-173.6 N·m) of
torque and safety wire (C10-071).

R (20) On the left reverser half (aft looking forward), install the air tubes (1-010 and -200,
R 78-32-11) and the flexible hose (1-410, 78-32-11). See figure 711.

(a) Apply grease (SAE-AMS-G-4343) to all threaded connectors used in the

installation of the air tube. Apply grease between the connector and the air
tube. Apply grease to all o-rings before installation.

(b) Connect the air tube (1-010, 78-32-11) to the bulkhead fitting, located at the
11 o'clock position, on the support assembly bulkhead bracket. Route the air
tube down and under the flexible shaft. Hand-tighten the B-nut.

(c) Attach the air tube to the support assembly, below the directional pilot valve,
with a loop clamp (1-180, 78-32-11), bolt (1-300, 78-32-11), and washer (1-310,
78-32-11). Tighten the bolt to 33-37 lb in. (3.7-4.2 N·m) of torque.

ASSEMBLY
PAGE 722
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MANUAL

683L SERIES

1120741-01-A
Installation of the Left Side Air Tubes and Flexible hose.
R Figure 711

ASSEMBLY
PAGE 723
78-32-00 JUN 01/15
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(d) Attach the air tube to the support assembly, in front of the flexible shaft support
bracket, with a loop clamp (1-360, -78-32-11), bolt (1-350, 78-32-11), washer
(1-340, 78-32-11), and nut (1-330, 78-32-11). Tighten the nut to 33-37 lb in.
(3.7-4.2 N·m) of torque.

(e) Connect the air tube (1-200, 78-32-11) to the saddle fitting on the air tube
(1-010, 78-32-11) and to the elbow (1-230, 78-32-11) on the directional pilot
valve. Tighten the B-nuts, at both ends, to 180-200 lb in. (20.3-22.6 N·m) of
torque and safety wire (C10-071).

(f) Connect the flexible hose (1-410, 78-32-11) to the air tube.

R (21) On the left reverser half, install the directional pilot valve signal air tubes (1-080, -240,
78-32-11).

(a) Connect the upper signal air tube (1-080, 78-32-11) to the bulkhead fitting,
located at the 11 o'clock position, on the support assembly bulkhead bracket
and to the tee fitting (1-270, 78-32-11) in the directional pilot valve.

(b) Attach the upper signal air tube and the air tube (1-010, 78-32-11) to the
support assembly, at the upper end actuator, with the loop clamps (1-170, -180,
78-32-11), bolt (1-140, 78-32-11), washer (1-150, 78-32-11), and spacer (1-
160, 78-32-11). Put the spacer between the clamps. Tighten the bolt to 33-37
lb in. (3.7-4.2 N·m) of torque.

R Pre SB 78-5061 * * * (RELOCATION OF DRAINAGE HOLES IN PNEUMATIC SIGNAL AIR TUBES)

R (c) Connect the lower signal air tube (1-240, 78-32-11) to the tee fitting (1-270,
R 78-32-11) on the directional pilot valve. Route the lower signal air tube down
R and under the flexible shaft support bracket.

R End Pre SB 78-5061

R Post SB 78-5061 * * * (RELOCATION OF DRAINAGE HOLES IN PNEUMATIC SIGNAL AIR TUBES)

R (c) Connect the lower signal air tube (1-241, 78-32-11) to the tee fitting (1-270,
R 78-32-11) on the directional pilot valve. Route the lower signal air tube down
R and under the flexible shaft support bracket.

R End Post SB 78-5061

(d) Attach the lower signal air tube to the support assembly, at the flexible shaft
support bracket, with a loop clamp (1-400, 78-32-11), bolt (1-370, 78-32-11),
washer (1-380, 78-32-11), and self-locking nut (1-390, 78-32-11). Tighten the
bolt to 33-37 lb in. (3.7-4.2 N·m) of torque.

(e) Attach the lower signal air tube to the bracket on the support assembly, before
the bend in the tube, with a loop clamp (MS21919WCJ4), bolt (MS9489-06),
and washer (AN960C10L). Tighten the bolt to 33-37 lb in. (3.7-4.2 N·m) of
torque.

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(f) Tighten the B-nut on the large air tube at the bulkhead fitting to 112-128 lb ft.
(151.9-173.6 N·m) of torque and safety wire (C10-071).

(g) Tighten the B-nuts on the upper and lower signal air tubes to 135-150 lb in.
(15.3-16.9 N·m) of torque and safety wire (C10-071).

(h) Tighten the locknut on the tee fitting and the elbow on the directional pilot valve
to 135-150 lb in. (15.3-16.9 N·m) of torque.

R C. Install the following onto the translating cowl assembly: See figure 712.

(1) Install the blocker door hinge assemblies (5-050, -055, 78-32-31) as follows:

(a) Install the blocker door hinge assemblies with the bolts (5-065 or -070 and -
075, 78-32-31) and washers (5-080, 78-32-31) in the forward leg. Tighten the
bolts with your fingers.

(b) Install the bolts (5-100, 78-32-31), washers (5-105, -125, 78-32-31), and nuts
(5-110, 78-32-31) in the aft leg of the blocker door hinge assemblies. Tighten
the nuts to 33-37 lb in. (3.7-4.2 N·m) of torque.

(c) Tighten the bolts in the forward leg of the blocker door hinge assemblies to 33-
37 lb in. (3.7-4.2 N·m) of torque.

ASSEMBLY
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1119540-00-A
Translating Cowl Hardware
R Figure 712

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(2) Install the six blocker doors (1-185, 78-32-31) as follows:

(a) Put three sleeves (1-201, 78-32-31), one flanged bushing (1-203, 78-32-31),
and three sliding bushings (1-205, 78-32-31) into the blocker door hinges.

(b) Attach each blocker door to the blocker door hinge assemblies (5-050, -055,
78-32-31) with the bolt (1-247, 78-32-31) and nut (1-249, 78-32-31). Tighten
the nuts to 55-70 lb in. (6.2-7.9 N·m) of torque.

CAUTION: MAKE SURE THAT THE SLEEVES IN THE BLOCKER DOOR

HINGES APPLY PRESSURE ON THE BEARINGS IN THE BLOCKER
DOOR HINGE ASSEMBLIES.

(c) Make sure the sleeves (1-201, -205 and/or -203, 78-32-31) in the blocker door
hinges (1-187, -189, 78-32-31) apply pressure on the spherical bearings (5-
060, 78-32-31) in the blocker door hinge assemblies. If necessary, tap the
sleeve(s) with a fiber mallet to seat and check the torque on the nut(s).

(d) DELETED

WARNING: DELETED

CAUTION: DELETED

(e) DELETED

(3) Install the eight bumpers (1-253, 78-32-31) with bolts (1-255, 78-32-31), washers
(1-260, 78-32-31), and nuts (1-265, 78-32-31). Tighten the bolts to 24-27 lb in. (2.7-3.1
N·m) of torque.

(4) Install the three lockout plates (1-270, 78-32-31) with bolts (1-275, 78-32-31), washers
(1-280, 78-32-31), and nuts (1-285, 78-32-31). Tighten the bolts to 24-27 lb in. (2.7-3.1
N·m) of torque.

D. Install the translating cowl assembly onto the support assembly.

(1) Lift the translating cowl assembly, engage the T-hinges into the guides on the support
assembly, and push the cowl assembly forward.

(2) Connect a blocker door link arm assembly (20-510, 78-32-21) to each of the six blocker
door assemblies (1-185, 78-32-31) as follows: See figure 712.

(a) Remove the tape from the link arm assembly.

(b) Push the link arm assembly through the link support (1-207, 78-32-31) on the
blocker door.

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WARNING: THIS MATERIAL/COMPOUND IS POISONOUS AND GIVES OFF

FUMES. MAKE SURE YOU USE IN AN AREA WITH GOOD AIR
FLOW. MAKE SURE YOU DO NOT BREATHE THE FUMES. DO
NOT GET ON YOUR SKIN OR INTO YOUR EYES OR MOUTH.
MAKE SURE YOU USE GLOVES AND CLOTHING TO PROTECT
YOURSELF.

(c) Apply a 0.125 inch (3,18 mm) bead of compound (C01-007) to the bottom of
the bolthead on the bolt (1-790, 78-32-01) and nut (1-795, 78-32-014). Attach
the link block assembly (1-765, 78-32-01) to the link arm assembly with the bolt
and nut. Tighten the nut to 55-70 lb in. (6.2-7.9 N·m) of torque.

(d) Install the cotter pin (1-800, 78-32-01). Apply compound (C01-007) to the
cotter pin to prevent chafing.

(e) Install the springs (1-762, 78-32-01) and spring retainer cap assembly (1-805,
78-32-01) on the blocker door link support with screws (1-810, 78-32-01) and
washers (1-815, 78-32-01). Tighten the screws to 55-70 lb in. (6.2 7.9 N·m) of
torque.

(3) Connect the upper and lower end actuators (10-090, -250, 78-32-11) to the translating
R cowl. See figure 714.

(a) If the translating cowl upper or lower inner actuator pin retainer (5-288,
R 78-32-31) was removed, install the retainer. See figure 714A. Tighten the
retainer to 200-220 lb in. (22.6-24.8 N m). Repeat for the other actuator pin
retainer if required.

(b) If the translating cowl upper or lower inner actuator pin access cap assembly
R (5-299, 78-32-31) was removed, install the cap assembly. See figure 714A.

1 Remove the old sealant from the cap assembly and from the opening in
the inner bondment. Clean both the cap assembly and the inner
bondment opening with solvent (C04-003 or C04-035). Allow to dry.

2 Apply a bead of sealant (C01-073 or equivalent) to the mating surface

of the cap assembly. Align the cap assembly with the opening in the
inner bondment, and install the cap assembly. Fare the outer edge of
the cap assembly with sealant (C01-073 or equivalent).

3 Let the sealant cure. Refer to the manufacturer’s instructions.

4 Install the screw in the center of the cap assembly.

5 Repeat for the other inner actuator pin access cap assembly if
required.

(c) Use fixture 2C6367 to install the upper and lower end actuators to the
translating cowl with the actuator pins.

(d) Rotate the clips (5-308, 78-32-31) 90 degrees to hold the upper and lower
actuator pins. Tighten the bolts to 55-70 lb in. (6.2-7.9 N·m) of torque.

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(e) At two locations, install an actuator pin cover (1-010, 78-32-31) with bolts
(1-015, 78-32-31). Tighten the bolts to 22-27 lb in. (2.5-3.1 N·m) of torque.

R E. Install the forward latch assembly (5-040, 78-32-01) on the left reverser half. See figure 716.

WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
USE IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU DO NOT
BREATHE THE FUMES. DO NOT GET ON YOUR SKIN OR INTO YOUR
EYES OR MOUTH. MAKE SURE YOU USE GLOVES AND CLOTHING TO
PROTECT YOURSELF.

(1) Apply primer (C03-005) to the bolts.

(2) Attach the handle end of the latch to the 6 o’clock end of the latch ring flange with bolts,
washers, and nuts. Tighten the nuts to 55-70 lb in (6.2-7.9 N.m) of torque.

(3) Attach the lower cable bracket (1-110, 78-32-41) to hole No. 60 with a bolt (5-810, 78-
32-01), washers (5-820, 78-32-01), and nut (5-830, 78-32-01) and the 10-32 bolt holes
on each end of the bracket with bolts (1-120, 78-32-41), washers (1-125, 78-32-41),
and nuts (1-130, 78-32-41).

(4) Remove the bolt, washer, and nut that attaches the rod-end of the cable to the upper
latch link mechanism. Remove the locknut from the cable assembly.

(5) Attach the forward latch assembly (5-040, 78-32-01) to the 12 o'clock end of the latch
ring flange with bolts (5-050, 78-32-01), washers (5-060, 78-32-01), and nuts (5-070,
78-32-01). Tighten the bolts to 55-70 lb in. (6.2-7.9 N·m) of torque.

(6) Put the cable assembly through the two holes in the brake bracket.

(7) Install the self-locking nut, removed in step E.(4), onto the cable assembly. Tighten the
nut to 42-47 lb ft (56.9-63.7 N·m) of torque.

(8) Install the rod-end feedback to the upper latch link mechanism with the bolt, washer,
and nut that were removed. Tighten the nut to 55-70 lb in. (6.2-7.9 N·m) of torque.

(9) Attach the four cable support brackets (1-015, 78-32-41) to the latch ring flange, at the
10-32 bolt holes between holes No. 23 and 24, 31 and 32, 38 and 39, and 51 and 52,
with bolts (1-020, 78-32-41), washers (1-025, 78-32-41), and nuts (1-030, 78-32-41).
Tighten the nuts to 24-27 lb in. (2.7-3.1 N·m) of torque.

(10) Attach the latch cable to the four brackets with loop clamps (1-035, 78-32-41), screws
(1-040, 78-32-41), washers (1-045, 78-32-41), and nuts (1-050, 78-32-41). The third
clamp down from the top is positioned away from the latch ring. Tighten the nuts to 24-
27 lb in.(2.7-3.1 N·m) of torque.

ASSEMBLY
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1120740-00-A
Installation of the Blocker Door Assembly Hardware
R Figure 713

ASSEMBLY
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1119539-02-A
Installation of the End Actuators
R Figure 714

ASSEMBLY
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MR60043-00-A
Installation of the Inner Actuator Pin Retainer and Inner Actuator Pin Access Cap Assembly
R Figure 714A

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F. Install the electro-mechanical brake assembly (2-010, 78-36-10) left and right side. See figure
R 715.

(1) Clamp the bracket (2-025 or -030, 78-36-10) to the latch ring at the bulkhead system
support bracket. Measure the gap between the bracket and the bulkhead.

(2) Remove layers from a laminated shim (2-035, 78-36-10) until it is the same thickness
as the gap that was measured.

(3) Remove the clamps, install the shim under the bracket, and attach the bracket to the
latch ring with the bolts (2-040, -050, -055, 78-36-10), washers (2-060, 78-36-10) and
nuts (2-065, 78-36-10). Tighten the nuts with your hand.

(4) Remove the bolts from the upper end actuator gear drive cover. Discard the cover and
keep the bolts.

(5) Install an interconnecting flex shaft (2-115, 78-36-10) into the electro-mechanical brake.

(6) Install the other end of the interconnecting flex shaft into the upper end actuator. Attach
the interconnecting flex shaft to the upper end actuator with the bolts that were
removed. Before you install the bolts, apply anti-seize compound (C02-032) to the bolt
threads. Tighten the bolts to 24-27 lb in. (2.7-3.1 N·m) of torque.

(7) Attach the electro-mechanical brake to the bracket with bolts (2-015, 78-36-10) and
washers (2-020, 78-36-10). Before you install the bolts, apply anti-seize compound
(C02-032) to the bolt threads. Tighten the bolts to 55-70 lb in. (6.2-7.9 N·m) of torque.

NOTE: The bracket has six holes. The electro-mechanical brake should be
aligned with three of these holes without forcing the interconnecting flex
shaft into an S shape condition.

(8) Install two electrical brackets (2-070,-075, 78-36-10) to the brake brackets with the
bolts (2-080, 78-36-10) and washers (2-085, 78-36-10). Tighten the bolts to 24-27 lb in.
(2.7-3.1 N·m) of torque. Align the brackets on the lower side of each leg with the spring
clips out.

ASSEMBLY
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MM60006-02-A
Installation of the Electro-Mechanical Disk Brake
R Figure 715

ASSEMBLY
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G. On the left reverser half, install the electrical brackets and support assembly brackets to the
R inner bolt holes of the latch ring flange. Refer to table 702 and figure 717.

Table 702. Left Reverser Half Inner Flange Brackets

Bracket CSN Hole Bolt Washer Nut

78-32-01 Location CSN CSN CSN

5-110 8-9 5-080 5-090 5-100

5-280 17-18 5-230,240 5-250 5-260
5-200 21-22 5-170 5-180 5-190
5-200 25-26 5-170 5-180 5-190
5-110 29-30 5-080 5-090 5-100
5-340 33-34 5-310 5-320 5-330
5-865 35-36 5-870 5-875 5-880
5-340 37-38 5-310 5-320 5-330
5-420 42-43 5-370 (LH) 5-390 5-400
5-520 45 5-490 5-500 5-510
5-600 45-46-47-48 5-450,455,490 5-460,500 5-470,510
5-670 or 5-672 57-58 5-640 5-650 5-660

(1) Attach the bracket (5-600, 78-32-01) to the four holes in the torque box stiffener with
the bolts (5-570, 78-32-01), washers (5-580, 78-32-01), and nuts (5-590, 78-32-01).

(2) Attach the latch cable, at two places, to the inside of the brackets (5-520 and 5-600, 78-
32-01) with the loop clamps (5-480, 78-32-01), bolts (5-450, 78-32-01), washers (5-460,
78-32-01), and nuts (5-470, 78-32-01). Tighten the nuts to 24- 27 lb in.(2.7-3.1 N·m) of
torque.

(3) Attach the latch cable to the upper hole on the bracket (5-420, 78-32-01), located at
holes 42 and 43, with a loop clamp (5-410, 78-32-01), bolt (5-380, 78- 32-01), washers
(5-390, 78-32-01), and nut (5-400, 78-32-01).

ASSEMBLY
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1121170-00-A
Installation of the Left Side Forward Latch Assembly
R Figure 716 (Sheet 1 of 2)

ASSEMBLY
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1121171-00-A
Installation of the Left Side Forward Latch Assembly
R Figure 716 (Sheet 2 of 2)

ASSEMBLY
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R (4) DELETED

(5) Attach the support assembly hinged loop clamp (1-565, 78-32-01) to the bracket (5-
670, 78-32-01) with the bolts (1-570, 78-32-01), washers (1-580, 78-32-01), and nuts
(1-590, 78-32-01). Tighten the nuts to 24-27 lb in. (2.7-3.1 N·m) of torque.

(6) Attach the hinged loop clamp (TA10950004-10) to the outer surface of the bracket
(5-520, 78-32-01), located at hole No. 45, with the bolts (MS9556-07). Align the clamp
with the hinge down. Tighten the bolts to 24-27 lb in. (2.7-3.1 N·m) of torque.

(7) Attach the hinged loop clamp (TA10950004-10) to the bracket (5-110, 78-32- 01),
located at holes No. 8 and 9, with the bolts (MS9556-06). Align the clamp with the
hinge out. Tighten the bolts to 24-27 lb in. (2.7-3.1 N·m) of torque. Tighten the latch
ring nuts/bolts to 55-70 lb in. (6.2-7.9 N·m) of torque.

H. On the right reverser half, install the forward latch assembly (5-040, 78-32-02). See figure 718.

WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
USE IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU DO NOT
BREATHE THE FUMES. DO NOT GET ON YOUR SKIN OR INTO YOUR
EYES OR MOUTH. MAKE SURE YOU USE GLOVES AND CLOTHING TO
PROTECT YOURSELF.

(1) Apply epoxy resin primer (C03-005) to the bolts.

(2) Attach the handle end of the latch to the 6 o'clock end of the latch ring flange with the
bolts, washers, and nuts. Tighten the nuts to 55-70 lb in. (6.2-7.9 N·m) of torque.

(3) Attach the lower cable bracket (1-115, 78-32-41) to hole No. 60 with a bolt (5-710,
78-32-01), washers (5-720, 78-32-01), and nut (5-730, 78-32-01) and the 10-32 bolt
holes on each end of the bracket with bolts (1-120, 78-32-41), washers (1-125, 78-32-
41), and nuts (1-130, 78-32-41).

(4) Remove the bolt, washer, and nut that attaches the rod end of the cable to the upper
latch link mechanism. Remove the locknut from the cable assembly.

(5) Attach the forward latch assembly to the 12 o'clock end of the latch ring flange with the
bolts (5-050, 78-32-02), washers (5-060, 78-32-02), and nuts (5-070, 78-32-02).
Tighten the bolts to 55-70 lb in. (6.2-7.9 N·m) of torque.

(6) Put the cable assembly through the two holes in the brake bracket.

(7) Install the self-locking nut, removed in step H.(4), onto the cable assembly. Tighten the
nut to 42-47 lb ft (56.9-63.7 N·m) of torque.

(8) Install the rod end feedback to the upper latch link mechanism with the bolt, washer,
and nut that were removed. Tighten the nut to 55-70 lb in. (6.2-7.9 N·m) of torque.

ASSEMBLY
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MR60043-00-A
Installation of the Left Side Electrical Brackets
R Figure 717
1121146-01-A

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(9) Attach the four cable support brackets (1-015, 78-32-41) to the latch ring flange, at the
10-32 bolt holes between holes No. 23 and 24, 31 and 32, 38 and 39, and 51 and 52,
with bolts (1-020, 78-32-41), washers (1-025, 78-32-41), and nuts (1-030, 78-32-41).
Tighten the nuts to 24-27 lb in. (2.7-3.1 N·m) of torque.

(10) Attach the latch cable to the four brackets with loop clamps (1-055, 78-32-41), screws
(1-060, 78-32-41), washers (1-065, 78-32-41), and nuts (1-070, 78-32-41). The second
and third clamps down from the top are positioned away from the latch ring. Tighten
the nuts to 24-27 lb in. (2.7-3.1 N·m) of torque.

(11) Attach the latch cable to the latch ring at bolt holes 18 and 43 with bolts (5-360, 78-32-
02), washers (5-370, 78-32-02), and nuts (5-380, 78-32-02). Tighten the nuts to 55-70
lb in. (6.2-7.9 N·m) of torque.

I. On the right reverser half, install the electrical brackets and support assembly brackets to the
R inner bolt holes of the latch ring flange. Refer to table 703 and figure 719.

Table 703. Right Reverser Half Inner Flange Brackets

Bracket CSN Hole Bolt Washer Nut

78-32-02 Location CSN CSN CSN

5-110 8-9 5-080 5-090 5-100

5-200 15-16 5-170 5-180 5-190
5-270 20-21 5-230 5-240 5-250
5-200 24-25 5-170 5-180 5-190
5-200 28-29 5-170 5-180 5-190
5-200 32-33 5-080 5-090 5-100
5-330 35-36 5-310 5-320 5-330
5-500 45-46-47-48 5-440 5-450 5-460
5-570 57-58 5-540 5-550 5-560

(1) Attach the bracket (5-500, 78-32-02) to the four holes in the torque box stiffener
with bolts (5-470, 78-32-02), washers (5-480, 78-32-02), and nuts (5-490, 78-32-02).
Tighten the nuts to 55-70 lb in. (6.2-7.9 N·m) of torque.

(2) Attach the latch cable, at two places, to the inside of the bracket (5-500, 78-32-02) with
loop the clamps (5-430, 78-32-02), bolts (5-400, 78-32-02), washers
(5-410, 78-32-02), and nuts (5-420, 78-32-02). Tighten the nuts to 24-27 lb in. (2.7-3.1
N·m) of torque.

(3) Attach the latch cable to hole No. 43 with a loop clamp (5-390, 78-32-02), bolt (5-360,
78-32-02), washers (5-370, 78-32-02), and nut (5-380, 78-32-02).

(4) Attach the support assembly hinged loop clamp (1-565, 78-32-01) to the bracket (5-
570, 78-32-02) with the bolts (1-570, 78-32-01), washers (1-580, 78-32-01), and nuts
(1-590, 78-32-01). Tighten the nuts to 24-27 lb in. (2.7-3.1 N·m) of torque.

ASSEMBLY
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1119538-02-A
Installation of the Right Side Forward Latch Assembly
R Figure 718 (Sheet 1 of 2)

ASSEMBLY
PAGE 741
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MANUAL

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MM60022-00-A
Installation of the Right Side Forward Latch Assembly
R Figure 718 (Sheet 2 of 2)

ASSEMBLY
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(5) Attach the hinged loop clamp (TA10950004-10) to the bracket (5-330, 78-32-02),
located at hole No. 35 and 36, with the bolts (MS9556-10). Align the clamp with the
hinge in. Tighten the bolts to 24-27 lb in. (2.7-3.1 N·m) of torque.

(6) Attach the hinged loop clamp (TA10950004-10) to the bracket (5-110, 78-32-02),
located at holes No. 8 and 9, with the bolts (MS9556-07). Align the clamp with the
hinge out. Tighten the bolts to 24-27 lb in. (2.7-3.1 N·m) of torque.

(7) Attach the hinged loop clamp (TA10950004-10) to the bulkhead bracket on the forward
latch with the bolts (MS9556-06). Align the clamp with the hinge up. Tighten the bolts
to 24-27 lb in. (2.7-3.1 N·m) of torque.

J. Attach the retractable support assembly (1-545, 78-32-01) to the support clevis on the bracket
(5-500, 78-32-02 and 5-600, 78-32-01) with the bolts (1-550, 78-32-01), washers (5-555,
78-32-01), and nuts (5-560, 78-32-01). Tighten the nuts to 190-230 lb in. (21.5-26.0 N·m) of
torque.

(1) Open the hinged loop clamps on the support bracket and secure the retractable support
assemblies.

R K. Install the feedback actuator assembly (CDU) (5-210, 78-32-11). See figure 720.

(1) To release the CDU brake, raise the handle approximately 60 degrees (until a flat can
be felt), and hand crank the center drive unit toward the deploy position several turns to
help the actuator pin alignment.

(2) Put the CDU into the support structure and align the ballscrew actuator with the clevis
on the translating cowl.

(3) If the translating cowl middle inner actuator pin retainer (5-288, 78-32-31) was
R removed, install the retainer. See figure 714A. Tighten the retainer to 200-220 lb in.
(22.6-24.8 N m).

(4) If the translating cowl middle inner actuator pin access cap assembly (5-299, 78-32-31)
R was removed, install the cap assembly. See figure 714A.

(a) Remove the old sealant from the cap assembly and from the opening in the
inner bondment. Clean both the cap assembly and the inner bondment
opening with solvent (C04-003 or C04-035). Allow to dry.

(b) Apply a bead of sealant (C01-073 or equivalent) to the mating surface of the
cap assembly. Align the cap assembly with the opening in the inner bondment,
and install the cap assembly. Fare the outer edge of the cap assembly with
sealant (C01-073 or equivalent).

(c) Let the sealant cure. Refer to the manufacturer’s instructions.

(d) Install the screw in the center of the cap assembly.

ASSEMBLY
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1121148-01-A
Installation of the Right Side Electrical Brackets
R Figure 719

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(5) Use fixture 2C6367 to install the actuator pin (D52B1502-11) and attach the actuator of
the CDU to the translating cowl.

(6) Rotate the clip 90 degrees to safety the actuator pin and tighten the bolt to 55-70 lb in.
(6.2-7.9 N·m) of torque.

(7) Install the actuator pin cover (1-010, 78-32-31) with bolts (1-015, 78-32-31). Tighten
the bolts to 22-27 lb in. (2.5-3.1 N·m) of torque.

(8) Install the CDU mounting flange shims (5-160, 78-32-11) and attach the CDU to the
support assembly with four bolts (5-120, 78-32-11), washers (5-130, -140, 78-32-11),
and nuts (5-150, 78-32-11).

(9) Install the CDU shock pins (5-090, -100, 78-32-11).

(a) Insert the shock pins into the CDU housing. Attach the pins to the support
assembly with the bolts (5-060, 78-32-11), washers (5-070, 78-32-11), shims
(5-110, 78-32-11), and nuts (5-080, 78-32-11).

(10) Crank the CDU, with your hand, toward the stow position until the CDU mounting flange
is flush against the support assembly. Stow the handle.

(11) Tighten the CDU mounting flange nuts to 55-70 lb in. (6.2-7.9 N·m) of torque.

(12) Tighten the CDU shock pin nuts to 100-120 lb in. (11.3-13.6 N·m) of torque.

(13) Connect the lower signal air tube (1-240, 78-32-11 and 1-270, 78-32-12) to the CDU.
Tighten the B-nut to 135-150 lb in. (15.3-16.9 N·m) and safety-wire (C10-071).

(14) On the right reverser half, tighten the lower directional signal air tube connection to the
upper directional signal air tube B-nut to 135-150 lb in. (15.3-16.9 N·m) of torque and
safety-wire.

(15) Connect the flexible air hose (1-410, 78-32-11 and 1-260, 78-32-12) to the CDU.
Tighten the B-nut to 112-128 lb ft. (151.9-173.6 N·m) of torque and safety-wire (C10-
071).

R ASSEMBLY
PAGE 745
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1119537-01-A
Installation of the Feedback Actuator Assembly (CDU)
R Figure 720 (Sheet 1 of 3)

ASSEMBLY
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1121149-00-A
Installation of the Feedback Actuator Assembly (CDU)
R Figure 720 (Sheet 2 of 3)

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1121177-00-C
Installation of the Feedback Actuator Assembly (CDU)
R Figure 720 (Sheet 3 of 3)

R L. Install the feedback drive unit (5-220 or 5-230, 78-32-11) as follows. See figure 720A.

NOTE: The left and right feedback drive units are different. On the left feedback drive unit the
feedback cable threaded housing is on the same side as the drive unit mount pad; on the
right feedback drive unit the feedback cable threaded housing is on the side opposite the
drive unit mount pad.

(1) Prepare the center drive unit.

(a) Release the center drive unit brake.

1 Pull the center drive unit brake handle out away from the center drive
unit (approximately 60°) until you feel a flat.

ASSEMBLY
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MR50210-00-A
Feedback Drive Unit and Feedback Push-Pull Cable Installation
R Figure 720A (Sheet 1)

ASSEMBLY
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MR60100-00-A
Installation of the Feedback Drive Unit
R Figure 720A (Sheet 2)

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MR60101-00-A
Installation of the Feedback Drive Unit
R Figure 720A (Sheet 3)

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(b) Make sure the center drive unit is in the stow rig position.

NOTE: The stow rig position length of the center drive unit, from the
mounting flange to the center of the tube assembly bearing bore
must be 24.349-24.543 in. (618.47-618.57 mm).

1 Hand crank the center drive unit to the stow rig position.

2 Push the button on the stow rig position indicator to make sure the
center drive unit is in the stow rig position. The button must depress
into the groove on the ballscrew as seen through the observation hole.

(2) Prepare the feedback drive unit.

(a) Make sure the feedback drive unit is in the stow rig position.

1 Hand crank the feedback drive unit to the stow rig position.

R 2 Install a depth gage into the guide cable cap as shown in figure 709,
and turn the feedback drive shaft until you get a measurement of
0.710-0.770 in. (18.03-19.56 mm).

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN
OR EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

(3) Clean the mating flanges of the center drive unit and the feedback drive unit with
solvent (C04-035).

(4) Align the splined shaft on the feedback drive unit with the splines in the mount pad on
the center drive unit and carefully install the feedback drive unit on the center drive unit.

(5) Install the bolts (5-081 and -085, 78-32-11) and the washers (5-083 and -087,
78-32-11). Tighten bolts (5-081, 78-32-11) to 33-37 lb in. (3.7-4.2 N·m) of torque.
Tighten bolts (5-085, 78-32-11) to 55-70 lb in. (6.2-7.9 N·m) of torque.

(6) Continue to tighten bolts (5-081, 78-32-11 or 78-32-12) to 48-52 lb in. (5.4-5.9 N·m) of
torque. Continue to tighten bolt (5-091, 78-32-11 or 78-32-12) to 114-126 lb in. (12.9-
14.2 N·m) of torque.

(7) After 10 minutes, tighten bolts (5-081, 78-32-11 or 78-32-12) again to 48-52 lb in. (5.4-
5.9 N·m) of torque, and tighten bolt (5-091, 78-32-11 or 78-32-12) again to 114-126 lb
in. (12.9-14.2 N·m) of torque.

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WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN
OR EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

(8) Clean the interface area of the center drive unit and the feedback drive unit with solvent
(C04-035).

(9) Apply sealing compound (C01-145) all around the interface of the center drive unit and
the feedback drive unit to a thickness of approximately 0.0005 in. (0.013 mm) to seal
the surface.

M. Insert the flexible shaft assemblies (25-120, -125, 78-32-11) into the feedback drive unit on the
CDU and attach with bolts (25-130, 78-32-11) and washers (25-140, 78-32-11). Before you
install the bolts, apply anti-seize compound (C02-032) to the bolt threads. Tighten the bolts
to 33-37 lb in. (3.7-4.2 N·m) of torque.

N. Adjust the fan reverser. Refer to 78-32-00, Rigging.

O. Install the CDU position feedback transducer (5-240, 78-32-11) as follows. See
R figure 721.

(1) On the shaft of the CDU position feedback transducer, install a new preformed packing
(P/N 299-4557-207A, FSCM 19710) if necessary, or install the preformed packing you
removed, if it is free of defects.

CAUTION: BEFORE YOU INSTALL THE CDU POSITION FEEDBACK TRANSDUCER,

MAKE SURE THE REVERSER IS IN THE STOW RIG POSITION. IF THE
REVERSER IS NOT IN THE STOW RIG POSITION, YOU CAN GET A FALSE
TRANSLATING COWL POSITION INDICATION.

(2) Turn the square shaft of the CDU position feedback transducer to align the lines as
seen through the sight glass at the end of the transducer.

NOTE: Actuator feedback subsystems are normally shipped from the factory or
overhaul facility with the cover plate installed on the manual drive pad of
the feedback drive unit and the lockout plate installed on the manual drive
pad of the CDU brake housing.

(3) On the left reverser half, remove the lockout plate and bolts from the manual drive pad
of the CDU brake housing. Install the position feedback transducer (5-240, 78-32-11)
on the manual drive pad of the CDU brake housing. Remove and discard the cover
R plate located on the manual drive pad of the feedback drive unit. See figure 722.
Make sure the electrical connectors point toward the engine (inboard).

NOTE: Further information on removal of the cover plate is available in MRAS SB

78-5051.

ASSEMBLY
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MM50006-00-A
Installation of the CDU Position Feedback Transducer
R Figure 721

ASSEMBLY
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MR60043-00-A
Removal of the Feedback Drive Unit Cover Plate
R Figure 722

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(4) On the right reverser half, remove the cover plate and bolts from the manual drive pad
of the feedback drive unit. Discard the cover plate. Install the position feedback
transducer (5-240, 78-32-11) on the manual drive pad of the feedback unit with bolts.
Tighten the bolts to 33-37lb in. (3.7-4.2 N·m) of torque. Make sure the electrical
connectors point toward the engine (inboard).

P. On the left reverser half, install the Goodrich-provided electrical harness (Goodrich CMM 71-50-
R 08). See figure 723.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

(1) Clean the area of the left interface bracket that will contact the harness connector with a
clean, lint-free cotton cloth (C10-182) made moist with solvent (C04-003 or C04-035).
Clean the tabs on the harness.

(2) Open the hinged clamp on the bracket (5-110, 78-32-01) and insert the harness. Close
the hinged clamp.

(3) Loosen the screws on the tabs on the interface bracket. Put the connector into the
opening of the bracket with the keyway pointing to 12 o'clock. Close the tabs over the
flange of the connector. Tighten the bolts to 33-37 lb in. (3.7-4.2 N·m) of torque.

(4) Put the harness into the spring clips on the nine brackets along the latch ring flange.

(5) Open the hinged clamp on the bracket (5-520, 78-32-01), located at hole No. 45 and
put the harness into the clamp. Close the clamp.

(6) Connect the connectors on the harness.

(a) Connector 4104KS2-A to the stow and deploy switch on the CDU.

(b) Connector 4003KS-A to the RVDT on the CDU.

(c) Connector 4112KS-B to the pressure switch on the directional pilot valve.

(d) Connector 4112KS-A to the pilot valve.

(7) Tighten the connectors with soft-jawed pliers until they slip.

(8) Adjust the harness until there are no sharp bends.

(9) Tighten the bolts on the hinged loop clamps to 5-8 lb in. (0.57-0.90 N·m) of torque.

ASSEMBLY
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1121150-01-A
Installation of the Left Reverser Half Electrical Harness
R Figure 723

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Q. On the right reverser half, install the Goodrich-provided electrical harness (Goodrich CMM
R 71-50-08). See figure 724.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

(1) Clean the area of the right interface bracket that will contact the harness connector with
a clean, lint-free cotton cloth (C10-182) made moist with solvent (C04-003 or C04-035).
Clean the tabs on the harness connector.

(2) Open the hinged loop clamp on the bracket (5-110, 78-32-02) and put the harness into
the clamp. Close the clamp.

(3) Loosen the screws on the tabs on the interface bracket. Put the connector into the
opening of the bracket with the keyway pointing to 12 o'clock. Close the tabs over the
flange of the connector. Tighten the bolts to 33-37 lb in. (3.7-4.2 N·m) of torque.

(4) Put the harness into the spring clips on the seven brackets along the latch ring flange.

(5) Open the hinged loop clamp on the bracket (5-330, 78-32-02), located at holes No. 35
and 36 and put the harness into the clamp. Close the clamp.

(6) Connect the connectors on the harness.

(a) Connector 4104KS1-A to the stow and deploy switch on the CDU.

(b) Connector 4004KS-A to the RVDT on the CDU.

(7) Tighten the connectors with soft-jawed pliers until they slip.

(8) Adjust the harness until there are no sharp bends.

(9) Tighten the bolts on the hinged loop clamps to 5-8 lb in. (0.57-0.90 N·m) of torque.

R. Check the electro-mechanical brake system lock electrical resistance.

(1) Use an ohm meter to check the resistance between the brake and the bulkhead
bracket. The resistance must be 0.0025 ohms or less.

(2) If the resistance is more than 0.0025 ohms, the laminated shim must be removed. The
bonding surface areas of the shim, bulkhead bracket, and actuator lock bracket must
be cleaned, assembled, and resistance checked again.

S. Adjust the fan reverser. Refer to 78-32-00, Rigging.

ASSEMBLY
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1121151-01-A
Installation of the Right Reverser Half Electrical Harness
R Figure 724

ASSEMBLY
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T. Check the electro-mechanical brake system lock torque.

(1) Release the electro-mechanical brake lock and the CDU manual release handles.

(2) Manually deploy the translating cowl approximately 1.0 in. (25.4 mm).

(3) Engage the electro-mechanical brake lock manual release handle.

(4) Use a 0.25 in. (6.4 mm) drive extension and a torque wrench and apply 90 lb in. (10.2
N·m) of torque to the CDU manual drive pad.

(a) The lock is good and serviceable if you can apply 90 lb in. (10.2 N·m) before
the wrench turns 450 degrees (1-1/4 turns).

(b) If the wrench turns more than 450 degrees, the long flexible shaft between the
CDU and the upper end actuator must be replaced and the check done again.

(c) The torque wrench must return to +30 degrees of the original position. If it
does not, replace the long flexible shaft between the CDU and the upper end
actuator, and do the torque check again.

(d) If you feel the lock turn, replace the lock and do the torque check again.

(5) Release the manual release handle on the electro-mechanical brake.

(6) Measure the running torque necessary to move the translating cowl. The running
torque must be 10.0 lb in. (1.1 N·m) or less.

(7) Stow the translating cowl.

(8) Replace the dust cover on the CDU. Tighten the bolts to 33-37 lb in. (3.7-4.2 N·m) of
torque.

U. Check the electrical continuity of the fan reverser. Refer to 78-32-00, Testing.

V. Install the lockout plates as follows:

(1) On the left reverser half, align the lockout plate on the manual drive pad on the top of
the center drive unit brake housing with the square drive exposed (open position), and
install two bolts to attach the lockout plate. Tighten the bolts to 33-37 lb in. (3.7-4.2
N·m) of torque.

(2) On the right reverser half, align the lockout plate on the manual drive pad on top of the
feedback drive unit with the square drive exposed (open position), and install two bolts
to attach the lockout plate. Tighten the bolts to 33-37 lb in. (3.7-4.2 N·m) of torque.

R ASSEMBLY
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FAN REVERSER TRANSLATING COWL - INSPECTION/CHECK

Refer to Page Block 78-32-31 for translating cowl Inspection and Repair procedures.

INSPECTION
PAGE 501
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 FAN REVERSER
CF6-80E1 CMM

THIS PAGE INTENTIONALLY BLANK

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FAN REVERSER SUPPORT ASSEMBLY - DISASSEMBLY

R 1. General.

R This procedure gives instructions for the disassembly of the support assembly in preparation for the
R repair or replacement of delaminated inner and outer skin, or for the replacement of the upper or lower
R duct sidewalls.

R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools. None required.

R (3) Locally Manufactured Tools. None required.

R (4) Equipment.

R Description Manufacturer

R Grinder, Pencil Local purchase

R Drill Motor Local purchase

R Disk, Carbide, 3-inch Local purchase

R (7.62 cm)

R B. Consumable Materials.

R Code No. Description

R C01-011 Adhesive, Paste, EA 934NA

R C. Referenced Procedures.

R 78-32-00, Disassembly

DISASSEMBLY
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R 3. Procedure.

R A. Do the steps that follow to disassemble the fixed structure from the core cowl support
R assembly.

R (1) Remove the items that follow from the support structure. Refer to 78-32-00,
R Disassembly.

R NOTE: You must remove these components from the support structure before you
R can place it in the support stand.

R (a) Remove the translating cowl assembly.

R (b) Remove the hinge cover.

R (c) Remove the electrical harness.

R (d) Remove the center drive unit.

R (e) Remove the latch ring assembly.

R (f) Remove the upper hinge bolts.

R (g) Remove the aft core cowl wear strips.

R (h) Remove the pneumatic and hydraulic tubing.

R (i) Remove the angle gear boxes.

R (j) Remove the upper wear strip.

R (k) Remove the blowout and access doors.

R (l) Remove the hold open rod and bracket.

R (m) Remove the lower latches or latch bolts.

R (n) Remove the flex shafts.

R (o) Remove the upper aft fairing.

R (p) Remove the upper fireseal assembly.

R (q) Remove the lower and upper sidewall forward seals.

R (r) Remove the outer torque box wear strip.

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R (2) Install the fixed structure into the support stand at the pickup locations shown in figure
R 301.

R NOTE: The data given in figure 301 and table 301 can be used to make a support
R stand and to inspect the reverser after assembly. Support is from three
R main hinge bolts and at three main latch striker plates.

R (3) Hold the upper and lower duct sidewalls to butt line surfaces as shown in figure 301.

R (4) Do a check to make sure the radius dimensions agree with those shown in figure 301.

DISASSEMBLY
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R MM50040-01-A
R Fixed Structure
R Figure 301 (Sheet 1)

DISASSEMBLY
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MR50155-01-A
HINGE LOCATIONS

HINGE
LOCATION STATION DIM “A” DIM “B” BL WL

FWD 211.500 1.800/1.790 0.902/0.892 85.700 151.590

MID 233.320 1.400/1.390 0.739/0.729 88.700 150.130

AFT 250.960 1.396/1.386 0.712/0.702 88.700 148.950

R MR50155-01-A
R Fixed Structure - Hinge Locations
R Figure 301 (Sheet 2)

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MR50156-00-A

LATCH LOCATIONS

LATCH LOCATION FWD STATION AFT STATION WL

FWD 213.790 215.710 50.412

MID 232.360 234.280 50.412

AFT 245.500 247.420 50.265

BL = 0.000

R MR50156-00-A
R Fixed Structure - Latch Locations
R Figure 301 (Sheet 3)

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R MR50157-01-A
R Fixed Structure - Engine Ring Locations
R Figure 301 (Sheet 4)

DISASSEMBLY
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R MR50158-01-A
R Fixed Structure - Aft Core Cowl Closeout/Torque Box Locations
R Figure 301 (Sheet 5)

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R MR50159-00-A
R Fixed Structure - Core Cowl Lift Locations
R Figure 301 (Sheet 6)

DISASSEMBLY
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R MR60126-00-A
R Fixed Structure - Torque Box Pick Up Locations
R Figure 301 (Sheet 7)

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R Table 301. Tooling Hole Locations

R LOCATION STATION WL

R A. Core Cowl

R FWD¹ 197.908 (FLOWPATH) 100.000

R AFT² 261.750 (FLOWPATH) 100.000

R NOTE 1: The above location is now insert location #26 from upper or #31 from lower.

R NOTE 2: The above location is now filled with a rivet.

R B. Lower Sidewall

R FWD 198.000 (FLOWPATH) 60.000

R AFT 251.000 (FLOWPATH) 60.000

R C. Upper Sidewall

R FWD 201.400 (FLOWPATH) 140.000

R AFT 263.650 (FLOWPATH) 140.000

R NOTE: The diameter of the tool holes is 0.250 in. (6.35 mm).

R NOTE: At the time of production, the tooling holes in the upper and lower sidewall bondment were
R used to locate the bondment into a tool and install the hinge/latch beams. The tooling holes
R in the core cowl held the core cowl in the proper location when the forward engine ring was
R installed. After production, the hinge/latch beams and engine ring became the reference
R locations to assemble the fixed structure. These tooling holes are filled by either a rivet
R fastener or insert after completion of the sub-assembly procedure.

R NOTE: You can fill the tool holes with a serrated MS20426AD8 rivet. Refer to figure 301A. Bond
R the serrated rivet in position with adhesive (C01-011). The head must be on the flowpath
R side.

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R MR50278-00-A
R Serrated Rivet
R Figure 301A

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R B. Remove the bolted-on component hardware from the inner surface of the core cowl. Refer to
R figures 302, 303 (left side), and 304 (right side).

R NOTE: Keep all serviceable hardware to use for assembly.

R (1) Remove the items that follow from the left support assembly. Refer to figures 302 and
R 303, and to 78-32-00, Disassembly.

R (a) Remove the power door opening actuator and cable or tubes, hoses, and
R hydraulic lines.

R (b) Remove the precooler duct and the bracket.

R (c) Remove the air tubes, the flexible hose, and the signal air tube.

R (d) Remove the six link box assemblies.

R (2) Remove the items that follow from the right support assembly. Refer to figures 302 and
R 304, and to 78-32-00, Disassembly.

R (a) Remove the power door opening actuator and cable or tubes, hoses, and
R hydraulic lines.

R (b) Remove the air tubes and the flexible hose.

R (c) Remove the six link box assemblies.

DISASSEMBLY
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R MR60127-00-A
R Power Door Opening Actuator
R Figure 302

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R MR60128-00-A
R Left Support Assembly
R Figure 303

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R MR60129-00-A
R Right Support Assembly
R Figure 304

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R C. Remove the upper and lower bifurcation extensions. Refer to figure 305.

R (1) Remove the upper sidewall bifurcation extension.

R (a) Remove the bolts (85-20, 78-32-21), washers (85-30, 78-32-21), nuts (85-50,
R 78-32-21), pins (85-60, 78-32-21), washers (85-70, 78-32-21) and nuts (85-80,
R 78-32-21) that attach the upper bifurcation extension assembly (85-10 and -15,
R 78-32-21) to the upper sidewall assembly (1-785 and -790, 78-32-21). Remove
R the upper bifurcation extension.

R (2) Remove the lower sidewall bifurcation extension.

R (a) Remove the bolts (85-740, 78-32-21), pins (85-760, and -790, 78-32-21), and
R nuts (85-780, 78-32-21) that attach the lower bifurcation extension assembly
R (85-730 and -735, 78-32-21) to the lower sidewall assembly (10-5, 78-32-21 or
R 78-32-22). Remove the lower bifurcation extension.

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R MR60130-00-A
R Upper and Lower Bifurcation Extensions
R Figure 305 (Sheet 1)

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MANUAL

683L SERIES

R MR60131-00-A
R Upper and Lower Bifurcation Extensions
R Figure 305 (Sheet 2)

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MANUAL

683L SERIES

R MR60132-00-A
R Upper and Lower Bifurcation Extensions
R Figure 305 (Sheet 3)

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D. Remove the fairings. Refer to figure 306.

(1) Remove the upper sidewall aft inner cowl fairing.

(a) Remove the rivets (1-400, -405, -410 and -415, 78-32-21 or 78-32-22) that
attach the upper sidewall aft inner cowl fairing (1-430 or -435, 78-32-21 or 78-
32-22) and clip (1-420 or -425, 78-32-21 or 78-32-22) to the upper sidewall
assembly (1-785 or -790, 78-32-21 or 78-32-22) and core cowl assembly (1-
810 or -815, 78-32-21). Remove the clip and upper sidewall aft inner cowl
fairing.

(2) Remove the lower sidewall to core cowl fillet fairing.

(a) Remove the rivets (10-365, -377 -380, -385 and -400, 78-32-21 or 78-32-22),
pins (10-370 and -390, 78-32-21 or 78-32-22) and nuts (10-375 and -395, 78-
32-21 or 78-32-22) that attach the lower sidewall fillet fairing (10-360, 78-32-21
or 78-32-22) to the lower sidewall assembly (10-5, 78-32-21 or 78-32-22) and
the core cowl assembly (1-810 or -815, 78-32-21). Remove the lower sidewall
to core cowl fillet fairing.

(3) Remove the upper sidewall forward fairing.

(a) Remove the rivets (5-175 and -180, 78-32-21 or 78-32-22) that attach the
R upper sidewall forward fairing (5-165 or -170, 78-32-21) to the upper sidewall
assembly (1-785 or -790, 78-32-21). Remove the upper sidewall forward
fairing.

(4) Remove the lower sidewall to latch beam fillet fairing.

(a) Remove the rivets (10-440, 78-32-21 or 78-32-22) that attach the lower
sidewall fillet fairing (10-435, 78-32-21 or 78-32-22) to the lower sidewall
assembly (10-5, 78-32-21 or 78-32-22) and brackets (10-405 and -415 78-32-
21 or 78-32-22). Remove the lower sidewall fillet fairing.

(5) Remove the upper sidewall lower fairing.

(a) Remove the rivets (1-15, -20, -10, -35 and -40, 78-32-21) that attach the upper
sidewall lower fairing (1-25 or -30, 78-32-21) to the upper sidewall assembly (1-
785 or -790, 78-32-21), seal retainer fitting (1-45, 78-32-21), forward bulkhead
attach strap (1-380, 78-32-21) and core cowl assembly (1-810 or -815, 78-32-
21). Remove the upper sidewall lower fairing.

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R MR60133-00-A
R Locator - Fairings
R Figure 306 (Sheet 1)

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R LM50085-00-A
R Upper Sidewall Aft Inner Cowl Fairing
R Figure 306 (Sheet 2)

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R MR60134-00-A
R Lower Sidewall to Core Cowl Fillet Fairing
R Figure 306 (Sheet 3)

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R MR60135-00-A
R Upper Sidewall Forward Fairing
R Figure 306 (Sheet 4)

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MANUAL

683L SERIES

R LM50089-00-A
R Lower Sidewall to Latch Beam Fillet Fairing
R Figure 306 (Sheet 5)

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R MR60175-00-A
R Upper Sidewall Lower Fairing
R Figure 306 (Sheet 6)

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R E. Remove the Upper Sidewall Assembly. Refer to figure 307.

R (1) Remove the rivets (1-550 and -553, 78-32-21) that attach the aft wear strips (1-555 and
R -560, 78-32-21) to the upper sidewall assembly. Remove the aft wear strips.

R (2) Remove the pins (1-490, -500, -510, -520, -530, -720, -730, -740, and -540, 78-32-21)
R and nuts (1-495, -505, -515, -525, -535, -725, -735, -745, and -545, 78-32-21) that
R attach the angles (1-675 or -680 and -775 or -780, 78-32-21) and deflection limiter
R fitting (1-765 or -770, 78-32-21) to the upper sidewall assembly.

R (3) Remove the pins (1-565, -750, -645, -655, -635, and -665, 78-32-21) and nuts (1-570,
R -755, -650, -660, -640 and -670, 78-32-21) that attach the shim (1-760, 78-32-21),
R angles (1-675 or -680 and -775 or -780, 78-32-21) and deflection limiter fitting (1-765 or
R -770, 78-32-21) to the core cowl assembly (1-810, or -815, 78-32-21). Remove the
R deflection limiter fitting.

R (4) Remove the pins (1-440, -450, -460, -470, -480, -685, -710, and -700, 78-32-21) and
R nuts (1-445, -455, -465, -475, -485, -690, -715, and -705, 78-32-21) that attach the
R angles (1-675 or -680 and -775 or -780, 78-32-21) and zee rib clips (1-590 or -595 and
R -620 or -625, 78-32-21) to the upper sidewall assembly.

R (5) Remove the pins (1-565, 78-32-21), nuts (1-570, 78-32-21) and rivets (1-585 and -615,
R 78-32-21) that attach the angles (1-675 or -680 and -775 or -780, 78-32-21) and zee rib
R clips (1-590 or -595 and -620 or -625, 78-32-21) and shims (1-600 and -630, 78-32-21)
R to the core cowl assembly (1-810 or -815, 78-32-21). Remove the angle (1-675 or
R -680, 78-32-21 or 78-32-22), zee rib clips (1-590 or -595 and -620 or -625, 78-32-21)
R and shims (1-600 and -630, 78-32-21).

R (a) Use care when you remove the shims. Make a note of the position of the
R shims, and attach the shims to the sidewall to use at assembly.

R (6) Remove the pins (1-63, -215, and -285, 78-32-21) and nuts (1-65, -220, and -690, 78-
R 32-21) that attach the angles (1-115 or -120, -245, or -250 and -775 or -780, 78-32-21)
R and zee rib clips (1-180, 78-32-21) to the upper sidewall assembly.

R (7) Remove the pins (1-105 and -565, 78-32-21), nuts (1-110 and -570, 78-32-21) and
R rivets (1-175, 78-32-21) that attach the angles (1-115 or -120, -245, or -250 and -775 or
R -780, 78-32-21), zee rib clips (1-180 or -185, 78-32-21) and shims (1-180, 78-32-21) to
R the core cowl assembly. Remove the angle (1-775 or -780, 78-32-21) and zee rib clips,
R shims, and filler block (1-805, 78-32-21).

R (a) Use care when you remove the shims. Make a note of the position of the
R shims, and attach the shims to the sidewall to use at assembly.

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R (8) Remove the rivets (1-255, and -265, 78-32-21), pins (1-310, -300, and 280, 78-32-21)
R and nuts (1-315, -305, and -285, 78-32-21) that attach the upper sidewall angles (1-155
R or -160 and -165 or -170, 78-32-21), shim (1-320, 78-32-21) and power opening device
R supports (1-325 or -330 and -290 or -295, 78-32-21) to the power opening device
R support assembly (1-380 or -383, 78-32-21). Remove the shim and power opening
R device supports.

R (a) Use care when you remove the shims. Make a note of the position of the
R shims, and attach the shims to the sidewall to use at assembly.

R (9) Remove the pins (1-125, -95, -145, and -135, 78-32-21) and nuts (1-130, -100, -150,
R and -140, 78-32-21) that attach the upper sidewall angles (1-155 or -160, and -165 or
R -170, 78-32-21) and angles (1-115 or -120 and -245 or -250, 78-32-21) to the core cowl
R assembly. Remove the upper sidewall angles.

R (10) Remove the pins (1-63, -67, and -75, 78-32-21) and nuts (1-65, -70, and -80, 78-32-21)
R that attach the power opening device support assembly (1-380 or -383, 78-32-21),
R angle (1-115 or -120, 78-32-21) and shim (1-375, 78-32-21) to the upper sidewall
R assembly.

R (11) Remove the pins (1-335 and -355, 78-32-21) and nuts (1-340 and -360, 78-32-21) that
R attach the power opening device support assembly (1-380 or -383, 78-32-21) and shim
R (1-375, 78-32-21) to the upper sidewall assembly.

R (12) Remove the pins (1-215, -205, -225, -235 and -365, 78-32-21) and nuts (1-220, -210,
R -230, -240 and -370, 78-32-21) that attach the angle (1-245 or -250, 78-32-21), shim
R (1-375, 78-32-21) and power opening device support assembly (1-380 or -383, 78-32-
R 21) to the upper sidewall assembly. Remove the shim and power opening device
R support assembly.

R (a) Use care when you remove the shims. Make a note of the position of the
R shims, and attach the shims to the sidewall to use at assembly.

R (13) Remove the pins (1-95, 78-32-21) and nuts (1-100, 78-32-21) that attach the angles (1-
R 115 or -120 and -245 or -250, 78-32-21) to the core cowl assembly.

R (14) On the left reverser half, remove the pins (1-67, -63, and -55, 78-32-21) and nuts (1-70,
R -65 and -60, 78-32-21) that attach the angle (1-115, 78-32-21) to the upper sidewall
R assembly. Remove the angle.

R (15) On the right reverser half, remove the pins (1-67, -63 and -55, 78-32-21) and nuts (1-70
R -65 and -60, 78-32-21) that attach the angles (1-120 and -250, 78-32-21) to the upper
R sidewall assembly. Remove the angle (1-120, 78-32-21).

R (16) Remove the pins (1-215, -205 and -195, 78-32-21) and nuts (1-220, -210 and -200, 78-
R 32-21) that attach the angle (1-245 or -250, 78-32-21) to the upper sidewall assembly.
R Remove the angle.

R (17) Remove the upper sidewall assembly (1-785 or -790, 78-32-21) from the fixed
R structure.

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R MR60136-00-A
R Upper Sidewall Assembly - Removal
R Figure 307 (Sheet 1)

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R MR60137-00-A
R Upper Sidewall Assembly - Removal
R Figure 307 (Sheet 2)

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R LM50092-00-A
R Upper Sidewall Assembly - Removal
R Figure 307 (Sheet 3)

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R MR60138-00-A
R Upper Sidewall Assembly - Removal
R Figure 307 (Sheet 4)

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MANUAL

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R MR60174-00-A
R Upper Sidewall Assembly - Removal
R Figure 307 (Sheet 5)

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MANUAL

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R MR60139-00-A
R Upper Sidewall Assembly - Removal
R Figure 307 (Sheet 6)

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MANUAL

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R LM50096-00-A
R Upper Sidewall Assembly - Removal
R Figure 307 (Sheet 7)

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R MR60140-00-A
R Upper Sidewall Assembly - Removal
R Figure 307 (Sheet 8)

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MANUAL

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R LM50098-00-A
R Upper Sidewall Assembly - Removal
R Figure 307 (Sheet 9)

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R MR60141-00-A
R Upper Sidewall Assembly - Removal
R Figure 307 (Sheet 10)

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R MR60142-00-A
R Upper Sidewall Assembly - Removal
R Figure 307 (Sheet 11)

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R F. Disassembly of the Upper Sidewall Assembly. Refer to figure 308.

R (1) Remove the screws (50-320, 78-32-21) that attach the panel assembly (50-310, 78-32-
R 21) to the hinge cover gussets (50-180, -210, -230, -245, and -265, 78-32-21). Remove
R the panel assembly.

R (2) Remove the screws (50-482, 78-32-21) that attach the hinge cover beaver tail (50-400,
R 78-32-21), to the hinge beam assembly (50-147 or -148, 78-32-21). Remove the hinge
R cover beaver tail.

R (3) Remove the rivets (50-680, -765, -657, -690, -685, -545, -659, and -715, 78-32-21) that
R attach the upper sidewall assembly (50-1 or -5, 78-32-21) fireseal support detail (50-
R 760, 78-32-21) leading edge cup (50-660 or -665, 78-32-21), joint plate 50-540, 78-32-
R 21), shim (50-550, 78-32-21), lower attaching angle (50-670 or -675, 78-32-21) and
R attaching angle (50-695 or -705 and 700 or -710, 78-32-21) to the upper sidewall
R bondment (50-10 or -15, 78-32-21). Remove the upper sidewall assembly, fireseal
R support detail, leading edge cup, joint plate, shim, and lower attaching angle.

R (a) Use care when you remove the shim. Make a note of the position of the shim,
R and attach the shim to the sidewall to use at assembly.

R (4) Remove the pins (50-30, -35, -40, -45, -50, -55, -60, -65, -70, -75, -80, -85, -90, -95,
R -100, -105, -110, -115, -120, -125, -130, and -135, 78-32-21) and nuts (50-140 and
R -145, 78-32-21) that attach the hinge beam assembly (50-147 or -148, 78-32-21) to the
R upper sidewall assembly. Remove the hinge beam assembly.

R (5) Remove the rivets (50-495, 78-32-21) that attach the aft block closeout (50-485 or -490,
R 78-32-21) to the upper sidewall assembly. Remove the aft block closeout.

R (6) Remove the rivets (50-530, -510, -and -535, 78-32-21) and shim (50-515, 78-30-21)
R that attach the fireseal support zee (50-500, 78-32-21) and seal retainer (50-520
R or -525, 78-32-21) to the upper sidewall bondment (50-10 or -15, 78-32-21).
R Remove the fireseal support zee and seal retainer.

R (a) Use care when you remove the shim. Make a note of the position of the shim,
R and attach the shim to the sidewall to use at assembly.

R (7) Put the upper sidewall bondment (50-10 or -15, 78-32-21) on a pad or pallet support, or
R on an applicable workstand.

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R MR60155-00-A
R Upper Sidewall Assembly - Disassembly
R Figure 308 (Sheet 1)

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R MR0156-00-A
R Upper Sidewall Assembly - Disassembly
R Figure 307 (Sheet 2)

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R MR60157-00-A
R Upper Sidewall Assembly - Disassembly
R Figure 308 (Sheet 3)

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R MR60158-00-A
R Upper Sidewall Assembly - Disassembly
R Figure 308 (Sheet 4)

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MANUAL

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R MR60159-00-A
R Upper Sidewall Assembly - Disassembly
R Figure 308 (Sheet 5)

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R MR60160-00-A
R Upper Sidewall Assembly - Disassembly
R Figure 308 (Sheet 6)

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MANUAL

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R MR60161-00-A
R Upper Sidewall Assembly - Disassembly
R Figure 308 (Sheet 7)

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R MR60162-00-A
R Upper Sidewall Assembly - Disassembly
R Figure 308 (Sheet 8)

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R G. Removal of the Lower Sidewall Assembly. Refer to figure 309.

R (1) On the left reverser half, remove the rivets (10-270, -280 and -285, 78-32-21), pins (10-
R 140, 78-32-21) and nuts (10-145, 78-32-21) that attach the seal (10-260, 78-32-21),
R backup seal strip (10-265, 78-32-21), angle (10-120, 78-32-21), strap (10-345, 78-32-
R 21), and clip (10-275, 78-32-21) to the core cowl assembly (1-810, 78-32-21). Remove
R the seal, backup seal strip, strap, and clip.

R (2) On the right reverser half, remove the rivets (10-265 and -270, 78-32-22), pins (10-140,
R 78-32-22) and nuts (10-145, 78-32-22) that attach the angle (10-120, 78-32-22), clip
R (10-260, 78-32-22), and strap (10-345, 78-32-22) to the core cowl assembly (1-815, 78-
R 32-22). Remove the clip and strap.

R (3) On the left reverser half, remove the rivets (10-255, -250, and -325, 78-32-21), pins (10-
R 300, -225, -235, -140, -300, -305 and -315, 78-32-21) and nuts (10-230, -240, -145, -
R 310, and -320, 78-32-21) that attach the angles (10-125 and -120, 78-32-21) and shim
R (10-350, 78-32-21) to the lower sidewall assembly (10-10, 78-32-21) and core cowl
R assembly (1-810, 78-32-21).

R (a) Use care when you remove the shim. Make a note of the position of the shim,
R and attach the shim to the sidewall to use at assembly.

R (4) On the right reverser half, remove the rivets (10-245, -255, 250, -310 and -335, 78-32-
R 22), pins (10-285, -225, -235, -140, -157, -285, -290, and -300, 78-32-22) and nuts (10-
R 230, -240, -145, -159, -295, and -305, 78-32-22) that attach the angles, zee rib clip (10-
R 125, -120 and -330, 78-32-22) and shims (10-340 and -350, 78-32-22) to the lower
R sidewall assembly (10-5, 78-32-22) and core cowl assembly (1-815, 78-32-22).

R (a) Use care when you remove the shims. Make a note of the position of the
R shims, and attach the shims to the sidewall to use at assembly.

R (5) Remove the pins (10-75, -85, -95, -20, -40, and -170, 78-32-21 or 78-32-22) and nuts
R (10-80, -90, -100, -25, -45, and -175, 78-32-21 or 78-32-22) that attach the angles (10-
R 10, -15, and -125, 78-32-21 or 78-32-22) and shim (10-350, 78-32-21 or 78-32-22) to
R the lower sidewall assembly (10-10, 78-32-21 or 78-32-22) and core cowl assembly (1-
R 810 or -815, 78-32-21).

R (a) Use care when you remove the shim. Make a note of the position of the shim,
R and attach the shim to the sidewall to use at assembly.

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R (6) Remove the pins (10-20, -30, -55, and -65, 78-32-21 or 78-32-22) and nuts (10-25, -35,
R -60 and -70, 78-32-21 or 78-32-22) that attach the angles (10-10 and -15, 78-32-21 or
R 78-32-22) and shim (10-350, 78-32-21 or 78-32-22) to the lower sidewall assembly (10-
R 5, 78-32-21 or 78-32-22), core cowl assembly (1-810 or -815, 78-32-21) and forward
R deflection limiter (10-50, 78-32-21 or 78-32-22).

R (a) Use care when you remove the shim. Make a note of the position of the shim,
R and attach the shim to the sidewall to use at assembly.

R (7) Remove the rivets (10-110, 78-32-21 or 78-32-22) that attach the shim (10-115, 78-
R 32-21 or 78-32-22) and zee rib end clip (10-105, 78-32-21 or 78-32-22) to the angle
R (10-10, 78-32-21 or 78-32-22) and core cowl assembly (1-810 or -815, 78-32-21).
R Remove the shim and the zee rib end clip.

R (a) Use care when you remove the shim. Make a note of the position of the shim,
R and attach the shim to the sidewall to use at assembly.

R (8) Remove the pins (10-185, -195, -205, -215, -130, -140, -150, -170, -290 and -300, 78-
R 32-21 or 78-32-22) and nuts (10-190, -200, -210, -220, -135, -145, -155, -175 and -295,
R 78-32-21 or 78-32-22) that attach the angles (10-125 and -120, 78-32-21 or 78-32-22)
R and shim (10-350, 78-32-21 or 78-32-22) to the lower sidewall assembly (10-5,
R 78-32-21 or 78-32-22), core cowl assembly (1-810 or -815, 78-32-21) and mid
R deflection limiter (10-180, 78-32-21 or 78-32-22).

R (a) Use care when you remove the shim. Make a note of the position of the shim,
R and attach the shim to the sidewall to use at assembly.

R (9) Remove the rivets (10-335, 78-32-21 or 78-32-22) that attach the zee rib end clip (10-
R 330, 78-32-21 or 78-32-22) and shim (10-340, 78-32-21 or 78-32-22) to the angle (10-
R 120, 78-32-21 or 78-32-22) and core cowl assembly (1-810 or -815, 78-32-21).
R Remove the zee rib end clip, angles and shims.

R (a) Use care when you remove the shims. Make a note of the position of the
R shims, and attach the shims to the sidewall to use at assembly.

R (10) Remove the filler block (10-355, 78-32-21 or 78-32-22).

R (11) Remove the lower sidewall assembly (10-5, 78-32-21 or 78-32-22).

DISASSEMBLY
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R MR60163-00-A
R Lower Sidewall Assembly - Removal
R Figure 309 (Sheet 1)

DISASSEMBLY
PAGE 352
78-32-02 DEC 01/10
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MANUAL

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R MR60164-00-A
R Lower Sidewall Assembly - Removal
R Figure 309 (Sheet 2)

DISASSEMBLY
PAGE 353
78-32-02 DEC 01/10
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MANUAL

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R MR60165-00-A
R Lower Sidewall Assembly (LH Side) - Removal
R Figure 309 (Sheet 3)

DISASSEMBLY
PAGE 354
78-32-02 DEC 01/10
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MANUAL

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R MR60166-00-A
R Lower Sidewall Assembly (RH Side)- Removal
R Figure 309 (Sheet 4)

DISASSEMBLY
PAGE 355
78-32-02 DEC 01/10
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MANUAL

683L SERIES

R MR60167-00-A
R Lower Sidewall Assembly - Removal
R Figure 309 (Sheet 5)

DISASSEMBLY
PAGE 356
78-32-02 DEC 01/10
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MANUAL

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R MR60168-00-A
R Lower Sidewall Assembly - Removal
R Figure 309 (Sheet 6)

DISASSEMBLY
PAGE 357
78-32-02 DEC 01/10
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MANUAL

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R MR60169-00-A
R Lower Sidewall Assembly - Removal
R Figure 309 (Sheet 7)

DISASSEMBLY
PAGE 358
78-32-02 DEC 01/10
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R H. Disassembly of the Lower Sidewall Assembly. Refer to figure 310.

R (1) Remove the rivets (40-95 and -105, 78-32-21), pins (40-55 and -65, 78-32-21) and nuts
R (40-60 and -75, 78-32-21) that attach the shims (40-20, 78-32-21), angle (40-35 or -40,
R 78-32-21) and latch beam sidewall assembly (40-25 or -30, 78-32-21) to the lower
R sidewall bondment (40-10 or -15, 78-32-21). Remove the angle.

R (a) Use care when you remove the shims. Make a note of the position of the
R shims, and attach the shims to the sidewall to use at assembly.

R (2) On the left reverser half, remove the rivets (40-110 and -120, 78-32-21), pins (40-65
R and -70, 78-32-21), nuts (40-75, 78-32-21) and fasteners (40-80 and -85, 78-32-21)
R that attach the shims (40-20, 78-32-21), angle (40-45 or -50, 78-32-21) and latch
R beam sidewall assembly (40-25 or -30, 78-32-21) to the lower sidewall bondment
R (40-10 or -15, 78-32-21). Remove the angle.

R (a) Use care when you remove the shims. Make a note of the position of the
R shims, and attach the shims to the sidewall to use at assembly.

R (3) Remove the rivets (40-90, 78-32-21)and the pins that attach the shims (40-20, 78-32-
R 21) and the latch beam sidewall assembly (40-25 or -30, 78-32-21) to the lower
R sidewall bondment (40-10 or -15, 78-32-21). Remove the shims and latch
R beam sidewall assembly from the lower sidewall bondment.

R (a) Use care when you remove the shims. Make a note of the position of the
R shims, and attach the shims to the sidewall to use at assembly.

R (4) Place the lower sidewall bondment on a pad or pallet support, or on an applicable
R workstand.

DISASSEMBLY
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R MR60170-00-A
R Lower Sidewall Assembly - Disassembly
R Figure 310 (Sheet 1)

DISASSEMBLY
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R MR60171-00-A
R Lower Sidewall Assembly (LH Side) - Disassembly
R Figure 310 (Sheet 2)

DISASSEMBLY
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MANUAL

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R MR60172-0A
R Lower Sidewall Assembly - Disassembly
R Figure 310 (Sheet 3)

DISASSEMBLY
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R MR60173-0-A
R Lower Sidewall Assembly (RH Side) - Disassembly
R Figure 310 (Sheet 4)

DISASSEMBLY
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 FAN REVERSER
CF6-80E1 CMM

THIS PAGE INTENTIONALLY BLANK

 COMPONENT
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MANUAL

683L SERIES

FAN REVERSER SUPPORT ASSEMBLY - INSPECTION/CHECK

1. General.

A. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable
Materials.

(1) Tools and Equipment. None required.

(2) Consumable Materials.

Code No. Description

C01-106 Adhesive, Epoxy Resin

R C03-005 Primer, Epoxy, Green, Spray Type,

R 463-12-8 and Catalyst CA-1169

C03-006 Compound, Chemical Surface Treatment,

R Alodine No. 1200S

C03-077 Primer, Water-reducible Epoxy,

BMS-10-11V, Type I

(3) Expendable Parts. None required.

(4) Referenced Procedures.

SPM 70-32-03

SPM 70-41-00

2. Do a Spot Fluorescent-Penetrant Inspection. Refer to the GE Standard Practices Manual, 70-32-03.

INSPECTION
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3. Make an Inspection of the Fan Reverser Support Assembly. See figure 501 and table 501.

NOTE: The following inspection is a visual inspection aided by the use of a 10X magnifying glass.

Table 501. Support Assembly

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

A. Core cowl honeycomb assembly for:

R (1) Cracks Not serviceable Any amount Repair 026

R (2) Holes Not serviceable Any amount Repair 026

R or
R contact MRAS Product
R Support Engineering
R for possible disposition

R (3) Delamination Not serviceable Any amount Repair 026

(4) Dents

(a) Inner skin Any number, with a Any number of repairs Repair 006
R maximum diameter of are permitted for dents or
R 0.09 in. (22.9 mm), a with a maximum size of Repair 026 if
R maximum depth of 0.09 0.09 in. (22.9 mm) wide damage exceeds
R in. (22.9 mm), and a by 0.09 in. (22.9 mm) limits of Repair 006
minimum of 6.0 in. (15.2 deep, with no
cm) apart delamination There
must be a minimum of
6.0 in. (15.2 cm)
between repairs

(b) Outer skin A maximum of three Any number of repairs Repair 006
R dents, with a maximum for each reverser half or
R diameter of 0.09 in. (22.9 for dents with a Repair 026 if
R mm), and a maximum maximum size of 0.09 damage exceeds
R depth of 0.09 in. (22.9 in. (22.9 mm) wide by limits of Repair 006
mm), with no 0.09 in. (22.9 mm) deep
delamination. Dents are permitted in
must be a minimum of damage areas shown in
6.0 in. (15.2 cm) apart figures 510 and 511.
There must be a
minimum of 6.0 in. (15.2
cm) between repairs

B. Sheet metal for cracks Not serviceable Any amount Weld. Refer to
outside the bonded area Standard Practices
Manual, 70-41-00

INSPECTION
PAGE 502
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Table 501. Support Assembly (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

C. Forward Flange for:

(1) Cracks at the Not serviceable Maximum of one crack Refer to MRAS SB
upper end up to 8.5 in. (21.6.cm) 78-5073. Outside of
long the repairable limits,
replace the forward
flange

D. Hinge beam for:

(1) Cracks Not serviceable Not repairable Replace the hinge

R (2) Bushing wear 0.020 in. (0,51 mm) Not repairable Replace bushing
R Depth. Refer to Table 502
R For dimensional
R Information.

E. Latch housings for Not serviceable Not repairable Replace the latch
cracks housing

F. Loose, missing or Not serviceable Any amount Repair 005

cracked rivets

G. Missing or damaged nut Not serviceable Any amount Replace the nut plate
plates

H. Forward outer support ring for:

(1) Lock out hole 0.430 in. (10.92 mm) Maximum elongation of Repair 016
damage elongation 0.55 in. (14.0 mm)
circumferentially parallel to the edge of
the ring and any
amount in the forward-
to-aft direction

I. Core cowl, duct sidewall or precooler duct silicone insulation (MA25S) coating for:

(1) Chipped, peeling, Not serviceable Any amount Repair 022

cracking, or
missing areas

INSPECTION
PAGE 503
78-32-02 DEC 01/15
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Table 501. Support Assembly (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

J. Corner fillet fairings for:

(1) Cracks or damage Not serviceable All damage that can be Refer to Repair 010,
on an upper fwd repaired up to a section 5.C or 5.E.
fillet fairing maximum repair For damage that is
(491B1313040) doubler size of 10 in. more than the
(25.4 cm) by 8.5 in. repairable limits,
(21.6 cm). A maximum replace the fairing
of three repair doublers
permitted on a fairing

(2) Cracks or damage Not serviceable Cracks or gouges on Refer to Repair 010,
on an upper aft fillet the trailing edge only, section 5.B.
fairing up to a maximum of
(491B1313050) 0.25 in. (6.4 mm) in
depth

All damage that can be Refer to Repair 010,

repaired up to a section 5.C or 5.E.
maximum repair For damage that is
doubler size of 10 in. more than the
(25.4 cm) by 8.5 in. repairable limits,
(21.6 cm). A maximum replace the fairing
of three repair doublers
permitted on a fairing

(3) Cracks or damage Not serviceable Cracks, only along the Refer to Repair 010,
on a lower upr fillet weld bead between the section 5.D. For all
fairing support bracket and the other damage, replace
(491B1313002) fairing the fairing

(4) Cracks or damage Not serviceable All damage that can be Refer to Repair 010,
on a lower lwr fillet repaired up to a section 5.C or 5.E.
fairing maximum repair For damage that is
(491B1313060) doubler size of 10 in. more than the
(25.4 cm) by 8.5 in. repairable limits,
(21.6 cm). A maximum replace the fairing.
of three repair doublers
permitted on a fairing

R INSPECTION
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Table 501. Support Assembly (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

K. Rub marks or dents on Rub depth 0.010 in. (0.25 Not repairable Repair to be supplied
the core cowl from mm), dent depth 0.060 in.
contact with the blocker (1.52 mm)
doors

L. Wear of the forward Must not be worn through Any amount Replace the wear strip
wear strip in any area

M. Tee track wear strip for Not serviceable Not repairable Replace the wear
pulled fasteners strip, Repair 002

N. Aft cascade support ring for:

(1) Wear grooves Not serviceable Not repairable Replace the aft
adjacent to the cascade support ring
uppermost
deflector

(2) Wear grooves Not serviceable Not repairable Replace the aft
adjacent to the cascade support ring
lowermost deflector

(3) Wear grooves Not serviceable 0.080 in. (2.03 mm) Within the repairable
adjacent to a deep groove. The limits, blend the repair
deflector between depth of the groove area until it is smooth,
the uppermost and must not be more than apply Alodine 1200
the lowermost 0.080 in. (2.03 mm) at (C03-006) and primer
deflectors any point (C03-077). More than
the repairable limits,
replace the aft
cascade support ring

(4) Cracks at the Not serviceable Not repairable Replace the aft
nutplate holes cascade support ring

R INSPECTION
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Table 501. Support Assembly (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

O. Duct sidewall for:

R (1) Upper and lower Not serviceable Any amount Repair 023
R duct sidewall outer
R (flowpath) skin
R disbond

R (2) Lower duct sidewall Not serviceable Two repairs are For damage that is in
R inner (non- permitted for each the repairable limits,
R flowpath) skin assembly. The do Repair 009. For
R damage and maximum size damage that is more
R disbond permitted for a repair is than the repairable
R 3.0 in. (76.2 mm) length limits, do Repair 023
R and width. The
R damaged and
R disbonded area must
R be limited to the
R damage envelope
R shown in figure 505.
R The distance between
R multiple damages must
R be a minimum of 2.5
R times the diameter of
R the first damage area
R plus 2.5 times the
R diameter of the second
R damage area (figure
R 507)

INSPECTION
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Table 501. Support Assembly (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

O. Duct sidewall for (cont'd):

(3) Upper duct sidewall Not serviceable Two repairs are For damage that is in
inner (non- permitted for each the repairable limits,
flowpath) skin assembly. One repair do Repair 004. For
damage and is permitted in each damage that is more
disbond damage area shown in than the repairable
figure 506. The limits, do Repair 023
maximum size damage
permitted in the forward
damage area is 4.0 in.
(10.2 cm) in length and
width. The maximum
size damage permitted
in the aft damage area
is 2.5 in. (6.35 cm) in
length and width. The
distance between
multiple damages must
be a minimum of 2.5
times the diameter of
the first damage area
plus 2.5 times the
diameter of the second
damage area (figure
507)

R (4) Lower Duct Five dents, 0.09 in. Five Dents, 0.09 in. For Damage that is in
R Sidewall Dents to (2,286 mm) Deep X 0.90 (2,286 mm) Deep X the repairable limits,
R Inner and Outer in (22,8 mm) diameter 0.90 in (22,8 mm) perform Repair 007.
R Skins with no disbonds. Dents diameter with disbonds. For Damage that is
R must be 6 in. (15,24 cm) Disbonded dents must more than the
R apart from each other. be 6 in. (15,24 cm) repairable limit,
R apart from each other. perform Repair 023.

P. Core cowl for:

(1) Delamination of Not serviceable Any amount Repair 026

inner skin on
honeycomb
bondment

(2) Blistered paint on Any amount Any amount Repair 013

aft airflow surfaces

INSPECTION
PAGE 507
78-32-02 DEC 01/15
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Table 501. Support Assembly (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

P. Core cowl for (cont’d):

Pre SB 78-5026
(3) Missing wire mesh Not serviceable Up to 18.4 ft2 For damage less than
(1.70 m2) for each or equal to the
reverser half if there is repairable limits, repair
no acoustic blockage. the wire mesh (Repair
The total amount for 014); for damage
the two halves must not more than the
be more than 22 ft2 repairable limits,
(2.04 m2). If there is replace the wire mesh
acoustic blockage, the (Repair 014)
maximum limit is 6.5 ft2
(0.60 m2) of acoustic
blockage for a full
reverser (two halves).
This can include areas
of missing wire mesh
plus areas of total
acoustic blockage. 4.0
ft2 (0.37 m2) of missing
wire mesh is
approximately equal to
1.0 ft2 (0.09 m2) of total
acoustic blockage

(4) Torn wire mesh Any number of tears, Any number of tears, Repair the wire mesh
each tear not longer than each tear not longer (Repair 014)
0.5 in (12.7 mm) than 6.0 in (152.4 mm)

End Pre SB 78-5026

R (5) Acoustic blockage Maximum blockage Any amount Repair 026

permitted is 0.73 ft2
(0.068 m2) for the left
half, and 0.98 ft2 (0.091
m2) for the right half.
Refer to figure 508 and
figure 509

INSPECTION
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Table 501. Support Assembly (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

Q. Torn or missing support Not serviceable Any amount Repair 015

assembly rubber
bumpers

R. Wear of aft wear strip Must not be cracked or Any amount Replace the wear strip
(Support OD) worn through in any area (Repair 008)

S. Precooler seal assembly Not serviceable Any number Replace the bolts
for damaged or missing
bolts

T. All seals for:

(1) Cracking, Not serviceable Not repairable Replace the seals

deterioration or
missing areas

U. Upper and lower fire

seals for:

(1) Cracking, deteriora- Not serviceable One damaged area Repair 019
tion or missing
areas

V. Forward (Dagmar) fairing surface (surface that the translating cowl seal touches) for:

(1) Dents Up to 0.060 in. (1.524 Any number No repair is

mm) necessary

Not serviceable between Any number Straighten the dent

0.061-0.120 in. (1.549- with a dent puller and
3.048 mm) apply Alodine No.
1200 (C03-006)

Not serviceable over Not repairable Replace the forward

0.120 in. (3.048 mm) fairing

R INSPECTION
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Table 501. Support Assembly (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

V. Forward (Dagmar) fairing surface (surface that the translating cowl seal touches) for (continued):

(2) Cracks (See figure 502)

(a) Cracks aft of Any number, any length Not repairable if out of If in the serviceable
the rivet line but up to 2.00 in. (50.8 mm). serviceable limits limits, stop-drill the
not within 0.25 Total length of all cracks crack(s) and fill with
in. (6.4 mm) of must be less than 12.0 silicone rubber
a rivet in the in. (30.48 cm). There adhesive (C01-007);
rivet line must be a minimum if out of serviceable
distance of 2.00 in. (50.8 limits, replace the
mm) between all cracks forward fairing

(b) Cracks longer Not serviceable Not repairable Replace the forward
than 2.00 in. fairing
(50.8 mm)

(c) Cracks within Not serviceable Not repairable Replace the forward
0.25 in. (6.4 fairing
mm) of a rivet in
the rivet line

(d) Cracks forward Not serviceable Not repairable Replace the forward
of the rivet line fairing

(3) Holes Four holes or less with a Not repairable if out of If in the serviceable
maximum diameter of serviceable limits limits, fill with silicone
0.10 in. (2.54 mm) and a rubber adhesive (C01-
minimum distance of 1.00 007); if out of
in. (25.4 mm) between serviceable limits,
the holes replace the forward
fairing

Not serviceable with five Not repairable if out of Replace the forward
or more holes serviceable limits fairing

(4) Loose fasteners Not serviceable Any number Replace the fasteners

R INSPECTION
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Table 501. Support Assembly (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

V. Forward (Dagmar) fairing surface (surface that the translating cowl seal touches) for (continued):

R (5) Wear marks on the Maximum permitted wear To be determined If the wear is in the
R fairing at the depth of 0.020 in. (0.51 serviceable limits,
R forward edge of mm) apply conversion
R each blocker door coating Alodine 1200S
R (C03-006) or
R equivalent to the wear
R mark, and let dry.
R Next, apply a layer of
R epoxy resin primer
R (C03-005) and let the
R area dry. If the wear
R is more than the
R serviceable limits,
R contact MRAS Product
R Support Engineering
R for possible disposition

W. Fire protective blankets for:

(1) Tears or rips Not serviceable Not repairable Replace the blankets

X. Drain tube for:

(1) Kinks or dents Not serviceable Not repairable Replace the drain tube

(2) Security Not serviceable Any amount Tighten the fittings and
clamps

Y. Lower closeout tee for:

Pre SB 78-5063
(1) Wear caused by Up to 0.040 in. (1.02 mm) Any amount Do MRAS SB 78-5063
the access and deep
blowout door
latches
End Pre SB 78-5063

Post SB 78-5063
(1) Wear caused by Up to 0.032 in. (0.81 mm) Any amount Replace the steel
the access and deep wear strip
blowout door
latches
End Post SB 78-5063
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Table 501. Support Assembly (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

Z. Power Opening Device (POD) Machined Fitting for:

(1) Worn or damaged Not serviceable A maximum of 0.8125 Less than the
bushing holes inch (20.638 mm) in repairable limits, use
diameter Repair 018. Above
the repairable limits,
replace the fitting

AA. Hinge Beam/Latch Beam for:

(1) Wear on the outer Maximum wear of 0.050 Not repairable Replace the beam
guide rail inch (1.27 mm) on the
edge of the guide.
Original guide rail width is
0.510 in. (12.95 mm).
Minimum serviceable
width is 0.460 in. (11.68
mm). See figure 503

(2) Cracks in the aft Not serviceable Not repairable Replace the beam
end of the tee track

AB. Zee Rib for:

(1) Wear to the inboard A minimum of 0.040 in. 3.0 in. (76.2 mm) long Within serviceable
flange (1.02 mm) of material (upper to lower), 0.55 limits, blend the area
must remain after in. (14.0 mm) deep. and apply Alodine
removal of the primer. Maximum of two 1200S (C03-004) and
See figure 504 defects on a zee rib. primer (C03-077).
Damage within 5.0 in. Outside of the
(12.7 cm) of the zee rib serviceable limits, do
clip (491B1313024) is Repair 024
not repairable. See
figure 504

(2) Damage to the Not serviceable 3.0 in. (76.2 mm) long Repair 024
inboard flange and (upper to lower), 0.55
web of a zee rib in. (14.0 mm) deep.
Maximum of two
defects on a zee rib.
Damage within 5.0 in.
(12.7 cm) of the zee rib
clip (491B1313024) is
not repairable. See
figure 504
R INSPECTION
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Table 501. Support Assembly (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

AC. Torque Box Outer Ring

Retainer for:

(1) Cracks Not serviceable A maximum of 3.0 Repair 025

Inches (7.62 cm) in
length

R AD. Core Cowl Fwd

R Bulkhead (491E1340023)
R for:

R (1) Wear 0.010 in. (0.25 mm) aft of None with the Within the serviceable
R the vee blade; 0.030 in. serviceable limits. limits, blend sharp
R (0.76 mm) at the lower Damage outside the edges smooth.
R 4.00 in. (101.6 mm) area serviceable limits is not Perform a
R where the vee blade repairable Fluorescent-Penetrant
R ends. See figure 512 Inspection (FPI) of the
R wear area for any
R cracking per the SPM,
R Section 70-32-02. If no
R cracking is detected,
R apply Alodine 1200S
R (C03-006) and epoxy
R primer (C03-005). If
R outside the
R serviceable limits,
R replace the bulkhead.

R (2) Cracks Not serviceable Not repairable Replace the bulkhead

INSPECTION
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R Table 502. Hinge Busing Diameters

R Max. Serviceable
R Bushing ID (Max wear =
Position/Lug Outer Diameter Inner Diameter
R Part Number 0.020 in. (0,51
R mm))

R FWD Hinge
R Fwd Lug 491C1361004-003 0.7500 – 0.7510 in. 0.4950 – 0.5000 in. 0.5200 in.
R (19,5000 – 19,0754 mm) (17,5730 – 17,7000 mm) (13,2080 mm)

R Aft Lug 491C1361004-003 0.7500 – 0.7510 in. 0.4950 – 0.5000 in. 0.5200 in.
R (19,5000 – 19,0754 mm) (17,5730 – 17,7000 mm) (13,2080 mm)

R MID Hinge
R Fwd Lug 491C1361004-005 0.7500 – 0.7510 in. 0.6670 – 0.6720 in. 0.6920 in.
R (19,5000 – 19,0754 mm) (16,9418 – 17,0688 mm) (17,5768 mm)

R Aft Lug 491C1361004-001 0.7500 – 0.7510 in. 0.6970 – 0.7020 in. 0.7220 in.
R (19,5000 – 19,0754 mm) (17,7038 – 17,8308 mm) (18,3388 mm)

R AFT Hinge
R Fwd Lug 491C1361004-001 0.7500 – 0.7510 in. 0.6970 – 0.7020 in. 0.7220 in.
R (19,5000 – 19,0754 mm) (17,7038 – 17,8308 mm) (18,3388 mm)

R Aft Lug 491C1361004-001 0.7500 – 0.7510 in. 0.6970 – 0.7020 in. 0.7220 in.
R (19,5000 – 19,0754 mm) (17,7038 – 17,8308 mm) (18,3388 mm)

INSPECTION
PAGE 514
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NACELLE ACOUSTIC ZONES

NOTE: This CMM gives the maximum acoustic blockage limits for each component that gives acoustic
suppression for the nacelle. There is a high level acoustic requirement for a fully installed nacelle
(inlet and full reverser). The view above shows the zone numbers for each component. The
allowance is based on a sliding scale formula*. To apply the formula correctly, an airline must
monitor all blockage to its acoustic components. The airline has the option of using this full nacelle
allowance for their reverser components.

*Use this formula if the damage area (including potential loss from previous repairs) is more than
the maximum permitted limits at the individual component level (see example):

(0.286 x Inlet Area Loss) + (0.154 x Exhaust Area Loss) < 1.0
Example:

R Inlet (ft2) 3.5 3.0 2.5 2.0 1.5 1.0 0.0

R Exhaust (ft2) 0.0 0.9 1.9 2.8 3.7 4.6 6.5

R Table 503. Maximum Acoustic Loss Independent Limits

R Acoustic Zone Component Description Maximum Permitted Area

R Losses
R 1 Inlet (Inner Barrel) 1.75 ft2 (0.163 m2)
R 2 Exhaust (Blocker Door, Translating Cowl,
R Fixed Structure) 3.24 ft2 (0.301 m2)

R Table 504. Maximum Acoustic Loss Independent Limits by Individual Exhaust Component

R Acoustic Zone Individual Exhaust Component Description Maximum Permitted Area

R Losses
R 2 Blocker Door 0.028 ft2 (0.0026 m2)
R 2 Translating Cowl (LH or RH) 0.60 ft2 (0.055 m2)
R 2 Fixed Structure (LH) 0.73 ft2 (0.068 m2)
R 2 Fixed Structure (RH) 0.98 ft2 (0.091 m2)

INSPECTION
PAGE 515
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CF8-7208-00-B
Support Assembly Inspection Areas
Figure 501 (Sheet 1 of 2)

R INSPECTION
PAGE 516
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CF8-D3378-00-A
Support Assembly Inspection Areas
Figure 501 (Sheet 2 of 2)

R INSPECTION
PAGE 517
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MR70388-00-A
Dagmar Fairing Inspection Area
Figure 502

R INSPECTION
PAGE 518
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MR50262-00-A
Hinge Beam and Latch Beam Guide Rail Wear
Figure 503

R INSPECTION
PAGE 519
78-32-02 DEC 01/15
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MR60108-02-A
Zee Rib Serviceable and Repairable Limits
Figure 504

R INSPECTION
PAGE 520
78-32-02 DEC 01/15
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MR60196-00-A
Lower Duct Sidewall Inner (Non-Flowpath) Skin Allowable Damage Area
Figure 505

R INSPECTION
PAGE 521
78-32-02 DEC 01/15
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MR60195-01-A
Upper Duct Sidewall Inner (Non-Flowpath) Skin Allowable Damage Area
Figure 506

R INSPECTION
PAGE 522
78-32-02 DEC 01/15
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MR60197-00-A
Duct Sidewall Damage Spacing Limits
Figure 507

R INSPECTION
PAGE 523
78-32-02 DEC 01/15
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MR60212-00-A
Left Side Fixed Structure Bondment Acoustic Blockage Limits
Figure 508

R INSPECTION
PAGE 524
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MR60213-00-A
Right Side Fixed Structure Bondment Acoustic Blockage Limits
Figure 509

R INSPECTION
PAGE 525
78-32-02 DEC 01/15
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MR60213-00-A
Core Cowl Allowable Damage Area, Left Reverser Half
Figure 510
MR60XXX-00-A

R INSPECTION
PAGE 526
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MR60213-00-A
Core Cowl Allowable Damage Area, Right Reverser Half
Figure 511

R INSPECTION
PAGE 527
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R
R Core Cowl Forward Bulkhead Inspection
R Figure 512 (Sheet 1 of 2)

INSPECTION
PAGE 528
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R
R Core Cowl Forward Bulkhead Inspection
R Figure 512 (Sheet 2 of 2)

INSPECTION
PAGE 529
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FAN REVERSER SUPPORT ASSEMBLY - REPAIR

1. Replacement of the Tee Track Wear Strip.

A. This procedure gives the instructions to replace the wear strip for the top tee track in the hinge
beam assembly or for the bottom tee track in the latch beam assembly.

2. Tools, Equipment and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

R (2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment. None required.

B. Consumable Materials.

Code No. Description Use

R
C04-003 Solvent, Acetone Clean the repair area
(Fed. Spec. O-A51)

R C10-182 Cloths, Cleaning Clean the repair area

C. Expendable parts.

Number Description

NAS1221-08E6 Flush Head Bolt (for latch beam assemblies)

NAS1221-08E5 Flush Head Bolt (for hinge beam assemblies)

R
D. SPD Identification.

SPD No. Description

R 491B1313139-007 Wear strip

491B0700015-001 Self-aligning nut

REPAIR 002
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E. Referenced Procedures. None required.

3. Dimensional Information. None required.

4. Setup Information. None required.

5. Procedure. Refer to figure 601.

CAUTION: THE SELF-ALIGNING NUT HAS A WASHER AND A NUT ASSEMBLED TOGETHER
AS ONE ITEM. THE WASHER CAN EASILY BECOME ISOLATED FROM THE NUT.
KEEP THE WASHER AND THE NUT TOGETHER FOR ASSEMBLY.

A. Remove the two self-aligning nuts and the two flush head bolts that attach the wear strip to the
R hinge beam assembly or the latch beam assembly. Discard the nuts and the bolts.

B. Remove and discard the wear strip.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE GAS.
IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT
AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR EYES
BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY
FLAMMABLE.

C. Use a clean cloth (C10-182) moist with solvent (C04-003) to clean the tee track.

R D. Install a new wear strip 491B1313139-007 made of nylon (gray to black metallic color). Install
R two flush head bolts and two self-aligning nuts. Tighten the nuts to 13-16 lb in. (1.5-1.8 N·m) of
R torque.

R (1) Make sure the flush head bolts do not distort the wear strip or protrude above the
R surface of the wear strip. If a flush head bolt is above the surface of the wear strip, or if
R the dimpled surface of the wear strip is distorted by the bolt head, remove the flush
head
R bolt, and do step 5.D. again.

R E. Use a serviceable tee hinge to do a check for areas that bind. Areas that bind are not
permitted.

REPAIR 002
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R MR60062-00-A
Tee Track Wear Strip Replacement
Figure 601

REPAIR 002
PAGE 603
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CF6-80E1 CMM

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MANUAL

683L SERIES

FAN REVERSER SUPPORT ASSEMBLY - REPAIR

R 1. Repair of Unbonded Areas in the Upper Duct Sidewall.

R A. This procedure gives the instructions for the repair of the upper duct sidewall due to disbonded
R or damaged inner skin. Use this repair only in the 0.025 in. (0.64) thick skin area shown in
R figure 601. The maximum size permitted for the repair area is 4.0 in. x 4.0 in.(10.2 cm x
R 10.2 cm) for the forward area and 2.5 in. x 2.5 in. (10.2 cm x 10.2 cm) for the aft area shown in
R figure 601. The edge of the damaged area must be within the damage envelope shown in
R figure 601. No more than one repair is permitted in a damage area, for a maximum of
R two repairs for each sidewall assembly. The distance between the two damaged areas
R must be a minimum of 2.5 times the diameter of the first damaged area plus 2.5 times the
R diameter of the second damaged area. Refer to figure 602. The total damage area for a
R sidewall must not be more than 22.25 sq in. (143.5 sq cm). For damage that is more than
R these limits, refer to 78-32-02 Repair 023.

R B. Make sure all the surfaces are clean when you prepare to apply the adhesive. Keep all
R surfaces clean during all of the steps.

R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools. None required.

R (3) Locally Manufactured Tools. None required.

R (4) Equipment.

R Description Manufacturer

R Heat Source that can Local purchase

R hold a temperature between
R 200-220F (93-104C)

R Oven Local purchase

R Drill Motor Local purchase

R Thermocouples Local purchase

R Mallet, Aluminum, 0.5-1.0 oz. Tap check

R (14-28 g)

REPAIR 004
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R B. Consumable Materials.

R Code Description Use

R C01-015 Insulation, Ablative Silicone, MA-25 Restore the insulation

R C01-126 Netting, Fabric, Dacron Polyester Bondline control

R C01-156 Adhesive, Paste, Duct sidewall repair

R EA9394/C2

R C04-003 Solvent, Acetone Clean the repair area

R C04-035 Isopropyl Alcohol Clean the repair area

R C10-009 Paper, Greaseproof, Grade A, Protect the cleaned

R Kraft repair details

R C10-105 Paper, Abrasive, 120 Grit Prepare the repair area

R C10-136 Tape, Flashbreaker Protect the surface

R adjacent to the repair

R C10-137 Film, Vacuum Bag Bondment repair

R C10-138 Tape, Sealant, Vacuum Bag Bondment repair

R C10-140 Gloves, Nylon Film/Polyethylene, Mix and apply the adhesive

R Disposable

R C10-182 Cloths, Cotton, Lint-free Clean the repair area

R Local Purchase Aluminum Stock, Bare, 0.025 inch Make the repair parts
R (0.64 mm) Thick and 0.032 inch
R (0.81 mm) Thick (2024-T42 or -T3)

R Local Purchase Abrasive, Grit, Blast Media, Prepare the bonding

R 120-180 Grit Virgin Aluminum surface
R Oxide

R Local Purchase Film, Polyethylene Prepare the repair area

R Local Purchase Tape, Fiber, Acetate Prepare the repair area

REPAIR 004
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R Code Description Use

R Local Purchase Sheet, Tedlar Protect the repair area

R Local Purchase Scraper, Plastic Removal of the insulation layer

R Local Purchase Brush, Acid Apply the adhesive

R Local Purchase Felt Tip Pen Mark the damage area

R C. Expendable Parts.

R Number Description

R NAS1738E5-X Rivets

R D. SPD Identification. None required.

R E. Referenced Procedures.

R SPM 70-13-00

R SPM 70-21-01

R SPM 70-21-04

R 78-32-02 Repair 022

R 78-32-02 Repair 023

R 3. Dimensional Information. Refer to figures 601, 602 and 603.

R 4. Setup Information. None required.

REPAIR 004
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R 5. Procedure. Refer to figure 603.

R A. Find the amount of the damage.

R (1) Remove the MA-25 silicone insulation coating from the area where you will do the tap
R check.

R NOTE: The edge of the damaged area must fall within the envelope
R shown in figure 601.

R (2) Do a tap check of the damaged sidewall area to find voids.

R (a) Tap around the bondment with a 0.5-1.0 oz. (14-28 gram) aluminum mallet held
R at a 90-degree angle to find the size and location of the void (disbond).

R (b) Tap the outer skin at the adjacent area to determine if the disbond is present
R on both the inner surface and the outer surface.

R (c) Use a felt-tip pen to make a line around the boundary of the void on the inner
R skin.

R B. Remove the MA-25 silicone insulation coating from all areas where you will attach plates.

R (1) Apply polyethylene film and acetate fiber tape to the areas of the upper duct sidewall
R where you will not remove the silicone insulation coating.

R (2) Use a plastic scraper and abrasive paper (C10-105) to remove as much of the silicone
R insulation coating as possible from the repair area and from the area 1.0-2.0 in. (25.4-
R 50.8 mm) around the repair area.

R (3) Use 120 grit or finer abrasive paper or cloth to remove the remaining insulation from
R the abraded area. Bevel the coating at the edges of the bare area.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR
R SKIN OR EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE,
R TOXIC, AND HIGHLY FLAMMABLE.

R (4) Use a clean cloth (C10-182) moist with solvent (C04-003 or C04-035) to fully clean the
R repair area. Make sure to remove all unwanted material from the abraded repair area.

REPAIR 004
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R C. Do the steps that follow to repair disbonds between the inner skin and the core, and fractures
R or holes in the inner (non-flow) skin up to 4.0 in. x 4.0 in. (10.2 cm x 10.2 cm) for the forward
R area and 2.5 in. x 2.5 in. (6.35 cm x 6.35 cm) for the aft area shown in figure 601.

R NOTE: The space between damaged areas must be a minimum of 2.5 times the diameter of
R the first damage area plus 2.5 times the diameter of the second damage area (figure
R 602). The damage must be within the limits shown in figure 601.

R CAUTION: BE VERY CAREFUL NOT TO DAMAGE THE HONEYCOMB CORE WHEN

R YOU REMOVE THE DELAMINATED FACE SHEET.

R (1) Use a hole saw, radial disc, or pencil grinder to remove the inner skin.

R (2) Use mylar film or equivalent to make a template of the cutout in the skin.

R (3) Use a felt-tip pen to transfer the hole size from the template to a sheet of 0.025 inch
R (0.64 mm) thick bare aluminum (2024-T42 or -T3).

R NOTE: The non-doubled areas of skin can have a thickness of 0.025-0.033 in.
R (0.64-0.84 mm). The filler piece must have the same thickness as the
R material removed.

R (4) Use the mark you made on the aluminum sheet as a guide to cut a flush patch plate to
R install in the hole where the inner skin was removed. Break all sharp edges.

R NOTE: The gap between the patch plate and the adjacent face sheet must not be
R more than 0.063 in. (1.60 mm). The patch plate and the adjacent face
R sheet must make a smooth, flush surface with finger pressure.

R (5) Use a felt-tip pen to transfer the hole size from the template to a sheet of 0.032 inch
R (0.81 mm) thick bare aluminum (2024-T42 or -T3). Make a second mark 1.6 inches
R (40.6 mm) away from the first mark, on all sides.

R (6) Use the second mark as a guide to cut a bridge plate from the aluminum sheet. The
R bridge plate must make an overlap on the duct sidewall inner skin by 1.6 inches (40.6
R mm) on all sides.

R (7) Break all sharp edges. The contour of the bridge plate must be the same as the
R contour of the repair area with finger pressure.

R (8) Drill a minimum of two 0.098 in. (2.49 mm) diameter alignment holes in the bridge plate
R at the locations shown in figure 603.

R (9) Locate the flush patch plate and the bridge plate in the center of the area over the hole
R where you removed the inner skin. Transfer drill the 0.098 in. (2.49 mm) diameter
R alignment holes into the inner skin. Use a drill stop to minimize core damage, and to
R make sure you do not drill through the opposite skin.

R (10) Deburr the holes.

REPAIR 004
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R (11) Clean the flush patch plate and the bridge plate.

R (a) Do a spot grit blast on the two sides of the patch plate, and on the bonding
R side of the bridge plate. Use virgin aluminum oxide 120-180 grit blast media.
R Refer to SPM 70-21-04.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT

R ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
R USE THE FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT
R BREATHE THE FUMES. IF YOU GET THE SOLVENT ON YOUR
R SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET
R MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
R SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R (b) Use a clean cloth (C10-182) moist with solvent (C04-003 or C04-035) to clean
R the bridge plate, the patch plate, and all surfaces of the repair area. Use a
R clean cloth to remove the solvent before it dries. Do not let the solvent dry on
R the surface.

R (c) Flush the area with deionized water, and look for water breaks. If you see
R water breaks, do steps (11)(a) and (11)(b) again.

R NOTE: If water does not flow over the parts in a smooth, continuous
R sheet, there are water breaks.

R NOTE: An area of the duct sidewall skin 1.5 in. (38 mm) wide around the
R repair area must pass the water break test.

R (d) Let the surface dry for a minimum of two hours, or oven dry at 150-200F (66-
R 93C) for a minimum of 30 minutes.

R (e) Wrap the patch plate and the bridge plate in clean kraft paper (C10-009).

R (12) After you remove all of the skin and/or repair details, do a visual inspection of the
R sidewall core for damage or unbonded areas, and/or do a tap test.

R (a) Tap the bondment outer skin surface to do a check for unbonded areas. Use a
R 0.5-1.0 ounce (14-28 gram) aluminum mallet held at a 90-degree angle.

R NOTE: If the material is fully bonded, you will hear a solid click when you
R tap. If the area is unbonded, you will hear a slightly hollow sound.
R If there is no damage or disbond, go to step (13). If you find
R damage or disbond, go step (12)(b).

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R (b) Remove all discolored, damaged, corroded, or disbonded core from the repair
R area.

R NOTE: Normal core material has a metallic silver color. Core material with
R corrosion damage has a milky gray color.

R (c) Remove all core cell walls of adjacent normal core around the edge of the
R discolored or damaged area, to a distance of one core cell beyond the damage.

R (d) Examine any core splice adhesive in the areas where you did not remove the
R core. Make a note, as necessary, of areas that will need repair when you
R prepare to bond.

R (e) Use a 120-240 grit aluminum oxide abrasive (sanding) disk or equivalent to
R remove core stubs and remaining adhesive on the skin, and core.

R (f) Do a spot grit blast on the inner side of the outer skin where the new core will
R be bonded. Use virgin aluminum oxide 120-180 grit blast media. Refer to
R SPM 70-21-04.

R (13) Do the steps that follow to clean the honeycomb core and skin that remains in the
R assembly.

R (a) Use abrasive paper (C10-105) to make the remaining adhesive on the core
R cells smooth and flush with adjacent cells. Remaining adhesive is permitted in
R the cell sidewall.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT

R ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
R USE THE FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT
R BREATHE THE FUMES. IF YOU GET THE SOLVENT ON YOUR
R SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET
R MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
R SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE

R AIRBORNE PARTICLES THAT CAN GO INTO YOUR EYES OR GO
R THROUGH YOUR SKIN. DO NOT USE MORE THAN 30 PSIG (207
R KPA) PRESSURE. USE GOGGLES. DO NOT POINT
R COMPRESSED AIR IN THE DIRECTION OF YOUR SKIN.

R (b) Clean the core with clean cloths (C10-182) moist with solvent (C04-003 or C04-
R 035). Let the area drain and dry in the air, or blow dry with clean, dry shop air.

R (c) Use flashbreaker tape (C10-136) to attach a Tedlar sheet to cover the repair
R area of the bondment. The tape must cover a minimum of a 0.25 inch (6.4 mm)
R area of the skin around the repair area. Put flashbreaker tape (C10-136)
R around the outer edge of the repair area.

REPAIR 004
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R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT

R ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
R USE THE FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT
R BREATHE THE FUMES. IF YOU GET THE SOLVENT ON YOUR
R SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET
R MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
R SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R (d) Use clean cloths (C10-182) moist with solvent (C04-003 or C04-035) to clean
R the repair area. Remove the solvent with a clean, dry cloth (C10-182) before it
R dries.

R (14) Do the steps that follow to install replacement honeycomb core.

R (a) Cut replacement honeycomb to match the size and type of the removed core.
R Refer to 78-32-02 Repair 023 for information about the correct replacement
R core.

R (b) Install the replacement honeycomb into the bondment to get a correct fit. The
R edges of the replacement honeycomb must interlock with the existing
R honeycomb, and have the same ribbon direction as the adjacent core.

R (c) Make a trial fit of the new honeycomb core. Make sure that high material on
R the inside surface will not prevent the patch from seating on the inner skin.

R (d) To prepare the aluminum honeycomb core, do a solvent degreasing procedure.

R Refer to SPM 70-21-01.

R (e) Mix a sufficient quantity of paste adhesive (C01-156) by weight, 100 parts resin
R with 20 parts catalyst. Mix fully until you can see no streaks of the two
R components. Do not mix more than 450 grams. You will need to apply
R adhesive to the bottom of the repair opening in the sidewall, the bottom of the
R honeycomb plug, the honeycomb walls of the repair opening, and the plug.

R (f) Use an acid brush to apply a 0.06 inch (1.4 mm) thick layer of epoxy adhesive
R to the bottom of the repair opening (inside surface of the inner skin). Use a
R criss-cross brushing pattern to make sure the opening is fully covered.

R (g) Brush the adhesive up the honeycomb walls of the repair opening.

R (h) Apply a 0.06 inch (1.4 mm) thick layer of epoxy adhesive on taped-down
R grease-proof paper to an area approximately 1.0 inch (25.4 mm) larger (length
R and width) than the flat surface of the honeycomb plug.

R (i) Push the honeycomb plug into the epoxy adhesive on the paper and slide the
R plug back and forth, and in a circular motion, to apply adhesive on the bottom
R of the honeycomb cell walls. Apply bondline netting (C01-126) to the
R bond side of the core. Fully soak the netting with adhesive.

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R (j) Use an acid brush to apply a layer of epoxy adhesive to the outer walls of the
R plug.

R (k) Push the plug into the repair opening with the adhesive-charged cell end
R against the bottom of the repair opening. Firmly hold the plug in the opening
R until the adhesive sets up (one hour at room temperature).

R (l) While the adhesive sets up, clean off unwanted adhesive around the plug.

R (m) Cure the adhesive for two hours at room temperature followed by 60-90
R minutes at 200°-220°F (93°-104°C).

R (15) Use flashbreaker tape (C10-136) to protect the surface adjacent to the repair area.

R WARNING: THIS MATERIAL IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR

R EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. USE
R CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES
R (C10-140) WHEN YOU MIX OR APPLY THE ADHESIVE.

R (16) Make a mixture of paste adhesive (C01-156) by weight, 100 parts resin with 20 parts
R catalyst. Mix fully until you can see no streaks of the two components. Do not mix
R more than 450 grams.

R (17) Apply a layer of the adhesive mixture to the core side of the flush patch plate. Put a
R piece of dacron polyester bondline netting (C01-126) on the adhesive. Use a tongue
R depressor to work the dacron polyester netting into the adhesive. Apply a layer of
R adhesive mixture to cover the dacron polyester netting. The total adhesive layer must
R be 0.05-0.10 inch (1.3-2.5 mm) thick.

R (18) Install the flush patch plate in position on the honeycomb core.

R (19) Apply a thin layer of adhesive (C01-156) to the bridge plate. Put a piece of dacron
R polyester bondline netting (C01-126) on the adhesive. Use a tongue depressor to work
R the dacron polyester netting into the adhesive. Apply a thin layer of adhesive
R (C01-156) to cover the dacron polyester netting.

R (20) Apply a thin layer of adhesive (C01-156) to the outer surface of the flush patch plate
R and the bond area of the sidewall skin. Align the bridge plate over the center of
R the flush patch plate. Align the rivet holes.

R (21) Insert a 3/32 (0.094) in. (2.38 mm) aluminum solid rivet into each of the alignment
holes.

R (22) Attach a thermocouple to the inner skin bridge plate.

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R (23) Cover the repaired area with a release film, as necessary, and apply sufficient pressure
R to make sure there is even contact between bridge plate and the duct sidewall inner
R skin.

R NOTE: Use only sufficient pressure to hold the patch plate tightly in position
R against the duct sidewall inner skin.

R (24) Cure the adhesive for one hour at room temperature followed by 60-90 minutes at
R 200°-220°F (93°-104°C).

R (25) When the adhesive is fully cured, remove the pressure devices and make an inspection
R for damage. Make sure the bonded plates are aligned correctly, and do a tap check to
R examine the repair for disbonds.

R (a) Use a 0.5-1.0 ounce (14-28 gram) aluminum mallet held at a 90-degree angle
R to tap test the bondment. No voids or delaminations (disbonds) are permitted.

R (26) Remove unwanted adhesive from around the bridge plate as necessary.

R (27) Drill out the rivets used for alignment.

R (28) Drill a series of 0.098 in. (2.49 mm) diameter pilot holes around the edge of the bridge
R plate. Refer to figure 603. Use a drill stop to minimize core damage, and to make sure
R you do not drill through the opposite skin.

R (29) Drill open the 0.098 in. (2.49 mm) holes to 0.160-0.164 in. (4.06-4.17 mm) for rivets.
R Make sure there is a 2D edge distance on the duct sidewall skin.

R (30) Deburr the holes.

R (31) Wet install the NAS1738E5-X rivets in the bridge plate and bondment. Refer to SPM
R 70-13-00.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
R AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
R SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
R GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
R ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R D. Clean the surface with clean cloths (C10-182) moist with solvent (C04-003 or C04-035).

R E. Apply silicone insulation coating MA-25 to the repair area. Refer to 78-32-02 Repair 022.

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R MR60195-01-A
R Allowable Damage Area
R Figure 601

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R MR60197-00-A
R Duct Sidewall Damage Spacing Limits
R Figure 602

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R MR60194-02-A
R Upper Duct Sidewall Repair – Rectangular Repair
R Figure 603

REPAIR 004
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THIS PAGE INTENTIONALLY BLANK

 COMPONENT
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MANUAL

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FAN REVERSER SUPPORT ASSEMBLY - REPAIR

R 1. Replacement of Rivets.

A. This procedure gives the instructions to replace loose or damaged rivets in the support
R assembly.

R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools. None required.

R (3) Locally Manufactured Tools. None required.

R (4) Equipment. None required.

R B. Consumable Materials.

Code Description Use

R C03-001 Primer, Zinc Chromate, Rivet replacement

R Fed. Spec. TT-P-1757,
R Color Y, Composition G

R C03-005 Primer, Epoxy Resin Rivet replacement

R (Spray Type), Finch 463-12-8

R C04-018 Naphtha, Fed. Spec. Clean the rivet hole

R TT-N-95, Type II

R C. Expendable Parts. Refer to the Illustrated Parts Catalog for quantity and required rivets.

R D. SPD Identification. None required.

R E. Referenced Procedures.

R SPM 70-13-00

R SPM 70-13-05

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R 3. Dimensional Information. None required.

R 4. Setup Information. None required.

R 5. Procedure.

R A. Drill out the loose or damaged rivet(s). Refer to Standard Practices Manual, 70-13-00. Deburr
R if necessary.

R WARNING: NAPHTHA IS FLAMMABLE. USE ONLY IN A WELL VENTILATED AREA AND TAKE
R PRECAUTIONS TO PREVENT FIRE.

R B. Clean the rivet hole(s) with naphtha (C04-018) and let dry.

R C. Replace the loose or damaged rivet with an equivalent rivet as specified in the CF6-80E Fan
R Reverser Illustrated Parts Catalog (MR99379) for the applicable location.

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU USE
R THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU DO NOT
R BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR SKIN OR INTO
R YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES AND CLOTHING TO
R PROTECT YOURSELF.

R D. Install the rivet(s). Refer to Standard Practices Manual, 70-13-00 and 70-13-05. Install the
R rivet(s) with a wet layer of epoxy resin primer (C03-005) or zinc chromate primer (C03-001) to
R fully cover the rivet(s).

R E. Remove unwanted primer after you install the rivet(s).

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FAN REVERSER SUPPORT ASSEMBLY - REPAIR

R 1. Honeycomb Dent Repair.

R A. This procedure gives the instructions for the repair of dents in the core cowl honeycomb
R bondment inner or outer skins. This repair is for dents with disbonded skin, with a maximum
R size of 0.9 in. (22.9 mm) in diameter by 0.09 in. (2.29 mm) deep. There can be any number of
R these repairs in the damage areas shown in figures 601 and 602, if there is a minimum of 6.0
R in. (15.2 cm) between repairs. The number and size of repaired dents on the acoustically
R treated bondment is also limited by the acoustic blockage limits given in 78-32-02 Inspection,
R step 3.A.(5).

R 2. Tools Equipment And Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools. None required.

R (3) Locally Manufactured Tools.

R Description Figure No.

R Core Piercing Tool Figure 603

R (4) Equipment.

R Description Manufacturer

R Gun, Filleting Semco Div. Products Research

R Semco Sealant & Chemical Company
R Los Angeles, CA

R Heat Source that can Local purchase

R raise the temperature to
R 200°-220°F (93°-104°C)

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R B. Consumable Materials.

R Code No Description Use

R C01-021 Adhesive, Epoxy, Two-Part, Fill dents

R Metal-Set A4, Part A and B

R C01-156 Adhesive, Paste, Two-Part, Honeycomb and face sheet repair

R EA9394/C2

R C03-059 Paint, Polyurethane, Finish layer

R Gray, Glossy, (BMS 1060
R Type 1 Grade A), 643-3-9
R and Catalyst X-310A

R C03-077 Primer, Epoxy, BMS-10-11Y, Primer layer

R Type I, Class A, Grade E

R C03-092 Conversion Coating, Chromated, Surface preparation

R Alodine 1132

R C04-003 Solvent, Acetone Clean the repair area

R (Fed. Spec. 0-A51)

R C04-035 Isopropyl Alcohol Clean the repair area

R C10-105 Paper, Abrasive, 120 Grit Surface preparation

R C10-136 Tape, Flashbreaker Adhesive support

R C10-140 Gloves, Nylon Film/Polyethylene, Mix and apply the adhesive

R Disposable

R C10-182 Cloths, Cleaning Clean the repair area

R Local Purchase Paper, Silicone Carbide, Surface preparation

R No. 240-320 Grit

R Local Purchase Film, Polyethylene Prepare the repair area

R Local Purchase Tape, Fiber, Acetate Prepare the repair area

R Local Purchase Scraper, Plastic Removal of the insulation layer

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R C. Expendable Parts. None required.

R D. SPD Identification. None required.

R E. Referenced Procedures.

R 78-32-02 Inspection

R 78-32-02 Repair 022

R 3. Dimensional Information. Damage areas are specified in figures 601 and 602.

R 4 Setup Information. None required.

R 5. Procedure.

R A. If the dent is in an area with MA-25 insulation, remove the MA-25 insulation and prepare the
R repair surface in the damage area.

R (1) Apply polyethylene film and acetate fiber tape to the areas where you will not remove
R the silicone insulation coating.

R (2) Use a plastic scraper and abrasive paper (C10-105) to remove as much of the silicone
R insulation coating as possible 1.0-2.0 in. (25.4-50.8 mm) around the repair area, at a
R minimum.

R (3) Use 120 grit or finer abrasive paper to sand the repair area and remove the remaining
R insulation coating. Bevel the coating at the edges of the bare area.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE. IF
R FUMES YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (4) Use clean cloths (C10-182) moist with solvent (C04-003 or C04-035) to fully clean the
R repair area.

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R B. Do a tap test in the area around the dent to find unbonded area. With a felt-tip marker, make a
R line around each unbonded area.

R (1) Use a 0.5-1.0 oz (14-28 g) aluminum mallet to lightly hit the surface of the area around
R the dent.

R NOTE: If you hear a solid “click” sound, there are no voids. If you hear an empty
R sound, the area is unbonded.

R (2) If there are no disbonds, it is not necessary to repair the dent. If a cosmetic repair is
desired, refer to paragraph E. Paragraph E gives instructions for a cosmetic fill repair
to restore aerodynamic smoothness.

R (3) If there are disbonds, go to paragraph C.

R C. Examine the skin to make sure there are no cracks or punctures. If there are cracks or
R punctures in the skin, refer to 78-32-02 Inspection.

R D. Do the steps that follow to repair areas with dents that have disbonds in the honeycomb
R bondment.

R (1) If the inner, solid skin is damaged, do the steps that follow. If the outer, perforated skin
R is damaged, go to step (2).

R (a) Put the core cowl in a position that permits easy access to the damaged area,
R and also permits good adhesive flow.

R (b) Drill a 0.098 in. (2.49 mm) hole at the center of the dent.

R (c) Locally make a core piercing tool from metal wire. Refer to figure 603. Use the
R dimensions given in figure 603, regardless of the size of the damage.

R (d) Insert the core piercing tool into the center hole and spoil the core around the
R dent.

R (e) Drill two 0.070 in. (1.78 mm) vent holes in the spoiled core area so that
R adhesive will vent from these holes while the center hole is gravity-fed with the
R adhesive. One vent hole must be located above the center hole, and the other
R vent hole must be below the center hole. The vent holes must be a distance of
R 0.40 in. (10.2 mm) from the center hole. Refer to figure 604.

R (f) Apply flashbreaker tape (C10-136) to the perforated (flow side) skin opposite
R the dent.

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R WARNING: ADHESIVE IS AN IRRITANT. DO NOT GET THE ADHESIVE IN

R YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE
R AIR. USE CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE
R GLOVES (C10-140) WHEN YOU MIX OR APPLY THE ADHESIVE.

R (g) Make a mixture of paste adhesive (C01-156) by weight, 100 parts resin with 20
R parts catalyst. Mix fully until you can see no streaks of the two components.
R Do not mix more than 450 grams.

R (h) Inject the adhesive mixture into the center hole until the adhesive leaks from
R the two vent holes.

R (i) Cover the holes with flashbreaker tape (C10-136).

R (j) Go to step D.(3).

R (2) If the outer, perforated skin is damaged, do the steps that follow.

R (a) If possible, put the bondment in a position where the damaged perforated skin
R is turned up.

R (b) Fill the disbonded area with adhesive (C01-156).

R 1 Mix the adhesive (C01-156). Refer to step (1)(g).

R 2 Use a filleting gun with a needle tip that has a 1/16 in. (1.59 mm) or a
R 1/32 in. (0.79 mm) orifice to apply the adhesive mixture.

R 3 Inject the adhesive mixture through the perforated holes in the

R disbonded area until you see adhesive flow from an adjacent hole.
R Continue to inject the adhesive until you see a flow of adhesive from all
R of the holes around the damaged area.

R (c) Cover the repair area with flashbreaker tape (C10-136) and, if possible, put the
R bondment in a position where the damaged perforated skin is turned down.
This position will let the adhesive fully fill the damaged area.

R (3) Cure the adhesive at room temperature for one hour, followed by 60-90 minutes at
R 200°-220°F (93°-104°C). Use a heat lamp, heat blanket or oven.

R (4) Use 120 grit abrasive paper (C10-105) to remove all unwanted adhesive from the repair
R area, and to make the surface of the repair area smooth and continuous with the
R adjacent surface.

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R (5) Make a visual inspection of the repaired area to look for disbonds. Do a tap test with a
R 0.5-1.0 oz (14-28 g) aluminum mallet to make sure all disbonds were repaired. If you
R find disbonds, refer to 78-32-02 Inspection.

R (6) If necessary, apply primer and MA-25 insulation to the inner skin surface adjacent to
R the repaired area. Refer to 78-32-02 Repair 022.

R E. Optional cosmetic repair: If desired, do the steps that follow to fill a dent and restore the
R surface contour. This procedure is applicable only for dents that have no disbonds.

R (1) Use 240-320 grit silicone carbide paper to make the repair area rough.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (2) Use clean cloths (C10-182) moist with solvent (C04-003 or C04-035) to fully clean the
R repair area. Use a clean, dry cloth to remove the solvent before it dries.

R (3) Apply conversion coating (C03-092) to the repair area.

R WARNING: ADHESIVE IS AN IRRITANT. DO NOT GET THE ADHESIVE IN YOUR EYES

R OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. USE CLEAN
R NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN
R YOU MIX OR APPLY THE ADHESIVE.

R (4) Fill the dent with Metal-Set A4 adhesive (C01-021) to restore the surface to its original
R contour.

R (5) Cure for two hours at 150°F (65°C).

R (6) When fully cured, blend with 120 grit abrasive paper (C10-105) to make the repair area
R smooth and flush with the adjacent surfaces.

REPAIR 006
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R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (7) Use clean cloths (C10-182) moist with solvent (C04-003 or C04-035) to clean the repair
R area. Use a clean, dry cloth to remove the solvent before it dries.

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
R USE THE MATERIAL IN AN AREA WITH GOOD AIR FLOW. MAKE SURE
R YOU DO NOT BREATHE THE FUMES. DO NOT GET THE MATERIAL ON
R YOUR SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE
R GLOVES AND CLOTHING TO PROTECT YOURSELF.

R (8) Apply epoxy primer (C03-077) to the core cowl repair surface.

R WARNING: THIS MATERIAL IS POISONOUS AND GIVES OFF FUMES. MAKE SURE
R YOU USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE
R YOU DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON
R YOUR SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE
R GLOVES AND CLOTHING TO PROTECT YOURSELF

R (9) If necessary, apply an equal layer of polyurethane paint (C03-059) to the core cowl
R outer perforated skin repair surface.

R (10) Cure the paint for seven hours at ambient temperature, or air dry for 30 minutes at
R ambient temperature, then cure for two hours at 180°-200°F (83°-93°C).

REPAIR 006
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R MM50077-00-A
R Core Cowl Allowable Damage Area, Left Reverser Half
R Figure 601

REPAIR 006
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R MM50077-00-A
R Core Cowl Allowable Damage Area, Right Reverser Half
R Figure 602

REPAIR 006
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R MM50077-00-A
R Core Piercing Tool
R Figure 603

R MM50077-00-A
R Vent Hole Position
R Figure 604

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R FAN REVERSER SUPPORT ASSEMBLY - REPAIR

R 1. Lower Duct Sidewall (LDSW) Dent Repair.

R This procedure gives the instructions for the repair of dents on the lower duct sidewall’s inner or outer
R skins. This repair is for dents with or without disbonds with a maximum size of 0.9 in. (22,9 mm) in
R diameter by 0.09 in. (2,29 mm) deep. The combined size of the dent and disbond cannot exceed 0.9 in.
R (22,9 mm) in diameter. There can be 5 of these dents in the specified damage area shown in Figure
R 601 as long as there is a minimum of 6 in. (15,24 cm) between dents. The distance between damages
R should be measured edge to edge.

R 2. Tools Equipment and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools. None required.

R (3) Locally Manufactured Tools.

R Core Piercing Tool, Figure 602

R (4) Equipment.

R Description Manufacturer

R Gun, Filleting Semco Div. Products Research

R Semco Sealant & Chemical Company
R Los Angeles, CA

R Heat Source that can Local purchase

R raise the temperature to
R 200°-220°F (93°-104°C)

R B. Consumable Materials.

R Code No Description Use

R C01-156 Adhesive, Paste, Honeycomb and inner skin repair

R EA9394/C2

R C01-021 Metal-Set 4A Fill dents

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R B. Consumable Materials. (Continued)

R Code No Description Use

R C03-006 Conversion Coating, Surface protection

R Alodine 1200S

R C03-017 Primer, Polyamide Epoxy Primer for the repair area

R MIL-P-23377

R C03-077 Primer, Polyamide Epoxy, Primer layer

R BMS-10-11Y

R C03-092 Conversion Coating, Chromated Surface preparation

R (Alodine 1132)

R C04-003 Solvent, Acetone Clean the repair area

R (Fed. Spec. 0-A51)

R C04-035 Isopropyl Alcohol Clean the repair area

R C10-105 Paper, Abrasive, 120 Grit Prepare the repair area

R C10-136 Tape, Flashbreaker Contain adhesive during cure

R C10-140 Gloves, Nylon Film/Polyethylene, Mix and apply the adhesive

R Disposable

R C10-182 Cloths, Cleaning Clean the repair area

R Local Purchase Paper, Silicon Carbide, Prepare the repair area

R No. 240-320 Grit

R Paint, Polyurethane, Finish layer

R MIL-C-85285, Type 1, Color is Customer Option
R Gray, Color Code 26306

R C. Expendable Parts. None required.

R D. SPD Identification. None required.

R E. Referenced Procedures.

R CMM 78-32-02 Repair 022

R 3. Dimensional Information. Damage Zones defined by Figure 601.

R 4 Setup Information. None required.

REPAIR 007
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R 5. Inner Skin Repair Procedure.

R A. For dents on the inner skin with MA-25 insulation, remove the MA-25 insulation and prepare the
R repair surface in the damage area.

R (1) Apply polyethylene film and acetate fiber tape to the areas where you will not remove
R the silicone insulation coating.

R (2) Use a non-metallic scraper to remove all of the silicone insulation coating from the area.
R At least 1 - 2 in. (25,4 - 50,8 mm) from repair area.

R (3) Sand the area to be repaired to remove residual coating using 120-grit or finer abrasive
R paper or cloth. Bevel coating at edges of bare area.

R (4) Thoroughly clean the area to be repaired using clean cloths moistened with acetone
R solvent (C04-003) to remove all visible contamination.

R (5) Examine the skin for cracks or punctures. If there are cracks or punctures in the skin,
R refer to 78-32-02 inspection section for the Lower Duct Sidewalls.

R B. Do a tap test in the area around the dent to determine if there are any disbonds.

R (1) Use a 0.5-1.0 oz. (14-28 g) aluminum mallet to lightly hit the surface of the area around
R the dent.

R NOTE: If you hear a solid “click” sound, there are no voids. If you hear a dull
R empty sound, the area is disbonded.

R (2) If no disbonding is present, a dent within limits can be left as is. If desired, dents can
R be cosmetically filled as outlined in Step 7 to restore a flush condition.

R (3) If disbonds are present, mark a line around each disbonded area with a felt-tip marker.
R Continue on to Paragraph 5.C.

R NOTE: The combined size of the dent and disbond must not exceed 0.9 in. (22,9
R mm) in diameter.

R C. Do the following steps to repair areas with dents that are disbonded in the honeycomb
R bondment.

R WARNING: ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR EYES

R OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. WEAR CLEAN
R NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN
R YOU MIX OR APPLY THE ADHESIVE.

R (1) Position sidewall in a manner to allow easy access to the damaged site and best
R orientation for adhesive flow.

R (2) Drill a 0.128 in. (3,26 mm) hole at the center of the dent.

REPAIR 007
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R (3) Locally make a core piercing tool. See Figure 602. (An equivalent size Allen wrench
R can also be used in place of the core piercing tool)

R (4) Insert core piercing tool into center hole and spoil the core around the dent.

R (5) Drill two 0.070 in. (1,78 mm) vent holes in the spoiled core area in such a way that the
R adhesive will vent from the holes while the center hole is gravity fed with the adhesive.
R One vent hole should be positioned above the center hole and the other below the
R center hole. The vent holes must be 0.4 in. (10,2 mm) from the center hole. See Figure
R 603.

R (6) Make a mixture of paste adhesive (C01-156) by weight, 100 parts resin with 20 parts
R catalyst (5 to 1). Mix fully until you can see no streaks of the two components. Do not
R mix more than 450 grams.

R (7) Inject the adhesive mixture (C01-156) into the center hole until leakage occurs from
R both vent holes.

R (8) Cover the holes with flash breaker tape (C10-136).

R (9) Cure the adhesive at room temperature for 1 hour followed by 60 – 90 minutes at 200°-
R 220°F (93°-104°C). Use a heat lamp, heat blanket, or oven.

R (10) Remove all excessive adhesive from around the repair area with 120 grit abrasive
R paper to make the repair area smooth and continuous with the adjacent surface.

R (11) Re-examine the repair area for disbonding. Do a tap test of the repaired area with a
R 0.5-1.0 oz. (14-28 g) aluminum mallet to ensure all disbonds have been eliminated. If
R disbonding is still present, refer to 78-32-02 inspection section for the Lower Duct
R Sidewalls.

R (12) If required, apply primer and MA-25S insulation to the surrounding area of the inner
R skin refer to CMM 78-32-02 Repair 022.

R 6. Outer Skin Procedure.

R A. For dents on the outer skin, repair per the following steps.

R (1) Examine the skin for cracks or punctures. If there are cracks or punctures in the skin,
R refer to 78-32-02 inspection section for the Lower Duct Sidewalls.

R (2) Use a 0.5-1.0 oz. (14-28 g) aluminum mallet to lightly hit the surface of the area around
R the dent.

R NOTE: If you hear a solid “click” sound, there are no voids. If you hear a dull
R empty sound, the area is disbonded.

R (3) If no disbond is present, a dent within limits can be left as is. If desired, dents can be
R cosmetically filled as outlined in Paragraph 8 to restore a flush condition.

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R (4) If disbonds are present, mark a line around each disbonded area with a felt-tip marker.
R Continue on to Paragraph 6.B.

R NOTE: The combined size of the dent and disbond must not exceed 0.9 in. (22,9
R mm) in diameter.

R B. Repair the outer skin dent as follows.

R (1) If possible, orient the bondment so that the damaged skin is facing up.

R (2) Drill a 0.128 in. (3,26 mm) hole at the center of the dent.

R (3) Locally make a core piercing tool. See Figure 602. (An equivalent size Allen wrench
R can also be used in place of the core piercing tool)

R (4) Insert core piercing tool into center hole and spoil the core around the dent.

R (5) Drill two 0.070 in. (1,78 mm) vent holes in the spoiled core area in such a way that the
R adhesive will vent from the holes while the center hole is gravity fed with the adhesive.
R One vent hole should be positioned above the center hole and the other below the
R center hole. The vent holes must be 0.4 in. (10,2 mm) from the center hole. See
R Figure 603.

R (6) Make a mixture of paste adhesive (C01-156) by weight, 100 parts resin with 20 parts
R catalyst (5 to 1). Mix fully until you can see no streaks of the two components. Do not
R mix more than 450 grams.

R (7) Inject the adhesive mixture (C01-156) into the center hole until leakage occurs from
R both vent holes.

R (8) Cover the holes with flash breaker tape (C10-136)

R (9) Cure the adhesive at room temperature for 1 hour followed by 60 – 90 minutes at 200°-
R 220°F (93°-104°C). Use a heat lamp, heat blanket, or oven.

R (10) Remove all excessive adhesive from around the repair area with 120 grit abrasive
R paper to make the repair area smooth and continuous with the adjacent surface.

R (11) Re-examine the repair area for disbonding. Do a tap test of the repaired area with a
R 0.5- 1.0 oz. (14-28 g) aluminum mallet to ensure all disbonds have been eliminated. If
R disbonding is still present, refer to 78-32-02 inspection section for the Lower Duct
R Sidewalls.

R 7. Do the following steps to fill a dent and restore the surface profile if desired on the inner skin.

R A. Make the repair area rough with 240-320 grit silicon carbide paper.

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R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE GAS.
R IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT
R AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR EYES
R BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R B. Clean the repair area with a clean, cotton, lint-free cloth (C10-182) made moist with
R solvent (C04-003 or C04-035). Use a clean dry cloth to remove the solvent before it
R dries.

R WARNING: ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR EYES

R OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. WEAR CLEAN
R NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN
R YOU MIX OR APPLY THE ADHESIVE

R C. Apply Alodine 1132 (C03-092) to the damage area.

R D. Fill the dent with Metal-Set A4 (C01-021) to restore the surface to its original profile.

R E. Cure for 2 hours at 150°F (65°C).

R F. When fully cured, blend to make the repair area smooth and flush with the adjacent
R surfaces with 120 grit abrasive paper (C10-105). Wipe area clean using clean, cotton,
R lint-free cloth (C10-182) made moist with solvent (C04-003 or C04-035). Use
R a clean dry cloth to remove the solvent before it dries.

R G. If required, apply primer and MA-25S insulation to the surrounding area of the inner
R skin refer to CMM 78-32-02 Repair 022.

R 8. Do the following steps to fill a dent and restore the surface profile if desired on the outer flow path skin.

R A. Make the repair area rough with 240-320 grit silicon carbide paper.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE GAS.
R IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT
R AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR EYES
R BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY
R FLAMMABLE.

R B. Clean the repair area with a clean, cotton, lint-free cloth (C10-182) made moist with
R solvent (C04-003 or C04-035). Use a clean dry cloth to remove the solvent before it
R dries.

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R WARNING: ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR EYES

R OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. WEAR CLEAN
R NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN
R YOU MIX OR APPLY THE ADHESIVE.

R C. Apply Alodine 1132 (C03-092) to the damage area.

R D. Fill the dent with Metal-Set A4 (C01-021) to restore the surface to its original profile.

R E. Cure for 2 hours at 150°F (65°C).

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE GAS.
R IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT
R AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR EYES
R BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY
R FLAMMABLE.

R F. When fully cured, blend to make the repair area smooth and flush with the adjacent
R surfaces with 120 grit abrasive paper (C10-105). Wipe area clean using clean, cotton,
R lint-free cloth (C10-182) made moist with solvent (C04-003 or C04-035). Use a clean
R dry cloth to remove the solvent before it dries.

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
R USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
R SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES AND
R CLOTHING TO PROTECT YOURSELF.

R G. If required, apply an equal layer of polyurethane paint MIL-PRF-85285, color # 26306

R (color is customer’s option) to the outer skin repair surface.

R H. Cure the paint for 30 minutes at ambient temperature, then cure for two hours at 140°F
R (83°C).

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R
R LDSW Inner/Outer Skin Allowable Damage Areas
R Figure 601

R NOTE: Area of the damage must be located away from any edge of the bondment as shown
R above. The area of the damage must also be located 2 times its diameter from any
R fastener, plus 2 times the diameter of the fastener. The distance between damages and
R fasteners should be measured edge to edge.

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R
R Core Piercing Tool
R Figure 602

R
R Vent Hole Position
R Figure 603

REPAIR 007
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 FAN REVERSER
CF6-80E1 CMM

THIS PAGE INTENTIONALLY BLANK

 COMPONENT
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MANUAL

683L SERIES

FAN REVERSER ASSEMBLY - REPAIR

1. Replacement of Core Cowl Assembly Aft Closeout Wear Strips.

A. This procedure gives the instructions for replacement of worn or damaged aft closeout wear
strips on the core cowl assembly. Do this procedure if the wear strips have cracks or are worn
through.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment. None required.

B. Consumable Materials.

Code No. Description Use

C03-001 Primer, Zinc Chromate Rivet installation

C03-005 Primer, Epoxy Resin Rivet installation

(Spray Type), Finch 463-12-8

C04-001 Solvent, Methyl-Ethyl-Ketone Clean the repair area

C05-003 Carter's Marks-A-Lot Mark the wear strip

(Black or Blue) axial location

C. Expendable Parts.

Number Description

5-235, 78-32-21 Rivets, Blind

5-240, 78-32-21 Rivets, Blind

5-245, 78-32-21 Rivets, Solid

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D. SPD Identification. None required.

E. Referenced Procedures.

SPM 70-13-00

3. Dimensional Information. None required.

4. Setup Information. None required.

5. Procedure.

A. Remove the worn or damaged aft closeout wear strip(s) (5-220, -225, -230, 78-32-21). See
figure 601.

(1) Use a felt-tip pen (C05-003) to make a mark that shows the axial location of the wear
strip(s) to be removed. Make a mark to show the location on the aft flange of the core
cowl assembly along the aft edge of the wear strip(s) so that you can install
replacement wear strip(s) in the same location as the wear strip(s) that you remove.

NOTE: There may be shims between the aft flange of the core cowl assembly and
the wear strips. The shims are independently riveted to the core cowl half.
Do not remove the shims.

(2) Drill out the rivets that attach the wear strips to the core cowl assembly. Refer to SPM
70-13-00. There are 12 rivets that attach the short wear strips and 24 rivets that attach
the extended wear strips.

(3) Use a small punch to drive out the rivet shanks.

B. Install the aft closeout wear strip(s) (5-220, -225, -230, 78-32-21). See figure 601.

(1) Put the replacement wear strip in position on the core cowl aft flange over the rivet
holes. Keep a 0.09 in. (2.29 mm) gap between each wear strip, a 0.06 in. (1.52 mm)
edge distance at lower sidewall end, and a 0.73-0.77 in. (18.54-19.56 mm) overhang
from the aft flange of the core cowl assembly.

(2) Hold the replacement wear strip in position on the core cowl aft flange with a clamp.
Back-drill holes to 0.128 in. (3.251 mm) diameter. Drill 12 holes for the short wear
strips and 24 holes for the extended wear strips.

(3) If the holes become too large, redrill and countersink. Refer to table 601. Use rivets
that are the same as the hole size.

(4) Remove the clamp and the wear strip. Deburr the holes.

REPAIR 008
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WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

(5) Use a clean cloth moist with solvent (C04-001) to clean the area on the core cowl
where you will attach the wear strip. Let the area air dry.

WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
SKIN OR INTO YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
AND CLOTHING TO PROTECT YOURSELF.

(6) Use the applicable size rivet to attach the wear strip to the core cowl assembly. Refer
to SPM 70-13-00. Install the rivets with a wet layer of zinc chromate primer (C03-001)
or epoxy resin primer (C03-005). After you install the wear strip, remove unwanted
primer.

(7) Flush-grind the rivet bucked heads on the farside.

Table 601. Rivet Hole Size

Maximum Nearside Farside

Hole Countersink Countersink
Rivet P/N Hole Diameter Diameter Dim. (100°) Dim. (100°)

MS20426AD4 0.128-0.132 in 0.140 in 0.225-0.235 in 0.188-0.218 in

(3.25-3.35 mm) (3.56 mm) (5.72-5.97 mm) (4.78-5.54 mm)

MS20426AD5 0.158-0.162 in 0.174 in 0.282-0.290 in 0.247-0.279 in

(4.01-4.11 mm) (4.41 mm) (7.16-7.37 mm) (6.27-7.09 mm)

MS20426AD 0.190-0.196 in 0.209 in 0.349-0.357 in 0.314-0.346 in

(4.83-4.98 mm) (5.31 mm) (8.86-9.07 mm) (7.98-8.79 mm)

REPAIR 008
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MM60009-01-A
Core Cowl Assembly Aft Closeout Wear Strip Replacement
Figure 601

REPAIR 008
PAGE 604
78-32-02 DEC 01/98
 COMPONENT
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FAN REVERSER SUPPORT ASSEMBLY - REPAIR

R 1. Repair of Disbonded or Damaged Lower Duct Sidewall Inner Skin.

R A. This procedure gives the instructions for the repair of the lower duct sidewall due to disbonded
R or damaged inner skin. Use this repair only for damage in the area shown in figure 601. The
R maximum size permitted for the repair area is 3.0 in. x 3.0 in.(76.2 mm x 76.2 mm). The edge
R of the damaged area must be within the damage envelope shown in figure 601. A maximum of
R two repairs are permitted on a sidewall assembly. The distance between the two damaged
R areas must be a minimum of 2.5 times the diameter of the first damaged area plus 2.5 times the
R diameter of the second damaged area. Refer to figure 602. The total damage area must be
R less than 9.0 sq in. (58.06 sq cm). For damage that is more than these limits, refer to 78-32-02
R Repair 023.

R B. Make sure all the surfaces are clean when you prepare to apply the adhesive. Keep all
R surfaces clean during all of the steps.

R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools. None required.

R (3) Locally Manufactured Tools. None required.

R (4) Equipment.

R Description Manufacturer

R Pyrometer Local purchase

R Heat source that can keep Local purchase

R a temperature between
R 200°-220°F (93°-104°C)

R Thermocouples Local purchase

R Oven Local purchase

R Drill Motor Local purchase

R Mallet, Aluminum, 0.5-1.0 oz. Tap Check

R (14-28 g)

REPAIR 009
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R B. Consumable Materials.

R Code Description Use

R C01-015 Insulation, Ablative Silicone, MA-25 Restore the insulation

R C01-126 Netting, Fabric, Dacron Polyester Bondline control

R C01-156 Adhesive, Paste, Duct sidewall repair

R EA9394/C2

R C04-003 Solvent, Acetone Clean the repair area

R C04-035 Isopropyl Alcohol Clean the repair area

R C10-009 Paper, Greaseproof, Grade A, Protect the cleaned

R Kraft repair details

R C10-105 Paper, Abrasive, 120 Grit Prepare the repair area

R C10-136 Tape, Flashbreaker Protect the surface

R adjacent to the repair

R C10-137 Film, Vacuum Bag Bondment repair

R C10-138 Tape, Sealant, Vacuum Bag Bondment repair

R C10-140 Gloves, Nylon Film/Polyethylene, Mix and apply the adhesive

R Disposable

R C10-182 Cloths, Cotton, Lint-free Clean the repair area

R Local Purchase Aluminum Stock, Bare, 0.020 inch Make the repair parts
R (0.51 mm) Thick and 0.025 inch
R (0.64 mm) Thick (2024-T42 or -T3)

R Local Purchase Abrasive, Grit, Blast Media, Prepare the bonding

R 120-180 Grit Virgin Aluminum surface
R Oxide

R Local Purchase Film, Polyethylene Prepare the repair area

R Local Purchase Tape, Fiber, Acetate Prepare the repair area

R Local Purchase Sheet, Tedlar Protect the repair area

REPAIR 009
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78-32-02 JUN 01/13
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R Code Description Use

R Local Purchase Scraper, Plastic Removal of the insulation layer

R Local Purchase Tongue Depressor Apply the adhesive

R Local Purchase Brush, Acid Apply the adhesive

R Local Purchase Felt Tip Pen Mark the damage area

R C. Expendable Parts.

R Number Description

R NAS1738E5-X Rivets

R D. SPD Identification. None required.

R E. Referenced Procedures.

R SPM 70-13-00

R SPM 70-21-01

R SPM 70-21-04

R 78-32-02 Repair 022

R 78-32-02 Repair 023

R 3. Dimensional Information. Refer to figures 601, 602 and 603.

R 4. Setup Information. None required.

REPAIR 009
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78-32-02 JUN 01/13
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R 5. Procedure. Refer to figure 603.

R A. Find the amount of the damage.

R (1) Remove the MA-25 silicone insulation coating from the area where you will do the tap
R check.

R NOTE: The edge of the damaged area must fall within the envelope shown in
R figure 601.

R (2) Do a tap check of the damaged sidewall area to find voids.

R (a) Tap around the bondment with a 0.5-1.0 oz. (14-28 gram) aluminum mallet
R held at a 90-degree angle to find the size and location of the void (disbond).

R (b) Tap the outer skin at the adjacent area to determine if the disbond is present
R on both the inner surface and the outer surface.

R (c) Use a felt-tip pen to make a line around the boundary of the void on the
R inner skin.

R B. Remove the MA-25 silicone insulation coating from all areas where you will attach plates.

R (1) Apply polyethylene film and acetate fiber tape to the areas of the lower duct sidewall
R where you will not remove the silicone insulation coating.

R (2) Use a plastic scraper and abrasive paper (C10-105) to remove as much of the silicone
R insulation coating as possible from the repair area and from the area 1.0-2.0 in. (25.4-
R 50.8 mm) around the repair area.

R (3) Use 120 grit or finer abrasive paper or cloth to remove the remaining insulation from the
R abraded area. Bevel the coating at the edges of the bare area.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR
R SKIN OR EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE,
R TOXIC, AND HIGHLY FLAMMABLE.

R (4) Use a clean cloth (C10-182) moist with solvent (C04-003 or C04-035) to fully clean the
R repair area. Make sure to remove all unwanted material from the abraded repair area.

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R C. Do the steps that follow to repair disbonds between the inner skin and the core, and fractures or
R holes in the inner (solid) skin up to 3.0 in. x 3.0 in. (76.2 mm x 76.2 mm) in size.

R NOTE: This repair is only for damaged areas a minimum of 2.5 times the diameter of the
R first damage area plus 2.5 times the diameter of the second damage area (figure
R 602). The damage must be only in the areas where the skin is 0.020 in. (0.51 mm)
R thick, and must be within the limits shown in figure 601.

R CAUTION: BE VERY CAREFUL NOT TO DAMAGE THE HONEYCOMB CORE WHEN

R YOU REMOVE THE DELAMINATED FACE SHEET.

R (1) Use a hole saw, radial disc, or pencil grinder to remove the inner skin.

R (2) Use mylar film or equivalent to make a template of the cutout in the skin.

R (3) Use a felt-tip pen to transfer the hole size from the template to a sheet of 0.020 inch
R (0.51 mm) thick bare aluminum (2024-T42 or -T3).

R NOTE: The non-doubled areas of skin can have a thickness of 0.020-0.028 in.
R (0.51-0.71 mm). The filler piece must have the same thickness as the
R material removed.

R (4) Use the mark you made on the aluminum sheet as a guide to cut a flush patch plate to
R install in the hole where the inner skin was removed. Break all sharp edges.

R NOTE: The gap between the patch plate and the adjacent face sheet must not
R be more than 0.063 in. (1.60 mm). The patch plate and the adjacent
R face sheet must make a smooth, flush surface with finger pressure.

R (5) Use a felt-tip pen to transfer the hole size from the template to a sheet of 0.025 inch
R (0.64 mm) thick bare aluminum (2024-T42 or -T3). Make a second mark 1.6 inches
R (40.6 mm) away from the first mark, on all sides.

R (6) Use the second mark as a guide to cut a bridge plate from the aluminum sheet. The
R bridge plate must make an overlap on the duct sidewall inner skin by 1.6 inches (40.6
R mm) on all sides.

R (7) Break all sharp edges. The contour of the bridge plate must be the same as the
R contour of the repair area with finger pressure.

R (8) Drill a minimum of two 0.098 in. (2.49 mm) diameter alignment holes in the bridge plate
R at the locations shown in figure 603.

R (9) Locate the flush patch plate and the bridge plate in the center of the area over the hole
R where you removed the inner skin. Transfer drill the 0.098 in. (2.49 mm) diameter
R alignment holes into the inner skin.

R (10) Deburr the holes.

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R (11) Clean the flush patch plate and the bridge plate.

R (a) Do a spot grit blast on the two sides of the patch plate, and on the bonding
R side of the bridge plate. Use virgin aluminum oxide 120-180 grit blast media.
R Refer to SPM 70-21-04.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT

R ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
R USE THE FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT
R BREATHE THE FUMES. IF YOU GET THE SOLVENT ON YOUR
R SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET
R MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
R SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R (b) Use a clean cloth (C10-182) moist with solvent (C04-003 or C04-035) to clean
R the bridge plate, the patch plate, and all surfaces of the repair area. Use a
R clean cloth to remove the solvent before it dries. Do not let the solvent dry
R on the surface.

R (c) Flush the area with deionized water, and look for water breaks. If you see
R water breaks, do steps (11)(a) and (11)(b) again.

R NOTE: If water does not flow over the parts in a smooth, continuous sheet,
R there are water breaks.

R NOTE: An area of the duct sidewall skin 1.5 in. (38 mm) wide around the
R repair area must pass the water break test.

R (d) Let the surface dry for a minimum of two hours, or oven dry at 150°-200°F (66°-
R 93°C) for a minimum of 30 minutes.

R (e) Wrap the patch plate and the bridge plate in clean kraft paper (C10-009).

R (12) After you remove all of the skin and/or repair details, do a visual inspection of the
R sidewall core for damage or unbonded areas, and/or do a tap test.

R (a) Tap the bondment outer skin surface to do a check for unbonded areas. Use a
R 0.5-1.0 ounce (14-28 gram) aluminum mallet held at a 90-degree angle.

R NOTE: If the material is fully bonded, you will hear a solid click when you
R tap. If the area is unbonded, you will hear a slightly hollow sound.
R If there is no damage or disbond, go to step (13). If you find
R damage or disbond, go step (12)(b).

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R (b) Remove all discolored, damaged, corroded, or disbonded core from the repair
R area.

R NOTE: Normal core material has a metallic silver color. Core material with
R corrosion damage has a milky gray color.

R (c) Remove all core cell walls of adjacent normal core around the edge of the
R discolored or damaged area, to a distance of one core cell beyond the damage.

R (d) Examine any core splice adhesive in the areas where you did not remove
R the core. Make a note, as necessary, of areas that will need repair when
R you prepare to bond.

R (e) Use a 120-240 grit aluminum oxide abrasive (sanding) disk or equivalent
R to remove core stubs and remaining adhesive on the skin, and core.

R (f) Do a spot grit blast on the inner side of the outer skin where the new
R core will be bonded. Use virgin aluminum oxide 120-180 grit blast media.
R Refer to SPM 70-21-04.

R (13) Do the steps that follow to clean the honeycomb core and skin that remains in the
R assembly.

R (a) Use abrasive paper (C10-105) to make the remaining adhesive on the core
R cells smooth and flush with adjacent cells. Remaining adhesive is permitted
R in the cell sidewall.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT

R ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
R USE THE FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT
R BREATHE THE FUMES. IF YOU GET THE SOLVENT ON YOUR
R SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET
R MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
R SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE

R AIRBORNE PARTICLES THAT CAN GO INTO YOUR EYES OR GO
R THROUGH YOUR SKIN. DO NOT USE MORE THAN 30 PSIG (207
R KPA) PRESSURE. USE GOGGLES. DO NOT POINT
R COMPRESSED AIR IN THE DIRECTION OF YOUR SKIN.

R (b) Clean the core with clean cloths (C10-182) moist with solvent (C04-003 or C04-
R 035). Let the area drain and dry in the air, or blow dry with clean, dry shop air.

R (c) Use flashbreaker tape (C10-136) to attach a Tedlar sheet to cover the repair
R area of the bondment. The tape must cover a minimum of a 0.25 inch (6.4 mm)
R area of the skin around the repair area. Put flashbreaker tape (C10-136)
R around the outer edge of the repair area.

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R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT

R ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
R USE THE FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT
R BREATHE THE FUMES. IF YOU GET THE SOLVENT ON YOUR
R SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET
R MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
R SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R (d) Use clean cloths (C10-182) moist with solvent (C04-003 or C04-035) to clean
R the repair area. Remove the solvent with a clean, dry cloth (C10-182) before
R it dries.

R (14) Do the steps that follow to install replacement honeycomb core.

R (a) Cut replacement honeycomb to match the size and type of the removed core.
R Refer to 78-32-02 Repair 023 for information about the correct replacement
R core.

R (b) Install the replacement honeycomb into the bondment to get a correct fit.
R The edges of the replacement honeycomb must interlock with the existing
R honeycomb, and have the same ribbon direction as the adjacent core.

R (c) Make a trial fit of the new honeycomb core. Make sure that high material on
R the inner surface will not prevent the patch from seating on the inner skin.

R (d) To prepare the aluminum honeycomb core, do a solvent degreasing procedure.

R Refer to SPM 70-21-01.

R (e) Mix a sufficient quantity of paste adhesive (C01-156) by weight, 100 parts resin
R with 20 parts catalyst. Mix fully until you can see no streaks of the two
R components. Do not mix more than 450 grams. You will need to apply
R adhesive to the bottom of the repair opening in the sidewall, the bottom of the
R honeycomb plug, the honeycomb walls of the repair opening, and the plug.

R (f) Use an acid brush to apply a 0.06 inch (1.4 mm) thick layer of epoxy adhesive
R to the bottom of the repair opening (inside surface of the inner skin). Use a
R criss-cross brushing pattern to make sure the opening is fully covered.

R (g) Brush the adhesive up the honeycomb walls of the repair opening.

R (h) Apply a 0.06 inch (1.4 mm) thick layer of epoxy adhesive on taped-down
R grease-proof paper (C10-009) to an area approximately 1.0 inch (25.4 mm)
R larger (length and width) than the flat surface of the honeycomb plug.

R (i) Push the honeycomb plug into the epoxy adhesive on the paper and slide the
R plug back and forth, and in a circular motion, to apply adhesive on the bottom
R of the honeycomb cell walls. Apply bondline netting (C01-126) to the bond side
R of the core. Fully soak the netting with adhesive.

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R (j) Use an acid brush to apply a layer of epoxy adhesive to the outer walls of
R the plug.

R (k) Push the plug into the repair opening with the adhesive-charged cell end
R against the bottom of the repair opening. Firmly hold the plug in the opening
R until the adhesive sets up (one hour at room temperature).

R (l) While the adhesive sets up, clean off unwanted adhesive around the plug.

R (m) Cure the adhesive for two hours at room temperature followed by 60-90
R minutes at 200°-220°F (93°-104°C).

R (15) Use flashbreaker tape (C10-136) to protect the surface adjacent to the repair area.

R WARNING: THIS MATERIAL IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR

R EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. USE
R CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES
R (C10-140) WHEN YOU MIX OR APPLY THE ADHESIVE.

R (16) Make a mixture of paste adhesive (C01-156) by weight, 100 parts resin with 20 parts
R catalyst. Mix fully until you can see no streaks of the two components. Do not mix
R more than 450 grams.

R (17) Apply a layer of the adhesive mixture to the core side of the flush patch plate. Put a
R piece of dacron polyester bondline netting (C01-126) on the adhesive. Use a tongue
R depressor to work the dacron polyester netting into the adhesive. Apply a layer of
R adhesive mixture to cover the dacron polyester netting. The total adhesive layer must
R be 0.05-0.10 inch (1.3-2.5 mm) thick.

R (18) Install the flush patch plate in position on the honeycomb core.

R (19) Apply a thin layer of adhesive (C01-156) to the bridge plate. Put a piece of dacron
R polyester bondline netting (C01-126) on the adhesive. Use a tongue depressor to work
R the dacron polyester netting into the adhesive. Apply a thin layer of adhesive
R (C01-156) to cover the dacron polyester netting.

R (20) Apply a thin layer of adhesive (C01-156) to the outer surface of the flush patch plate
R and the bond area of the sidewall skin. Align the bridge plate over the center of the
R flush patch plate. Align the rivet holes.

R (21) Insert a 3/32 (0.094) in. (2.38 mm) aluminum solid rivet into each of the alignment
holes.

R (22) Attach a thermocouple to the inner skin bridge plate.

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R (23) Cover the repaired area with a release film, as necessary, and apply sufficient pressure
R to make sure there is even contact between bridge plate and the duct sidewall inner
R skin.

R NOTE: Use only sufficient pressure to hold the patch plate tightly in position
R against the duct sidewall inner skin.

R (24) Cure the adhesive for one hour at room temperature followed by 60-90 minutes at
R 200°-220°F (93°-104°C).

R (25) When the adhesive is fully cured, remove the pressure devices and make an inspection
R for damage. Make sure the bonded plates are aligned correctly, and do a tap check to
R examine the repair for disbonds.

R (a) Use a 0.5-1.0 ounce (14-28 gram) aluminum mallet held at a 90-degree angle
R to tap test the bondment. No voids or delaminations (disbonds) are permitted.

R (26) Remove unwanted adhesive from around the bridge plate as necessary.

R (27) Drill out the rivets used for alignment.

R (28) Drill a series of 0.098 in. (2.49 mm) diameter pilot holes around the edge of the bridge
R plate. Refer to figure 603. Use a drill stop to minimize core damage, and to make sure
R you do not drill through the opposite skin.

R (29) Drill open the 0.098 in. (2.49 mm) holes to 0.160-0.164 in. (4.06-4.17 mm) for rivets.
R Do not drill through the opposite side. Make sure there is a 2D edge distance on the
R duct sidewall skin.

R (30) Deburr the holes.

R (31) Wet install the NAS1738E5-X rivets in the bridge plate and bondment. Refer to SPM
R 70-13-00.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN
R AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET
R THE SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH
R WATER. GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
R SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R D. Clean the surface with clean cloths (C10-182) moist with solvent (C04-003 or C04-035).

R E. Apply silicone insulation coating MA-25 to the repair area. Refer to 78-32-02 Repair 022.

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R MR60196-00-A
R Allowable Damage Area
R Figure 601

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R MR60197-00-A
R Duct Sidewall Damage Spacing Limits
R Figure 602

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R MR60194-02-A
R Lower Duct Sidewall Repair – Rectangular Repair
R Figure 603

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FAN REVERSER SUPPORT ASSEMBLY - REPAIR

R 1. Repair/Replacement of Sidewall Fairings.

R A. This procedure gives instructions for the repair or replacement of the fixed structure sidewall
R fairings. The four fairings covered by this procedure are identified in paragraph 1.B. Different
R repair techniques are given for each fairing for different types of damage.

R (1) There is a blend repair for cracks or damage up to a maximum of 0.25 in. (6.4 mm)
R deep.

R (2) For cracks or damage more than 0. 25 in. (6.4 mm) deep, repairs include a stop-drill
R repair and a procedure for material removal with flow side or non-flow side doubler
R repairs, and a weld repair.

R (3) For damage that is more than the limits given for each repair, there is a procedure for
R replacement of a damaged fairing.

R B. This procedure is applicable to the fairings listed below.

R Description IPC Reference

R Upper/Fwd Sidewall Fairing 78-32-21-05-165

R 491B1313040 78-32-21-05-170

R Upper/Aft Sidewall Fairing 78-32-21-01-430

R 491B1313050 78-32-21-01-435

R Lower/Upr Sidewall Fillet 78-32-21-10-360

R Fairing 491B1313002 78-32-22-10-360

R Lower/Lwr Sidewall Fairing 78-32-21-10-435

R 491B1313060 78-32-22-10-435

R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools. None required.

R (3) Locally Manufactured Tools. None required.

R (4) Equipment. None required.

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R B. Consumable Materials.

R Code Description Use

R C01-011 Adhesive, Epoxy Resin, EA934NA, Rivet stem capture

R (Parts A and B)

R C01-073 Compound, Sealing, Temperature- Seal the repair parts

R Resistant, AMS 3276, PR 1750 B-2

R C03-005 Primer, Epoxy Resin (Spray Type), Repair of attach angle;

R Finch 463-12-8 rivet installation

R C03-006 Conversion Coating, Alodine 1200S Surface protection

R C03-017 Primer, Epoxy, Yellow, MIL-P-23377, Prime the repair parts

R Type I, Class C

R C03-064 Conversion Coating, Iridite 14-2 Protect the repair parts

R C04-014 Alcohol, Denatured Clean the repair area

R C04-222 Surfactant, APR 2 Agent Used with C03-064

R C04-018 Naphtha, Fed. Spec. TT-N-95, Type II Clean the repair area

R C10-010 Scotch Brite Pads No. 7447 Surface preparation

R C10-182 Cloths, Cleaning Clean the repair area

R Local Purchase Sheet Stock, Aluminum Alloy, Filler material

R 0.040 in. (1.02 mm) and 0.050 in.
R (1.27 mm) Thick,
R 2024-T3 QQ-A-250/5

R Local Purchase Sheet Stock, Aluminum Alloy, Filler material

R 0.050 in. (1.27 mm) Thick,
R 2024-T42 QQ-A-250/5

R Local Purchase Sheet Stock, Aluminum Alloy, Filler material

R 0.040 in. (1.02 mm) Thick,
R 2024-T42 QQ-A-250/5

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R B. Consumable Materials (Cont'd).

R Code Description Use

R Local Purchase Sheet Stock, Aluminum Alloy, Doubler material

R 0.063 in. (1.60 mm) Thick,
R 2024-T0 QQ-A-250/5 and
R 2024-T3 QQ-A-250/5

R Local Purchase Weld Wire, AA4042, AMS 4190, Weld filler material

R Local Purchase Topcoat, Polyurethane, Finish layer for the

R MIL-C-85285, Type I fairing replacement section

R C. Expendable Parts.

R Before you make a fastener selection, do a visual check of the fastener hole to see whether it
R has the original diameter, or has an oversize condition. Use this hole size information to make
R a selection of the correct rivet size.

R Number Description

R CR3245-5-X Rivets

R CR3555P-5-X Rivets

R D. SPD Identification. None required.

R E. Referenced Procedures.

R 78-32-02 Disassembly

R 78-32-02 Assembly

R IPC MR 99379

R SPM 70-13-00

R SPM 70-13-05

R SPM 70-30-00

R SPM 70-41-00

R 3. Dimensional Information. None required.

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R 4. Setup Information. None required.

R 5. Procedure.

R A. The paragraphs below give a short description of the five sidewall fairing repair types.

R (1) Paragraph 5.B. gives a blend repair for the aft edge of the upper/aft (491B1313050)
R fairing. The blend repair is for damage up to a maximum depth of 0.25 in. (6.4 mm) and
R a maximum width of 1.25 in. (31.8 mm). Cracks must be blended to a 5X minimum
R depth-to-width ratio.

R (2) Paragraph 5.C. gives repair data for cracks more than 0.25 in. (6.4 mm) in length on the
R upper/fwd (491B1313040), upper/aft (491B1313050), or lower/lwr (491B1313060)
R fairing. The repair data includes a stop-drill repair and a procedure for the removal of
R the damaged area and the installation of a repair doubler on the non-flow path side of
R the fairing. The maximum doubler size permitted is 10 in. (25.4 cm) by 8.5 in.
R (21.6 cm).

R NOTE: The total number of repair doublers permitted for the procedures in
R paragraphs 5.C. and 5.E. is limited to a maximum of three. The number of
R repair fasteners used on a fairing must not be more than 66.

R (3) Paragraph 5.D. is a weld repair for the lower/upr (491B1313002) fillet fairing.

R (4) Paragraph 5.E. gives repair data for cracks or other damage on the upper/fwd
R (491B1313040), upper/aft (491B1313050), or lower/lwr (491B1313060) fairing. The
R repair data includes a stop-drill repair and a procedure for the removal of the damaged
R area and the installation of a repair doubler on the flow path side of the fairing. The
R maximum doubler size permitted is 10 in. (25.4 cm) by 8.5 in. (21.6 cm).

R NOTE: The total number of repair doublers permitted for the procedures in
R paragraphs 5.C. and 5.E. is limited to a maximum of three. The number of
R repair fasteners used on a fairing must not be more than 66.

R (5) If it is not possible to do the repairs listed above, paragraph 5.F. gives a procedure to
R replace the sidewall fairings.

R B. Do the steps that follow to repair minor aft edge damage to the 491B1313050 fairing. This
R repair can be used for damage that is not more than 0.25 in. (6.4 mm) deep.

R (1) Do a non-destructive inspection procedure to find all of the damage. Refer to SPM
R 70-30-00.

R (2) Blend or trim all damaged, torn, or fretted aft edges of the fairing to get a 5X minimum
R depth-to-width ratio. Refer to figure 601, sheets 1 and 2.

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R MR60XXX184-00-A
R Upper/Aft Fairing 491B1313050 Blend Repair
R Figure 601 (Sheet 1)

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R MR60178-00-A
R Upper/Aft Fairing 491B1313050 Blend Repair
R Figure 601 (Sheet 2)

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R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (3) Use clean cloths (C10-182) wet with solvent (C04-014) to clean the repair area. Do this
R until a clean cloth stays clean. Let the area air dry.

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
R USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
R SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
R AND CLOTHING TO PROTECT YOURSELF.

R (4) Apply yellow epoxy primer (C03-017) to the repaired surface.

R (5) Let the primer cure a minimum of 3-4 hours at room temperature.

R C. This procedure gives instructions for a stop-drill or doubler repair procedure for cracks that are
R more than 0.25 in. (6.4 mm) in length. This procedure can be used on the upper/fwd fairing
R 491B1313040, the upper/aft fairing 491B1313050, and the lower/lwr fairing 491B1313060.

R The maximum doubler size permitted is 10 in. (25.4 cm) by 8.5 in. (21.6 cm). You can do this
R repair only in areas where a doubler of the correct size can be put in position on the non-flow
R side of the fairing. If you cannot install the correct size doubler on the non-flow path surface,
R refer to the repair in paragraph 5.E.

R CAUTION: BE CAREFUL NOT TO DAMAGE THE RIVET HOLES IN THE SUPPORT

R ASSEMBLY WHEN YOU REMOVE THE RIVETS.

R (1) Drill out the rivets adjacent to the damaged area. Refer to GE Standard Practices
R Manual (GEK 9230) procedure SPM 70-13-00.

R (2) Use a small punch to drive out the rivet shanks.

R (3) Do a non-destructive inspection procedure to find all of the damage. Refer to SPM
R 70-30-00.

R (4) Do one of the two procedures that follow.

R (a) Use a 0.125 in. (3.18 mm) drill bit to stop-drill the crack. Refer to figure 602.

R OR

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R (b) Cut out and remove the damaged section of the fairing. A replacement section
R of fairing will be installed. The corners of the replacement section of fairing
R must have a minimum radius of 0.50 in, (12.7 mm). Refer to figure 603.

R NOTE: Keep the damaged section of the fairing for use as a template to
R drill the rivet holes in the replacement fairing section.

R (5) Deburr the exposed rivet holes in the support assembly duct sidewall.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (6) Use a clean cloth (C10-182) moist with naphtha (C04-018) to clean the rivet holes in
R the support assembly duct sidewall.

R (7) If you removed a damaged fairing section, use the removed fairing section as a
R template to make a filler. Refer to the material specifications below. If you do not need
R to make a filler, go to step (8).

R Fairing Part Number Material Specification

R 491B1313040 and 2024-T42 Clad Aluminum 0.050 in.

R 491B1313060 (1.27 mm) thick

R 491B1313050 2024-T42 Clad Aluminum 0.040 in.

R (1.02 mm) thick

R NOTE: You can make the fairing filler with an equivalent thickness of QQ-A-250/5
R 2024-T42 or 2024-T3 aluminum.

R (8) Make a repair doubler from 2024-0 aluminum sheet stock heat treated to T42 or 2024-
R T3. The corners of the doubler must have a minimum radius of 0.050 in. (1.27 mm).
R The doubler must be sufficiently large to have two rows of repair fasteners around the
R damaged area of the fairing.

R (a) Cut a piece of aluminum sheet stock and make the doubler in a shape that
R aligns with the radius of the damaged fairing.

R (b) If you use 2024-T0 sheet stock, heat treat the doubler to a -T42 condition.

R (9) Put the doubler in position, center-aligned on the edge of the damaged fairing. Use a
R clamp to hold the doubler in position.

R (10) Match-drill the rivet holes through the damaged fairing section and the doubler.

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R (11) Remove the doubler from the fairing and deburr the rivet holes.

R (12) Use a Scotch-Brite pad (C10-010) on the doubler and the replacement fairing section (if
R applicable) to make the surface rough.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (13) Use a clean cloth (C10-182) moist with solvent (C04-014 or C04-018) to clean the rivet
R holes in the fairing section and the doubler.

R WARNING: DO NOT LET THE IRIDITE SOLUTION DRY IN THE BRUSH, CLOTH, OR
R SPONGE BECAUSE SPONTANEOUS COMBUSTION CAN OCCUR. FULLY
R CLEAN THE ITEMS IN WATER, OR WRING OUT AS MUCH OF THE IRIDITE
R SOLUTION AS POSSIBLE, AND PUT THE BRUSH, CLOTH, OR SPONGE IN
R A FIREPROOF CONTAINER.

R (14) Mix 3.0 oz/gal (22.5 g/liter) of Iridite (C03-064) and 1.25 fl oz/gal (10 cc/liter) of
R surfactant (C04-222).

R (15) Use a nylon brush, cellulose sponge, or clean cloth (C10-182) to apply the Iridite
R solution to the doubler, the damaged area, and the fairing replacement section (if
R applicable). Keep the surface wet until you see a small color change (usually 2-3
R minutes).

R (16) Flush the doubler and fairing repair section (if applicable) with deionized water.

R (17) Air dry for 8 hours or oven dry at a maximum temperature of 135° F (57° C) for 1 hour
R or until dry.

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
R USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
R SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
R AND CLOTHING TO PROTECT YOURSELF.

R (18) Make a mixture of epoxy primer (C03-017). Refer to the manufacturer's instructions.

R (19) Apply a box coat of primer to a dry film thickness of 0.0006-0.0018 inch (0.015-0.046
R mm).

R (20) Cure the primer at room temperature for 1 to 3 hours, or air cure for 5-10 minutes
R followed by 20-40 minutes at 140°-160° F (60°-71° C).

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R MR60179-00-A
R Repair for Fairings with a Crack and a Stop Drill Hole
R Figure 602

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R MR60180-00-A
R Repair for Fairings with Damage Removed and a Filler
R Figure 603

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R WARNING: THIS MATERIAL IS POISONOUS AND GIVES OFF FUMES. MAKE SURE
R YOU USE THE MATERIAL IN AN AREA WITH GOOD AIR FLOW. MAKE
R SURE YOU DO NOT BREATHE THE FUMES. DO NOT GET THE MATERIAL
R ON YOUR SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE
R GLOVES AND CLOTHING TO PROTECT YOURSELF.

R (21) If the fairing had a painted surface, apply a layer of polyurethane topcoat (MIL-C-85285
R Type I) to the replacement fairing section flow path side (if applicable) with a dry film
R thickness of 0.0016-0.0024 inch (0.041-0.61 mm).

R (22) Cure at room temperature for 7 hours or air cure for 30 minutes followed by 2 hours at
R 130°-140° F (54°-60° C).

R WARNING: THIS MATERIAL IS POISONOUS AND GIVES OFF FUMES. MAKE SURE
R YOU USE THE MATERIAL IN AN AREA WITH GOOD AIR FLOW. MAKE
R SURE YOU DO NOT BREATHE THE FUMES. DO NOT GET THE MATERIAL
R ON YOUR SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE
R GLOVES AND CLOTHING TO PROTECT YOURSELF.

R (23) Apply a layer of sealing compound (C01-073) to the mating surfaces of the doubler, the
R fairing, and the replacement fairing section (if applicable).

R (24) Put the doubler and the replacement section of the fairing (if applicable) in position on
R the remaining section of the fairing. Align the rivet holes and hold the pieces in position
R with clamps.

R WARNING: THIS MATERIAL IS POISONOUS AND GIVES OFF FUMES. MAKE SURE
R YOU USE THE MATERIAL IN AN AREA WITH GOOD AIR FLOW. MAKE
R SURE YOU DO NOT BREATHE THE FUMES. DO NOT GET THE MATERIAL
R ON YOUR SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE
R GLOVES AND CLOTHING TO PROTECT YOURSELF.

R (25) Install the CR3245-5 or CR3555P-5 rivets (as applicable) to attach the doubler and the
R replacement section of the fairing (if applicable) to the fairing. Refer to Standard
R Practices Manual, 70-13-00 and 70-13-05. Install the rivets with sealing compound
R (C01-073).

R (26) Remove unwanted sealing compound after rivet installation.

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R D. Re-weld procedure for cracked welds on lower/upr sidewall fillet fairing 491B1313002. Refer to
R figure 604.

R (1) Remove the pins and nuts that attach the fillet fairing to the lower sidewall assembly.
R Refer to 78-32-02 Disassembly, paragraph 3.D.(2)(a).

R CAUTION: DO NOT CAUSE DAMAGE TO THE RIVET HOLES IN THE SUPPORT

R ASSEMBLY WHEN YOU REMOVE THE RIVETS.

R (2) Drill out all the rivets that attach the fairing to the support assembly. Refer to SPM 70-
R 13-00.

R (3) Use a small punch to drive out the rivet shanks, or push them into the bondment core,
R as applicable.

R (4) Remove the fairing.

R (5) Deburr the rivet holes in the support assembly duct sidewall.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (6) Clean the rivet holes in the support assembly duct sidewall with a clean cloth (C10-182)
R and naphtha (C04-018).

R (7) Re-weld the crack. Refer to SPM 70-41-00. No re-heat treatment is necessary.

R NOTE: The fairing material is 6061-T62 aluminum. The weld filler is AA4043 weld
R wire (AMS 4190).

R WARNING: THIS MATERIAL IS POISONOUS AND GIVES OFF FUMES. MAKE SURE
R YOU USE THE MATERIAL IN AN AREA WITH GOOD AIR FLOW. MAKE
R SURE YOU DO NOT BREATHE THE FUMES. DO NOT GET THE MATERIAL
R ON YOUR SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE
R GLOVES AND CLOTHING TO PROTECT YOURSELF.

R (8) Apply Alodine 1200S (C03-006) to all bare aluminum surfaces, then apply yellow epoxy
R primer (C03-017).

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MR60181-00-A
R Repair of a Cracked Weld on a Lower/Upr Fillet Fairing 491B1313002
Figure 604

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R (9) If the rivet stems stay in the bondment holes, do the steps that follow:

R WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE

R MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA
R OPEN TO THE AIR. USE CLEAN NYLON FILM OR POLYETHYLENE
R DISPOSABLE GLOVES (C10-140) WHEN YOU MIX OR APPLY THE
R ADHESIVE.

R (a) Make a mixture of epoxy resin adhesive (C01-011). Refer to the

R manufacturer's instructions.

R (b) Inject the epoxy resin adhesive mixture into the rivet holes so that the stems
R stay in the holes.

R NOTE: You must install the rivets before the epoxy resin adhesive cures.
R Refer to step (11).

R (10) Put the repaired fairing on the duct sidewall and attach in position with a clamp.

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
R USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
R SKIN OR INTO YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
R AND CLOTHING TO PROTECT YOURSELF.

R (11) Install the applicable fasteners. Refer to 78-32-02 Assembly, paragraph 3.E.(10).
R Refer to SPM 70-13-00 and 70-13-05. Install the rivets with sealing compound
R (C01-073).

R (12) Remove unwanted sealing compound after rivet installation.

R E. This procedure gives instructions for a stop-drill or doubler repair procedure for cracks or other
R damage. Up to a maximum of three flow side doubler repairs are permitted on a fairing, with a
R maximum of 66 repair fasteners. The maximum doubler size permitted is 10 in. (25.4 cm) by
R 8.5 in. (21.6 cm).

R This procedure can be used on the upper/fwd fairing 491B1313040, the upper/aft fairing
R 491B1313050, and the lower/lwr fairing 491B1313060.

R CAUTION: BE CAREFUL NOT TO DAMAGE THE RIVET HOLES IN THE SUPPORT

R ASSEMBLY WHEN YOU REMOVE THE RIVETS.

R (1) Drill out the rivets adjacent to the damaged area. Refer to SPM 70-13-00.

R (2) Use a small punch to drive out the rivet shanks.

R (3) Do a non-destructive inspection procedure to find all of the damage. Refer to SPM
R 70-30-00.

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R (4) Do one of the two procedures that follow.

R (a) Use a 0.125 in. (3.18 mm) drill bit to stop-drill the crack. Refer to figure 605.

R OR

R (b) Cut out and remove the damaged section of the fairing. A replacement section
R of fairing will be installed. The corners of the replacement section of fairing
R must have a minimum radius of 0.50 in, (12.7 mm). Refer to figure 606.

R NOTE: Keep the damaged section of the fairing for use as a template to
R drill the rivet holes in the replacement fairing section.

R (5) Deburr the exposed rivet holes in the support assembly duct sidewall.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (6) Use a clean cloth (C10-182) moist with naphtha (C04-018) to clean the rivet holes in
R the support assembly duct sidewall.

R (7) If you removed a damaged fairing section, use the removed fairing section as a
R template to make a filler. Refer to the material specifications below. If you do not need
R to make a filler, go to step (8).

R Fairing Part Number Material Specification

R 491B1313040 and 2024-T42 Clad Aluminum 0.050 in.

R 491B1313060 (1.27 mm) thick

R 491B1313050 2024-T42 Clad Aluminum 0.040 in.

R (1.02 mm) thick

R NOTE: You can make the fairing filler with an equivalent thickness of QQ-A-250/5
R 2024-T42 or 2024-T3 aluminum.

R (8) Make a repair doubler from 2024-0 aluminum sheet stock heat treated to T42 or 2024-
R T3. The corners of the doubler must have a minimum radius of 0.050 in. (1.27 mm).
R The doubler must be sufficiently large to have two rows of repair fasteners around the
R damaged area of the fairing.

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R MR60182-00-A
R Repair for Fairings with a Crack and a Stop Drill Hole
R Figure 605

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R MR60183-00-A
R Repair for Fairings with Damage Removed and a Filler
R Figure 606

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R (a) Cut a piece of aluminum sheet stock and make the doubler in a shape that
R aligns with the radius of the damaged fairing.

R (b) If you use 2024-T0 sheet stock, heat treat the doubler to a -T42 condition.

R (9) Put the doubler in position, center-aligned on the edge of the damaged fairing. Use a
R clamp to hold the doubler in position.

R (10) Match-drill the rivet holes through the damaged fairing section and the doubler.

R (11) Remove the doubler from the fairing, chamfer all edges, and deburr the rivet holes.

R (12) Use a Scotch-Brite pad (C10-010) on the doubler and the replacement fairing section (if
R applicable) to make the surface rough.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (13) Use a clean cloth (C10-182) moist with solvent (C04-014 or C04-018) to clean the rivet
R holes in the fairing section and the doubler.

R WARNING: DO NOT LET THE IRIDITE SOLUTION DRY IN THE BRUSH, CLOTH, OR
R SPONGE BECAUSE SPONTANEOUS COMBUSTION CAN OCCUR. FULLY
R CLEAN THE ITEMS IN WATER, OR WRING OUT AS MUCH OF THE IRIDITE
R SOLUTION AS POSSIBLE, AND PUT THE BRUSH, CLOTH, OR SPONGE IN
R A FIREPROOF CONTAINER.

R (14) Mix 3.0 oz/gal (22.5 g/liter) of Iridite (C03-064) and 1.25 fl oz/gal (10 cc/liter) of
R surfactant (C04-222).

R (15) Use a nylon brush, cellulose sponge, or clean cloth (C10-182) to apply the Iridite
R solution to the doubler, the damaged area, and the fairing replacement section (if
R applicable). Keep the surface wet until you see a small color change (usually 2-3
R minutes).

R (16) Flush the doubler and fairing repair section (if applicable) with deionized water.

R (17) Air dry for 8 hours or oven dry at a maximum temperature of 135° F (57° C) for 1 hour
R or until dry.

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R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
R USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
R SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
R AND CLOTHING TO PROTECT YOURSELF.

R (18) Make a mixture of epoxy primer (C03-017). Refer to the manufacturer's instructions.

R (19) Apply a box coat of primer to a dry film thickness of 0.0006-0.0018 inch (0.015-0.046
R mm).

R (20) Cure the primer at room temperature for 1 to 3 hours, or air cure for 5-10 minutes
R followed by 20-40 minutes at 140°-160° F (60°-71° C).

R WARNING: THIS MATERIAL IS POISONOUS AND GIVES OFF FUMES. MAKE SURE
R YOU USE THE MATERIAL IN AN AREA WITH GOOD AIR FLOW. MAKE
R SURE YOU DO NOT BREATHE THE FUMES. DO NOT GET THE MATERIAL
R ON YOUR SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE
R GLOVES AND CLOTHING TO PROTECT YOURSELF.

R (21) If the fairing had a painted surface, apply a layer of polyurethane topcoat (MIL-C-85285
R Type I) to the replacement fairing section flow path side (if applicable) with a dry film
R thickness of 0.0016-0.0024 inch (0.041-0.61 mm).

R (22) Cure at room temperature for 7 hours or air cure for 30 minutes followed by 2 hours at
R 130°-140° F (54°-60° C).

R WARNING: THIS MATERIAL IS POISONOUS AND GIVES OFF FUMES. MAKE SURE
R YOU USE THE MATERIAL IN AN AREA WITH GOOD AIR FLOW. MAKE
R SURE YOU DO NOT BREATHE THE FUMES. DO NOT GET THE MATERIAL
R ON YOUR SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE
R GLOVES AND CLOTHING TO PROTECT YOURSELF.

R (23) Apply a layer of sealing compound (C01-073) to the mating surfaces of the doubler, the
R fairing, and the replacement fairing section (if applicable).

R (24) Put the doubler and the replacement section of the fairing (if applicable) in position on
R the remaining section of the fairing. Align the rivet holes and hold the pieces in position
R with clamps.

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R WARNING: THIS MATERIAL IS POISONOUS AND GIVES OFF FUMES. MAKE SURE
R YOU USE THE MATERIAL IN AN AREA WITH GOOD AIR FLOW. MAKE
R SURE YOU DO NOT BREATHE THE FUMES. DO NOT GET THE MATERIAL
R ON YOUR SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE
R GLOVES AND CLOTHING TO PROTECT YOURSELF.

R (25) Install the CR3245-5 or CR3555P-5 rivets (as applicable) to attach the doubler and the
R replacement section of the fairing (if applicable) to the fairing. Refer to Standard
R Practices Manual, 70-13-00 and 70-13-05. Install the rivets with sealing compound
R (C01-073).

R (26) Remove unwanted sealing compound after rivet installation.

R F. If a fairing has more damage than the repairable limits for the repairs given in paragraphs 5.B.
R through 5.E., do the steps that follow to replace the fairing.

R Description Reference

R Upper/Fwd Sidewall Fairing 78-32-02 Disassembly para. 3.D.(3)

R 491B1313040 78-32-02 Assembly para. 3.E.(6) and 3.E.(7)

R Upper/Aft Sidewall Fairing 78-32-02 Disassembly para. 3.D.(1)

R 491B1313050 78-32-02 Assembly para. 3.E. (11) and 3.E.(12)

R Lower/Upr Sidewall Fillet 78-32-02 Disassembly para. 3.D.(2)

R Fairing 491B1313002 78-32-02 Assembly para. 3.E. (9) and 3.E.(10)

R Lower/Lwr Sidewall Fairing 78-32-02 Disassembly para. 3.D.(4)

R 491B1313060 78-32-02 Assembly para. 3.E.(3) and 3.E.(4)

R CAUTION: DO NOT CAUSE DAMAGE TO THE RIVET HOLES IN THE SUPPORT

R ASSEMBLY WHEN YOU REMOVE THE RIVETS.

R (1) Drill out all rivets that attach the fairing to the support assembly. Refer to SPM 70-13-
R 00.

R (2) Use a small punch to drive out the rivet shanks, or push them into the bondment core,
R as applicable.

R (3) For removal of the lower/upr sidewall fillet fairing (491B1313002), remove the pins and
R nuts that attach the fillet fairing to the lower sidewall assembly. Refer to 78-32-02
R Disassembly, paragraph 3.D.(2)(a).

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R (4) Remove the fairing.

R NOTE: Keep the damaged fairing for use as a template to drill rivet holes in the
R new fairing.

R (5) Deburr the rivet holes in the support assembly duct sidewall.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (6) Clean the rivet holes in the support assembly duct sidewall with a clean cloth (C10-182)
R and naphtha (C04-018).

R (7) Set the replacement fairing in position, flat with the edge of the support assembly duct
R sidewall, or use the damaged fairing as a template. Attach in position with a clamp.

R (8) Use a hole transfer tool to mark rivet hole locations along the edges of the replacement
R fairing.

R (9) Remove the replacement fairing and drill 0.129-0.132 inch (3.28-3.35 mm) diameter or
R 0.160-0.164 inch (4.06-4.17 mm) diameter holes, as applicable, through the fairing at
R the marked locations. Countersink and deburr the holes.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (10) Clean the rivet holes in the replacement fairing with a clean cloth (C10-182) and
R naphtha (C04-018).

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R (11) If the rivet stems stay in the bondment holes, do the steps that follow:

R WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE

R MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA
R OPEN TO THE AIR. USE CLEAN NYLON FILM OR POLYETHYLENE
R DISPOSABLE GLOVES (C10-140) WHEN YOU MIX OR APPLY THE
R ADHESIVE.

R (a) Make a mixture of epoxy resin adhesive (C01-011). Refer to the

R manufacturer's instructions.

R (b) Inject the epoxy resin adhesive mixture into the rivet holes so that the stems
R stay in the holes.

R NOTE: You must install the rivets before the epoxy resin adhesive cures.
R Refer to step (13).

R (12) Put the replacement fairing on the duct sidewall and attach in position with a clamp.

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
R USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
R SKIN OR INTO YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
R AND CLOTHING TO PROTECT YOURSELF.

R (13) Install the applicable rivets identified in the IPC (MR 99379), and/or repair rivets
R CR3555P-5, maximum repair hole diameter 0.173 in. (4.39 mm). Refer to SPM 70-13-
R 00 and 70-13-05. Install the rivets with a wet layer of epoxy resin primer (C03-005).
R Make sure you install the rivets before the epoxy resin adhesive (C01-011) cures.

R (14) Remove unwanted primer after the rivet installation.

R (15) For installation of the lower/upr sidewall fillet fairing (491B1313002), install the pins and
R nuts that attach the fillet fairing to the lower sidewall assembly. Refer to 78-32-02
R Assembly, paragraphs 3.E.(9) and 3.E.(10).

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 FAN REVERSER
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THIS PAGE INTENTIONALLY BLANK

 COMPONENT
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MANUAL

683L SERIES

FAN REVERSER ASSEMBLY - REPAIR

1. Repair of Blistered Paint on Aft Core Cowl Surfaces.

A. This procedure gives the instructions to remove the fairing compound layer from the aft core
cowl surfaces. This procedure also gives the instructions to repair the aft core cowl surfaces
and paint the repair surfaces.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment. None required.

B. Consumable Materials.

Code Description Use

C01-129 Adhesive, Structural, Room Fill the damaged area

Temperature, Hysol EA960F

C03-017 Primer, Polymide Epoxy Primer for the repair area

MIL-P-23377

C03-059 Polyurethane Paint, Paint the repair area

BAC-707 Topcoat,
X-310A Catalyst

C04-001 Solvent, Methyl-Ethyl-Ketone Clean the repair area

C04-014 Alcohol, Denatured Clean the repair area

C10-010 Scotch Brite Pads, No. 7447 Clean the repair area

C10-105 Sandpaper, Roll, Aluminum Remove the fairing compound

Oxide, 20 Grit from the repair area

C10-140 Gloves, Nylon Film/Polyethylene, Mix and apply the adhesive

Disposable

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C. Expendable Parts. None required.

D. SPD Identification. None required.

E. Referenced Procedures. None required.

3. Dimensional Information. None required.

4. Setup Information. None required.

5. Procedure.

A. Use 120 grit aluminum oxide sandpaper (C10-105) to remove the fairing compound from all aft
core cowl surfaces. Do not remove the fairing compound from countersinks and joint recesses.

NOTE: Removal of loose fairing compound around countersinks and joint recesses is
permitted.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

B. Use Scotch Brite pads (C10-010) soaked with solvent (C04-001) to clean the repair area.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

C. Clean the repair area with cloths made moist with denatured alcohol (C04-014) until the cloth
stays clean. Dry the area in the air.

WARNING: THE ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR EYES
OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. WEAR CLEAN NYLON
FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN YOU MIX OR
APPLY THE ADHESIVE.

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D. Prepare the structural adhesive (C01-129).

(1) Make sure that the shelf life of the structural adhesive has not expired.

(2) Mix the component parts of the structural adhesive. Refer to the manufacturer's
instructions.

(3) Record the date and time you made the mixture.

WARNING: THE ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR EYES
OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. WEAR CLEAN NYLON
FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN YOU MIX OR
APPLY THE ADHESIVE.

E. Use a clean spatula to apply the structural adhesive (C01-129) on the repair area. Fill the voids
and the fastener heads. Make the adhesive smooth and flush with the aft core cowl surfaces.

F. Cure the structural adhesive for 24 hours at ambient temperature or cure for a minimum of one
hour at 160°F (71°C).

NOTE: You can use abrasive paper to make the repair area smooth after the area cures for
six hours at ambient temperature.

G. Use abrasive paper to give the cured structural adhesive a smooth finish. Clean with clean, dry
cloths.

WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU USE
THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU DO NOT
BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR SKIN OR INTO
YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES AND CLOTHING TO
PROTECT YOURSELF.

H. Apply an equal layer of epoxy polymide primer (C03-017) to the aft core cowl surfaces.

I. Cure the primer a minimum of three to four hours at ambient temperature.

WARNING: THIS MATERIAL IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU USE
THE MATERIAL IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU DO NOT
BREATHE THE FUMES. DO NOT GET THE MATERIAL ON YOUR SKIN OR IN
YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES AND CLOTHING TO
PROTECT YOURSELF.

J. Apply an equal layer of polyurethane paint (C03-059) to the aft core cowl surfaces.

K. Cure the paint for seven hours at ambient temperature, or dry in the air for 30 minutes at
ambient temperature then cure for two more hours at 180°F to 200°F (83°C to 93°C).

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THIS PAGE INTENTIONALLY BLANK

 COMPONENT
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MANUAL

683L SERIES

FAN REVERSER SUPPORT ASSEMBLY - REPAIR

1. Repair of Core Cowl Wire Mesh.

A. This procedure gives the instructions for the repair of damaged and/or missing wire mesh that is
part of the core cowl perforated skin.

R B. The acoustic blockage caused by adhesive applied to the repair area must be within the
R acoustic blockage limits given in the 78-32-02 Inspection section

(1) Paragraph 5 gives the instructions to repair damage to torn wire mesh and to bond the
edges of missing wire mesh.

(2) Paragraph 6 gives the instructions to replace missing wire mesh.

B. If you find damage to the perforated skin, you cannot do this procedure.

C. Apply the primer, adhesive, and wire mesh in a controlled environment with the temperature
between 65°F and 85°F (18°C and 29°C), and a maximum relative humidity of 60 percent.

D. Make sure all surfaces are clean when you prepare to apply the adhesive. Keep all surfaces
clean during all of the steps.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment. None required.

B. Consumable Materials.

Code No. Description Use

C01-106 Adhesive, Epoxy Resin, EA 956 Bond the wire to the skin

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R Code No. Description Use

R C01-133 Primer, Structural Bond the wire to the skin

R Adhesive, EC 3917

R C01-134 Adhesive, Sprayable, EC 3964 Bond the wire to the skin

R C01-147 Adhesive, Liquid, Structural, Make the pressure plate

R EA 9396, Parts A and B

R C03-064 Conversion Coating, Chromated, Prepare the surface

R Iridite 14-2

R C04-001 Solvent, Methyl-Ethyl-Ketone Clean the repair area

R (MEK)

R C04-003 Solvent, Acetone Clean the repair area

R C04-014 Alcohol, Denatured Clean the repair area

R C04-035 Isopropyl Alcohol Clean the repair area

R C04-068 Turco 4215-S or Clean the wire mesh

R Turco 4215-NC-LT

R C04-222 Surfactant, ARP 2 Agent Use with C03-064

R C10-003 Fabric, Glass, No. 181 Make the pressure plate

R C10-009 Paper, Greaseproof, Put paper around

R Grade A (Kraft) the wire mesh

R C10-010 Scotch Brite Pads No. 7447 Make the surface rough

R C10-048 Bleeder Cloth Vacuum bagging

R C10-118 Mesh, Wire, Aluminum, Replacement

R 200 x 600

R C10-136 Tape, Flashbreaker Mask the repair area

R C10-137 Film, Vacuum Bag Vacuum bagging

R C10-138 Tape, Sealant, Vacuum Bag Vacuum bagging

R C10-139 Gloves, White Cotton, Touch clean parts

R Disposable

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R Code No. Description Use

R C10-140 Gloves, Nylon Film/Polyethylene, Mix and apply the adhesive

R Disposable

R C10-182 Cloth, Cleaning Clean the repair area

R Local Purchase Abrasive Paper, Silicon Carbide, Prepare the surface

R 280-320 Grit

R Local Purchase Brush, Nylon Apply the Iridite solution

R Local Purchase Sponge, Cellulose Apply the Iridite solution

R Local Purchase Sheet, Solid Tedlar Protect the clean area

R Local Purchase Spatula, Non-metallic Apply the adhesive

R C. Expendable Parts. None required.

R D. SPD Identification. None required.

R E. Referenced Procedures. None required.

R 3. Dimensional Information. None required.

R 4. Set-up Information. None required.

R 5. Repair Torn Wire Mesh and Bond the Edges of Missing Wire Mesh. Refer to figure 601.

R NOTE: Do not try this repair if there is indication of perforated skin damage.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
R AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
R SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
R GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
R ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R A. Clean the damaged area from contamination with a clean cloth (C10-182) made moist with
R solvent (C04-001, C04-003, C04-014, or C04-035). Let the area dry in the air.

R B. Put flashbreaker tape (C10-136) around the repair area. Make sure that all unbonded wire
R mesh is located on the inner side of the area you put tape around.

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R 1084865-00-C
R Repair of Core Cowl Wire Mesh
R Figure 601

R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE PARTICLES
R THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR SKIN. DO NOT USE
R MORE THAN 30 PSIG (207 KPA) PRESSURE. PUT ON GOGGLES. DO NOT POINT
R COMPRESSED AIR IN THE DIRECTION OF YOUR SKIN.

R C. Make the repair area lightly rough with 280-320 grit silicon carbide sandpaper. Blow away the
R dust with dry shop air.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
R AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
R SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
R GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
R ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R D. Clean the repair area with a cloth (C10-182) made moist with solvent (C04-001, C04-003,
R C04-014, or C04-035). Let the area dry in the air.

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R WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN

R YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. USE
R CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN
R YOU MIX OR APPLY THE ADHESIVE.

R E. Prepare the epoxy adhesive (C01-106) approximately 15 to 20 minutes before the you apply the
R adhesive. Refer to the manufacturer's instructions.

R F. Apply a sufficient layer of epoxy adhesive equally to the repair area with a nonmetallic spatula
R or a brush. Do not let the adhesive flow out of the repair area.

R G. Remove all unwanted epoxy adhesive so the adhesive is flush with the wire mesh. Use a clean
R nonmetallic spatula.

R H. Alternative procedure available. Cure the adhesive.

R (1) Cure for one hour at ambient temperature.

R (2) Cure for one hour more at a thermocouple controlled temperature between 180°F and
R 200°F (82°C and 93°C) with a heat lamp or heating blanket.

R H.A. Alternative Procedure. Cure the adhesive for 24 hours at ambient temperature.

R I. Remove the tape.

R J. Use 280-320 grit silicon carbide sandpaper to make the repair area lightly rough and flush
R ± 0.002 inch (0.05 mm) with the adjacent finish.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
R AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
R SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
R GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
R ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R K. Clean the repair area with a clean cloth (C10-182) made moist with solvent (C04-001, C04-003,
R C04-014, or C04-035). Let the area dry in the air.

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R 6. Replacement of Missing Wire Mesh.

R NOTE: Do not do this repair if there is indication of perforated skin damage.

R A. Make a pressure plate to the shape and contour of the repair area.

R WARNING: THE ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR

R EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. USE
R CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-
R 140) WHEN YOU MIX OR APPLY THE ADHESIVE.

R (1) Prepare the structural liquid adhesive (C01-147). Refer to the manufacturer's
R instructions.

R (2) Put the Tedlar sheet in position on the repair area.

R (3) Put 10 plies of glass fabric (C10-003) bonded with structural liquid adhesive (C01-147)
R on the repair area. The pressure plate must be flat above the Teflon sheet on the
R repair area.

R (4) Cure the pressure plate.

R (a) Cure for 3 -5 days at 65°F - 85°F (21°C - 27°C), or cure for 1 hour at 140°-
R 160°F (60°-71°C).

R (5) Remove the pressure plate from the repair area.

R B. Cut a piece of wire mesh (C10-118) sufficiently larger than the repair area to make the wire
R mesh easy to work with.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
R AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
R SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
R GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
R ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R C. Clean the wire mesh in a vapor or aqueous degreaser, or flush with solvent (C04-001, C04-003,
R C04-014, or C04-035).

R D. Mix an alkaline solution of Turco 4215 (C04-068).

R (1) Mix a solution of Turco 4215-S. Refer to step (1).A. for an alternative procedure.

R (a) Mix 6 oz/gallon (170 grams/liter) of Turco 4215-S with 0.36 fl oz/gallon (2.81
R cc/liter) of Turco 4215-S additive at a temperature of 145°-155° F (63°-68° C).
R Use demineralized water.

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(1) A. Alternative procedure. Mix a solution of Turco 4215-NC-LT.

R (a) Mix 7 oz/gallon (52.4 grams/liter) of Turco 4215-NC-LT with 0.16 fl oz/gallon
(1.25 cc/liter) of Turco 4215-NC-LT additive at a temperature of 120°-130° F
R (49°-54° C). Use demineralized water.

E. Put the wire mesh fully into the alkaline solution. Shake the solution for 13-17 minutes to
remove all oil, grease, or other contamination.

F. Flush the alkaline cleaned screen with clean 80°-110° F (27°-43° C) water for a minimum of 5
minutes. Do not let the wire mesh dry.

WARNING: THE CHEMICALS USED IN THIS SOLUTION CAN CAUSE CORROSION. USE
RESPIRATORS, GOGGLES OR A FACE SHIELD, RUBBER OR NEOPRENE
GLOVES, BOOTS AND APRONS WHEN YOU MIX OR HANDLE IT. IF YOU GET
THE CHEMICALS OR SOLUTION ON YOUR SKIN, FLUSH IT AWAY WITH WATER
IMMEDIATELY. IF YOU GET THE CHEMICALS OR SOLUTION IN YOUR EYES,
FLUSH YOUR EYES WITH CLEAR WATER AND GET IMMEDIATE MEDICAL AID.

G. Mix an etching solution.

Contents Strength

Sodium Dichromate 4.2 oz/gallon (31.5 g/liter)

Sulfuric Acid 22 fl oz/gallon (172 cc /liter)

Demineralized Water To make 1 gallon or 1 liter

or equivalent purity

H. Heat the sodium

dichromate-sulfuric acid solution to a temperature between 150°F and 160°F (66° and 71°C).

CAUTION: DO NOT KEEP THE WIRE MESH IN THE SOLUTION MORE THAN THE TIME LIMIT
OR YOU WILL CAUSE DAMAGE.

I. Put the wire mesh in the heated sodium dichromate-sulfuric acid solution for 3 minutes ± 5
seconds and remove from the solution.

J. Immediately flush the wire mesh with demineralized or distilled water for a minimum of 5
minutes.

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R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE PARTICLES
R THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR SKIN. DO NOT USE
R MORE THAN 30 PSIG (207 KPA) PRESSURE. PUT ON GOGGLES. DO NOT POINT
R COMPRESSED AIR IN THE DIRECTION OF YOUR SKIN.

R K. Alternative procedure available. Use clean, dry compressed air or nitrogen to dry the wire
mesh.

R K.A. Alternative Procedure. Shake off the water and dry the wire mesh in an oven for 15 to 30
R minutes at a temperature between 120°F and 150°F (49°C and 66°C), or until dry.

R L. Put Kraft paper (C10-009) around the cleaned wire mesh to prevent contamination.

R M. Prepare the core cowl perforated skin.

R (1) Carefully use a razor blade to remove loose wire mesh ends.

R (2) Apply flashbreaker tape (C10-136) to the areas adjacent to the repair area.

R (3) Use Scotch Brite Pads (C10-010) or equivalent to remove the glossy finish from the old
R adhesive remaining on the perforated skin in the repair area.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R CAUTION: DO LET THE PERFORATED SKIN BECOME SOAKED WITH SOLVENT.

R (4) Use a two-cloth method to clean the repair area with a clean cloth (C10-182) soaked
R with solvent (C04-001, C04-003, C04-014, or C04-035).

R NOTE: The two-cloth method is when you use a clean cloth soaked with solvent in
R one hand to apply the solvent, and a clean dry cloth to clean the solvent
R from the surface before it dries.

R (5) After the surface has dried, do a water break check. If you see water breaks, do steps
L.(3) through L.(5) again.
R (6) Put Kraft paper (C10-009) on the repair area to prevent contamination.

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R N. Prepare and apply the Iridite solution.

R WARNING: DO NOT LET THE IRIDITE SOLUTION DRY IN THE BRUSH. CLOTH, OR
R SPONGE BECAUSE SPONTANEOUS COMBUSTION CAN OCCUR. FULLY
R CLEAN THE ITEMS WITH WATER, OR WRING OUT AS MUCH SOLUTION
R AS POSSIBLE, AND STORE IN A FIREPROOF CONTAINER.

R (1) Mix the ingredients of the Iridite solution.

R Iridite (C03-064) 3.0 oz/gallon (22.5 g/liter)

R Surfactant (C04-222) 1.25 fl oz/gallon (10 cc/liter)

R Water 1 gallon or 1 liter

R (2) Use a nylon brush, cellulose sponge, or clean cotton cloth (C10-182) to apply the Iridite
R solution to the repair area. Keep the surface wet until you see a small color change
R (usually 2-3 minutes).

R (3) Flush the repair area with deionized water.

R (4) Drain the repair area and oven dry at a maximum temperature of 135°F (57°C) for 1
R hour or until dry.

R (5) Put Kraft paper (C10-009) on the repair area to prevent contamination.

R NOTE: Apply the primer and adhesive to the core cowl not less than eight hours
R and not more than 24 hours after the last Iridite solution is applied.

R O. Application of adhesives (C01-133 and C01-134).

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
R USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
R SKIN OR INTO YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
R AND CLOTHING TO PROTECT YOURSELF.

R (1) Shake the primer as you apply a 0.0002-0.0003 inch (0.005-0.008 mm) thick layer of
R adhesive primer (C01-133) to the prepared perforated skin.

R (2) Cure the adhesive primer for 30 minutes at ambient temperature; remove all tape and
R do the steps that follow to continue the cure.

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R (a) Cure the adhesive with heat lamps or heat blankets thermostatically controlled
R at a temperature between 240°F and 260°F (115.5°C and 126.6°C) for 50-70
R minutes.

R (b) Cool until the surface temperature is equal to ambient temperature.

R (3) Apply tape to the surface adjacent to the area where the adhesive will be applied.

R WARNING: THE ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR

R EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. USE
R CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-
R 140) WHEN YOU MIX OR APPLY THE ADHESIVE.

R (4) Shake the adhesive as you apply a 0.0012-0.0014 inch (0.030-0.036 mm) thick layer of
R adhesive (C01-134) to the skin you primed. If it is necessary to apply more than one
R layer, let the repair area dry in the air 20-30 minutes between each layer you apply.

R (5) Stage (partially cure) the last layer of the adhesive for 50 minutes at ambient
R temperature. Remove all tape and do the steps that follow to continue the cure.

R (a) Stage (partially cure) the adhesive with heat lamps or heat blankets
R thermostatically controlled at a temperature between 190° and 210°F (88° and
R 99°C) for 50-70 minutes.

R (b) Cool until the surface temperature is equal to ambient temperature.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (6) Put on clean white cotton gloves (C10-139) and examine the adhesive on the core cowl
R for rough high spots. Remove rough high spots with a sharp knife or sandpaper. Clean
R the surface with a clean cloth (C10-182) soaked with solvent (C04-001, C04-003, C04-
R 014, or C04-035). Let the area dry in the air.

R NOTE: Remove only the high spots. Make sure there is adhesive remaining after
R the high spot is removed.

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R P. Replace the wire mesh.

R CAUTION: APPLY THE WIRE MESH TO THE CORE COWL NO MORE THAN 36
R HOURS AFTER YOU APPLY THE ADHESIVE.

R (1) Put on clean white cotton gloves (C10-139) and remove the cleaned wire mesh from
R the Kraft paper.

R (2) Cut the wire mesh to install in the prepared repair area.

R (3) Put the wire mesh on the repair area lightly. Move the wire mesh around to get a good
R fit.

R (4) Heat tack the wire mesh with a thermostatically controlled heat gun set at
R approximately 200°F (93°C). Set the heat gun 2.0 inches (50.8 mm) from the wire
R mesh and move the heat gun constantly.

R Q. Bond the wire mesh to the perforated skin.

R (1) Install two thermocouples around the wire mesh to record temperatures.

R (2) Put a Teflon sheet on the repair area. Make sure you do not move the wire mesh.

R (3) Put the cured pressure plate on the repair area with the Teflon sheet above it followed
R by eight plies of folded bleeder cloth (C10-048).

R (4) Make a vacuum bag from vacuum bag film (C10-137), fittings, and vacuum bag sealant
R (C10-138).

R (5) Connect a vacuum source to the fitting and evacuate between 28.5 and 24 inches of
R mercury (in. Hg).

R (6) Cure the adhesive with a vacuum for three hours at a temperature between 275°F and
R 285°F (135°C and 141°C).

R (7) Cool to 150°F (66°C) or less before you remove the vacuum bag, bleeder cloth,
R pressure plate, Teflon sheet, and thermocouples.

R WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN

R YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. USE
R CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN
R YOU MIX OR APPLY THE ADHESIVE.

R R. Mix and apply epoxy adhesive (C01-106) to the wire mesh edges.

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R (1) Prepare the epoxy adhesive (C01-106) approximately 15 to 20 minutes before you
R apply it. Refer to the manufacturer's instructions.

R NOTE: Do not let the adhesive flow out of the repair area. Apply the adhesive not
R less than 20 minutes after you mix it.

R (2) Apply a layer of adhesive, 0.5 inch (12.7 mm) wide, to the edges of the repair area with
R a clean, nonmetallic spatula or brush.

R (3) Use a clean, nonmetallic spatula to remove unwanted adhesive. The adhesive must be
R flush with adjacent surfaces.

R (4) Alternative procedure available. Cure the adhesive.

R (a) Cure for one hour at ambient temperature.

R (b) Cure for one hour more at a thermocouple controlled temperature between
R 180°F and 200°F (82°C and 93°C) with a heat lamp or heating blanket.

R (4) A. Alternative Procedure. Cure the adhesive for 24 hours at ambient temperature.

R (5) Use 280-320 grit silicon carbide abrasive paper to make the repair area lightly rough
R and flush ± 0.002 inch (± 0.05 mm) with the adjacent finish.

R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

R PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
R SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE. USE
R GOGGLES. DO NOT POINT COMPRESSED AIR IN THE DIRECTION OF
R YOUR SKIN.

R (6) Use clean, dry compressed air or nitrogen to blow off the abrasive residue.

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FAN REVERSER ASSEMBLY - REPAIR

1. Replacement of Support Assembly Rubber Bumper.

A. This procedure gives the instructions for the replacement of worn and/or damaged rubber seal
bumpers on the support assembly.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment. None required.

B. Consumable Materials.

Code No. Description Use

C03-005 Epoxy Resin Primer Finch Rivet replacement

R 463-12-8 (Spray Type)

C04-003 Solvent, Acetone Clean the repair area

(Fed. Spec. O-A-51)

C10-140 Gloves, Nylon Film/Polyethylene, Mix and apply the adhesive

Disposable

C. Expendable Parts. Refer to the Illustrated Parts Catalog for latest part numbers.

Number Description

491E1330057-001 Rubber Bumper

D. SPD Identification. None required.

E. Referenced Procedures. None required.

3. Dimensional Information. None required.

4. Setup Information. None required.

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5. Procedure.

A. Replace worn, damaged, and/or missing rubber bumpers.

(1) Deploy the translating cowl until you get access to the rubber bumpers. Refer to
figure 601.

(2) Center-punch and drill the rivets to attach the bumper to the support assembly. Punch
out the rivets. Remove the bumper and the support plate. Discard the bumper and
keep the support plate to use when you replace the bumper.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

(3) Clean the repair area with acetone (C04-003).

(4) Put the rubber bumper on the support assembly and center the bumper on the hole
pattern. Attach the bumper in position with a C-clamp.

(5) Use the rivet holes on the support assembly as a template to drill 0.125 inch (3.17 mm)
diameter holes through the replacement bumper.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

(6) Remove the clamp and the bumper. Deburr and clean the repair area with acetone
(C04-003).

WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL

IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR.
WEAR CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES
(C10-140) WHEN YOU MIX OR APPLY THE ADHESIVE.

(7) Apply a thin layer of epoxy resin primer (C03-005) to the drilled holes in support
assembly.

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1088269-00-C
Typical Rubber Seal Bumper Replacement
Figure 601

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(8) Find the correct length of the rivets that are necessary for the total thickness of the
support assembly, rubber bumper, and support plate. Refer to IPC 78-32-21, figure 65.

NOTE: If the holes in the bumper are too small to accept the rivets, make the holes
larger as necessary to get a good fit.

WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
SKIN OR INTO YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
AND CLOTHING TO PROTECT YOURSELF.

(9) Apply primer (C03-005) to the rivets and install them while the primer stays wet.

(10) Do steps (1) through (9) again to replace all defective rubber bumpers.

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FAN REVERSER SUPPORT ASSEMBLY - REPAIR

R 1. Support Assembly Damaged Lockout Bolthole Repair.

R A. This procedure gives the instructions to use locally made doublers for the repair of damaged or
R torn lockout boltholes. Do this repair if the lockout boltholes are elongated between 0.43-0.55
R in. (10.9-14.0 mm) circumferentially, and elongated any amount in the forward-to-aft direction.

R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools. None required.

R (3) Locally Manufactured Tools. None required.

R (4) Equipment.

R Description Manufacturer

R Grinder, Pencil Local purchase

R B. Consumable Materials.

R Code Description Use

R C03-005 Epoxy Resin Primer (Spray type) Prepare the repair area
R Finch 463-12-8

R --- Stainless Steel, 300 Series, Make the doubler

R 1/4 Hard Minimum, 0.063 in.
R (1.6 mm) Thick

R C. Expendable Parts.

R Number Description

R MS20426AD5-4 Rivet

R NAS1097D6-8 Rivet

R NAS1097AD5-10 Rivet

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R D. SPD Identification. None required.

R E. Referenced Procedures.

R SPM 70-13-00

R 3. Dimensional Information. None required.

R 4. Setup Information. None required.

R 5. Procedure.

R A. Repair the support assembly lockout boltholes.

R (1) Locally make a doubler from 300 series stainless steel, 1/4 hard minimum, 0.063 in.
R (1.6 mm) thick. See figure 601.

R (2) Remove all damaged or torn material and blend all sharp edges on the outer ring with a
R pencil grinder.

R (3) Remove the aft hoist point blocks and fasteners above and below the damaged holes.

R (4) Make four countersink washers (fillers) to fill the countersinks in the outer ring next to
R the aft lockout holes.

R (a) Make countersink fillers from MS20426AD5 rivets.

R 1 Remove the head of the rivet and open a hole through the center of the
R head to 0.159-0.165 in. (4.04-4.19 mm).

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE

R SURE YOU USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW.
R MAKE SURE YOU DO NOT BREATHE THE FUMES. DO NOT GET
R THE PRIMER ON YOUR SKIN OR INTO YOUR EYES OR MOUTH.
R MAKE SURE YOU USE GLOVES AND CLOTHING TO PROTECT
R YOURSELF.

R (b) Apply epoxy resin primer (C03-005) to each countersink hole and countersink
R filler, and install each one in position.

R NOTE: Each countersink filler must be flush to -0.010 in. (0.25 mm) of the
R outer ring surface when installed.

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R (5) Measure the distance between the lockout holes or aft hoist holes to find the centerline.
R Make a mark with a felt-tip pen to show the location of the centerline on the outer ring.

R (6) Manually shape the doubler and put it in position on the centerline. Hold the doubler in
R position with a clamp. The doubler must be on the outer surface of the ring, and flush
R with the aft edge of the ring.

R (7) Transfer the two 0.285-0.289 in. (7.24-7.34 mm) diameter hoist point holes, and the
R four 0.160-0.166 in. (4.06-4.22 mm) diameter hoist point fastener holes from the outer
R ring to the doubler. Drill a 0.191-0.197 in. (4.85-5.00 mm) diameter hole through the
R doubler and the support at the center. Countersink each side to 0.297-0.302 in. (7.54-
R 7.67 mm) diameter X 100°. See figure 602.

R (8) Countersink the four hoist point rivet holes in the doubler to 0.240-0.247 in. (6.10-6.27
R mm) diameter X 100° and deburr the holes.

R (9) Install the doubler to the support with five rivets. Refer to SPM 70-13-00. Use a
R NAS1097D6-8 rivet for the center location, and NAS1097AD5-10 rivets for the hoist
R point block fasteners. Make sure a countersink washer is in position between the outer
R ring and the doubler at the four hoist point block fastener locations The five rivets must
R be flush with the outer flow path. The center rivet also must be flush with the inner
R surface of the ring.

R (10) With the translating cowl stowed on the fixed structure, transfer the two lockout holes
R from the lockout plates and drill the two 0.327-0.334 in. (8.31-8.48 mm) diameter holes.
R See figure 602.

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
R USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
R SKIN OR INTO YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
R AND CLOTHING TO PROTECT YOURSELF.

R (11) Apply a layer of epoxy resin primer (C03-005) to all bare metal.

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R MR60037-00-A
R Locally Manufactured Doubler
R Figure 601

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R MR60038-00-A
R Translating Cowl Lockout Points
R Figure 602 (Sheet 1)

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R MR60039-00-A
R Translating Cowl Lockout Points
R Figure 602 (Sheet 2)

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R FAN REVERSER SUPPORT ASSEMBLY - REPAIR

R 1. Repair of Worn or Damaged Power Opening Device (POD) Support Bushing Holes.

R A. This procedure gives the instructions necessary to repair worn or damaged bushing holes in the
R Power Opening Device (POD) support fitting.

R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools. None required.

R (3) Locally Manufactured Tools.

R Description Figure No.

R Drill fixture 601

R (4) Equipment. None required.

R B. Consumable Materials.

R Code No. Description Use

R C01-007 Adhesive, Silicone Rubber, Repair damaged

R RTV 106 sealant

R C03-001 Primer, Zinc Chromate Install repair bushing 001

R C03-008 Compound, Chemical Apply to bare metal

R Surface Treatment, surfaces
R Alodine 1500

R C04-014 Alcohol, Denatured Clean the repair area

R C10-140 Gloves, Nylon Film/ Protection

R Polyethylene, Disposable

R C10-182 Cloth, Cleaning Clean the repair area

R --- 17-4 PH CRES (AMS 5643) Bushing and washer

R HT H 1025 1.0 in. (25.4 mm) material
R diameter bar

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R C. Expendable Parts. None required.

R D. SPD Identification. None required.

R E. Referenced Procedures.

R MIL-C-5541

R SPM 70-32-03

R 3. Dimensional Information. See figure 602.

R 4. Setup Information. None required.

R 5. Procedure.

R A. Do the steps that follow to repair the forward and aft POD support bushing holes.

R (1) Measure the inside diameter of the forward POD support bushing. If it is larger than
R 0.316 inch (8.03 mm), remove and discard the forward POD support bushing.

R (2) Measure the diameter of the hole for the forward POD support bushing.

R (3) Measure the inside diameter of the aft POD support bushing. If it is larger than 0.313
R inch (7.95 mm), remove and discard the aft POD support bushing.

R (4) Measure the diameter of the hole for the aft POD support bushing.

R (5) If the forward or aft POD support bushing hole diameters are more than 0.5010 inch
R (12.73 mm), you must rework the hole diameter(s) for oversize bushing(s).

R (a) To locate the tool (figure 601), center the tool bushings in the forward and aft
R POD support bushing counterbores.

R NOTE: The concentricity and perpendicularity tolerances between the

R forward and aft bushing holes are 0.001 inch (0.025 mm). MRAS
R recommends the use of a tool similar to figure 601. You can make
R this tool locally or purchase the tool from MRAS. You can make
R and use incremental bushing sizes of 0.5625 inch (14.288 mm),
R 0.6250 inch (15.875 mm), 0.6875 inch (17.463 mm) and 0.7500
R inch (19.050 mm) to a maximum bushing hole diameter of 0.8125
R inch (20.638 mm).

R (b) Step ream the aft bushing hole 0.5625 inch (14.288 mm), 0.6250 inch (15.875
R mm), 0.6875 inch (17.463 mm), 0.7500 inch (19.050 mm) or a maximum of
R 0.8125 inch (20.638 mm) as necessary, until the hole cleans up with the
R smallest reamer possible. The surface finish must be at least 0.000063 inch
R (0.0016 mm) AA. The hole diameter must not vary more than 0.0005 in. (0.013
R mm) total indicator reading.

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R MR60044-01-A
R Bushing/Drill Guide
R Figure 601 (Sheet 1)

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R MR60045-00-A
R Bushing/Drill Guide
R Figure 601 (Sheet 2)

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R MR60046-00-A
R Bushing/Drill Guide
R Figure 601 (Sheet 3)

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R MR60047-00-A
R Bushing/Drill Guide
R Figure 601 (Sheet 4)

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R MR60048-01-A
R Bushing/Drill Guide
R Figure 601 (Sheet 5)

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R MR60073-00-A
R Bushing/Drill Guide
R Figure 601 (Sheet 6)

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R MM50021-04-A
R Repair Bushing 001
R Figure 602

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(c) Step ream the forward bushing hole 0.5625 inch (14.288 mm), 0.6250 inch
(15.875 mm), 0.6875 inch (17.463 mm), 0.7500 inch (19.050 mm) or a
maximum of 0.8125 inch (20.638 mm) as necessary, until the hole cleans up
with the smallest reamer possible. The surface finish must be at least
0.000063
inch (0.0016 mm) AA. The hole diameter must not vary more than 0.0005 in.
(0.013 mm) total indicator reading.

(6) Use a ball gage and micrometers to measure the hole diameter(s). Record the
diameter(s).

(7) If you increase the diameter of the forward bushing hole, increase the diameter of the
0.880 in. (22.35 mm) counterbore around the hole to 1.0 in. (25.4 mm). Keep the same
counterbore depth and 0.06 inch (1.5 mm) fillet radius.

(8) Do a dye penetrant inspection on the holes to make sure there are no cracks. Refer to
SPM 70-32-03.

(9) Clean the repair area with a clean cloth (C10-182) made moist with denatured alcohol
(C04-014). Immediately dry the area with a clean dry cloth. Do not let the alcohol dry on
the surface.

R (10) Make the repair bushing (001) and washer for the aft bushing hole. Refer to the
dimensions that follow, and to figure 602.

(11) Apply chemical surface treatment compound (C03-008) to all bare metal areas. Refer to
MIL-C-5541.

(a) For repair bushing 001, find the outside “C” diameter as shown below:

0.XXXX RECORDED HOLE DIAMETER

+ 0.0005 IN. (0.0127 MM) INTERFERENCE FIT
= 0.XXXX MINIMUM OUTSIDE “C” DIAMETER

0.XXXX RECORDED HOLE DIAMETER

+ 0.0015 IN. (0.0381 MM) INTERFERENCE FIT
= 0.XXXX MAXIMUM OUTSIDE “C” DIAMETER

(b) For repair bushing 001, find the “A” diameter as shown below:

0.XXXX DIAMETER “C”

+ 0.1280 IN. (3.2512 MM) FLANGE MINIMUM TOLERANCE
= 0.XXXX MINIMUM “A” DIAMETER

0.XXXX DIAMETER “C”

+ 0.1580 IN. (4.0132 MM) FLANGE MAXIMUM TOLERANCE
= 0.XXXX MAXIMUM “A” DIAMETER

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R (c) For repair bushing 001, find the “B” diameter as shown below:

R 0.XXXX DIAMETER “C”

R - 0.0267 IN. (0.6782 MM) DIAMETER
R = 0.XXXX MAXIMUM “B” DIAMETER

R 0.XXXX DIAMETER “C”

R - 0.0467 (1.1862 MM) DIAMETER
R = 0.XXXX MINIMUM “B” DIAMETER

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
R USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
R SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
R AND CLOTHING TO PROTECT YOURSELF.

R (12) Apply a layer of zinc chromate primer (C03-001) to the reamed bushing hole.

R (13) Press fit repair bushing 001 into the bushing hole.

R (14) Make the repair bushing (002). Refer to the dimensions that follow, and to figure 604.

R (a) For repair bushing 002, find the outside “D” diameter as shown below:

R 0.XXXX RECORDED DIAMETER

R - 0.0010 IN. (0.0254 MM) MINIMUM TOLERANCE
R = 0.XXXX MINIMUM OUTSIDE “D” DIAMETER

R 0.XXXX RECORDED DIAMETER

R - 0.0002 IN. (0.0051 MM) MAXIMUM TOLERANCE
R = 0.XXXX MAXIMUM OUTSIDE “D” DIAMETER

R (15) Install repair bushing 002 into the reamed bushing hole.

R (16) If MA25 coating or RTV sealant has been damaged or removed during the repair, apply
R silicone rubber adhesive (C01-007) to the area as necessary. Refer to the
R manufacturer’s instructions to cure the adhesive.

R (17) Assemble all components. See figure 603.

R NOTE: The repair washer is non-standard. Repair bushing 002 is a slip fit
bushing,
R and can come out upon disassembly of the joint. You must keep the repair
R washer and the slip fit repair bushing 002 with the reverser when it is
R removed, because they are non-standard sizes.

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R MM50022-01-A
R Component Assembly
R Figure 603

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R MM50039-01-A
R Repair Bushing 002
R Figure 604

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FAN REVERSER ASSEMBLY - REPAIR

1. Fireseal Repair.

A. This procedure gives the instructions to repair or replace the fireseals. Paragraph 5 gives the
procedure to repair the fireseals. Paragraph 6 gives the procedure to replace the upper forward
fireseal (1-645, 78-32-01) on the left reverser half. Paragraph 7 gives the procedure to replace
the forward fireseal (1-670, 78-32-01). Paragraph 8 gives the procedure to replace the lower
forward fireseal (1-710, 78-32-01) on the left reverser half. Paragraph 9 gives the procedure to
replace the upper sidewall fireseal (1-310, 78-32-01).

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment. None required.

B. Consumable Materials.

Code No. Description Use

C01-007 Adhesive, Silicone Rubber, Bond the repair area

RTV 106

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C. Expendable Parts.

CSN Description

78-32-01-01-290 Aft Seal Block

78-32-01-01-295 Aft Seal Block
78-32-01-01-300 Leading Edge Fireseal
78-32-01-01-305 Leading Edge Fireseal
78-32-01-01-310 Upper Sidewall Fireseal
78-32-01-01-625 Seal Block
78-32-01-01-630 Seal Block
78-32-01-01-635 Splice Plug
78-32-01-01-640 Splice Plug
78-32-01-01-645 Upper Forward Fireseal
78-32-01-01-650 Seal Block
78-32-01-01-655 Seal Block Fireseal
78-32-01-01-670 Forward Fireseal
78-32-01-01-690 Seal Block
78-32-01-01-695 Seal Block Fireseal
78-32-01-01-700 Splice Plug
78-32-01-01-705 Splice Plug
78-32-01-01-710 Lower Forward Fireseal
78-32-01-01-730 Seal Block
78-32-01-01-735 Seal Block

D. SPD Identification. None required.

E. Referenced Procedures. None required.

3. Dimensional Information. None required.

4. Setup Information. None required.

5. Procedure - Repair of Damaged Fireseals.

NOTE: If the fireseal has more than one damaged area, replace it with a new fireseal.

A. Do the steps that follow to repair a damaged fireseal.

(1) Use a sharp knife to remove the damaged part of the fireseal.

(2) Make sure the inner diameter of the remaining serviceable part of the fireseal is free
from unwanted material.

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WARNING: SILICONE RUBBER ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN
TO THE AIR. DO NOT BREATHE THE FUMES.

(3) Use silicone rubber adhesive (C01-007) to install splice plugs into the open ends of the
remaining serviceable parts of the fireseal.

(4) Make sure that a minimum length of 0.50 inch (12.7 mm) of the splice plug is installed
in the serviceable part of the fireseal. Also make sure the splice plugs extend a
minimum of 0.50 inch (12.7 mm) above the serviceable part of the fireseal.

(5) Cut a replacement fireseal to the necessary length to replace the part that you
removed. Make sure the inner diameter of the replacement part is free from unwanted
material.

WARNING: SILICONE RUBBER ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN
TO THE AIR. DO NOT BREATHE THE FUMES.

(6) Use silicone rubber adhesive (C01-007) to install the replacement fireseal part on the
two splice plugs.

WARNING: SILICONE RUBBER ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN
TO THE AIR. DO NOT BREATHE THE FUMES.

(7) Use silicone rubber adhesive (C01-007) to bond all edges between the replacement
and the serviceable part of the fireseal.

(8) Make sure the fireseal is installed correctly in the fireseal retainer.

(9) Do not move the fireseal for 24 hours after the repair.

(10) Do a check to make sure the fireseal compresses correctly.

6. Procedure - Replacement of the Upper Forward Fireseal (Left Side Only).

A. Remove the upper forward fireseal and the seal block. Refer to figure 601.

(1) Remove the screw (1-620, 78-32-01), the washer (1-615, 78-32-01), and the nut (1-
610, 78-32-01) that hold the seal block (1-625 or 1-630, 78-32-01) in position.

(2) Remove the seal block (1-625 or 1-630, 78-32-01), the upper forward fireseal (1-645,
78-32-01), and the two splice plugs (1-635 or 1-640, 78-32-01).

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MM60019-00-A
Fireseal Replacement
Figure 601 (Sheet 1)

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MM60020-00-A
Upper Sidewall Fireseal Replacement
Figure 601 (Sheet 2)

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B. Install a replacement upper forward fireseal and seal block. Refer to figure 601.

(1) Make sure the inner diameter of the replacement upper forward fireseal (1-645, 78-32-
01) is free from unwanted material.

WARNING: SILICONE RUBBER ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN
TO THE AIR. DO NOT BREATHE THE FUMES.

(2) Use silicone rubber adhesive (C01-007) to install splice plugs (1-635 or 1-640, 78-32-
01) into the open ends of the replacement upper forward fireseal (1-645, 78-32-01).

(3) Make sure that a minimum length of 0.50 inch (12.7 mm) of the splice plug (1-635 or 1-
640, 78-32-01) is installed in the replacement upper forward fireseal (1-645, 78-32-01).
Also make sure the splice plugs extend a minimum of 0.50 inch (12.7 mm) above the
replacement upper forward fireseal.

WARNING: SILICONE RUBBER ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN
TO THE AIR. DO NOT BREATHE THE FUMES.

(4) Use silicone rubber adhesive (C01-007) to install the replacement upper forward
fireseal (1-645, 78-32-01) on the upper seal block (1-650 or 1-655, 78-32-01) of the
forward fireseal (1-670, 78-32-01).

(5) Install the replacement upper forward fireseal (1-645, 78-32-01) in the fireseal retainer.

WARNING: SILICONE RUBBER ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN
TO THE AIR. DO NOT BREATHE THE FUMES.

(6) Use silicone rubber adhesive (C01-007) to install the replacement seal block (1-625 or
1-630, 78-32-01) on the splice plug (1-635 or 1-640, 78-32-01) in the end of the upper
forward fireseal (1-645, 78-32-01).

(7) Install the screw (1-620, 78-32-01), the washer (1-615, 78-32-01), and the nut (1-610,
78-32-01) on the replacement seal block (1-625 or 1-630, 78-32-01). Tighten the nut
hand-tight.

WARNING: SILICONE RUBBER ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN
TO THE AIR. DO NOT BREATHE THE FUMES.

(8) Use silicone rubber adhesive (C01-007) to bond the edges at each end of the
replacement upper forward fireseal (1-645, 78-32-01).

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(9) Make sure the upper forward fireseal (1-645, 78-32-01) is installed correctly in the
fireseal retainer.

(10) Do not move the fireseal for 24 hours after the replacement.

(11) Do a check to make sure the upper forward fireseal (1-645, 78-32-01) compresses
correctly.

7. Procedure - Replacement of the Forward Fireseal.

A. Remove the forward fireseal. Refer to figure 601.

(1) Remove the two screws (1-620 and 1-685, 78-32-01), washers (1-615 and 1-680, 78-
32-01), and nuts (1-610 and 1-675, 78-32-01) that hold the seal blocks (1-650 and 1-
690 or 1-655 and 1-695, 78-32-01) in position.

(2) Remove the forward fireseal (1-670, 78-32-01) and the splice plugs (1-635 or 1-640
and 1-700 or 1-705, 78-32-01) at the ends of the seal.

B. Install a replacement forward fireseal. Refer to figure 601.

(1) Make sure the inner diameters at the ends of the replacement forward fireseal (1-670,
78-32-01) are free from unwanted material. On the left reverser half, make sure the
inner diameters at the ends of the upper forward fireseal (1-645, 78-32-01) and the
lower forward fireseal (1-710, 78-32-01) are free from unwanted material.

WARNING: SILICONE RUBBER ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN
TO THE AIR. DO NOT BREATHE THE FUMES.

(2) On the left reverser half, use silicone rubber adhesive (C01-007) to install splice plugs
(1-635 or 1-640 and 1-700 or 1-705, 78-32-01) in the open ends of the upper forward
fireseal (1-645, 78-32-01) and the lower forward fireseal (1-710, 78-32-01).

(3) Make sure that a minimum length of 0.50 inch (12.7 mm) of the splice plug (1-635 or 1-
640 and 1-700 or 1-705, 78-32-01) is installed in the fireseals. Also make sure the
splice plugs extend a minimum of 0.50 inch (12.7 mm) above the fireseals.

WARNING: SILICONE RUBBER ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN
TO THE AIR. DO NOT BREATHE THE FUMES.

(4) Use silicone rubber adhesive (C01-007) to install the replacement forward fireseal (1-
670, 78-32-01) on the splice plugs (1-635 or 1-640 and 1-700 or 1-705, 78-32-01).

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(5) Install the replacement forward fireseal (1-670, 78-32-01) in the fireseal retainer.

(6) Install the two screws (1-620 and 1-685, 78-32-01), washers (1-615 and 1-680, 78-32-
01), and nuts (1-610 and 1-675, 78-32-01) on the forward fireseal seal blocks (1-650
and 1-690 or 1-655 and 1-695, 78-32-01). Tighten the nuts hand-tight.

WARNING: SILICONE RUBBER ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN
TO THE AIR. DO NOT BREATHE THE FUMES.

(7) Use silicone rubber adhesive (C01-007) to bond the edges at each and of the
replacement forward fireseal (1-670, 78-32-01).

(8) Make sure the replacement forward fireseal (1-670, 78-32-01) is installed correctly in
the fireseal retainer.

(9) Do not move the forward fireseal (1-670, 78-32-01) for 24 hours after the installation.

(10) Do a check to make sure the forward fireseal (1-670, 78-32-01) compresses correctly.

8. Procedure - Replacement of the Lower Forward Fireseal (Left Side Only).

A. Remove the lower forward fireseal and the seal block. Refer to figure 601.

(1) Remove the screw (1-725, 78-32-01), the washer (1-720, 78-32-01), and the nut (1-
715, 78-32-01) that hold the seal block (1-730 or 1-735, 78-32-01) in position.

(2) Remove the seal block (1-730 or 1-735, 78-32-01), the lower forward fireseal (1-710,
78-32-01), and the two splice plugs (1-700 or 1-705, 78-32-01).

B. Install a replacement lower forward fireseal and seal block. Refer to figure 601.

(1) Make sure the inner diameter of the replacement lower forward fireseal (1-710, 78-32-
01) is free from unwanted material.

WARNING: SILICONE RUBBER ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN
TO THE AIR. DO NOT BREATHE THE FUMES.

(2) Use silicone rubber adhesive (C01-007) to install splice plugs (1-700 or 1-705, 78-32-
01) into the open ends of the replacement lower forward fireseal (1-710, 78-32-01).

(3) Make sure that a minimum length of 0.50 inch (12.7 mm) of the splice plug (1-700 or 1-
705, 78-32-01) is installed in the replacement lower forward fireseal (1-710, 78-32-01).
Also make sure the splice plugs extend a minimum of 0.50 inch (12.7 mm) above the
replacement lower forward fireseal.

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WARNING: SILICONE RUBBER ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN
TO THE AIR. DO NOT BREATHE THE FUMES.

(4) Use silicone rubber adhesive (C01-007) to install the replacement lower forward
fireseal (1-710, 78-32-01) on the lower seal block (1-690 or 1-695, 78-32-01) of the
forward fireseal (1-670, 78-32-01).

(5) Install the replacement lower forward fireseal (1-710, 78-32-01) in the fireseal retainer.

WARNING: SILICONE RUBBER ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN
TO THE AIR. DO NOT BREATHE THE FUMES.

(6) Use silicone rubber adhesive (C01-007) to install the replacement seal block (1-730 or
1-735, 78-32-01) on the splice plug (1-700 or 1-705, 78-32-01) in the end of the lower
forward fireseal (1-710, 78-32-01).

(7) Install the screw (1-725, 78-32-01), the washer (1-720, 78-32-01), and the nut (1-715,
78-32-01) on the replacement seal block (1-730 or 1-735, 78-32-01). Tighten the nut
hand-tight.

WARNING: SILICONE RUBBER ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN
TO THE AIR. DO NOT BREATHE THE FUMES.

(8) Use silicone rubber adhesive (C01-007) to bond the edges at each end of the
replacement lower forward fireseal (1-710, 78-32-01).

(9) Make sure the lower forward fireseal (1-710, 78-32-01) is installed correctly in the
fireseal retainer.

(10) Do not move the fireseal for 24 hours after the replacement.

(11) Do a check to make sure the lower forward fireseal (1-710, 78-32-01) compresses
correctly.

9. Procedure - Replacement of the Upper Sidewall Fireseal.

A. Remove the upper sidewall fireseal (1-310, 78-32-01), the aft fireseal block (1-290 or 1-295, 78-
32-01), and the leading edge fireseal (1-300 or 1-305, 78-32-01) from the seal retainer. Refer
to figure 601.

B. Make sure the seal retainer is free from unwanted material.

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WARNING: SILICONE RUBBER ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN

YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. DO NOT
BREATHE THE FUMES.

C. Use silicone rubber adhesive (C01-007) to install a replacement aft fireseal block (1-290 or 1-
295, 78-32-01) and a replacement leading edge fireseal (1-300 or 1-305, 78-32-01) in the seal
retainer.

D. Cut the replacement upper sidewall fireseal (1-310, 78-32-01) to fit between the aft fireseal
block (1-290 or 1-295, 78-32-01) and the leading edge fireseal (1-300 or 1-305, 78-32-01).

WARNING: SILICONE RUBBER ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN

YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. DO NOT
BREATHE THE FUMES.

E. Use silicone rubber adhesive (C01-007) to install the replacement upper sidewall fireseal (1-
310, 78-32-01) between the aft seal block (1-290 or 1-295, 78-32-01) and the leading edge
fireseal (1-300 or 1-305, 78-32-01).

WARNING: SILICONE RUBBER ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN

YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. DO NOT
BREATHE THE FUMES.

F. Use silicone rubber adhesive (C01-007) to bond the edges at each end of the replacement
upper sidewall fireseal (1-310, 78-32-01).

G. Make sure the upper sidewall fireseal (1-310, 78-32-01) is installed correctly in the seal retainer.

H. Do a check to make sure the replacement seals compress correctly.

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FAN REVERSER SUPPORT ASSEMBLY - REPAIR

R 1. Repair of Damaged MA-25S Insulation Coating.

R A. This procedure gives instructions for the repair and/or replacement of damaged MA25S
R insulation coating.

R (1) You can use this procedure to repair the core cowl inner skin, the duct sidewall,
R and the precooler duct insulation coating.

R (2) This procedure uses these methods: spray application of MA-25S (paragraph 5.);
R installation of SPD MA-25S sheet material (paragraph 6.); and an alternative method
R that uses silicone rubber adhesive instead of MA-25S insulation (paragraph 7.).

R (a) You can use the alternative silicone rubber adhesive method in paragraph 7.
R if the damage is in the limits that follow:

R 1 The damaged area must not be more than 12.0 in. (30.5 cm) by
R 12.0 in. (30.5 cm).

R B. The following special instructions are necessary for successful completion of this repair.

R WARNING: IF SKIN COMES IN CONTACT WITH SOLVENT, IMMEDIATELY FLUSH

R WITH WATER. FUMES ARE TOXIC AND FLAMMABLE. AVOID
R PROLONGED INHALATION.

R CAUTION: THE INCREASED USE OF SILICONE MATERIALS REQUIRES EXTREME

R CARE TO PREVENT CONTAMINATION OF PARTS, EQUIPMENT, AND
R MATERIALS. SILICONE CONTAMINATION RESULTS IN COMPLETE
R FAILURE OF ALL COATING AND FILMS.

R (1) Cleaning, mixing, and spraying of all applications of primer, MA-25S, and sealant must
R be done in a spray booth equipped with an exhaust type ventilating system and a
R grounding devices. Make sure the air supply is filtered, and free of oil and water.

R (2) You must wear safety equipment during all phases of coating, cleaning, and mixing.

R (3) You must use grounding clamps during cleaning, mixing, and spraying operations to
R prevent static electricity.

R (4) All equipment used for silicone applications must be identified and used ONLY for this
R purpose.

R (5) Make sure you clean all equipment identified for use of silicone applications with
R solvent (C04-003) immediately after use.

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R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools. None required.

R (3) Locally Manufactured Tools. None required.

R (4) Equipment.

R Description Manufacturer

R Gun, Spray, DeVilbiss Company

R JGA 502, P. O. Box 913
R "E" Tip Toledo, OH 43692

R Gun, Spray, Binks Mfg Company

R No. 18; Fluid 9205 W. Belmont Avenue
R Nozzle No. 64VT; Franklin Park, IL 60131
R Aircap No. 64PA;
R 45 in. (114 cm) extension

R Hose, Fluid, 3/8 in. (9.5 mm); Binks Mfg Company

R Connections, Binks 71-282, 9205 W. Belmont Avenue
R 71-217 Teflon or Nylon Lined Franklin Park, IL 60131
R (No substitute permitted)

R Hose, Air, 3/8 in. (9.5 mm); Binks Mfg Company

R Connections, Binks 71-5301, 9205 W. Belmont Avenue
R 71-6307 Franklin Park, IL 60131

R Cable, Grounding, and Clamps Local purchase

R Pot, Pressure, 10 gal. (37.9 liters), Binks Mfg Company

R 2 gal. (7.6 liters), Pneumatic 9205 W. Belmont Avenue
R Agitator, 110 psi (759 kPa), Franklin Park, IL 60131
R Insert, Binks 83-1618

R Respirator, Organic Vapor, Local purchase

R 3M8712; Filter 3M8742

R Oven, Air Circulating, Local Purchase

R 150-170F (66-77C)

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B. Consumable Materials.

Code Description Use

C01-005 Catalyst, Tin Octoate, RTV catalyst

Nuocure 28

C01-007 Adhesive, Silicone Sealant

Rubber, RTV-106

C01-008 Compound, Silicone Sealant

Rubber, RTV-560

C01-014 Sealant, Primer, Adhesive Surface preparation

Silicone

C01-015 Compound, Ablative, Fire protection

Silicone Insulation MA-25S

C04-003 Solvent, Acetone Clean the repair area

C04-018 Solvent, Naphtha Insulation component

R C04-024 Solvent, Brolite Insulation component

C10-010 Scotch Brite Pads No. 7447 Clean the repair area

C10-141 Abrasive Paper, 120-180 Grit Prepare the repair area

C10-182 Cloths, Cleaning Clean the repair area

--- Solvent, Heptane Insulation component

--- Scraper, Acrylic Remove the insulation

--- Gloves, Natural Rubber Apply the insulation

--- Abrasive Paper, 80-90 Grit Surface preparation

--- Abrasive Cloth, 50-80 Grit Surface preparation

C. Expendable Parts. None required.

D. SPD Identification.

SPD No. Description

3040M40P01 Insulation, MA-25S

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R E. Referenced Procedures. None required.

R 3. Dimensional Information. None required.

R 4. Setup Information. None required.

R 5. Procedure to Spray the Insulation Compound.

R A. Prepare the surface for primer application.

R (1) Do the steps that follow to remove the remaining unbonded insulation:

R (a) Use a plastic scraper to remove all of the damaged insulation coating from the
R surface to be primed.

R (b) Sand the area to be repaired to remove the remaining insulation coating. Use
R 120 grit or finer abrasive paper(C10-141). Bevel the insulation coating at the
R edges of the bare area.

R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE

R AIRBORNE PARTICLES THAT CAN GO INTO YOUR EYES OR GO
R THROUGH YOUR SKIN. DO NOT USE MORE THAN 30 PSIG (207
R KPA) PRESSURE. USE GOGGLES. DO NOT POINT
R COMPRESSED AIR IN THE DIRECTION OF YOUR SKIN.

R (c) Use dry, filtered, oil-free shop air to remove unwanted material.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN
R OR EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC,
R AND HIGHLY FLAMMABLE.

R (2) Use a clean cloth (C10-182) moist with solvent (C04-003) to fully clean the repair area.
R Immediately dry the surface with a clean cloth. Do not let the solvent dry on the
surface.

R (3) Apply masking materials to the area to be primed. Refer to figure 601.

R (4) Use Scotch Brite pads (C10-010) to abrade all primed or phenolic surfaces to get an
R equal, dull appearance.

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R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

R PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
R SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE. USE
R GOGGLES. DO NOT POINT COMPRESSED AIR IN THE DIRECTION OF
R YOUR SKIN.

R (5) Use a vacuum or dry, filtered, oil-free shop air to remove unwanted material from the
R repair surface. Use a vacuum to clean the adjacent area.

R (6) Clean the repair area with clean cloths (C10-182) and clean water. Use sufficient water
R to do a check for water breaks. If you see water breaks, do steps (2) through (6)
again.

R NOTE: If water does not flow over the surface in a smooth, continuous sheet, there
R are water breaks.

R (7) Dry the surface to be primed with clean dry cloths, then dry for one hour at 165°-185F
R (74°-85C) before you apply the primer.

R NOTE: There must not be more than 16 hours between the surface preparation
R and the primer application. If more time than 16 hours passes, you must
R clean the surface again.

R B. Prepare and apply the primer (C01-014).

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
R USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
R SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
R AND CLOTHING TO PROTECT YOURSELF.

R (1) Fully mix and strain the amount of primer (C01-014) needed for immediate use.
R Examine the mix for unmixed solid particles. If you see particles, discard the primer.

R NOTE: You must discard unused primer. Never pour unused primer back into the
R original container.

R (2) Fill a spray gun (DeVilbiss, JGA 502 or equivalent) with primer.

R (3) Use a spray pressure of 35-60 psi (241-413 kPa) to spray the primer in a continuous,
R equal film. The thickness of the primer must not be more than 0.0002 inch (0.005 mm).

R NOTE: A thin equal layer will give the best results. The light pink color of this
R primer is difficult to see when the primer is wet. This causes a tendency to
R apply too much primer. A thick layer gives a dark red surface. Thick layers
R must be kept to a minimum.

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R MR60088-00-A
R Masking Application
R Figure 601

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(4) Visually examine the primed area for voids. Use a brush to touch up all the voided
areas with primer as necessary.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

(5) If the primer separates, bunches, or discolors, partially remove the affected areas with a
clean cloth moist with solvent (C04-003).

(6) If necessary, clean the applicable surface and apply the primer again. Refer to
paragraphs 5.A. and 5.B.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

CAUTION: MAKE SURE THE SPRAY GUN IS GROUNDED WHEN YOU FLUSH IT WITH
SOLVENT.

(7) Flush the spray gun and equipment immediately after use with solvent (C04-003) to
remove all remaining primer.

C. Cure the primed parts.

(1) If the relative humidity is 20-30 percent and the temperature is 65°-100°F (18°-38° C),
cure for a minimum of 6 hours. If humidity is 40-59 percent, cure for a minimum of 3
hours. If humidity is 60 percent or more, cure for 1 hour.

R D. Prepare the insulation compound (C01-015).

NOTE: Persons who mix and apply this compound must be familiar with all phases of the
spraying operation and the importance of operator technique.

NOTE: The coating system materials are supplied in matched sets as follows:

R 5 gallons (18.9 liters) Part A Base Resin

R 1 quart (0.95 liter) Part B Catalyst
The quart container is approximately 1/5 full.

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R (1) Put the 5 gallon (18.9 liter) container of Part A resin in position on a paint
mixer or equivalent and shake for approximately 20 minutes, or until the ingredients are
mixed into an equal mass.

NOTE: Mixing by hand is permitted but difficult. Use an air motor with a paddle for
the best results. You must get a creamy, equal mass regardless of the
method you use to mix the material.

(2) Pour and scrape the mixed Part A from the 5 gallon (18.9 liter) container into a 10
gallon (37.9 liter) insert of a pressure pot or equivalent. Tightly close the pressure pot
lid and shake.

R (3) Fill the one quart container of Part B catalyst with Heptane and mix fully.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN
OR EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
AND HIGHLY FLAMMABLE.

(4) Partially remove the pressure pot lid while agitator is operating and add the Part
B/Heptane mixture to the Part A. Close the lid tightly and adjust the agitator to high.
Mix for 5 minutes.

(a) Keep the pressure pot lid on at all times, except when you add the Part B
mixture to the Part A. To avoid premature gelation of the material, do not
expose the mixture to moisture or high humidity. If premature gelation occurs,
discard the remaining material in the pressure pot and flush the system with
solvent (C04-003).

NOTE: Pot life of the blended material is approximately 2 hours from the addition
of the catalyst. Normally a 5 gallon (18.9 liter) quantity of blended
compound will give from 1 to 1.5 hours of spraying time, but this depends
on the ability of the equipment to force the material through the lines and
gun.

(5) If more than one 5 gallon (18.9 liter) application of insulation is necessary, you can
make additional batches of the Part A resin. Do not mix Part A with the Part B catalyst
until you are ready to apply the mixture.

NOTE: It is not necessary to flush the spray system between applications unless
premature gelation has occurred.

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R E. Prepare the spray equipment.

R (1) Visually examine the spray equipment to make sure that hoses and nozzles are clean
R and are the correct equipment for this application.

R NOTE: The fluid hoses must be lined with teflon or nylon. No alternatives are
R permitted.

R (2) Adjust the spray equipment as follows:

R (a) Adjust the line pressure to 80-110 psig (552-759 kPa gage); adjust the
R pressure pot pressure to 20-35 psig (138-242 kPa gage); adjust the atomization
R pressure to 45 psig (311 kPa gage).

R (b) Adjust the agitator motor to 1/2 to 3/4 open.

R (c) With the gun trigger fully open and the fluid control screw open, adjust the
R spray width to approximately 8 inches (20 cm) with the spray gun at a
R distance of 12-14 inches (31-36 cm) from the work piece.

R F. Apply the insulation compound.

R NOTE: Operator technique is very important in relation to the final density of the insulation
R layer. Unlike conventional spraying, this operation depends on spray gun distance
R from the work and rate of travel to get a somewhat porous condition.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN
R OR EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC,
R AND HIGHLY FLAMMABLE.

R (1) Do not let more than 16 hours pass between the primer cure and the insulation
R application. If more time than 16 hours passes, clean the primed surface with a clean
R cloth (C10-182) lightly moist with solvent (C04-003).

R (2) Apply an equal layer of insulation, 0.010 inch (0.25 mm) nominal thickness, to give a
R wet, glossy appearance.

R NOTE: A layer thicker than 0.010 inch (0.25 mm) can run, sag, or form pin holes.

R (3) Let the solvent vapors bleed off for a minimum of 20 minutes before you apply a second
R layer. Do this process again until you get the correct thickness. See figure 602 for the
R correct thickness.

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R MR60104-01-A
Coating Requirements Per Area
Figure 602 (Sheet 1)

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R CF8-7278-00-A
Coating Requirements Per Area
Figure 602 (Sheet 2)

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R CF8-7279-00-A
Coating Requirements Per Area
Figure 602 (Sheet 3)

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R CF8-7281-00-A
Coating Requirements Per Area
Figure 602 (Sheet 4)

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R CF8-7282-00-A
Coating Requirements Per Area
Figure 602 (Sheet 5)

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R CF8-7283-00-A
Coating Requirements Per Area
Figure 602 (Sheet 6)

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R CF8-7284-00-A
Coating Requirements Per Area
Figure 602 (Sheet 7)

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R CF8-7286-00-A
Coating Requirements Per Area
Figure 602 (Sheet 8)

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R CF8-7288-00-A
Coating Requirements Per Area
Figure 602 (Sheet 9)

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R (4) Let the coated areas set up for a minimum of 4 hours. Do not bump, move, or shake.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN
R OR EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC,
R AND HIGHLY FLAMMABLE.

R CAUTION: MAKE SURE THE SPRAY EQUIPMENT IS GROUNDED WHEN YOU FLUSH
R IT WITH SOLVENT.

R (5) Immediately after the spray application is completed, flush the system with solvent
R (C04-003). Make sure you remove all of the insulation compound from the
R pressure pot, the lines, and the spray gun.

R G. Cure the insulation compound and prepare the insulation layer for the application of the sealant.

R (1) Alternative procedure available. Cure the insulation compound at 70°-110°F (21°-43°C)
R for 24 hours.

R (1).A. Alternative procedure. Cure the insulation compound at 70°-110°F (21°-43°C) for 12
R hours, then cure for 4 hours at 150-175°F (66°-79°C) in a vented air circulating oven.

R (2) After the insulation is cured, lightly sand the edges with 80-90 grit abrasive paper.

R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

R PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
R SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE. USE
R GOGGLES. DO NOT POINT COMPRESSED AIR IN THE DIRECTION OF
R YOUR SKIN.

R (3) Remove all dust and abrasive material with a vacuum cleaner or blow off the area with
R clean, dry, oil-free shop air. Clean the repair area with clean dry cloths (C10-182).

R (4) Apply masking material to the repair area in preparation for the application of the
R sealer. Refer to figure 601.

R H. Prepare the silicone rubber compound (C01-008).

R WARNING: THIS MATERIAL IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR

R EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. DO NOT
R BREATHE THE FUMES.

R (1) Remove the tube of catalyst and pour the material in the 12 pound (5.44 kg) container
R into a clean pressure pot.

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R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN
R OR EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC,
R AND HIGHLY FLAMMABLE.

R (2) Use a gram balance and a clean metal or glass container to weigh out 1361 grams of
R naphtha (C04-018).

R (3) Pour the naphtha into the empty silicone rubber compound container and fully mix with
R the remaining silicone rubber compound material in the container.

R (4) Pour the solvent/material mixture into the pressure pot containing the silicone rubber
R compound, tightly close the pressure pot lid and shake for 10 minutes.

R (5) With agitator running, partially remove the pressure pot lid and slowly add the catalyst
R from the squeeze tube.

R NOTE: A Dibutyl Tin Dilaurate catalyst is supplied in a squeeze tube with the 12
R pound (5.44 kg) container of silicone rubber compound. We strongly
R recommend the use of plural component equipment (in which the catalyst is
R added in the spray nozzle) to spray the silicone rubber compound (C01-
R 008).

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN
R OR EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC,
R AND HIGHLY FLAMMABLE.

R (6) Tightly close the pressure pot lid and continue to shake for a minimum of 5 minutes
R before the spray operation. If it becomes too difficult to spray the mixture, immediately
R flush and clean the system with solvent (C04-003).

R NOTE: The normal pot life of catalyzed compound is 1-2 hours. However, the
R actual pot life depends on the ability to properly spray the mixture.

R I. Apply the silicone rubber compound sealant.

R CAUTION: MAKE SURE YOU GROUND THE SPRAY EQUIPMENT TO PREVENT

R STATIC ELECTRICITY.

R (1) Adjust pressure setting on pressure pot to 20 psig (137 kPa gage) and the spray gun
R pressure to 40 psig (274 kPa gage).

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R (2) Spray an equal layer of the silicone rubber compound sealant over the repair area.

R (a) Let the sealant dry to a tack-free condition before you apply a second layer
R (approximately 20 minutes).

R (b) Apply sufficient layers of the silicone rubber compound sealant until you get a
R thickness of 0.005-0.011 inch (0.13-0.27 mm).

R (3) Visually examine the sealant layers for voids or thin areas where you can see the pink
R insulation. Touch up these areas as necessary.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN
R OR EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC,
R AND HIGHLY FLAMMABLE.

R CAUTION: MAKE SURE THE SPRAY EQUIPMENT IS GROUNDED WHEN YOU FLUSH
R IT WITH SOLVENT.

R (4) Immediately after the sealant spraying operation is completed, flush the equipment with
R solvent (C04-003) to remove all of the silicone rubber compound sealant.

R J. Cure and touch up the silicone rubber compound sealant.

R NOTE: The final appearance of properly applied and cured silicone rubber compound
R sealant is that of a uniform glaze in most areas. Surface porosity in the insulation
R coating in certain areas causes the sealant to be absorbed, which gives a dark,
R unglazed appearance. This condition is cause for rejection.

R (1) Alternative procedure available. Cure the sealant for 16 hours at 70°-100°F (21°-38°C).

R (1).A. Alternative procedure. Cure for 30 minutes at 70°-100°F (21°-38°C), then cure for 4
R hours at 140°-160°F (60°-71°C) in an air circulating oven.

R (2) After the cure is complete, carefully remove the masking material. Use plastic knives
R as necessary to minimize possible peeling or tearing of the silicone rubber
R compound sealant.

R (3) Examine the sealant layer for pin holes, blisters, edge peels, tears, and bare areas.
R Touch up all such areas with properly mixed and catalyzed silicone rubber compound
R sealant. Use a brush to apply the sealant.

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R (4) If wet spots are detected, perform the following:

R (a) Mix a solution of 15 grams naphtha (C04-018) or Brolite (C04-024) with 11

R drops Tin Octoate (C01-005).

R (b) Brush a light coat of this mixture onto the set spots

R (c) Allow to cure for a minimum of 2 hours at ambient.

6. Procedure for the SPD Insulation Sheet Material.

A. Prepare the patch and the area to be patched.

(1) Measure the damaged area and cut out of the SPD insulation sheet material a patch
larger than the damaged area.

NOTE: On inside of core cowl, the repair patch must not be larger than 2 inches
(50.8 mm) square because this repair surface is spherical in shape. Use
as many patches as necessary to fill the repair area. On flat surfaces
such as the sidewall, there is no limit to the size of the patch.

(2) Use the patch as a template, and cut into (but not through) the insulation coating with a
plastic knife.

(3) Remove the patch and carefully make the cut deeper down through the coating. If
possible, chamfer the edge of the patch and the insulation coating repair area.

(4) Use a plastic scraper to remove all damaged material so that the patch will fit into the
repair cavity and make contact around the complete circumference of the cavity. Do
not insert the patch at this time.

(5) Use 120 grit or finer sandpaper (C10-141) to remove the insulation material from the
cowl surface. Use a vacuum to remove unwanted material.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN
OR EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

(6) Use a clean cloth (C10-182) moist with solvent (C04-003) to clean the repair surface.
Dry the surface with a clean cloth.

(7) Clean the repair area with clean cloths (C10-182) and clean water. Use sufficient water
to do a check for water breaks. If you see water breaks, clean the surface again with
solvent and repeat the water break test. Remove most of the water from the surface
with clean dry cloths.

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R NOTE: If water does not flow over the surface in a smooth, continuous sheet, there
R are water breaks.

R (8) Dry the repair surface for one hour at 150°F (65.5° C) before you apply the primer.

R NOTE: There must not be more than 16 hours between the surface preparation
R and the primer application. If more time than 16 hours passes, you must
R clean the surface again.

R B. Mix and apply the primer.

R (1) Prepare the primer (C01-014). Refer to step 5.B.(1).

R (2) Use a small paint brush to apply the primer to the repair surface.

R (3) Cure the primer. Refer to paragraph 5.C.

R C. Prepare the silicone rubber compound sealant and install the patches.

R WARNING: THIS MATERIAL IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR

R EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. DO NOT
R BREATHE THE FUMES.

R (1) Mix 75 grams of the silicone rubber compound resin (C01-008) with 11 drops of Tin
R Octoate (C01-005). Mix fully with a tongue depressor or equivalent. Mix multiple
R batches as necessary.

R NOTE: The pot life of the adhesive mixture is approximately 20 minutes.

R (2) Use an acid brush and a plastic spatula to apply the adhesive mixture to the repair
R surface and the mating surfaces.

R (3) Carefully put the patch into the repair cavity. Gently roll the patch into position. Start at
R the center of the patch and roll toward the edges. Do not trap air under the patch.

R (4) Cure the adhesive mixture. Refer to step 5.J.(1) or 5.J.(1).A.

R (5) Use 50-80 grit abrasive cloth to make the insulation layer flush with adjacent surfaces.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID
R IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF
R YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT
R AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR EYES
R BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY
R FLAMMABLE.

R (6) Clean the repair surface with solvent (C04-003).

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R (7) If necessary, make a new mixture of silicone rubber compound sealant (C01-008). Use
R a spatula and an acid brush to apply the sealant to the edges that were sanded. Make
R sure that all areas are covered with a 0.005-0.011 inch (0.12-0.28 mm) thick layer of
R sealant.

R 7. Insulation Repair with Silicone Rubber Adhesive.

R A. Do the steps that follow to remove the damaged MA-25S insulation material:

R NOTE: The damaged area must not be more than 12.0 in. (30.5 cm) by 12.0 in. (30.5 cm).

R (1) Use a plastic knife to remove loose MA-25S insulation material from the damaged area.

R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

R PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
R SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE. USE
R GOGGLES AND A PARTICLE MASK. DO NOT POINT COMPRESSED AIR I
R IN THE DIRECTION OF YOUR SKIN.

R (2) Use clean, dry filtered air to remove unwanted material.

R B. Apply the primer.

R (1) Prepare the surface for the application of the primer. Refer to paragraph 5.A.

R (2) Prepare and apply the primer. Refer to paragraphs 5.B. and 5.C. You can use a brush
R to apply the primer.

R C. Apply a sufficient amount of silicone rubber adhesive (C01-007) to all of the damaged area.

R WARNING: SILICONE RUBBER ADHESIVE IS AN IRRITANT. DO NOT GET THE

R MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN
R TO THE AIR. DO NOT BREATHE THE FUMES.

R (1) With the silicone rubber adhesive (C01-007), seal the exposed edges of the MA-25S
R insulation.

R (2) Fill all of the damaged area with the silicone rubber adhesive (C01-007). The thickness
R of the adhesive must be a minimum of two times the thickness of the undamaged
R MA-25S insulation.

R NOTE: The thickness of the adhesive must be a minimum of two times the
R thickness of the undamaged MA-25S insulation because of thermal
R considerations.

R (a) The silicone rubber adhesive quickly forms a skin after it is applied. Fill the
R repair area and make the surface smooth before the skin forms.

R (b) Make sure you fully close the adhesive container after you apply the adhesive.

R D. Let the adhesive cure at a room temperature of 60-100F (16-38C) for a minimum of 6 hours.
R The cure time will vary with temperature, humidity, and the thickness of the adhesive.

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FAN REVERSER SUPPORT ASSEMBLY - REPAIR

1. Replacement of Disbonded Upper and Lower Duct Sidewall Outer (Flowpath) Skins.

A. This procedure gives the instructions for the replacement of disbonded outer (flowpath) skins
in the upper and lower duct sidewall. This procedure assumes that the sidewalls have been
removed from the fan reverser fixed structure, and the components which are bolted to the
sidewalls have been removed.

R B. This repair procedure is for both Pre and Post S/B 78-5126 sidewall panels. It is important to
R note that the construction of Pre and Post 78-5126 are significantly different and attention must
R be given to the specific figures for each configuration.

R NOTE: Pre S/B 78-5126 sidewall P/Ns will be 491B1352000-XXX and 491B1362000-XXX
R and Post S/B 78-5126 sidewall P/Ns will be 491E1352000-XXX and 491E1362000-
R XXX.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools.

Tool No. Description

--- You can make the bond tooling by reverse

engineering from a production sidewall.
Tooling hole locations are given in figures 603-606.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment.

Description Manufacturer

Piloted Counterbore Local purchase

Thermocouples Local purchase

Pressure probes Local purchase

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B. Consumable Materials.

Code Description Use

C01-011 Adhesive, Epoxy Resin, Bond the repair area

EA 934NA, Parts A and B

C01-073 Compound, Sealing, Seal the repair area

PR 1750

C01-132 Adhesive, Foam, MA557 Bond the repair area

C01-136 Adhesive, Supported Film Bond the repair area

R C01-139 Adhesive, Unsupported Film Bond the repair area

C01-155 Adhesive, Paste, Two-Part, Alternative adhesive to

EA 9394, B Catalyst C01-011

C01-166 Primer, Corrosion-Inhibiting, Prime the repair area

(Use the specific primer called
out by the adhesive manufacturer)

C03-008 Compound, Chemical Surface Protect the outer

Treatment, Alodine 1500 aluminum surfaces

R DELETED

C04-003 Solvent, Acetone (ASTM D 329) Prepare the repair details

C04-018 Naphtha, Fed. Spec. TTN-95 Clean the repair area

C04-035 Solvent, Isopropyl Alcohol Prepare the repair details

C10-048 Cloth, Bleeder Bond the repair area

C10-140 Gloves, Nylon Film/Polyethylene, Mix and apply the adhesive

Disposable

C10-141 Abrasive Paper, 120-180 Grit Surface preparation

--- Abrasive Paper, Aluminum Oxide, Surface preparation

400 Grit

--- Abrasive Disk, Aluminum Oxide, Surface preparation

220-240 Grit

--- Blast Media, Abrasive Grit, Surface preparation

Virgin Aluminum Oxide,
120-180 Mesh

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C. Expendable Parts. None required.

D. SPD Identification. None required.

E. Referenced Procedures.

SPM 70-21-01

R SPM 70-21-04

SPM 70-43-18

SPM 70-43-20

SPM 70-43-21

SPM 70-71-05

SPM 70-71-07

78-32-02, Assembly

78-32-02, Disassembly

3. Dimensional Information. None required.

4. Setup Information. None required.

5. Procedure.

WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE PARTICLES
THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR SKIN. DO NOT USE
MORE THAN 30 PSIG (207 KPA) PRESSURE. WEAR GOGGLES. DO NOT POINT
COMPRESSED AIR IN THE DIRECTION OF YOUR SKIN.

A. Use a plastic scraper and/or 120-180 grit abrasive paper (C10-141) to remove all of the MA25
insulation coating from the bondment. Use compressed air to remove unwanted material.

B. Use 120-180 grit abrasive paper (C10-141) to remove all sealant and paint from the bondment.
Use compressed air to remove unwanted material.

C. On the upper duct sidewall only, use the correct size piloted counterbore to remove the heads
of all countersunk inserts (491B1313132-001 and 491B1313132-005) before you remove the
outer skin.

D. Use a putty knife or equivalent to work the edge of the flowpath skin free from the core.
Remove the outer (flowpath) skin.

E. After you remove all of the outer (flowpath) skin and/or P.O.D. fitting, do a visual inspection of
the remaining bondment structure.

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F. Remove all discolored, corroded, or damaged core from the sidewall.

NOTE: Normal core material has a metallic silver color. Corroded core has a milky gray
color.

G. Remove all core cell walls of adjacent normal core around the perimeter of the discolored or
damaged area.

H. Remove all delaminated core from the inner skin.

I. Examine the shear ties in the areas where you did not remove the core. Make a note, as
necessary, of areas that will need repair when you prepare to bond.

J. Use a 220-240 grit aluminum oxide abrasive (sanding) disk to remove core stubs and remaining
adhesive on the inner skin and details (except the honeycomb) to be bonded.

K. Use 400 grit aluminum oxide abrasive paper to remove all remaining unwanted material.

L. Use 180 grit (or finer) aluminum oxide abrasive paper to remove all remaining adhesive on the
honeycomb core. Make the surface flush with the adjacent cells. Remaining adhesive is
permitted within the cell sidewall.

M. If necessary, do the steps that follow to fill small irregular areas in the core. The maximum
number of irregularities permitted for each sidewall is five. The maximum size permitted for
each irregularity is 1.0 in. (25.4 mm) diameter, separated by a maximum of 3.0 in. (76.2 mm).

WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL

IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR.
WEAR CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES
(C10-140) WHEN YOU MIX OR APPLY THE ADHESIVE.

(1) Make a mixture of epoxy resin adhesive (C01-011). Refer to the manufacturer's
instructions.

NOTE: You can use adhesive (C01-155) as an alternative to (C01-011).

(2) Fill all irregular areas with the adhesive until the adhesive surface is smooth and flush
with the adjacent cells.

(3) Do the steps that follow to cure the (C01-011) adhesive. If you use the (C01-155)
adhesive, refer to paragraph (3) A. for alternative instructions.

(a) Cure the (C01-011) adhesive for 24 hours at 60°-80°F (16°-27°C), or cure for
one hour at 200°-220°F (93°-104°C).

(3)A. Alternative instruction. Do the steps that follow to cure the (C01-155) adhesive.

(a)A. Cure the (C01-155) adhesive for two hours at 68°-75°F (20°-24°C), then cure
for two hours at 170°-190°F (77°-88°C).

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MR60116-00-A
Figure 601
R Core Ribbon Direction - Upper Duct Sidewall (PRE S/B 78-5126)

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R
R Figure 602
R Core Ribbon Direction - Upper Duct Sidewall (POST S/B 78-5126)

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LM50080-01-A
Figure 603
R Core Ribbon Direction - Lower Duct Sidewall (PRE S/B 78-5126)

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R
R Figure 604
R Core Ribbon Direction - Lower Duct Sidewall (POST S/B 78-5126)

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N. Do the steps that follow to replace the honeycomb and the details of the duct sidewall:

(1) Remove all of the sheet metal details from the bondment.

(2) Visually examine the sheet metal details for dents, irregularities, or cracks. Replace all
damaged details.

(3) Install replacement honeycomb into the bondment to get a correct fit. The edges of
R the replacement honeycomb must interlock with the existing honeycomb. Refer to the
R following figures for the correct honeycomb density and ribbon direction. For the
R Upper Duct Sidewall, refer to Figure 601 (Pre S/B 78-5126) and Figure 602 (Post S/B
R 78-5126). For the Lower Duct Sidewall, refer to Figure 603 (Pre S/B 78-5126) and
R Figure 604 (Post S/B 78-5126).

(4) Use the correct size piloted counterbore to shave the inserts so that they are flush with
the adjacent honeycomb core.

(5) Make a trial fit of all of the new outer flowpath details.

O. Do the steps that follow to prepare the replacement details for adhesive application and
bonding:

(1) Prepare the faying surface of the bondment. Refer to SPM 70-43-21.

NOTE: As a permitted alternative to the procedure in step (1), you can do a spot
blast with virgin 120-180 aluminum oxide grit. Refer to SPM 70-21-04.

(2) Prepare all of the replacement aluminum details, except for the honeycomb core.
Refer to SPM 70-43-20.

R Pre SB 78-5126 * * * (ACOUSTIC CONFIGURATION FOR INCREASED GROSS WEIGHT)

(a) If necessary, you can apply corrosion-inhibiting primer (C01-166) to the

prepared details to preserve the “etch” during transport. Refer to SPM
70-43-20.

R End Pre SB 78-5126 * * *

R Post SB 78-5126 * * * (ACOUSTIC CONFIGURATION FOR INCREASED GROSS WEIGHT)

R (a) Apply corrosion-inhibiting primer (C01-166) to the prepared details. Refer to

R SPM 70-43-20.

R End Post SB 78-5126 * * *

(3) To prepare the aluminum honeycomb core, do a solvent degreasing procedure. Refer
to SPM 70-21-01. Refer to step (3).A. for an alternative method.

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WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC,
AND HIGHLY FLAMMABLE.

(3).A. Alternative method. To prepare the aluminum honeycomb core, spray the core with
solvent (C04-003 or C04-035).

P. Do the steps that follow to prepare process control specimens. It is necessary to make a
minimum of three specimens for each test type.

(1) Prepare lap shear specimens. Refer to SPM 70-71-05.

(2) If core material will be replaced, prepare flatwise tensile specimens. Refer to SPM 70-
71-07.

NOTE: It is necessary to use unsupported adhesive only if unsupported adhesive

will be used in the repair.

(3) For process control specimen strength requirements, refer to table 601.

Table 601. In-Process Control Tests for Supported Single Stage

Acceptance Values
Test Type
Minimum and Individual

Tensile Shear, PSI (MPa), after

10 minutes at 250°F (121°C) 2400 PSI (16.55 MPa)

Flatwise Shear, PSI (KPa), after

10 minutes at 250°F (121°C) 600 PSI (4136.8 KPa)

Q. Do the steps that follow to bond the sidewall assembly:

R Pre SB 78-5126 * * * (ACOUSTIC CONFIGURATION FOR INCREASED GROSS WEIGHT)

R (1) Use one to two layers of foam adhesive (C01-132) as a shear tie between the
R honeycomb details.

R (2) Use one layer of supported film adhesive (C01-136) on all other bonded surfaces in the
R bondment.

R (3) Install cleaned outer skin.

R End Pre SB 78-5126 * * *

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R Post SB 78-5126 * * * (ACOUSTIC CONFIGURATION FOR INCREASED GROSS WEIGHT)

R (1) In all areas (including core to inner skin bondline), except 0.50 in. (12.7 mm) acoustic
R core, use one layer of supported adhesive (C01-136).

R (2) Use one to two layers of foam adhesive (C01-132) as a shear tie between the
R honeycomb details.

R (3) Application of unsupported adhesive to the acoustic core:

R (a) Use one layer of unsupported adhesive (C01-139) at all of the 0.50 in. (12.7
R mm) honeycomb areas that bond to the perforated outer skin.

R (b) Reticulate the unsupported adhesive (C01-139) using a blower heat gun to
R make the unsupported adhesive flow.

R NOTE: Unsupported film adhesive (C01-139) may be manually perforated

R to aide in the reticulation process.

R WARNING: YOU MUST HAVE LOCAL EXHAUST AIRFLOW SYSTEM

R FOR THE FUMES WHEN YOU USE A BLOWER HEAT GUN
R ON ADHESIVE.

R CAUTION: MAKE SURE YOU KEEP THE BLOWER HEATER GUN AT

R THE CORRECT DISTANCE FROM THE ADHESIVE, AND
R MOVE IT AT THE CORRECT SPEED. TOO MUCH HEAT
R CAN REDUCE THE ADHESIVE FLOW, AND THUS REDUCE
R THE STRENGTH OF THE BOND.

R 1 Move the blower heat gun over the unsupported adhesive in a

R constant, equal back and forth motion, while you move the blower heat
R gun in a forward direction. Keep a distance of approximately 3.0 in.
R (76 mm) between the tip of the heat gun and the adhesive surface.
R The heat plus the air velocity from the blower heat gun will cause the
R adhesive to attach to the cell edges and make a continuous bead over
R all of the core surface.

R NOTE: The inserts are bonded into the core cowl after the final
R bondment cure.

R (c) Install cleaned and primed outer perforated skin.

R End Post SB 78-5126 * * *

(4) Put thermocouples and pressure probes in position on the repair area. Put bleeder
cloth (C10-048) over the sidewall assembly and the bond tooling. Use more than one
layer of bleeder cloth over sharp corners.

(5) Put a vacuum bag on the assembly and the tool. Connect the vacuum lines to a
vacuum pump. Draw a vacuum pressure of 8-10 inches of mercury.

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(6) Pressurize and cure the repair in an autoclave. Refer to SPM 70-43-20.

(7) Remove the repair from the autoclave and disassemble it from the tool.

(8) Refer to SPM 70-43-20, Quality Assurance, for acceptance of bonding, except for the
flatwise tensile process control specimen.

(9) Use the insert as a guide and back drill the outer (flowpath) skin to the diameter of the
holes in the inserts.

(10) Replace the inserts as necessary. Refer to figures 603 through 611.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT

ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
USE THE FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT
BREATHE THE FUMES. IF YOU GET THE SOLVENT ON YOUR
SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET
MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

(a) Clean the insert(s) with naphtha (C04-018). Dry the areas with a clean dry
cloth.

WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA
OPEN TO THE AIR. WEAR CLEAN NYLON FILM OR
POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN YOU MIX
OR APPLY THE ADHESIVE.

(b) Make a mixture of epoxy resin adhesive (C01-011). Refer to the

manufacturer's instructions.

NOTE: You can use adhesive (C01-155) as an alternative to (C01-011).

(c) Use the adhesive mixture to bond the applicable insert(s) in position. Remove
unwanted adhesive.

(d) Do the steps that follow to cure the (C01-011) adhesive. If you use the (C01-
155) adhesive, refer to paragraph (d) A. for alternative instructions.

1 Cure the (C01-011) adhesive for 24 hours at 60°-80°F (16°-27°C), or

cure for one hour at 200°-220°F (93°-104°C).

(d)A. Alternative instruction. Do the steps that follow to cure the (C01-155) adhesive.

1A. Cure the (C01-155) adhesive for two hours at 68°-75°F (20°-24°C),
then cure for two hours at 170°-190°F (77°-88°C).

R REPAIR 023
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R. Seal each bondment edge or adhesive joint that can let fluids or gases into the core cavities,
and do a leak check.

(1) Apply a layer of clear protective coating (C03-008) to all outer aluminum surfaces.
Refer to SPM 70-43-18.

(2) Seal all the bondment edges and adhesive joints.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT

ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
USE THE FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT
BREATHE THE FUMES. IF YOU GET THE SOLVENT ON YOUR
SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET
MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

(a) Clean the bondment edges and adhesive joints with naphtha (C04-018). Dry
the areas with a clean dry cloth.

WARNING: SEALANT IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR

EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR.
DO NOT BREATHE THE FUMES.

(b) Apply sealant (C01-073) to all the bondment edges and adhesive joints. The
sealant must have a thickness of 0.002-0.010 inch (0.05-0.25 mm). The seal
must be continuous. No pin holes or leak paths are permitted.

R Post SB 78-5126 * * * (ACOUSTIC CONFIGURATION FOR INCREASED GROSS WEIGHT)

R (c) For outer perforated skins apply chemical conversion coating per MIL-DTL-
R 5541, Class 1A, followed by one coat of MIL-PRF-85285 Type I Polyurethane
R Topcoat, Color No. 26306 Sand Gray, per FED-STD-595. Refer to 78-32-02
R Repair 027 for re-finishing.

R End Post SB 78-5126 * * *

S. Assemble the repaired duct sidewall to the support assembly. Refer to 78-32-02, Assembly.

REPAIR 023
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R MR60117-00-A
Figure 605
Left Upper Duct Sidewall Inserts

REPAIR 023
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MR60119-00-A
Figure 606
Right Upper Duct Sidewall Inserts

R REPAIR 023
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78-32-02 DEC 01/15
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MR60120-00-A
Figure 607
Left Lower Duct Sidewall Inserts

R REPAIR 023
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78-32-02 DEC 01/15
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MR60121-00-A
Figure 608
Right Lower Duct Sidewall Inserts

R REPAIR 023
PAGE 617
78-32-02 DEC 01/15
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R MR50287-00-A
Figure 609
Lower Duct Sidewall Aluminum Details

REPAIR 023
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78-32-02 DEC 01/15
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R MR50288-00-A
Figure 610
Forward End of the Lower Duct Sidewalls

REPAIR 023
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78-32-02 DEC 01/15
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MR50289-00-A
Figure 611
R Lower Duct Sidewall Sheet Metal Details (PRE and POST S/B 78-5126)

REPAIR 023
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78-32-02 DEC 01/15
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MR60122-00-A
Figure 612
R Left Upper Duct Sidewall Details (PRE S/B 78-5126)

REPAIR 023
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R
R Figure 613
R Left Upper Duct Sidewall Details (POST S/B 78-5126)

REPAIR 023
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MR60118-01-A
Figure 614
R Right Upper Duct Sidewall Details (PRE S/B 78-5126)

REPAIR 023
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78-32-02 DEC 01/15
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R
R Figure 615
R Right Upper Duct Sidewall Details (POST S/B 78-5126)

REPAIR 023
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FAN REVERSER SUPPORT ASSEMBLY - REPAIR

R 1. Repair of Minor Damage to the Core Cowl Zee Rib.

R A. This procedure gives the instructions for repair of minor damage to the core cowl zee rib
R assembly. The damage must be no more than 3.0 in. (76.2 mm) wide by 0.55 in. (14.0 mm)
R deep. Up to two repairs are permitted on a zee rib. The two repairs must be a minimum of 6.0
R in. (15.2 cm) apart. Damage within 5.0 in. (12.7 cm) of the zee rib clip (491B1313024) is not
R repairable. If more than two repairs are necessary on a zee rib, replace the zee rib.

R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable
R Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools. None required.

R (3) Locally Manufactured Tools. None required.

R (4) Equipment. None required.

R B. Consumable Materials.

R Code Description Use

R
R C03-005 Primer, Epoxy, Green Preparation of
R (GE Spec A50TF107, the repair doubler;
R Class A, Spray Type) rivet installation

R C03-092 Conversion Coating, Surface preparation

R Chromated - Alodine
R 1132

R C04-035 Isopropyl Alcohol Clean the repair area

R --- Sheet Stock, Aluminum, Material for an alternative

R 2024-T3 Clad, 0.050 in. repair doubler
R (1.27 mm) thick, QQ-A-250/5

R --- Sheet Stock, Aluminum, Material for an alternative

R 2024-T3 Clad, 0.063 in. repair doubler
R (1.60 mm) thick, QQ-A-250/5

REPAIR 024
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R C. Expendable Parts.

R Part No. Description

R CR3213-4 Rivets

R CR3213-5 Rivets

R MS20470AD4 Alternative for CR3213-4

R MS20470AD5 Alternative for CR3213-5

R D. SPD Identification.

R Part No. Description

R 491B1340012 Zee Rib, Sta. 210.130

R 491B1340013 Zee Rib, Sta. 230

R 491B1340014 Zee Rib, Sta. 238

R 491B1340015 Zee Rib, Sta. 250

R E. Referenced Procedures.

R 78-32-02 Repair 022

R 3. Dimensional Information. None required.

R 4. Setup Information. None required.

R 5. Procedure.

R A. Prepare the damaged area for repair.

R (1) Blend the repair area of the zee rib to remove sharp edges and high metal.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR
R SKIN OR EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE,
R TOXIC, AND HIGHLY FLAMMABLE.

R (2) Clean the repair area with a clean lint-free cotton cloth made moist with alcohol (C04-
R 035). Immediately wipe the surface with a dry clean lint-free cotton cloth. Do not let
R the alcohol dry on the repair area. Do this again until the repair area is clean.

REPAIR 024
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R B. Make a repair doubler.

R (1) Make a splice doubler from a left or right zee rib for the same station as the repair area.
R Refer to figure 601. The doubler must extend 4.0 in. (10.2 cm) above and below the
R edge of the damage. Refer to step (1)A. below for an alternative procedure.

R (1)A. Alternative to step (1): Make a repair doubler from 2024-T3 clad aluminum sheet stock,
R 0.050 in. (1.27 mm) or 0.063 in. (1.60 mm) thick, QQ-A-250/5. Make the doubler of a
R sufficient size to extend 4.0 in. (10.2 cm) above and below the edge of the damage.
R Refer to figure 601.

R (2) Drill eleven holes in the repair doubler. Refer to figure 602.

R (a) With a #20 drill bit, drill ten holes, five on each side of the repair.

R (b) With a #30 drill bit, drill one hole in the center of the repair area.

R (3) Surface treat all bare metal with Alodine (C03-092).

R (4) Apply primer (C03-005) to all bare metal.

R C. Attach the repair doubler to the damaged zee rib. Wet install the rivets with primer (C03-005).

R (1) Use a CR3213-4 (or alternative MS20470AD4) rivet in the center hole of the doubler.

R (2) Use CR3213-5 (or alternative MS20470AD5) rivets in the remaining ten holes.

R D. Touch up the MA-25 insulation as necessary. Refer to 78-32-02 Repair 022.

REPAIR 024
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R MR60107-02-A
R Make the Zee Rib Doubler
R Figure 601

REPAIR 024
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78-32-02 DEC 01/10
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R MR60176-01-A
Zee Rib Doubler Repair
Figure 602

REPAIR 024
PAGE 605
78-32-02 JUN 01/16
 FAN REVERSER
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THIS PAGE INTENTIONALLY BLANK

 COMPONENT
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MANUAL

683L SERIES

FAN REVERSER SUPPORT ASSEMBLY - REPAIR

R 1. Doubler Repair of the Upper Torque Box Retainer (491E1330011).

A. This procedure gives instructions for the repair of cracks of up to 3.0 inches (7.62 cm) in length,
in the torque box outer ring retainer. Refer to figure 601.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment. None required.

B. Consumable Materials.

Code No. Description Use

C01-011 Adhesive, Epoxy Resin, Bond the repair doubler

EA 934NA, Parts A and B

C01-126 Fabric, Netting, Dacron Bondline control

Polyester

C03-005 Primer, Epoxy Resin, Refinish the repair area

Finch 463-12-8 (Spray Type)

C03-006 Conversion Coating, Chromated, Prepare the repair area

MIL-C-5541, Yellow
(Alodine 1200)

C03-007 Primer, Epoxy, Prepare the repair area

BR-127

C04-001 Solvent, Methyl-Ethyl-Ketone Clean the repair area

(MEK)

C10-010 Scotch Brite Pads, Surface preparation

No. 7447

REPAIR 025
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R Code No. Description Use

R C10-140 Gloves, Nylon Film/Polyethylene, Mix and apply the adhesive

R Disposable

R Local purchase Clad Aluminum Sheet, Make the repair doubler

R 0.063 in. (1.60 mm) thick,
R 2024-T3

R C. Expendable Parts.

R Part No. Description Manufacturer

R CR3213-5-X Fastener Local purchase

R CR3243-5-X Alternative fastener Local purchase

R for oversize condition

R CR3213-6-X Alternative fastener Local purchase

R for oversize condition

R MS20470AD5 Fastener Local purchase

R D. SPD Identification. None required.

R E. Referenced Procedures.

R SPM 70-32-02

R IPC 78-32-21 Figure 5

R 3. Dimensional Information. None required.

R 4. Set-up Information. None required.

R 5. Procedure.

R A. Remove the rivets from the damaged area.

R (1) On a right side reverser half you can remove the name plate if necessary.

R (a) Remove the fasteners and the name plate.

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE

R SURE YOU USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW.
R MAKE SURE YOU DO NOT BREATHE THE FUMES. DO NOT GET
R THE PRIMER ON YOUR SKIN OR IN YOUR EYES OR MOUTH.
R MAKE SURE YOU USE GLOVES AND CLOTHING TO PROTECT
R YOURSELF.

R (b) Apply epoxy resin primer (C03-005) to the fastener holes.

REPAIR 025
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R B. Stop drill the crack with a 0.090-0.125 inch (2.29-3.18 mm) diameter drill bit. Deburr the hole.

R C. Blend the crack to remove all sharp or rough edges.

R D. Do a visual inspection of the retainer for cracks or other defects. No cracks or defects are
R permitted.

R E. Do a fluorescent-penetrant inspection of the retainer to find residual cracks. Refer to SPM

R 70-32-02 (GEK 9250).

R F. Make the repair doubler.

R (1) Make a repair doubler from 2024-T3 Clad Aluminum with a stock thickness of 0.063
R inch (1.60 mm). Make the doubler sufficiently large to make an overlap of two
R fasteners. Edge distances for all fasteners must be a minimum of 0.38 in. (9.7 mm).
See figure 602.

R CAUTION: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
R USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
R SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
R AND CLOTHING TO PROTECT YOURSELF.

R (2) Apply a layer of epoxy primer (C03-007) to the doubler. Cure at room temperature for
R 30 minutes, followed by 30 minutes at 250ºF (121ºC).

R G. Use Scotch-Brite pads (C10-010) to abrade the surface of the repair area and the attaching
R surface of the repair doubler.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
R AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
R SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
R GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
R ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R H. Clean the repair area with solvent (C04-001) and apply conversion coating
R (C03-006).

R WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN

R YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR.
R USE CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140)
R WHEN YOU MIX OR APPLY THE ADHESIVE.

R I. Make a mixture of epoxy resin adhesive (C01-011). Refer to the manufacturer's instructions.

R J. Bond the repair doubler to the retainer with the epoxy resin adhesive (C01-011). Use Dacron
R polyester netting (C01-126) for bondline control.

REPAIR 025
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R K. Cure the repair at 68-75 F (20-24 C) for 24 hours, or at 200-220 F (93-104C) for 50-70
R minutes.

R L. Wet install MS20470AD5 fasteners in the top two rows of the repair doubler with primer (C03-
R 005). Install CR3213-5-X fasteners in the bottom row of the repair doubler for the original hole
R size. Use CR3243-5-X or CR3213-6-X fasteners for an oversize condition. Use an applicable
R grip. Refer to figure 602.

R M. On right thrust reverser halves, install the name plate if you removed it.

R NOTE: It is permitted to install the name plate in a different place if interference with the
R repair doubler occurs.

R N. Remove all unwanted material (FOD) from the torque box cavity. Use the FOD access holes
R (MR 99379 5-260, 78-32-21) to get access to the torque box cavity.

REPAIR 025
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R MR50191-00-C
R Damage Area - Torque Box Outer Ring Retainer
R Figure 601

REPAIR 025
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78-32-02 DEC 01/10
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R MR50192-05-C
R Repair Doubler - Torque Box Upper Retainer
R Figure 602

REPAIR 025
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R FAN REVERSER SUPPORT ASSEMBLY - REPAIR

R 1. Replacement of the Core Cowl Skin and Doublers.

R A. This procedure gives the instructions for the replacement of core cowl skins, doublers, and
R details. This procedure can also be used to convert a core cowl with wire mesh (491B1342000-
R 019, 491B1342000-010) to a screenless core cowl (491B1342000-049, 491B1342000-020).

R NOTE: No more than 2 additional cure cycles above the initial production cure cycle are
R allowed for this repair.

R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable
R materials.

R A. Tools and Equipment.

R (1) Special Tools

R Tool No. Description

R --- You can make the bond tooling by reverse

R engineering from a production core cowl.
R Tooling hole locations are given in Figure 612

R (2) Standard Tools. None required.

R (3) Locally Manufactured Tools.

R Description Figure No.

R Delamination Inspection Tool, Figure 613

R (4) Equipment.

R Description Manufacturer

R Aircraft rivet shaver Local purchase

R Thermocouples Local purchase

R Pressure probes Local purchase

R Blower heat gun Local purchase

REPAIR 026
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78-32-02 DEC 01/14
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B. Consumable Materials.

Code No. Description Use

C01-011 Adhesive, Epoxy Resin, Bond the repair area

EA 934NA, Parts A and B

C01-073 Compound, Sealing, Seal the repair area

PR 1750

C01-132 Adhesive, Foam, MA557 Bond the repair area

C01-136 Adhesive, Supported Film Bond the repair area

R Only EA9658.100 allowed

C01-139 Adhesive, Unsupported Bond the repair area

R Only EA9658.060 allowed

C01-166 Primer, Corrosion-Inhibiting, Prime the repair area

(Use the specific primer called
out by the adhesive manufacturer)

C03-064 Iridite 14-2 Surface finish

C04-003 Solvent, Acetone Clean the part

C04-018 Naphtha, Fed. Spec. TT-N-95 Clean the repair area

C04-035 Solvent, Isopropyl Alcohol Clean the part

C10-048 Cloth, Bleeder Bond the repair area

C10-140 Gloves, Nylon Film/Polyethylene, Mix and apply the adhesive

Disposable

C10-182 Cloths, Cleaning Clean the repair area

--- Compound, Chemical Surface Surface finish

Treatment, Alodine 600

REPAIR 026
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R B. Consumable Materials (Con’t).

R Code No. Description Use

R --- Paint, Polyurethane, Finish layer

R MIL-C-85285, Type 1,
R Gray, Color Code 26306

R --- Abrasive Paper, 120-240 Grit Surface preparation

R --- Abrasive Paper, Aluminum Surface preparation

R Oxide, 400 Grit

R --- Abrasive Disk, Aluminum Surface preparation

R Oxide, 120-240 Grit

R Primer, Corrosion-Inhibiting, Alternative to C01-166

R Hysol EA 9258.1 (Alternative is for the
R Hysol EA 9205 option only)

R C. Expendable Parts. None required.

R D. SPD Identification. None required.

R E. Referenced Procedures.

R ASTM D 2651

R ASTM D 3933

R SPM 70-21-01

R SPM 70-21-04

R SPM 70-43-08

R SPM 70-43-20

R SPM 70-43-21

R SPM 70-71-05

R SPM 70-71-07

R 3. Dimensional Information. None required.

R 4. Set-up Information. None required.

REPAIR 026
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5. Procedure.

WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE PARTICLES
THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR SKIN. DO NOT USE
MORE THAN 30 PSIG (207 KPA) PRESSURE. USE GOGGLES. DO NOT POINT
COMPRESSED AIR IN THE DIRECTION OF YOUR SKIN.

A. Use a plastic scraper and/or 120-240 grit abrasive paper to remove all of the insulation coating
from the bondment. Use compressed air to remove unwanted material.

B. Use 120-240 grit abrasive paper or equivalent to remove all sealant and paint from the
bondment. Use compressed air to remove unwanted material.

C. If damage assessment has not been previously accomplished, perform a visual inspection of
the core cowl bondment for unbonded areas, and do a tap test.

(1) Tap the bondment surface to find the unbonded areas using the delamination
inspection tool shown in Figure 613 or equivalent.

NOTE: If the material is fully bonded, you will hear a solid click when you tap. If
the area is unbonded, you will hear a slightly hollow sound.

D. Use a chisel or equivalent to work the edge of the skin or detail free from the core. After you
work an edge free, you can peel away the skin or detail. If necessary, use a heat gun to help
remove the skin or detail.

E. Remove all discolored, damaged, or delaminated core from the core cowl.

NOTE: Normal core material has a metallic silver color. Core material with corrosion
damage has a milky gray color.

F. Remove all core cell walls of adjacent normal core around the perimeter of the discolored or
damaged area.

G. Examine the core splice adhesive in the areas where you did not remove the core. Make a
note, as necessary, of areas that will need repair when you prepare to bond.

H. Use a 120-240 grit aluminum oxide abrasive (sanding) disk or equivalent to remove core stubs
and remaining adhesive on the skin, details, and core.

I. If necessary, do the steps that follow to fill small irregular areas in the core splice adhesive. The
maximum number of irregular areas permitted for each core cowl half is 10. Damage size is
limited to a maximum of 4 inches (101.6mm) in length (L), a maximum surface area of 1 square
inch (645.2mm2), and a maximum depth of 0.25 inches (6.35mm). Damage sites must be
separated by a minimum of 2.0 x L1 + 2.0 x L2 edge to edge, where L1 and L2 represents the
larger dimension of the individual damage sites. Damage that exceeds this limit will be repaired
R by adding C01-132 foam adhesive.

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R WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL

R IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR.
R USE CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES
R (C10-140) WHEN YOU MIX OR APPLY THE ADHESIVE.

R (1) Mix the epoxy resin adhesive (C01-011) by weight, 100 parts A (resin) to 33 parts B
R (catalyst). Mix fully until you can see no streaks of the two components.

R NOTE: The pot life of a 4.66 ounce (132 gram) mixture of the adhesive is
R approximately 40 minutes.

R (2) Fill all irregular areas with the prepared epoxy resin adhesive (C01-011) until the
R adhesive surface is smooth and flush with the adjacent cells.

R (3) Cure the adhesive for 24 hours at 60-80F (15.6-26.7C), or cure for one hour at
R 200-220F (93-104C).

R J. Do the steps that follow to replace the honeycomb and the details to the core cowl.

R NOTE: Figures 601 through 608 show the lay-up of the left and right core cowls by layers.
R The layers go from the perforated skin to the inner skin. The core cowl is built on a
R male tool in production. Layer 1 (figures 601 and 605) is the perforated skin and
R internal doublers that bond between the perforated skins and the honeycomb core.
R Layer 2 (figures 602 and 606) is the honeycomb core layer. Layer 3 (figures 603
R and 607) is the internal doublers that are between the core and the inner skin.
R These figures also show the inner skin. Layer 4 (figures 604 and 608) is the inner
R skin and the innermost doubler details.

R (1) Remove all dents or irregular areas in the sheet metal pieces of the bondment. Form
R the pieces to their correct contour.

R (2) Visually examine the sheet metal pieces for cracks. Replace all cracked details.

R (3) Install replacement honeycomb into the bondment to get a correct fit. The edges of the
R replacement honeycomb must interlock with the existing honeycomb. Refer to figures
R 602 and 606 for the correct honeycomb density and ribbon direction.

R (4) Perform a trial fit of all new honeycomb core to be replaced.

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R K. Do the steps that follow to prepare the replacement details for adhesive application and
R bonding. Refer to figures 601, 603, 604, 605, 607, and 608 for detail definition.

R (1) Prepare the faying surface of the bondment. Refer to SPM 70-43-21.

R (2) Prepare all of the replacement aluminum details, except for the honeycomb core. The
R preferred method is the Phosphoric Acid Anodizing procedure in ASTM D 3933. An
R alternative method is the FPL method in ASTM D 2651.

R (3) To prepare the aluminum honeycomb core, do a solvent degreasing procedure. Refer
R to SPM 70-21-01.

R (4) If the Abex pump pans (491E1342047) need to be replaced, prepare the applicable
R bond surfaces. Refer to SPM 70-21-04, method 4A. Use virgin grit for the procedure.

R (5) Apply corrosion-inhibiting primer (C01-166) to the prepared details, the honeycomb
R core, and the bondment. Refer to SPM 70-43-20. The thickness of the cured primer
R must be 0.0001-0.0003 in. (0.0025-0.0076 mm).

R L. Do the steps that follow to prepare process control specimens.

R (1) Prepare lap shear specimens. Refer to SPM 70-71-05.

R (2) If core material will be replaced, prepare flatwise tensile specimens. Refer to SPM
R 70-71-07.

R (3) For process control specimen strength requirements, refer to table 1.

Table 1 – In-process Control Tests for Supported and Unsupported Single Stage

Acceptance Values
Minimum and Individual
Test Type
Unsupported Supported

Tensile Shear, PSI (MPa), after 2300 2400

10 minutes at 250F (121C) (15.85) (16.55)

Flatwise Tension, PSI (KPa), after 380 600

10 minutes at 250F (121C) (2620.0) (4136.8)

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RRRMR60150-00-A
R Replacement Details - Internal Doublers - Left Core Cowl - Arrangement
R Figure 601

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RMR60151-00-A
Core Density and Ribbon Direction - Left Core Cowl
Figure 602

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RMR60152-00-A
R Replacement Details - Internal Doublers and Inner Skin - Left Core Cowl - General Arrangement
R Figure 603

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491B1342046-023

RMR60153-00-A
R Replacement Details -External Doublers and Inner Skin - Left Core Cowl - General Arrangement
R Figure 604

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RMR50176-02-A
R Replacement Details - Internal Doublers - Right Core Cowl - Arrangement
R Figure 605

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RMR50171-01-A
Core Density and Ribbon Direction - Right Core Cowl
Figure 606

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RMR50175-02-A
R Replacement Details - Internal Doublers and Inner Skin - Right Core Cowl - General Arrangement
R Figure 607

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R7-04-A
R Replacement Details - External Doublers and Inner Skin - Right Core Cowl - General Arrangement
R Figure 608

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R M. Do the steps that follow to bond the core cowl assembly.

R (1) Use one to two layers of foam adhesive (C01-132) as a shear tie between the
R honeycomb details. The maximum gap between the honeycomb core is 0.125 in.
R (3.175 mm).

R NOTE: The use of cleaned, primed, corrugated aluminum foil, 5056H191, 0.0020-
R 0.0045 in. (0.05-0.11 mm) thick, is permitted between two strips of foam.
R This will prevent the adhesive from sagging down between the core
R sections.

R (2) Apply the correct adhesive to bond the core cowl.

R (a) Use one layer of unsupported adhesive (C01-139) at all of the 0.5 in. (12.7 mm)
R honeycomb areas that bond to the perforated outer skin.

R (b) Reticulate the unsupported adhesive (C01-139) using a blower heat gun to
R make the unsupported adhesive flow.

R NOTE: Unsupported film adhesive (C01-139) may be manually perforated

R to aide in the reticulation process.

R WARNING: YOU MUST HAVE LOCAL EXHAUST AIRFLOW SYSTEM

R FOR THE FUMES WHEN YOU USE A BLOWER HEAT GUN
R ON ADHESIVE.

R CAUTION: MAKE SURE YOU KEEP THE BLOWER HEATER GUN AT

R THE CORRECT DISTANCE FROM THE ADHESIVE, AND
R MOVE IT AT THE CORRECT SPEED. TOO MUCH HEAT
R CAN REDUCE THE ADHESIVE FLOW, AND THUS REDUCE
R THE STRENGTH OF THE BOND.

R 1 Move the blower heat gun over the unsupported adhesive in a

R constant, equal back and forth motion, while you move the blower heat
R gun in a forward direction. Keep a distance of approximately 3 inches
R (76 mm) between the tip of the heat gun and the adhesive surface.
R The heat plus the air velocity from the blower heat gun will cause the
R adhesive to attach to the cell edges and make a continuous bead over
R all of the core surface.

R (c) In all other areas (including core to inner skin bondline), except inserts, use one
R layer of supported adhesive (C01-136).

R NOTE: The inserts are bonded into the core cowl after the final bondment
R cure.

R (3) Put thermocouples and pressure probes in position on the repair area. Put bleeder
R cloth (C10-048) over the fixed structure bondment assembly, the process control
R samples, and the bond tooling. Use more than one layer of bleeder cloth over sharp
R corners.

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R (4) Put a vacuum bag on the assembly and the tool. Connect the vacuum lines to a
R vacuum pump. Draw a vacuum pressure of 8-10 inches of mercury.

R (5) Pressurize and cure the repair along with the process control samples in an autoclave.
R Refer to SPM 70-43-20.

R (6) Remove the repair from the autoclave and disassemble it from the tool.

R (7) Do a visual inspection of the core cowl for unbonded areas, and do a tap test of both
R the inner and outer skins. Refer to the inspection sheet for the appropriate repair if
R unbonded areas are found.

R (a) Tap the bondment surface to find the unbonded areas using the delamination
R inspection tool shown in Figure 613 or equivalent.

R NOTE: If the material is fully bonded, you will hear a solid click when you
R tap. If the area is unbonded, you will hear a slightly hollow sound.

R (8) Do the lab tests in SPM 70-43-20.

R (9) Prepare the inserts. Refer to ASTM D 3933, ASTM D 2651, or SPM 70-43-20.

R (10) Use epoxy resin adhesive (C01-011) to bond the inserts into the core cowl. Refer to
R figures 609 and 610.

R WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL

R IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR.
R USE CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES
R (C10-140) WHEN YOU MIX OR APPLY THE ADHESIVE.

R (11) Mix the epoxy resin adhesive (C01-011) by weight, 100 parts A (resin) to 33 parts B
R (catalyst). Mix fully until you can see no streaks of the two components.

R NOTE: The pot life of a 4.66 ounce (132 gram) mixture of the adhesive is
R approximately 40 minutes.

R (12) Apply a layer of the prepared epoxy resin adhesive (C01-011) to the side of the insert to
R be bonded. Install the inserts into the core cowl. Refer to figures 609 and 610.

R (13) Cure the adhesive for 24 hours at 60-80F (15.6-26.7C), or cure for one hour at
R 200-220F (93-104C).

R N. Seal all the bondment edges and adhesive joints.

R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

R PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
R SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE. USE
R GOGGLES. DO NOT POINT COMPRESSED AIR IN THE DIRECTION OF
R YOUR SKIN.

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R
R Inserts - Left Core Cowl
R Figure 609

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R00-A
R Inserts - Right Core Cowl
R Figure 610

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R
R Half Core Properties
R Figure 611

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RMR60154-00-A
R Tooling Hole Locations
R Figure 612

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R (1) Clean the bondment edges and adhesive joints with Naphtha (C04-018). Dry the areas
R with a clean dry cloth.

R WARNING: SEALANT IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR EYES

R OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. DO NOT
R BREATHE THE FUMES.

R (2) Apply sealant (C01-073) to all the bondment edges and adhesive joints. The sealant
R must have a thickness of 0.002-0.010 in. (0.05-0.25 mm). The seal must be
R continuous. No pin holes or leak paths are permitted.

R CAUTION: MIDDLE RIVER AIRCRAFT SYSTEMS SUPPLIES ONLY THE SCREENLESS

R VERSION OF THE PERFORATED SKINS (FIGURES 601 AND 605). DO NOT BOND
R WIRE MESH ONTO THESE SKINS. IF YOU BOND WIRE MESH ONTO THE
R SCREENLESS SKINS, THE REVERSER WILL NOT HAVE THE CORRECT
R ACOUSTIC PROPERTIES.

R O. Apply the final finish layer to the outer perforated flow skin surface.

R (1) Prepare the outer perforated skin flow surface for painting by lightly abrading with #180
R grit sand paper.

R (2) Use a clean, lint-free cotton cloth (C10-182) moist with solvent (C04-003 or C04-035)
R to clean the surface. Remove the solvent with a clean, dry, lint-free cotton cloth. Do
R not let the solvent dry on the repair area. Do this again until the surface is clean.

R WARNING: ACID SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. DO
R NOT GET ACID ON YOUR SKIN, IN YOUR EYES, OR ON YOUR CLOTHES.
R DO NOT BREATHE THE FUMES. WEAR ACID-RESISTANT CLOTHING,
R GLOVES, AND FACE PROTECTION. IF YOU GET ACID ON YOUR SKIN OR
R IN YOUR EYES, FLUSH IT AWAY WITH WATER AND GET MEDICAL AID
R IMMEDIATELY.

R (3) Apply Iridite 14-2 (C03-064) or Alodine 600. Refer to SPM 70-43-08.

R WARNING: THIS PAINT IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
R USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE THE FUMES. DO NOT GET THE PAINT ON YOUR SKIN
R OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES AND
R CLOTHING TO PROTECT YOURSELF.

R (4) Apply one layer of gray polyurethane paint, MIL-C-85285, type 1. The paint must have
R a dry film thickness of 0.0015-0.0020 in. (0.038-0.051 mm).

R NOTE: Color # 26306 matches the OEM color scheme.

R P. Assemble the repaired core cowl to the support assembly. Refer to 78-32-02 Assembly.

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Item Number Material

1. ½” (12.7mm) diameter. x 3” (76.2mm) long 6061 – T6 Aluminum
2. 3/16” (4.8mm) diameter x 7” (177.8mm) long 6061 – T6 Aluminum
3. ½” (12.7mm) diameter x 3 1/2 “ (88.9mm) long Wood

R
Delamination Inspection Tool
Figure 613

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FAN REVERSER FIXED STRUCTURE - REPAIR

R 1. Fan Thrust Reverser Fixed Structure Re-Finishing.

R A. This procedure provides instructions to re-apply the exterior protective finishes and
R recommended markings to the Fixed Structure and Fixed Structure sub-assemblies.

R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools.

R Description Manufacturer

R Orbital sander Local purchase

R Fine dust vacuum Local purchase

R (3) Locally Manufactured Tools. None required.

R (4) Equipment.

R Description Manufacturer

R HVLP Spray equipment Devilbiss

R JGHV-531-33FX

R Paint Shaker Local purchase

R Zahn viscosity cup #2 Local purchase

R Paint Booth Local purchase

R B. Consumable Materials:

R Code No. Description Use

R C02-027 Lubricant, Solid Film Apply to concave surfaces

R of all aft core cowl wear strips

R C03-006 Chemical Conversion Coating Touch up bare Aluminum

R (Alternates: C03-008, C03-092)

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R B. Consumable Materials (Continued):

R Code No. Description Use

R C03-009 Orange Epoxy Coating Caution Stencil

R (Alternate: Orange Polyurethane
R per MIL-PRF-85285, Color 12197)

R C03-010 Flat Black Epoxy Coating Stenciling

R (Alternate: C03-076)

R C03-063 Urethane Compatible Prime before Top Coat

R Corrosion Resistant Primer (Alternate: C03-017)
R Per BMS 10-79, Type II or III,
R Class A, Grade A

R C03-077 Epoxy Primer Prime Fixed Structure

R C03-104 Polyurethane Top Coat Topcoat hinge & latch beams

R C04-003 Acetone Solvent wipe areas to be coated

R or taped (Alternate: C04-035)

R C04-035 Isopropyl Alcohol Solvent wipe areas to be coated

R or taped (Alternate: C04-003)

R C10-009 Paper, Greaseproof Mask off areas that are not to

R (MIL-B-121 Type II, Grade A, receive coating
R Class 2 (Kraft))

R C10-102 Masking Tape Mask off areas that are not to

R receive coating

R C10-105 Abrasive Paper, 120 grit Lightly abrade surfaces to be

R re-finished

R C10-141 Abrasive Paper, 180 grit Lightly abrade surfaces to be

R re-finished

R C10-182 Cloth (lint-free) Solvent wipe areas to be coated

R or taped

R Local Purchase Polyurethane Top Coat per Topcoat C-Duct flow surfaces
R MIL-PRF-85285, Type1
R Color #26306

R C. Expendable Parts. None required.

R D. SPD Identification. None required.

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R E. Referenced Procedures.

R 78-32-00 CLEANING

R SPM 70-21-04

R SPM 70-21-23

R SPM 70-43-08

R 3. Dimensional Information. None required.

R 4. Setup Information. None required.

R 5. Procedure.

R A. MRAS recommends that existing primers and top coats be removed without damaging the
R underlying anodized finishes. Recommended stripping processes are Plastic Bead blasting,
R Baking Soda blasting, Dry Ice blasting, or an equivalent blasting method as these types of
R blasting methods will remove primers and top coats without harming anodized surfaces. Refer
R to SPM 70-21-04.

R NOTE: MRAS recommends that the blasting be performed prior to Inspection, Rescreening,
R Repairs and Re-assembly.

R B. Lightly abrade all surfaces to be re-finished using #120 - #180 grit paper. Use an orbital sander
R when possible. Vacuum all dust from structure.

R C. Solvent wipe areas to be coated using Isopropyl Alcohol (C04-035) or Acetone (C04-003) using
R the two-cloth method. Refer to SPM 70-21-23 and 78-32-00 CLEANING.

R D. Mask off areas that are not to receive coating using masking tape (C10-102) and Kraft paper
R (C10-009) as necessary.

R E. Apply Chemical Conversion Coating (Alodine; C03-006, C03-008 or C03-092) to any bare
R Aluminum areas. Refer to SPM 70-43-08.

R F. PRIMED, NON-TOPCOATED AREAS:

R Mix Epoxy Resin Primer (C03-077) according to manufacturer’s instructions and apply to areas
R indicated in Tables 601, 602, 603, 604 and 605. Apply one box coat of primer to a dry film
R thickness of 0.0005 inch - 0.0010 inch (0,0127 mm – 0,0254 mm). Allow to cure according to
R manufacturer’s recommendations.

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R G. PRIMED AND TOPCOATED AREAS:

R Mix Urethane Compatible Corrosion Resistant Primer (C03-063) BMS 10-79 Type II or III,
R Class A, Grade A or Epoxy Resin Primer MIL-PRF-23377 (C03-017) according to
R manufacturer’s instructions. Apply to the areas indicated in Tables 601, 602, 603, 604 and 605.
R Apply one box coat of primer to a dry film thickness of 0.0005 inch - 0.0018 inch (0,0127 mm –
R 0,0457 mm). Allow to cure according to manufacturer’s recommendations.

R NOTE: It is best practice to use a primer and top coat from the same manufacturer.

R H. EXTERIOR TOPCOAT:
R Apply Exterior Surface Topcoat(s) per Airline Customer direction.

R NOTE: It is best practice to use a primer and top coat from the same manufacturer.

R I. EXTERIOR MARKINGS:
R After Top Coat is applied, apply Markings/Stencils per figures 601 and 602. All lettering
R (except CAUTION) is to be Flat Black Epoxy Coating (C03-010 or C03-076). “CAUTION” is to
R be Gloss Orange Color #12197 (C03-009). Characters are to be Capitalized Box Style lettering
R (No Serifs).

R NOTE 1: Airframer or FAA-PMA Approved Decals may be used instead of painted Markings on
R Non-Acoustic surfaces.

R NOTE 2: Aircraft Maintenance Manual (AMM) Chapter 11 data may differ with this Repair
R information. The Airline Customer should be consulted when a conflict occurs.

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R Table 601. Core Cowl Assembly Re-Finishing

R A B C D F
R
R Chemical Epoxy Epoxy Urethane Polyurethane
R Conversion Resin Resin Compatible Top Coat MIL-
Fixed
R Coating Primer Primer Corrosion PRF-85285 Re-
Structure Part Original
R Alodine (Formerly MIL-PRF- Resistant Color #26306 Finishing
Sub- Number(s) Plating
R (C03-006) C03-005) 23377 Primer, BMS Application
Assembly
R (C03-008) (C03-077) (C03-017) 10-79 Type II
R (C03-092) or III, Class A,
R Grade A
R (C03-063)
R Core Cowl
491B1340000
R Assembly
R Touch up
R Chem. bare Alum.
R Outer Skin Film using A.
R (Screen- 491B1342043 (MIL-C- X Optional Optional X Optional to
R less) 5541, Prime using
R CL. 1A) C or D plus
R Topcoat F.
R Touch up
R bare Alum.
R using A.
EA9205
R 491B1342042, Refinish
R
Inner Skins
491B1342046
Bond X during
Primer
R Firecoat
R (MA-25)
R application
R Touch up
R bare Alum.
R using A plus
R Primer B on
Aft EA9205
R Non-
R
Closeout 491B1342002 Bond X X X Firecoated
Ring Primer
R surfaces.
R Topcoat F
R on Flowpath
R surface.
R FEP –
Touch up
R Fluoro-
bare Alum.
R carbon
using A.
R Engine Resin
R Ring
491B1340023
Impreg- X Optional Optional Optional Optional to
Prime using
R nated
C or D plus
R Hard
Topcoat F.
R Anodize
R Chem.
Touch up
R Strap, Film
bare Alum.
R Engine 491B1340040 (MIL-C- X X using A plus
R Ring 5541,
primer B.
R CL. 1A)
R Chem.
491B1340012, Touch up
R Film
491B1340013, bare Alum.
R Zee Ribs
491B1340014,
(MIL-C- X X using A plus
R 5541,
491B1340015 primer B.
R CL. 1A)

R --- Continued ---

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Table 601. Core Cowl Assembly Re-Finishing (Continued)

A B C D F

Chemical Epoxy Epoxy Urethane Polyurethane

Conversion Resin Resin Compatible Top Coat MIL-
Fixed
Coating Primer Primer Corrosion PRF-85285 Re-
Structure Part Original
Alodine (Formerly MIL-PRF- Resistant Color #26306 Finishing
Sub- Number(s) Plating
(C03-006) C03-005) 23377 Primer, BMS Application
Assembly
(C03-008) (C03-077) (C03-017) 10-79 Type II
(C03-092) or III, Class A,
Grade A
(C03-063)
Core Cowl
491B1340000
Assy
Chromic
Acid
Touch up
Deflection Anodize
bare Alum.
Limiter 491B1313028 (MIL-A- X X using A plus
R Fittings 8625,
primer B.
TY.1,
CL.1)

Chem.
Touch up
Deflection Film
491B1340020, bare Alum.
Limiter
491B1340021
(MIL-C- X X using A plus
Bracketry 5541,
primer B.
CL. 1A)

Chem.
Touch up
Precooler 491B1340016, Film
bare Alum.
Bridge 491B134020, (MIL-C- X X using A plus
Bracketry 491B1340030 5541,
primer B.
CL. 1A)

Apply
N/A Primer C or
Precooler
Inlet
491B1341000 (Non- X X X D plus
Metallic) Topcoat F
on flowpath.

Touch up
Chem. bare Alum.
Precooler Film using A.
491B1341004,
Inlet
491B1341008
(MIL-C- X X X X Prime using
Fairings 5541, C or D plus
CL. 1A) Topcoat F
on flowpath.
Chromic Touch up
Acid bare Alum.
Anodize using A.
IDG Door 491B1345000 (MIL-A- X X X X Prime using
8625, C or D plus
TY.1, Topcoat F
CL.1) on flowpath.

--- Continued ---

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MANUAL

683L SERIES

Table 601. Core Cowl Assembly Re-Finishing (Continued)

A B C D F

Chemical Epoxy Epoxy Urethane Polyurethane

Conversion Resin Resin Compatible Top Coat MIL-
Fixed
Coating Primer Primer Corrosion PRF-85285 Re-
Structure Part Original
Alodine (Formerly MIL-PRF- Resistant Color #26306 Finishing
Sub- Number(s) Plating
(C03-006) C03-005) 23377 Primer, BMS Application
Assembly
(C03-008) (C03-077) (C03-017) 10-79 Type II
(C03-092) or III, Class A,
Grade A
(C03-063)
Core Cowl
491B1340000
Assy
Chromic
Acid
Touch up
Anodize
IDG Door 491B1345005, bare Alum.
Hinges 491B1345009
(MIL-A- X X using A plus
8625,
primer B.
TY.1,
CL.1)
Chem.
Touch up
Film
PDO bare Alum.
Bracketry
491B1313051 (MIL-C- X X using A plus
5541,
primer B.
CL. 1A)
Chromic Touch up
Acid bare Alum.
Seal Anodize using A.
Retainer 491B1313018 (MIL-A- X X X X Prime using
Fitting 8625, C or D plus
TY.1, Topcoat F
CL.1) on flowpath.
Passiva-
No primer or
Precooler tion
491B1343002 Topcoat
R Duct (AMS270
required.
0E)
Touch up
bare Alum.
using A.
Prime using
C or D plus
Topcoat F
on Convex
surface of
Chem. Lower most
Film Convex Convex wear strip.
Aft (MIL-C- Surface Surface Convex Convex Touch up
Corecowl 5541, Only Only on Surface Only Surface Only bare Alum.
Wear
491B1313100
CL. 1A) X except lower on lower most on lower most using A plus
Strips on lower most most wear strip wear strip primer B on
Convex wear strip wear strip Convex
Surfaces Surface of
remaining
wear strips.
Apply C02-
027 to
Concave
surfaces of
all wear
strips.

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MANUAL

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Table 602. Upper Duct Sidewall (UDSW) Assembly Re-Finishing

A B C D E

Chemical Epoxy Epoxy Urethane Polyurethane

Conversion Resin Resin Compatible Top Coat
Fixed
Coating Primer Primer Corrosion MIL-PRF- Re-
Structure Part Original
Alodine (Formerly MIL-PRF- Resistant 85285 Finishing
Sub- Number(s) Plating
(C03-006) C03-005) 23377 Primer, BMS Color #16440 Application
Assembly
(C03-008) (C03-077) (C03-017) 10-79 Type II (C03-104)
(C03-092) or III, Class A,
Grade A
(C03-063)
Upper
Duct 491B1360000
R Sidewall
Assy
Chromic
Touch up
Acid
bare Alum.
Anodize
Hinge using A.
Beam
491B1361001 (MIL-A- X X X X Prime using
R 8625,
C or D plus
TY.1,
Topcoat E.
CL.1)
Touch up
Chem. bare Alum.
UDSW Film Faying using A.
Outer 491B1362002 (MIL-C- X Surfaces Optional Optional Optional to
R Skin 5541, only Prime using
CL. 1A) C or D plus
Topcoat F*.
Chem.
Touch up
UDSW Film
bare Alum.
Inner 491B1362002 (MIL-C- X X using A plus
R Skin 5541,
primer B.
CL. 1A)
Touch up
bare Alum.
using A plus
primer B on
Chem.
Interior inner
Leading Film
And surfaces.
Edge 491B1360021 (MIL-C- X Faying
Optional Optional
Optional to
Assy 5541,
Surfaces Prime using
CL. 1A)
C or D plus
Topcoat F*
on Flowpath
surface.
Chromic
Acid
Touch up
Anodize
PDO bare Alum.
Fitting
491B1360011 (MIL-A- X X using A plus
R 8625,
primer B.
TY.1,
CL.1)
Chem.
Hinge Touch up
R 491E1220021, Film
Cover bare Alum.
R
Panel &
491E1360004, (MIL-C- X X using A plus
R 491E1360006 5541,
Bracketry primer B.
R CL. 1A)
* NOTE: F = Polyurethane Top Coat MIL-PRF-85285 Color #26306 (Optional for UDSW Outer Skin & Leading Edge Assy
Flowpath Surface)
--- Continued ---

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 COMPONENT
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MANUAL

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Table 602. Upper Duct Sidewall (UDSW) Assembly Re-Finishing (Continued)

A B C D E

Chemical Epoxy Epoxy Urethane Polyurethane

Conversion Resin Resin Compatible Top Coat
Fixed
Coating Primer Primer Corrosion MIL-PRF- Re-
Structure Part Original
Alodine (Formerly MIL-PRF- Resistant 85285 Finishing
Sub- Number(s) Plating
(C03-006) C03-005) 23377 Primer, BMS Color #16440 Application
Assembly
(C03-008) (C03-077) (C03-017) 10-79 Type II (C03-104)
(C03-092) or III, Class A,
Grade A
(C03-063)
Upper
Duct 491B1360000
R Sidewall
Assy

Hinge Passiva-
R
Cover and tion Prime with
R
Bracketry (AMS270 X B.
R
0E)

Touch up
bare Alum.
using A.
Chem.
Aft Prime with
Film
Upper C or D Plus
R Beam
491B1360010 (MIL-C- X X X Customer
5541,
R Fairing required
CL. 1A)
Top Coat on
Flow Path
surface
Passiva- Primer B on
Faying
Fire Seal tion faying
491B1360029 Surfaces
R Bracketry (AMS270 surfaces
only
0E) only

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 COMPONENT
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MANUAL

683L SERIES

Table 603. Lower Duct Sidewall (LDSW) Assembly Re-Finishing

A B C D E

Chemical Epoxy Epoxy Urethane Polyurethane

Conversion Resin Resin Compatible Top Coat
Fixed
Coating Primer Primer Corrosion MIL-PRF- Re-
Structure Part Original
Alodine (Formerly MIL-PRF- Resistant 85285 Finishing
Sub- Number(s) Plating
(C03-006) C03-005) 23377 Primer, BMS Color #16440 Application
Assembly
(C03-008) (C03-077) (C03-017) 10-79 Type II (C03-104)
(C03-092) or III, Class A,
Grade A
(C03-063)
Lower
Duct
491B1350000
Sidewall
Assy
Chromic
Touch up
Acid
bare Alum.
Anodize
Latch using A.
Beam
491B1351001 (MIL-A- X X X X Prime using
8625,
C or D plus
TY.1,
Topcoat E.
CL.1)
Touch up
bare Alum.
Chromic
using A.
Acid
Aft Prime with
Anodize
Lower C or D Plus
R Beam
491B1350002 (MIL-A- X X X Customer
8625,
Fairing required
TY.1,
Top Coat on
CL.1)
Flow Path
surface
Touch up
Chem. bare Alum.
LDSW Film using A.
Outer 491B1352012 (MIL-C- X Optional Optional Optional to
Skin 5541, Prime using
CL. 1A) C or D plus
Topcoat F*.
Touch up
bare Alum.
Chem.
using A plus
LDSW Film
primer B.
Inner 491B1352012 (MIL-C- X X Firecoat
Skin 5541,
(MA-25)
CL. 1A)
application
required.
Chem.
Touch up
Film
Guide bare Alum.
Tube
491B1313112 (MIL-C- X X using A plus
5541,
primer B.
CL. 1A)
Passiva-
Latch
491B1200061, tion Prime using
Cover
491B1200062 (AMS270 X B.
Details
0E)
* NOTE: F = Polyurethane Top Coat MIL-PRF-85285 Color #26306 (Optional for LDSW Outer Skin)

--- Continued ---

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R Table 603. Lower Duct Sidewall (LDSW) Assembly Re-Finishing (Continued)

R A B C D E
R
R Chemical Epoxy Epoxy Urethane Polyurethane
R Conversion Resin Resin Compatible Top Coat
Fixed
R Coating Primer Primer Corrosion MIL-PRF- Re-
Structure Part Original
R Alodine (Formerly MIL-PRF- Resistant 85285 Finishing
Sub- Number(s) Plating
R (C03-006) C03-005) 23377 Primer, BMS Color #16440 Application
Assembly
R (C03-008) (C03-077) (C03-017) 10-79 Type II (C03-104)
R (C03-092) or III, Class A,
R Grade A
R (C03-063)
R Lower
R Duct
491B1350000
R Sidewall
R Assy
R Chromic
R Acid
Touch up
R Deflection Anodize
bare Alum.
R Limiter 491B1313026 (MIL-A- X X using A plus
R Fittings 8625,
primer B.
R TY.1,
R CL.1)
R Chromic
R Acid
Touch up
R Anodize
Attach bare Alum.
R
Angles
491B1350009 (MIL-A- X X using A plus
R 8625,
primer B.
R TY.1,
R CL.1)

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R Table 604. Torque Box Assembly Re-Finishing

R A B C D F
R
R Chemical Epoxy Epoxy Urethane Polyurethane
R Conversion Resin Resin Compatible Top Coat MIL-
Fixed
R Coating Primer Primer Corrosion PRF-85285 Re-
Structure Part Original
R Alodine (Formerly MIL-PRF- Resistant Color #26306 Finishing
Sub- Number(s) Plating
R (C03-006) C03-005) 23377 Primer, BMS Application
Assembly
R (C03-008) (C03-077) (C03-017) 10-79 Type II
R (C03-092) or III, Class A,
R Grade A
R (C03-063)
R Torque
491B1330000
R Box Assy
R Chromic
R Acid Touch up
R Anodize bare Alum.
Forward
R
Frame
491B1330001 (MIL-A- X X using A plus
R 8625, primer B.
R TY.1,
R CL.1)
R Chromic
R Acid
Touch up
R Anodize
bare Alum.
R Aft Frame 491B1330014 (MIL-A- X X using A plus
R 8625,
primer B.
R TY.1,
R CL.1)
R Chem.
Touch up
R Film
Cone bare Alum.
R
Webs
491B1330010 (MIL-C- X X using A plus
R 5541,
primer B.
R CL. 1A)
R Chem.
Touch up
R Film
bare Alum.
R Retainers 491B1330011 (MIL-C- X X using A plus
R 5541,
primer B.
R CL. 1A)
R Touch up
R bare Alum.
Chromic
R using A.
Acid
R Prime with
Anodize
R C or D Plus
R
Outer Ring 491B1330003 (MIL-A- X X X Customer
8625,
R required
TY.1,
R Top Coat on
CL.1)
R Flow Path
R surface
R Touch up
R bare Alum.
R using A plus
R primer B on
Chem.
R faying
Film Faying
R (Concave)
R
Flow Webs 491B1330020 (MIL-C- X Concave Optional Optional Optional
surfaces.
5541, Surfaces
R Optional to
CL. 1A)
R Prime using
R C or D plus
R Topcoat F
R on flowpath.

R --- Continued ---

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 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

Table 604. Torque Box Assembly Re-Finishing (Continued)

A B C D F

Chemical Epoxy Epoxy Urethane Polyurethane

Conversion Resin Resin Compatible Top Coat MIL-
Fixed
Coating Primer Primer Corrosion PRF-85285 Re-
Structure Part Original
Alodine (Formerly MIL-PRF- Resistant Color #26306 Finishing
Sub- Number(s) Plating
(C03-006) C03-005) 23377 Primer, BMS Application
Assembly
(C03-008) (C03-077) (C03-017) 10-79 Type II
(C03-092) or III, Class A,
Grade A
(C03-063)
Torque
491B1330000
Box Assy
Chromic
Acid
Touch up
Anodize
Actuator bare Alum.
Castings
491B1330005 (MIL-A- X X using A plus
8625,
primer B.
TY.1,
CL.1)
Chromic
Acid
Touch up
Gear Box Anodize
bare Alum.
Mount 491B1330026 (MIL-A- X X using A plus
Fittings 8625,
primer B.
TY.1,
CL.1)
Chem.
Actuation Touch up
Film
System bare Alum.
Support
491B1330027 (MIL-C- X X using A plus
5541,
Bracketry primer B.
CL. 1A)
Chem.
Touch up
Film
Bulkhead 491B1330015 bare Alum.
R Bracket (Refer to note)
(MIL-C- X X using A plus
5541,
primer B.
CL. 1A)
Chem.
Touch up
Film
Stiffener bare Alum.
Gussets
491B1330033 (MIL-C- X X using A plus
5541,
primer B.
CL. 1A)
Chem.
Touch up
Film
End 491B1330054, bare Alum.
Fittings 491B1330055
(MIL-C- X X using A plus
5541,
primer B.
CL. 1A)
Chromic
Touch up
Acid
bare Alum.
Forward Anodize
using A. No
Seal 491B1330053 (MIL-A- X primer or
Depressor 8625,
top coat
TY.1,
required.
CL.1)

R NOTE: Omit primer on surface common to electrical connector interface.

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 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

Table 605. Fixed Structure Details Re-Finishing

A B C D F

Chemical Epoxy Epoxy Urethane Polyurethane

Conversion Resin Resin Compatible Top Coat MIL-
Fixed
Coating Primer Primer Corrosion PRF-85285 Re-
Structure Part Original
Alodine (Formerly MIL-PRF- Resistant Color #26306 Finishing
Sub- Number(s) Plating
(C03-006) C03-005) 23377 Primer, BMS Application
Assembly
(C03-008) (C03-077) (C03-017) 10-79 Type II
(C03-092) or III, Class A,
Grade A
(C03-063)
Fixed
R Structure 491B1313000
Details
Chromic
Inner Acid
Touch up
Core Cowl Anodize
491B1313005, bare Alum.
/Sidewall
491B1313007,
(MIL-A- X X using A plus
R Attach 8625,
primer B.
Angles TY.1,
CL.1)
Touch up
bare Alum.
Outer Chem.
using A plus
Core Cowl Film Flowpath
491B1313003, Prime using
/Sidewall
491B1313006
(MIL-C- X X X Surface
C or D plus
Attach 5541, only
R Topcoat F
Angles CL. 1A)
on Flowpath
surface.
Touch up
bare Alum.
using A plus
Forward Chem. primer B on
Fillet Film Faying faying
491B1313040,
Fairings,
491B1313060
(MIL-C- X Surfaces Optional Optional Optional surfaces.
Sidewall to 5541, only Optional to
Beam CL. 1A) Prime using
C or D plus
Topcoat F
on flowpath.
Touch up
bare Alum.
Forward Chem.
using A plus
Lower Fillet Film Flowpath
Prime using
Fairing, 491B1313002 (MIL-C- X X X Surface
C or D plus
Core Cowl 5541, only
Topcoat F
to Sidewall CL. 1A)
on Flowpath
surface.
Touch up
bare Alum.
using A plus
Forward primer B on
Chem.
Upper Non- non-
Film
Fairing, Flowpath flowpath
Core Cowl
491B1360022 (MIL-C- X Surface
Optional Optional Optional
surface.
5541,
to Leading only Optional to
CL. 1A)
Edge Prime using
C or D plus
Topcoat F
on flowpath.

--- Continued ---

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 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

Table 605. Fixed Structure Details Re-Finishing (Continued)

A B C D F

Chemical Epoxy Epoxy Urethane Polyurethane

Conversion Resin Resin Compatible Top Coat MIL-
Fixed
Coating Primer Primer Corrosion PRF-85285 Re-
Structure Part Original
Alodine (Formerly MIL-PRF- Resistant Color #26306 Finishing
Sub- Number(s) Plating
(C03-006) C03-005) 23377 Primer, BMS Application
Assembly
(C03-008) (C03-077) (C03-017) 10-79 Type II
(C03-092) or III, Class A,
Grade A
(C03-063)
Fixed
Structure 491B1313000
R Details
Touch up
Chem.
Aft bare Alum.
Film Flowpath
Upper using A.
R Fillet
491B1313052 (MIL-C- X X X Surface
Prime using
5541, only
Fairing C or D plus
CL. 1A)
Topcoat F.
Chem.
Upper Touch up
491B1313102, Film
Torque Box bare Alum.
Closeout
491B1313104, (MIL-C- X X using A plus
491B1313151 5541,
Details primer B.
CL. 1A)
Chromic
Lower 491B1313033, Acid
Touch up
Closeout 491B1313135, Anodize
bare Alum.
Assembly 491B1313032, (MIL-A- X X using A plus
Tee & 491B1313136, 8625,
primer B.
Bracketry 491B1313148 TY.1,
CL.1)
Touch up
bare Alum.
using A plus
primer B on
Non-
Topcoated
Non- Panel.
Lower Chem. Flowpath Touch up
All
Closeout Film Surface All bare Alum.
Surfaces
Assembly 491B1313137 (MIL-C- X only
if top-
Surfaces using A.
Outer 5541, unless if top-coated Prime with
coated
Panel CL. 1A) top- C or D Plus
coated Customer
required
Top Coat on
Flow Path
surface for
Top Coated
Panels.
Chromic Touch up
1313M61, Acid bare Alum.
1313M63, Anodize Faying using A plus
Aluminum
Cascades
1313M65, (MIL-A- X Surfaces primer B on
933M85, 8625, only faying
9333M87 TY.1, surfaces
CL.1) only.

--- Continued ---

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 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

Table 605. Fixed Structure Details Re-Finishing (Continued)

A B C D F

Chemical Epoxy Epoxy Urethane Polyurethane

Conversion Resin Resin Compatible Top Coat MIL-
Fixed
Coating Primer Primer Corrosion PRF-85285 Re-
Structure Part Original
Alodine (Formerly MIL-PRF- Resistant Color #26306 Finishing
Sub- Number(s) Plating
(C03-006) C03-005) 23377 Primer, BMS Application
Assembly
(C03-008) (C03-077) (C03-017) 10-79 Type II
(C03-092) or III, Class A,
Grade A
(C03-063)
Fixed
R Structure 491B1313000
Details
N/A No exterior
Composite
1378M58 (Non- finish
Cascades
Metallic) required
Chem.
Aft Touch up
Film
Cascade bare Alum.
Support
491B1320001 (MIL-C- X X using A plus
5541,
Ring primer B.
CL. 1A)
Chromic
Aft Acid
Touch up
Cascade Anodize
491B1320004, bare Alum.
Support
491B1320002
(MIL-A- X X using A plus
Ring 8625,
primer B.
Brackets TY.1,
CL.1)
Chromic
Acid
Touch up
Anodize
Link bare Alum.
Fittings
491B1215005 (MIL-A- X X using A plus
8625,
primer B.
TY.1,
CL.1)
X Prime using
Lower Passiva-
B. Omit
Fire tion (Omit from
491B1330052 primer from
Barrier (AMS270 seal Seal contact
Details 0E) contact surface
surface)

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 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

NOTE: Left-Hand Fixed Structure Assembly is shown looking inboard.

R MR50317-00-A
R Fixed Structure Assembly Marking Locations
R Figure 601 (Sheet 1 of 6)

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R STENCIL USING FLAT BLACK (C03-010 OR C03-076) AT ALL LOCATIONS (EXCEPT “CAUTION”) AFTER
R TOPCOAT. THE WORD “CAUTION” IS TO BE ORANGE (C03-009).

R MR50317-00-A
R Fixed Structure Assembly Marking Locations
R Figure 601 (Sheet 2 of 6)

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MANUAL

683L SERIES

R MR50317-00-A
R Fixed Structure Assembly Marking Locations
R Figure 601 (Sheet 3 of 6)

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MANUAL

683L SERIES

R MR50317-00-A
R Fixed Structure Assembly Marking Locations
R Figure 601 (Sheet 4 of 6)

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MANUAL

683L SERIES

R STENCIL USING FLAT BLACK (C03-010 OR C03-076) 0.25 IN. (6.35 MM) HIGH LETTERS - TYPICAL BOTH
R FAN REVERSER HALVES.

R MR50317-00-A
R Fixed Structure Assembly Marking Locations
R Figure 601 (Sheet 5 of 6)

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MANUAL

683L SERIES

R STENCIL USING FLAT BLACK (C03-010 OR C03-076) AT ALL LOCATIONS (EXCEPT “CAUTION”) AFTER
R TOPCOAT. THE WORD “CAUTION” IS TO BE ORANGE (C03-009).

NOTE: Lower end of LH torque box shelf is shown (looking aft); RH torque box is opposite.

R MR50317-00-A
R Fixed Structure Assembly Marking Locations
R Figure 601 (Sheet 6 of 6)

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MANUAL

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R MR50317-00-A
R Fixed Structure Assembly Marking Locations
R Figure 602 (Sheet 1 of 5)

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MANUAL

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R MR50317-00-A
R Fixed Structure Assembly Marking Locations
R Figure 602 (Sheet 2 of 5)

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MANUAL

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R STENCIL USING FLAT BLACK (C03-010 OR C03-076) AT ALL LOCATIONS (EXCEPT “CAUTION”) AFTER
R TOP COAT. THE WORD “CAUTION” IS TO BE ORANGE (C03-009).

NOTE: Stencil is “CAUTION OPEN 7 ORANGE HANDLES BEFORE OPENING FAN REVERSER HALVES.”

R MR50317-00-A
R Fixed Structure Assembly Marking Locations
R Figure 602 (Sheet 3 of 5)

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MANUAL

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R MR50317-00-A
R Fixed Structure Assembly Marking Locations
R Figure 602 (Sheet 4 of 5)

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MANUAL

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R MR50317-00-A
R Fixed Structure Assembly Marking Locations
R Figure 602 (Sheet 5 of 5)

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 FAN REVERSER
CF6-80E1 CMM

THIS PAGE INTENTIONALLY BLANK

 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

FAN REVERSER SUPPORT ASSEMBLY - REPAIR

1. Fan Thrust Reverser Fixed Structure Re-Sealing.

A. This procedure provides instructions to re-apply the Aerodynamic and Fireseal Sealants to the
fixed structure.

NOTE: Old sealant can deteriorate and crack allowing air and moisture to enter structural
joints causing damage and corrosion to components.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools.

Description Manufacturer

R Mixer, Model 285A SEMCO / PPG Aerospace

R Dispensing Gun, Model 250A SEMCO / PPG Aerospace

R Cartridges and Nozzles SEMCO / PPG Aerospace

R Spatulas, Smoothing SEMCO / PPG Aerospace

Scrapers, Non-Metallic Local Purchase

SR Cutters 3M

(3) Locally Manufactured Tools. None required.

(4) Equipment. None Required

B. Consumable Materials:

Code No. Description Use

C01-073 PR 1750 Sealant Aero Sealant

P/S 870 Aero Sealant

(MIL-PRF-81733, TY.2-2)

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B. Consumable Materials (Continued):

Code No. Description Use

C01-007 RTV 106

R (STMG-M530-CL-A) Fire Seal Sealant

C01-153 RTV 730 Seal Blocks

C01-011 EA934NA AFT PERF. Skin Gap (AFT)

R PR1435G Sealant

R MIL-S-83430

C04-003 Acetone Cleaning

C04-035 Alcohol, Isopropyl Cleaning

C. Expendable Parts. None required.

D. SPD Identification. None required.

E. Referenced Procedures.

78-32-00 CLEANING

SPM 70-21-23

3. Dimensional Information. Refer to Figures.

4. Setup Information. None required.

5. Procedure.

A. Remove old sealant from fixed structure using non-metallic tools that will not damage the
underlying structure.

B. Touch-up any bare aluminum with Chem-Film C03-006, C03-008, or C03-092.

C. Solvent wipe areas to be coated using Isopropyl Alcohol (C04-035) or Acetone (C04-003) using
the two-cloth method. Refer to SPM 70-21-23 and 78-32-00, CLEANING.

D. Mask off areas as necessary that are not to receive sealant using masking tape and Kraft paper
as necessary.

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E. Aerodynamic Sealing using P/S 870:

Mix P/S 870 per manufacturer’s recommendations. Using a SEMCO type Gun, Cartridge
R and Nozzle apply sealant to all joints in Figures 603, 604, 605, 606, 607, 609, 610, and 612.
Smooth Sealant as necessary with a suitable spatula. Remove any masking while Sealant is
still wet.

F. Aerodynamic Sealing using PR 1750:

Mix PR 1750 per manufacturer’s recommendations. Using a Semco type Gun, Cartridge and
R Nozzle apply sealant to all joints in Figures 608, 610, 611, 612, 614, and 615. Smooth Sealant
as necessary with a suitable spatula. Remove any masking while Sealant is still wet.

G. Sealing with RTV 106:

RTV 106 is a one‐component Sealant and does not require mixing.
R Apply sealant to all Fire Seal type joints in Figures 613 and 616. Smooth Sealant as
necessary with a suitable spatula. Remove any masking while Sealant is still wet.

NOTE: Sealant will cure faster at higher humidity.

H. Sealing with RTV 730:

RTV 730 is a one‐component Sealant and does not require mixing.
R Apply sealant to Seal Depressor and Seal Block joints in Figures 603, 604, and 607. Smooth
Sealant as necessary with a suitable spatula. Remove any masking while Sealant is still wet.

NOTE: Sealant will cure faster at higher humidity.

I. For Screenless Corecowls it is permissible to fill the gap at the aft edge of the aft outer
skin with C01‐011 (EA934NA). Mix and cure per manufacturer’s recommendation.

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R
R Sealing Non-Aero Surfaces
R Figure 601 (Sheet 1 of 3)

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R
R Sealing Non-Aero Surfaces
R Figure 601 (Sheet 2 of 3)

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R
R Sealing Non-Aero Surfaces
R Figure 601 (Sheet 3 of 3)

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R
R Fixed Structure Sealing Locations
R Figure 602

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R
Torque Box Sealing
Figure 603

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R
Fairing and Closeout Blocks Sealing
Figure 604

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R
Core Cowl to Fairing Sealing
Figure 605

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R
Attach Angle to Core Cowl Sealing
Figure 606

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R
Torque Box to Fairing Sealing
Figure 607

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MANUAL

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R
Fairing to Attach Angle Sealing
Figure 608

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R
Precooler Inlet and Link Box Sealing
Figure 609

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R
Core Cowl to Lower Sidewall Sealing
Figure 610

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R
Forward Seal Depressor Sealing
Figure 611

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R
Upper Sidewall to Fairing Sealing
Figure 612

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R
R Torque Box Retainer Web Sealing
R Figure 613

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R
R Core Cowl to Sidewall Sealing
R Figure 614 (Sheet 1 of 2)

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R
R Core Cowl to Sidewall Sealing
R Figure 614 (Sheet 2 of 2)

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R
Closeout Fairing, Hinge Beam, End Fitting Sealing
Figure 615

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R
R Lower End Sealing (Racetrack Flange)
R Figure 616

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FAN REVERSER SUPPORT ASSEMBLY - ASSEMBLY

R 1. General.

R This procedure gives instructions for the assembly of the support assembly after the repair or
R replacement of damaged areas is completed.

R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools. None required.

R (3) Locally Manufactured Tools. None required.

R (4) Equipment. None required.

R B. Consumable Materials.

R Code No. Description Use

R C01-011 Adhesive, Paste, EA 934NA Bond fairing block

R C01-015 Ablative Silicone Compound Firecoat insulation

R MA-25S

R C01-073 Compound, Sealing, Seal the repair area

R PR 1750

R C01-126 Fabric, Netting, Dacron Bondline control

R Polyester

R C01-153 RTV, Fluorosilicone Sealant Bond sidewall

R FRV1106

R C01-172 Silicone Rubber Sealant, Bond filler block

R 3145 RTV, MIL-A-46146

R C03-005 Epoxy Resin Primer Finch Rivet replacement

R 463-12-8 (Spray Type)

R C03-063 Epoxy Primer (Green) Shim installation

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R B. Consumable Materials (continued).

R Code No. Description Use

R C04-001 Solvent, Methyl-Ethyl-Ketone Clean the bonding area

R (MEK)

R C04-003 Solvent, Acetone (ASTM D329) Clean the bonding area

R C04-035 Alcohol, Isopropyl Clean the bonding area

R C10-140 Polyethylene Gloves Adhesive application

R --- Abrasive Paper, 180 Grit Surface preparation

R C. Referenced Procedures.

R 78-32-00, Assembly

R 78-32-02, Repair 022

R 3. Procedure.

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU USE
R THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU DO NOT
R BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR SKIN OR IN YOUR
R EYES OR MOUTH. MAKE SURE YOU USE GLOVES AND CLOTHING TO PROTECT
R YOURSELF.

R A. Assemble the Lower Sidewall Assembly. Refer to figure 701.

R (1) Put the lower sidewall bondment (40-10 or -15, 78-32-21) on the latch beam sidewall
R assembly (40-25 or -30, 78-32-21). Use Cleco clamps to attach the lower sidewall
R bondment to the latch beam sidewall assembly.

R (a) If a new shim is to be installed, put it in position before the drill procedure. Drill
R through the shim and lower sidewall bondment at the same time.

R (2) Back drill the rivet holes from the flow side into the lower sidewall bondment.

R (3) Remove the lower sidewall bondment from the latch beam sidewall assembly. Clean
R and deburr all holes.

R (4) Apply a layer of epoxy primer (C03-063) to the shim (40-20, 78-32-21).

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R (5) Apply a layer of epoxy resin primer (C03-005) to the rivets (40-90, 78-32-21).

R (6) Attach the shim (40-20, 78-32-21) and lower sidewall bondment (40-10 or -15, 78-32-
R 21) to the latch beam sidewall assembly (40-25 or -30, 78-32-21) with the rivets (40-90,
R 78-32-21.

R (7) Put the angle (40-45 or -50, 78-32-21) in position on the lower sidewall bondment.
R Back drill a hole at the forward and aft ends of the angle (40-45 or -50, 78-32-21)
R through the flow side of the lower sidewall bondment.

R (8) At the hole locations drilled, use Cleco clamps to attach the angle (40-45 or -50, 78-32-
R 21) to the lower sidewall bondment. Drill the remaining attachment holes into the lower
R sidewall bondment.

R (9) Remove the angle (40-45 or -50, 78-32-21) from the lower sidewall bondment. Clean
R and deburr all holes.

R (10) Put the angle (40-35 or -40, 78-32-21) in position on the lower sidewall bondment.
R Back drill a hole at the forward and aft ends of the angle (40-35 or -40, 78-32-21)
R through the flow side of the lower sidewall bondment.

R (a) If a new shim is to be installed, put it in position before the drill procedure. Drill
R through the shim and lower sidewall bondment at the same time.

R (11) At the hole locations drilled, use Cleco clamps to attach the angle (40-35 or -40, 78-32-
R 21) to the lower sidewall bondment (40-10 or -15, 78-32-21). Drill the remaining
R attachment holes into the lower sidewall bondment.

R (12) Remove the angle (40-35 or -40, 78-32-21) from the lower sidewall bondment. Clean
R and deburr all holes.

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU USE
R THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU DO NOT
R BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR SKIN OR IN YOUR
R EYES OR MOUTH. MAKE SURE YOU USE GLOVES AND CLOTHING TO PROTECT
R YOURSELF.

R (13) For the left reverser half, apply a layer of epoxy primer (C03-063) to the shims (40-20,
R 78-32-21).

R (14) For the left reverser half, apply a layer of epoxy resin primer (C03-005) to the rivets (40-
R 110 and -120, 78-32-21), pins (40-65 and -70, 78-32-21) and fasteners (80 and
R -85, 78-32-21).

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R (15) Install the shims (40-20, 78-32-21), angle (40-45 or -50, 78-32-21) and lower sidewall
R bondment (40-10 or -15, 78-32-21) to the latch beam sidewall assembly (40-25 or -30,
R 78-32-21) with rivets (40-110 and -120, 78-32-21), pins (40-65 and -70, 78-32-21), nuts
R (40-75, 78-32-21) and fasteners (40-80 and -85, 78-32-21).

R (16) Apply a layer of epoxy resin primer (C03-005) to the rivets (40-95 and -105, 78-32-21)
R and pins (40-55 and -65, 78-32-21).

R (17) Install the shims (40-20, 78-32-21), angle (40-35 or -40, 78-32-21) and lower sidewall
R bondment (40-10 or -15, 78-32-21) to the latch beam sidewall assembly (40-25 or -30,
R 78-32-21) with the rivets (40-95 and -105, 78-32-21) pins (40-55 and -65, 78-32-21)
R and nuts (40-60 and -75, 78-32-21).

ASSEMBLY
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R MR60170-00-A
R Lower Sidewall Assembly - Assembly
R Figure 701 (Sheet 1)

ASSEMBLY
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R MR60171-00-A
R Lower Sidewall Assembly - Assembly
R Figure 701 (Sheet 2)

ASSEMBLY
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MANUAL

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R MR60172-00-A
R Lower Sidewall Assembly - Assembly
R Figure 701 (Sheet 3)

ASSEMBLY
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R MR60173-00-A
R Lower Sidewall Assembly - Assembly
R Figure 701 (Sheet 4)

ASSEMBLY
PAGE 708
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MANUAL

683L SERIES

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU USE
R THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU DO NOT
R BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR SKIN OR IN YOUR
R EYES OR MOUTH. MAKE SURE YOU USE GLOVES AND CLOTHING TO PROTECT
R YOURSELF.

R B. Install the Lower Sidewall Assembly. Refer to figure 702.

R (1) Apply a layer of sealant (C01-172) to the filler block (10-355, 78-32-21 or 78-32-22).

R (2) Install the filler block (10-355, 78-32-21 or 78-32-22) to fill the gap between the lower
R sidewall assembly (10-5, 78-32-21 or 78-32-22) and the core cowl assembly (1-810 or
R -815, 78-32-21). Trim the filler block as necessary to fill the gap.

R (3) Cure the sealant (C01-172) at 77 degrees F (25 degrees C) for 48 hours.

R (4) Apply a layer of epoxy primer (C03-063) to the shims (10-340, 78-32-21 or 78-32-22).

R (5) Apply a layer of epoxy resin primer (C03-005) to the rivets (10-335, 78-32-21 or 78-32-
R 22).

R (6) Install the zee rib end clip (10-330, 78-32-21 or 78-32-22), shim (10-340, 78-32-21 or
R 78-32-22) and angle (10-120 and -125, 78-32-21 or 78-32-22) on the core cowl
R assembly (1-810 or -815, 78-32-21) with the rivets (10-335, 78-32-21 or 78-32-22).

R (7) Put the angles (10-10, -120 and -125, 78-32-21 or 78-32-22) in position on the lower
R sidewall assembly. Back drill a hole at the forward and aft ends of the angles (10-10,
R -120 and -125, 78-32-21 or 78-32-22) through the flow side of the lower sidewall
R assembly.

R (a) If a new shim is to be installed, put it in position before the drill procedure. Drill
R through the shim and lower sidewall bondment at the same time.

R (8) At the hole locations drilled, use Cleco clamps to attach the angles (10-10, 120 and
R -125, 78-32-21 or 78-32-22) to the lower sidewall assembly. Drill the remaining
R attachment holes into the lower sidewall assembly.

R (9) Remove the angles (10-10, 120 and -125, 78-32-21 or 78-32-22) from the lower
R sidewall assembly. Clean and deburr all holes.

R (10) Apply a layer of epoxy primer (C03-063) to the shims (10-350, 78-32-21 or 78-32-22).

R (11) Apply a layer of epoxy resin primer (C03-005) to the pins (10-185, -195, -205, -215,
R -130, -140 and -150, -170, -290, and –300, 78-32-21 or 78-32-22).

ASSEMBLY
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R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU USE
R THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU DO NOT
R BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR SKIN OR IN YOUR
R EYES OR MOUTH. MAKE SURE YOU USE GLOVES AND CLOTHING TO PROTECT
R YOURSELF.

R (12) Install the shims (10-350, 78-32-21 or 78-32-22) and angles (10-15 and -120, 78-32-21
R or 78-32-22) to the lower sidewall assembly (10-5, 78-32-21 or 78-32-22), core cowl
R assembly (1-810 or -815, 78-32-21) and mid deflection limiter (10-180, 78-32-21 or 78-
R 32-22) with the pins (10-185, -195, -205, -215, -130, -140 and -150, -170, -290, and
R -300, 78-32-21 or 78-32-22)) and nuts (10-190, -200, -210, -220, -135, -145, -155, -175
R and -295, 78-32-21 or 78-32-22).

R (13) Apply a layer of epoxy primer (C03-063) to the shims (10-340, 78-32-21 or 78-32-22).

R (14) Apply a layer of epoxy resin primer (C03-005) to the rivets (10-110, 78-32-21 or 78-32-
R 22).

R (15) Install the shim (10-340, 78-32-21 or 78-32-22), zee rib end clip (10-105, 78-32-21 or
R 78-32-22) and angle (10-10, 78-32-21 or 78-32-22) to the core cowl assembly (1-810 or
R -815, 78-32-21) with the rivets (10-110, 78-32-21 or 78-32-22).

R (16) Apply a layer of epoxy resin primer (C03-005) to the pins (10-20, -30, -55 and -65, 78-
R 32-21 or 78-32-22).

R (17) Install the shim (10-350, 78-32-21 or 78-32-22) and angles (10-10 and -15, 78-32-21 or
R 78-32-22) to the lower sidewall assembly (10-5, 78-32-21 or 78-32-22), core cowl
R assembly (1-810 or -815, 78-32-21) and forward deflection limiter (10-50, 78-32-21 or
R 78-32-22) with the pins (10-20, -30 and -65, 78-32-21 or 78-32-22) and nuts 10-25,
R -35, -60 and -70, 78-32-21 or 78-32-22).

R (18) Apply a layer of epoxy resin primer (C03-005) to the pins (10-75, -85, -95, -20, -40 and
R -170, 78-32-21 or 78-32-22).

R (19) Install the angles (10-10 and-15, 78-32-21 or 78-32-22) and shim (10-350, 78-32-21 or
R 78-32-22) to the lower sidewall assembly (10-10, 78-32-22) and core cowl assembly (1-
R 810 or -815, 78-32-21) with the pins (10-75, -85, -95, -20, -30 and -170, 78-32-21 or 78-
R 32-22) and nuts (10-80, -90, -100, -25, -45 and -175, 78-32-21 or 78-32-22).

R (20) Apply a layer of epoxy resin primer (C03-005) to the pins (10-225, -235, -140, and/or
R -300, and -315, 78-32-21 or 10-225, -235, -140, -285, -290 and -300, 78-32-21 or 78-
R 32-22).

R (21) Apply a layer of epoxy resin primer (C03-005) to the rivets (10-250, -255 and -325, 78-
R 32-21 or 78-32-22).

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R (22) On the right reverser half, install the angles (10-120 and -125, 78-32-22) and shim (10-
R 350, 78-32-22) to the lower sidewall assembly (10-5, 78-32-22) and core cowl
R assembly (1-815, 78-32-22) with the rivets (10-250, -255 and -310, 78-32-22), and pins
R (10-225, -235, -140, -285, -290, and -300, 78-32-22).

R (23) On the left reverser half, install the angles (10-120 and -125, 78-32-21) and shim (10-
R 350, 78-32-21) to the lower sidewall assembly (10-10, 78-32-21) and core cowl
R assembly (1-810, 78-32-21) with the rivets (10-250, -255 and -325, 78-32-21), pins (10-
R 300, -225, -235, -140, and/or -300, -305, and -315, 78-32-21) and nuts (10-230,-240,
R -145, -310 and -320, 78-32-21).

R (24) Apply a layer of epoxy resin primer (C03-005) to the pins (10-140, 78-32-21 or 78-32-
R 22).

R (25) Apply a layer of epoxy resin primer (C03-005) to the rivets (10-270, -280 and -285, 78-
R 32-21 or 10-265 and -270, 78-32-22).

R (26) On the right reverser half, install the angle (10-120, 78-32-22), clip (10-260, 78-32-22),
R and strap (10-345, 78-32-22) to the core cowl assembly (1-815, 78-32-22) with the
R rivets (10-265 and -270, 78-32-22), pins (10-140, 78-32-22) and nuts (10-145, 78-32-
R 22).

R (27) On the left reverser half, install the seal (10-260, 78-32-21), backup seal strip (10-265,
R 78-32-21), angle (10-120, 78-32-21), strap (10-345, 78-32-21), and clip (10-215, 78-32-
R 21) to the core cowl assembly (1-810, 78-32-21) with the rivets (10-270, -280 and -285,
R 78-32-21), pins (10-140, 78-32-21) and nuts (10-145, 78-32-21).

ASSEMBLY
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MANUAL

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R MR60163-00-A
R Lower Sidewall Assembly - Installation
R Figure 702 (Sheet 1)

ASSEMBLY
PAGE 712
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MANUAL

683L SERIES

R MR61064-00-A
R Lower Sidewall Assembly - Installation
R Figure 702 (Sheet 2)

ASSEMBLY
PAGE 713
78-32-02 DEC 01/11
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MAINTENANCE
MANUAL

683L SERIES

R MR60165-00-A
R Lower Sidewall Assembly - Installation
R Figure 702 (Sheet 3)

ASSEMBLY
PAGE 714
78-32-02 DEC 01/11
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MAINTENANCE
MANUAL

683L SERIES

R MR60166-00-A
R Lower Sidewall Assembly - Installation
R Figure 702 (Sheet 4)

ASSEMBLY
PAGE 715
78-32-02 DEC 01/11
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MAINTENANCE
MANUAL

683L SERIES

R MR60167-00-A
R Lower Sidewall Assembly - Installation
R Figure 702 (Sheet 5)

ASSEMBLY
PAGE 716
78-32-02 DEC 01/11
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MAINTENANCE
MANUAL

683L SERIES

R MR60168-00-A
R Lower Sidewall Assembly - Installation
R Figure 702 (Sheet 6)

ASSEMBLY
PAGE 717
78-32-02 DEC 01/11
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MAINTENANCE
MANUAL

683L SERIES

R MR60169-00-A
R Lower Sidewall Assembly - Installation
R Figure 702 (Sheet 7)

ASSEMBLY
PAGE 718
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MANUAL

683L SERIES

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU USE
R THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU DO NOT
R BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR SKIN OR IN YOUR
R EYES OR MOUTH. MAKE SURE YOU USE GLOVES AND CLOTHING TO PROTECT
R YOURSELF.

R C. Assemble the Upper Sidewall assembly. Refer to figure 703.

R (1) Put the fireseal support zee (50-500, 78-32-21) in position on the upper sidewall
R bondment (50-10 or -15, 78-32-21). Back drill a hole at the forward and aft ends of the
R fireseal support zee (50-500, 78-32-21) through the flow side of the upper sidewall
R bondment.

R (a) If a new shim is to be installed, put it in position before the drill procedure. Drill
R through the shim and lower sidewall bondment at the same time.

R (2) At the hole locations drilled, use Cleco clamps to attach the fireseal support zee (50-
R 500, 78-32-21) to the upper sidewall bondment. Drill the remaining attachment holes
R into the upper sidewall bondment.

R (3) Remove the fireseal support zee (50-500, 78-32-21) from the upper sidewall bondment.
R Clean and deburr all holes.

R (4) Apply a layer of epoxy primer (C03-063) to the shim (50-515, 78-32-21).

R (5) Apply a layer of epoxy resin primer (C03-005) to the rivets (50-510, -530 and -535, 78-
R 32-21).

R (6) Apply a layer of sealant (C01-153) to the seal retainer (50-520 or -525, 78-32-21).

R (7) Install the shim (50-515, 78-32-21), fireseal support zee (50-500, 78-32-21) and seal
R retainer (50-520 or -525, 78-32-21) to the upper sidewall bondment (50-10 or -15, 78-
R 32-21) with the rivets (50-510, -530 and -535, 78-32-21).

R (8) Apply a layer of epoxy resin primer (C03-005) to the rivets (50-495, 78-32-21).

R (9) Apply a layer of sealant (C01-153) to the aft block closeout (50-485, 78-32-21).

R (10) Install the aft block closeout (50-485, 78-32-21) to the upper sidewall bondment (50-10
R or -15, 78-32-21) with the rivets (50-495, 78-32-21).

R (11) Put the upper sidewall bondment (50-10 or -15, 78-32-21) in position on the hinge
R beam assembly (50-147, or -148, 78-32-21). Use Cleco clamps to attach the upper
R sidewall bondment to the hinge beam assembly.

R (12) Back drill the attachment holes from the flow side into the upper sidewall bondment.

ASSEMBLY
PAGE 719
78-32-02 DEC 01/11
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MAINTENANCE
MANUAL

683L SERIES

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU USE
R THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU DO NOT
R BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR SKIN OR IN YOUR
R EYES OR MOUTH. MAKE SURE YOU USE GLOVES AND CLOTHING TO PROTECT
R YOURSELF.

R (13) Remove the upper sidewall bondment from the hinge beam assembly. Clean and
R deburr all holes.

R (14) Apply a layer of epoxy resin primer (C03-005) to the pins (50-30, -35, -40, -45, -50, -55,
R -60, -65, -70, -75, -80, -85, -90, -95, -100, -105, -110, -115, -120, -125, -130, and -135,
R 78-32-21).

R (15) Install the hinge beam assembly (50-147 or -148, 78-32-21) to the upper sidewall
R bondment (50-10 or -15, 78-32-21) with the pins (50-30, -35, -40, -45, -50, -55, -60, -65,
R -70, -75, -80, -85, -90, -95, -100, -105, -110, -115, -120, -125, -130, and -135, 78-32-21)
R and nuts (50-140 and -145, 78-32-21).

R (16) Apply a layer of epoxy primer (C03-063) to the shim (50-550, 78-32-21).

R (17) Apply a layer of epoxy resin primer (C03-005) to the rivets (50-680, -765, -657, -690,
R -685, -545 –659, -715, -680 and -685, 78-32-21).

R (18) Install the fireseal support detail (50-760, 78-32-21), leading edge cup (50-660, 78-32-
R 21), joint plate (50-540, 78-32-21), shim (50-550, 78-32-21), lower attaching angle (50-
R 670 or -675, 78-32-21) and attaching angle (50-695 or -705 and -700 or -710, 78-32-21)
R to the upper sidewall bondment (50-10 or -15, 78-32-21) with the rivets (50-680, -765,
R -657, -690, -685, -545 –659, -715, -680 and -685, 78-32-21).

R (19) Install the hinge cover beaver tail (50-400, 78-32-21) to the hinge beam assembly (50-
R 147 or -148, 78-32-21) with the screws (50-482, 78-32-21).

R (20) Install the panel assembly (50-310, 78-32-21) and hinge cover gussets (50-180, -210,
R -230, -245, and -265, 78-32-21) with screws (50-320, 78-32-21).

ASSEMBLY
PAGE 720
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60155-00-A
R Upper Sidewall Assembly - Assembly
R Figure 703 (Sheet 1)

ASSEMBLY
PAGE 721
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60156-00-A
R Upper Sidewall Assembly - Assembly
R Figure 703 (Sheet 2)

ASSEMBLY
PAGE 722
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60157-00-A
R Upper Sidewall Assembly - Assembly
R Figure 703 (Sheet 3)

ASSEMBLY
PAGE 723
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60158-00-A
R Upper Sidewall Assembly - Assembly
R Figure 703 (Sheet 4)

ASSEMBLY
PAGE 724
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60159-00-A
R Upper Sidewall Assembly - Assembly
R Figure 703 (Sheet 5)

ASSEMBLY
PAGE 725
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60160-00-A
R Upper Sidewall Assembly - Assembly
R Figure 703 (Sheet 6)

ASSEMBLY
PAGE 726
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60161-00-A
R Upper Sidewall Assembly - Assembly
R Figure 703 (Sheet 7)

ASSEMBLY
PAGE 727
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60162-00-A
R Upper Sidewall Assembly - Assembly
R Figure 703 (Sheet 8)

ASSEMBLY
PAGE 728
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU USE
R THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU DO NOT
R BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR SKIN OR IN YOUR
R EYES OR MOUTH. MAKE SURE YOU USE GLOVES AND CLOTHING TO PROTECT
R YOURSELF.

R D. Install the Upper Sidewall Assembly. Refer to figure 704.

R (1) Apply a layer of adhesive (C01-172) to the filler block (1-800, 78-32-21) and shim (1-
R 805, 78-32-21).

R (2) Install the shim (1-805, 78-32-21) and the filler block (1-800, 78-32-21) to fill the gap
R between the upper sidewall assembly (1-785 or -790, 78-32-21) and core cowl
R assembly (1-810 or -815, 78-32-21). Trim the filler block as necessary to fill the gap.

R (3) Cure the adhesive at 77 degrees F (25 degrees C) for 48 hours.

R (4) Put the angles (1-115 or -120, -245 or -250, -675 or -680, and -775 or -780, 78-32-21)
R in position on the upper sidewall assembly. Back drill a hole at the forward and aft ends
R of the angles (1-115 or -120, -245 or -250, -675 or -680, and -775 or -780, 78-32-21)
R through the flow side of the upper sidewall assembly.

R (a) If a new shim is to be installed, put it in position before the drill procedure. Drill
R through the shim and lower sidewall bondment at the same time.

R (5) At the hole locations drilled, use Cleco clamps to attach the (1-115 or -120, -245 or
R -250, -675 or -680, and -775 or -780, 78-32-21) to the upper sidewall assembly.
R Drill the remaining attachment holes into the upper sidewall assembly.

R (6) Remove the angles (1-115 or -120, -245 or -250, -675 or -680, and -775 or -780, 78-32-
R 21) from the upper sidewall assembly. Clean and deburr all holes.

R (7) Apply a layer of epoxy resin primer (C03-005) to the pins (1-215, -205 and -195, 78-32-
R 21) and nuts (1-220, -210 and -200, 78-32-21).

R (8) Install the angle (1-245 or -250, 78-32-21) to the upper sidewall assembly (1-785 or
R -790, 78-32-21) with the pins (1-215, -205 and -195, 78-32-21) and nuts (1-220, -210
R and -200, 78-32-21).

R (9) Apply a layer of epoxy resin primer (C03-005) to the pins (1-67, -63, and -55, 78-32-21).

R (10) On the right reverser half, install the angles (1-120 and -200, 78-32-21) to the upper
R sidewall assembly (1-790, 78-32-21) with the pins (1-67, -63, and -55, 78-32-21) and
R nuts (1-70, -65, and -60, 78-32-21).

R (11) On the left reverser half, install the angle (1-115, 78-32-21) to the upper sidewall
R assembly (1-785, 78-32-21) with the pins (1-67, -63, and -55, 78-32-21) and nuts (1-70,
R -65, and -60, 78-32-21).

ASSEMBLY
PAGE 729
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R (12) Apply a layer of epoxy resin primer (C03-005) to the pins (1-95, 78-32-21).

R (13) Install the angles ((1-115 or -120, -245 or –250, 78-32-21) to the core cowl assembly
R (1-810 or -815, 78-32-21) with the pins (1-95, 78-32-21) and nuts (1-100, 78-32-21).

R (14) Apply a layer of epoxy primer (C03-063) to the shim (1-375, 78-32-21).

R (15) Apply a layer of epoxy resin primer (C03-005) to the pins (1-215, -205, -225, -235, and
R -365, 78-32-21).

R (16) Install the angle (1-245 or -250, 78-32-21), shim (1-375, 78-32-21) and power opening
R device support assembly (1-380 or -383, 78-32-21) to the upper sidewall assembly
R (1-785 or 790, 78-32-21) with the pins (1-215, -205, -225, -235, and -365, 78-32-21)
R and nuts (1-220, -210, -230, -240, and -370, 78-32-21) .

R (17) Apply a layer of epoxy resin primer (C03-005) to the pins (1-335 and -355, 78-32-21)
R and threaded fastener (1-345, 78-32-21).

R (18) Install the power opening device support assembly (1-380 or -383, 78-32-21) and shim
R (1-375, 78-32-21) to the upper sidewall assembly (1-785 or -790, 78-32-21) with the
R pins (1-335 and -355, 78-32-21), nuts (1-340 and -360, 78-32-21) and threaded
R fastener (1-345, 78-32-21).

R (19) Apply a layer of epoxy resin primer (C03-005) to the pins (1-63, -67, and -75, 78-32-21)
R and threaded fastener (1-85, 78-32-21).

R (20) Install the power opening device support assembly (1-380 or -383, 78-32-21), angle (1-
R 115 or -120, 78-32-21) and shim (1-375, 78-32-21) to the upper sidewall assembly (1-
R 785 or -790, 78-32-21) with the pins (1-63, -67, and -75, 78-32-21), nuts (1-65, -70, and
R -80, 78-32-21), and threaded fastener (1-85, 78-32-21).

R (21) Apply a layer of epoxy resin primer (C03-005) to the pins (1-125, -95, -145 and -135,
R 78-32-21).

R (22) Install the upper sidewall angles (1-155 or -160 and –165 or 170, 78-32-21) and angles
R (1-115 or -120 and -245 or -250, 78-32-21) to the core cowl assembly (1-810 or -815,
R 78-32-21) with the pins (1-125, -95, -145 and -135, 78-32-21) and nuts (1-130, -100,
R -150 and -140, 78-32-21).

R (23) Apply a layer of epoxy primer (C03-063) to the shim (1-320, 78-32-21).

ASSEMBLY
PAGE 730
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R (24) Apply a layer of epoxy resin primer (C03-005) to the pins (1-310, -300, and -280, 78-32-
R 21).

R (25) Apply a layer of epoxy resin primer (C03-005) to the rivets (1-255 and -265, 78-32-21).

R (26) On the left reverser half, install the upper sidewall angles (1-155 or -160 and –165 or
R 170, 78-32-21), shim (1-320, 78-32-21) and power opening device supports (1-325 or
R –330 and –290 or –295, 78-32-21) to the power opening device support assembly
R (1-380 and -383, 78-32-21) with the rivets (1-255 and -265, 78-32-21), pins (1-310,
R -300 and -280, 78-32-21) and nuts (1-315, -305, -482, and -285, 78-32-21).

R (27) Apply a layer of epoxy primer (C03-063) to the shims (1-190, 78-32-21).

R (28) Apply a layer of epoxy resin primer (C03-005) to the pins (1-105 and -565, 78-32-21).

R (29) Apply a layer of epoxy resin primer (C03-005) to the rivets (1-175, 78-32-21).

R (30) Install the angle (1-115 or -120 and -245 or -250, and –775 or –780, 78-32-21), zee rib
R clips (1-180 or 185, 78-32-21) and shims (1-190, 78-32-21) to the core cowl assembly
R (1-810 or -815, 78-32-21) with the pins (1-105 and -565, 78-32-21), nuts (1-110 and
R -570, 78-32-21) and rivets (1-175, 78-32-21).

R (31) Apply a layer of epoxy resin primer (C03-005) to the pins (1-63, -215, and -285, 78-32-
R 21).

R (32) Install the angle (1-115 or -120 and -245 or -250, and –775 or –780, 78-32-21) and zee
R rib clips (1-180, 78-32-21) to the upper sidewall assembly (1-785 or -790, 78-32-21)
R with the pins (1-63, -215, and -285, 78-32-21)) and nuts (1-65, -220, and -690, 78-32-
R 21).

R (33) Apply a layer of epoxy resin primer (C03-005) to the pins (1-565, 78-32-21).

R (34) Apply a layer of epoxy resin primer (C03-005) to the rivets (1-585 and -615, 78-32-21).

R (35) Install the angles (1-675 or –680 and –775 or -780, 78-32-21), zee rib clips (1-590 or
R -595 and –620 or -625, 78-32-21) and shims (1-600, -630, 78-32-21) to the core cowl
R assembly (1-810 or -815, 78-32-21) with the pins (1-565, 78-32-21), nuts (1-570, 78-32-
R 21) and rivets (1-585 and -615, 78-32-21).

R (36) Apply a layer of epoxy resin primer (C03-005) to the pins (1-440, -450, -460, 470, -480,
R -685, -710 and -700, 78-32-21).

R (37) Install the angles (1-675 or –680 and –775 or -780, 78-32-21) and zee rib clips (1-590
R or -595 and –620 or -625, 78-32-21) to the upper sidewall assembly (1-785 or –790, 78-
R 32-21) with the pins (1-440, -450, -460, 470, -480, -685, -710 and -700, 78-32-21) and
R nuts (1-445, -455, -465, 475, -485, -690, -715 and -705, 78-32-21).

ASSEMBLY
PAGE 731
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R (38) Apply a layer of epoxy primer (C03-063) to the shims (1-760, 78-32-21).

R (39) Apply a layer of epoxy resin primer (C03-005) to the pins (1-565, -750, -645, -655, 635
R and -665, 78-32-21).

R (40) Install the angles (1-675 or –680 and –775 or -780, 78-32-21), shim (1-760, 78-32-21)
R and deflection limiter fitting (1-765 or -770, 78-32-21) to the core cowl assembly (1-810
R or -815, 78-32-21) with the pins (1-565, -750, -645, -655, 635 and -665, 78-32-21) and
R nuts (1-570, -755, -650, -660, -640 and -670, 78-32-21).

R (41) Apply a layer of epoxy resin primer (C03-005) to the pins (1-490, -500, -510, 520, -530,
R -720, -730, -740 and -540, 78-32-21).

R (42) Install the angles (1-675 or –680 and –775 or -780, 78-32-21) and deflection limiter
R fitting (1-765 or -770, 78-32-21) to the upper sidewall assembly (1-785 or -790, 78-32-
R 21) with the pins (1-490, -500, -510, 520, -530, -720, -730, -740 and -540, 78-32-21)
R and nuts (1-495, -505, -515, -525, -535, -725, -735, -745 and -545, 78-32-21).

R (43) Apply a layer of epoxy resin primer (C03-005) to the rivets (1-550 and –553, 78-32-21).

R (44) Install the aft wear strips (1-555 and -560, 78-32-21) on the upper sidewall assembly
R (1-785 or -790, 78-32-21) with the rivets (1-550 and -553, 78-32-21).

ASSEMBLY
PAGE 732
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60136-00-A
R Upper Sidewall Assembly - Installation
R Figure 704 (Sheet 1)

ASSEMBLY
PAGE 733
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60137-00-A
R Upper Sidewall Assembly - Installation
R Figure 704 (Sheet 2)

ASSEMBLY
PAGE 734
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R LM50092-00-A
R Upper Sidewall Assembly - Installation
R Figure 704 (Sheet 3)

ASSEMBLY
PAGE 735
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60138-00-A
R Upper Sidewall Assembly - Installation
R Figure 704 (Sheet 4)

ASSEMBLY
PAGE 736
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60174-00-A
R Upper Sidewall Assembly - Installation
R Figure 704 (Sheet 5)

ASSEMBLY
PAGE 737
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60139-00-A
R Upper Sidewall Assembly - Installation
R Figure 704 (Sheet 6)

ASSEMBLY
PAGE 738
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R LM50096-00-A
R Upper Sidewall Assembly - Installation
R Figure 704 (Sheet 7)

ASSEMBLY
PAGE 739
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60140-00-A
R Upper Sidewall Assembly - Installation
R Figure 704 (Sheet 8)

ASSEMBLY
PAGE 740
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R LM50098-00-A
R Upper Sidewall Assembly - Installation
R Figure 704 (Sheet 9)

ASSEMBLY
PAGE 741
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60141-00-A
R Upper Sidewall Assembly - Installation
R Figure 704 (Sheet 10)

ASSEMBLY
PAGE 742
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60142-00-A
R Upper Sidewall Assembly - Installation
R Figure 704 (Sheet 11)

ASSEMBLY
PAGE 743
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU USE
THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU DO NOT
BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR SKIN OR IN YOUR
EYES OR MOUTH. MAKE SURE YOU USE GLOVES AND CLOTHING TO PROTECT
YOURSELF.

E. Install the fairings. Refer to figure 705.

(1) Apply a layer of epoxy resin primer (C03-005) to the rivets (1-15, -20, -10, -35, and -40,
78-32-21).

(2) Install the upper sidewall lower fairing (1-25, or –30, 78-32-21), seal retainer fitting (1-
145, 78-32-21) and forward bulkhead attach strap (1-380, 78-32-21) to the core cowl
assembly (1-810 or -815, 78-32-21) and upper sidewall assembly (1-785 or -790, 78-
32-21) with the rivets (1-15, -20, -10, -35, and -40, 78-32-21).

(3) Apply a layer of epoxy resin primer (C03-005) to the rivets (10-440, 78-32-21 or 78-32-
22).

(4) Install the lower sidewall to latch beam fillet fairing (10-435, 78-32-21 or 78-32-22) to
the lower sidewall assembly (10-5, 78-32-21 or 78-32-22) and brackets (10-405 and
-415, 78-32-21 or 78-32-22) with the rivets (10-440, 78-32-21 or 78-32-22).

R (5) Do the steps that follow to install the lower fairing block (10-430, 78-32-21 or 78-32-22).

(a) Prepare the surfaces of the fixed structure and the fairing block (10-430, 78-32-
21 or 78-32-22) for bonding.

1 Use 180 grit abrasive paper to abrade the bonding surfaces.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR

EYES. PUT ON PROTECTIVE CLOTHING, GOGGLES, AND
A FACE MASK. USE THE FLUID IN AN AREA WITH GOOD
AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU
GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF
YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE

2 Clean the bonding surfaces with solvent (C04-001, C04-003 or C04-

035). Dry the surfaces with a clean cloth.

WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA
OPEN TO THE AIR. WEAR CLEAN NYLON FILM OR
POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN YOU MIX
OR APPLY THE ADHESIVE.

(b) Follow the manufacturer’s instructions to make a mixture of epoxy adhesive

(C01-011).

ASSEMBLY
PAGE 744
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

(c) Apply the adhesive mixture (C01-011) to the bonding surfaces of the lower
fairing block (10-430, 78-32-21 or 78-32-22) and the fixed structure. It is
recommended to apply dacron polyester netting (C01-126) to the fairing block
for bondline control. Make sure the netting is fully wetted with the adhesive.

(d) Put the fairing block (10-430, 78-32-21 or 78-32-22) in position on the fixed
structure and apply pressure. Remove unwanted adhesive.

(e) Cure the adhesive. Refer to the adhesive manufacturer’s instructions for the
cure process.

(f) Apply sealing compound (C01-073) around the edges of the fairing block, into
any remaining openings between the block and the fixed structure. Apply a thin
layer of the sealant over the surface of the block to supply additional fairing.

NOTE: Current production units appear to have the fairing block fully
coated with this sealant to smooth the transition between the fillet
fairing and the other adjacent structures. The sealant also helps to
keep the block in position.

R (6) Apply a layer of epoxy resin primer (C03-005) to the rivets (5-175 and -180, 78-32-21).

R (7) Install the upper sidewall forward fairing (5-165 or -170, 78-32-21) to the upper sidewall
assembly (1-785 or -790, 78-32-21) with the rivets (5-175 and -180, 78-32-21).

(8) Apply a layer of epoxy resin primer (C03-005) to the rivets (10-365 -377, -385 and
-400, 78-32-21 or 78-32-22).

(9) Apply a layer of epoxy resin primer (C03-005) to the pins (10-370 and -390, 78-32-21 or
78-32-22).

(10) Install the lower sidewall to core cowl fillet fairing (10-360, 78-32-21 or 78-32-22) to the
lower sidewall assembly (10-5, 78-32-21 or 78-32-22) and core cowl assembly (1-810
or -815, 78-32-21) with the rivets (10-365 -377, -385 and -400, 78-32-21 or 78-32-22),
pins (10-370 and -390, 78-32-21 or 78-32-22) and nuts (10-375 and -395, 78-32-21 or
78-32-22).

(11) Apply a layer of epoxy resin primer (C03-005) to the rivets (1-400, -405, -410 and -415,
78-32-21).

(12) Install the upper sidewall aft inner cowl fairing (1-430 or -435, 78-32-21) to the upper
sidewall assembly (1-785 or -790, 78-32-21) and core cowl assembly (1-810 or -815,
78-32-21) with the rivets (1-400, -405, -410 and -415, 78-32-21).

ASSEMBLY
PAGE 745
78-32-02 DEC 01/11
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60133-00-A
R Locator - Fairings
R Figure 705 (Sheet 1)

ASSEMBLY
PAGE 746
78-32-02 DEC 01/10
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R LM50085-00-A
R Upper Sidewall Aft Inner Cowl Fairing
R Figure 705 (Sheet 2)

ASSEMBLY
PAGE 747
78-32-02 DEC 01/10
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60134-00-A
R Lower Sidewall to Core Cowl Fillet Fairing
R Figure 705 (Sheet 3)

ASSEMBLY
PAGE 748
78-32-02 DEC 01/10
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60135-00-A
R Upper Sidewall Forward Fairing
R Figure 705 (Sheet 4)

ASSEMBLY
PAGE 749
78-32-02 DEC 01/10
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R LM5008901-A
R Lower Sidewall to Latch Beam Fillet Fairing
R Figure 705 (Sheet 5)

ASSEMBLY
PAGE 750
78-32-02 DEC 01/10
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60175-00-A
R Upper Sidewall Lower Fairing
R Figure 705 (Sheet 6)

ASSEMBLY
PAGE 751
78-32-02 DEC 01/10
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MANUAL

683L SERIES

R F. Install the upper and lower bifurcation extensions. Refer to figure 706.

R (1) Install the upper sidewall bifurcation extension.

R (a) Apply a layer of epoxy resin primer (C03-005) to the pins (85-60, 78-32-21).

R (b) Install the upper bifurcation extension (85-10 or -15, 78-32-21) to the upper
R sidewall assembly (1-785 or 1-790, 78-32-21) with pins (85-60, 78-32-21), nuts
R (85-80, 78-32-21), bolts (85-20, 78-32-21), and nuts (85-50, 78-32-21). Tighten
R the nuts (85-50 and 85-80, 78-32-21) to 24-27 lb in. (2.7-3.1 N·m) of torque.

R (2) Install the lower sidewall bifurcation extension.

R (a) Apply a layer of epoxy resin primer (C03-005) to the pins (85-760 and -790, 78-
R 32-21).

R (b) Install the lower bifurcation extension assembly (85-730 or -735, 78-32-21) to
R the lower sidewall assembly (10-5, 78-32-21 or 78-32-22) with pins (85-760,
R 85-790, 78-32-21), nuts (85-780, 78-32-21) and bolts (85-740, 78-32-21).
R Tighten the bolts (85-740, 78-32-21) and nuts (85-780, 78-32-21) to 24-27 lb in.
R (2.7-3.1 N·m) of torque.

R G. Install the bolted-on component hardware to the inner surface of the core cowl. Refer to figures
R 707, 708 (left side), and 709 (right side).

R (1) Install the items that follow on the left support assembly. Refer to figures 707, and 708,
R and to 78-32-00, Assembly.

R (a) Install the six link box assemblies.

R (b) Install the air tubes, the flexible hose, and the signal air tube.

R (c) Install the precooler duct and the bracket.

R (d) Install the power door opening actuator and cable or tubes, hoses, and
R hydraulic lines.

R (2) Install the items that follow on the right support assembly. Refer to figures 707, 709,
R and to 78-32-00, Assembly.

R (a) Install the six link box assemblies.

R (b) Install the air tubes and the flexible hose.

R (c) Install the power door opening actuator and cable or tubes, hoses, and
hydraulic lines.

R H. Apply silicone insulation (C01-015). Refer to 78-32-02 Repair 022.

ASSEMBLY
PAGE 752
78-32-02 DEC 01/10
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MANUAL

683L SERIES

R MR60130-00-A
R Upper and Lower Bifurcation Extensions
R Figure 706 (Sheet 1)

ASSEMBLY
PAGE 753
78-32-02 DEC 01/10
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60131-00-A
R Upper and Lower Bifurcation Extensions
R Figure 706 (Sheet 2)

ASSEMBLY
PAGE 754
78-32-02 DEC 01/10
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MANUAL

683L SERIES

R MR60132-00-A
R Upper and Lower Bifurcation Extensions
R Figure 706 (Sheet 3)

ASSEMBLY
PAGE 755
78-32-02 DEC 01/10
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MANUAL

683L SERIES

R I. Do the steps that follow to assemble the core cowl support assembly and fixed structure.

R (1) Install the items that follow on the support structure. Refer to 78-32-00, Assembly.

R NOTE: These components were removed from the support structure to allow the
R support structure to be placed in the support stand.

R (a) Install the translating cowl assembly.

R (b) Install the hinge cover.

R (c) Install the electrical harness.

R (d) Install the center drive unit.

R (e) Install the latch ring assembly.

R (f) Install the upper hinge bolts.

R (g) Install the aft core cowl wear strips.

R (h) Install the pneumatic and hydraulic tubing.

R (i) Install the angle gear boxes.

R (j) Install the upper wear strip.

R (k) Install the blowout and access doors.

R (l) Install the hold open rod and bracket.

R (m) Install the lower latches or latch bolts.

R (n) Install the flex shafts.

R (o) Install the upper aft fairing.

R (p) Install the upper fireseal assembly.

R (q) Install the lower and upper sidewall forward seals.

R (r) Install the outer torque box wear strip.

ASSEMBLY
PAGE 756
78-32-02 DEC 01/10
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MANUAL

683L SERIES

R MR60127-00-A
R Power Door Opening Actuator
R Figure 707

ASSEMBLY
PAGE 757
78-32-02 DEC 01/10
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60128-00-A
R Left Support Assembly
R Figure 708

ASSEMBLY
PAGE 758
78-32-02 DEC 01/10
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MM50044-00-A
R Right Support Assembly
R Figure 709

ASSEMBLY
PAGE 759
78-32-02 DEC 01/10
 FAN REVERSER
CF6-80E1 CMM

THIS PAGE INTENTIONALLY BLANK

 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

FAN REVERSER BLOCKER DOOR - INSPECTION/CHECK

1. General.

A. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable
Materials.

(1) Tools and Equipment. None required.

(2) Consumable Materials.

Code No. Description

C01-011 Adhesive, Epoxy Resin,

EA 934 NA

C01-073 Compound, Sealing,

Temperature Resistant,
(PR 1750)

C01-106 Adhesive, Epoxy Resin,

EA 956

C04-001 Solvent, Methyl-Ethyl-Ketone

(MEK)

C04-003 Solvent, Acetone

C04-014 Alcohol, Denatured

C04-035 Alcohol, Isopropyl

(3) Expendable Parts. None required.

(4) Referenced Procedures.

SPM 70-43-07

INSPECTION
PAGE 501
78-32-03 DEC 01/98
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2. Clean the Blocker Door and Associated Hardware before you make an Inspection.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

CAUTION: DO NOT PUT SOLVENTS DIRECTLY ON THE BLOCKER DOOR. DO NOT PUT THE
BLOCKER DOOR IN A CONTAINER OF SOLVENT. DAMAGE CAN OCCUR.

A. Clean the blocker door and associated hardware with a clean lint-free cotton cloth made moist
with solvent (C04-001, C04-003, or C04-035). Immediately dry the surface with a dry clean lint-
free cotton cloth. Do not let the solvent dry on the blocker door. Do this again until the repair
area is clean.

R 3. Make an Inspection of the Blocker Door and Associated Hardware. See figures 501 and 502, and table
501.

NOTE: The following inspection is a visual inspection aided by the use of a 10X magnifying glass.

Table 501. Blocker Door and Associated Hardware

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

A. Blocker Door Face for:

Pre SB 78-5026
(1) Missing wire screen Up to 18.4 ft2 Any amount Clean with alcohol
(1.70 m2) for each (C04-014) and seal
reverser half. The total the screen edges with
amount for the two halves adhesive (C01-106),
must not be more than 22 or replace the screen,
ft2 (2.04 m2) Repair 008
End Pre SB 78-5026

INSPECTION
PAGE 502
78-32-03 DEC 01/13
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Serviceable Repairable Repair

Inspect/Check Limits Limits Method

A. Blocker Door Face for: (continued)

R (2) Punctures, tears, Not serviceable Not more than 0.50 in. Repair 010
R cracks, and dents (12.7 mm) diameter
R damage to face sheet
R with less than 2.00 in.
R (50.8 mm) diameter
R damage to the
R honeycomb core.
R Minimum of 10.0 in.
R (25.4 cm) between
R damage areas. Repair
R must be a minimum of
R 1.0 in. (25.4 mm) from
R the support fitting

R (3) Delamination Not serviceable Not more than 0.50 in. Repair 010
R (12.7 mm) diameter
R damage to face sheet
R with less than 2.00 in.
R (50.8 mm) diameter
R damage to the
R honeycomb core.
R Minimum of 10.0 in.
R (25.4 cm) between
R damage areas. Repair
R must be a minimum of
R 1.0 in. (25.4 mm) from
R the support fitting

R (4) Crushed Nomex Not serviceable Not more than 0.50 in. Repair 010
R Honey comb core (12.7 mm) diameter
R damage to face sheet
R with less than 2.00 in.
R (50.8 mm) diameter
R damage to the
R honeycomb core.
R Minimum of 10.0 in.
R (25.4 cm) between
R damage areas. Repair
R must be a minimum of
R 1.0 in. (25.4 mm) from
R the support fitting

INSPECTION
PAGE 503
78-32-03 JUN 01/06
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Table 501. Blocker Door and Associated Hardware (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

A. Blocker Door Face for: (continued)

(5) Torn or frayed Not serviceable 2.0 inch (50.8 mm) Repair 007
screen diameter, if no more
than 0.75 in. (38.1 mm)
diameter of screen is
missing.
NOTE:
There is a maximum
missing wire mesh limit
of 18.4 ft2 (1.70 m2) for
each reverser half if
there is no acoustic
blockage. The total
amount for the two
halves must not be
more than 22 ft2 (2.04
m2). If there is acoustic
blockage, the maximum
limit is 6.5 ft2 (0.60 m2)
of acoustic blockage for
a full reverser (two
halves). This can
include areas of
missing wire mesh plus
areas of total acoustic
blockage. 4.0 ft2 (0.37
m2) of missing wire
mesh is approximately
equal to 1.0 ft2 (0.09
m2) of total acoustic
blockage.

(6) Dents in screen wire Serviceable, if screen is

mesh not delaminated or cut

(7) Pin holes in screen Not serviceable 100 holes per door Clean the area with
wire mesh alcohol (C04-014). Fill
the holes with
adhesive (C01-106) to
seal the frayed screen

R INSPECTION
PAGE 504
78-32-03 JUN 01/06
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Table 501. Blocker Door and Associated Hardware (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

A. Blocker Door Face for: (continued)

R (1) Acoustic blockage The maximum acoustic Any amount To be supplied

R blockage permitted for a
R single door is 0.028 ft2
R (0.0026 m2). Refer to
R figure 502

B. Blocker Door Back Plate for:

(1) Punctures, tears, Not serviceable 0.75 in. (19.1 mm) Repair 009
cracks and dents maximum diameter with
a minimum of 10.0 in.
(25.4 cm) between
damage areas

(2) Frayed composite Not serviceable Any amount Clean the area with
carbon material alcohol (C04-014) and
seal the edge with
adhesive (C01-106)

(3) Missing epoxy Three areas 1.0 in.2 Not repairable Replace the blocker
polymide coating (6.45 cm2) each door
separated by 1.0 in. (25.4
mm) minimum spacing

C. Blocker Door Edges for:

(1) Delamination, Not serviceable Three areas, 2.0 in.2 Repair 006
cracks, or chips (12.90 cm2) each,
separated by 2.0 in.
(50.8 mm) minimum
spacing

Any amount, if there is Repair 011

no door distortion and
damage is a minimum
of 1.0 in. (25.4 mm)
from a hinge or link

(2) Cuts or scratches in 0.750 in. (19.05 mm) Not repairable Replace the wear
the wear strips each, total accumulation strips,
of 3.0 in. (76.2 mm) Repair 004

INSPECTION
PAGE 505
78-32-03 DEC 01/13
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MANUAL

683L SERIES

Table 501. Blocker Door and Associated Hardware (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

C. Blocker Door Edges for: (continued)

(3) Dents in the wear Four areas 0.250 in. Not repairable Replace the wear
strips (6.35 mm) in diameter strips,
each separated by 1.0 in. Repair 004
(25.4 mm)

(4) Missing material in Three areas each Not repairable Replace the wear
the wear strips separated by 1.0 in. strips,
(25.4 mm), total Repair 004
accumulation of
0.250 in.2 (1.61 cm2)

(5) Evidence of Not serviceable Not repairable Replace the blocker

interference with the door
dagmar fairing

D. Link Support for:

(1) Scratches or dents Not serviceable Any amount Touch up alodine.

Refer to Standard
Practices Manual,
70-43-07

(2) Wear strips for wear 0.010 in. (0.25 mm) depth Not repairable Replace the wear
strips, Repair 005

(3) Abrasions on the Not serviceable Any amount, to a depth Blend and polish the
forward and aft walls of 0.040 in. (1.02 mm) area, then touch up
of the cavity (per- alodine. Refer to
pendicular to the Standard Practices
wear strips) Manual, 70-43-07

(4) Sleeve surfaces for 0.020 in. (0.51 mm) depth Not repairable Replace the sleeves
wear

(5) Unbonding Not serviceable Edge void depth, 0.200 Sealing compound
in. (5.08 mm). Number (C01-073) or adhesive
of voids, no limit. (C01-011). If more
Length, 1.0 in. (25.4 than the maximum
mm) at each location. limits, replace the
Total cumulative length, blocker door
2.0 inches (50.8 mm)

R INSPECTION
PAGE 506
78-32-03 JUN 01/06
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MANUAL

683L SERIES

Table 501. Blocker Door and Associated Hardware (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

D. Link Support for: (continued)

(6) Cracks in the Not serviceable 100 percent of the fillet, Use a hand held
bonding adhesive if the link support is grinder to remove the
fillet repairable for cracks. Clean the fillet
unbonding with alcohol
(C04-014). Fill in the
fillet with adhesive
(C01-011) or sealing
compound (C01-073)

(7) Loose or missing Not serviceable Any amount Replace the loose or
hardware missing hardware

E. Door Hinges for:

(1) Cracks Not serviceable Not repairable Replace the hinge,

Repair 001

(2) Hole wear Not serviceable Any amount Repair 003

(3) Unbonding Not serviceable Edge void depth, 0.200 Repair 001
in. (5.08 mm). Number
of voids, no limit.
Length, 1.0 in.
(25.4 mm) at each
location

(4) Cracks in the Not serviceable 100 percent of the fillet, Use a hand held
bonding adhesive if the door hinge is grinder to remove the
fillet repairable for cracks. Clean the fillet
unbonding with alcohol
(C04-014). Fill in the
fillet with adhesive
(C01-011) or sealing
compound (C01-073)

R INSPECTION
PAGE 507
78-32-03 JUN 01/06
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MANUAL

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Table 501. Blocker Door and Associated Hardware (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

E. Door Hinges for: (continued)

(5) Wear or fretting Not serviceable 0.030 in. (0.76 mm) for Hand file the high
each hinge lug material, then touch
up alodine. Refer to
Standard Practices
Manual, 70-43-07

(6) Worn or damaged Not serviceable Not repairable Replace the sleeve
sleeves or flanged and/or the flanged
sleeve sleeve, Repair 003

F. Cap for:

(1) Cracking Not serviceable Not repairable Replace the cap

(2) Spring retainers for Not serviceable Not repairable Replace retainer
looseness of
attachment

F. Cap for: (continued)

(3) Spring retainers for 0.010 in. (0.25 mm) Not repairable Replace the retainer
wear

(4) Scratches, dents, or Not serviceable Any amount Touch up alodine.

marks Refer to Standard
Practices Manual,
70-43-07

G. Springs for:

(1) Wear in ID Any amount, if some Not repairable Replace the spring
resistance is felt when
the spring is installed on
the retainer post

(2) Cracking Not serviceable Not repairable Replace the spring

R INSPECTION
PAGE 508
78-32-03 JUN 01/06
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MANUAL

683L SERIES

Table 501. Blocker Door and Associated Hardware (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

H. Link Block for:

(1) Cracks Not serviceable Not repairable Replace the block

(2) Flanged sleeve hole 0.010 in. (0.25 mm) depth Not repairable Replace the block
wear

(3) Wear on sides or 0.020 in. (0.51 mm) depth Not repairable Replace the block
end

(4) Bore wear in the 0.005 in. (0.13 mm) depth Not repairable Replace the flanged
flanged sleeves sleeve

(5) Spring retainers 0.010 in. (0.25 mm) depth Not repairable Replace the spring
retainer

R INSPECTION
PAGE 509
78-32-03 JUN 01/06
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MANUAL

683L SERIES

R NACELLE ACOUSTIC ZONES

R NOTE: This CMM gives the maximum acoustic blockage limits for each component that gives acoustic
R suppression for the nacelle. There is a high level acoustic requirement for a fully installed nacelle
R (inlet and full reverser). The view above shows the zone numbers for each component. The
R allowance is based on a sliding scale formula*. To apply the formula correctly, an airline must
R monitor all blockage to its acoustic components. The airline has the option of using this full nacelle
R allowance for their reverser components.

R *Use this formula if the damage area (including potential loss from previous repairs) is more than
R the maximum permitted limits at the individual component level (see example):

R (0.286 x Inlet Area Loss) + (0.154 x Exhaust Area Loss) < 1.0
R Example:

R Inlet (ft2) 3.5 3.0 2.5 2.0 1.5 1.0 0.0

R Exhaust (ft2) 0.0 0.9 1.9 2.8 3.7 4.6 6.5

R Table 502. Maximum Acoustic Loss Independent Limits

R Acoustic Zone Component Description Maximum Permitted Area

R Losses
R 1 Inlet (Inner Barrel) 1.75 ft2 (0.163 m2)
R 2 Exhaust (Blocker Door, Translating Cowl,
R Fixed Structure) 3.24 ft2 (0.301 m2)

R Table 503. Maximum Acoustic Loss Independent Limits by Individual Exhaust Component

R Acoustic Zone Individual Exhaust Component Description Maximum Permitted Area

R Losses
R 2 Blocker Door 0.028 ft2 (0.0026 m2)
R 2 Translating Cowl (LH or RH) 0.60 ft2 (0.055 m2)
R 2 Fixed Structure (LH) 0.73 ft2 (0.068 m2)
R 2 Fixed Structure (RH) 0.98 ft2 (0.091 m2)

INSPECTION
PAGE 510
78-32-03 DEC 01/13
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

CF8-7191-01-A
Blocker Door Repair Area
Figure 501 (Sheet 1)

R INSPECTION
PAGE 511
78-32-03 DEC 01/13
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

CF8-7192-01-A
Blocker Door Repair Area
Figure 501 (Sheet 2)

R INSPECTION
PAGE 512
78-32-03 DEC 01/13
 COMPONENT
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MANUAL

683L SERIES

R MR60215-00-A
R Blocker Door Acoustic Blockage Limits
R Figure 502

INSPECTION
PAGE 513
78-32-03 DEC 01/13
 FAN REVERSER
CF6-80E1 CMM

THIS PAGE INTENTIONALLY BLANK

 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

FAN REVERSER BLOCKER DOOR - REPAIR

1. Blocker Door Hinge Replacement.

A. This procedure gives the instructions for replacement of the hinge(s) on the blocker door. This
procedure addresses the replacement of one hinge. Perform steps simultaneously for each
hinge, if both hinges on a blocker door need replacement.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools.

Tool No. Description

2C15618G01 Fixture, Bond - Blocker Door Hinge

2C15619G01 Fixture, Machine - Blocker Door Hinge

(2) Standard Tools. None required.

(3) Locally Manufactured Tools.

Description Figure No.

Template 602

Blocker Door Hinge 603

Drill Fixture

REPAIR 001
PAGE 601
78-32-03 DEC 01/98
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MANUAL

683L SERIES

(4) Equipment.

Description Manufacturer

Oven, capable of heating part Local purchase

uniformly to 250°F (121°C) and
holding the part temperature between
240° and 260°F (116° and 126°C)

End Mill, 0.500 inch (12.70 mm) Local purchase

Hand Grinder Local purchase

Tilting Rotab Local purchase

Heat Gun Master Appliance Co.

Model No. HG201 Racine, Wisconsin

B. Consumable Materials.

Code No. Description Use

C01-128 Adhesive, Epoxy Film, AF 3109-2 Bond the hinge

C01-132 Adhesive, Foam, AF-3024 Fill the Nomex core

C03-006 Compound, Chemical Surface Anodize the repair

Treatment - Alodine No. 1200

C03-007 Primer, Epoxy Adhesive, Paint the bonding

BR-127 surface

C04-001 Solvent, Methyl-Ethyl-Ketone Clean the repair area

C04-005 Solvent, Chlorothene NU, Clean the repair area

Fed. Spec. O-T-620a

C10-003 Fabric, Glass, No. 181, Bond the hinge

MIL-C-9084 Type VIII

C10-011 Compound, Mold Release, Coat the alignment pin

R MS-143XD

R C10-021 Tape, Plastic Use during grit blast

C10-040 Tape, Teflon - Scotch Brand, 5490 Use when the Nomex core is filled

C10-049 Aluminum Oxide Grit, 180 Mesh Grit blast

C10-140 Gloves, Nylon Film/Polyethylene, Mix and apply the adhesive

Disposable

REPAIR 001
PAGE 602
78-32-03 DEC 01/12
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MANUAL

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C. Expendable Parts. None required.

D. SPD Identification. None required.

E. Referenced Procedures.

SPM 70-21-04

78-32-03, Repair 003

R

3. Dimensional Information. None required.

4. Setup Information. None required.

5. Procedure.

A. Remove the sleeves and flanged sleeves from the damaged hinge. Refer to 78-32-03, Repair
003.

B. Set up the blocker door hinge machine fixture, 2C15619, on a suitable machine bed or table.

C. Install the blocker door in fixture 2C15619. See figure 601.

(1) Loosen the toggle screw hand knob on the two clamp arms.

(2) Loosen the quarter-turn screw and open the hinged arm.

(3) Install the blocker door on the mounting plate with the hinges at the smaller radius end
of the mounting plate.

(4) Retract the swivel head screw clamps into the arm by turning them counterclockwise.

(5) Retract the expander/locator assembly into the arm.

(a) Loosen the knurled head screw.

(b) Pull the expander/locator assembly up.

(c) Tighten the knurled head screw.

(6) Carefully close the hinged arm over the blocker door and hold in place with the quarter-
turn screw.

REPAIR 001
PAGE 603
78-32-03 JUN 01/08
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

CF8-7291-00-A
Blocker Door Hinge Machine Fixture, 2C15619
Figure 601

REPAIR 001
PAGE 604
78-32-03 DEC 01/98
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MANUAL

683L SERIES

(7) Put the blocker door in position in the fixture.

(a) Turn the knurled nut counterclockwise to lower the outer expander of the
expander/locator assembly until it touches the depression in the blocker door
link support.

(b) Turn the hand knob clockwise to tighten the inner expander until it is snug.

(c) Align the sides of the blocker door until they are parallel with the sides of
fixture.

CAUTION: DO NOT TIGHTEN THE CLAMPS MORE THAN HAND-TIGHT. DAMAGE TO

THE GRAPHITE STRUCTURE OF THE BLOCKER DOOR CAN OCCUR.

(8) Tighten the toggle screw hand knob on each clamp arm with your hand.

(9) Tighten the swivel head screw clamps by turning them CW with your hand.

(10) Make sure that the expander/locator is secure in the blocker door link support and
tighten the knurled head screw with your fingers.

D. Remove the damaged hinge using one of the following methods:

(1) Machine method.

(a) Set the machine in the manual mode.

WARNING: THE STEPS THAT FOLLOW REQUIRE THAT YOU CUT, SAND
AND/OR ROTARY FILE GRAPHITE FIBER FILLED EPOXIES. USE A
VACUUM CLEANER, WITH THE INTAKE ADJACENT TO THE
REPAIR AREA, TO DRAW OFF GRINDING/FILING DUST. WEAR AN
APPROVED DUST MASK SO YOU DO NOT BREATHE THE
GRINDING/FILING DUST. WEAR SAFETY GLASSES SO YOU DO
NOT GET GRINDING/FILING DUST IN YOUR EYES.

CAUTION: BE CAREFUL NOT TO MACHINE INTO THE NOMEX HONEYCOMB

CORE OR THE GRAPHITE STRUCTURE OF THE BLOCKER DOOR.

(b) Using a 0.500 inch (12.70 mm) end mill, or equivalent, machine away the
aluminum hinge casting until the adhesive bond line is reached.

NOTE: The adhesive bond material is blue.

CAUTION: BE CAREFUL NOT TO SAND INTO THE GRAPHITE STRUCTURE

OF THE BLOCKER DOOR; 0.005 INCH (0.127 MM) IS THE
MAXIMUM AMOUNT OF REMOVED GRAPHITE MATERIAL
ALLOWED.

(c) Using 120-180 grit abrasive cloth, sand the blue adhesive bond material from
the graphite structure and the Nomex honeycomb core. Do not sand into the
graphite structure or the core.

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(2) Hand grinder method.

WARNING: THE STEPS THAT FOLLOW REQUIRE THAT YOU CUT, SAND
AND/OR ROTARY FILE GRAPHITE FIBER FILLED EPOXIES. USE A
VACUUM CLEANER, WITH THE INTAKE ADJACENT TO THE
REPAIR AREA, TO DRAW OFF GRINDING/FILING DUST. WEAR AN
APPROVED DUST MASK SO YOU DO NOT BREATHE THE
GRINDING/FILING DUST. WEAR SAFETY GLASSES SO YOU DO
NOT GET GRINDING/FILING DUST IN YOUR EYES.

(a) Using a hand grinder with a cutting wheel, cut away the hinge clevises.

CAUTION: BE CAREFUL NOT TO GRIND INTO THE NOMEX HONEYCOMB

CORE OR THE GRAPHITE STRUCTURE OF THE BLOCKER DOOR.

(b) Grind away the aluminum hinge casting base plate until the adhesive bond line
is reached.

NOTE: The adhesive bond material is blue.

CAUTION: USE CARE NOT TO SAND INTO THE GRAPHITE STRUCTURE OF

THE BLOCKER DOOR; 0.005 INCH (0.127 MM) IS THE MAXIMUM
AMOUNT OF REMOVED GRAPHITE MATERIAL ALLOWED.

(c) Use 120-180 grit abrasive cloth to remove the blue adhesive bond material
from the graphite structure and the Nomex honeycomb core. Do not sand into
the graphite structure or the core.

E. Remove the blocker door from the blocker door hinge machine fixture.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

F. Flush the repair area with solvent (C04-005) and let the area dry.

G. Make a visual inspection of the repair area to make sure that the graphite structure and core
are not damaged. Cracks or delaminations are not permitted.

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H. Prepare the blocker door for the new hinge casting installation.

WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL

IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR.
WEAR CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES
(C10-140) WHEN YOU MIX OR APPLY THE ADHESIVE.

(1) Make sure that the pieces of the Nomex honeycomb core are not folded over and
R closing off the honeycomb cells. Apply the foam adhesive (C01-132) to the base and
honeycomb walls of the hinge casting cutout. Then fill the cutout with foam adhesive
until it aligns with the contour of the blocker door hinge.

(2) Apply teflon tape (C10-040) into the cutout.

(3) Use a new hinge casting to work foam adhesive into the Nomex honeycomb core.

(4) Remove the teflon tape and inspect the foam adhesive. If there are voids, fill with
additional foam adhesive and do steps 5.H.(2) through 5.H.(4) again.

I. Prepare the adhesive/cloth kit for the new hinge casting installation.

(1) Lay-up one ply of epoxy film adhesive (C01-128), one ply of glass fabric (C10-003), one
ply of epoxy film adhesive (C01-128), one ply of glass fabric (C10-003), and one ply of
epoxy film adhesive (C01-128).

CAUTION: DO NOT OVERHEAT THE ADHESIVE/CLOTH KIT.

(2) Use a heat gun to tack the lay-up stack together.

(3) Use a locally manufactured template (see figure 602) or a hinge casting as a guide to
cut the adhesive/cloth kit, as necessary.

NOTE: If the adhesive/cloth kit will not be used within eight hours, seal the
adhesive/cloth kit in a plastic bag and keep it in a freezer.

J. Drill a tooling alignment pin hole in the new hinge casting.

(1) Locate the new hinge casting in a locally manufactured blocker door hinge drill fixture.
See figure 603.

(2) With a slip renewable bushing (item 16, figure 603), drill one 0.109 inch (2.769 mm)
diameter alignment pin hole in the hinge casing.

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CF8-7292-00-C
Locally Manufactured Template
Figure 602

(3) Replace the slip renewable bushing (16) with a slip renewable bushing (17), and ream
the alignment pin hole to 0.125 inch (3.175 mm) diameter.

(4) Remove the hinge from the fixture.

(5) Deburr as necessary.

K. Prepare the new hinge casting surface.

R (1) Deleted.

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ITEM
NO. NOMENCLATURE/MATERIAL/DESCRIPTION/ROUGH STOCK SIZE QTY

1. ASSEMBLY ................................................................................................................................ -
2. BASE PLATE, ROLL HARDENED STEEL, 1.00 X 7.50 X 8.00 IN (25.4 X 190.5 X 203.2 MM)
(DETAIL A) ....................................................................................................................................... 1
3. SOCKET HEAD CAP SCREW, STANDARD, 5/16-18 IN THREAD X 1.00 IN (25.4 MM)
LONG ............................................................................................................................................ 18
4. EYE BOLT, AMERICAN NO. ADB-32404 (DETAIL B) .................................................................. 1
5. BOTTOM WASHER, AMERICAN NO. ADB-26455. ...................................................................... 1
6. SPHERICAL FLANGE NUT, AMERICAN NO. ADB-25255. .......................................................... 1
7. HEAD BUSHING, 0.250 IN (6.350 MM) ID, 0.40625 IN (10.3188 MM) OD X 0.500 IN (12.70
MM) LONG ...................................................................................................................................... 4
8. SIDE PLATE, ROLL HARDENED STEEL, 1.00 X 4.00 X 6.50 IN (25.4 X 101.6 X 165.1 MM)
(DETAIL C) ...................................................................................................................................... 2
9. SWIVEL HEAD SCREW, CARR LANE NO. CL-34-SHS .............................................................. 2
10. HINGED CLAMP PLATE, ROLL HARDENED STEEL, 2.00 X 4.625 X 8.25 IN (50.8 X 117.5
X 209.6 MM) (DETAIL D) ................................................................................................................. 1
11. SPHERICAL REST BUTTON, CARR LANE NO. CL-4-SLB ......................................................... 2
12. REST BUTTON, CARR LANE NO. CL-2-RB................................................................................. 2
13. SWIVEL HEAD SCREW, CARR LANE NO. CL-6-SHS ................................................................ 2
14. LOWER END PLATE, ROLL HARDENED STEEL, 1.00 X 4.00 X 7.75 IN (25.4 X 101.6 X
196.9 MM) (DETAIL E) ................................................................................................................... 1
15. HEADLESS LINER, 0.3125 IN (7.9375 MM) ID, 0.500 IN (12.70 MM) OD X 0.750 IN (19.05
MM) LONG ...................................................................................................................................... 4
16. SLIP RENEWABLE BUSHING, 0.10938 IN (2.77825 MM) ID,0.3125 IN (7.9375 MM) OD X
1.375 IN (34.925 MM) LONG (DETAIL F) ...................................................................................... 1
17. SLIP RENEWABLE BUSHING, 0.125 IN (3.175 MM) ID, 0.3125 IN (7.9375 MM) OD X 1.375
IN (34.925 MM) LONG (DETAIL F) ................................................................................................. 4
18. LOCK SCREW, LS-1....................................................................................................................... 4
19. SLIP RENEWABLE BUSHING, 0.10938 IN (2.77825MM) ID, 0.3125 IN (7.9375 MM) OD X
1.00 IN (25.4 MM) LONG ................................................................................................................ 1
20. HINGE PIN, DRILL ROD, 0.250 IN (6.350 MM) DIAMETER X 6.50 IN (165.1 MM) LONG
(DETAIL G) ...................................................................................................................................... 1
21. SOCKET HEAD SET SCREW, STANDARD, 1/4-20 IN THREAD X 0.375 IN (9.525 MM)
LONG ............................................................................................................................................. 1
22. HEAD BUSHING, 0.250 IN (6.350 MM) ID, 0.40625 IN (10.3188 MM) OD X 0.750 IN (19.05
MM) LONG ...................................................................................................................................... 4
23. PLASTIC STEEL, DEVCON OR EQUIVALENT .......................................................................... A/R
24. UPPER END PLATE, ROLL HARDENED STEEL, 1.00 x 4.00 x 7.75 IN (25.4 x 101.6 x 196.9
MM) (DETAIL H).............................................................................................................................. 1

Locally Manufactured Blocker Door Hinge Drill Fixture

Figure 603 (Sheet 1)

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ITEM
NO. NOMENCLATURE/MATERIAL/DESCRIPTION/ROUGH STOCK SIZE QTY

25. DOWEL, 0.250 IN (6.350 MM) DIAMETER x 1.50 IN (38.1 MM) LONG ........................................ 1
26. BUTTON HEAD SCREW, NO. 4-40 IN THREAD x 0.50 IN (12.7 MM) LONG ............................. 4
27. CLAMP SCREW BUSHING, ROLL HARDENED STEEL, 1.50 IN (38.1 MM) DIAMETER X
0.8750 IN (22.225 MM) LONG (DETAIL J) ..................................................................................... 2
28. CENTER CLAMP BLOCK, AISI 4140, 1.25 X 1.25 X 2.125 IN1 (31.75 X 31.75 X 53.975 MM)
(DETAIL K) ...................................................................................................................................... 1
29. SOCKET HEAD SCREW, NO.4-40 IN THREAD X 0.625 IN (15.875 MM) LONG ........................ 6
30. END CLAMP BLOCK, AISI 4140, 1.25 X 1.25 X 1.25 IN2 (31.75 X 31.75 X 31.75 MM) (DETAIL
L) ..................................................................................................................................................... 2
31. DOWEL, 0.125 IN (3.175 MM) DIAMETER X 0.750 IN (19.05 MM) LONG ................................... 6
32. CLAMP BLOCK SUPPORT, ROLL HARDENED STEEL, 1.00 X 2.375 X 6.00 IN (25.4 X
60.325 X 152.4 MM) (DETAIL M).................................................................................................... 1

NOTES:

1. DIMENSION IS A FUNCTIONAL CHARACTERISTIC.

2. BREAK ALL SHARP CORNERS.

3. BUSHING ID MAY BE 0.001 INCH (0.025 MM) OVERSIZE AT CYCLE (ITEMS 16, 17, AND
19).

4. POUR PLASTIC STEEL (DEVCON) TO CONFORM TO LEFT HINGE CASTING AND RIGHT
HINGE CASTING.

Locally Manufactured Blocker Door Hinge Drill Fixture

Figure 603 (Sheet 2)

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CF8-7293-00-A
Locally Manufactured Blocker Door Hinge Drill Fixture
Figure 603 (Sheet 3)

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CF8-7294-00-A
Locally Manufactured Blocker Door Hinge Drill Fixture
Figure 603 (Sheet 4)

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CF8-7295-00-A
Locally Manufactured Blocker Door Hinge Drill Fixture
Figure 603 (Sheet 5)

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LM50081-00-A
Locally Manufactured Blocker Door Hinge Drill Fixture
Figure 603 (Sheet 6)

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CF8-7297-00-A
Locally Manufactured Blocker Door Hinge Drill Fixture
Figure 603 (Sheet 7)

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CF8-7298-00-A
Locally Manufactured Blocker Door Hinge Drill Fixture
Figure 603 (Sheet 8)

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MM60021-00-A
Locally Manufactured Blocker Door Hinge Drill Fixture
Figure 603 (Sheet 9)

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CF8-7300-00-A
Locally Manufactured Blocker Door Hinge Drill Fixture
Figure 603 (Sheet 10)

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CF8-7301-00-A
Locally Manufactured Blocker Door Hinge Drill Fixture
Figure 603 (Sheet 11)

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CF8-7302-00-A
Locally Manufactured Blocker Door Hinge Drill Fixture
Figure 603 (Sheet 12)

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R (2) Apply plastic tape (C10-021) on the non-bonding surfaces of the hinge casting in
preparation for grit blasting.

(3) Grit blast the entire bonding surface of the hinge casting (Standard Practices Manual,
Chapter/Section 70-21-04). Use 180 mesh aluminum oxide grit (C10-049).

R (4) Remove the plastic tape from the hinge casting.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

(5) Fully clean the hinge casting with solvent (C04-001) and let the area dry.

WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
AND CLOTHING TO PROTECT YOURSELF.

(6) Apply a layer of epoxy adhesive primer (C03-007) at a thickness of 0.0001-0.0003 inch
(0.0025-0.0076 mm) on all of the bonding surface of the hinge casting. To dry the
primer, refer to the manufacturer's instructions.

L. Apply the adhesive/cloth kit on the new hinge casting. Use a punch to make a tooling alignment
pin hole in the adhesive/cloth kit corresponding to the tooling alignment pin hole made in the
hinge casting in step J.

M. Install the blocker door, adhesive/cloth kit, and new hinge casting in the blocker door hinge
bond fixture, 2C15618. See figure 604.

(1) Swing the toggle clamp on the six swivel screw angle clamps open.

(2) Loosen the star hand knob and move the pivot knob out of the way; open the hinged
arm.

(3) Install the blocker door on the fixture base with the hinge casting cutout facing up on
the lower end of the base.

(4) To retract the three guide plate/locating pin assemblies into the hinged arm, turn the
adjustable torque handles CCW.

(5) Apply a layer of mold release compound (C10-011) on the round alignment pin of the
applicable guide plate or locating pin assembly for the hinge that is replaced.

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CF8-7303-00-A
Blocker Door Hinge Bond Fixture 2C15618
Figure 604

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(6) Put the adhesive/cloth kit and the new hinge casting on the blocker door hinge casting
cutout.

(7) Carefully close the hinged arm over the blocker door and hold it in position with the star
hand knob.

(8) Put the blocker door in position in the fixture.

(a) Lower the center guide plate/locating pin assembly.

1 Turn the adjustable torque handle clockwise while you carefully move
the pressure block of the guide plate/locating pin assembly into the
depression in the blocker door link support.

(b) Align the round alignment pin and the diamond alignment pin with
corresponding holes in the blocker door link support.

(c) Continue to tighten the adjustable torque handle until you feel some pressure.
The pressure shows that there is contact between the pressure block and the
depression in the blocker door link support.

(9) Turn the adjustable torque handle clockwise to lower the applicable guide plate/locating
pin assembly for the hinge being replaced.

(10) Move the hinge and adhesive/cloth kit as necessary to align the tooling alignment pin
holes with the round alignment pin on the guide plate/locating pin assembly. Tighten
adjustable torque handle with your hand.

(11) Close and secure the toggle clamp on the six swivel screw angle clamps.

N. Place the blocker door hinge bond fixture, with the blocker door installed, into an oven and cure
the adhesive/cloth kit at 240° to 260°F (115° to 126°C) for 90 minutes.

WARNING: WEAR THERMAL OR INSULATED GLOVES TO PREVENT HAND INJURY WHEN

YOU TOUCH HOT OR COLD PARTS.

O. Remove the blocker door hinge bond fixture and blocker door from the oven.

P. Remove the blocker door from the blocker door hinge bond fixture.

Q. Dimensionally inspect blocker door hinge for proper location (figure 605). Visually inspect for
unbonded adhesive/cloth kit and obvious defects. Repair minor defects as follows:

(1) Air bubbles, up to 0.15 inch (3.81 mm) in length, on the surface of the adhesive are
permitted if they are not immediately adjacent to the hinge.

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(2) Air bubbles longer than 0.15 inch (3.81 mm) in length on the surface of the adhesive
must be abraded out. There must be a smooth fillet of adhesive from the hinge to the
back sheet of the blocker door. No cracks are permitted after abrading. The adhesive
fillet must not undercut the hinge casting after abrading.

(3) Folds in the adhesive must be abraded out. There must be a smooth fillet of adhesive
from the hinge to the back sheet of the blocker door. No cracks are permitted after
abrading. The adhesive fillet must not undercut the hinge casting after abrading.

R. Set up blocker door hinge machining fixture 2C15619 on a tilting rotab. Indicate the edge of the
fixture to 0.002 inch (0.051 mm) F.I.R.

S. Tilt the rotab to the vertical position.

T. Install the blocker door in fixture 2C15619. Refer to step C.

U. Mill, drill, and ream the hinge casting. See figure 605.

NOTE: All references to left and right are given, looking at the blocker door back plate, with
the leading edge down.

(1) Machine the inside of the left clevis of the right hinge casting and the inside of the right
clevis of the left hinge casting 6.806-6.816 inch (172.9-173.1 mm) from datum C, such
that the dimension between machined surfaces is 13.617-13.627 inch (345.87-346.12
mm), see figure 605. Machine the inside of the hinge casting to a clearance of 0.380-
0.390 inch (9.652-9.906 mm) with 0.10-0.12 inch (2.54-3.05 mm) radius at base of
hinge.

(2) Drill and ream three hinge sleeve holes to a finished dimension of 0.5003-0.5010 inch
(12.708-12.725 mm) diameter. Drill two holes in the left hinge casting and one hole in
the right clevis (outside) of the right hinge casting. See figure 605.

(3) Drill and ream one hinge sleeve hole in the left clevis (inside) of the right hinge casting
to a finished dimension of 0.3750-0.3754 inch (9.525-9.535 mm) diameter; see figure
605. Machine a 0.030-0.040 inch (0.762-1.016 mm), 45 degree chamfer on the hinge
sleeve hole on inside surface of clevis. Spot face the hinge sleeve hole on the outside
surface of the clevis (surface E) to a diameter of 0.51-0.55 inch (12.95-13.97 mm).
Keep a 0.02-0.05 inch (0.51-1.27 mm) radius on the spot face.

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R MR50279-00-A
Milling, Drilling, and Reaming of Blocker Door Hinge Casting
Figure 605 (Sheet 1)

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CF8-7305-00-A
Milling, Drilling, and Reaming of Blocker Door Hinge Casting
Figure 605 (Sheet 2)

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V. Remove the blocker door from the blocker door hinge machine fixture and make a dimensional
inspection of the blocker door. Refer to figure 605.

W. Touch up the milled and drilled hinge casting surfaces.

WARNING: ACID SOLUTIONS ARE VERY ACTIVE AND CAN CAUSE SERIOUS BURNS.
DO NOT GET ACID ON YOUR SKIN, IN YOUR EYES, OR ON YOUR
CLOTHES. DO NOT BREATHE THE FUMES. WEAR ACID-RESISTANT
CLOTHING, GLOVES, AND FACE PROTECTION. IF YOU GET ACID ON
YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER AND GET
MEDICAL AID IMMEDIATELY.

(1) Apply chemical surface treatment compound (C03-006) to all milled, drilled, and
reamed surfaces of the hinge casting.

(2) Keep the surfaces wet with chemical surface treatment compound for approximately
three minutes.

(3) Wash the chemical surface treatment compound off the hinge casting with clean water.

X. Install new sleeves, wear sleeves, and flanged sleeve in the hinge. Refer to 78-32-03, Repair
R 003.

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FAN REVERSER BLOCKER DOOR - REPAIR

R 1. Blocker Door Hinge - Clevis Sleeve, Wear Sleeve and/or Flanged Sleeve Replacement.

A. This repair gives the instructions for replacement of worn blocker door wear sleeves and/or
flanged sleeves with standard or oversized replacement sleeves. You can also repair a hinge
R with worn or distorted sleeve holes. For this repair you must use one lug of each hinge to keep
R the blocker door aligned in the drill fixture. If you cannot keep the blocker door aligned, or if the
R wear sleeve hole is worn more than 0.5510 inch (13.995 mm) diameter, or if the flanged sleeve
R hole is worn more than 0.4524 inch (10.805 mm) diameter, you must replace the fitting. Refer
to 78-32-03, Repair 001.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools.

Description Drawing No.

Fixture, Drill - Blocker Door 2R1227

(2) Standard Tools. None required.

(3) Locally Manufactured Tools.

Description Figure No.

Blocker Door Hinge Sleeve Figure 603

Installation Fixture

(4) Equipment. None required.

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B. Consumable Materials.

Code Description Use

C03-001 Primer, Zinc Chromate Paint the surface

R DELETED

C04-003 Solvent, Acetone Clean the repair area

C04-035 Solvent, Isopropyl Alcohol Clean the repair area

C10-071 Safety Wire, AMS 5690 Hold the sleeves in position

0.020 in. (0.51 mm) or
0.032 inch (0.81 mm)

C10-140 Gloves, Nylon Film/Polyethylene, Mix and apply the adhesive

Disposable

C10-182 Cleaning Cloths to AMS 3819 Clean the repair area

C. Expendable Parts.

CSN Description

R 78-32-31-01-203 Sleeve, flanged

78-32-31-01-201 Sleeve (wear)

D. SPD Identification.

Drawing Number Title

1291M23P05 Sleeve (wear)

1291M23P06 Sleeve (wear)
1291M23P07 Sleeve (wear)
1291M23P08 Sleeve (wear)
1291M23P09 Sleeve (wear)
1291M26P04 Sleeve, flanged
1291M26P05 Sleeve, flanged
1291M26P06 Sleeve, flanged
1291M26P07 Sleeve, flanged
1291M26P08 Sleeve, flanged

E. Referenced Procedures.

78-32-03 Repair 001

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3. Dimensional information.

Reamed Hole Size/Description Sleeve Drawing Number

0.5003-0.5010 inch (12.708-12.725 mm)/Standard 1291M23P04

0.5103-0.5110 inch (12.962-12.979 mm)/First Oversize 1291M23P05
0.5203-0.5210 inch (13.216-13.233 mm)/Second Oversize 1291M23P06
0.5303-0.5310 inch (13.470-13.487 mm)/Third Oversize 1291M23P07
0.5403-0.5410 inch (13.723-13.741 mm)/Fourth Oversize 1291M23P08
0.5503-0.5510 inch (13.978-13.995 mm)/Fifth Oversize 1291M23P09
0.375-0.3754 inch (9.525-9.535 mm)/Standard 1291M26P03
0.385-0.3854 inch (9.779-9.789 mm)/First Oversize 1291M26P04
0.395-0.3954 inch (10.003-10.043 mm)/Second Oversize 1291M26P05
0.405-0.4054 inch (10.287-10.297 mm)/Third Oversize 1291M26P06
0.415-0.4154 inch (10.541-10.551 mm)/Fourth Oversize 1291M26P07
0.425-0.4254 inch (10.795-10.805 mm)/Fifth Oversize 1291M26P08

4. Setup information. None required.

5. Procedure.

A. Clean the hinge area.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

CAUTION: DO NOT PUT SOLVENTS DIRECTLY ON THE BLOCKER DOOR. DO NOT

PUT THE BLOCKER DOOR IN A CONTAINER OF SOLVENT. DAMAGE CAN
OCCUR.

(1) Clean the hinge area of the blocker door with a clean lint-free cotton cloth (C10-182)
R made moist with solvent (C04-003 or C04-035). Immediately dry the surface with a dry
clean lint-free cotton cloth (C10-182). Do not let the solvent dry on the hinge area. Do
this again until the hinge area is clean.

(2) Let the hinge area dry for a minimum of 15 minutes.

B. Remove the three sliding sleeves from the wear sleeves. See figure 601.

REPAIR 003
PAGE 603
78-32-03 JUN 01/15
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CF8-7306-00-A
Blocker Door Hinge Sleeve Installation
Figure 601 (Sheet 1)

REPAIR 003
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MM50002-00-A
Blocker Door Hinge Sleeve Installation
Figure 601 (Sheet 2)

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C. Make an inspection of the wear sleeves and flanged sleeves.

(1) Measure the inner diameter of the wear sleeves and flanged sleeves. Make a record of
the measurements.

(2) Make an inspection of the hole in the aluminum hinge for wear or distortion.

(3) Examine the hinge for loose wear sleeves or flanged sleeves.

D. If the results of the inspection shows:

-- a hinge hole is worn or distorted

-- a loose wear sleeve

-- the inside diameter of a wear sleeve is more than 0.3764 inch (9.561 mm)

-- the inside diameter of a flanged sleeve is more than 0.252 inch (6.401 mm).

The damaged sleeve will have to be removed.

E. Remove the damaged sleeve.

CAUTION: MAKE SURE YOU DO NOT DAMAGE THE HINGE CLEVIS. SECURELY
HOLD THE BLOCKER DOOR HINGE CLEVISES DURING WEAR SLEEVE
REMOVAL.

(1) Carefully tap out the sleeve with a light weight mallet and a drift.

F. If necessary, deburr the holes in the aluminum hinge.

G. Make an inspection of the holes in the aluminum hinge.

R (1) If the wear sleeve hole diameter is between 0.5010 inch (12.725 mm) and 0.5510 inch
R (13.995 mm), or the flanged sleeve hole diameter is between 0.3754 inch (9.535 mm)
R and 0.4524 inch (10.805 mm), an oversize wear sleeve or flanged sleeve will be
R necessary. Go to step H.

R (2) If the wear sleeve hole diameter is 0.5010 inch (12.725 mm) or less and the flanged
R sleeve diameter is 0.3754 inch (9.535 mm) or less, you can install a standard wear
R sleeve or flanged sleeve. Go to step J.

R (3) If the wear sleeve hole is more than 0.5510 inch (13.995 mm) diameter, or the flanged
R sleeve hole is more than 0.4254 inch (10.805 mm) diameter, you must replace the
R fitting. Refer to 78-32-03 Repair 001.

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H. Use drill fixture 2R1227 to ream the hole in the aluminum hinge large enough to install an
oversize wear sleeve and/or flanged sleeve. See figure 602.

(1) Put the blocker door on the contour pads with each hinge and link fitting held by a pad.

(2) Put the bushing guide plate on its supporting fasteners so that the lugs fit around the
hinge clevises.

R (3) Make a selection of one wear sleeve or flanged sleeve hole on each hinge to align the
R blocker door in the tool. The hole must accept a tooling locator pin that picks up the
R center of the hole to align the door. If you cannot keep the blocker door aligned, you
R must replace the fitting. Refer to 78-32-03 Repair 001.

R (4) Put the correct length and diameter location pins through the bushing guide plate into
R the selected wear/flanged sleeves or the sleeve holes, if the sleeves have been
R removed.

(5) Put the toggle clamps on the door to hold the door to the contour pads.

(6) Install the screw clamps on the door edge. Apply only sufficient force to hold the door
firmly. Be careful not to damage the edge of the door.

(7) Adjust the jam nuts to hold the bushing guide plate in position.

(8) Remove the location pins.

(9) Put the first oversize reamer guide into the bushing guide plate and lock in position with
R the reamer guide locking screw. Refer to the dimensional information in paragraph 3.

WARNING: THIS PROCESS GIVES OFF AIRBORNE DUST PARTICLES THAT ARE
POISONOUS. PUT ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE
MASK. MAKE SURE YOU USE IN AN AREA WITH GOOD AIR FLOW. MAKE
SURE YOU DO NOT BREATHE IN THE DUST PARTICLES.

(10) Ream out the worn hole to the first oversize.

(11) Make sure the hole is cylindrical and has a constant diameter with all evidence of wear
removed.

(12) If necessary, ream to the next larger oversize until the hole is cylindrical and constant in
R diameter with all evidence of wear removed. Refer to the dimensional information in
R paragraph 3.

(13) Make a record of the size of the hole.

REPAIR 003
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MM50003-00-A
Blocker Door Drill Fixture (2R1227)
Figure 602

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(14) Do steps 5.H.(9) through 5.H.(13) until all the worn holes have been cleaned up to a
constant diameter with all evidence of wear removed. If the wear sleeve hole does not
clean up at 0.5510 inch (13.995 mm) maximum diameter, you must replace the fitting.
If the flanged sleeve hole does not clean up at 0.4254 inch (10.805 mm) maximum
diameter, you must replace the fitting. Refer to 78-32-03 Repair 001.

(15) Release all the clamps and remove the door from the drill fixture.

I. Clean the hinge area.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

CAUTION: DO NOT PUT SOLVENTS DIRECTLY ON THE BLOCKER DOOR. DO NOT

PUT THE BLOCKER DOOR IN A CONTAINER OF SOLVENT. DAMAGE CAN
OCCUR.

(1) Clean the hinge area of the blocker door with a clean lint-free cotton cloth (C10-182)
R made moist with solvent (C04-003 or C04-035). Immediately dry the surface with a dry
clean lint-free cotton cloth (C10-182). Do not let the solvent dry on the hinge area. Do
this again until the hinge area is clean.

(2) Let the hinge area dry for a minimum of 15 minutes.

J. If you have not done this repair before, locally manufacture the blocker door hinge sleeve
installation fixture. See figure 603.

K. Install the standard or oversize wear sleeves or flanged sleeves.

(1) Get the correct standard or oversize wear sleeves or flanged sleeves. Refer to the
dimensional information in paragraph 3.

WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
AND CLOTHING TO PROTECT YOURSELF.

(2) Apply zinc chromate primer (C03-001) on the inner surface of the hole.

(3) While the primer is wet, push the new wear sleeve into the sleeve hole with the blocker
door hinge installation fixture.

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(4) Remove unwanted primer with a clean lint-free cotton cloth (C10-182).

(5) Do steps 5.K.(1) through 5.K.(4) until all of the sleeves have been installed.

L. Install a new sliding sleeve in each of the three wear sleeves and temporarily attach with safety
wire (C10-071).

NOTE: Use the safety wire to hold the sliding sleeves in position until you are ready to
R install the blocker door.

REPAIR 003
PAGE 610
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R LM50083-03-A
Locally Manufactured Blocker Door Hinge Sleeve Installation Fixture
Figure 603 (Sheet 1)

REPAIR 003
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R LM50082-03-A
Locally Manufactured Blocker Door Hinge Sleeve Installation Fixture
Figure 603 (Sheet 2)

REPAIR 003
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R MM50067-01-A
Locally Manufactured Blocker Door Hinge Sleeve Installation Fixture
Figure 603 (Sheet 3)

REPAIR 003
PAGE 613
78-32-03 JUN 01/01
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MANUAL

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R MR60030-01-A
Locally Manufactured Blocker Door Hinge Sleeve Installation Fixture
Figure 603 (Sheet 4)

REPAIR 003
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R MR60070-00-A
Locally Manufactured Blocker Door Hinge Sleeve Installation Fixture
Figure 603 (Sheet 5)

REPAIR 003
PAGE 615
78-32-03 JUN 01/01
 FAN REVERSER
CF6-80E1 CMM

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 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

FAN REVERSER BLOCKER DOOR - REPAIR

1. Blocker Door Teflon Wear Strip Replacement.

A. This procedure gives the instructions for replacement of the Teflon wear strips on the blocker door.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment.

Description Manufacturer

R Spatula, Wooden Local purchase

Heat source capable of heating Local purchase

R part to 190°F-210°F
R (88°C-99°C)

B. Consumable Materials.

Code Description Use

R
C01-126 Fabric Netting, Dacron Adhesive carrier cloth
Polyester

R C01-155 Adhesive, Paste, Bond the wear strip

R EA9394

C04-001 Solvent, Methyl-Ethyl-Ketone Clean the repair area

(MEK)

C04-003 Solvent, Acetone Clean the repair area

R C10-136 Tape, Flashbreaker Show the location of

R the replacement wear strips
R and hold the replacement parts
R in position

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Code Description Use

R C10-139 Gloves, White Cotton, Touch cleaned parts

R Disposable

C10-140 Gloves, Nylon Film/Polyethylene, Mix and apply the adhesive

Disposable

R C10-182 Cloths, Cleaning Clean the repair area

R --- Stiff-bristle brush Apply the adhesive

R --- Cloth, Abrasive, 180-240 Grit, Remove unwanted adhesive

R Aluminum Oxide, Waterproof

C. Expendable Parts. None required.

D. SPD Identification.

SPD No. Description

3046M82P04 TFE Tape, brown ceramic filled - etched on one side

E. Referenced Procedures. None required.

3. Dimensional Information. None required.

4. Setup Information. None required.

5. Procedure.

R A. Use the damaged wear strip or another blocker door as a pattern to cut the SPD Teflon wear
R strip to the correct length and width. See figure 601.

R B. Peel the damaged Teflon wear strip away from the blocker door with a spatula or a knife.

R WARNING: THE STEPS THAT FOLLOW REQUIRE THAT YOU CUT, SAND AND/OR ROTARY
R FILE GRAPHITE FIBER FILLED EPOXIES. USE A VACUUM CLEANER, WITH THE
R INTAKE ADJACENT TO THE REPAIR AREA, TO DRAW OFF GRINDING/FILING
R DUST. WEAR AN APPROVED DUST MASK SO YOU DO NOT BREATHE THE
R GRINDING/FILING DUST. WEAR SAFETY GLASSES SO YOU DO NOT GET
R GRINDING/FILING DUST IN YOUR EYES.

R CAUTION: BE CAREFUL NOT TO SAND INTO THE GRAPHITE FIBERS OF THE BLOCKER
R DOOR.

R C. Lightly sand the repair area with 180-240 grit aluminum oxide cloth to remove residual adhesive.

REPAIR 004
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R D. Clean the blocker door repair area and the replacement wear strips.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID
R IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF
R YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT
R AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR EYES
R BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY
R FLAMMABLE.

R CAUTION: DO NOT PUT SOLVENT DIRECTLY ON THE BLOCKER DOOR. DO NOT

R PUT THE BLOCKER DOOR IN A CONTAINER OF SOLVENT. DAMAGE CAN
R OCCUR.

R (1) Clean the blocker door repair area with a clean lint-free cotton cloth (C10-182) made
R moist with solvent (C04-001 or C04-003). Immediately dry the repair area with a dry,
R clean lint-free cotton cloth. Do not let the solvent dry on the repair area. Do this again
R until the repair area is clean.

R (2) Clean the etched (brown) side of the SPD wear strip material with a clean lint-free cotton
R cloth (C10-182) made moist with solvent (C04-003). Use gentle pressure so that you do
R not remove the etched surface from the Teflon. Immediately dry the material with a dry,
R clean lint-free cotton cloth. Do not let the solvent dry on the Teflon. Do this again until
R the Teflon is clean.

R (3) Let the blocker door and the wear strips dry for a minimum of 15 minutes.

R NOTE: Wear cotton gloves (C10-139) when you touch the cleaned surfaces.

R E. Apply flashbreaker tape (C10-136) to the blocker door to show the location of the wear strips.

R F. Cut strips of fabric netting (C01-126) to the same length and width as the blocker door wear
R strips.

R WARNING: ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR EYES OR ON

R YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. WEAR CLEAN NYLON FILM OR
R POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN YOU MIX OR APPLY
R THE ADHESIVE.

R G. Prepare paste adhesive (C01-155) by weight, 100 parts A with 17 parts B. Mix fully until you can
R see no streaks of the two compounds.

R NOTE: The pot life of a 3.53 ounce (100 gram) batch of mixed epoxy is approximately 60
R minutes.

R H. Use a stiff-bristle brush or a wooden spatula to apply a thin equal layer of paste adhesive (C01-
R 155), approximately 0.007 inch (0.178 mm), to the blocker door.

R I. Work the strip of fabric netting into the wet paste adhesive on the blocker door.

REPAIR 004
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R J. Make the netting smooth and apply a second thin layer of paste adhesive (C01-155) to cover the
R netting.

R K. Align the Teflon wear strip, with the etched (brown) side down, on the blocker door in the repair
R areas. The wear strip must be flush with, or 0.060 inch (1.52 mm) back from, the edge of the
R blocker door, and must not extend into the radius.

R L. Use flashbreaker tape (C10-136) in several areas to hold the wear strip in position.

R M. Put aluminum strips covered with flashbreaker tape (C10-136) in position over the wear strip
R and on the opposite side of the blocker door. Use clamps to hold the wear strips in position.

R NOTE: Use only sufficient clamping force to hold the Teflon wear strip in position with a
R constant, equal bondline. Do not damage the Teflon wear strip or blocker door.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
R AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
R SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
R GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS ARE
R VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R CAUTION: DO NOT PUT SOLVENTS DIRECTLY ON THE BLOCKER DOOR. DO NOT PUT THE
R BLOCKER DOOR IN A CONTAINER OF SOLVENT. DAMAGE CAN OCCUR.

R N. Use a spatula and a clean lint-free cotton cloth (C10-182) made moist with solvent (C04-001 or
R C04-003) to remove unwanted adhesive.

R O. Cure the adhesive for a minimum of one hour at 200°-220°F (93°-104°C).

R P. Remove the clamps, the aluminum strips, and the flashbreaker tape.

R Q. Examine the blocker door for: wrinkles in the wear strip, adhesive on the Teflon surface,
R unbonded areas, and too much adhesive on the blocker door. Remove unwanted adhesive with
R 180-240 grit aluminum oxide cloth.

REPAIR 004
PAGE 604
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R MR60063-01-A
R Location of Blocker Door Teflon Wear Strips
R Figure 601

REPAIR 004
PAGE 605
78-32-03 DEC 01/06
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 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

FAN REVERSER BLOCKER DOOR - REPAIR

1. Blocker Door Link Support Wear Strip Replacement.

A. This procedure gives the instructions for replacement of worn/damaged wear strips on
the blocker door link support assembly.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment.

Description Manufacturer

Spatula,Teflon Local purchase

Heat source capable of heating a Local purchase

part to 160°-200°F (71°-93°C)

B. Consumable Materials.

Code Description Use

C01-011 Adhesive, Epoxy Resin (EA 934) Bond the wear strip

C04-001 Solvent, Methyl-Ethyl-Ketone Clean the repair area

(MEK)

C10-049 Aluminum Oxide Grit, 180 Mesh Grit blast

C. Expendable Parts. None required.

D. SPD Identification. None required.

E. Referenced Procedures.

SPM 70-21-04

REPAIR 005
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3. Dimensional Information. None required.

4. Setup Information. None required.

5. Procedure.

CAUTION: USE A SAND BAG TO CORRECTLY SUPPORT THE INNER ARCH OF BLOCKER
DOOR TO PREVENT DAMAGE DURING LINK SUPPORT WEAR STRIP REMOVAL.

CAUTION: THE LINK SUPPORT HOUSING IS MADE OF ALUMINUM. BE CAREFUL NOT TO

DAMAGE THE LINK SUPPORT HOUSING SURFACE DURING WEAR STRIP
REMOVAL.

A. Remove the wear strip from the link support assembly with a light weight mallet and a thin, fine-
edged chisel.

B. Use 180-240 grit aluminum oxide cloth lightly to remove unwanted adhesive from the repair
area.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

CAUTION: DO NOT PUT SOLVENTS DIRECTLY ON THE BLOCKER DOOR. DO NOT PUT THE
BLOCKER DOOR IN A CONTAINER OF SOLVENT. DAMAGE CAN OCCUR.

C. Clean the repair area with a clean lint-free cotton cloth made moist with solvent (C04-001).
Immediately dry the repair area with a dry, clean lint-free cotton cloth. Do not let the solvent dry
on the repair area. Do this again until the repair area is clean.

D. Let the repair area dry a minimum of 15 minutes.

E. Grit blast the entire bonding surface of wear strip with 180 mesh aluminum oxide grit (C10-049).
Refer to SPM 70-21-04.

REPAIR 005
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WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

F. Clean the wear strip material with a clean lint-free cotton cloth made moist with solvent (C04-
003). Dry with a clean lint-free cotton cloth.

NOTE: Wear clean cotton gloves when you touch cleaned surfaces.

WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN

YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. WEAR
CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN
YOU MIX OR APPLY THE ADHESIVE.

G. Prepare epoxy resin adhesive (C01-011) by weight, 100 parts A to 33 parts B, and mix fully.

NOTE: The pot life of a 4.66 ounce (133 gram) batch of mixed epoxy is approximately 40
minutes.

H. Use a stiff bristle brush and a scrubbing action to apply a thin equal layer of epoxy resin
adhesive (C01-011), approximately 0.007 inch (0.178 mm), to the link support assembly.

I. Put the wear strip on the link support assembly. See figure 601.

J. Hold the wear strip in position with a clamp.

NOTE: Use only sufficient clamping force to hold the wear strip in position. Do not damage the
wear strip or the link support assembly.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

K. Use a spatula and a clean lint-free cotton cloth made moist with solvent (C04-001), to remove
unwanted epoxy resin adhesive.

L. Cure the adhesive for a minimum of one hour at 175° to 200°F (79° to 93°C) or refer to the
manufacturer's instructions.

M. Remove the clamps and make a visually inspection of the wear strip for unbonded areas.

REPAIR 005
PAGE 603
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 COMPONENT
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MANUAL

683L SERIES

CF8-7311-00-A
Blocker Door Link Support Assembly Wear Strip Replacement
Figure 601

REPAIR 005
PAGE 604
78-32-03 DEC 01/98
 COMPONENT
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MANUAL

683L SERIES

FAN REVERSER BLOCKER DOOR - REPAIR

1. Repair of Damage to Blocker Door Edges.

A. This procedure gives the instructions to repair delamination, cracks, or chipped edges in the fan
reverser blocker door edges.

(1) Paragraph 5 gives instructions to repair delaminated edges.

(2) Paragraph 6 gives instructions to repair cracked edges with possible delamination.

(3) Paragraph 7 gives instructions to repair chipped edges on the back plate.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment.

Description Manufacturer

Syringe Local purchase

Spatula, Teflon Local purchase

Heat source capable of heating a Local purchase

part to 160°-200°F (71°-93°C)

B. Consumable Materials.

Code Description Use

C01-106 Adhesive, Epoxy Resin, EA 956 Fill the repair area

C04-014 Alcohol, Denatured Clean the repair area

C10-140 Gloves, Nylon Film/Polyethylene, Mix and apply the adhesive

Disposable

--- Abrasive paper, 180-200 Grit Make the repair area smooth

REPAIR 006
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C. Expendable Parts. None required.

D. SPD Identification. None required.

E. Referenced Procedures. None required.

3. Dimensional Information. None required.

4. Setup Information. None required.

5. Repair of Blocker Door Edge Delamination.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

CAUTION: DO NOT PUT SOLVENT DIRECTLY ON THE BLOCKER DOOR. DO NOT PUT THE
BLOCKER DOOR IN A CONTAINER OF SOLVENT. DAMAGE CAN OCCUR.

A. Clean the repair area with a clean lint-free cotton cloth made moist with alcohol (C04-014).
Immediately dry the repair area with a dry, clean lint-free cotton cloth. Do not let the alcohol dry
on the repair area. Do this again until the repair area is clean.

B. Let the repair area dry a minimum of 15 minutes.

CAUTION: BE CAREFUL NOT TO CAUSE MORE DAMAGE WHEN YOU SEPARATE THE
BLOCKER DOOR AT THE DELAMINATED AREA.

C. Slightly separate and hold open the blocker door edge where there is delamination.

WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN

YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. WEAR
CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN
YOU MIX OR APPLY THE ADHESIVE.

D. Prepare the epoxy resin adhesive (C01-106) by weight, 100 parts A to 58 parts B, and mix fully.

E. Apply the epoxy resin adhesive (C01-106) as follows:

(1) Apply the adhesive into the delaminated area with a standard syringe.

(2) Use clamps to hold the repair in position. Use a spatula to make the adhesive smooth
and flush with the edge while you remove unwanted adhesive.

(3) Cure the adhesive for one hour at ambient temperature; then cure for one hour at 160°-
200°F (71°- 93°C); or cure at ambient temperature for 24 hours.

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F. After the adhesive has fully cured, remove the clamps

WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN

YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. WEAR
CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN
YOU MIX OR APPLY THE ADHESIVE.

G. Apply a light layer of newly mixed adhesive (C01-106) to the repair area. Make an overlap of
0.5 inch (12.7 mm) on the edges and sides of the repair. Refer to step 5.D. to mix the adhesive.

H. Cure the adhesive. Refer to step 5.E.(3).

6. Repair of Blocker Door Edge Cracks with Possible Delamination .

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

CAUTION: DO NOT PUT SOLVENT DIRECTLY ON THE BLOCKER DOOR. DO NOT PUT THE
BLOCKER DOOR IN A CONTAINER OF SOLVENT. DAMAGE CAN OCCUR.

A. Clean the repair area with a clean lint-free cotton cloth made moist with alcohol (C04-014).
Immediately dry the repair area with a dry, clean lint-free cotton cloth. Do not let the alcohol dry
on the repair area. Do this again until the repair area is clean.

B. Let the repair area dry a minimum of 15 minutes.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

CAUTION: DO NOT PUT SOLVENT DIRECTLY ON THE BLOCKER DOOR. DO NOT PUT THE
BLOCKER DOOR IN A CONTAINER OF SOLVENT. DAMAGE CAN OCCUR.

C. If the crack causes a step in the door edge, use 180-200 grit abrasive paper to make the step
flush with the adjacent surface. Clean the surface with alcohol (C04-014).

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WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

CAUTION: DO NOT PUT SOLVENT DIRECTLY ON THE BLOCKER DOOR. DO NOT PUT THE
BLOCKER DOOR IN A CONTAINER OF SOLVENT. DAMAGE CAN OCCUR.

CAUTION: BE CAREFUL NOT TO CAUSE MORE DAMAGE WHEN YOU SEPARATE THE
BLOCKER DOOR AT THE DELAMINATED AREA.

D. If the door is delaminated, slightly separate and hold open the door edge where there is
delamination. Wipe the surface with alcohol (C04-014).

WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN

YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. WEAR
CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN
YOU MIX OR APPLY THE ADHESIVE.

E. Prepare the epoxy resin adhesive (C01-106) by weight, 100 parts A with 58 parts B, and mix
fully.

F. Apply the epoxy resin adhesive (C01-106) as follows:

(1) Apply the adhesive into the cracked area and delaminated area, if applicable, with a
standard syringe.

(2) Use clamps to hold the repair area in position. Use a spatula to make the adhesive
smooth and flush with the edge while you remove unwanted adhesive.

(3) Cure the adhesive for one hour at ambient temperature, then cure for one hour at 160°-
200°F (71°-93°C); or cure at ambient temperature for 24 hours.

G. After the adhesive has fully cured, remove the clamps.

H. Apply a light layer of newly mixed adhesive (C01-106) to the repair area. Make an overlap of
0.5 inch (12.7 mm) on the edges and sides of the repair. Refer to step 6.F. to mix the adhesive.

I. Cure the adhesive. Refer to step 6.F.(3).

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7. Repair of Chipped Edges on Blocker Door Back Plate.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

CAUTION: DO NOT PUT SOLVENT DIRECTLY ON THE BLOCKER DOOR. DO NOT PUT THE
BLOCKER DOOR IN A CONTAINER OF SOLVENT. DAMAGE CAN OCCUR.

A. Clean the repair area with a clean lint-free cotton cloth made moist with alcohol (C04-014).
Immediately dry the repair area with a dry, clean lint-free cotton cloth. Do not let the alcohol dry
on the repair area. Do this again until the repair area is clean.

B. Let the repair area dry a minimum of 15 minutes.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

CAUTION: DO NOT PUT SOLVENT DIRECTLY ON THE BLOCKER DOOR. DO NOT PUT THE
BLOCKER DOOR IN A CONTAINER OF SOLVENT. DAMAGE CAN OCCUR.

C. Lightly hand sand any steps or rough edges with 180-200 grit abrasive paper. Wipe with
denatured alcohol.

WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN

YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. WEAR
CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN
YOU MIX OR APPLY THE ADHESIVE.

D. Do the steps that follow to apply the epoxy resin adhesive (C01-106).

(1) Prepare the epoxy resin adhesive (C01-106) by weight, 100 parts A to 58 parts B, and
mix fully.

(2) Apply a light layer of epoxy resin adhesive (C01-106) to the damaged area. Use a
spatula to make the adhesive smooth and flush with the adjacent surfaces.

(3) Cure the adhesive for one hour at ambient temperature, then cure for one hour at 160°-
200°F (71°-93°C); or cure at ambient temperature for 24 hours.

REPAIR 006
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 FAN REVERSER
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 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

FAN REVERSER BLOCKER DOOR - REPAIR

1. Repair of Tears and Cuts in the Blocker Door Screen.

R A. This procedure gives the instructions to repair tears, cuts and delaminations up to 2.0 inches
R (50.8 mm) diameter in the face sheet screen of the fan reverser blocker doors.

R NOTE: This repair changes the acoustic properties of the thrust reverser, thus the standard
R acoustic limits apply. The maximum permitted loss of effective acoustic treatment
R area (total blockage) is 6.5 sq ft (0.60 sq m) for a full reverser (two halves). This 6.5
R sq ft (0.60 sq m) includes all areas with a partial loss of effective acoustic treatment
R (missing wire mesh). A 4.0 sq ft (0.37 sq m) area of partial loss of effective acoustic
R treatment (missing wire mesh) is approximately equal to a 1.0 sq ft (0.09 sq. m) area
R of effective acoustic treatment loss (total blockage).

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment.

Description Manufacturer

R Spatula, Acrylic Local purchase

Heat source that can heat a part Local purchase

R between 200°-220°F (93°-104°C)

B. Consumable Materials.

Code Description Use

R C01-147 Adhesive, Structural Liquid, Fill the repair area

R EA 9396 and bond the screen

R C04-001 Solvent, Methyl Ethyl Clean the repair area

R Ketone (MEK)

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Code Description Use

R C04-003 Solvent, Acetone Clean the repair area

C04-014 Alcohol, Denatured Clean the repair area

R C10-136 Flashbreaker Tape Protect the area adjacent to the repair

C10-140 Gloves, Nylon Film/Polyethylene, Mix and apply the adhesive

Disposable

R C10-141 Abrasive Cloth, 120-180 Grit Prepare the surface

R C10-182 Cloths, Cleaning Clean the repair area

R --- Film, Teflon, 0.002-0.004 in. Protect the surface

R (0.051-0.102 mm) Thick

R --- Sheet, Rubber, High- Apply pressure

R Temperature Silicone

C. Expendable Parts. None required.

D. SPD Identification. None required.

R E. Referenced Procedures.

R 78-32-03 Repair 008

R 78-32-03 Repair 010

3. Dimensional Information. None required.

4. Setup Information. None required.

5. Procedure.

R A. Find the extent of the damage and find what repair is necessary.

R (1) Make an inspection of the damaged screen. If the screen damage is a maximum of 2.0
R inches (50.8 mm) diameter, and not more than a 0.75 inch (19.1 mm) area of wire
R screen is missing, go to step 5.B. If the damage is more than these limits, use 78-32-
R 03 Repair 008.

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R B. Non-acoustic repair of damaged or missing screen.

R (1) Remove loose strands of screen and expose the face sheet under the unbonded or
R damaged screen.

R (a) Use scissors to remove loose strands of screen.

R CAUTION: MAKE SURE YOU DO NOT DAMAGE THE FACE SHEET WHEN
R YOU CUT THE SCREEN.

R (b) If the screen is unbonded, use a utility knife to cut the screen diagonally to get
R access to the face sheet under the screen.

R (2) Apply flashbreaker tape (C10-136) to keep the loose screen away from the face sheet
R when you prepare the surface. Apply the tape 1.0 inch (25.4 mm) around the repair
R area.

R (3) Make an inspection of the face sheet in the repair area. Look for cracks, splits, dents,
R or delaminations. If you find damage, refer to 78-32-03 Repair 010.

R WARNING: THE STEPS THAT FOLLOW REQUIRE THAT YOU SAND GRAPHITE FIBER
R FILLED EPOXIES. USE A VACUUM CLEANER, WITH THE INTAKE
R ADJACENT TO THE REPAIR AREA, TO DRAW OFF GRINDING/FILING
R DUST. WEAR AN APPROVED DUST MASK SO YOU DO NOT BREATHE
R THE GRINDING/FILING DUST. WEAR SAFETY GLASSES SO YOU DO NOT
R GET GRINDING/FILING DUST IN YOUR EYES.

R CAUTION: BE CAREFUL NOT TO SAND INTO THE GRAPHITE FIBERS OF THE

R BLOCKER DOOR. DO NOT DAMAGE THE FIBERS.

R (4) Use 120-180 grit abrasive cloth (C10-141) to remove surface resin glaze, unwanted
R adhesive and other unwanted material from the face sheet. It is not necessary to
R remove all of the adhesive if the repair area has an equal, non-glazed surface.

R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

R PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
R SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE. WEAR
R GOGGLES. DO NOT POINT COMPRESSED AIR IN THE DIRECTION OF
R YOUR SKIN.

R WARNING: THIS PROCESS GIVES OFF AIRBORNE DUST PARTICLES THAT ARE
R POISONOUS. PUT ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE
R MASK. MAKE SURE THE AREA HAS GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE IN THE DUST PARTICLES.

R (5) Use clean, dry, oil-free shop air to remove unwanted material from the repair area.

R (6) Remove the flashbreaker tape.

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R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R CAUTION: DO NOT PUT ALCOHOL DIRECTLY ON THE BLOCKER DOOR. DO NOT

R PUT THE BLOCKER DOOR IN A CONTAINER OF ALCOHOL. DAMAGE
R CAN OCCUR.

R (7) Clean the repair area, the screen, the face sheet, and the area 1.0 inch (25.4 mm)
R around the damage area with a clean, lint-free cotton cloth (C10-182) moist with solvent
R (C04-001, C04-003, or C04-014). Remove the solvent from the repair area with a dry,
R clean lint-free cotton cloth. Do not let the solvent dry on the repair area. Do this again
R until the repair area is clean.

R (8) Let the repair area dry for a minimum of 30 minutes.

R (9) Do the steps that follow to prepare the structural liquid adhesive (C01-147).

R (a) Use a clean metal or uncoated paper container to mix the adhesive.

R (b) Make an estimate of the quantity of adhesive that you will need.

R WARNING: ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN

R YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE
R AIR. WEAR CLEAN NYLON FILM OR POLYETHYLENE
R DISPOSABLE GLOVES (C10-140) WHEN YOU MIX OR APPLY THE
R ADHESIVE.

R (c) Weigh out sufficient quantities of the two components of the adhesive in the
R ratio that follows.

R 1 Resin (aqua blue color) - 100 parts

R 2 Catalyst (reddish dark amber color) - 30 parts

R WARNING: DO NOT MAKE A MIXTURE LARGER THAN 18 OUNCES (457

R GRAMS). IF YOU MIX MORE THAN THIS, DANGEROUS HEAT
R BUILDUP CAN OCCUR.

R (d) Mix the resin and the catalyst until the mixture is one color.

R (10) Apply a thin layer of adhesive to cover the unbonded and/or the frayed screen fibers in
R the repair area, on the face sheet, and in the area up to 1.0 inch (25.4 mm) around the
R repair area. Push the loose screen into position. Make the outer screen fibers wet with
R adhesive to make sure that all of the screen is fully soaked with the adhesive.

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R (11) Use a spatula to make the adhesive smooth and flush with the screen. Remove
R unwanted adhesive.

R (12) Put Teflon film and flashbreaker tape (C10-136) over the repair area. Apply a rubber
R pad and add weight as necessary to hold the screen to the contour of the blocker door.

R (13) Cure the adhesive for 1 hour at 200°-220°F (93°-104°C).

R (14) Remove the Teflon film and the flashbreaker tape. If necessary, use 180 grit abrasive
R cloth (C10-141) to make the repair area smooth.

REPAIR 007
PAGE 605
78-32-03 JUN 01/02
 FAN REVERSER
CF6-80E1 CMM

THIS PAGE INTENTIONALLY BLANK

 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

FAN REVERSER BLOCKER DOOR - REPAIR

1. Blocker Door Screen Replacement.

R A. This procedure gives the instructions to replace damaged or missing blocker door screen. This
R repair keeps the acoustic properties of the blocker door.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment.

Description Manufacturer

R Spatula, Acrylic Local purchase

Oven capable of heating a Local purchase

part between 140°-160°F (60°-71°C)
and 275°-285°F (135°-141°C)

R Spray Gun, Model 115, Brinks Manufacturing Company

R Air Cap 785D, Nozzle 78 9205 West Belmont Avenue
Franklin Park, Illinois

B. Consumable Materials.

Code Description Use

R
C01-066 Adhesive, Epoxy Film, Make a border for the screen
FM-123-5
R
C01-134 Adhesive, Spray, EC 3964 Bond the screen

C04-001 Solvent, Methyl Ethyl Clean the repair area

Ketone (MEK)

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Code Description Use

C04-003 Solvent, Acetone Clean the repair area

C04-014 Alcohol, Denatured Clean the repair area

C10-012 High Temperature Tape, Mask the repair area

Fluorglas 2905-7

C10-040 Tape, Teflon, 1.0 x 0.002 inch Mask the repair area

C10-048 Bleeder Cloth, Osnaburg, Vacuum bag material

6.5 oz/sq yd, 40 in. (102 cm)
wide

C10-051 Film, Release, Perforated Vacuum bag material

(E3760-P2) 0.001 inch (0.03 mm)
thick

C10-119 Wire Mesh, Stainless Steel Screen material

R C10-134 Bleeder cloth, N10 Polyester Felt Vacuum bag, air bleeder

C10-137 Film, Vacuum Bag Vacuum bag material

C10-138 Sealant Tape, Vacuum Bag, Vacuum bag sealant

GS-213

C10-140 Gloves, Nylon Film/Polyethylene, Mix and apply the adhesive

Disposable

R C10-141 Abrasive Cloth, 120-180 Grit Prepare the surface

R C10-182 Cloths, Cleaning Clean the repair area

--- Polyester (Mylar) Film Protect the surface

0.002-0.004 inch (0.05-0.10 mm)
thick

R --- Film, Teflon, 0.002-0.004 inch Protect the surface

(0.05-0.10 mm) thick

C. Expendable Parts. None required.

D. SPD Identification. None required.

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E. Referenced Procedures.

78-32-03 Repair 010

R
3. Dimensional Information. None required.

4. Setup Information. None required.

5. Procedure.

A. Find the extent of the damage and find what repair is necessary.

(1) Make an inspection of the damaged screen. You can use this repair to replace all or
part of the screen, or you can remove all of the screen and replace the face sheet to
R have a screenless blocker door with the same acoustic properties. Contact MRAS
R PSE for further instruction.

B. Replace the screen.

NOTE: This repair keeps the acoustic properties of the blocker door.

NOTE: If a large area of wire screen is damaged, you can use this repair to replace all of
the screen on the blocker door.

CAUTION: DO NOT CUT INTO THE FACE SHEET WHEN YOU CUT THE WIRE MESH.

(1) Use a utility knife and/or scissors to cut out a regularly shaped measurable area around
the damaged or missing screen. If possible, make the cutout area the minimum size
needed to do the repair. Remove the damaged screen.

NOTE: The purpose of this cut is to clean up the edges of the repair area and
make it easier to replace the screen.

(2) Make an inspection of the face sheet in the repair area.

(a) Look for cracks, splits, dents, or delaminations.

(b) If there is face sheet damage up to a maximum of 1.5 inches (38.1 mm)
diameter, refer to 78-32-03 Repair 010. For larger areas of face sheet damage,
R replace the face sheet. Contact MRAS PSE.

(3) Make a measurement of the area where the damaged screen has been removed. Cut a
piece of wire mesh replacement screen (C10-119) to fit. The orientation of the
replacement screen must be the same as the adjacent screen on the blocker door.

NOTE: Gaps between the replacement screen and the existing screen must not be
more than 0.063 inch (1.60 mm). No overlap is permitted.

REPAIR 008
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R (4) Use 120-180 grit abrasive cloth (C10-141) to remove surface resin glaze, unwanted
R adhesive, and other unwanted material from the face sheet. It is not necessary to
R remove all of the adhesive if the repair area has an equal, non-glazed surface.

R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

R PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
R SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE. WEAR
R GOGGLES. DO NOT POINT COMPRESSED AIR IN THE DIRECTION OF
R YOUR SKIN.

R WARNING: THIS PROCESS GIVES OFF AIRBORNE DUST PARTICLES THAT ARE
R POISONOUS. PUT ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE
R MASK. MAKE SURE THE AREA HAS GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE IN THE DUST PARTICLES.

R (5) Use clean, dry, oil-free shop air to remove unwanted material from the repair area.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R CAUTION: DO NOT PUT SOLVENTS DIRECTLY ON THE BLOCKER DOOR. DO NOT

R PUT THE BLOCKER DOOR IN A CONTAINER OF SOLVENT. DAMAGE CAN
R OCCUR.

R (6) Clean the repair area and the wire mesh replacement screen with a clean lint-free cotton
R cloth (C10-182) made moist with solvent (C04-001, C04-003, or C04-014). Immediately
R dry the repair area with a clean lint-free cotton cloth. Do not let the solvent dry on the
R surface. Do this again until the repair area is clean.

R (7) Let the repair area dry for a minimum of 15 minutes.

R (8) Use an eye dropper to apply water to several areas of the face sheet surface to do a
R check for a water break free surface.

R (a) If the water beads up in the face sheet surface, do steps 5.B.(4) through 5.B.(7)
R again.

R (b) Blow dry the surface with a heat gun, at a maximum temperature of 250° F
(121° C).

R (9) Mask the area around the repair with tape (C10-040 or C10-012) and Mylar film.

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R WARNING: ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR EYES

R OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. WEAR CLEAN
R NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN
R YOU MIX OR APPLY THE ADHESIVE.

R (10) Prepare a sufficient quantity of spray adhesive (C01-134). Shake the material on a
R vibrating paint shaker for approximately 5 minutes. Filter the material if it has small
R crystals in it.

R (11) Use a spray gun to apply a thin, equal layer of adhesive to a thickness of 0.0012-0.0016
R in. (0.030-0.040 mm) on the exposed area of perforated face sheet. Apply as many
R layers as necessary to reach the correct thickness. Let the adhesive dry for 15 to 30
R minutes between each application.

R (12) Put the blocker door in a clean, dust free oven preheated to 140°-160°F (60°-71°C) and
R pre-cure the spray adhesive for 60 minutes.

R WARNING: WEAR THERMAL OR INSULATED GLOVES TO PREVENT HAND INJURY

R WHEN YOU TOUCH HOT OR COLD PARTS.

R (13) Remove the blocker door from the oven.

R NOTE: The wire mesh replacement screen must be bonded within 48 hours after
R oven cure.

R (14) Cut the epoxy film adhesive (C01-066) into strips 0.150 in. (3.81 mm) wide and
R sufficiently long to fit around the outside border of the exposed area of the perforated
R face sheet. Include the edges of the face sheet and the link arm slot, if exposed.

R (15) Apply strips of epoxy film adhesive (C01-066) around the outside border of the exposed
R area of the perforated face sheet and at the abutting edges of the existing screen.

R (16) Lay the previously cut piece of replacement screen over the exposed area of perforated
R face sheet. Make sure that gaps between the replacement screen and the existing
R screen are not larger than 0.063 in. (1.60 mm).

R (17) Use an acrylic spatula (see figure 601) to push the wire mesh replacement screen down
R into the epoxy film adhesive and the spray adhesive on the face sheet bond area. Work
R out any wrinkles in the replacement screen. If necessary, you can warm the film
R adhesive lightly with a heat gun.

R (18) Use scissors to remove all unwanted replacement screen. Make sure that there is no
R overlap between the replacement screen and the existing screen edges.

R (19) Apply a strip of the film adhesive (C01-066) over the joint between the existing screen
R and the replacement screen and push down firmly with the acrylic spatula before you
R remove the backing. If necessary, you can warm the film adhesive lightly with a heat
R gun.

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R (20) Do the steps that follow to prepare the vacuum bag.

R (a) Cut the temperature resistant bagging film (C10-137) to cover the blocker door
R shape with a minimum of 10 in. (25.4 cm) allowance around the area of the
R door. Make sure there is a sufficient quantity for connection of the vacuum line
R connections.

R (b) Cut two pieces of Osnaburg cloth (C10-048) or N10 polyester felt bleeder cloth
R (C10-134) and a piece of perforated film (C10-051) 1.0 in. (25.4 mm) smaller all
R round than the bagging film.

R (c) Make two vacuum fitting cushions from 12.0 in. (30.5 cm) square pieces of
R bleeder cloth folded to 4.0 in. (10.2 cm) square, nine-ply thick cushions.

R (d) Attach the vacuum bag sealant tape (C10-138) tightly around the edge of the
vacuum bag. Do not remove the paper backing from the sealant tape.

R (e) Install the vacuum bag stems in the bag 180° apart and positioned well clear of
R the repair area. See figure 602.

R (f) Attach the vacuum fitting cushions to the vacuum bag over the vacuum bag
R fittings with Teflon tape (C10-040).

R (g) Put the perforated film (C10-051) over the blocker door face and attach the film
R lightly in position with Teflon tape (C10-040).

R (h) Fold the first layer of bleeder cloth over the screen surface and attach the
R bleeder cloth lightly in position with Teflon tape (C10-040).

R (i) Attach a minimum of two thermocouples to the outside of the bleeder cloth in
R the center of the repair area with a small piece of Teflon tape.

R (j) Wrap the second layer of bleeder cloth over the blocker door and attach lightly
R in position with Teflon tape (C10-040). Use bleeder cloth to protect the vacuum
R bag from sharp corners and to give an evacuation path for the bag.

R (k) Peel off the backing paper from the sealant tape and push the vacuum bag
R edges together. Work with one edge at a time. Put two tucks or "ears" in each
R edge to avoid local stretching that will cause tears in the bag. See figure 603.
R You can use an acrylic spatula (figure 601) to push down the sealant tape.
R Make sure that the wires from the thermocouples are led out through the
R sealant for later use.

R (21) Cure the blocker door.

R (a) Attach the vacuum lines.

R (b) Evacuate the bag to 10-18 in. of mercury (Hg) minimum. Examine the bag for
R leaks and repair the bag as necessary

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MM50071-01-A
R Acrylic Spatula "Bone"
Figure 601

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R (c) Install the bagged blocker door in the oven and attach the thermocouples and
R the vacuum lines.

R NOTE: The oven must be able to increase the temperature of the part to
R 275°-285°F (135°-141°C). Make a measurement of the
R temperature with the thermocouples attached to the part. The
R recommended rate of temperature increase is 4°-5°F (or
R equivalent) per minute.

R (d) Keep the blocker door temperature at 275°-285°F (135°-141°C) for 1 hour.

R (e) Lower the temperature of the blocker door to 120°F (49°C) or lower before you
vent the vacuum lines.

R WARNING: WEAR THERMAL OR INSULATED GLOVES TO PREVENT HAND INJURY

R WHEN YOU TOUCH HOT OR COLD PARTS.

R (22) Remove the bagged blocker door from the oven. Remove the vacuum bag fittings, the
R vacuum bag, the bleeder cloth, and the thermocouples from the blocker door.

R (23) Make an inspection of the wire mesh replacement screen for unbonded areas.

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1093873-00-A
Vacuum Fitting Installation
Figure 602 (Sheet 1 of 2)

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1093874-00-A
Vacuum Fitting Installation (Alternative)
Figure 602 (Sheet 2 of 2)

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1093875-00-A
Formation of Tuck or "Ear" in the Edge of the Vacuum Bag
Figure 603

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 FAN REVERSER
CF6-80E1 CMM

THIS PAGE INTENTIONALLY BLANK

 COMPONENT
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R FAN REVERSER BLOCKER DOOR - REPAIR

R 1. Repair of Blocker Door Back Plate Damage.

R A. This procedure gives the instructions to repair punctures, tears, cracks, and dents in the back
R plate of the blocker door.

R NOTE: This repair changes the acoustic properties of the thrust reverser; thus the standard
R acoustic limits apply. The maximum permitted loss of effective acoustic treatment
R area (total blockage) is 6.5 sq ft (0.60 sq m) for a full reverser (two halves). This 6.5
R sq ft (0.60 sq m) includes all areas with a partial loss of effective acoustic treatment
R (missing wire mesh). A 4.0 sq ft (0.37 sq m) area of partial loss of effective acoustic
R treatment (missing wire mesh) is approximately equal to a 1.0 sq ft (0.09 sq m) area
R of effective acoustic treatment loss (total blockage).

R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools. None required.

R (3) Locally Manufactured Tools. None required.

R (4) Equipment.

R Description Manufacturer

R Spatula, Acrylic Local purchase

R Heat source capable of heating a Local purchase

R part to 200°-220°F (93°-104°C)

R Filleting Gun Semco Division

R Products, Research and Chemical Co.
R Los Angeles, CA

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B. Consumable Materials.

Code Description Use

R C01-155 Adhesive, Paste, EA 9394 Fill the repair area

C03-010 Paint, Epoxy Polyamide, Paint the repair area

MIL-C-22750

R DELETED

C04-003 Solvent, Acetone Clean the repair area

C04-035 Isopropyl Alcohol Clean the repair area

C10-136 Tape, Flashbreaker Protect the surface adjacent

to the repair area

C10-140 Gloves, Nylon Film/Polyethylene, Mix and apply the adhesive

Disposable

C10-142 Film, Polyester (Mylar), Protect the surface adjacent

0.002-0.004 in. (0.05-0.10 mm) to the repair area
thick

C10-182 Cloths, Cleaning Clean the repair area

--- Cloth, Abrasive, 180-240 Grit, Prepare the repair area

Aluminum Oxide, Waterproof

--- Marker, Water-soluble Make a mark around

the damaged area

C. Expendable Parts. None required.

D. SPD Identification. None required.

E. Referenced Procedures.

SPM 70-43-22

3. Dimensional Information. None required.

4. Setup Information. None required.

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5. Procedure.

A. Find the extent of the damage and find what repair is necessary.

(1) Do a tap test in the area around the damage, and the skin opposite the damaged area,
to find the unbonded area.

(a) Use a 0.5-1.0 oz (14-28 g) aluminum mallet to lightly hit the surface of the area
in and around the damaged area.

NOTE: If you hear a solid "click" sound, there are no voids. If you hear an
empty sound, the area is unbonded.

(b) Use a felt-tip marker to make a line around the unbonded area or areas.

(2) You can do this repair if the damage is in the limits that follow.

(a) This repair is for fractures or holes in the back plate less than 0.75 inch (19.1
mm) diameter with damage to the panel core less than 2.0 inches (50.8 mm)
diameter. This repair is only applicable to the horizontal, raised area of the
back plate that has core below. This repair is not applicable to the back plate
edges, the vertical surfaces, or the radius areas. There must be a minimum of
10.0 inches (25.4 cm) between the damaged areas. Refer to figure 601.

B. Surface preparation.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

CAUTION: DO NOT PUT SOLVENT DIRECTLY ON THE BLOCKER DOOR. DO NOT

PUT THE BLOCKER DOOR IN A CONTAINER OF SOLVENT.
DAMAGE CAN OCCUR.

(1) Clean the repair area with a clean lint-free cotton cloth (C10-182) made moist with
R solvent (C04-003 or C04-035). Immediately dry the repair area with a clean,
lint-free cotton cloth. Do not let the solvent dry on the repair surface. Do this again
until the repair area is clean.

(2) Use a drill bit up to a maximum diameter of 0.750 in. (19.1 mm) to drill a hole into the
back plate. Remove all of the damaged back plate and honeycomb core.

NOTE: Be careful not to drill too deep and cause damage to the opposite skin.

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R MR60072-00-C
R Repair of Back Plate Damage Less than 0.75 Inch (19.1 mm) Diameter
R Figure 601

R (3) Spoil (cut into honeycomb cells of core) the core to a minimum of 1.0 in. (25.4 mm)
R diameter and a maximum of 2.0 in. (50.8 mm) diameter.

R NOTE: Spoiled core can stay in the repair cavity; however, make sure that the
R pieces of spoiled core do not fold over and close off the honeycomb cells.

R (4) Drill a maximum of four 0.040 inch (1.02 mm) vent holes in the back plate with a No. 60
R drill. Make sure there is an equal distance between the holes. Put the holes 0.10 inch
R (2.54 mm) inside the outer edge of the spoiled core circle.

R (5) Use flashbreaker tape (C10-136) to protect the area adjacent to the repair area.

R (6) Use abrasive cloth to make the repair area around the drilled holes lightly rough.

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R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

R PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
R SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE. WEAR
R GOGGLES. DO NOT POINT COMPRESSED AIR IN THE DIRECTION OF
R YOUR SKIN.

R WARNING: THIS PROCESS GIVES OFF AIRBORNE DUST PARTICLES THAT ARE
R POISONOUS. PUT ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE
R MASK. MAKE SURE THE AREA HAS GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE IN THE DUST PARTICLES.

R (7) Remove unwanted material with clean, dry, oil-free shop air.

R C. Apply the adhesive.

R (1) Do the steps that follow to prepare the paste adhesive (C01-155).

R WARNING: ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR EYES

R OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. WEAR CLEAN
R NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN
R YOU MIX OR APPLY THE ADHESIVE.

R (a) In a clean metal or uncoated paper container, combine by weight: 100 parts
R resin (A) with 17 parts catalyst (B).

R (b) Mix fully until you can see no streaks of the two components.

R NOTE: The pot life of a 4.66 ounce (132 gram) batch of mixed epoxy is
R approximately 40 minutes.

R (2) Use a filleting gun filled with paste adhesive (C01-155) to fill the spoiled core area. Fill
R through the center hole in the back plate and each vent hole until the adhesive
R comes out of the four vent holes. Fill the repair holes flush with the adjacent surface of
R the blocker door back plate. See figure 601.

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WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

R (3) Use a spatula and a clean, lint-free cotton cloth (C10-182) moist with solvent (C04-003
or C04-035) remove unwanted adhesive and make the adhesive smooth and
flush with the back plate surface.

NOTE: You can install a mask-off plate over the adhesive-filled repair during the
cure to help get a good bond with the adjacent area. Use flashbreaker tape
(C10-136) or film over the mask-off area as necessary.

(4) Cure the adhesive for 1 hour at 200°-220°F (93°-104°C).

(5) Use 180-200 grit abrasive paper to make the repair area smooth and flush with the
adjacent back plate surface.

WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE.
WEAR GOGGLES. DO NOT POINT COMPRESSED AIR IN THE DIRECTION
OF YOUR SKIN.

WARNING: THIS PROCESS GIVES OFF AIRBORNE DUST PARTICLES THAT ARE
POISONOUS. PUT ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE
MASK. MAKE SURE THE AREA HAS GOOD AIR FLOW. MAKE SURE YOU
DO NOT BREATHE IN THE DUST PARTICLES.

(6) Remove unwanted material with clean, dry, oil-free shop air.

(7) Do a tap test of the repaired area with a 0.5-1.0 oz. aluminum mallet to make sure there
are no unbonded areas.

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WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

R (8) Clean the repair area with a lint-free cotton cloth (C0-182) moist with solvent (C04-003
or C04-035).

(9) Let the repair area dry a minimum of 15 minutes.

WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL

IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR.
WEAR CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES
(C10-140) WHEN YOU MIX OR APPLY THE ADHESIVE.

(10) If pores are exposed in the repair area, fill the pores with paste adhesive (C01-155)
until flush with the back plate. Cure the adhesive. Refer to steps (4) through (10).

D. Do the steps that follow to apply the protective layer of paint.

(1) Apply epoxy polyamide paint (C03-010) to the repair area on the back plate.

(a) Mask around the blocker door back plate repair area with mylar film (C10-142)
and flashbreaker tape (C10-136).

WARNING: THIS PAINT IS POISONOUS AND GIVES OFF FUMES. MAKE SURE
YOU USE THE PAINT IN AN AREA WITH GOOD AIR FLOW. MAKE
SURE YOU DO NOT BREATHE THE FUMES. DO NOT GET THE
PAINT ON YOUR SKIN OR IN YOUR EYES OR MOUTH. MAKE
SURE YOU USE GLOVES AND CLOTHING TO PROTECT
YOURSELF.

CAUTION: DO ONLY STEP 3.E. IN SPM 70-43-22. DO NOT DO THE GRIT

BLAST OR THE PRIMER STEPS. IF YOU DO THE GRIT BLAST
OR THE PRIMER STEPS, DAMAGE TO THE BLOCKER DOOR
BACK PLATE CAN OCCUR.

(b) Apply the paint (C03-010) with a spray gun or a brush. Refer to SPM 70-43-22,
step 3.E. Hold the spray gun at a 15-degree angle to the back plate surface.
Move the spray gun in an alternating direction perpendicular to the hinge line.

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R (c) Look for runs in the paint. Runs must not be more than 0.010 in. (0.25 mm)
R above the painted surface.

R (2) Let the blocker door dry for 30 minutes.

R (3) Cure the blocker door in an oven at 165°-185°F (74°-85°C) for 60-90 minutes.

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FAN REVERSER BLOCKER DOOR - REPAIR

1. Repair of Blocker Door Face Sheet Damage in the Acoustic Area.

A. This repair gives the instructions for repair of punctures, tears, cracks and dents in the blocker
door face sheet. This repair changes the acoustic properties of the blocker door in the repair
area.

R B. The acoustic blockage caused by adhesive applied to the repair area must be within the
R acoustic blockage limits given in the 78-32-03 Inspection section

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools.

Description Figure No.

Delamination Inspection Tool, None required

Round End Steel Rod,
0.375 inch (9.53 mm) diameter
X 2.0 inch (51.0 mm) length

(4) Equipment.

Description Manufacturer

Oven that can heat a part Local purchase

to 200°-220°F (93°-104°C)

Spatula, Acrylic Local purchase

Semco Sealant Filleting Gun Semco Division

Products, Research, and Chemical Co. (PRC)
Los Angeles, CA

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R B. Consumable Materials.

R Code Description Use

R C01-155 Adhesive, Paste, EA 9394 Fill the repair area

R C03-010 Paint, Epoxy, Black, Paint for the repair area

R MIL-C-22750

R C04-001 Solvent, Methyl- Clean the repair area

R Ethyl-Ketone (MEK)

R C04-003 Solvent, Acetone Clean the repair area

R C04-035 Isopropyl Alcohol Clean the repair area

R C10-040 Tape, Teflon Mask the repair area

R 1.0 X 0.002 inch

R C10-136 Tape, Flashbreaker Mask the repair area

R C10-140 Gloves, Nylon Film/Polyethylene, Mix and apply the adhesive

R Disposable

R C10-141 Abrasive Cloth, 120-180 Surface preparation

R Grit

R C10-142 Polyester (Mylar) Film Surface protection

R 0.002-0.004 inch thick

R C10-182 Cloths, Cleaning Clean the repair area

R --- Marker, Water-soluble Make a mark around

the damaged area

R C. Expendable Parts. None required.

R D. SPD Identification. None required.

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R E. Referenced Procedures.

R SPD 70-43-07

R SPD 70-43-22

R 78-32-03 Repair 008

R 3. Dimensional Information. None required.

R 4. Setup Information. None required.

R 5. Procedure. See figure 601.

R A. Find the size of the damage, and find out what repair is necessary.

R (1) If the blocker door face sheet has wire screen, use a utility knife and pliers to remove
R the wire screen from the repair area.

R (2) Do a tap test around the damaged area, and on the skin opposite the damaged area, to
R find the unbonded area.

R (a) Use a 0.5-1.0 oz (14-28 g) aluminum mallet to lightly hit the surface of the area
R around the damaged area, and the surface of the skin opposite the damaged
R area.

R NOTE: If you hear a solid "click" sound, there are no voids. If you hear an
R empty sound, the area is unbonded.

R (b) Use a felt-tip marker to make a line around the unbonded area.

R NOTE: You can only do this repair for holes in the face sheet with a
R maximum diameter of 0.50 in. (12.7 mm) with damage to the panel
R core less than 2.0 in. (50.8 mm) diameter. You can only do this
R repair in areas where normally there is honeycomb bonded to the
R face sheet. There must be a minimum of 10.0 in. (25.4 cm)
R between the damage areas, and the repair must be a minimum of
R 1.0 in. (25.4 mm) from the support fitting. See figure 601.

R (3) If necessary, do step 5.A.(1) again.

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R MM60103-00-C
R Repair of Face Sheet Damage Less than 0.50 in. (12.7 mm) Diameter
R Figure 601

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R B. Prepare the damaged area for repair.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE
R THE FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR
R EYES, FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR
R SKIN OR EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE,
R TOXIC, AND HIGHLY FLAMMABLE.

R (1) Clean the repair area of the blocker door with a clean lint-free cotton cloth (C10-182)
R made moist with solvent (C04-001, C04-003, or C04-035). Immediately dry the surface
R with a clean, lint-free cotton cloth. Do not let the solvent dry on the repair area. Do this
R again until the repair area is clean.

R (2) Let the blocker door dry for a minimum of 15 minutes.

R WARNING: THIS PROCESS GIVES OFF AIRBORNE DUST PARTICLES THAT ARE
R POISONOUS. PUT ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE
R MASK. MAKE SURE THE AREA HAS GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE IN THE DUST PARTICLES.

R CAUTION: BE CAREFUL NOT TO DISBOND THE FACE SHEET FROM THE

R HONEYCOMB MATERIAL. MAKE SURE YOU CUT THROUGH THE FACE
R SHEET ONLY OR DAMAGE WILL OCCUR.

R (3) Use a drill bit up to a maximum diameter of 0.50 inch (12.7 mm) to drill a hole into the
R face sheet. Remove the damaged face sheet and honeycomb core.

R (4) Spoil (cut into the honeycomb cells of the core) the core to a minimum of 1.0 in. (25.4
R mm) diameter and a maximum of 2.0 in. (50.8 mm) diameter.

R NOTE: Spoiled core can stay in the repair cavity; however, make sure that the
R pieces of spoiled core do not fold over and close off the honeycomb cells.

R (5) Use 180-200 grit abrasive paper (C10-141) to lightly abrade the face sheet and to
R remove the adhesive or paint.

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R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

R PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
R SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE. WEAR
R GOGGLES. DO NOT POINT COMPRESSED AIR IN THE DIRECTION OF
R YOUR SKIN.

R WARNING: THIS PROCESS GIVES OFF AIRBORNE DUST PARTICLES THAT ARE
R POISONOUS. PUT ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE
R MASK. MAKE SURE THE AREA HAS GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE IN THE DUST PARTICLES.

R (6) Remove all unwanted material from the repair area with clean, dry, oil-free shop air.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE
R THE FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR
R EYES, FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR
R SKIN OR EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE,
R TOXIC, AND HIGHLY FLAMMABLE.

R (7) Clean the repair area of the blocker door with a clean lint-free cotton cloth (C10-182)
R made moist with solvent (C04-001, C04-003, or C04-035). Remove the solvent with a
R clean, lint-free cotton cloth. Do not let the solvent dry on the repair area. Do this again
R until the repair area is clean.

R (8) Let the blocker door dry for a minimum of 15 minutes.

R (9) Make a visual inspection of the repair area. Make sure that all loose and damaged
R material has been removed, and the face sheet is not damaged.

R (10) Protect the area around the repair area with mylar (C10-142) or film (C10-133) held in
R position with tape (C10-040 or C10-136).

R C. Apply the adhesive.

R (1) Prepare paste adhesive (C10-155) in a clean metal or uncoated paper container.

R WARNING: ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR EYES

R OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. USE CLEAN
R NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN
R YOU MIX OR APPLY THE ADHESIVE.

R (a) Combine by weight: 100 parts resin (A) with 17 parts catalyst (B).

R (b) Mix fully until you can see no streaks of the two components.

R NOTE: The pot life of a 4.66 ounce (132 gram) epoxy mixture is
R approximately 40 minutes.

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R (2) Use a filleting gun filled with paste adhesive (C01-155) to fill the spoiled core area. Fill
R through the center hole in the face sheet. Fill until the repair hole and the holes in the
R face sheet are filled flush with the adjacent surface of the face sheet. See figure 601.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE
R THE FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR
R EYES, FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR
R SKIN OR EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE,
R TOXIC, AND HIGHLY FLAMMABLE.

R (3) Use a spatula and a clean, lint-free cotton cloth (C10-182) moist with solvent (C04-001,
R C04-003, or C04-035) to remove unwanted adhesive and make the adhesive smooth
R and flush with the face sheet surface.

R NOTE: You can install a mask-off plate over the adhesive during the cure time to
R help get a good bond with the adjacent area. Use flashbreaker tape (C10-
R 136) or film (C10-133) over the mask-off area as necessary.

R (4) Cure the adhesive for 1 hour at 200°-220°F (93°-104°C).

R (5) Use 180-200 grit abrasive paper (C10-141) lightly to make the repair area smooth and
R flush with the adjacent face sheet surface.

R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

R PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
R SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE. WEAR
R GOGGLES. DO NOT POINT COMPRESSED AIR IN THE DIRECTION OF
R YOUR SKIN.

R WARNING: THIS PROCESS GIVES OFF AIRBORNE DUST PARTICLES THAT ARE
R POISONOUS. PUT ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE
R MASK. MAKE SURE THE AREA HAS GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE IN THE DUST PARTICLES.

R (6) Remove unwanted material with clean, dry oil-free shop air.

R (7) Do a tap test of the repaired area with a 0.5-1.0 oz (14-28 g) aluminum mallet to make
R sure there are no unbonded areas.

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R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE
R THE FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR
R EYES, FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR
R SKIN OR EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE,
R TOXIC, AND HIGHLY FLAMMABLE.

R (8) Clean the repair area with a clean lint-free cotton cloth (C10-182) made moist with
R solvent (C04-001, C04-003, C04-035). Immediately dry the repair area with a clean,
R lint-free cotton cloth. Do not let the solvent dry on the repair area. Do this again until
R the repair area is clean.

R (9) Let the repair area dry a minimum of 15 minutes.

R WARNING: ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR EYES

R OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. WEAR CLEAN
R NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN
R YOU MIX OR APPLY THE ADHESIVE.

R (10) If there are exposed pores in the repair area, fill the pores with paste adhesive (C01-
R 155) until the adhesive in the repair area is flush with the face sheet. Cure the
R adhesive. Refer to steps (4) through (9).

R D. Apply wire screen or paint to the repair area, as applicable.

R (1) If this is a 1291M28G12 blocker door (not modified to a screenless 1291M28G13

R configuration), apply wire screen to the repair area on the face sheet. Refer to 78-32-
R 03 Repair 008.

R (2) If this is a 1291M28G13 blocker door (or a 1291M28G12 door modified to the
R screenless 1291M28G13 configuration), apply epoxy polyamide paint (C03-010) to the
R repair area on the face sheet.

R WARNING: THIS PAINT IS POISONOUS AND GIVES OFF FUMES. MAKE SURE
R YOU USE THE PAINT IN AN AREA WITH GOOD AIR FLOW. MAKE
R SURE YOU DO NOT BREATHE THE FUMES. DO NOT GET THE
R PAINT ON YOUR SKIN OR IN YOUR EYES OR MOUTH. MAKE
R SURE YOU USE GLOVES AND CLOTHING TO PROTECT
R YOURSELF.

R (a) Use mylar film (C10-142) and flashbreaker tape (C10-136) to protect the area
R adjacent to the repair area.

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R CAUTION: DO ONLY STEP 3.A.(5) IN SPM 70-43-22. DO NOT DO THE GRIT

BLAST OR PRIMER STEPS. IF YOU DO THE GRIT BLAST OR
PRIMER STEPS THE FACE SHEET CAN BE DAMAGED.

(b) Apply the paint (C03-010) with a spray gun. Refer to SPM 70-43-22, step
R 3.A.(5). Hold the spray gun at a 15-degree angle to the face sheet surface.
Move the spray gun in an alternating, forward-to-aft direction.

1 Full coverage of the edges of the perforations is not necessary. Over-

spray is permitted on the edge of the assembly.

2 Runs must not be more than 0.010 in. (0.254 mm) above the coated
surface.

(c) Let the blocker door dry for 30 minutes.

(d) Cure the blocker door in an oven at 165°-186°F (74°-85°C) for 60-90 minutes.

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THIS PAGE INTENTIONALLY BLANK

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FAN REVERSER BLOCKER DOOR - REPAIR

1. Blocker Door Edge Repair.

A. This repair gives the instructions to repair the blocker door edge flange areas that are covered
with the Teflon wear strip. This includes the corner areas. This repair is for damaged, cracked
or missing flange up to the radius of the flange (any length).

B. For small amounts of damage and delamination to the blocker door edge flange areas, refer to
78-32-03 Repair 006.

C. For a damaged or missing Teflon wear strip, refer to 78-32-03 Repair 004.

2. Tools, Equipment and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools.

Description Figure No.

Teflon spatula 601

Local Intensifiers None required

Local Contour Plate None required

Delamination Inspection Tool, None required

Round End Steel Rod,
0.375 inch (9.53 mm) diameter
X 2.0 inch (51.0 mm) length

(4) Equipment.

Description Manufacturer

An autoclave that can heat the part equally Local purchase

to 300°F (149°C) and hold the part at 290°-310°F
(143°-154°C) with 20 psig (138 kPa) pressure
or
An oven that can heat the part equally to
300°F (149°C) and hold the part at 290°-310°F
(143°-154°C)

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B. Consumable Materials.

Code No. Description Use

C01-086 Compound, Silicone Rubber, Make the intensifier

RTV 664, General Electric Co.

C01-147 Adhesive, Liquid, EA 9396, Hysol Make the contour plate

C04-001 Solvent, Methyl-Ethyl-Ketone (MEK) Clean the repair area

C04-003 Solvent, Acetone Clean the repair area

C04-035 Solvent, Isopropyl Alcohol Clean the repair area

C10-040 Tape, Teflon Hold the bagging materials

3M Scotch Brand 5490 in position

C10-112 Fabric, High Strength, Woven Make the form tool

Graphite, 12.5 x 12.5 tows/in.
W-322 (GE Spec. A50TF211 CL-B)
ICI Composites Corp. Fiberite Div.

C10-130 Cloth, Glass Fiber, Impregnated Replacement material for the

(A50TF273 CL-A) face sheet

C10-131 Peel Ply, Style Repair material

R 52006/51789, SRB

C10-132 A4000P3 Perforated FEP Film, Release film

Airtech International

C10-133 A4000 Unperforated FEP Film, Release film

Airtech International

C10-134 Breather Cloth, N10, Air bleed from the vacuum bag
Airtech International

C10-136 Tape, Flashbreaker Protection of the clean

surfaces

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Code No. Description Use

C10-137 Bagging Film, Wrightlon 6400, Make templates

Airtech International

C10-138 Sealant Tape, Vacuum Bag, Vacuum bag sealant

Airtech International

C10-139 Gloves, White Cotton, Protect the part

Disposable during installation

C10-140 Gloves, Nylon Film/Polyethylene, Mix and apply the

Disposable adhesive

C10-141 Abrasive Cloth, 120-180 Grit Prepare the surface

C10-142 Polyester (Mylar) Film Protect the clean surfaces

0.002-0.004 inch thick

C10-182 Cleaning Cloths Clean the repair area

--- Fabric, Impregnated, Woven graphite Backsheet flange

R (A50TF213 CL-C), Cytec replacement material
R CE324/T300, 3K, 4 Harness
R Satin Crowfoot

C. Expendable Parts. None required.

D. SPD Identification. None required.

E. Referenced Procedures.

78-32-03, Repair 004

78-32-03, Repair 008

3. Dimensional Information. None required.

4. Setup Information. None required.

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5. Procedure.

A. Prepare the damaged area for repair.

(1) Remove any loose or damaged material. Make sure that you do not make the
damaged area larger.

(2) Remove the Teflon wear strip and the adhesive from the damaged edge(s). Refer to
78-32-03, Repair 004.

(3) Remove the wire screen. Make an inspection of the face sheet and repair if necessary.
Refer to 78-32-03, Repair 008.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

CAUTION: DO NOT PUT SOLVENTS DIRECTLY ON THE BLOCKER DOOR. DO NOT

PUT THE BLOCKER DOOR IN A CONTAINER OF SOLVENT. DAMAGE CAN
OCCUR.

(4) Clean the repair area of the blocker door with a clean lint-free cotton cloth made moist
with solvent (C04-001, C04-003, or C04-035). Immediately dry the surface with a
clean, lint-free cotton cloth (C10-182). Do not let the solvent dry on the repair area. Do
this again until the repair area is clean.

(5) Let the blocker door dry for a minimum of 15 minutes.

(6) Make an inspection of the blocker door flange for disbond and delamination.

(a) Lightly hit the face sheet side of the blocker door with the locally manufactured
tool that was made to check for delamination, and listen to the sound.

(b) If you hear a solid "click", the area does not have a delamination.

(c) If you hear a hollow or dull sound the area has a delamination. Do this until
you have identified the size of the delamination.

(7) Make a mark with a water-soluble marker to identify the outer edges of the damaged
area. This includes:

-- the outer edges of the delamination or disbond

-- the area that is cracked or broken.

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(8) Make a mark to identify the area to be cut out with a water-soluble marker. Make the
shape simple so that it will be easy to install the pre-impregnated repair materials. Use
the damage area outline marks as an aid.

WARNING: THIS PROCESS GIVES OFF AIRBORNE DUST PARTICLES THAT ARE
POISONOUS. PUT ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE
MASK. MAKE SURE THE AREA HAS GOOD AIR FLOW. MAKE SURE YOU
DO NOT BREATHE IN THE DUST PARTICLES.

(9) Cut around the outline of the shape with a small grinder with a small diameter cut-off
disk. Remove the damaged material.

B. Alternative procedure available. If you have not made a local contour plate, make the contour
plate as follows:

(1) Get a piece of 0.08 inch (2.03 mm) thick aluminum and cut to a shape 4 inch (101.6
mm) larger all round than the size of the damage area.

(2) Make the plate align with the contour of the face sheet. The maximum gap between the
plate and the contour must be less than 0.040 inch (1.0 mm).

B.A. Alternative procedure. If you have not already made a local contour plate, make a wet lay-up
composite plate as follows:

(1) Get an undamaged blocker door.

(2) Cover the face sheet with unperforated FEP film (C10-133).

(3) Make a decision on the size and shape of the plies that will be used to make the tool.
Use Mylar (C10-142) or film (C10-137) to make templates that are the size and shape
of the plies.

(4) Make a decision about the quantity plies you will need to make a form tool 0.08 inch
(2.03 mm) thick (approximately 14 plies for C10-112).

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(5) Prepare the adhesive (C01-147) as follows:

WARNING: THIS ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN

YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE
AIR. WEAR CLEAN NYLON FILM OR POLYETHYLENE
DISPOSABLE GLOVES (C10-140) WHEN YOU MIX OR APPLY THE
ADHESIVE.

CAUTION: IF THE ADHESIVES HAVE BEEN STORED BELOW ROOM

TEMPERATURE, MAKE SURE THE ADHESIVE REACHES ROOM
TEMPERATURE BEFORE YOU OPEN THE CONTAINER.

(a) Make an estimate of how much adhesive (C01-147) is necessary.

(b) Mix the adhesive (C01-147) in a metal or uncoated paper container. Mix 100
parts resin to 30 parts catalyst by weight. Mix until the adhesive is one color.

NOTE: Mix less than 300 grams to prevent premature cure or overheating
of the resin mix. Use the adhesive in less than 75 minutes.

(6) Get a piece of carbon fiber cloth (C10-112) large enough to cover all of the templates
without overlap.

(7) Get two pieces of film (C10-137). Each piece must be larger than the carbon fiber cloth
(C10-112).

(8) Put one piece of film (C10-137) on a clean table.

(9) Put the carbon fiber cloth (C10-112) on the film (C10-137).

WARNING: THIS ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR

EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. WEAR
CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-
140) WHEN YOU MIX OR APPLY THE ADHESIVE.

CAUTION: IF THE ADHESIVES HAVE BEEN STORED BELOW ROOM TEMPERATURE,

MAKE SURE THE ADHESIVE REACHES ROOM TEMPERATURE BEFORE
YOU OPEN THE CONTAINER.

(10) Pour the adhesive (C01-147) onto the carbon fiber cloth (C10-112).

(11) Put the second piece of film (C10-137) on top of the carbon fiber cloth (C10-112).

(12) Use the Teflon spatula, (see figure 601) to rub the top piece of film so that you spread
the adhesive (C01-147) and soak the carbon fiber cloth (C10-112).

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(13) Turn over the carbon fiber cloth (C10-112) and the two pieces of film (C10-137). Use
the Teflon spatula to rub the new top piece of film (C10-137) to spread the adhesive
(C01-147) and soak the carbon fiber cloth (C10-112).

(14) Put the templates on top of the film and make a mark of the shapes onto the film. The
warp direction of the ply templates should alternate between the longitudinal and
circumferential directions.

(15) Use a sharp pair of scissors to cut-out the shapes of carbon fiber cloth (C10-112).

(16) Remove one piece of film (C10-137) from the shape and apply the first shape of carbon
fiber cloth (C10-112) to the face of the door in the area you want the tool. Use a
squeegee to push the fabric against the face of the door, smooth out the wrinkles and
push out caught air. Remove the other piece of film (C10-137) from the shape.

(17) Do step (16) again for the remaining plies.

(18) Put a piece of unperforated FEP film (C10-133) over the carbon fiber fabric plies and
lightly hold in position with Teflon tape, (C10-040) or tape, (C10-136). Use a squeegee
to push the fabric against the face of the door, remove the wrinkles and push out
caught air.

(19) Cure for five days at ambient temperature or cure for a minimum of one hour at 180°F
(82°C).

(20) Remove the contour plate molding.

(21) Remove the unperforated FEP film (C10-133) from the contour plate molding.

(22) Trim the extra material from the contour plate molding.

C. Make the local intensifiers as follows:

(1) Use an undamaged blocker door with the Teflon strips removed. Refer to 78-32-03
Repair 003.

(2) Apply tape (C10-136) to the flange in the area that needs repair. Make sure that there
are no wrinkles and a minimum number of tape overlaps.

(3) Use aluminum foil tape or similar material to make a dam around the flange in the area
that needs repair.

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WARNING: THIS COMPOUND IS POISONOUS AND GIVES OFF FUMES. MAKE SURE
YOU USE THE COMPOUND IN AN AREA WITH GOOD AIR FLOW. MAKE
SURE YOU DO NOT BREATHE THE FUMES. DO NOT GET THE
COMPOUND ON YOUR SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE
YOU USE GLOVES AND CLOTHING TO PROTECT YOURSELF.

(4) Mix the silicone rubber compound (C01-086).

(5) Vacuum de-gas the silicone rubber compound (C01-086) as follows:

(a) Put the mixed silicone rubber compound in a container that will be resistant to a
vacuum.

(b) Apply a vacuum of 20 Hg inch (67.72 millibars) minimum until all frothing has
stopped. This process helps to produce a part without voids.

(6) Pour in the silicone rubber compound until the mold is filled and if possible vacuum de-
gas again to remove any voids. Add more silicone rubber compound if necessary.

(7) Cure at ambient temperature for four days, or cure in an oven at 150°F (65.5°C) for five
hours.

(8) After the cure, remove the intensifier from the container. Cut off any extra material and
cut the upper edges to a 45° chamfer with a sharp knife.

(9) Record the block door part number and the number of this repair on the intensifier.

D. Make six templates from Mylar film (C10-142) the size of each of the carbon fiber pre-
impregnated repair plies. Make the first template the size of the cut-out area. Make each
subsequent template 0.5 inch(12.7 mm) larger than the last template.

E. Make four templates from Mylar film (C10-142) the size of each of the pre-impregnated glass
fiber repair plies. Make the first template the size of the cut-out area. Make each subsequent
template 0.5 inch (12.7 mm) larger than the last template.

WARNING: THIS PROCESS GIVES OFF AIRBORNE DUST PARTICLES THAT ARE
POISONOUS. PUT ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
MAKE SURE THE AREA HAS GOOD AIR FLOW. MAKE SURE YOU DO NOT
BREATHE IN THE DUST PARTICLES.

F. Use a 1.0 inch (25.4 mm) disc sander to remove the back sheet woven plies in half inch steps,
flange area only, to match the templates made in step 5.D. Each step area should be at the
surface of one ply. There are four plies in the back sheet, the last two repair plies are put on
the surface of the back sheet flange.

NOTE: If you have not done this repair before, practice on a scrap blocker door or a similar
laminate consisting of woven carbon fiber cloth pre-impregnated plies. Each step
should be masked in turn using the templates as a guide.

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G. Use 120 to 180 grit abrasive cloth (C10-141) on an area 0.25 inch (6.35 mm) larger than the
largest template to make the area rough.

WARNING: THIS PROCESS GIVES OFF AIRBORNE DUST PARTICLES THAT ARE
POISONOUS. PUT ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
MAKE SURE THE AREA HAS GOOD AIR FLOW. MAKE SURE YOU DO NOT
BREATHE IN THE DUST PARTICLES.

H. Use a 1.0 inch (25.4 mm) disc sander to remove the face sheet to a 1.5 inch (38.1 mm) long
taper. See figure 602.

I. Put a 2.0 inch (50.8 mm) width piece of tape (C10-136) around the repair area. Make the tape
start 0.25 inch (6.35 mm) from the edge of the largest template on both the face sheet and the
back sheet sides of the blocker door.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

CAUTION: DO NOT PUT SOLVENTS DIRECTLY ON THE BLOCKER DOOR. DO NOT PUT THE
BLOCKER DOOR IN A CONTAINER OF SOLVENT. DAMAGE CAN OCCUR.

J. Clean the repair area of the blocker door with a clean lint-free cotton cloth made moist with
solvent (C04-001, C04-003, or C04-035). Immediately dry the surface with a clean, lint-free
cotton cloth (C10-182). Do not let the solvent dry on the repair area. Do this again until the
repair area is clean.

(1) Let the blocker door dry for a minimum of 15 minutes.

K. Put a piece of clean Mylar film (C10-142) over the repair area until you are ready to add the
pieces of pre-impregnated repair materials.

L. Prepare the pre-impregnated repair materials as follows:

WARNING: THIS MATERIAL/COMPOUND IS POISONOUS AND GIVES OFF FUMES.

MAKE SURE YOU USE THE MATERIAL IN AN AREA WITH GOOD AIR
FLOW. MAKE SURE YOU DO NOT BREATHE THE FUMES. DO NOT GET
THE MATERIAL ON YOUR SKIN OR IN YOUR EYES OR MOUTH. MAKE
SURE YOU USE GLOVES AND CLOTHING TO PROTECT YOURSELF.

(1) Unroll the carbon fiber pre-impregnated repair material on a clean cutting table.

(2) Put the templates for the carbon fiber pre-impregnated repair material that you made
earlier on the separator film of the carbon fiber repair material. Put the template on the
repair material so that the warp direction will be as shown in figure 602. Make a mark
around each template.

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(3) Use scissors or a sharp knife to cut around four marked plies.

(4) Cut the pieces of pre-impregnated glass fiber repair material (C10-130) in the same
way.

M. Apply the carbon fiber pre-impregnated repair material to the repair area as follows: See figure
603.

(1) Remove the separator films and put the four pre-impregnated glass fiber repair material
(C10-130) plies together so that the edges are in line.

(2) Use a squeegee to push the glass fiber repair material (C10-130) together. Use the
squeegee to remove wrinkles and push out caught air.

(3) Put the glass fiber repair material (C10-130) plies onto the face sheet. Make the
smallest ply fit into the cut-out area.

(4) Cut out a piece of peel ply (C10-131) at least as big as the contour plate. Put the piece
of peel ply (C10-131) over the pre-impregnated glass fiber repair material (C10-130).

(5) Put a piece of unperforated FEP film (C10-133) over the peel ply (C10-131).

(6) Put the contour plate onto the face sheet over the unperforated FEP film (C10-133).

(7) Turn the door and the contour plate over so the back sheet faces upwards.

(8) Remove the separator film from the smallest pre-impregnated carbon fiber ply. Put the
smallest pre-impregnated carbon fiber ply into the cut out and onto the pre-impregnated
glass fiber(C10-130) ply.

(9) Remove the separator film from the next ply. Put the next ply of pre-impregnated
carbon fiber onto the first step. When you repair a corner area you can cut a maximum
of two triangle-shaped pieces from the pre-impregnated material to prevent folds or
wrinkles. The cut edges must not make an overlap and must have a maximum gap of
0.040 inch (1.02 mm). Distortion of the weave is permitted.

(10) Put the remaining plies on the other steps in the same way. The last two plies will be
on the top of the back sheet and cover the last step.

(11) Use a squeegee to push the pre-impregnated carbon fiber together, remove the
wrinkles and push out caught air.

(12) Count all the pieces of separator film to make sure that all the film has been removed.

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(13) Cut-out a piece of peel ply (C10-131) at least as big as the top piece of carbon fiber
fabric. Put the piece of peel ply (C10-131) over the top ply of pre-impregnated carbon
fiber.

(14) Put a piece of unperforated FEP film (C10-133) over the peel ply (C10-131).

N. Make the vacuum bag as follows:

(1) Cut the film (C10-137) large enough to enclose the blocker door. Allow a minimum of
10.0 inches (254 mm) around all edges of the part. Make sure there is enough material
to make the vacuum connections.

(2) Cut a piece of breather cloth (C10-134) 1.0 inch (25.4 mm) smaller than the film (C10-
137).

(3) Make two vacuum fitting cushions from pieces of breather cloth breather cloth (C10-
134) 12.0 inches (305 mm) square folded into 4.0 inch (101 mm) square, 9 ply thick
cushions. See figure 604.

(4) Attach the vacuum bag sealant tape (C10-138) around the edge of the vacuum bag.
Do not remove the paper backing from the sealant tape.

(5) Install the vacuum bag fittings in opposite corners of the bag and positioned well clear
of the repair area.

(6) Use Teflon tape (C10-040) or flashbreaker tape (C10-136) to attach the vacuum fitting
cushions to the vacuum bag over the vacuum bag fittings.

(7) Do one edge at a time . Peel off the backing paper from the sealant tape (C10-138)
and push the vacuum bag edges together along the two adjacent edges of the part.
Put two tucks or "ears" in each edge to avoid local stretching which will cause tears in
the bag. See figure 604. You can use a Teflon spatula to push down the sealant tape
(C10-138).

(8) Put the breather cloth (C10-134) over the part.

CAUTION: THE PART MUST BE UNDER VACUUM BAG PRESSURE OF 20 HG IN.

(67.72 MILLIBARS) MINIMUM WHILE THE ADHESIVE ON THE PROCESS
CONTROL SAMPLE IS STILL SOFT.

(9) Put a minimum of two thermocouples on the blocker door adjacent to the repair area.
Hold the thermocouples in position with Teflon tape (C10-040) or flashbreaker tape
(C10-136).

(11) Push down the sealant tape (C10-138) along the open edge with the Teflon spatula.
Make sure the vacuum bag fittings and cushions are at opposite ends of the bag.
Evacuate the bag to 24 Hg in. (81.264 millibars) minimum and check for leaks. To
repair leaks, apply more pressure with the Teflon spatula to the sealant tape (C10-138)
in the area of the leak.

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O. Alternative procedure available. Cure in an autoclave as follows:

(1) Apply 15-25 psig (103.5-172.5 kPa). Vent the bag when pressure reaches 20 psig (138
kPa).

(2) Increase the temperature at 3-5°F (or equivalent) per minute to 300°F (148.8°C).

(3) Hold the temperature for two hours at 290-310°F (143.3-154.4°C).

(4) Decrease the temperature at 5-10°F (or equivalent) per minute.

(5) At 120°F (48.9°C), remove the pressure.

O.A. Alternative Procedure. Cure in an oven as follows:

(1) Apply a vacuum of 24 Hg in. (81.264 millibars) minimum.

(2) Increase the temperature at 3-5°F (or equivalent) per minute to 300°F (148.8°C).

(3) Hold the temperature for two hours at 290-310°F (143.3-154.4°C).

(4) Decrease the temperature at 5-10°F (or equivalent) per minute.

(5) At 120°F (48.9°C), remove the vacuum.

WARNING: MAKE SURE YOU USE GLOVES TO PROTECT YOURSELF. MAKE SURE YOU
USE TONGS OR SIMILAR EQUIPMENT WHEN YOU MOVE THE COMPONENTS.

P. Remove the vacuum bag, breather cloth, peel ply and masking materials.

Q. Make an inspection of the repair area for the following:

(1) Make a visual inspection of the repaired area of the face sheet. Examine the surface
for folds or unevenness in the surface layer. If the height above the flange face is less
than 0.010 inch (0.25 mm), do the steps that follow.

(a) Use 320 grit abrasive paper (C10-121) by hand to make the surface smooth.

(b) Remove the minimum amount necessary to make the flange smooth.

(c) If you can see fibers on the surface, do the steps that follow:

1 Make a mixture of adhesive (C01-147). Refer to paragraph 5.B.A.(5).

2 Apply a thin layer of adhesive to the surface.

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(2) Make a measurement of the thickness of the flange in the repaired and unrepaired
areas. The repaired thickness should be the same as the unrepaired thickness +/-
0.010 inch (0.25 mm) with no steps. Repair any local thick areas as follows:

(a) Use 120 grit abrasive paper by hand to make the thickness the same as the
unrepaired thickness +/- 0.010 inch (0.25 mm).

(b) Remove the minimum amount necessary to make the flange within tolerance.

(c) If you can see fibers on the surface, do the steps that follow:

1 Make a mixture of adhesive (C01-147). Refer to paragraph 5.B.A.(5).

2 Apply a thin layer of adhesive to the surface.

(3) Find possible disbonds as follows:

(a) Lightly hit the face sheet and back sheet in the area of the repair with a round
end 0.375 inch (9.53 mm) diameter steel rod that has a length of 2.0 inches (51
mm) and listen to the sound.

1 If you hear a solid "click", area does not have disbonds.

2 If you hear a hollow sound, the area has disbonds.

NOTE: The different thicknesses of the back sheet and face sheet
will produce different pitches of sound. This is normal and
does not indicate a disbond.

(b) Use a water-soluble marker to make a mark around the outer edges of the
disbond.

(c) You must repair disbonds larger than 0.25 square inch (13 square mm). Use
this repair to repair the disbonded areas.

R. Replace the Teflon wear strip(s). Refer to 78-32-03 Repair 004.

S. Replace the wire mesh screen. Refer to 78-32-03 Repair 008.

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MM50071-00-A
Teflon Spatula
Figure 601

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MM50010-00-A
Door Preparation
Figure 602

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MM50011-00-A
Repair Ply Lay-up
Figure 603

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1093873-00-A
Vacuum Fitting Installation
Figure 604 (Sheet 1)

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1093874-00-A
Vacuum Fitting (Alternative)
Figure 604 (Sheet 2)

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1093875-00-A
Formation of Tuck or "Ear" in Edge of Vacuum Bag
Figure 605

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CF6-80E1 CMM

THIS PAGE INTENTIONALLY BLANK

 COMPONENT
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FAN REVERSER BLOCKER DOOR – REPAIR

R 1. Replacement of the Blocker Door Face Sheet

R A. This repair gives the instructions for the removal of the wire mesh and the face sheet from
R 1291M28G12 blocker doors, and the installation of a new face sheet, 1291M24P03, to make a
R screenless blocker door. Repair can also be used to replace a damaged face sheet on
R 1291M28G13 and 1291M28G16 screenless blocker doors.

R NOTE: The below table provides the allowable number of cure cycles for the removal and
R replacement of the Blocker Door face sheet skins for each Blocker Door part
R number.

R Repairs
Blocker Door P/N
R Allowed

R 1291M28G04, G05, G06, G08 converted to 1291M28G12, G13 & G16

R 1291M28G13 Original 1
R Original G13 converted to G16

R 1291M28G16 (Original) 2

R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools.

R Description Tool No.

R Bonding Tool: You can

R make the bond tooling
R by reverse engineering
R from a production blocker
R door. The tool must be
R more rigid than the blocker
R door.

R (2) Standard Tools. None required.

R (3) Locally Manufactured Tools.

R Description Figure No.

R Tap Check Inspection Figure 607

R Tool

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R (4) Equipment.

R Description Manufacturer

R Grinder, Air Driven, Rotor Tools, Cleveland, OH

R Right Angle
R M1122SA-150

R Spray Gun, DeVilbiss DeVilbiss, Toledo, OH

R Heat gun Local purchase

R with temperature
R range up to 300°F
R (149°C)

R Autoclave, Local purchase

R with temperature
R range up to 260°F
R (127°C) and
R 45 psi positive
R pressure

R Oven with temperature Local purchase

R range up to 185°F
R (85°C)

R B. Consumable Materials:

R Code No. Description Use

R C01-126 Fabric, Netting, Dacron Polyester Bondline control

R C01-128 Adhesive, Epoxy Film Supported Bond the face sheet

R AF3109-2K

R C01-132 Adhesive, Foam Core Splice Bond the honeycomb core

R C01-155 Adhesive, Structural Paste, EA9394 Bond the name plate

R C01-175 Adhesive, Epoxy Film, Unsupported, Bond the face sheet

R AF3109-2U

R C03-010 Paint, Epoxy-Polyamide, Face sheet coating

R MIL-C-22750, Color Code 27038

R C04-003 Solvent, Acetone Clean the part

R C04-035 Solvent, Isopropyl Alcohol Clean the part

R C10-040 Tape, Teflon, 1.0 x 0.002 inch Attach the vacuum bag

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R B. Consumable Materials (Cont’d):

R Code No. Description Use

R C10-051 Film, Release, Perforated Vacuum bag material

R (E3760-P2) 0.001 inch thick

R C10-108 Brush, Disposable, Natural Bristle Apply the adhesive

R C10-133 Film, Polymer, FEP, A4000, Surface protection

R 0.001 in. (0.03 mm) thick

R C10-134 Cloth, Breather/Bleeder, N10 Vacuum bag material

R C10-136 Tape, Flashbreaker Mask the core area

R C10-137 Film, Vacuum Bag Vacuum bag material

R C10-138 Tape, Sealant Vacuum Bag Seal the vacuum bag

R C10-140 Gloves, Nylon Film/Polyethylene, Mix and apply the adhesive

R Disposable

R C10-141 Abrasive Paper, 120-180 Grit Make the face sheet rough

R C10-182 Cloths, Cleaning Clean the repair area

R --- Honeycomb, Replacement core material

3
R Nomex HRH10 – 3/8 – 3 lbs/ft
R 0.94-0.96 in. (24.0-24.4 mm) thick

R --- Marker, Water-soluble Make a mark around

R the damaged area

R --- Sheet, Silicone Rubber Use during honeycomb

R core replacement

R --- Silicone Rubber, 1.0 inch (25.4 mm) thick Intensifiers for bonding

R C. Expendable Parts. None required.

R D. SPD Identification.

R SPD No. Description

R 1291M24P03 Face sheet - blocker door

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R E. Referenced Procedures.

R SPM 70-16-00

R SPM 70-16-05

R SPM 70-43-22

R SPM 70-43-07

R SPM 70-71-05

R 3. Dimensional Information. None required.

R 4. Setup Information. None required.

R 5. Procedure.

R A. Prepare the blocker door for repair.

R (1) Remove the anti-rotation clips.

R (a) Remove the four nuts, the four screws, and the four dimpled washers from the
R flow surface of the blocker door. See figure 601. Keep the parts to use during
R assembly.

R (b) Remove the anti-rotation clips. Keep the clips to use during assembly.

R (c) Lightly tap the back sheet side of the blocker door with the locally manufactured
R Tap Check inspection tool (refer to Figure 607), and listen to the sound.

R 1 If you hear a solid "click", the area does not have a disbond.

R 2 If you hear a hollow or dull sound, the area has a disbond. Do this until
you find the size of the disbond.

R (d) Make a mark on the back sheet with a water-soluble marker to identify the
R outer edges of the disbond.

R (e) If core is disbonded, it is recommended that the entire core be replaced.

R (2) If the face sheet of the blocker door has wire mesh, remove the wire mesh from the
R blocker door.

R (3) Remove the face sheet.

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R CAUTION: DO NOT LET THE TEMPERATURE OF THE HEAT GUN GO ABOVE

R 300° F (149° C). TEMPERATURES ABOVE 300° F (149° C) WILL
R DAMAGE THE BLOCKER DOOR.

R (a) Apply local heat to peel off the face sheet. Use a heat gun at a maximum of
R 300°F (149°C) to apply the heat.

R WARNING: THIS PROCESS GIVES OFF AIRBORNE DUST PARTICLES THAT

R ARE POISONOUS. PUT ON PROTECTIVE CLOTHING, GOGGLES,
R AND A FACE MASK. MAKE SURE THE AREA HAS GOOD AIR
R FLOW. MAKE SURE YOU DO NOT BREATHE IN THE DUST
R PARTICLES.

R (b) Use a right-angle air-driven grinder to grind off areas of the face sheet that
R cannot be removed using heat. When you see the blue color of the adhesive
R under the face sheet, you will know that the face sheet is removed.

R (4) Apply flashbreaker tape (C10-136) over the entire honeycomb core.

R CAUTION: MAKE A VISUAL INSPECTION OF THE PART AT INTERVALS WHEN YOU

R REMOVE THE ADHESIVE, TO MAKE SURE YOU DO NOT PENETRATE THE
R FIBERS.

R (5) Use 120-180 grit aluminum oxide paper to remove the old adhesive from the back
R sheet around the core, and to make the surface rough for bonding. This area
R represents the ends of the door around the perimeter where the perforated face sheet
R bonds directly to the non-flow path solid skin back sheet. Refer to Figure 602 for
R Blocker Door Cross Sectional views. Remove all surface resin build-up and gloss from
R the back sheet. Make sure you do not damage the fibers.

R (6) Remove the flashbreaker tape from the honeycomb core.

R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

R PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
R SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE. WEAR
R GOGGLES. DO NOT POINT COMPRESSED AIR IN THE DIRECTION OF
R YOUR SKIN.

R (7) Use dry, filtered shop air to blow off all dust and loose particles from the back sheet and
R honeycomb material.

R (8) Examine the blocker door core for disbonding and damage. If the core is disbonded or
R damaged, refer to paragraph 5.B. If the core is not damaged or disbonded, refer to
R paragraph 5.E.

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R
R Remove the Anti-Rotation Clips
R Figure 601

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R
R Blocker Door Cross Sectional Views
R Figure 602

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R B. Remove the damaged honeycomb core.

R (1) Remove the damaged or disbonded honeycomb core. If necessary, you can replace
R the entire honeycomb core.

R CAUTION: DO NOT CUT INTO THE BACK SHEET.

R (a) Use a razor knife or a hand-held router to cut the damaged honeycomb core to
R a regular shape.

R (b) Use needle-nose pliers to remove the cut-out part of the honeycomb core.

R (2) Prepare the back sheet for bonding.

R (a) Carefully remove the remaining adhesive and core with a right angle air driven
R grinder using 120 -180 grit disc or scotch brite pad. Remaining adhesive is
R permitted if the surface is flat and smooth.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT

R ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
R USE THE FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT
R BREATHE THE FUMES. IF YOU GET THE SOLVENT ON YOUR
R SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET
R MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
R SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R CAUTION: DO NOT PUT SOLVENTS DIRECTLY ON A BLOCKER DOOR. DO

R NOT PUT THE BLOCKER DOOR IN A CONTAINER OF SOLVENT.
R DAMAGE CAN OCCUR.

R (b) Use a clean, lint-free cotton cloth (C10-182) moist with solvent (C04-003, or
R C04-035) to remove all remaining oil, grease, or other unwanted material from
R the blocker door repair area. Remove the solvent with a clean, dry, lint-free
R cotton cloth. Do not let the solvent dry on the repair area. Do this again until
R the repair area is clean.

R (c) Use abrasive cloth (C10-141) to remove the gloss from the remaining adhesive
R and to make the surface of the back sheet rough.

R (3) Clean the repair area.

R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE

R AIRBORNE PARTICLES THAT CAN GO INTO YOUR EYES OR GO
R THROUGH YOUR SKIN. DO NOT USE MORE THAN 30 PSIG (207
R KPA) PRESSURE. WEAR GOGGLES. DO NOT POINT
R COMPRESSED AIR IN THE DIRECTION OF YOUR SKIN.

R (a) Use clean, dry compressed air to remove dust and unwanted material from the
R repair area.

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R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT

R ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
R USE THE FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT
R BREATHE THE FUMES. IF YOU GET THE SOLVENT ON YOUR
R SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET
R MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
R SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R CAUTION: DO NOT PUT SOLVENTS DIRECTLY ON A BLOCKER DOOR. DO

R NOT PUT THE BLOCKER DOOR IN A CONTAINER OF SOLVENT.
R DAMAGE CAN OCCUR.

R (b) Use a clean, lint-free cotton cloth (C10-182) moist with solvent (C04-003, or
R C04-035) to clean the blocker door repair area. Remove the solvent with a
R clean, dry, lint-free cotton cloth. Do not let the solvent dry on the repair area.
R Do this again until the repair area is clean.

R (c) Do a water break test on the repair area to make sure the surface is clean.

R (d) Shake out unwanted water from the blocker door and dry the blocker door for a
R minimum of 2 hours in an air circulating oven at 160°-180°F (71°-82°C).

R (4) If the repair area includes the link or hinge fitting, prepare the area for bonding.

R WARNING: THIS PROCESS GIVES OFF AIRBORNE DUST PARTICLES THAT

R ARE POISONOUS. PUT ON PROTECTIVE CLOTHING, GOGGLES,
R AND A FACE MASK. MAKE SURE THE AREA HAS GOOD AIR
R FLOW. MAKE SURE YOU DO NOT BREATHE IN THE DUST
R PARTICLES.

R CAUTION: DO NOT CUT INTO THE LINK OR HINGE FITTING.

R (a) Carefully cut the honeycomb core from around the link or hinge fitting with a
R razor knife or hand-held router.

R (b) Carefully remove the remaining adhesive with a right angle air driven grinder.
R Remaining adhesive is permitted if the surface is flat and smooth.

R (c) Use abrasive cloth (C10-141) to make the surface of the link or hinge fitting
R rough.

R (d) Apply Alodine to the bare aluminum. Refer to SPM 70-43-07.

R C. Prepare the replacement honeycomb core.

3
R (1) Make a mark with a waterproof marker on new NOMEX HRH10 3/8 - 3lb/ft honeycomb
R core the same size, height (0.94-0.96 in. (23.9-24.4 mm)), and ribbon direction (hoop
R upper to lower) as the piece that was removed.

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R WARNING: THIS PROCESS GIVES OFF AIRBORNE DUST PARTICLES THAT ARE
R POISONOUS. PUT ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE
R MASK. MAKE SURE THE AREA HAS GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE IN THE DUST PARTICLES.

R (2) Cut the honeycomb core along the mark with a razor knife or a grinder with a cut-off
R disc. The replacement core must be 0.00-0.030 inch (0.0-0.76 mm) smaller than the
R dimensions of the removed core to allow for a correct fit.

R (3) Make a trial fit of the replacement core in the blocker door. Use a small disc sander to
R adjust the size or contour around the fittings, as necessary.

R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

R PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
R SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE. WEAR
R GOGGLES. DO NOT POINT COMPRESSED AIR IN THE DIRECTION OF
R YOUR SKIN.

R (4) Use dry, filtered shop air to blow off all unwanted material from the replacement
R honeycomb core.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (5) Use a clean, lint-free cotton cloth (C10-182) moist with solvent (C04-003, or C04-035)
R to clean the replacement core. Remove the solvent with a clean, dry, lint-free cotton
R cloth. Do not let the solvent dry on the surface. Do this again until the bonding
R surfaces are clean.

R (6) Let the replacement core dry for a minimum of 15 minutes.

R D. Install the replacement honeycomb core.

(1) Prepare the unsupported film adhesive (C01-175) to bond the replacement core to the
R blocker door back sheet.

R (a) Cut the unsupported film adhesive (C01-175) to the correct size to go over all
R of the area where the core was removed. If it is necessary to use more than
R one piece of film adhesive, splice the two pieces to make an overlap of 0.5 in.
R (12.7 mm).

R CAUTION: USE CLEAN WHITE COTTON GLOVES WHEN YOU TOUCH THE CLEAN
R PARTS.

R (2) Apply the film adhesive to the back sheet.

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R (3) Cut the foam adhesive.

R (a) Cut a piece of foam adhesive (C01-132) a sufficient length to go around the
R honeycomb with a 0.50 inch (12.7 mm) overlap. Cut the adhesive to the same
R height as the honeycomb.

R (b) Cut a piece of foam adhesive (C01-132) a sufficient length to go between the
R hinges and/or the link and the honeycomb.

R (4) Put the foam adhesive (C01-132) around the edge of the honeycomb, and between the
R honeycomb and link or hinge fitting, as applicable.

R (5) Install and align the replacement core plug onto the back sheet, with the core ribbon in
R line with the hinges in the repair cavity.

R (6) Apply heat up to a maximum of 200°F (93°C) until the core seats into position.

R (7) Put a layer of film (C10-133) on top of the repair area.

R E. Prepare the surface for the face sheet bond.

R WARNING: THIS PROCESS GIVES OFF AIRBORNE DUST PARTICLES THAT ARE
R POISONOUS. PUT ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE
R MASK. MAKE SURE THE AREA HAS GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE IN THE DUST PARTICLES.

R CAUTION: THE HONEYCOMB CORE AND THE SURROUNDING BACK SHEET

R SURFACE MUST BE A UNIFORM SURFACE +/-0.005 INCH (0.13 MM) TO
R CONTOUR, TO MAKE SURE THERE IS A SATISFACTORY BOND TO THE
R REPLACEMENT FACE SHEET.

R (1) Use a spline or straight edge to compare the height of the replacement core to the
R adjacent core. Use 180 grit abrasive paper (C10-141) to abrade the replacement core
R to the correct contour.

R (2) Lightly abrade all of the honeycomb core surface, the back sheet, and the replacement
R SPD face sheet to remove the gloss and all high spots, and to prepare the surface for
R bonding. It is not necessary to remove all of the adhesive.

R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

R PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
R SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE. WEAR
R GOGGLES. DO NOT POINT COMPRESSED AIR IN THE DIRECTION OF
R YOUR SKIN.

R (3) Use dry, filtered shop air to blow off all dust and loose particles from the core, the back
R sheet, and the SPD face sheet.

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R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (4) Use a clean, lint-free cotton cloth (C10-182) moist with solvent (C04-003, or C04-035)
R to clean the honeycomb core, the back sheet, and the SPD face sheet. Remove the
R solvent with a clean, dry, lint-free cotton cloth. Do not let the solvent dry on the repair
R area. Do this again until the repair area is clean.

R (5) Do a water break test of the repair area to make sure the surface is clean.

R (6) Shake out excess water and dry the blocker door for a minimum of 2 hours in an air
R circulating oven at 160°-180°F (71°-82°C).

R (7) Prepare the unsupported film adhesive (C01-175) to bond the replacement SPD face
R sheet to the blocker door and reticulate the adhesive.

R (a) Cut the unsupported film adhesive (C01-175) to the correct size to go over the
R entire honeycomb core. If it is necessary to use more than one piece of film
R adhesive, splice the two pieces to make an overlap of 0.5 in. (12.7 mm).

R CAUTION: USE CLEAN WHITE COTTON GLOVES WHEN YOU TOUCH THE
R CLEANED PARTS.

R (b) Apply the unsupported film adhesive (C01-175) to the honeycomb core.

R NOTE: Unsupported film adhesive (C01-175) may be manually perforated

R to aide in the reticulation process.

R WARNING: USE AN ORGANIC VAPOR RESPIRATOR WHEN YOU APPLY HEAT

R TO THE FILM ADHESIVE.

R (c) Put a heat gun (300°F (149°C) maximum) in position at a 30-50-degree angle
R and a distance of 1.0-2.0 in. (25.4-50.8 mm) from the repair area.

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R CAUTION: MAKE SURE THE ADHESIVE DOES NOT BECOME TOO HOT. IF
R THE ADHESIVE BECOMES TO HOT, IT WILL CURE TOO SOON.
R KEEP THE HEAT GUN IN CONTINUOUS MOTION AND AT THE
R CORRECT DISTANCE FROM THE REPAIR. IF THE HEAT GUN
R TOUCHES THE ADHESIVE, YOU MUST REPLACE THE ADHESIVE
R IN THE AREA OF CONTACT.

R CAUTION: MAKE SURE YOU DO NOT BLOW THE ADHESIVE DOWN THE
R CELL WALLS OF THE HONEYCOMB CORE WITH THE HEAT GUN.

R (d) Reticulate adhesive by moving the heat gun from left to right over an area
R approximately 6-10 in. (152.4-254 mm) square. When heated correctly the film
R adhesive will attach itself to the edges of the honeycomb core. When applied
R correctly, the adhesive will not cover any of the holes in the honeycomb core.

R (e) Do step (d) again as necessary to apply the adhesive until all of the honeycomb
R core edge has adhesive on it. Make sure that there is no adhesive over the
R honeycomb core cells.

R (8) Prepare the supported film adhesive (C01-128) to bond the replacement SPD face
R sheet to the blocker door.

R (a) Cut the supported film adhesive (C01-128) to the correct size to go over all of
R the solid areas of the blocker door around the honeycomb core. If it is
R necessary to use more than one piece of film adhesive, splice the two pieces to
R make an overlap of 0.5 in. (12.7 mm). Cut additional pieces of adhesive to
R support the process control specimens defined in paragraph 8(c).

R CAUTION: USE CLEAN WHITE COTTON GLOVES WHEN YOU TOUCH THE
R CLEAN PARTS.

R (b) Apply the supported film adhesive (C01-128) to the solid surfaces of the
R blocker door around the honeycomb core. If necessary, apply adhesive to the
R core splice areas so that they are the same height as the adjacent adhesive.

R (c) Prepare process control lap shear specimens per SPM 70-71-05 using C01-
R 128 supported film adhesive. Test specimen strength requirements are defined
R in Table 601.

R Table 601. In-Process Control Tests for Adhesive Blocker Door Bondlines

R Acceptance Values
Test Type
R Minimum and Individual
R Tensile Shear, PSI (MPa),
2100 PSI (14.48 MPa)
R after 10 minutes at 250°F (121°C)

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R F. Install the replacement SPD face sheet.

R (1) Put the replacement SPD face sheet in position on the blocker door and heat tack it as
R necessary with a heat gun (200°F (93°C) maximum).

R (2) Put the blocker door in a locally manufactured bonding fixture. The contour of the
R bonding fixture must match the contour of the face sheet side of the blocker door, and
R must cover the full face surface of the blocker door. The bonding fixture must be more
R rigid than the blocker door to keep the contour of the blocker door during bonding.

R (3) Prepare the vacuum bag as follows:

R (a) Cut the temperature resistant bagging film (C10-137) to cover the blocker door
R shape with a minimum of 10 in. (25.4 cm) allowance around the area of the
R door. Make sure there is a sufficient quantity for connection of the vacuum line
R connections.

R (b) Insure that there is room under the bag to accommodate the lap shear
R specimens or if bagged separately that they share the same vacuum line.

R (c) Put polymer film (C10-133) on all of the blocker door surface. Apply Teflon
R tape (C10-040) as necessary. Put breather/bleeder cloth (C10-134) on all
R sharp surfaces.

R (d) Make two vacuum fitting cushions from 12.0 in. (30.5 mm) square pieces of
R breather/bleeder cloth (C10-134) folded to 4.0 in. (10.2 cm) square, nine-ply
R thick cushions.

R (e) Attach the vacuum bag sealant tape (C10-138) tightly around the edge of the
R vacuum bag. Do not remove the paper backing from the sealant tape.

R (f) Install the vacuum bag stems in the bag 180° apart and away from the repair
R area. See figure 603.

R (g) Attach the vacuum fitting cushions to the vacuum bag over the vacuum bag
R fittings with Teflon tape (C10-040).

R (h) Put the perforated film (C10-051) over the blocker door face and attach the film
R lightly in position with Teflon tape (C10-040).

R (i) Fold the first layer of bleeder cloth over the screen surface and attach the
R bleeder cloth lightly in position with Teflon tape (C10-040).

R (j) Attach a minimum of two thermocouples to the outside of the bleeder cloth in
R the center of the repair area with a small piece of Teflon tape (C10-040).

R (k) Wrap the second layer of bleeder cloth over the blocker door and attach lightly
R in position with Teflon tape (C10-040). Use bleeder cloth to protect the vacuum
R bag from sharp corners and to give an evacuation path for the bag.

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R (l) Peel off the backing paper from the sealant tape and push the vacuum bag
R edges together. Work with one edge at a time. Put two tucks or “ears” in each
R edge to avoid local stretching that will cause tears in the bag. See figure 604.
R You can use a Teflon spatula (figure 605) to push down the sealant tape.
R Make sure that the wires from the thermocouples are led out through the
R sealant for later use.

R (4) Attach the vacuum lines.

R (5) Evacuate the bag using FULL vacuum, 15 in. of mercury (Hg) (34-51 kPa) minimum.
R Examine the bag for leaks and repair as necessary. The leak rate must not be more
R than 2.5 in. of Hg in 5 minutes.

R (6) Install the bagged blocker door with lap shear specimens in the autoclave and attach
R the thermocouples.

R (7) Set the temperature of the autoclave to 240°-260°F (116°-127°C). The heat-up rate
R must be 2°-6° F per minute.

R (8) Set the pressure to 45 psi positive pressure. Release the vacuum to the atmosphere.

R (9) Cure the blocker door for 60 minutes after both thermocouples reach 240°F (116°C).

R WARNING: WEAR THERMAL OR INSULATED GLOVES TO PREVENT HAND INJURY

R WHEN YOU TOUCH HOT PARTS.

R (10) Remove the blocker door from the autoclave.

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R
R Vacuum Fitting Installation
R Figure 603 (Sheet 1 of 2)

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R
R Vacuum Fitting Installation (Alternative)
R Figure 603 (Sheet 2 of 2)

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R
R Formation of Tuck or “Ear” in the Edge of the Vacuum Bag
R Figure 604

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R
R Acrylic Spatula
R Figure 605

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R G. Visual inspection of the repair area.

R (1) Make a visual inspection of the repair area. Look for a good bond, surface finish, and
R contour.

R (2) Make an inspection for Disbonds of the blocker door face sheet and back sheet.

R (a) Lightly tap the face sheet and the back sheet of the blocker door with the locally
R made Tap Check inspection tool (refer to paragraph 2), and listen to the sound.

R 1 If you hear a solid "click," the area does not have a disbond.

R 2 If you hear a hollow or dull sound, the area has a disbond.

R (3) Examine 2.0 in. by 2.0 in. (50.8 by 50.8 mm) areas of the face sheet for holes filled with
R adhesive.

R (a) It is permissible for a maximum of 20% of the face sheet holes (over areas with
R full-depth honeycomb) to be blocked. A hole is blocked if you cannot put a
R 0.037 inch (0.94 mm) pin into the hole.

R (b) You can drill open blocked holes with a 0.065 inch (1.66 mm) diameter drill bit.
R Drill through the perforated skin only, and do not open holes over cell walls or
R core splice areas.

R H. Trim the edges of the face sheet.

R CAUTION: BE CAREFUL NOT TO DAMAGE THE EDGES OF THE FACE SHEET.

R (1) Cut the edges of the face sheet so that they are flush with the edges of the back sheet.

R I. Apply the epoxy-polyamide paint (C03-010).

R (1) Make the surface rough with abrasive paper (C10-141).

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R CAUTION: DO NOT PUT SOLVENTS DIRECTLY ON THE BLOCKER DOOR. DO NOT

R PUT THE BLOCKER DOOR IN A CONTAINER OF SOLVENT. DAMAGE CAN
R OCCUR.

R (2) Use a clean, lint-free cotton cloth (C10-182) moist with solvent (C04-003, or C04-035)
R to clean the face sheet of the blocker door. Immediately dry the surface with a dry, lint-
R free cotton cloth. Do not let the solvent dry on the surface. Clean and dry the surfaces
R again until the surface is clean.

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R (3) Let the blocker door dry for a minimum of 15 minutes.

R WARNING: THIS PAINT IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
R USE THE PAINT IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE THE FUMES. DO NOT GET THE PAINT ON YOUR SKIN
R OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES AND
R CLOTHING TO PROTECT YOURSELF.

R CAUTION: DO ONLY STEP 3.A.(5) IN SPM 70-43-22. DO NOT DO THE GRIT BLAST
R OR PRIMER STEPS. IF YOU DO THE GRIT BLAST OR PRIMER STEPS
R THE FACE SHEET CAN BE DAMAGED.

R (4) Apply the paint (C03-010) with a spray gun. Refer to SPM 70-43-22, step 3.A.(5). Hold
R the spray gun at a 15-degree angle to the face sheet surface. Move the spray gun in
R an alternating, forward-to-aft direction.

R (a) Full coverage of the edges of the perforations is not necessary. Over-spray is
R permitted on the edge of the assembly.

R (b) Runs must not be more than 0.010 in. (0.254 mm) above the coated surface.

R (5) Let the blocker door dry for 30 minutes.

R (6) Cure the blocker door in an oven at 165°-185°F (74°-85°C) for 60-90 minutes.

R J. Make sure that the blocker door face sheet is in the limits for acoustic blockage.

R (1) Measure the effective open area ratio (OAR) of the painted face sheet.

R (a) The effective OAR must be 10.0% to 13.0% when averaged over one random
R 2.0 in. x 2.0 in. (50.8 mm x 50.8 mm) area on the face sheet.

R (b) A perforation is defined as blocked if you cannot easily put a 0.037 in. (0.94
R mm) pin into the hole.

R (c) If necessary, you can use a drill bit to remove paint from a blocked hole. Use a
R drill bit only to remove paint. Do not remove adhesive from holes that are
R blocked by reticulated adhesive.

R K. Install the anti-rotation clips.

R (1) Back drill through the face sheet with a 0.190 in. (4.83 mm) diameter drill bit. Drill from
R the back side of the blocker door at the four anti-rotation clip mounting holes.

R (2) Use a 0.218 in. (5.54 mm) diameter drill bit to make the anti-rotation clip attachment
R holes full size.

R (3) Countersink the holes on the face sheet side to 0.385-0.405 inch (9.78-10.29 mm) x
R 100° countersink.

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R (4) Install the anti-rotation clips with the four screws, nuts, and dimpled washers that were
R removed in step 5.A.(1). Tighten the nuts hand tight.

R (5) Use a hinge installation bolt to verify the alignment of anti-rotation clips. Alignment is
R correct if the bolt passes easily through the blocker door hinge and the anti-rotation clip.

R (6) Adjust the position of the anti-rotation clip as necessary and torque the nuts to 33-37
R in.-lbs (3.73 - 4.18 N·m).

R L. At the completion of the repairs on the blocker door, do the steps that follow:

R (1) Refer to the GE Aircraft Engines Commercial Engine Standard Practices Manual, GEK
R 9250, Section 70-16-00, MARKING PRACTICES. Letter size is optional.

R (2) For Blocker Door PN 1291M28G12, mark a line through “12” at the end of
R “1291M28G12”. Mark either a “13” or a “16” next to “12” depending on whether or not
R SB 78-5091 was implemented. Epoxy paint is the recommended method of marking.

R Marking for door without the incorporation of SB 78-5091:

R Old Part Number New Part Number

R 1291M28G12 1291M28G12 13

R Marking for door with SB 78-5091 implemented:

R Old Part Number New Part Number

R 1291M28G12 1291M28G12 16

R (3) Mark “Repaired per CMM 78-32-03 Repair 014 Cure Cycle 1” on the back of the door. If
R performing the 2nd and final repair cure cycle on an original 1291M28G16 door, scratch
R out the “1” and enter “2” mark Epoxy paint is the recommended method of marking.
R Refer to Figure 606.

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R
R Blocker Door Repair Nameplate
R Figure 606

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R NOTE: Break sharp corners and edges.

R Item Number Material

R 1. ½” (12.7mm) diameter. x 3” (76.2mm) long 6061 – T6 Aluminum

R 2. 3/16” (4.8mm) diameter x 7” (177.8mm) long 6061 – T6 Aluminum
R 3. ½” (12.7mm) diameter x 3 1/2 “ (88.9mm) long Wood

R
R Tap Check Inspection Tool
R Figure 607

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FAN REVERSER VANED DEFLECTORS - INSPECTION/CHECK

1. General.

A. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable
Materials.

(1) Tools and Equipment. None required.

(2) Consumable Materials. None required.

(3) Expendable Parts. None required.

(4) Referenced Procedures.

SPM 70-32-03

2. Do a Spot Fluorescent-Penetrant Inspection. Refer to GE Standard Practices Manual, 70-32-03.

R 3. Make an Inspection of the Deflectors. See figure 501 and table 501 for inspection of the vaned
R deflectors. See table 502 for inspection of the blank deflectors.

NOTE: The following inspection is a visual inspection aided by the use of a 10X magnifying glass.

Table 501. Vaned Deflectors

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

A. Cracks in the vane Not serviceable 0.125 in. (3.18 mm) Blend and polish to the
leading or trailing edge length original finish

B. Nick or dent in vane Not serviceable 0.125 in. (3.18 mm) Blend and polish to the
leading or trailing edge length original finish

C. Broken or missing Not serviceable Not repairable Replace the deflector

vanes

D. Cracks in the straight 0.125 in. (3.18 mm) Not repairable Replace the deflector
deflectors length

E. Wear on forward and Not serviceable 1.0 inch (25.4 mm) Blend and polish to the
aft ribs length, 0.15 inch (3.81 original finish
mm) depth

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R Table 502. Blank Deflectors

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

R A. Cracks in the joggle Not serviceable Not repairable Replace the deflector
R area adjacent to the
R forward-to-aft axial row
R of fasteners

R B. Cracks at the One crack up to 0.5 in. Not repairable If out of the serviceable
R mounting bolt holes (12.7 mm) in length is limits, replace the
R permitted for each bolt deflector
R hole. One crack on each
R edge of the deflector is
R permitted (maximum of 4
R cracks on each deflector)

R C. Dents Any number of dents Not repairable If out of the serviceable

R permitted. Maximum limits, replace the
R depth permitted for each deflector
R dent is 0.12 in. (3.1 mm)

R D. Doublers that are Not serviceable Not repairable Replace the deflector
R gone, broken, or not
R fully bonded along
R each row of the
R mounting bolt holes

R E. Loose bolts or bolts Not serviceable Any number Replace the bolts that
R that are gone are gone. Tighten the
R bolts to 33-37 lb in. (3.7-
R 4.2 N·m) of torque

INSPECTION
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R MR50165-00-A
Vaned Deflector Inspection Areas
Figure 501 (Sheet 1)

INSPECTION
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MM50054-01-A
Vaned Deflector Inspection Areas
Figure 501 (Sheet 2)

R INSPECTION
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FAN REVERSER DEFLECTOR GANG CHANNELS - INSPECTION/CHECK

1. General.

A. Tools Equipment and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable
Materials.

(1) Tools and Equipment. None required.

(2) Consumable Materials. None required.

(3) Expendable Parts. None required.

(4) Referenced Procedure.

SPM 70-32-03

2. Do a Spot Fluorescent-Penetrant Inspection. Refer to GE Standard Practices Manual, 70-32-03.

3. Make an Inspection of the Deflector Gang Channels. See figure 501 and table 501.

NOTE: The following inspection is a visual inspection aided by the use of a 10X magnifying glass.

Table 501. Deflector Gang Channels

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

A. All areas for:

(1) Cracks Not serviceable Not repairable Replace the channel

(2) Wear One-half the thickness of Not repairable Replace the channel
the wear material can be
missing

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CF8-D3383-00-A
Deflector Gang Channels Inspection Areas
Figure 501

INSPECTION
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FAN REVERSER ANGLE GEARBOX HOUSING - INSPECTION/CHECK

1. General.

A. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable
Materials.

(1) Tools and Equipment. None required.

(2) Consumable Materials. None required.

(3) Expendable Parts. None required.

(4) Referenced Procedure. None required.

SPM 70-32-03

SPM 70-41-00

2. Do a Spot Fluorescent-Penetrant Inspection. Refer to GE Standard Practices Manual, 70-32-03.

3. Make an Inspection of the Angle Gearbox Housing. See figure 501 and table 501.

NOTE: The following inspection is a visual inspection aided by the use of a 10X magnifying glass.

Table 501. Angle Gearbox Housing

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Methods

A. All areas for cracks Not serviceable 0.5 in. (12.7 mm) crack Weld. Refer to
length, total Standard Practices
accumulation of 1.5 in. Manual, 70-41-00
(38 mm)

R B. Bushings for wear 0.4491 in. (11.407 mm) Any amount Replace the bushings,
R inner diameter for the Repair 001
R larger bushing; 0.3867 in.
R (9.822 mm) inner
R diameter for the smaller
R bushing

INSPECTION
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CF8-7211-01-B
Angle Gearbox and Gearbox Housing Inspection Areas
Figure 501

INSPECTION
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FAN REVERSER ANGLE GEARBOX HOUSING - REPAIR

1. Replacement of Bushings.

A. This procedure gives the instructions to replace the worn angle gearbox housing bushings.

B. Each bushing has a unique outside diameter. The two bushings are installed in the housing
R with an interference fit. Make sure the correct bushing is installed into the correct hole.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment. None required.

B. Consumable Materials.

Code No. Description Use

C03-005 Primer, Epoxy Resin (Spray Type), Corrosion protection

Finch 463-12-8

R C03-064 Conversion Coating, Chromated, Protect the surface

R Iridite 14-2

C04-001 Solvent, Methyl-Ethyl-Ketone Clean the repair area

(MEK)

C04-003 Solvent, Acetone Fed. Clean the repair area

Spec. (0-A51)

C04-035 Solvent, Isopropyl Alcohol Clean the repair area

R C04-222 Surfactant, APR 2 Agent Use with C03-064

C10-182 Cloths, Cleaning Clean the repair area

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C. Expendable Parts. None required.

D. SPD Identification.

SPD No. Description

R 9007M82P03 Bushing, actuator pin, 78-32-11-15-060

R 9007M82P04 Bushing, actuator pin, 78-32-11-15-050

E. Referenced Procedures. None required.

3. Dimensional Information. None required.

4. Setup Information. None required.

5. Procedure.

A. Remove the worn/damaged bushing(s) with a hydraulic press.

R B. Inspect the hole(s).

R (1) If the diameter of the holes is 0.5010- 0.5015 inch (12.725-12.738 mm) on one side,
R and 0.5634-0.5639 inch (14.310-14.323 mm) in the opposite hole, hone the hole to
R remove all scoring or non-uniformity from the hole.

R (2) Make sure the hole has a cylindrical shape and a constant diameter. You must remove
R all evidence of wear from the hole.

R (3) If the holes do not clean up at 0.5015 inch (12.738 mm) and 0.5639 inch (14.323 mm),
R respectively, replace the angle gearbox housing.

R (4) Deburr the edges of the angle gearbox housing bushing hole(s) as necessary.

R C. Prepare the angle gearbox housing and bushings.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (1) Clean the bushing holes(s) and the area(s) next to the bushing hole(s) on the angle
R gearbox housing with a clean, lint-free cotton cloth (C10-182) made moist with solvent
R (C04-001, C04-003, C04-014, or C04-035). Immediately dry the surface with a clean,
R lint-free cotton cloth (C10-182). Do not let the solvent dry on the repair surface. Do this
R again until the bushing holes are clean.

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R WARNING: DO NOT LET THE IRIDITE SOLUTION DRY IN THE BRUSH, CLOTH, OR
R SPONGE BECAUSE SPONTANEOUS COMBUSTION CAN OCCUR. FULLY
R CLEAN THE ITEMS IN WATER, OR WRING OUT AS MUCH SOLUTION AS
R POSSIBLE AND STORE IN A FIREPROOF CONTAINER.

R (2) Mix 3.0 oz/gallon (22.5 g/liter) of Iridite (C03-064) and 1.25 fl oz/gallon (10 cc/liter) of
R surfactant (C04-222).

R (3) Use a nylon brush, cellulose sponge, or clean cloth (C10-182) to apply the Iridite
R solution to the hinge hole diameter. Keep the surface wet until you see a small color
R change (usually 2-3 minutes).

R (4) Flush the angle gearbox housing with deionized water.

R (5) Air dry for 8 hours or oven dry at a maximum temperature of 135°F (57°C) for 1 hour or
R until dry.

R D. Install the replacement bushings. Refer to figure 601. Do not apply primer to the bushing or to
R the angle gearbox housing hole before or during bushing installation.

R (1) If the hole diameter is 0.5010-0.5015 inch (12.725-12.738 mm), install bushing
R 78-32-11-15-060 into the angle gearbox housing. Use a hydraulic press to install the
R bushing.

R (2) If the hole diameter is 0.5634-0.5639 inch (14.310-14.323 mm), install bushing
R 78-32-11-15-050 into the angle gearbox housing. Use a hydraulic press to install the
R bushing.

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
R USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
R SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
R AND CLOTHING TO PROTECT YOURSELF.

R (3) Touch up exposed or abraded surfaces with epoxy resin primer (C03-005). Apply the
R primer at the interface between the bushings and the housing.

R (4) Cure the primer. Refer to the manufacturer's instructions.

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R MR60054-00-C
R Angle Gearbox Housing Bushings
R Figure 601

REPAIR 001
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FAN REVERSER MOUNTING RING LATCH ASSEMBLY - INSPECTION/CHECK

1. General.

A. Tools Equipment and Materials. None required.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable
Materials.

(1) Tools and Equipment. None required.

(2) Consumable Materials.

Code Description

C02-003 Lubricant, Molykote 321-R

R C03-009 Orange Epoxy Coating

R C03-010 Black Epoxy Coating

R C03-017 Primer, Urethane Compatible Corrosion Resistant (Alternate)

R C03-063 Primer, Urethane Compatible Corrosion Resistant

(3) Expendable Parts. None required.

(4) Referenced Procedures.

SPM 70-32-03

SPM 70-13-00

SPM 70-41-00

SPM 70-42-00

2. Do a Spot Fluorescent-Penetrant Inspection. Refer to GE Standard Practices Manual, 70-32-03.

INSPECTION
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3. Make an Inspection of the Mounting Ring Latch Assembly. See figures 501, 502, 503 and table 501.

NOTE: The following inspection is a visual inspection aided by the use of a 10X magnifying glass.

Table 501. Mounting Ring Latch Assembly

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

A. Outer ring for cracks Not serviceable Not repairable Replace the outer ring

B. Standoff brackets for Not serviceable Not repairable Replace the standoff
cracks bracket

C. Cable for:

(1) Broken, kinked or Not serviceable Not repairable Replace the cable
damaged

R SB 78-5047, SB 78-5133

(2) Looseness in the Not serviceable Any amount Tighten the nut to 24-27
cable attach bolt lb in. (5.7-7.9 N·m)

R End SB 78-5047, End SB 78-5133

D. Lower latch handle for:

(1) Cracks, bending, Not serviceable Not repairable Replace the lower latch
and thread damage handle
at the pin hole

(2) Dents/scratches Not serviceable 0.060 in. (1.52 mm) Blend to contour. Refer
to Standard Practices
Manual, 70-42-00

(3) Lower latch handle Not serviceable Not repairable Replace the lower latch
bent handle

(4) Lower latch handle Not serviceable Any amount Replace the pin
pin loose, cracked,
broken, bent, or
missing

INSPECTION
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Table 501. Mounting Ring Latch Assembly (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

E. Cracked or missing Not serviceable Any amount Install new rivets. Wet
rivets coat the rivets with
primer (C03-005). Refer
to Standard Practices
Manual, 70-13-00

Pre SB 78-5047

F. Cracks in upper latch Not serviceable Any amount Weld. Refer to Standard
hook Practices Manual, 70-
41-00

G. Latch cam for cracks Not serviceable Not repairable Replace the cam

End Pre SB 78-5047

H. Fretting in contact area Not serviceable Any amount Lubricate with lubricant
between the lower latch (C02-003)
hook and the hinge bolt

K. Lower latch bracket for Not serviceable Not repairable Replace the latch
cracks bracket

L. Latch link hardware for Not serviceable Any amount Replace the washers
washer deformation

R SB 78-5047, SB 78-5133

M. Barrel nut turnbuckle for Not serviceable Any amount Replace the safety wire
missing safety wire

N. Upper latch for:

(1) Cracks in the Not serviceable Not repairable Replace the upper latch.
R sideplates Refer to SB 78-5133

(2) Corrosion on the Not serviceable Not repairable Replace the upper latch.
R sideplates Refer to SB 78-5133

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Table 501. Mounting Ring Latch Assembly (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

R O. Upper latch handle for:

R (Refer to Figure 503)

R (1) Wear to the handle Not serviceable Any amount Blend to contour. Refer
R from contact with to Standard Practices
R fan cowl. Manual, 70-42-00.

R (2) Bushing wear Not serviceable Not repairable Replace Bushings.

R (3) Worn or Missing Not serviceable Any amount Touch up with:

R finish coatings. Urethane Compatible
R Corrosion Resistant
R Primer per BMS 10-79,
R Type II or III, Class A,
R Grade A (C03-063,
R alternate C03-017).

R Orange Epoxy Coating

R (C03-009, Alternate:
R Orange Polyurethane
R per MIL-PRF-85285,
R Color 12197).

R Black Epoxy Coating

R (C03-010, 37038-
R lusterless).

INSPECTION
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CF8-7212-00-B
Mounting Ring Latch Assembly Inspection Areas
Figure 501

R INSPECTION
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MR60102-00-A
Inspection of Improved Upper Latch (Post MRAS SB 78-5047; Post MRAS SB 78-5133)
Figure 502

R INSPECTION
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R
R Inspection of the Upper Latch Handle
R Figure 503

INSPECTION
PAGE 507
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 FAN REVERSER
CF6-80E1 CMM

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 COMPONENT
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MANUAL

683L SERIES

FAN REVERSER LINK AND SUPPORT - INSPECTION/CHECK

1. General.

A. Tools Equipment and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable
Materials.

(1) Tools and Equipment. None required.

(2) Consumable Materials. None required.

(3) Expendable Parts. None required.

(4) Referenced Procedures.

SPM 70-21-05

SPM 70-32-03

SPM 70-42-00

2. Do a Spot Fluorescent-Penetrant Inspection. Refer to GE Standard Practices Manual, 70-32-03.

3. Make and Inspection of the Link and Support: See figure 501 and table 501.

NOTE: The inspection that follows is a visual inspection aided by the use of a 10X magnifying
glass.

Table 501. Link and Support

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

A. Link for:

(1) Cracks Not serviceable 0.060 in. (1.52 mm) Blend to remove
length cracks. Refer to
Standard Practices
Manual, 70-42-00

(2) Dents, nicks, or Not serviceable 0.100 in. (2.54 mm) Blend to contour.
gouges not on diameter; 0.020 in. Refer to Standard
leading edges (0.508 mm) depth Practices Manual, 70-
42-00

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Table 501. Link and Support (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

A. Link for: (continued)

(3) Scratches Not serviceable Any amount Blend to contour.

Refer to Standard
Practices Manual,
70-42-00

(4) Dents, nicks, Not serviceable 0.060 in. (1.52 mm) Blend to remove
gouges, scratches diameter distress. Refer to
on leading edges Standard Practices
Manual, 70-42-00

(5) Bushing wear 0.005 in. (0.13 mm) Not repairable Replace the bushing,
scoring Repair 001

(6) Wear on inner and Not serviceable 0.030 in. (0.76 mm) Replace the bushing,
outer faces deep each side Repair 001

(7) Elongated bushing Not serviceable 0.010 in. (0.25 mm) out Replace the bushing,
holes of round Repair 001

(8) Corrosion Not serviceable 0.030 in. (0.76 mm) Use wet abrasive blast
deep each side procedure to remove
the corrosion. Refer
to Standard Practices
Manual, 70-21-05

B. Support for:

(1) Cracks Not serviceable 0.060 in. (1.52 mm) Blend to remove
length cracks. Refer to
Standard Practices
Manual, 70-42-00

(2) Nicks, dents, gouges Any amount less than 0.100 in. (2.54 mm) Blend to contour.
0.005 in. (0.13 mm) diameter, 0.020 in. Refer to Standard
(0.51 mm) depth Practices Manual,
70-42-00

(3) Scratches Any amount that cannot Any amount Polish to remove
be felt with 0.010 in. scratches
(0.25 mm) diameter
scribe

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Table 501. Link and Support (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

B. Support for: (continued)

(4) Pin hole elongation Not serviceable Not repairable Replace the support

C. Pin and bolt for:

(1) Thread damage or Not serviceable Not repairable Replace the pin and
wear the bolt

(2) Pin external 0.003 in. (0.08 mm) Not repairable Replace the pin
diameter wear diameter reduction

D. Link block for:

R (1) Surface wear 0.786 in. (19.96 mm) Refer to Dimensional Repair 002
R Dimension E; 1.282 in. Information, Repair 002
R (32.56 mm) Dimension F

INSPECTION
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1121651-00-A
Link Assembly
Figure 501

INSPECTION
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FAN REVERSER LINK AND SUPPORT - REPAIR

1. Replacement of Link Sleeve Bearings.

A. This procedure gives the instructions to replace the bearings in the fan reverser blocker door
link arm assembly.

R B. Each bearing has a unique outside diameter and length. The two bearings are installed in the
R link with interference fits.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment.

Description Manufacturer

Hydraulic press Local purchase

B. Consumable Materials.

Code No. Description Use

C03-005 Primer, Epoxy Resin Bearing replacement

(Spray Type), 463-12-8

R C03-064 Conversion Coating, Chromated, Protect the surface

R Iridite 14-2

C04-001 Solvent, Methyl-Ethyl-Ketone Clean the repair area

(MEK)

C04-003 Solvent, Acetone Clean the repair area

(Fed. Spec. 0-A51)

C04-035 Isopropyl Alcohol Clean the repair area

REPAIR 001
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Code No. Description Use

R C04-222 Surfactant, ARP 2 Agent Use with C03-064

C10-182 Cloths, Cleaning Clean the repair area

C. Expendable Parts. None required.

R D. SPD Identification.

SPD No. Description

R M81934/1-06A012 Bearing, Sleeve

R 9633M07P01 Bearing, Sleeve

E. Referenced Procedures. None required.

3. Dimensional Information. None required.

4. Setup Information. None required.

5. Procedure.

A. Remove the worn and/or damaged sleeve bearing(s) with a hydraulic press.

R B. Inspect the bearing hole(s).

R NOTE: The link arm has two bearings with different diameters and lengths. Refer to figure
R 601 to identify the bearing hole diameters.

R (1) If the diameter of the hole on the narrow end of the link arm is 0.4996-0.5005 inch
R (12.690-12.713 mm), hone the hole to 0.4996-0.5005 inch (12.690-12.713 mm) to
R remove all scoring or non-uniformity from the hole.

R (2) If the diameter of the hole on the wide end of the link arm is 0.4993-0.4997 inch
R (12.682-12.692 mm), hone the hole to 0.4993-0.4997 inch (12.682-12.692 mm) to
R remove all scoring or non-uniformity from the hole.

R (3) Make sure the holes have a cylindrical shape and a constant diameter. You must
R remove all evidence of wear from the holes.

R (4) If the holes do not clean up at 0.5005 inch (12.713 mm) and 0.4997 inch (12.692 mm),
R respectively, replace the link arm.

R (5) Deburr the edges of the link arm bearing hole(s), as necessary.

REPAIR 001
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R MR600555-01-A
R Link Arm Bushings
R Figure 601

REPAIR 001
PAGE 603
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R C. Prepare the holes.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

R (1) Clean the bearing(s), the bearing hole(s) and the area(s) next to the bearing hole(s) on
the link with a clean, lint-free cotton cloth (C10-182) made moist with solvent (C04-001,
C04-003, or C04-035). Immediately clean the surface with a clean, lint-free cotton cloth
(C10-182). Do not let the solvent dry on the surface. Do this again until the bearing
holes are clean.

(2) Let the repair area dry a minimum of 15 minutes.

R WARNING: DO NOT LET THE IRIDITE SOLUTION DRY IN THE BRUSH, CLOTH, OR
R SPONGE BECAUSE SPONTANEOUS COMBUSTION CAN OCCUR. FULLY
R CLEAN THE ITEMS IN WATER, OR WRING OUT AS MUCH SOLUTION AS
R POSSIBLE AND STORE IN A FIREPROOF CONTAINER.

R (3) Mix 3.0 oz/gallon (22.5 g/liter) of Iridite (C03-064) and 1.25 fl oz/gallon (10 cc/liter) of
R surfactant (C04-222).

R (4) Use a nylon brush, cellulose sponge, or clean cloth (C10-182) to apply the Iridite
R solution to the hinge hole diameter. Keep the surface wet until you see a small color
R change (usually 2-3 minutes).

R (5) Flush the link arm with deionized water.

R (6) Air dry for 8 hours or oven dry at a maximum temperature of 135°F (57°C) for 1 hour or
R until dry.

R D. Install the bearing(s).

WARNING: THIS MATERIAL IS POISONOUS AND GIVES OFF FUMES. MAKE SURE
YOU USE IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. DO NOT GET THE MATERIAL ON YOUR SKIN OR IN YOUR EYES
OR MOUTH. MAKE SURE YOU USE GLOVES AND CLOTHING TO
PROTECT YOURSELF.

CAUTION: DO NOT APPLY PRIMER TO THE INSIDE DIAMETER OF THE BEARING(S).

PRIMER WILL DAMAGE THE SELF LUBRICATING PROPERTIES OF THE
BEARING(S).

(1) Apply an equal layer of epoxy primer (C03-005) to the outside diameter of the new
bearing(s).

REPAIR 001
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R (2) While the primer is wet, install bearing M81934/1-06A012 into the hole at the narrow
R end of the link arm. Use a hydraulic press to install the bearing. Make sure the bearing
R is flush to below the link arm surface.

R (3) While the primer is wet, install bearing 9633M07P01 into the hole at the wide end of the
R link arm. Use a hydraulic press to install the bearing. Make sure the bearing is flush to
R below the link arm surface.

(3) Remove unwanted primer and touch up exposed or abraded surfaces with the epoxy
primer (C03-005).

REPAIR 001
PAGE 605
78-32-08 JUN 01/01
 FAN REVERSER
CF6-80E1 CMM

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 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

FAN REVERSER LINK AND SUPPORT - REPAIR

1. Link Block and Support Repair.

R A. This repair gives the instructions to restore the worn areas on the blocker door link block by
R welding or flame spray. The welding repair is the preferred process, but the flame spray repair
R is an acceptable alternative.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment.

Description Manufacturer

R Flame spray equipment Local purchase

R for aluminum powder

R Gas shielded tungsten Local purchase

R arc welding equipment

B. Consumable Materials.

Code No. Description Use

C03-005 Primer, Epoxy Resin Parts installation

(Spray Type), Finch 463-12-8

R C03-064 Conversion Coating, Chromated, Protect the surface

R Iridite 14-2

C04-001 Solvent, Methyl-Ethyl-Ketone Clean the repair area

(MEK)

C04-003 Solvent, Acetone Clean the repair area

(Fed. Spec. 0-A51)

C04-035 Isopropyl Alcohol Clean the repair area

REPAIR 002
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Code No. Description Use

R C04-114 Grit, Abrasive, 120 Mesh Surface preparation

R C04-173 Grit, Aluminum Oxide, 60 Mesh Surface preparation

R C04-222 Surfactant, APR 2 Agent Used with C03-064

R C10-012 Tape, Masking, High Temperature Surface protection

C10-062 Abrasive Cloth, 320 Grit, Prepare the repair area

Silicon Carbide, Waterproof

C10-182 Cloths, Cleaning Clean the repair area

R --- Abrasive Paper, 120-160 grit Clean the repair area

R --- Filler Material, Welding, Weld repair

R AMS 4246

R --- Powder, Aluminum, Al 12Si, Flame spray

R B50TF92, Class A

C. Expendable Parts. None required.

D. SPD Identification. None required.

E. Referenced Procedures.

R SPM 70-21-01

SPM 70-21-02

R SPM 70-32-02

R SPM 70-41-00

R SPM 70-49-00

SPM 70-49-01

3. Dimensional Information. See figure 601 and table 601.

REPAIR 002
PAGE 602
78-32-08 JUN 01/02
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R MR60074-00-A
Blocker Door Link Block
Figure 601

REPAIR 002
PAGE 603
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Table 601. Fan Reverser Link and Support

In-Process Finish
Dimension Dimension

R Weld Repair Flame spray Reference

Description Min. Min. Min. Max. Dimension

R Dimension E 0.776 in. 0.786 in. 0.796 in. 0.806 in L

(19.71 mm) (19.96 mm) (20.22 mm) (20.47mm) -

R Dimension F 1.272 in. 1.282 in. 1.292 in. 1.302 in M

R (32.30 mm) (32.56 mm) (32.82 mm) (33.07mm) -

R Dimension G - - 2.088 in. 2.108 in -

R (Ref) - - (53.04 mm) (53.54mm) -

R Dimension H 0.275 in. 0.275 in. 0.295 in. 0.305 in D, K

R (6.99 mm) (6.99 mm) (7.50 mm) (7.74 mm) -

R Dimension I 2.643 in. 2.643 in. 2.663 in. 2.673 in D, K

R (67.13 mm) (67.13 mm) (57.64 mm) (67.89mm) -

R Dimension J - - 2.958 in. 2.978 in -

R (Ref) - - (75.14 mm) (75.64mm) -

4. Setup Information. None required.

5. Procedure.

R A. Remove and discard the four spring retainers and the two flanged bushings from link block.

R B. Degrease the parts. Refer to Standard Practices Manual (SPM) 70-21-01 or 70-21-02.

R C. Do a fluorescent penetrant inspection (P3TF2 Class A) to look for cracks. If there are cracks,
R discard the link block.

R D. Make a dimensional inspection of the link block. Refer to figure 601 and table 601. If the
R dimensions are less than the in-process minimums; the link block is not repairable. Link blocks
R with dimensions between the in-process minimum and the finish dimension minimum will need
R repair. Use the weld repair in paragraph 5.E. or the flame spray repair in paragraph 5.F.

R E. Do the steps that follow to weld repair the link block.

R (1) Use a stainless steel brush, grit blast, or 80-320-grit abrasive roll, disk, or sheet to
R remove all primer, dirt, scale, and carbon deposits from the part.

REPAIR 002
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R (2) Use chemical stripping, grit blast, or 160-180 grit abrasive roll, disk, or sheet to remove
R the anodize layer from the non-machined surfaces. Make sure that the weld repair
R minimum in-process dimensions stay in the repairable limits.

R (a) If you use the chemical stripping method, use 160-180 grit abrasive paper to
R remove all oxidation from the surface to be welded.

R (3) Use AMS 4246 filler material to do a weld repair on the worn L, M, D, or K surfaces.
Refer to SPM 70-41-00, process P8G. If necessary, fill the counter-bore area.

R (4) After the weld repair, solution heat treat and age the repaired part. Refer to AMS 4260.

R (5) Go to paragraph 5.G.

R F. Do the steps that follow to do the flame spray repair on the link block.

R (1) Machine the repair surface (L, M, D, or K, as necessary) with milling cutters to get a
R uniform surface for the flame spray repair. Deburr as necessary. Do not machine past
R the flame spray in-process minimum dimensions. Refer to figure 601 and table 601.

R NOTE: Do not use the flame spray repair if the counter-bore is penetrated.

R (2) Degrease the part. Refer to SPM 70-21-01 or 70-21-02.

R (3) Use high temperature masking tape (C10-012) to protect the area adjacent to the flame
R spray repair area.

R WARNING: PUT ON A FACE SHIELD, GLOVES, PROTECTIVE CLOTHES AND

R PROTECTIVE SHOES.

R CAUTION: AVOID EXCESSIVE ABRASIVE BLASTING. MAKE SURE THE ABRASIVE

R JET DOES NOT STAY IN THE SAME AREA FOR MORE THAN 2 SECONDS.
R SWEEP THE ABRASIVE JET AT AN OBLIQUE ANGLE TO THE SURFACE.

R (4) Grit blast the repair area with clean 60 mesh aluminum oxide grit (C04-173) or 120
R mesh grit (C04-114) to get a surface finish of 0.00008-0.00015 inch (0.0020-0.0038
R mm).

R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

R PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
R SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE. USE
R GOGGLES. DO NOT POINT COMPRESSED AIR IN THE DIRECTION OF
R YOUR SKIN.

R (5) Use dry, clean, filtered, oil-free shop air to remove the dust from the part.

R (6) Examine the repair area for shiny spots or other indications of insufficient roughness. If
R necessary, do steps (4) through (6) again.

REPAIR 002
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R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (7) Clean the flame spray repair area with a lint-free cotton cloth (C10-182) made moist
R with solvent (C04-001, C04-003, or C04-035). Immediately wipe the surface with a
R clean, dry cloth. Do not let the solvent dry on the repair surface. Do this again until the
R repair area is clean.

R (8) Raise the temperature of the part to 150°-300°F (66°-149°C).

R (9) Flame spray the repair surface. Apply the build-up within 30 minutes. Do not raise the
R temperature of the part to more than 300°F (149°C) during the flame spray. Refer to
R SPM 70-49-00 and 70-49-01.

R (10) Make a visual inspection of the sprayed surface. There must be no oil in the surface
R layer, no lumps, no flakes, and no spattered particles that are loosely bonded. The
R sprayed surface must have a smooth, equal surface layer with no cracks, chips,
R blisters, or voids.

R G. Machine the repair area.

R (1) Set up and machine the repair areas to the finish dimensions. Refer to table 601.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (2) Clean the repair area with a lint-free cotton cloth (C10-182) made moist with solvent
R (C04-001, C04-003, or C04-035). Immediately wipe the surface with a clean, dry cloth.
R Do not let the solvent dry on the repair surface. Do this again until the repair area is
R clean.

R (3) Let the repair area dry for a minimum of 15 minutes.

R (4) Make a dimensional inspection to make sure dimensions E, F, H, and I are in the finish
R dimensional limits.

REPAIR 002
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R (5) Make a visual inspection of the machined repair surface. There must be no oil in the
R surface layer, no lumps, no flakes, and no spattered particles that are loosely bonded.
R The machined surface must have a smooth, equal surface layer with no cracks, chips,
R blisters, or voids.

R (6) For weld repaired parts, apply a protective hard anodize layer to all surfaces except
R original machined surfaces (AMS 2469 Class A).

R (7) For flame spray repaired parts, apply conversion coating to areas where you removed
R the anodize layer.

R WARNING: DO NOT LET THE IRIDITE SOLUTION DRY IN THE BRUSH, CLOTH, OR
R SPONGE BECAUSE SPONTANEOUS COMBUSTION CAN OCCUR. FULLY
R CLEAN THE ITEMS IN WATER, OR WRING OUT AS MUCH SOLUTION AS
R POSSIBLE AND STORE IN A FIREPROOF CONTAINER.

R (a) Mix 3.0 oz/gal. (22.5 g/liter) of Iridite (C03-064) and 1.25 fl oz/gal. (10 cc/liter) of
R surfactant (C04-222).

R (b) Use a nylon brush, cellulose sponge, or clean cloth (C10-182) to apply the
R Iridite solution to the repair area. Keep the surface wet until you see a small
R color change (usually 2-3 minutes).

R (c) Flush the repair area with deionized water.

R (d) Air dry for 8 hours or oven dry at a maximum temperature of 135°F (57°C) for 1
R hour, or until dry.

R H. Apply the primer and finish the assembly.

R WARNING: THIS MATERIAL IS POISONOUS AND GIVES OFF FUMES. MAKE SURE
R YOU USE IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. DO NOT GET THE MATERIAL ON YOUR SKIN OR IN YOUR EYES
R OR MOUTH. MAKE SURE YOU USE GLOVES AND CLOTHING TO
R PROTECT YOURSELF.

R (1) Fully mix the primer (C03-005) base material and catalyst in the manufacturer's
R containers.

R (2) Move the base material to a different container. Add the catalyst until you have a 1-to-1
R ratio with the base. Mix the two components continuously while you add the catalyst.

REPAIR 002
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R (3) Let the primer stand for a minimum of 15 minutes at an ambient temperature of 50°-
R 100°F (10°-38°C).

R NOTE: The primer has a pot life of 8 hours.

R CAUTION: DO NOT APPLY PRIMER TO THE INSIDE DIAMETER OF THE FLANGED

R BUSHINGS AND THE SPRING RETAINERS.

R (4) Apply an equal layer of primer (C03-005) to the new spring retainers and flanged
R bushings, and to the bushing holes. Make sure you do not apply primer to the inside
R diameter of the flanged bushings and the spring retainers. Install the parts while the
R primer is wet.

R (5) Remove unwanted primer, especially on the inside diameter of the flanged bushings
R and the spring retainers.

R (6) Cure the primer at ambient temperature for 1-3 hours, or air cure for 5-10 minutes, and
R then cure at 190°-210°F (88°-99°C) for 15-20 minutes.

R (7) The primer must be a smooth, equal layer and have no pin holes, blisters, runs, or thin
R spots.

REPAIR 002
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FAN REVERSER BLOWOUT AND ACCESS DOORS - INSPECTION/CHECK

1. General.

A. Tools Equipment and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable
Materials.

(1) Tools and Equipment. None required.

(2) Consumable Materials. None required.

(3) Expendable Parts. None required.

(4) Referenced Procedures.

SPM 70-32-03

SPM 70-41-00

SPM 70-43-18

2. Do a Spot Fluorescent-Penetrant Inspection. Refer to GE Standard Practices Manual, 70-32-03.

3. Make an Inspection of the Blowout and Access Doors. See figure 501 and table 501.

NOTE: The inspection that follows is a visual inspection aided by the use of a 10X magnifying
glass.

Table 501. Blowout and Access Doors

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Methods

A. Interior and exterior surfaces for:

(1) Distortion, bending, Any amount within Any amount Reform to within
or warping 0.060 in. (1.52 mm) of serviceable
contour dimensions. Check
contour against a
plaster cast, or
equivalent, made from
a new door

INSPECTION
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Table 501. Blowout and Access Doors (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Methods

A. Interior and exterior surfaces for: (continued)

(2) Cracks in the sheet Not serviceable Any amount not closer Repair weld and touch
metal (outside than 0.500 in. up. Refer to Standard
bonded area) (12.70 mm) to the bond Practices Manual,
line 70-41-00 and
70-43-18

R (3) Nicks and scratches, Not serviceable Interior surface, 0.008 Repair 001
R blowout door in. (0.20 mm) deep
after removal of high
metal

R Exterior surface, 0.013 Repair 001. Touch up

R in. (0.33 mm) deep the exterior surface of
after removal of high the door. Refer to
metal Standard Practices
Manual, 70-43-18

R (4) Nicks and scratches, Not serviceable Interior surface, 0.020 Repair 001
R access door (except in. (0.51 mm) deep
R air scoop) after removal of high
R metal

R Exterior surface, 0.020 Repair 001. Touch up

R in. (0.51 mm) deep the exterior surface of
R after removal of high the door. Refer to
R metal Standard Practices
R Manual, 70-43-18

R (5) Nicks and scratches, Not serviceable Interior surface, 0.008 Repair 001
R access door air in. (0.20 mm) deep
R scoop after removal of high
R metal

R Exterior surface, 0.008 Repair 001

R in. (0.20 mm) deep
R after removal of high
R metal

INSPECTION
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Table 501. Blowout and Access Doors (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Methods

R (6) Nicks and scratches, Not serviceable Interior surface, 0.017 Repair 001
R IDG door in. (0.43 mm) deep
R after removal of high
R metal

R Exterior surface, 0.017 Repair 001. Touch up

R in. (0.43 mm) deep the exterior surface of
R after removal of high the door. Refer to
R metal Standard Practices
R Manual, 70-43-18

(7) Missing protective Not serviceable Interior surface, any Repair 001
coating amount

Exterior surface, any Touch up the exterior

amount surface of the door.
Refer to Standard
Practices Manual, 70-
43-18

(8) Wear on forward 0.032 in. (0.81 mm) Not repairable Replace the door
and aft overlap
areas

B. Exterior skin for:

(1) Dents 0.125 in. (3.18 mm) deep Any amount Form to contour
provided dent does not
extend to edge of door NOTE: 0.375 in.
(9.53 mm) diameter
access holes, on
0.750 in. (19,05 mm)
centers, can be drilled
through reinforcement
blisters for access to
the back side of the
face sheet

INSPECTION
PAGE 503
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Table 501. Blowout and Access Doors (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Methods
C. Door edges for:

(1) Cracks, tears, or Any number 0.060 in. Five areas, 0.625 in. Blend out defects and
gouges (hinge side) (1.52 mm) long (15.88 mm) wide by touch up the coating,
0.250 in. (6.35 mm) Repair 001
deep, separated by
0.625 in. (15.88 mm)
minimum

(2) Cracks, tears, or Any number 0.060 in. Three areas, 0.250 in. Blend out defects and
gouges (all other (1.52 mm) long (6.35) wide by 0.125 in. touch up the coating,
sides) (3.18 mm) deep, Repair 001
separated by 0.625 in.
(15.88 mm) minimum

D. Areas other than the door Not serviceable Not repairable Replace the door
edges for cracks

E. Rivets for:

(1) Loose, missing or Not serviceable Any amount Replace the rivets,
damaged Repair 002

F. Latches for:

(1) Broken or missing Not serviceable Not repairable Replace the latch

R (2) Latch Release force 55.8 lbs to 68.2 lbs (25.3 None Replace the latch
R for blowout door kg to 30.9 kg). See Fig.
R 502

G. Hinge(s) for:

(1) Cracks, bends, or Not serviceable Not repairable Replace the hinge,
distortion Repair 003

H. Cable attach angles for:

(1) Cracks Not serviceable Not repairable Replace the angle,

Repair 004

(2) Elongated holes Not serviceable Not repairable Replace the angle,
Repair 004

INSPECTION
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Table 501. Blowout and Access Doors (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Methods
I. Axial gap between the The gap must not be Not repairable Replace the cable
cable and the plastic more than 1.0 in. (25.4
sheath, exposed cable mm) (shows the cable
from under the sheath has been stretched due
to overstress)

J. Blowout door for:

(1) Wear to the forward 0.032 in. (0.81 mm) deep 0.032 in. (0.81 mm) Repair 001
edge x 0.375 in. (9.53 mm) deep x 0.375 in. (9.53
wide mm) wide

Any depth x 0.375 in. Repair 005

(9.53 mm) wide

(2) Wear to the aft edge 0.032 in. (0.81 mm) deep 0.032 in. (0.81 mm) Repair 001
x 0.375 in. (9.53 mm) deep x 0.375 in. (9.53
wide mm) wide

Any depth x 0.375 in. Repair 006

(9.53 mm) wide

R K. IDG Door Hinges for:

R (1) 491B1345005 0.190 in. (4,829 mm). Not repairable Replace the hinge
R Maximum Diameter See fig. 503

R (2) 491B1345009 0.190 in. (4,829 mm). Not repairable Replace the hinge
R Maximum Diameter See fig. 503.

R (3) MS20392-2C33 0.186 in. (4,724 mm). Not repairable Replace the pin
R Minimum diameter See fig 503.

INSPECTION
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CF8-7207-00-B
Blowout and Access Doors Inspection Areas
Figure 501 (Sheet 1 of 3)

R INSPECTION
PAGE 506
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CF8-7274-00-A
Blowout and Access Doors Inspection Areas
Figure 501 (Sheet 2 of 3)

R INSPECTION
PAGE 507
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CF8-7273-00-A
Blowout and Access Doors Inspection Areas
Figure 501 (Sheet 3 of 3)

R INSPECTION
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R
R Blowout Door Latches
R Figure 502

INSPECTION
PAGE 509
78-32-09 DEC 01/16
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MANUAL

683L SERIES

R
R IDG Door Hinge
R Figure 503

INSPECTION
PAGE 510
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FAN REVERSER BLOWOUT AND ACCESS DOORS - REPAIR

1. Epoxy Resin (Green) Touch-Up Repair.

A. This procedure gives the instructions for touch-up of worn or scraped area(s) in the coating on
the blowout and access door assemblies.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment. None required.

B. Consumable Materials.

Code Description Use

R C03-006 Conversion Coating, Alodine Surface protection

R 1200S

R C03-077 Primer, Epoxy, Water-Reducible Corrosion protection

R (BMS-10-11Y Type I Class A
R Grade E)

C04-001 Solvent, Methyl-Ethyl-Ketone Clean the repair area

(MEK)

C04-003 Solvent, Acetone Clean the repair area

(Fed. Spec. 0-A51)

C04-035 Isopropyl Alcohol Clean the repair area

C10-182 Cotton Cloth, Lint-free Clean the repair area

-- Abrasive Cloth, 240 Grit Silicone Prepare the repair area

Waterproof for paint

REPAIR 001
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C. Expendable Parts. None required.

D. SPD Identification. None required.

E. Referenced Procedures. None required.

3. Dimensional Information. None required.

4. Setup Information. None required.

5. Procedure.

A. Remove oil, grease, oxides and other contaminants from the area(s) to be repaired as follows:

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

(1) Clean the repair area(s) with a clean, lint-free cotton cloth (C10-182) made moist with
solvent (C04-001, C04-003, or C04-035). Immediately dry the surface with a clean, lint-
free cotton cloth (C10-182). Do not let the solvent dry on the repair surface. Do this
again until the repair area(s) is clean.

(2) Let the repair area(s) dry a minimum of 15 minutes.

(3) Lightly sand the repair area(s) with 240 grit silicon carbide or aluminum oxide abrasive
paper or cloth.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

(4) Wipe sanded area(s) with clean, lint-free cotton cloth (C10-182) made moist with
solvent (C04-001, C04-003, or C04-035) to remove the sanding residue.

NOTE: Do not touch the cleaned area(s) or permit other contaminants to contact
the cleaned repair area(s).

R REPAIR 001
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R B. Apply conversion coating and primer to the cleaned repair area(s) as follows:

R (1) Apply Alodine 1200S (C03-006) to all of the repair area(s).

R (2) Apply an equal layer of epoxy-polyamine primer (C03-077) to the repair area(s).

REPAIR 001
PAGE 603
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CF6-80E1 CMM

THIS PAGE INTENTIONALLY BLANK

 COMPONENT
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MANUAL

683L SERIES

FAN REVERSER BLOWOUT AND ACCESS DOORS - REPAIR

1. Replacement of Rivets.

A. This procedure gives the instructions for replacing loose/damaged rivets in the blowout and
access door assemblies.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment. None required.

B. Consumable Materials.

Code Description Use

C03-001 Primer, Zinc Chromate, Rivet replacement

Fed. Spec. TT-P-1757,
Color Y, Composition G

C03-005 Primer, Epoxy Resin (Spray Type), Rivet replacement

Finch 463-12-8

C04-001 Solvent, Methyl-Ethyl-Ketone Clean the rivet hole

(MEK)

C04-003 Solvent, Acetone Clean the rivet hole

(Fed. Spec. 0-A51)

R C04-018 Solvent, Naphtha, Fed. Spec. Clean the rivet hole

R TT-N-95, Type II

C04-035 Isopropyl Alcohol Clean the rivet hole

C10-182 Cotton Cloth, Lint-free Clean the repair area

R C. Expendable Parts. Refer to the Illustrated Parts Catalog, MM 99379, 78-32-22.

REPAIR 002
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78-32-09 DEC 01/00
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D. SPD Identification. None required.

E. Referenced Procedures.

SPM 70-13-00

SPM 70-13-05

3. Dimensional Information. None required.

4. Setup Information. None required.

5. Procedure.

R A. Remove all the loose or damaged rivets.

R (1) Find all the loose or damaged rivets.

R (2) Center punch the rivets that you will remove.

R (3) Drill out the loose or damaged rivet(s). Use an applicable drill bit for the rivet diameter.
R Refer to Standard Practices Manual, 70-13-00. Deburr as necessary.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

B. Clean the rivet hole(s) with a clean, lint-free cotton cloth (C10-182) made moist with solvent
(C04-001, C04-003, C04-018, or C04-035). Immediately dry the surface with a clean, lint-free
cotton cloth (C10-182). Do not let the solvent dry on the repair surface. Do this again until the
rivet hole(s) are clean.

C. Let the rivet hole(s) dry a minimum of 15 minutes.

R D. Replace each loose or damaged rivet with an equivalent rivet, as specified in the CF6-80E
R Illustrated Parts Catalog MM 99379, 78-32-22.

WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU USE
THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU DO NOT
BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR SKIN OR IN YOUR
EYES OR MOUTH. MAKE SURE YOU USE GLOVES AND CLOTHING TO PROTECT
YOURSELF.

R E. Install the rivets with a wet layer of epoxy resin primer (C03-005) or zinc chromate primer
R (C03-001). Make sure each rivet has a full layer of primer. Refer to Standard Practices
Manual, 70-13-00 and 70-13-05.

F. Remove unwanted primer after rivet installation.

REPAIR 002
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78-32-09 DEC 01/00
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FAN REVERSER BLOWOUT AND ACCESS DOORS - REPAIR

R 1. Blowout, Access, and IDG Access Doors Hinge Replacement.

A. This procedure gives the instructions to replace the hinge(s) on the blowout door, access door,
R and IDG access door assemblies.

(1) Paragraph 5 gives instructions for the replacement of the hinges on the blowout door
and access door.

(2) Paragraph 6 gives instructions for the replacement of the hinges on the IDG access
door.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment. None required.

B. Consumable Materials.

Code Description Use

C03-005 Primer, Epoxy Resin (Spray Type), Rivet replacement

Finch 463-12-8

C04-001 Solvent, Methyl-Ethyl-Ketone Clean the repair area

(MEK)

C04-003 Solvent, Acetone Clean the repair area

(Fed. Spec. 0-A51)

C04-035 Isopropyl Alcohol Clean the repair area

C10-182 Cotton Cloth, Lint-free Clean the repair area

C. Expendable Parts. Refer to the Illustrated Parts Catalog (MM 99379) for quantity and required
rivets, cotter pins, nuts, and pins.

REPAIR 003
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D. SPD Identification. None required.

E. Referenced Procedures.

SPM 70-13-00

SPM 70-13-05

78-32-09, Repair 001

3. Dimensional Information. None required.

4. Setup Information. None required.

5. Replacement of Blowout Door and Access Door Hinges.

R A. Remove the blowout door or the access door from the reverser.

R (1) Use a felt-tip marker to make an outline of the hinge location all the way around on the
R blowout door or the access door, and on the reverser supporting flange.

R (2) For removal of the blowout door only, remove the nuts, bolts, and washers that attach
R the blowout door forward and aft cables to the reverser. Keep the nuts, bolts, and
R washers for use at installation. For removal of the access door, go to step (3).

R (3) Remove the nuts, shear pins, and washers that attach the blowout door or access door
R to the reverser. Keep the nuts, shear pins, and washers for use at installation.

R (4) Remove the blowout door or access door, and the shim, from the reverser. Keep the
R shim for use at installation.

B. Remove the old hinge.

R (1) Grind off the rivet tails on the hinge side, and drive out the rivets. Be careful not to
R damage the rivet holes in the door.

R (2) Remove the old hinge from the door.

R C. Put the new hinge on the door, aligned with the outline of the old hinge. Hold the hinge in
position with a clamp.

NOTE: Use only sufficient clamping force to hold the hinge in place. Do not damage the
hinge or the door.

D. Match drill 0.158-0.164 inch (4.02-4.16 mm) diameter rivet holes in the hinge. Use the rivet
holes in the door as a template. Deburr as necessary.

REPAIR 003
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E. Remove the hinge from the door.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R F. Clean the hinge, the hinge mounting area, and the rivet holes with a clean, lint-free cotton cloth
(C10-182) moist with solvent (C04-001, C04-003, or C04-035). Immediately dry the surface
with a clean, lint-free cotton cloth (C10-182). Do not let the solvent dry on the repair surface.
Do this again until the hinge and hinge mounting area are clean.

G. Let the hinge and hinge mounting area dry a minimum of 15 minutes.

H. Touch up the areas missing epoxy resin primer (C03-005). Refer to 78-32-09, Repair 001.

I. Attach the new hinge to the door as follows:

R
WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
AND CLOTHING TO PROTECT YOURSELF.

(1) Apply primer (C03-005) to the rivets. Install the rivets while the primer is wet. Refer to
Standard Practices Manual, 70-13-00 and 70-13-05.

J. Remove unwanted primer after rivet installation.

R K. Attach the door to the reverser.

R (1) Attach the door hinge, and the shim you kept, to the reverser with clamps. Make sure
R the hinge and shims are in position with the outline of the old hinge on the supporting
R flange. Make sure the holes in the shim are aligned.

R (2) Latch the door and do a check of the steps and gaps. There must be a gap of 0.060-
R 0.235 inch (1.52-5.97 mm) streamwise, and a gap of 0.060-0.170 inch (1.52-4.32 mm)
R forward and aft. The mismatch must be between +/- 0.090 inch (2.29 mm). Adjust the
R hinge position or the shim thickness as necessary to get the correct gap. Refer to
figure
R 601.

R (3) Match drill holes 0.164-0.166 inch (4.17-4.22 mm) diameter into the hinge. Use the
R reverser mounting flange and shim as a template.

R (4) Remove the door and deburr as necessary.

REPAIR 003
PAGE 603
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R MR60052-00-A
R Blowout Door and Access Door Gaps
R Figure 601

REPAIR 003
PAGE 604
78-32-09 JUN 01/01
 COMPONENT
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MANUAL

683L SERIES

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (5) Clean the hinge, the shim, the hinge mounting area, and the fastener holes with a
R clean, lint-free cotton cloth (C10-182) moist with solvent (C04-001, C04-003, or C04-
R 035). Immediately dry the surface with a clean, lint-free cotton cloth. Do not let the
R solvent dry on the repair surface. Do this again until the hinge, the shim, and the hinge
R mounting area are clean.

R (6) Let the hinge, the shim, and the hinge mounting area dry a minimum of 15 minutes.

R (7) Touch up the areas missing epoxy resin primer (C03-005). Refer to 78-32-09 Repair
R 001.

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
R USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
R SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
AND CLOTHING TO PROTECT YOURSELF.

R (8) Apply primer (C03-005) to the shear pins. Install the shear pins, nuts, and washers
R while the primer is wet.

R (9) Remove unwanted primer after installation.

R (10) Examine the door for operation and fit.

R (11) if you removed the blowout door cables, install the cables with the nuts, bolts, and
R washers that you kept.

6. Replacement of IDG Access Door Hinges.

R A. Remove the MA-25S insulation from the IDG access door hinge fasteners and from the area
R around the base of the hinge.

R B. Use a felt-tip marker to make an outline around the hinge location on the door.

R C. Remove and discard the cotter pins and the pins that attach the IDG access door hinges to the
R hinge brackets on the core cowl assembly.

D. Remove the IDG access door from the core cowl assembly.

REPAIR 003
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R E. Remove the nuts, washers, shear pins, and the shim that attach the hinge to the door. Discard
R the pins, nuts, and washers. Keep the hinge for use during installation.

R F. Remove the hinges from the door.

R G. Put the replacement hinges in position on the IDG access door, aligned with the outline of the
R removed hinges. Use clamps to hold the hinges in position.

R NOTE: Use only sufficient clamping force to hold the hinge in place. Do not damage the
hinge or the door.

R H. Back drill 0.192-0.203 inch (4.88-5.16 mm) diameter holes in four places on each hinge. Use
the hole location in the IDG access door as a template.

R I. Remove the hinges and deburr the holes.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

J. Clean the replacement hinge and the hinge mounting area with a clean, lint-free cotton cloth
(C10-182) made moist with solvent (C04-001, C04-003, or C04-035). Immediately wipe the
surface with a clean, lint-free cotton cloth (C10-182). Do not let the solvent dry on the surface.
Do this again until the hinge and hinge mounting area are clean.

K. Let the hinge and hinge mounting area dry a minimum of 15 minutes.

L. Touch up the areas missing epoxy resin primer (C03-005). Refer to 78-32-09, Repair 001.

R M. Install the replacement hinge on the door with new shear pins, nuts, and washers, and the shim
R that you removed. Tighten the nuts to 13-16 lb in. (1.5-1.8 N·m) of torque.

N. Put the door on the core cowl assembly and attach the IDG access door hinges to the hinge
R brackets with new pins and new cotter pins.

R O. Do a check of the new door for operation, steps, and gaps. There must be a gap of 0.03-0.12
R inch (0.8-3.0 mm) at the side and aft edges, with a mismatch of +/- 0.45 inch (1.14 mm). At the
R forward edge there must be a gap of 0.06-0.12 inch (1.5-3.0 mm) with a mismatch of 0.00-0.03
R inch (0.0-0.8 mm). Adjust the shim thickness if necessary. Refer to figure 602.

R P. Use standard procedures to apply MA-25S insulation to the hinges and fasteners, and to areas
R where it was removed from the door.

REPAIR 003
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MANUAL

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R MR60053-00-A
R Blowout Door and Access Door Gaps
R Figure 601

REPAIR 003
PAGE 607
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 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

FAN REVERSER BLOWOUT AND ACCESS DOORS - REPAIR

1. Blowout Door Cable Attach Angles (Clips) Replacement.

A. This procedure gives the instructions to replace the cable attach angles (clips) on the blowout
door assembly.

NOTE: Access doors do not have cable attach angles (clips).

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tool. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment. None required.

B. Consumable Materials.

Code Description Use

C03-005 Primer, Epoxy Resin (Spray Rivet replacement

Type), Finch 463-12-8

C04-001 Solvent, Methyl-Ethyl-Ketone Clean the repair area

(MEK)

C04-003 Solvent, Acetone Clean the repair area

(Fed. Spec. 0-A51)

C04-035 Isopropyl Alcohol Clean the repair area

C10-182 Cotton Cloth, Lint-free Clean the repair area

C. Expendable Parts. None required.

D. SPD Identification. None required.

E. Referenced Procedures.

78-32-09, Repair 001

REPAIR 004
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3. Dimensional Information. None required.

4. Setup Information. None required.

5. Procedure.

A. Remove the nut, washer, and bolt that attach the cable to the angles (clips) and remove the
cable. Keep the nut, washer, bolt, and cable for use during installation.

B. Remove the nuts, washers, and screws that attach the angles (clips) to the door. Keep the
nuts, washers, and screws for use during installation.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

C. Clean the replacement angles (clips) and mounting area with a clean, lint-free cotton cloth
(C10-182) made moist with solvent (C04-001, C04-003, or C04-035). Immediately dry the
surface with a clean, lint-free cotton cloth (C10-182). Do not let the solvent dry on the repair
surface. Do this again until the angles (clips) and mounting area are clean.

D. Let the angles (clips) and mounting area dry a minimum of 15 minutes.

E. Use a clamp to attach a 0.105-0.115 inch (2.67-2.92 mm) thick spacer between the two angles
(clips) vertical sides. Make sure that the pre-drilled cable boltholes (0.190-0.196 inch (4.83-
4.97 mm) diameter) are aligned.

R F. Adjust the angles (clips) and spacer to the center of the holes in the blowout door as shown in
R figure 601. Hold the parts in position with a clamp.

NOTE: Use only sufficient clamping force to hold the angles (clips) in place. Do not damage
the door.

G. Match drill 0.208-0.214 inch (5.29-5.43 mm) diameter fastener holes in the angles (clips). Use
the holes in the door as a template.

H. Remove the angles (clips) from the door and deburr as necessary.

WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU USE
THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU DO NOT
BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR SKIN OR IN YOUR
EYES OR MOUTH. MAKE SURE YOU USE GLOVES AND CLOTHING TO PROTECT
YOURSELF.

I. Touch up the areas missing epoxy resin primer and the fastener holes with primer (C03-005).
Refer to 78-32-09, Repair 001.

REPAIR 004
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MANUAL

683L SERIES

CF8-7272-00-C
Cable Attach Angle (Clip)
Figure 601

R K. Examine the screws, washers, and nuts that you removed, and replace if necessary. Install the
new angles (clips) on the door with the screws, washers, and nuts. Tighten the nuts to 33-37 lb
in. (3.8-4.1 N·m) of torque.

R K. Examine the bolt, washers, and nut that you removed, and replace if necessary. Attach the
cable to the angles (clips) with the bolt, washer, and nut. Tighten the nut to 33-37 lb in. (3.8-4.1
N·m) of torque.

REPAIR 004
PAGE 603
78-32-09 JUN 01/01
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CF6-80E1 CMM

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 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

FAN REVERSER BLOWOUT AND ACCESS DOORS - REPAIR

R 1. Repair of a Worn Forward Edge on the Blowout Door.

R A. This repair gives the procedure for a doubler repair for wear on the forward edge of the thrust
R reverser pressure relief (blowout) door.

R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools. None required.

R (3) Locally Manufactured Tools. None required.

R (4) Equipment. None required.

R B. Consumable Materials.

R Code Description Use

R C01-126 Fabric Netting, Bondline control

R Dacron Polyester,
R D117

R C01-155 Adhesive, Paste, Bond the doubler

R B Catalyst, EA 9394

R C03-006 Conversion Coating, Alodine Surface protection

R 1200S

R C03-007 Primer, Epoxy, BR-127 Prime the bond surfaces

R C03-077 Primer, Epoxy, Water-Reducible Corrosion protection

R (BMS-10-11Y Type I Class A
R Grade E)

R C04-003 Solvent, Acetone Clean the repair area

R C10-140 Gloves, Film Latex or Mix and apply the adhesive

R Nylon/Polyethylene, Disposable

REPAIR 005
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78-32-09 DEC 01/13
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R Code No. Description Use

R --- Grit, Abrasive, Aluminum Oxide, Grit blast

R No. 120

R --- Sheet Stock, Stainless Steel, Make the repair doubler

R AMS 5604, 17-4 PH Cond
R H1025, 0.085 in. (2.16 mm)
R thick

R or

R --- Sheet Stock, Stainless Steel, Make the repair doubler

R AMS 5862, 15-5 PH Cond
R H1025, 0.085 in. (2.16 mm)
R thick

R C. Expendable Parts.

R Part Number Description

R MS20426AD5 Rivet, solid, 5/32 in.

R or equivalent (4.0 mm)

R MS20426AD4 Rivet, solid, 1/8 in.

R or equivalent (3.2 mm)

R D. SPD Identification. None required.

R E. Referenced Procedures.

R SPM 70-32-02

R 78-32-09 Inspection

R 3. Dimensional Information. See figure 602 and figure 603.

R 4. Setup Information. None required.

R 5. Procedure.

R A. Prepare the blowout door for the doubler repair.

R (1) Remove the applicable stiffener, bracket and forward latch from the repair area. Refer
R to figure 601.

R (2) If the door does not have the correct shape, carefully bend the metal to get the door
R back to the correct shape.

REPAIR 005
PAGE 602
78-32-09 DEC 01/13
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MANUAL

683L SERIES

R MR50272-00-A
R Blowout Door Forward Edge Wear Area
R Figure 601

REPAIR 005
PAGE 603
78-32-09 DEC 01/13
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MANUAL

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R (3) Do a fluorescent penetrant inspection of the repair area to look for cracks. Refer to
R SPM 70-32-02. If you find cracks outside of the doubler trim area, refer to 78-32-09
R Inspection.

R (4) Make the repair doubler from 17-4 or 15-5 stainless steel, 0.085 in. (2.16 mm) thick.
R Refer to figure 602.

R (5) Cut and remove the forward section of the latch doubler. Refer to figure 603.

R (6) On the blowout door, cut and remove a section of outer skin 0.375 in. (9.53 mm) wide.
R Refer to figure 603.

R (7) Chamfer the inner edge of the outer skin on the blowout door to make sufficient space
R for the radius of the doubler.

R B. Use the doubler you made as a template and do the step that follows. Refer to figure 603.

R (1) On the blowout door, cut and remove a section of inner skin that is 1.65 in. (41.9 mm)
R wide through the center of the latch location and 1.15 in. (29.2 mm) wide near the hinge
R side location. Match the radius of the doubler when you cut around the inner skin bead.

R C. Put the doubler in position on the door. Use a clamp to hold the doubler in position. Transfer
R drill the fastener holes and the drainage hole into the doubler. Refer to figure 604.

R D. Remove the doubler from the door and deburr the holes.

R E. Grit blast the bond surface of the repair doubler. Use no. 120 aluminum oxide grit.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
R AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
R SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
R GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
R ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R F. Clean the doubler with a clean cloth that is moist with solvent (C04-003). Dry the doubler with a
R clean, dry cloth. Do not let the solvent dry on the surface.

R G. Spot blast the bond surface of the blowout door and the cut latch doubler section. Use no. 120
R aluminum oxide grit.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
R AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
R SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
R GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
R ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R H. Clean the repair area with a clean cloth that is moist with solvent (C04-003). Dry the blowout
R door and latch doubler section with a clean, dry cloth. Do not let the solvent dry on the surface.

REPAIR 005
PAGE 604
78-32-09 DEC 01/13
 COMPONENT
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MANUAL

683L SERIES

R MR60205-00-A
R Repair Doubler
R Figure 602

REPAIR 005
PAGE 605
78-32-09 DEC 01/13
 COMPONENT
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MANUAL

683L SERIES

R MR50273-01-A
R Trim Lines for Doubler Installation
R Figure 603

REPAIR 005
PAGE 606
78-32-09 DEC 01/13
 COMPONENT
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MANUAL

683L SERIES

R MR60204-00-A
R Section through the Repair Doubler
R Figure 604

REPAIR 005
PAGE 607
78-32-09 DEC 01/13
 COMPONENT
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MANUAL

683L SERIES

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU USE
R THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU DO NOT
R BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR SKIN OR IN YOUR
R EYES OR MOUTH. MAKE SURE YOU USE GLOVES AND CLOTHING TO PROTECT
R YOURSELF.

R I. Apply a layer of primer (C03-007) to the bond surfaces of the doubler, the blowout door, and the
R latch doubler section. Let the primer dry in the air for 30 minutes, then cure for 30 minutes at
R 240-260 F (116-127 C).

R WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN

R YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. USE
R CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN
R YOU MIX OR APPLY THE ADHESIVE.

R J. Make a mixture of the adhesive (C01-155).

R (1) Mix the adhesive by weight, 100 parts A (resin) with 17 parts B (catalyst). Mix fully until
R you can see no streaks of the two components.

R NOTE: The pot life of a 4.66 ounce (133 gram) batch of mixed adhesive is
R approximately 40 minutes.

R K. Apply the adhesive mixture to the bond area of the door. Use bondline netting (C01-126).

R L. Install the repair doubler, and then install the latch doubler section that you removed.

R M. Install the detail parts that you removed. Use production fasteners or the equivalent. Wet
install
R the fasteners with an epoxy-polyamine primer (C03-077). Refer to figure 605.

R N. Use a clean, dry cloth to remove unwanted adhesive.

R O. Cure at room temperature for two hours, then cure for two hours at 170-190 F (77-88 C).

R P. Apply Alodine 1200S (C03-006) to all bare aluminum surfaces, then apply a layer of epoxy-
R polyamine primer (C03-077).

REPAIR 005
PAGE 608
78-32-09 DEC 01/13
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR50315-00-A
R Installation of the Removed Detail Parts
R Figure 605

REPAIR 005
PAGE 609
78-32-09 DEC 01/13
 FAN REVERSER
CF6-80E1 CMM

THIS PAGE INTENTIONALLY BLANK

 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

FAN REVERSER BLOWOUT AND ACCESS DOORS - REPAIR

R 1. Repair of a Worn Aft Edge on the Blowout Door.

R A. This repair gives the procedure for a doubler repair for wear on the aft edge of the thrust
R reverser pressure relief (blowout) door.

R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools. None required.

R (3) Locally Manufactured Tools. None required.

R (4) Equipment. None required.

R B. Consumable Materials.

R Code Description Use

R C01-126 Fabric Netting, Bondline control

R Dacron Polyester,
R D117

R C01-155 Adhesive, Paste, Bond the doubler

R EA 9394, B Catalyst

R C03-006 Conversion Coating, Alodine Surface protection

R 1200S

R C03-007 Primer, Epoxy, BR-127 Prime the bond surfaces

R C03-077 Primer, Epoxy, Water-Reducible Corrosion protection

R (BMS-10-11Y Type I Class A
R Grade E)

R C04-003 Solvent, Acetone Clean the repair area

R C10-140 Gloves, Film Latex or Mix and apply the adhesive

R Nylon/Polyethylene, Disposable

REPAIR 006
PAGE 601
78-32-09 JUN 01/14
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R Code No. Description Use

R --- Grit, Abrasive, Aluminum Oxide, Grit blast

R No. 120

R --- Sheet Stock, Stainless Steel, Make the repair doubler

R AMS 5604, 17-4 PH Cond
R H1025, 0.085 in. (2.16 mm)
R thick

R or

R --- Sheet Stock, Stainless Steel, Make the repair doubler

R AMS 5862, 15-5 PH Cond
R H1025, 0.085 in. (2.16 mm)
R thick

R C. Expendable Parts.

R Part Number Description

R NAS1097AD3 Rivet, solid, 3/32 in.

R or equivalent (2.4 mm)

R MS20426AD4 Rivet, solid, 1/8 in.

R or equivalent (3.2 mm)

R D. SPD Identification. None required.

R E. Referenced Procedures.

R SPM 70-32-02

R 78-32-09 Inspection

R 3. Dimensional Information. See figure 602 and figure 603.

R 4. Setup Information. None required.

R 5. Procedure.

R A. Prepare the blowout door for the doubler repair.

R (1) Remove the aft latch from the repair area. Refer to figure 601.

R (2) If the door does not have the correct shape, carefully bend the metal to get the door
R back to the correct shape.

REPAIR 006
PAGE 602
78-32-09 JUN 01/14
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60206-00-A
R Blowout Door Aft Edge View
R Figure 601

REPAIR 006
PAGE 603
78-32-09 JUN 01/14
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R MR60207-00-A
R Repair Doubler
R Figure 602

REPAIR 006
PAGE 604
78-32-09 JUN 01/14
 COMPONENT
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MANUAL

683L SERIES

R MR60208-00-A
R Blowout Door Aft Edge Latch Doubler Cut Location
R Figure 603

REPAIR 006
PAGE 605
78-32-09 JUN 01/14
 COMPONENT
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MANUAL

683L SERIES

R (3) Do a fluorescent penetrant inspection of the repair area to look for cracks. Refer to
R SPM 70-32-02. If you find cracks outside of the doubler trim area, refer to 78-32-09
R Inspection.

R (4) Make the repair doubler from 17-4 or 15-5 stainless steel, 0.085 in. (2.16 mm) thick.
R Refer to figure 602.

R (5) Cut and remove the aft section of the latch doubler. Refer to figure 603.

R (6) On the blowout door, cut and remove a section of outer skin 0.375 in. (9.53 mm) wide.
R Refer to figure 604.

R (7) Chamfer the inner edge of the outer skin on the blowout door to make sufficient space
R for the radius of the doubler.

R B. Use the doubler you made as a template and do the step that follows. Refer to figure 604.

R (1) On the blowout door, cut and remove a section of inner skin that is 1.65 in. (41.9 mm)
R wide through the center of the latch location, 1.05 in. (26.7 mm) wide at the center, and
R 0.81 in. (20.6 mm) wide near the hinge side location. Match the radius of the doubler
R when you cut around the inner skin bead.

R C. Put the doubler in position on the door. Use a clamp to hold the doubler in position. Transfer
R drill the fastener holes and the drainage hole into the doubler. Refer to figure 605.

R D. Lay out seven double flush repair fastener holes with a hole diameter of 0.097-0.102 in. (2.46-
R 2.59 mm). Touch-countersink the holes on both sides. Refer to figure 605.

R E. Remove the doubler from the door and deburr the holes.

R F. Grit blast the bond surface of the repair doubler. Use no. 120 aluminum oxide grit.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
R AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
R SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
R GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
R ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R G. Clean the doubler with a clean cloth that is moist with solvent (C04-003). Dry the doubler with a
R clean, dry cloth. Do not let the solvent dry on the surface.

R H. Spot blast the bond surface of the blowout door and the cut latch doubler section. Use no. 120
R aluminum oxide grit.

REPAIR 006
PAGE 606
78-32-09 JUN 01/14
 COMPONENT
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MANUAL

683L SERIES

R MR60209-00-A
R Trim Lines for Doubler Installation
R Figure 604

REPAIR 006
PAGE 607
78-32-09 JUN 01/14
 COMPONENT
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MANUAL

683L SERIES

R MR60210-00-A
R Fastener Locations
R Figure 605

REPAIR 006
PAGE 608
78-32-09 JUN 01/14
 COMPONENT
MAINTENANCE
MANUAL

683L SERIES

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
R AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
R SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
R GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
R ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R I. Clean the repair area with a clean cloth that is moist with solvent (C04-003). Dry the blowout
R door and latch doubler section with a clean, dry cloth. Do not let the solvent dry on the surface.

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU USE
R THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU DO NOT
R BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR SKIN OR IN YOUR
R EYES OR MOUTH. MAKE SURE YOU USE GLOVES AND CLOTHING TO PROTECT
R YOURSELF.

R J. Apply a layer of primer (C03-007) to the bond surfaces of the doubler and the blowout door.
R Let the primer dry in the air for 30 minutes, then cure for 30 minutes at 240°-260° F
R (116°-127° C).

R WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN

R YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. USE
R CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN
R YOU MIX OR APPLY THE ADHESIVE.

R K. Make a mixture of the adhesive (C01-155).

R (1) Mix the adhesive by weight, 100 parts A (resin) with 17 parts B (catalyst). Mix fully until
R you can see no streaks of the two components.

R NOTE: The pot life of a 4.66 ounce (133 gram) batch of mixed adhesive is
R approximately 40 minutes.

R L. Apply the adhesive mixture to the bond area of the door and the repair doubler. Use bondline
R netting (C01-126).

R M. Install the repair doubler.

R N. Wet install, rivet-head side through the outer skin, seven NAS1097AD3 rivets with an epoxy-
R polyamine primer (C03-077). Refer to figure 605.

R O. Use a clean, dry cloth to remove unwanted adhesive.

R P. Cure at room temperature for two hours, then cure for two hours at 170°-190° F (77°-88° C).

R Q. Shave the formed tail of the repair rivets on the repair doubler side to make flush. Refer to
R figure 605.

REPAIR 006
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MANUAL

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R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU USE
R THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU DO NOT
R BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR SKIN OR IN YOUR
R EYES OR MOUTH. MAKE SURE YOU USE GLOVES AND CLOTHING TO PROTECT
R YOURSELF.

R R. Apply a layer of primer (C03-007) to the bond surface of the steel repair doubler and the latch
R doubler. Let the primer dry in the air for 30 minutes, then cure for 30 minutes at 240°-260° F
R (116°-127° C).

R WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN

R YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. USE
R CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN
R YOU MIX OR APPLY THE ADHESIVE.

R S. Make a mixture of the adhesive (C01-155).

R (1) Mix the adhesive by weight, 100 parts A (resin) with 17 parts B (catalyst). Mix fully until
R you can see no streaks of the two components.

R NOTE: The pot life of a 4.66 ounce (133 gram) batch of mixed adhesive is
R approximately 40 minutes.

R T. Apply the adhesive mixture to the bond area of the steel repair doubler and the latch doubler.
R Use bondline netting (C01-126).

R U. Use standard practice to install the latch and the latch doubler with production fasteners. Use
R four production latch fasteners and two MS20426AD4 rivets. Refer to figure 606.

R V. Use a clean, dry cloth to remove unwanted adhesive.

R W. Cure at room temperature for two hours, then cure for two hours at 170°-190° F (77°-88° C).

R X. Apply Alodine 1200S (C03-006) to all bare aluminum surfaces, then apply a layer of epoxy-
R polyamine primer (C03-077).

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R MR60211-00-A
R Installation of the Latch and the Latch Doubler
R Figure 606

REPAIR 006
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MANUAL

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FAN REVERSER HINGE COVER - INSPECTION/CHECK

1. General.

A. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable
Materials.

(1) Tools and Equipment. None required.

(2) Consumable Materials. None required.

(3) Expendable Parts. None required.

(4) Referenced Procedures.

SPM 70-13-01

SPM 70-32-03

2. Do a Spot Fluorescent-Penetrant Inspection. Refer to GE Standard Practices Manual, 70-32-03.

3. Make an Inspection of the Fan Reverser Hinge Cover. See figures 501 and 502, and table 501.

NOTE: The following inspection is a visual inspection aided by the use of a 10X magnifying glass.

Table 501. Hinge Cover

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Methods

R A. Hinge cover panel for:

R (1) Cracks at one of Not serviceable Crack migration aft from Repair 001, Damage
R the three fwd the fastener hole must Location 1
R fastener holes not be more than 0.6 in.
R (15.2 mm) in length. No
R more than one fwd
R fastener hole repair is
R permitted on a panel

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Table 501. Hinge Cover (Cont'd)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Methods

R A. Hinge cover panel for (continued):

R (2) Small cracks Not serviceable Cracks must have an Repair 001, Damage
R area no larger than 1.5 in. Locations 2,3 or 4
R by 1.0 in. (38.1 mm by
R 25.4 mm). Fwd or aft
R crack migration from the
R fastener hole must not be
R more than 0.65 in. (16.5
R mm) in length, and not
R more than 0.4 in. (10.2
R mm) migration inboard or
R outboard

R (3) Large cracks Not serviceable Cracks must have an Repair 001, Damage
R area no larger than 2.75 Locations 2,3 or 4
R in. by 1.0 in. (69.9 mm by
R 25.4 mm). Fwd or aft
R crack migration from the
R fastener hole must not be
R more than 1.375 in.
R (34.92 mm) in length, and
R not more than 0.4 in.
R (10.2 mm) migration
R inboard or outboard

R (4) Damaged or Not serviceable Any amount Replace damaged or

R missing fasteners missing fasteners.
R Refer to SPM 70-13-01

R B. Hinge cover support angle (491E1360004-003/-004) for:

R (1) Cracks Not serviceable Crack length is limited to Repair 001, paragraph
R a maximum of 0.25 in. 5.B.
R (6.4 mm) on the vertical
R flange, extending to the
R inner radius

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Table 501. Hinge Cover (Cont'd)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Methods

R C. Hinge cover air seal (491E1220022-005/-006) for:

R (1) Cracks or missing Not serviceable Not repairable Replace the seal
R material

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CF8-7205-00-B
Hinge Cover Inspection Area
Figure 501

R INSPECTION
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MR60185-00-C
R Hinge Cover Crack Damage Locations
R Figure 502

INSPECTION
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FAN REVERSER HINGE COVER - REPAIR

R 1. Repair of Cracks in the Thrust Reverser Hinge Cover Panel.

R A. This procedure gives the instructions for the repair of cracks in the thrust reverser hinge cover
R panel assembly. This repair is limited to cracks at the fastener holes, and cracks in the inboard
R hinge cover support angle (P/N 491E1360004). An unlimited number of repairs is permitted on
R a hinge cover panel.

R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools. None required.

R (3) Locally Manufactured Tools. None required.

R (4) Equipment. None required.

R B. Consumable Materials.

R Code Description Use

R C01-073 Compound, Sealing, Seal the skin washers

R PR 1750, B-2

R C01-126 Fabric Netting, Dacron Bondline control

R Polyester

R C01-155 Adhesive, Epoxy Resin, Bond the doubler

R Paste, Two Part,
R EA 9394, B Catalyst

R C03-077 Primer, Epoxy, Water- Surface protection

R Reducible

R C04-035 Alcohol, Isopropyl Clean the repair area

R C10-140 Gloves, Film Latex or Mix and apply the adhesive

R Nylon/Polyethylene,
R Disposable

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R Code Description Use

R Local Purchase Aluminum Sheet, Clad, Make the panel repair

R 0.050 in. (1.27 mm) Thick doubler and the mount
R 2024-T3 (QQ-A-250/5) pad

R Local Purchase Aluminum Sheet, Bare, Make the support angle

R 0.050 in. (1.27 mm) Thick repair doubler and the
R 2024-T3 (QQ-A-250/4) panel repair filler

R Local Purchase Abrasive, Grit, Blast Media, Prepare the bonding

R 120 Grit Virgin Aluminum surface
R Oxide

R C. Expendable Parts.

R Part No. Description

R NAS1097AD4 Rivet

R NAS1097AD5 Rivet

R NAS1169C10L Skin Washer

R D. SPD Identification. None required.

R E. Referenced Procedures.

R SPM 70-21-04

R SPM 70-32-02

R 3. Dimensional Information. Refer to table 601.

R 4. Setup Information. None required.

R 5. Procedure.

R A. Do the steps that follow to repair cracking damage at the hinge cover attachment fastener
holes.

R (1) Find the location and the amount of the damage. Refer to table 601.

R (2) Remove all fasteners from the repair area.

R (3) Make the repair doubler from 0.050 in. (1.27 mm) thick 2024-T3 clad aluminum sheet
R stock. The doubler must have a minimum 0.40 in. (10.2 mm) fastener edge distance
R from all repair edges, and a minimum 4D space between all fasteners. Refer to Table
R 601 for the applicable location figure.

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R (4) Put the doubler in position over the repair area. Use clamps to hold the doubler in
R position. Back drill all existing fastener holes from the back side of the hinge cover
R panel. Make sure that the two existing center mount screw holes are transferred to the
R doubler.

R (5) Chamfer the fwd and aft edges of the doubler to a 45° angle. Put the doubler aside for
R use at step (12).

R (6) Remove the bonded mount pad from the back side of the damage area.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR
R SKIN OR EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE,
R TOXIC, AND HIGHLY FLAMMABLE.

R (7) Remove old adhesive. Clean the area with isopropyl alcohol (C04-035).

R (8) Do a fluorescent-penetrant inspection to find the length(s) of the crack(s). Refer to

R SPM 70-32-02 (GEK 9250).

R (9) Cut out the cracked area(s). Refer to the applicable reference figure. The corners of
R all cut-out areas must have a minimum radius of 0.25 in. (6.4 mm) to align with the
R applicable fillers.

R (10) Make fillers to align with the cut-out areas of the panel. Make the fillers from 0.050 in.
R (1.27 mm) thick 2024-T3 bare aluminum sheet stock.

R (11) Make replacement mount pads from 0.050 in. (1.27 mm) thick 2024-T3 clad aluminum
R sheet stock. Refer to the applicable location figure for the correct dimensions.

R (12) Attach the three repair pieces (doubler, mount pad and filler) to the repair area of the
R panel with clamps. Lay up and drill the remaining fastener locations. After you drill all
R repair fastener holes and back drill the existing hole locations, remove the repair pieces
R and deburr all holes.

R (13) Grit blast all bond surfaces with virgin aluminum oxide 120-grit blast media, or use an
R equivalent process. Refer to SPM 70-21-04.

REPAIR 001
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R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR
R SKIN OR EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE,
R TOXIC, AND HIGHLY FLAMMABLE.

R (14) Use a clean cloth moist with isopropyl alcohol (C04-035) to clean all repair surfaces.
R Immediately dry the surface with a clean, dry cloth. Do not let the solvent dry on the
R surface.

R WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL

R IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR.
R USE CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES
R (C10-140) WHEN YOU MIX OR APPLY THE ADHESIVE.

R (15) Prepare a sufficient quantity of epoxy adhesive (C01-155). Refer to the manufacturer's
R instructions.

R (16) Use the prepared epoxy adhesive to bond the mount pad, the filler, and the repair
R doubler to the hinge cover. Use Dacron polyester fabric netting (C01-126) for bondline
R control on all bonding surfaces. Use clamps to hold the mount pad, the filler, and the
R doubler in position

R (17) Cure the adhesive for a minimum of one hour at 180°-200°F (82°-93°C).

R (18) Countersink the repair fastener holes. Refer to the applicable fastener specification for
R the countersink requirements.

R (19) Install the fasteners wet with primer (C03-077).

R (20) Countersink two attachment fastener holes at each repair location for the two
R NAS1169C10L skin washers.

R (21) Install the two NAS1169C10L skin washers.

R WARNING: THIS MATERIAL IS AN IRRITANT. DO NOT GET THE

R MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN
R AREA OPEN TO THE AIR. DO NOT BREATHE THE FUMES.

R (a) Apply a small amount of sealant (C01-073) to the back side of the skin
washers.

R (b) Bond the skin washers in position at all repaired attachment fastener hole
R locations.

R (c) Remove unwanted sealant.

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R (22) Treat all bare metal with epoxy primer (C03-077), and apply a topcoat finish layer, if
R necessary.

R B. Repair of cracks in the hinge cover support angle (P/N 491E160004).

R (1) Do a fluorescent-penetrant inspection to find the length(s) of the crack(s). Refer to

R SPM 70-32-02 (GEK 9250).

R (2) Use a 1.0 in. (25.4 mm) radius trim to trim out the crack. Refer to figure 608.

R (3) Make a repair doubler for the hinge cover support angle. Refer to figure 608. Make the
R repair doubler from 0.050 in. (1.27 mm) thick 2024-T3 bare aluminum sheet stock.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (4) Use a clean cloth moist with isopropyl alcohol (C04-035) to clean all repair surfaces.
R Immediately dry the surface with a clean, dry cloth. Do not let the solvent dry on the
R surface.

R (5) Put the repair doubler in position on the support angle. Refer to figure 608.

R WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE

R MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA
R OPEN TO THE AIR. WEAR CLEAN NYLON FILM OR
R POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN YOU
R MIX OR APPLY THE ADHESIVE.

R (6) Prepare a sufficient quantity of epoxy adhesive (C01-155). Refer to the manufacturer's
R instructions.

R (7) Use the prepared epoxy adhesive to bond the repair doubler to the support angle. Use
R Dacron polyester fabric netting (C01-126) for bondline control.

R (8) Cure the adhesive for a minimum of one hour at 180°-200°F (82°-93°C).

R (9) Back drill the two existing fasteners. Locate and drill holes for the seven repair
R fasteners. Refer to figure 608. Deburr all holes.

R (10) Install the fasteners wet with primer (C03-077).

R (11) Apply a protective layer of epoxy primer (C03-077) to all bare metal surfaces.

REPAIR 001
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R Table 601 - Damage location and Limits

R Damage Repair
R Location Damage Description Procedure

R Location 1 Cracks at one of the three forward fastener holes. Figure 601
R Crack migration aft from the fastener hole must not be more
R than 0.6 in. (15.2 mm) in length. No more than one forward
R fastener hole repair is permitted on a panel.

R Location 2
R Small Cracks Small cracks are limited to a 1.5 in. (38.1 mm) by 1.0 in. (25.4 Figure 602
R mm) area. Fwd or aft crack migration from the fastener hole
R must not be more than 0.65 in. (16.5 mm) in length, and not
R more than 0.4 in. (10.2 mm) migration inboard or outboard.

R Large Cracks Large cracks are limited to a 2.75 in. (69.9 mm) by 1.0 in. (25.4 Figure 603
R mm) area. Fwd or aft crack migration from the fastener hole
R must not be more than 1.375 in. (34.92 mm) in length, and not
R more than 0.4 in. (10.2 mm) migration inboard or outboard.

R Location 3
R Small Cracks Small cracks are limited to a 1.5 in. (38.1 mm) by 1.0 in. (25.4 Figure 604
R mm) area. Fwd or aft crack migration from the fastener hole
R must not be more than 0.65 in. (16.5 mm) in length, and not
R more than 0.4 in. (10.2 mm) migration inboard or outboard.

R Large Cracks Large cracks are limited to a 2.75 in. (69.9 mm) by 1.0 in. (25.4 Figure 605
R mm) area. Fwd or aft crack migration from the fastener hole
R must not be more than 1.375 in. (34.92 mm) in length, and not
R more than 0.4 in. (10.2 mm) migration inboard or outboard.

REPAIR 001
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R Table 601 - Damage location and Limits (Continued)

R Damage Repair
R Location Damage Description Procedure

R Location 4
R Small Cracks Small cracks are limited to a 1.5 in. (38.1 mm) by 1.0 in. (25.4 Figure 606
R mm) area. Fwd or aft crack migration from the fastener hole
R must not be more than 0.65 in. (16.5 mm) in length, and not
R more than 0.4 in. (10.2 mm) migration inboard or outboard.

R Large Cracks Large cracks are limited to a 2.75 in. (69.9 mm) by 1.0 in. Figure 607
R (25.4 mm) area. Fwd or aft crack migration from the fastener
R hole must not be more than 1.375 in. (34.92 mm) in length,
R and not more than 0.4 in. (10.2 mm) migration inboard or
R outboard.

REPAIR 001
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R MR60186-03-A
Location 1 Repair - Cracks at One of the Three Forward Fastener Holes
Figure 601

REPAIR 001
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R MR60187-03-A
Location 2 Repair - Small Cracks
Figure 602

REPAIR 001
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R MR60188-03-A
Location 2 Repair - Large Cracks
Figure 603

REPAIR 001
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R MR60189-03-A
Location 3 Repair - Small Cracks
Figure 604

REPAIR 001
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R MR60190-03-A
Location 3 Repair - Large Cracks
Figure 605

REPAIR 001
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R MR60191-03-A
Location 4 Repair - Small Cracks
Figure 606

REPAIR 001
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R MR60192-03-A
Location 4 Repair - Large Cracks
Figure 607

REPAIR 001
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R MR60193-01-A
R Repair of Cracks in the Inboard Hinge Cover Support Angle
R Figure 608

REPAIR 001
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 COMPONENT
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MANUAL

683L SERIES

FAN REVERSER HARDWARE - INSPECTION/CHECK

1. General.

A. Tools and Equipment Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable
Materials.

(1) Tools and Equipment. None required.

(2) Consumable Materials.

Code Description

C02-003 Lubricant, Molykote 321-R

(3) Expendable Parts. None required.

(4) Referenced Procedures.

SPM 70-32-01

SPM 70-32-03

SPM 70-41-00

SPM 70-47-01

2. Do a Spot Fluorescent-Penetrant Inspection. Refer to GE Standard Practices Manual, 70-32-03.

3. Do a Magnetic-Particle Inspection. Refer to GE Standard Practices Manual, 70-32-01,

Class A, B, C, or D.

INSPECTION
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4. Make an Inspection of the Fan Reverser Hardware: Refer to figure 501 and table 501.

NOTE: The following inspection is a visual inspection aided by the use of a 10X magnifying glass.

Table 501. Fan Reverser Hardware

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Methods

A. Lower latches for:

(1) Cracks Not serviceable Not repairable Replace the latch

(2) Fretting on the Not serviceable Any amount 0.50 sq in. Shotpeen. Standard
latch hook (3.2sq mm) area that Practices Manual,
contact area cannot be felt by 0.030 in. 70-47-01
(0.76 mm) radius scribe

(3) Missing lubricant Not serviceable Any amount Lubricate with lubricant
on the latch hook if felt with 0.010 inch (C02-003)
contact areas (0.25 mm) radius scribe

B. Latch wear pad for 0.030 in. (0.76 mm) depth Not repairable Replace the latch wear
wear pad

C. Deflection limiters for:

(1) Cracks Not serviceable Not repairable Replace the deflection

limiter

(2) Wear on the wear 0.020 in. (0.51 mm) depth Not repairable Replace the deflection
surface limiter

(3) Missing wear Not serviceable Not repairable Replace the deflection
surface limiter

D. Upper, lower deflection limiter brackets and bracket supports for:

(1) Bending Not serviceable Not repairable Replace the bracket/

support

(2) Deformation Not serviceable Not repairable Replace the bracket/

support

(3) Cracks Not serviceable Not repairable Replace the bracket/

support

INSPECTION
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Table 501. Fan Reverser Hardware (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Methods

E. Deflection limiter (bumper) tube assembly for: (Engine mounted aft end of fwd engine mount.)

(1) Cracks Not serviceable Not repairable Replace the tube

(2) Bent or buckled Not serviceable Not repairable Replace the tube

(3) Wear on the wear 0.020 inch (0.51 mm) Not repairable Replace the tube
surface depth

(4) Missing split Not serviceable Any amount Replace the sleeve
sleeve on the left
or right side

(5) Freedom of Not serviceable Any amount Replace the bumper

movement assembly
(laterally by
rotation)

F. Hold open rod ball lock pin hole for:

(1) Wear/elongation Any amount if the pin Any amount Plug weld the pin hole.
stays engaged Standard Practices
Manual, 70-41-00. Use
AMS 4190 filler, then re-
drill

G. Hold open rod stow bracket for:

(1) Wear in the mount Any amount if the hole is Any amount Weld. Standard
hole not torn out Practices Manual,
70-41-00. Drill as
necessary

(2) Wear in the pin 0.030 in. (0.76 mm) Not repairable Replace the stow
hole oversized bracket

(3) Wear in the bearing Any amount if the ball is Not repairable Replace the stow
retained bracket

R INSPECTION
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Table 501. Fan Reverser Hardware (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Methods

R H. Hold open rod for:

1) Looseness in the Not serviceable Any amount Repair 001

R rod end bearing

R (2) Wear groove on 0.020 in. (0.51 mm) One weld repair If the wear is more than
R the inner strut the serviceable limits,
R repair the inner strut.
R Refer to MRAS SB
R 78-5114. If the wear is
R more than the
R serviceable limits, and
R the inner strut has a
R weld from a previous
R repair, replace the inner
R strut

INSPECTION
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1088254-00-A
Fan Reverser Hardware - Inspection Areas
Figure 501

R INSPECTION
PAGE 505
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FAN REVERSER HARDWARE - REPAIR

R 1. Repair of the Hold Open Rod.

R A. This procedure gives the instructions to repair a hold open rod end connector with a worn
R bearing.

R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools. None required.

R (3) Locally Manufactured Tools. None required.

R (4) Equipment.

R Description Manufacturer

R Roller Staking Tool Local purchase

R Press, Hydraulic Local purchase

R B. Consumable Materials:

R Code No. Description Use

R C03-005 Primer, Epoxy Resin (Spray Type) Install the replacement

R Finch 463-12-8 bearing

R C03-064 Conversion Coating, Chromated, Protect the surface

R Iridite 14-2

R C04-014 Alcohol, Denatured Clean the repair area

R C04-222 Surfactant, APR 2 Agent Use with C03-064

R C10-182 Cloths, Cleaning Clean the repair area

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R C. Expendable Parts.

R CSN Description

R 78-32-02-20-60 Rod end bearing

R 9077M81P03 0.010 in. (0.25 mm) oversize rod end bearing

R 9077M81P04 0.020 in. (0.51 mm) oversize rod end bearing

R D. SPD Identification. None required.

R E. Referenced Procedures. None required.

R 3. Dimensional Information. None required.

R 4. Setup Information. None required.

R 5. Procedure.

R CAUTION: BE CAREFUL NOT TO DAMAGE INSIDE DIAMETER OF THE CONNECTOR WHEN

R YOU REMOVE THE BEARING.

R A. Grind a groove approximately 80% through the swaged lip of the bearing at the rod end
R connector bore diameter.

R B. Use a hydraulic press to remove the bearing from the rod end connector.

R C. Measure the hole diameter in the rod end connector. If the diameter is less than 0.9071 inch
R (23.040 mm), hone the hole to increase the diameter to a minimum of 0.9060 inch (23.012 mm).
R If the diameter is more than 0.9071 inch (23.040 mm), do step C.(1), C.(2), or C.(3).

R (1) If the hole diameter is 0.9071-0.9171 inch (23.040-23.294 mm), make the hole larger, to
R a diameter of 0.9160-0.9171 inch (23.266-23.294 mm).

R (2) If the hole diameter is 0.9171-0.9271 inch (23.294-23.548 mm), make the hole larger, to
R a diameter of 0.9260-0.9271 inch (23.520-23.548 mm).

R (3) If the hole diameter is larger than 0.9271 inch (23.548 mm), do one of the steps that
R follow:

R (a) Remove the rod end connector assembly retractable support and replace it with
R a new part; or

R (b) Remove the rod end connector assembly retractable support, replace it with a
R connector rod end, and install a new bearing. Refer to steps G. through K.

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R D. Measure the chamfers in the rod end connector. If they are 0.035-0.040 inch (0.89-1.02 mm)
R deep by 45 degrees, go to step E. If not, countersink the chamfers to 0.035-0.040 inch (0.89-
1.02 mm) deep by 45 degrees.

R E. Remove burrs, and break sharp edges to 0.005-0.015 inch (0.13-0.38 mm).

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
R AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
R SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
R GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
R ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R F. Use a clean cloth (C10-182) moist with denatured alcohol (C04-014) to clean the rod end
R connector. Use a clean, dry cloth to remove the solvent before it dries.

R G. Apply an Iridite (C03-064) solution to the rod end connector.

R WARNING: DO NOT LET THE IRIDITE SOLUTION DRY IN THE BRUSH, CLOTH, OR
R SPONGE BECAUSE SPONTANEOUS COMBUSTION CAN OCCUR. FULLY
R CLEAN THE ITEMS IN WATER, OR WRING OUT AS MUCH SOLUTION AS
R POSSIBLE AND STORE IN A FIREPROOF CONTAINER.

R (1) Mix 3.0 oz/gal. (22.5 g/liter) of Iridite (C03-064) and 1.25 fl oz/gal. (10 cc/liter) of
R surfactant (C04-222).

R (2) Use a nylon brush, cellulose sponge, or clean cloth (C10-182) to apply the Iridite
R solution to the rod end connector hole diameter and chamfer. Keep the surface wet
R until you see a small color change (usually 2-3 minutes).

R (3) Flush the rod end connector with deionized water.

R (4) Air dry for 8 hours or oven dry at a maximum temperature of 135° F (57° C) for 1 hour
R or until dry.

R H. Install a replacement rod end connector bearing.

R (1) Get a replacement bearing. Use the applicable hole diameter from step 5.C. as the
R factor for the selection of a replacement bearing.

R (a) If the hole diameter is 0.9060-0.9071 inch (23.012-23.040 mm), install bearing
R 78-32-02-20-60.

R (b) If the hole diameter is 0.9160-0.9171 inch (23.266-23.294 mm), install bearing
R 9077M81P03.

R (c) If the hole diameter is 0.9260-0.9271 inch (23.520-23.548 mm), install bearing
R 9077M81P04.

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R CF8-7246-00-C
R Roller Staking Tool Use
R Figure 601

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
R USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
R SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
R AND CLOTHING TO PROTECT YOURSELF.

R (2) Apply a layer of epoxy resin primer (C03-005) to the outer diameter of the replacement
R rod end connector bearing.

R (3) Press fit the replacement bearing into the hole in the rod end connector Make sure that
R the bearing is straight and not canted to the housing bore during insertion.

R I. Roll stake the replacement bearing in position.

R (1) Hold the bearing outer race on an anvil.

R (2) Install a roller staking tool into a drill press.

R (3) Put the roller staking tool on the bearing and align the pilot with the bearing inner race.
R See figure 601.

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R CAUTION: DO NOT LET THE BEARING OUTER RACE LIP BECOME WORK
R HARDENED DURING THE STAKING OPERATION.

R (4) Operate the drill press at a low speed (6 to 100 RPM) to stake the bearing outer race to
R the rod end connector.

R (5) Do steps (1) through (4) on the opposite side of the bearing.

R J. Make sure the rod end connector and the replacement bearing do not have cracks, and that no
R more than 40% of the circumference of the swaged lip will accept a 0.005 inch (0.127 mm)
R feeler gauge.

R K. Apply a 150 pound (68.0 kg) axial load to each side of the bearing to test the installation. See
R figure 602.

R L. Make sure the bearing has not loosened.

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R MR60096-00-A
R Proof Test Setup
R Figure 602

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FAN REVERSER TRANSLATING COWL - INSPECTION/CHECK

1. General.

A. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

(1) Tools and Equipment. None required.

(2) Consumable Materials.

Code Description

C01-011 Adhesive, Epoxy Resin

C01-106 Adhesive, Epoxy Resin,

EA 956

C03-005 Primer, Epoxy Resin,

463-12-8

(3) Expendable Parts. None required.

(4) Referenced Procedures.

SPM 70-32-03

SPM 70-41-00

2. Do a Spot-Fluorescent-Penetrant Inspection. Refer to Standard Practices Manual, 70-32-03.

R 3. Make an Inspection of the Fan Reverser Translating Cowl. See figures 501 through 506, and table 501.

INSPECTION
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Table 501. Fan Reverser Translating Cowl

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

A. Honeycomb/inner skin/outer skin for:

NOTE: All damaged honeycomb/composite skin areas must be separated from any other damaged area
by a minimum of 6.0 inches (152.4 mm).

(1) Cracks Not serviceable 0.75 inches (19.1 mm) Repair 002
length with penetration from
the outer skin but not into
the inner skin

0.75 inches (19.1 mm) Repair 002

length or more not to exceed
2.0 inches (50.8 mm) length
with penetration from the
outer skin but not into the
inner skin

2.0 inches (50.8 mm) length Repair 002

or more not to exceed 4.0
inches (101.6 mm) length with
penetration from the outer
skin but not into the inner skin

4.0 inches (101.6 mm) length Repair 002

penetration into the outer skin
and 2.0 inches (50.8 mm)
length penetration into the
inner skin

(2) Holes Not serviceable 0.75 inches (19.1 mm) Repair 002
diameter with penetration
from the outer skin but not
into the inner skin

0.75 inches (19.1 mm) Repair 002

diameter or more not to
exceed 2.0 inches (50.8
mm) diameter with
penetration from the outer
skin but not into the inner
skin

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Table 501. Fan Reverser Translating Cowl (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

A. Honeycomb/inner skin/outer skin for: (continued)

NOTE: All damaged honeycomb/composite skin areas must be separated from any other damaged area
by a minimum of 6.0 inches (152.4 mm).

(2) Holes (continued) Not serviceable 2.0 inches (50.8 mm) Repair 002
diameter or more not to
exceed 4.0 in. (101.6 mm)
diameter with penetration
from the outer skin but not
into the inner skin

4.0 in. (101.6 mm) diameter Repair 002

penetration into the outer skin
and 2.0 in. (50.8 mm)
diameter penetration into the
inner skin

(3) Delamination and/or dents

(a) Outer Not serviceable Area not more than 0.563 Repair 002
bondment in.2 (3.63 cm2) with
penetration from the outer
skin but not into the inner
skin

Area 0.563 in.2 (3.63 cm2) or Repair 002

more not to exceed 4.0 in.2
(25.8 cm2) with penetration
from the outer skin but not
into the inner skin

INSPECTION
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Table 501. Fan Reverser Translating Cowl (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

(3) Delamination and/or dents (continued)

(b) Inner Not serviceable Area not more than 0.563 Repair 002
bondment in.2 (3.63 cm2) with
penetration from the outer
skin but not into the inner
skin

Area 0.563 in.2 (3.63 cm2) or Repair 002

more not to exceed 4.0 in.2
(25.8 cm2) with penetration
from the outer skin but not
into the inner skin

Area 4.0 in.2 (25.8 cm2) or Repair 002

more not to exceed 16 in.2
(103.2 cm2) diameter with
penetration from the outer
skin but not into the inner skin

R Up to 1,000 in.2 (6,452 cm2)

(4) Missing wire Up to 18.4 ft2 (1.70 m2) Repair 019 (on-wing)
R of missing screen
screen for each reverser half.
The total amount for the
two reverser halves
must not be more than
22 ft2 (2.04 m2)

R More than 1,000 in.2 (6,452 Repair 014

R cm2) of missing screen
R

R The maximum acoustic Any amount To be supplied

(5) Acoustic
R blockage permitted for a
blockage
R translating cowl half is
R 0.60 ft2 (0.055 m2).
R Refer to figure 504

INSPECTION
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Table 501. Fan Reverser Translating Cowl (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

R B. DELETED

C. Bulb Seal for:

(1) Radial cuts, splits Up to 5 cuts, splits, or Not repairable Replace the seal
or tears tears over the length of
the seal

(2) Circumferential At the vent holes, any Not repairable Replace the seal
cuts, splits, or number of cuts, splits,
tears or tears through the
fabric up to 0.5 inch
(12.7 mm) in length. In
the areas between the
vent holes, no cuts,
splits or tears are
permitted

(3) Nicks that do not Any number up to a Not repairable Replace the seal
go through the maximum length or
seal width of 0.25 inch (6.35
mm) if separated by 5.0
in. (127 mm)
circumferentially

(4) Punctures No visible holes through Not repairable Replace the seal
the seal or punctures
through the seal are
permitted

(5) Missing sections Not serviceable Not repairable Replace the seal
of the seal

D. Rivets for:

(1) Missing, loose, Not serviceable Any number Repair 001

or damaged

INSPECTION
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Table 501. Fan Reverser Translating Cowl (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

E. Nut Plates for:

(1) Cracked or Not serviceable Any number Replace the nut plates
damaged

F. Blocker Door Hinges (Blades) for:

(1) Cracks Not serviceable Not repairable Replace the hinges

(blades)

(2) Wear at bearing Not serviceable 0.6140 in. (15.596 mm) hinge Replace the bearings,
outer race to hole diameter Repair 006. If the
hinge casting damage is more than
interface the repairable limits,
replace the hinge
(blade)

(3) Spherical Minimum spherical Not repairable Replace the bearing

bearing ball for diameter of inner ball
wear bearing is 0.4366 inch
(11.090 mm)

(4) Elongated Not serviceable Not repairable Replace the hinges

bearing holes (blades)

G. Aft C-Ring for:

(1) Missing or Not serviceable Not repairable Replace the translating

damaged cowl
segment

H. Tee-Hinge/Piano Hinge Assembly for:

R (1) Worn or One half thickness of Not repairable Replace the wear strip,
R damaged wear material may be Repair 016
R strips missing

(2) Cracks Not serviceable Not repairable Replace both

components if either is
cracked

INSPECTION
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Table 501. Fan Reverser Translating Cowl (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

H. Tee-Hinge/Piano Hinge Assembly for (continued):

(3) Movement in Not serviceable Any amount Reinsert the hinge pin
hinge pin

(4) Bent or Not serviceable Not repairable Replace the hinge pin
distressed hinge
pin

(5) Bent or Not serviceable Not repairable Replace the retainers

distressed hinge
pin retainers

I. Lower/Upper Cowl Guides for:

(1) Cracks Not serviceable Not repairable Replace the guide

(2) Loose or Not serviceable Any number Repair 015

missing teflon
wear strips

(3) Wear Minimum thickness of Not repairable Replace the guide

0.170 in. (4.32 mm).
See figure 503

(4) Wear to Hole Maximum I.D. of 0.194 Not repairable Replace guides
in. (4.93 mm). Refer to
Figure 503

(5) Wear to throat Minimum thickness of Not Repairable Replace guides

0.440 in. (11.18 mm).
Refer to Figure 503

R (6) Wear to Minimum O.D. 0.186 in. Not repairable Replace bolts
R attachment (4,72 mm). Refer to
R bolts Figure 507

J. Ballscrew Actuator/Clevis Pin Areas for:

(1) Wear in pin ID 0.393 inch (10.0 Not repairable Replace the clevis
holes mm)

(2) Loose or worn Not serviceable Not repairable Replace the nuts
pin retainer clip
nuts

INSPECTION
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Table 501. Fan Reverser Translating Cowl (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

J. Ballscrew Actuator/Clevis Pin Areas for (continued):

(3) Cracked, Not serviceable Not repairable Replace the clevis

broken, or
dislodged clevis

(4) Worn pins Min. diameter of Not repairable Replace the pins
0.3705 in. (9.411 mm)

(5) Oversized clevis Not serviceable 0.285 inch (7.24 mm) hole Repair 018
or longeron diameter
attach fastener
holes

R (6) Wear to the Not serviceable Not Repairable Replace Clevis

R inner surfaces of
R the clevises.
R Refer to Figures
R 505 and 506.

R (7) Any damage to Not Serviceable Not Repairable Replace Longeron(s)

R the Longeron(s)
R at the clevis
R attachments.

K. Translating Cowl Bumpers for:

(1) Wear 0.06 inch (1.5 mm) Not repairable Replace the bumpers
depth (Repair 008)

L. Inner and Outer Bondment Mateline for:

(1) Crazing in Any amount Any amount Repair 003

exterior paint

M. Outer Skin Upper/Lower Aft Fairing (Areas C and E) for:

(1) Cracks 2.0 inches (50.8 mm) Any number Replace the fairing
length

INSPECTION
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Table 501. Fan Reverser Translating Cowl (continued)

Maximum Maximum
Serviceable Repairable Repair
Inspect/Check Limits Limits Method

N. Translating Cowl Forward Seal Support for:

(1) Wear at the Up to 0.100 inch (2.54 Up to 0.100 inch (2.54 mm) Blend out the wear
cascade bolt contact mm) depth by 0.25 inch depth; any amount of width marks to 0.100 inch
points (6.35 mm) width (2.54 mm) deep by a
minimum of 1.00 inch
(25.4 mm) wide. Apply a
layer of epoxy resin
primer (C03-005) to the
bare edges. Over the
repairable limits, replace
the forward seal support

O. Actuator Access Panel for:

(1) Cracks Up to four cracks, with Any amount Stop drill the cracks and repair
a maximum of 2.0 with epoxy resin adhesive
inches (50.8 mm) for (C01-011)
the total length of all
cracks. Minimum
distance from other
damage must be 2.0
inches (50.8 mm)

P. Inner Flow Path Fiberglass Closure Ply for:

(1) Delaminated ply Maximum delaminated Any amount Repair 012

or ply that is area of 0.5 in. (12.7
missing mm) by 0.5 in. (12.7
mm)

(2) Forward closure Any amount if the Any amount Repair 012
ply for screen is bonded and
delamination extends under the
blocker door fairings
and spacers

Q. Blocker Door Fairings (3 Types) for:

(1) Cracks in blocker Not serviceable Not repairable Replace the fairing
door fairings, filler
R fairings, or pie- NOTE: MRAS SB 78-5129
R shaped blocker introduces more
R door fairings durable blocker door
R fairings (3 types).

INSPECTION
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78-32-31 DEC 01/15
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R NACELLE ACOUSTIC ZONES

R NOTE: This CMM gives the maximum acoustic blockage limits for each component that gives acoustic
R suppression for the nacelle. There is a high level acoustic requirement for a fully installed nacelle
R (inlet and full reverser). The view above shows the zone numbers for each component. The
R allowance is based on a sliding scale formula*. To apply the formula correctly, an airline must
R monitor all blockage to its acoustic components. The airline has the option of using this full nacelle
R allowance for their reverser components.

R *Use this formula if the damage area (including potential loss from previous repairs) is more than
R the maximum permitted limits at the individual component level (see example):

R (0.286 x Inlet Area Loss) + (0.154 x Exhaust Area Loss) < 1.0
R Example:

R Inlet (ft2) 3.5 3.0 2.5 2.0 1.5 1.0 0.0

R Exhaust (ft2) 0.0 0.9 1.9 2.8 3.7 4.6 6.5

R Table 502. Maximum Acoustic Loss Independent Limits

R Acoustic Zone Component Description Maximum Permitted Area

R Losses
R 1 Inlet (Inner Barrel) 1.75 ft2 (0.163 m2)
R 2 Exhaust (Blocker Door, Translating Cowl, 3.24 ft2 (0.301 m2)
R Fixed Structure)

R Table 503. Maximum Acoustic Loss Independent Limits by Individual Exhaust Component

R Acoustic Zone Individual Exhaust Component Description Maximum Permitted Area

R Losses
R 2 Blocker Door 0.028 ft2 (0.0026 m2)
R 2 Translating Cowl (LH or RH) 0.60 ft2 (0.055 m2)
R 2 Fixed Structure (LH) 0.73 ft2 (0.068 m2)
R 2 Fixed Structure (RH) 0.98 ft2 (0.091 m2)

INSPECTION
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MR60028-01-A
Translating Cowl Inspection Areas
Figure 501

R INSPECTION
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R
R DELETED
Figure 502 (Sheet 1)

INSPECTION
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CF8-6919-00-C
Translating Cowl (Inner/Outer Bondments)
Figure 502 (Sheet 2)

R INSPECTION
PAGE 513
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R
Cowl Guide Wear Inspection
Figure 503

INSPECTION
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R MR60216-00-A
R Translating Cowl Acoustic Blockage Limits
R Figure 504

INSPECTION
PAGE 515
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R
R Clevis/Longeron Assembly for Upper and Lower End Actuators
R Figure 505

INSPECTION
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R
R Clevis/Longeron Assembly for CDU
R Figure 506

INSPECTION
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R
R Attachment Bolt Wear
R Figure 507

INSPECTION
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FAN REVERSER TRANSLATING COWL - REPAIR

1. Replacement of Rivets.

A. This procedure gives the instructions to replace loose or damaged rivets in the translating cowl.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

R (2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment. None required.

B. Consumable Material.

Code Description Use

R C01-115 Adhesive, Sealant Rivet installation

R (MIL-PRF-81733, Type II-2),
R PR1440-B-2

R C03-001 Primer, Zinc Chromate, Rivet installation

R Fed. Spec. TT-P-1757,
R Color Y, Composition G

R C03-005 Primer, Epoxy Resin (Spray Type) Rivet installation

R Finch 463-12-8

C04-001 Solvent, Methyl-Ethyl-Ketone Clean the rivet hole

(MEK)

R C04-003 Solvent, Acetone Clean the rivet hole

R Fed. Spec. 0-A51

C04-018 Naphtha, Fed. Spec. Clean the rivet hole

TT-N-95, Type II

C04-035 Isopropyl Alcohol Clean the rivet hole

R C10-182 Cloths, Cotton, Lint-free, Clean the repair area

REPAIR 001
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R C. Expendable Parts. Refer to the Illustrated Parts Catalog (MM 99379), 78-32-31.

D. SPD Identification. None required.

E. Referenced Procedures.

R SPM 70-13-00

SPM 70-13-05

3. Dimensional Information. None required.

4. Setup Information. None required.

5. Procedure.

R A. Replace loose or damaged rivets in the translating cowl.

R (1) To replace rivets that attach metal parts to metal parts, refer to step 5.B.

R (2) To replace rivets that attach metal parts to composite parts (except as indicated in step
R 5.A.(3)), refer to step 5.C.

R (3) For blind rivets where the rivet stem is trapped in a composite bondment, refer to the
R removal procedure for the applicable part.

R B. Do the steps that follow to replace loose or damaged rivets that attach metal parts to metal
R parts.

R (1) Remove all the loose or damaged rivets.

R (a) Find all the loose or damaged rivets.

R (b) Center punch the rivets that you will remove.

R (c) Drill out the loose or damaged rivet(s). Use an applicable drill bit for the rivet
R diameter. Refer to Standard Practices Manual, 70-13-00. Deburr as
R necessary.

REPAIR 001
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WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

(2) Clean the rivet hole(s) with a clean, lint-free cotton cloth (C10-182) made moist with
solvent (C04-001, C04-003, C04-018, or C04-035). Immediately dry the surface with a
clean, lint-free cotton cloth (C10-182). Do not let the solvent dry on the repair surface.
Do this again until the rivet hole(s) is clean.

(3) Let the rivet hole(s) dry a minimum of 15 minutes.

(4) Replace each loose or damaged rivet with an equivalent rivet, as specified in the CF6-
80E Illustrated Parts Catalog MM 99379, 78-32-31.

WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
AND CLOTHING TO PROTECT YOURSELF.

(5) Install the rivets with a wet layer of epoxy resin primer (C03-005) or zinc chromate
primer (C03-001). Make sure each rivet has a full layer of primer. Refer to Standard
Practices Manual, 70-13-00 and 70-13-05.

(6) Remove unwanted primer after rivet installation.

C. Do the steps that follow to replace loose or damaged rivets that attach metal parts to composite
R parts or composite parts to composite parts.

(1) Remove all the loose or damaged rivets.

(a) Find all the loose or damaged rivets.

(b) Center punch the rivets that you will remove.

(c) Drill out the loose or damaged rivet(s). Use an applicable drill bit for the rivet
diameter. Refer to Standard Practices Manual, 70-13-00. Deburr as
necessary.

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R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (2) Clean the rivet hole(s) with a clean, lint-free cotton cloth (C10-182) made moist with
R solvent (C04-001, C04-003, C04-018, or C04-035). Immediately dry the surface with a
R clean, lint-free cotton cloth (C10-182). Do not let the solvent dry on the repair surface.
R Do this again until the rivet hole(s) is clean.

R (3) Let the rivet hole(s) dry a minimum of 15 minutes.

R (4) Replace each loose or damaged rivet with an equivalent rivet, as specified in the CF6-
R 80E Illustrated Parts Catalog MM 99379, 78-32-31.

R WARNING: THIS MATERIAL IS POISONOUS AND GIVES OFF FUMES. MAKE SURE
R YOU USE THE MATERIAL IN AN AREA WITH GOOD AIR FLOW. MAKE
R SURE YOU DO NOT BREATHE THE FUMES. DO NOT GET THE MATERIAL
R ON YOUR SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE
R GLOVES AND CLOTHING TO PROTECT YOURSELF.

R (5) Apply a wet layer of sealant adhesive (C01-115) around each rivet stem when you
R install the rivet. Refer to Standard Practices Manual, 70-13-05.

R (6) Remove unwanted sealant adhesive from the translating cowl after rivet installation.

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FAN REVERSER TRANSLATING COWL - REPAIR

1. Repair of Penetration Type Damage.

R A. This procedure gives the instructions for the repair of penetration type damage to the translating
R cowl. Refer to table 601.

2. Tools and Equipment.

NOTE: Equivalent alternatives are permitted for Tools, Equipment and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment.

Description Manufacturer

Grinder, Air Driven Right Angle Rotor Tools, Cleveland, OH

M1122SA-150

Spray Gun, DeVilbiss, No. Local purchase

EGA502-395

Arbor, Air Driven - 3.0 in. Local purchase

(76.2 mm) 3M-923

Scraping Tool, 0.5 - 1.0 in. Local purchase

(12.7 - 25.4 mm) wide blade

Stiff Bristle Brush Local purchase

Acid Brush Local purchase

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B. Consumable Materials.

Code Description Use

R C01-073 Compound, Sealing Fillet Seal

R PR 1750

R C01-115 Adhesive, Sealant (MIL-PRF-81733, Fillet seal

R Type II-2), PR 1440-B-2

R DELETED

C01-126 Netting, Fabric, Dacron Adhesive carrier cloth

Polyester, D117

C01-155 Adhesive, Epoxy Resin, Repair adhesive

EA9394

C03-007 Primer, Epoxy Adhesive Prime the doubler

BR-127 (Spray Type)

C03-056 Paint, Epoxy High Solids Finish layer

P/N 4222T36231, MIL -C-22750,
Flat Gray

R DELETED

C04-003 Solvent, Acetone Clean the repair area

C04-035 Isopropyl Alcohol Clean the repair area

C04-280 Cleaner, Surface Treatment, Clean the doublers

Pasa-Jell 101

C10-008 Honeycomb, Nomex HRH-10- Core replacement

1/8-3.0, 1/8 in. Cell by
1.0 in. thick, Density 3 lb ft3

C10-009 Paper, Grease-Proof, Grade A, Mask the repair area

Type 2, Class 2, (Kraft)

C10-010 Scotch Brite Pads, Surface preparation

No. 7447, 6.0 X 9.5 in.
(152.4 X 241.3 mm)

C10-040 Tape, Teflon, 1.0 X 0.002 in. Tape the repair area
(25.4 X 0.05 mm) thick
Scotch Brand 5490

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Code Description Use

C10-139 Gloves, White Cotton, Disposable Handle the doubler

C10-140 Gloves, Nylon Film/ Mix and apply

Polyethylene the adhesive

C10-141 Abrasive Paper, Aluminum, Prepare the surface

Oxide 120-180 Grit

C10-247 Fabric Netting Adhesive carrier cloth

R DELETED

R DELETED

R DELETED

Local Purchase 17-7 PH Stainless Steel Repair doubler

Sheet, Cond Th 1050
Thickness - 0.018-0.022 in.
(0.46-0.56 mm) MIL-S-25043

Local Purchase Scotch Brite Surface Prepare the surface

Conditioning Disc, 3.0 in.
(76.2 mm) Coarse (Brown)

Local Purchase Litmus paper Test repair area

Local Purchase Film, Polyester (Mylar) Mask repair area

C. Expendable Parts. None required.

D. SPD Identification. None required.

E. Referenced Procedures. None required.

3. Dimensional Information. None required.

4. Setup Information. None required.

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5. Procedure.

CAUTION: REPAIR OF PENETRATION TYPE DAMAGE TO THE TRANSLATING COWL IS

LIMITED TO AMBIENT TEMPERATURES AT THE REPAIR AREA OF 60°-100°F
(15.6° -37.8°C). CONTROL OF THE AIR TEMPERATURE IS NECESSARY IF THE
AMBIENT TEMPERATURE IS NOT WITHIN THE SPECIFIED LIMITS.

A. Repair of penetration damage to the translating cowl.

(1) Find the extent of the damage.

(a) Use a 0.5-1.0 oz (14-28 g) aluminum mallet to hit lightly around the damaged
area on the surface of the translating cowl outer skin to find the edge of the
delaminated material. Use a felt-tip pen to make a mark around the edge of the
delaminated material.

NOTE: If you hear a solid “click” sound, the material is not delaminated. If
you hear a hollow sound, the material is delaminated.

(b) Use a felt-tip pen to mark the boundary of the delaminated material. If the
maximum dimension across the damaged area (penetration hole plus
delaminated area) is more than 4.0 in. (101.6 mm), do not use this procedure to
repair the damage.

(c) Use a cut-off disk on the grinder to cut through the surface plies along the
delaminated area where you made a mark. Remove the damaged material.

WARNING: USE A VACUUM CLEANER WITH THE INTAKE HELD ADJACENT

TO THE REPAIR AREA TO COLLECT CUTTING DUST AND
RESIDUE. USE AN APPROVED DUST MASK TO PREVENT
INHALATION OF CUTTING RESIDUE AND DUST.

CAUTION: MAKE SURE YOU DO NOT MAKE THE DAMAGED AREA LARGER.

(d) Use a cutting disk and an air driven right angle grinder, pliers, diagonal cutter,
scissors, etc., as necessary to remove the broken, delaminated, and/or cracked
pieces of the surface. Remove all of the exposed, crushed and/or loose
material from the damaged area.

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(e) Examine the inside diameter surface of the translating cowl under the damaged
area on the outer skin to give additional assurance that the inner skin plies
have, or have not, been damaged. If you find damage, refer to step (c) to
remove the damaged material. If the maximum dimension across the damaged
area of the inner skin is more than 2.0 in. (50.8 mm), do not use this procedure
to repair the damage.

(f) Select the repair method as shown in table 601.

(2) Remove liquids (fuel, engine oil, water) from the damaged area.

(a) Remove as much liquid as possible with a sponge, towel, shop cloths, etc.

NOTE: You can also use a wet-or-dry vacuum cleaner.

WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE

AIRBORNE PARTICLES THAT CAN GO INTO YOUR EYES OR GO
THROUGH YOUR SKIN. DO NOT USE MORE THAN 30 PSIG (207
KPA) PRESSURE. WEAR GOGGLES. DO NOT POINT
COMPRESSED AIR IN THE DIRECTION OF YOUR SKIN.

(b) Blow dry the area with compressed dry air.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT

ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
USE THE FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT
BREATHE THE FUMES. IF YOU GET THE SOLVENT ON YOUR
SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET
MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

(c) Clean the repair area with a clean, lint-free cotton cloth made moist with solvent
R (C04-003 or C04-035). Immediately dry the surface with a dry, clean, lint-free
cotton cloth before the solvent dries.

WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE

AIRBORNE PARTICLES THAT CAN GO INTO YOUR EYES OR GO
THROUGH YOUR SKIN. DO NOT USE MORE THAN 30 PSIG (207
KPA) PRESSURE. WEAR GOGGLES. DO NOT POINT
COMPRESSED AIR IN THE DIRECTION OF YOUR SKIN.

(d) Blow dry the area with compressed dry air.

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Table 601

Repair Method
R Damage Type Damage Description Paragraph

A. The maximum dimension of the opening in the outer 5.A. (3)

skin is not more than 0.75 in. (19.1 mm). The inner
skin is undamaged.

B. The maximum dimension of the opening in the outer 5.A. (4)

skin is more than 0.75 in. (19.1 mm) but is not more
than 2.0 in. (50.8 mm). The inner skin is
undamaged.

C. The maximum dimension of the opening in the outer 5.A. (5)

skin is more than 2.0 in. (50.8 mm) but is not more
than 4.0 in. (101.6 mm). The inner skin is
undamaged.

D. The maximum dimension of the opening in the outer Not repairable

skin is more than 4.0 in. (101.6 mm).

R E. The maximum dimension of the opening in the inner 5.A. (6)

skin is not more than 2.0 in. (50.8 mm) and the
opening in outer skin is not more than 4.0 in. (101.6
mm).

R F. The maximum dimension of the opening in the inner Not repairable

skin is more than 2.0 in. (50.8 mm) and/or the
opening in the outer skin is more than 4.0 in. (101.6
mm).

NOTE: Dimension limits on the openings in the inner and outer skin surfaces apply after broken,
delaminated, and/or cracked skin removal.

NOTE: Adjacent damage and/or repairs must be separated by a minimum of 6.0 in. (152.4 mm) of
undamaged structure.

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(3) Repair Type A penetration damage. Refer to figure 601.

(a) Examine the surface opening for unwanted material. Remove unwanted
material.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT

ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
USE THE FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT
BREATHE THE FUMES. IF YOU GET THE SOLVENT ON YOUR
SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET
MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

(b) Clean the repair area with a clean, lint-free cotton cloth made moist with solvent
R (C04-003 or C04-035). Immediately dry the surface with a dry, clean, lint-free
cotton cloth before the solvent dries.

WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE

AIRBORNE PARTICLES THAT CAN GO INTO YOUR EYES OR GO
THROUGH YOUR SKIN. DO NOT USE MORE THAN 30 PSIG (207
KPA) PRESSURE. WEAR GOGGLES. DO NOT POINT
COMPRESSED AIR IN THE DIRECTION OF YOUR SKIN.

(c) Blow dry the opening with compressed dry air.

WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA
OPEN TO THE AIR. WEAR CLEAN NYLON FILM OR
POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN YOU MIX
OR APPLY THE ADHESIVE.

R (d) Prepare the epoxy adhesive (C01-155) in a clean metal or uncoated paper
R container as follows:

R 1 Combine by weight, 100 parts resin A with 17 parts catalyst B.

R 2 Mix thoroughly until you can see no streaks of the two components.

R NOTE: The pot life of a 3.53 oz (100 g) batch of mixed epoxy is

R approximately 60 minutes.

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1118032-00-C
R
Translating Cowl Repair - Type A
Figure 601

(e) Use a clean spatula, tongue depressor, or equivalent, and wet the honeycomb
cell walls (adjacent to the opening in the outer skin) with the mixed adhesive.
Fill the remaining cavity with mixed adhesive, smooth with the outer skin.

(f) Cure the adhesive for 16 hours at a minimum ambient temperature of 70˚F
(21˚C), or cure for a minimum of two hours at ambient temperature, followed by
60 minutes at 140˚-160˚F (60˚-71˚C).

(g) Use abrasive paper (C10-141) lightly to make the repair area smooth and
continuous with the adjacent translating cowl outer skin.

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WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE

AIRBORNE PARTICLES THAT CAN GO INTO YOUR EYES OR GO
THROUGH YOUR SKIN. DO NOT USE MORE THAN 30 PSIG (207
KPA) PRESSURE. WEAR GOGGLES. DO NOT POINT
COMPRESSED AIR IN THE DIRECTION OF YOUR SKIN.

(h) Use compressed dry air to remove unwanted material.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT

ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
USE THE FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT
BREATHE THE FUMES. IF YOU GET THE SOLVENT ON YOUR
SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET
MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

(i) Clean the repair area with a clean, lint-free cotton cloth made moist with solvent
R (C04-003 or C04-035). Immediately dry the surface with a dry, clean, lint-free
cotton cloth before the solvent dries.

(j) If you can see the pores after the area is made smooth in step (g), use a new
mixture of the epoxy adhesive used in step (e) to fill the pores flush with the
outer skin. Refer to step (d) to mix and step (f) to cure the adhesive.

(k) Apply the surface protective layer. Refer to paragraph 5.A. (8).

(4) Repair Type B penetration damage. Refer to figure 602.

(a) Examine the surface opening for unwanted material. Remove unwanted
material.

NOTE: It is not necessary to remove partial core material which is firmly

attached to the inside surface of the inner skin.

CAUTION: DO NOT DAMAGE THE GRAPHITE SURFACE FIBERS WHEN YOU

REMOVE THE SURFACE RESIN.

(b) Use a 3.0 in (76.2 mm) Scotch Brite disc attached to an air driven 3M 923 arbor
to remove the paint, charcoal colored anti-static coating, and yellow and green
primer. Remove within a 1.5-1.75 in. (38.1-44.5 mm) wide band immediately
around the damage opening in the translating cowl outer skin. Remove all
surface resin.

REPAIR 002
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11180340-C
R
Translating Cowl Repair - Type B
Figure 602

WARNING: USE A VACUUM CLEANER WITH THE INTAKE HELD ADJACENT

TO THE REPAIR AREA TO COLLECT CUTTING DUST AND
RESIDUE. USE AN APPROVED DUST MASK TO PREVENT
INHALATION OF CUTTING RESIDUE AND DUST.

(c) Use low pressure, clean, dry, filtered air, and a vacuum to remove dust
particles.

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WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT

ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
USE THE FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT
BREATHE THE FUMES. IF YOU GET THE SOLVENT ON YOUR
SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET
MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

(d) Clean the repair area with a clean, lint-free cotton cloth made moist with solvent
R (C04-003 or C04-035). Immediately dry the surface with a dry, clean, lint-free
cotton cloth before the solvent dries.

WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA
OPEN TO THE AIR. WEAR CLEAN NYLON FILM OR
POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN YOU MIX
OR APPLY THE ADHESIVE.

R (e) Prepare the epoxy adhesive (C01-155) in a clean metal or uncoated paper
R container as follows:

R 1 Combine by weight, 100 parts resin A with 17 parts catalyst B.

R 2 Mix thoroughly until you can see no streaks of the two components.

R NOTE: The pot life of a 3.53 oz (100 g) batch of mixed epoxy is

R approximately 60 minutes.

(f) Use a clean spatula, tongue depressor, or equivalent, and wet the honeycomb
cell walls (adjacent to the opening in the outer skin) with the mixed adhesive.
Fill the remaining cavity with mixed adhesive until the adhesive layer is flush
with the outer skin. The adhesive must extend a minimum of 0.25 in. (6.4 mm)
deep into the undamaged core surface or full depth if less than 0.25 in. (6.4
mm) of core stays.

(g) Cure the adhesive for 16 hours at a minimum ambient temperature of 70˚F
(21˚C), or cure for a minimum of two hours at ambient temperature, followed by
60 minutes at 140˚-160˚F (60˚-71˚C).

(h) Use abrasive paper (C10-141) lightly to make the repair area smooth and flush
with the adjacent translating cowl outer skin.

WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE

AIRBORNE PARTICLES THAT CAN GO INTO YOUR EYES OR GO
THROUGH YOUR SKIN. DO NOT USE MORE THAN 30 PSIG (207
KPA) PRESSURE. WEAR GOGGLES. DO NOT POINT
COMPRESSED AIR IN THE DIRECTION OF YOUR SKIN.

(i) Use low pressure, clean, dry, filtered air, and a vacuum to remove dust
particles.

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WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT

ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
USE THE FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT
BREATHE THE FUMES. IF YOU GET THE SOLVENT ON YOUR
SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET
MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

(j) Clean the repair area with a clean, lint-free cotton cloth made moist with solvent
R (C04-003 or C04-035). Immediately dry the surface with a dry, clean, lint-free
cotton cloth before the solvent dries.

(k) Make the CRES repair doubler (17-7 PH, 0.020 in. (0.51 mm) thick) 2.00-2.50
in. (50.8-63.5 mm) wider than the damage opening. Make an overlap of 1.00-
1.25 in. (25.4-31.8 mm) around the opening of the doubler. Make the doubler
contour align with the cowl contour when finger pressure is applied.

NOTE: A 0.030 in. (0.76 mm) maximum gap is permitted.

(l) Cut an opening in the grease-proof paper (C10-009) or equivalent. The

opening must be the correct size to go around the repair area. The opening
must be the same shape as the sanded area and at least 0.25 in. (6.4 mm)
larger. Put Teflon tape (C10-040) along the edges of the opening. Use tape on
the outer edges of the paper to hold it in position and out of the way.

R (m) Use the doubler as a pattern and cut a piece of fabric netting (C01-126 or C10-
R 247) to support the epoxy adhesive.

WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA
OPEN TO THE AIR. WEAR CLEAN NYLON FILM OR
POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN YOU MIX
OR APPLY THE ADHESIVE.

(n) Do the steps that follow to prepare the epoxy adhesive (C01-155). Use a clean
metal or uncoated paper container.

1 Mix by weight, 100 parts resin A with 17 parts catalyst B.

2 Mix until you can see no streaks of the two components.

NOTE: Pot life of a 3.53 oz (100 g) batch of mixed epoxy is

approximately 60 minutes.

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(o) Do the steps that follow to apply the epoxy adhesive and piece of netting:

1 Use a stiff bristle brush and apply a thin, equal layer of epoxy adhesive
to the doubler.

2 Put the netting in the wet epoxy adhesive on the doubler. Push the
netting into the epoxy adhesive with a tongue depressor, or equivalent,
until it is soaked.

3 Remove all wrinkles in the netting, and apply a second thin, equal layer
of epoxy adhesive on the netting.

(p) Put the doubler on the repair area. Make the doubler overlap the cutout equally
all around. Refer to figure 602. Examine the repair area for unwanted epoxy
adhesive. Remove unwanted epoxy adhesive with a tongue depressor.

(q) Apply partial vacuum pressure (15-20 in. Hg) or mechanical pressure (10-15
psi (69-104 kPa)) and cure for 120 minutes at an ambient temperature. Cure
120 minutes more at 150° - 170°F (65.4° - 76.6°C) or seven days at an ambient
temperature.

(r) Remove the grease-proof paper from the translating cowl skin.

(s) Examine the doubler for unbonded areas.

1 Make a visual inspection to look for unbonded areas.

2 Use a 0.5-1.0 oz (14-28 g) aluminum mallet to lightly hit around the

doubler area to find unbonded areas.

NOTE: If you hear a solid “click” sound, the area is fully bonded. If you
hear a hollow sound, the area is unbonded.

R (t) Use (C01-115 or C01-073) sealing compound to seal around the outer surface
of the doubler and make the skin surface smooth.

(u) Cure for 5 hours at 110°F - 130°F (43.4°C - 54.6°C).

(v) Apply the surface protective layer. Refer to paragraph 5.A. (8).

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(5) Repair Type C penetration damage. Refer to figure 603.

WARNING: USE A VACUUM CLEANER WITH THE INTAKE HELD ADJACENT

TO THE REPAIR AREA TO COLLECT CUTTING DUST AND
RESIDUE. USE AN APPROVED DUST MASK TO PREVENT
INHALATION OF CUTTING RESIDUE AND DUST.

CAUTION: DO NOT DAMAGE THE INNER SKIN.

(a) Use a rotary file, cutting disk, sanding disk, diagonal cutters, pliers, and a
scraping tool and remove the remaining honeycomb (within the limits of the
surface opening in the outer skin) down to the inner skin. With most of the
honeycomb removed, remove the residual honeycomb with a rotary file,
scraper, or small sanding disk.

1118035-00-C
R
Translating Cowl Repair - Type C
Figure 603

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CAUTION: DO NOT DAMAGE THE GRAPHITE SURFACE FIBERS WHEN YOU

REMOVE THE SURFACE RESIN.

(b) Remove the paint, charcoal colored anti-static coating, and yellow and green
primer to within a 1.5-1.75 in. (38.1-44.5 mm) wide band around the damage
opening in the translating cowl outer skin. Use a 3.0 in. (76.2 mm) Scotch Brite
surface conditioning disc attached to a 3M 923 air driven arbor. Remove all
surface resin.

WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE

AIRBORNE PARTICLES THAT CAN GO INTO YOUR EYES OR GO
THROUGH YOUR SKIN. DO NOT USE MORE THAN 30 PSIG (207
KPA) PRESSURE. WEAR GOGGLES. DO NOT POINT
COMPRESSED AIR IN THE DIRECTION OF YOUR SKIN.

(c) Use low pressure, clean, dry, filtered air, and a vacuum to remove dust
particles.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT

ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
USE THE FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT
BREATHE THE FUMES. IF YOU GET THE SOLVENT ON YOUR
SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET
MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

(d) Clean the repair area with a clean, lint-free cotton cloth made moist
R with solvent (C04-003 or C04-035). Immediately dry the surface with a
dry, clean, lint-free cotton cloth before the solvent dries.

(e) Make the CRES repair doubler (17-7 PH, stainless steel) 2.00-2.50 in. (50.8-
63.5 mm) wider than the damage opening. Make an overlap of 1.00-1.25 in.
(25.4-31.8 mm) around the opening of the doubler. Refer to paragraph 5.A. (7).

(f) Cut a plug of honeycomb core material (C10-008) to fit the opening, with 0.05-
0.10 in. (1.3-2.5 mm) interference around the plug. The plug must be aligned
with the outer skin surface around the damaged area.

(g) Put a clean piece of tape (C10-040) (approximately 12.0 X 18.0 in. (304.8 X
457.2 mm) on grease-proof paper (C10-009), or mylar film, and attach to a
work surface.

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MANUAL

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WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA
OPEN TO THE AIR. WEAR CLEAN NYLON FILM OR
POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN YOU MIX
OR APPLY THE ADHESIVE.

CAUTION: STEPS (H), (I), AND (J) MUST BE DONE WITH A MINIMUM TIME
DELAY SINCE THE ADHESIVE WILL SET UP IN APPROXIMATELY 5
MINUTES AT 77°F (25°C). HAVE ALL MATERIALS PREPARED
PRIOR TO STARTING THESE STEPS SO THAT THE ADHESIVE IN
THE CAVITY WILL NOT SET UP BEFORE INSTALLING THE
HONEYCOMB PLUG.

R (h) Mix a quantity of epoxy adhesive (C01-155) to apply to the bottom of the hole in
the transcowl, bottom of the plug, and the adjacent walls of the parent
honeycomb and plug. The mixing proportion of adhesive is 1:1 by weight or
volume.

R 1 Mix by weight, 100 parts resin A with 17 parts catalyst B.

R 2 Mix until you can see no streaks of the two components.

R NOTE: Pot life of a 3.53 oz (100 g) batch of mixed epoxy is

R approximately 60 minutes.

(i) Use an acid brush, or equivalent, and apply to the bottom of the hole with a
large quantity of mixed epoxy adhesive in a crisscross pattern. Apply the
adhesive with a brush up the side walls of parent honeycomb.

(j) Apply a thick layer of mixed epoxy adhesive on the grease-proof paper. Put
the epoxy adhesive on an area a little larger than the Nomex plug.

(k) Push the plug into the adhesive on the paper and move the plug back and forth
and in a circular movement to pick up the adhesive on the bottom of the cell
walls.

(l) Use an acid brush, or equivalent, and apply a layer of epoxy adhesive to the
outside walls of the plug.

(m) Push the plug into the hole, with the epoxy adhesive charged cell ends, against
the bottom of the hole. Hold the plug tightly in the hole until the epoxy adhesive
sets up.

R (n) Cure the adhesive for 16 hours at a minimum ambient temperature of

R 70°F (21°C), or cure for a minimum of two hours at ambient temperature,
R followed by 60 minutes at 140°-160°F (60°-71°C).

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R (o) Remove unwanted adhesive around the plug while the adhesive sets up. Align
the plug with the outer skin surface at the edge of the damaged area.

R (p) If necessary, after the epoxy adhesive has cured, use abrasive paper (C10-
141) lightly to make the core plug surface smooth with the undamaged outer
skin.

WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE

AIRBORNE PARTICLES THAT CAN GO INTO YOUR EYES OR GO
THROUGH YOUR SKIN. DO NOT USE MORE THAN 30 PSIG (207
KPA) PRESSURE. WEAR GOGGLES. DO NOT POINT
COMPRESSED AIR IN THE DIRECTION OF YOUR SKIN.

R (q) Use low pressure, clean, dry, filtered air, and a vacuum to remove dust
particles.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT

ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
USE THE FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT
BREATHE THE FUMES. IF YOU GET THE SOLVENT ON YOUR
SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET
MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R (r) Clean the repair area with a clean, lint-free cotton cloth made moist with solvent
R (C04-003 or C04-035). Immediately dry the surface with a dry, clean, lint-free
cotton cloth before the solvent dries.

R (s) Cut an opening in grease-proof paper (C10-009), or equivalent, around the

repair area. Make the opening the same shape as the sanded area and at
least 0.25 in. (6.4 mm) larger. Put Teflon tape (C10-040) along the edges of
the opening. Put tape on the outer edges of the paper to hold it in position and
out of the way.

R (t) Use the doubler as a pattern and cut a piece of fabric netting (C01-126 or C10-
R 247) to support the epoxy adhesive.

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WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA
OPEN TO THE AIR. WEAR CLEAN NYLON FILM OR
POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN YOU MIX
OR APPLY THE ADHESIVE.

R (u) Do the steps that follow to prepare the epoxy adhesive (C01-155). Use a clean
metal or uncoated paper container.

1 Mix by weight, 100 parts resin A with 17 parts catalyst B.

2 Mix until you can see no streaks of the two components.

NOTE: The pot life of a 3.53 oz (100 g) batch of mixed epoxy

adhesive is approximately 60 minutes.

R (v) Apply the epoxy and piece of netting as follows:

1 Use a stiff bristle brush and apply a thin equal layer of epoxy adhesive
to the doubler.

2 Put the netting in the wet epoxy adhesive on the doubler. Push the
netting into the epoxy adhesive with a tongue depressor, or equivalent,
until it is soaked.

3 Make wrinkles in the netting smooth and apply a second thin equal
layer of epoxy adhesive over the netting.

R (w) Put the doubler on the repair area. Make the doubler overlap the cutout equally
all around. Refer to figure 603. Examine the repair area for unwanted epoxy
adhesive. Remove unwanted epoxy adhesive with a tongue depressor.

R (x) Apply partial vacuum pressure (15-20 in. Hg) or mechanical pressure (10-15
psi (69-104 kPa)) and cure for 120 minutes at an ambient temperature. Cure
for 120 minutes more at 150° - 170°F (65.4° - 76.6°C) or seven days at ambient
temperature.

R (y) Remove the grease-proof paper from the translating cowl skin.

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R (z) Examine the doubler for unbonded areas.

R 1 Make a visual inspection to look for unbonded areas.

R 2 Use a 0.5-1.0 oz (14-28 g) aluminum mallet. Lightly hit around the

doubler area to find unbonded areas.

R (aa) Use (C01-115 or C01-073) sealing compound to seal around the outer surface
of the doubler and make the skin surface smooth.

R (ab) Cure for 5 hours at 110° - 130°F (43.4° - 54.6°C).

R (ac) Apply surface protective coatings. Refer to paragraph 5.A. (8).

(6) Repair Type E penetration damage. Refer to figure 604.

WARNING: USE A VACUUM CLEANER WITH THE INTAKE HELD ADJACENT

TO THE REPAIR AREA TO COLLECT CUTTING DUST AND
RESIDUE. USE AN APPROVED DUST MASK TO PREVENT
INHALATION OF CUTTING RESIDUE AND DUST.

CAUTION: DO NOT MAKE A HOLE OR CRACK THE INNER SKIN.

(a) Use a rotary file, cutting disk, sanding disk, diagonal cutters, pliers, and a
scraping tool to remove the damaged/delaminated outer skin, remaining
honeycomb and undamaged honeycomb as necessary to permit the installation
of an inside patch over the opening in the inner skin of the translating cowl.
Trim away remaining loose or broken pieces of the inner skin.

NOTE: Do not exceed the 2.0 in. (50.8 mm) maximum dimension limit.

(b) Examine the doubler for unbonded areas.

1 Make a visual inspection to look for unbonded areas.

2 Use a 0.5-1.0 oz (14-28 g) aluminum mallet. Lightly hit around the

doubler area to find unbonded areas.

NOTE: If you hear a solid “click” sound, the area is fully bonded. If you
hear a hollow sound, the area is unbonded.

(c) Remove the damaged and undamaged honeycomb to fully expose a 1.0-1.25
in. (25.4-31.8 mm) wide band of inside surface around the opening in the inner
skin. Make the opening in the outer skin larger to a maximum opening
dimension of 4.0 in. (101.6 mm) is permitted in order to get access to the inner
skin. Use the cutoff disk to cut through the outer skin.

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R
1118036-00-CTranslating Cowl Repair - Type E
Figure 604

WARNING: USE AN APPROVED DUST MASK TO PREVENT INHALATION OF

GRINDING/SANDING DISK.

CAUTION: APPLY LITTLE OR NO PRESSURE ON THE INNER SKIN TO

PREVENT DELAMINATION OF THE INNER SKIN.

(d) Use an air grinder with a sanding disk on the inside surface of the inner skin to
provide a smooth surface on which to bond the inside patch.

NOTE: Use a rubber backing plate on the outside surface of the skin to
prevent sanding pressure from disbonding the skin.

CAUTION: DO NOT DAMAGE THE GRAPHITE SURFACE FIBERS WHEN YOU

REMOVE THE SURFACE RESIN.

(e) Use a 3.0 in. (76.2 mm) Scotch Brite surface conditioning disc attached to an
air driven 3M 923 arbor to remove the paint, charcoal colored anti-static
coating, and yellow and green primer. Remove within a 1.5-1.75 in. (38.1-44.5
mm) wide band immediately around the damage opening in the translating cowl
outer skin. Remove all surface resin.

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WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE

AIRBORNE PARTICLES THAT CAN GO INTO YOUR EYES OR GO
THROUGH YOUR SKIN. DO NOT USE MORE THAN 30 PSIG (207
KPA) PRESSURE. WEAR GOGGLES. DO NOT POINT
COMPRESSED AIR IN THE DIRECTION OF YOUR SKIN.

(f) Use low pressure clean, dry filtered air and a vacuum to remove dust particles.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT

ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
USE THE FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT
BREATHE THE FUMES. IF YOU GET THE SOLVENT ON YOUR
SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET
MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

(g) Clean the repair area with a clean, lint-free cotton cloth made moist with solvent
R (C04-003 or C04-035). Immediately dry the surface with a dry, clean, lint-free
cotton cloth before the solvent dries.

(h) Cut an opening in grease-proof paper (C10-009), or equivalent, around the

repair area. Make the opening 1.0 in. (25.4 mm) larger than the edge of the
opening in the inner skin.

(i) Make the CRES repair doubler (17-7 PH stainless steel) to match the template
in step (f). Refer to paragraph 5.A.(7) to make the doubler. Examine the fit of
the patch in the repair opening. Make sure that the high material on the
cleaned off surface will permit the patch to be installed against the inner skin. If
necessary trim the patch and/or sand the inner skin surface.

R (j) Use the doubler as a pattern and cut a piece of fabric netting (C01-126 or C10-
R 247) to be used to support the epoxy adhesive. Make the netting in the shape
of a doughnut. Extend the netting 1.0-1.25 in. (25.4-31.8 mm) from the edges
of the doubler.

WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA
OPEN TO THE AIR. WEAR CLEAN NYLON FILM OR
POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN YOU MIX
OR APPLY THE ADHESIVE.

(k) Do the steps that follow to prepare the epoxy adhesive (C01-155). Use a clean
metal or uncoated paper container.

1 Mix by weight, 100 parts resin A with 17 parts catalyst B.

2 Mix until you can see no streaks of the two components.

NOTE: The pot life of a 3.53 oz (100 g) batch of mixed epoxy is

approximately 60 minutes.

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(l) Do the steps that follow to apply the epoxy adhesive and piece of netting.

1 Use a stiff bristle brush and apply a thin equal layer of epoxy adhesive
to the doubler.

2 Put the netting in the wet epoxy adhesive on the doubler. Push the
netting into the epoxy adhesive with a tongue depressor, or equivalent,
until it is soaked.

3 Make wrinkles in the netting smooth and apply a second thin equal
layer of epoxy adhesive on the netting.

(m) Apply a layer of mixed epoxy adhesive to wet the cleaned area on the inside
surface of the inner skin. Use an acid brush, or equivalent, to apply the epoxy
adhesive in a criss-cross pattern. If the inside diameter surface of the inner
skin has wire mesh on it, apply some of the epoxy adhesive on the open area.

CAUTION: DO NOT USE EXCESSIVE PRESSURE TO PUT THE DOUBLER

INTO POSITION BECAUSE DELAMINATION OF THE INNER SKIN
CAN RESULT. PUT A RUBBER PAD BELOW THE OUTER
SURFACE OF THE SKIN.

(n) Put the doubler on the repair area and push into position.

(o) Apply partial vacuum pressure (15-20 in. Hg) or mechanical pressure (10-15
psi (69-104 kPa)) and cure for 120 minutes at ambient temperature. Cure for
120 minutes more at 150° - 170°F (65.4° - 76.6°C) or seven days at ambient
temperature.

(p) Remove the grease-proof paper from the translating cowl skin.

(q) Examine the doubler for unbonded areas.

1 Make a visual inspection to look for unbonded areas.

2 Use a 0.5-1.0 oz (14-28 g) aluminum mallet. Lightly hit around the

doubler area to find unbonded areas.

NOTE: If you hear a solid “click” sound, the area is fully bonded. If you
hear a hollow sound, the area is unbonded.

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(r) Make the CRES repair doubler (17-7 PH, 0.020 in. [0.51 mm] thick) 2.00-2.50
in. (50.8-63.5 mm) larger than the damage opening. Make an overlap of 1.00-
1.25 in. (25.4-31.8 mm) around the opening of the doubler. Make the doubler
contour align with the translating cowl contour when finger pressure is applied.

(s) Cut a plug of honeycomb core material (C10-008) to fit the hole, with 0.05-0.10
in. (1.3-2.5 mm) interference around the plug. Align the plug with the outer skin
surface around the damaged area.

(t) Put a clean piece of tape (C10-040) (approximately 12.0 X 18.0 in. (304.8 X
457.2 mm) on grease-proof paper (C10-009), or mylar film, and attach to a
work surface.

WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA
OPEN TO THE AIR. WEAR CLEAN NYLON FILM OR
POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN YOU MIX
OR APPLY THE ADHESIVE.

CAUTION: STEPS (R), (S), AND (T) MUST BE DONE WITH A MINIMUM TIME
DELAY SINCE THE ADHESIVE WILL SET UP IN APPROXIMATELY 5
MINUTES AT 77°F (25°C). HAVE ALL MATERIALS PREPARED
PRIOR TO STARTING THESE STEPS SO THAT THE ADHESIVE IN
THE HOLE WILL NOT SET UP BEFORE INSTALLING THE
HONEYCOMB PLUG.

R (u) Prepare a quantity of epoxy adhesive (C01-155) to apply to the bottom of the
hole in the translating cowl, bottom of the plug, and the adjacent walls of the
parent honeycomb and plug. The mixing proportion of adhesive is 1:1 by
weight or volume.

R 1 Mix by weight, 100 parts resin A with 17 parts catalyst B.

R 2 Mix until you can see no streaks of the two components.

R NOTE: The pot life of a 3.53 oz (100 g) batch of mixed epoxy is

R approximately 60 minutes.

(v) Use an acid brush, or equivalent, and apply a large quantity to the bottom of
the hole with the mixed epoxy adhesive in a crisscross pattern. Use a brush to
apply the epoxy adhesive up the side walls of parent honeycomb.

REPAIR 002
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(w) Apply a thick layer of mixed epoxy adhesive on the grease-proof paper. Put
epoxy adhesive on an area a little larger than the Nomex plug.

(x) Push the plug into the epoxy adhesive on the paper and move the plug back
and forth and in a circular movement to pick up the adhesive on the bottom of
the cell walls.

(y) Use an acid brush, or equivalent, and apply to the outside walls of the plug with
epoxy adhesive.

(z) Push the plug into the hole, with the epoxy adhesive charged cell ends, against
the bottom of the hole. Hold the plug tightly in the hole until the adhesive sets
up.

R (aa) Cure the adhesive for 16 hours at a minimum ambient temperature of

R 70°F (21°C), or cure for a minimum of two hours at ambient temperature,
R followed by 60 minutes at 140°-160°F (60°-71°C).

R (ab) While the epoxy adhesive sets up, remove unwanted epoxy adhesive around
the plug. Align the plug with the outer skin surface at the edge of the damaged
area.

R (ac) It is permitted to lightly sand the core plug surface, after the epoxy adhesive
has cured, to make a smooth aligned surface with the undamaged outer skin.

WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE

AIRBORNE PARTICLES THAT CAN GO INTO YOUR EYES OR GO
THROUGH YOUR SKIN. DO NOT USE MORE THAN 30 PSIG (207
KPA) PRESSURE. WEAR GOGGLES. DO NOT POINT
COMPRESSED AIR IN THE DIRECTION OF YOUR SKIN.

R (ad) Use low pressure, clean, dry, filtered air and a vacuum to remove dust
particles.

REPAIR 002
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683L SERIES

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT

ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
USE THE FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT
BREATHE THE FUMES. IF YOU GET THE SOLVENT ON YOUR
SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET
MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

(ae) Clean the repair area with a clean, lint-free cotton cloth made moist with solvent
R (C04-003 or C04-035). Immediately dry the surface with a dry, clean, lint-free
cotton cloth before the solvent dries.

R (af) Cut an opening in the grease-proof paper (C10-009 or equivalent) around the
repair area. Make the opening the same shape as the sanded area and at
least 0.25 in. (6.4 mm) larger. Put Teflon tape (C10-040) down the edges of
the opening. Use tape on the outer edges of the paper to hold in position and
out of the way.

R (ag) Use the doubler as a pattern and cut a piece of fabric netting (C01-126 or C10-
R 247) to be used to hold the epoxy adhesive.

WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE

MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA
OPEN TO THE AIR. WEAR CLEAN NYLON FILM OR
POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN YOU MIX
OR APPLY THE ADHESIVE.

R (ah) Do the steps that follow to prepare the epoxy adhesive (C01-155). Use a clean
metal or uncoated paper container:

1 Mix by weight, 100 parts resin A with 17 parts catalyst B.

2 Mix until you can see no streaks of the two components.

NOTE: The pot life of a 3.53 oz (100 g) batch of mixed epoxy

adhesive is approximately 60 minutes.

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R (ai) Do the steps that follow to apply the epoxy adhesive and piece of netting.

1 Use a stiff bristle brush and apply a thin, equal layer of epoxy adhesive
to the doubler.

2 Put the netting in the wet epoxy adhesive and put on the doubler. Push
the netting into the epoxy adhesive with a tongue depressor, or
equivalent, until it is soaked.

3 Make wrinkles in the netting smooth and apply a second thin, equal
layer of epoxy adhesive on the netting.

R (aj) Put the doubler on the repair area. Make the doubler overlap the cutout equally
all around. Refer to figure 604. Examine the repair area for unwanted epoxy
adhesive. Remove unwanted epoxy adhesive with a tongue depressor.

R (ak) Apply partial of vacuum pressure (15-20 in. Hg) or mechanical pressure (10-15
psi (69-104 kPa)) and cure for 120 minutes at ambient temperature. Cure for
120 minutes more at 150° - 170°F (65.4° - 76.6°C) or seven days at ambient
temperature.

R (al) Remove the grease-proof paper from the translating cowl skin.

R (am) Examine the doubler for unbonded areas.

R (an) Use (C01-115) sealing compound to seal around the outer surface of the
doubler and make the skin surface smooth.

R (ao) Cure for 5 hours at 110° - 130°F (43.4° - 54.6° C).

R (ap) Apply surface protective coatings. Refer to paragraph 5.A. (8).

(7) Make the stainless steel repair doubler.

(a) Use a 17-7 PH CRES sheet 0.018-0.022 in. (0.46-0.56 mm) thick condition
TH1050 (MIL-S-23043) to make the doubler. Make the doubler in the correct
shape to make a good fit.

REPAIR 002
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WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT

ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
USE THE FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT
BREATHE THE FUMES. IF YOU GET THE SOLVENT ON YOUR
SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET
MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

(b) Clean the stainless steel doublers with a clean, lint-free, cotton cloth made
R moist with solvent (C04-003 or C04-035). Immediately dry the surface with a
dry, clean, lint-free cotton cloth before the solvent dries.

NOTE: Wear clean white gloves (C10-139) when you touch the doublers.

(c) Use abrasive paper (C10-141) lightly to make both sides of the doubler smooth.

WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE

AIRBORNE PARTICLES THAT CAN GO INTO YOUR EYES OR GO
THROUGH YOUR SKIN. DO NOT USE MORE THAN 30 PSIG (207
KPA) PRESSURE. WEAR GOGGLES. DO NOT POINT
COMPRESSED AIR IN THE DIRECTION OF YOUR SKIN.

(d) Use low pressure, clean, dry, filtered air and a vacuum to remove dust
particles.

(e) Clean the doubler, refer to step (b). Continue to clean until residue from the
surface no longer shows on the clean cloths.

WARNING: ALWAYS WEAR PROTECTIVE GLOVES (C10-140) WHEN YOU

WORK WITH PASA-JELL.

(f) Apply Pasa-Jell 101 (C04-280) to the surfaces. Apply as necessary during the
exposure period before the Pasa-Jell dries on the surface. After 8-10 minutes,
use a sponge and water to remove the Pasa-Jell. Do not rub the surface.

(g) Do step (f) again. Flush fully with tap water or deionized water until the
surfaces can go through an acid-free test satisfactory. Make sure you follow
chromate disposal provisions when you discard the rinse water.

NOTE: Touch the surface being tested with moist blue or neutral litmus
paper. If the paper turns pink, this shows that there is acid on the
surface, and the surface fails the test. If the litmus paper does not
change color, the surface passes the test.

REPAIR 002
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(h) Make sure the surface is water break-free. A water break-free surface is one
that can keep a continuous water film on vertical surfaces for at least 15
seconds. If the guide does not have a water break-free surface, do steps (f)
and (g) again.

WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE

AIRBORNE PARTICLES THAT CAN GO INTO YOUR EYES OR GO
THROUGH YOUR SKIN. DO NOT USE MORE THAN 30 PSIG (207
KPA) PRESSURE. WEAR GOGGLES. DO NOT POINT
COMPRESSED AIR IN THE DIRECTION OF YOUR SKIN.

(i) Blow dry the area with compressed dry air.

(j) Put the doublers in a polyethylene bag until you apply the primer. This protects
the surfaces of the doublers from contamination. Apply primer within 16 hours
after you clean the doublers.

(k) Get the primer (C03-007) from cold storage and allow 2 hours for the primer to
become warm at ambient temperature before opening.

WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE

SURE YOU USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW.
MAKE SURE YOU DO NOT BREATHE THE FUMES. DO NOT GET
THE PRIMER ON YOUR SKIN OR IN YOUR EYES OR MOUTH.
MAKE SURE YOU USE GLOVES AND CLOTHING TO PROTECT
YOURSELF.

(l) Apply the primer to the doublers. Shake the primer before and during spray
applications.

NOTE: A separate 4.0 in. (101.6 mm) square panel should be sprayed
along with the guide and cured to measure the cured film thickness
of the primer.

(m) Let the primer cure at ambient temperature for 30 minutes minimum. Cure the
primer at 240°-260°F (116°-127°C) for one hour in 24 hours or less after you
apply it. Make sure the thickness of the cured primer is 0.0002-0.0004 in.
(0.0051-0.0102 mm).

(n) After the primer is cured, seal the doubler in a polyethylene bag. Keep the
doubler in the bag until you are ready to bond.

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(8) Apply the Surface Protective Layer.

(a) Use abrasive pads (C10-010) lightly on the outer surface and on the translating
cowl painted surface. Make the surfaces rough in an area approximately 1.0 in.
(25.4 mm) wide around the repair area. Use abrasive pads (C10-010) to make
the surface rough only as necessary to remove the shine and remove loose
oxidized paint if present.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT

ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
USE THE FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT
BREATHE THE FUMES. IF YOU GET THE SOLVENT ON YOUR
SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET
MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

(b) Clean the repair area with a clean, lint-free cotton cloth made moist with solvent
R (C04-003 or C04-035). Immediately dry the surface with a dry, clean, lint-free
cotton cloth before the solvent dries.

WARNING: THIS PAINT IS POISONOUS AND GIVES OFF FUMES. MAKE SURE
YOU USE THE PAINT IN AN AREA WITH GOOD AIR FLOW. MAKE
SURE YOU DO NOT BREATHE THE FUMES. DO NOT GET THE
PAINT ON YOUR SKIN OR IN YOUR EYES OR MOUTH. MAKE
SURE YOU USE GLOVES AND CLOTHING TO PROTECT
YOURSELF.

(c) Prepare the epoxy paint (C03-056) for the spray procedure.

(d) Pour the paint into the spray cup of the spray gun. Adjust the spray gun to
spray the paint. Use higher air pressure for a thicker paint mixture.

WARNING: USE A BREATHING MASK SO YOU WILL NOT BREATHE THE

PAINT.

(e) Apply the first thin layer thoroughly to the prepared area (repair area plus 1.0
in. (25.4 mm) edge). Overspray is permitted.

(f) Let the solvents flash off for 20-30 minutes.

(g) Shake the mixture in the paint cup.

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WARNING: USE A BREATHING MASK SO YOU WILL NOT BREATHE THE

PAINT.

(h) Apply a second wet layer to give a final dry layer of approximately 0.002 in.
(0.08 mm) thickness.

NOTE: Cure the paint to a tack-free condition in four hours at ambient

temperature. Protect the surface from contamination by airborne
dust.

NOTE: A full cure at ambient temperature will occur after seven days, or
let the solvents flash off for one hour followed by hot air application
for two hours at 150°F (66°C). Protect the surface from
contamination by airborne dust.

REPAIR 002
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FAN REVERSER TRANSLATING COWL - REPAIR

1. Repair of the Filler Material Joint.

A. This procedure gives the instructions for the repair of the translating cowl external finish. This
includes removal of the filler material at the inner and outer bondment transition, and the
R application of filler material and epoxy primer.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment.

Description Manufacturer
R
Grinder, Right Angle, Rotor Tools
Air Driven, M1122SA-150 Cleveland, OH

Orbital Sander Local purchase

R
B. Consumable Materials.

Code No. Description Use

C01-174 Filler Material, EA9395 Fill the damaged area

R
C03-063 Epoxy Primer, Green Primer for the repair area

C04-001 Solvent, Methyl-Ethyl-Ketone Clean the repair area

(MEK) Fed. Spec, TT-M-261

C04-003 Solvent, Acetone Clean the repair area

C04-035 Solvent, Isopropyl Alcohol Clean the repair area

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Code No. Description Use

C10-010 Scotch Brite Pad, No. 7447 Surface preparation

C10-140 Gloves, Nylon Film/Polyethylene, Mix and apply the

Disposable filler material

C10-182 Cloths, Cleaning Clean the repair area

--- Abrasive Paper, Aluminum Surface preparation

Oxide, Wet/Dry, 320 Grit

--- Abrasive Paper, Aluminum Surface preparation

Oxide, Wet/Dry, 100-400 Grit

--- Tape, Masking, 1.00 inch Protect the adjacent area

(25.4mm) Wide during filler application

--- Squeegee, Plastic or Rubber Apply the filler material

R
C. Expendable Parts. None required.

D. SPD Identification. None required.

E. Referenced Procedures. None required.

3. Dimensional Information. None required.

4. Setup Information. None required.

5. Procedure.

A. Remove the paint and the primer.

WARNING: THIS PROCESS GIVES OFF AIRBORNE PARTICLES THAT ARE

POISONOUS. PUT ON PROTECTIVE CLOTHING, GOGGLES, AND A
FACE MASK, AND USE A RESPIRATOR. MAKE SURE YOU DO NOT
BREATHE IN THE DUST PARTICLES.

CAUTION: MAKE SURE THAT YOU DO NOT DAMAGE THE TRANSLATING COWL
COMPOSITE STRUCTURE WHEN YOU REMOVE THE PAINT.

(1) If the finish is cracked, crazed, or damaged over the mateline area, use 100 grit
abrasive paper and an orbital sander to remove the paint and primer from the
translating cowl over the filler material joint and up to 1.00 inch (25.4 mm) forward of
the ASP fasteners.

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(2) If the finish is cracked, crazed, or damaged past the mateline area, use 100 grit
abrasive paper and an orbital sander to remove the paint and primer from the
translating cowl external surface down to where there is no damage and you can get an
equal surface transition.

(3) Remove the filler material from the joint between the inner and outer bondments.

CAUTION: THE JOINT BETWEEN THE INNER AND OUTER BONDMENTS CAN
BE DIFFERENT BASED ON THE AMOUNT OF FILLER USED TO
BLEND THE CONTOUR. THE FILLER BAND WIDTH CAN RANGE
FROM 0.75 TO 8.00 INCHES (19.1 TO 203.2 MM) ON THE
BONDMENTS. BE CAREFUL NOT TO DAMAGE THE BONDMENTS
WHEN YOU REMOVE THE FILLER MATERIAL.

(a) Use a punch to crack the filler over the fastener heads, and then use a router
bit attached to a right angle grinder to remove the filler material remaining in the
countersunk holes.

(b) Use a plastic hammer with a fiber tool and/or a wood chisel to remove the filler
material in small pieces from the bondment joint.

(c) Use 100 grit abrasive paper or Scotch Brite pads (C10-010) with an orbital
sander to remove the filler material joint down to the translating cowl surface.

(d) Use 320 grit aluminum oxide abrasive paper to lightly hand sand the repair
area. Include the aft edge of the outer bondment.

(4) Grind a 0.020-0.060 inch (0.6-1.5 mm) x 45° chamfer on the outer bondment aft edge to
make point A. See figure 601.

(5) Remove the filler material from around the beavertail trailing edge fairing at the upper
and lower ends of the translating cowls.

WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE. USE
GOGGLES. DO NOT POINT COMPRESSED AIR IN THE DIRECTION OF
YOUR SKIN.

(6) Use low pressure, clean, dry filtered shop air to remove dust particles and unwanted
material. Vacuum as necessary.

R REPAIR 003
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R MR60064-00-A
Filler Material Line Definition
Figure 601

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WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

(7) Use a clean cloth (C10-182) moist with solvent (C04-001, C04-003, or C04-035) to
clean the repair area. Use a clean, dry cloth to remove the solvent before it dries.
Clean the surface until a clean, dry cloth stays clean.

(8) Examine the outer surface of the translating cowl.

(a) Look for damage to the translating cowl outer surface.

(b) Make sure there are no cracked or crazed filler or finishes on the translating
cowl outer surface.

B. Apply the filler material. See figure 601.

(1) Apply 1.00 inch (25.4 mm) wide masking tape on the aft edge of the outer bondment at
point A. Cut the tape as necessary so that you can see the countersunk holes.

(2) Put a straight edge across the joint line between the forward and aft bondments. The
point where the straight edge touches the aft bondment is point T. The area between
point A and point T defines the forward and aft edges of the area that needs filler
material. The line made by the straight edge (between points A and T) defines the
external contour of the filler material. See figure 601.

(3) Apply 1.00 inch (25.4 mm) wide masking tape from point T aft.

WARNING: THIS MATERIAL IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR

EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. USE
CLEAN NYLON FILM OR POLYETHYLENE GLOVES (C10-140) WHEN YOU
MIX OR APPLY THE FILLER MATERIAL.

(4) Mix the filler material (C01-174) by weight, 100 parts resin to 17 parts catalyst. Mix fully
until you can see no streaks of the two components.

(5) Use a squeegee to apply the filler material mixture between the masking tape lines.

(6) Make sure that the applied filler material is free of pin holes and air bubbles. Make
sure it has a smooth continuous surface, and follows the contour between point A and
point T.

R REPAIR 003
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(7) Remove the masking tape.

(8) Air cure the filler material for 24 hours at ambient temperature, or cure for 3 hours at
ambient temperature, followed by 2 hours at 150°-170°F (66°-77°C).

(9) Use 320 grit aluminum oxide abrasive paper to keep the filler material within the
smoothness and contour requirements. See figure 601.

WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE. USE
GOGGLES. DO NOT POINT COMPRESSED AIR IN THE DIRECTION OF
YOUR SKIN.

(10) Use low pressure, clean, dry filtered shop air to remove dust particles and unwanted
material. Vacuum as necessary.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

(11) Use a clean cloth (C10-182) moist with solvent (C04-001, C04-003, or C04-035) to
clean the repair area. Use a clean, dry cloth to remove the solvent before it dries.
Clean the surface until a clean, dry cloth stays clean.

(12) Let the repair area dry for 30 minutes at ambient temperature.

(13) Apply a second thin layer of filler material (C01-174). Refer to steps 5.B.(4) through
5.B.(12).
R
(14) Make all of the filled areas smooth. Use 320-400 grit aluminum oxide abrasive paper,
an orbital sander or a styrofoam sanding block, and clean tap water.

(a) Use the abrasive paper only as necessary to get the correct contour. Make
frequent checks with a straight edge between point A and point T to make sure
of the contour.

(b) Use a Scotch Brite pad (C10-010) to abrade a band 1.0 inch (25.4 mm) wide
around the repair area, only as necessary to dull the surface shine and remove
loose, oxidized paint.

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WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE. USE
GOGGLES. DO NOT POINT COMPRESSED AIR IN THE DIRECTION OF
YOUR SKIN.

(15) Use low pressure, clean, dry filtered shop air to remove dust particles and unwanted
material. Vacuum as necessary.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

(16) Use a clean cloth (C10-182) moist with solvent (C04-001, C04-003, or C04-035) to
clean the repair area. Use a clean, dry cloth to remove the solvent before it dries.
Clean the surface until a clean, dry cloth stays clean.

C. Apply the green epoxy primer. See figures 602 and 603.

WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
AND CLOTHING TO PROTECT YOURSELF.

(1) Shake the epoxy primer (C03-063) in a paint shaker. Mix the primer base and the
catalyst in a one-to-one ratio.

(2) Let the mixture set 30 minutes before you use it.

NOTE: The pot life of the mixture is eight hours maximum.

(3) Mix the primer mixture fully. Use a DeVilbiss spray gun type MBC-510-EX and Type
"A" cup (or equivalent) to apply the primer to the external surface of the translating
cowl. Include the beavertail trailing edge fairing. Apply the primer in one or two cross
layers.

(4) The completed dry film thickness of the primer must be 0.0006-0.0018 inch
(0.015-0.046 mm).

(5) Cure the primer at ambient temperature for 3 hours or cure at ambient temperature for
30 minutes, followed by 1 hour at 130°-150°F (54°-66°C).

R REPAIR 003
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R MM50018-02-A
R Aft Joint Filler and Primer
Figure 602

REPAIR 003
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MR60065-00-A
Beavertail Trailing Edge Fairing
Figure 603

R REPAIR 003
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(6) Under good lighting conditions, examine the green epoxy primer surface for equal
coverage, discrepancies, and smoothness of the paint film. If the primed surface is
unacceptable, wet-sand the layer of primer, examine for a water break-free surface,
and apply a second layer of the primer. Refer to steps 5.B.(16) through 5.C.(6).

(7) Wet-sand the layer of primer, examine for a water break-free surface, and apply a
second layer of the primer. Refer to steps 5.B.(16) through 5.C.(6).

(8) Cure 7 days at ambient temperature, or 1 hour at ambient temperature followed by

2 hours at 130°-150°F (54°-66°C).

(9) Use 320-400 grit aluminum oxide abrasive paper lightly with an orbital sander to give
the surface of the repair area a smooth, dull finish.

WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE. USE
GOGGLES. DO NOT POINT COMPRESSED AIR IN THE DIRECTION OF
YOUR SKIN.

(10) Use low pressure, clean, dry filtered shop air to remove dust particles and unwanted
material. Vacuum as necessary.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

(11) Use a clean cloth (C10-182) moist with solvent (C04-001, C04-003, or C04-035) to
clean the repair area. Use a clean, dry cloth to remove the solvent before it dries.
Clean the surface until a clean, dry cloth stays clean.

(12) Let the repair area dry for 15 minutes at ambient temperature.
R

REPAIR 003
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FAN REVERSER TRANSCOWL - REPAIR

1. Remove and Replace the Blocker Door Hinge Bearing.

A. This procedure gives the instructions for the replacement of the spherical bearing in the
translating cowl blocker door hinge assembly.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment.

Description Manufacturer

Roller Staking Tool, Rexnord Corporation

Rexnord-Shafer RST2203, Bearing Division
RST2385, or equivalent 2400 Curtiss Street
Downers Grove, IL 60515
Telephone (708) 969-1770
Fax (708) 969-1612

Arbor Press Local purchase

Drill Press Local purchase

B. Consumable Materials.

Code Description Use

C03-005 Primer, Epoxy Resin (Spray Type), Bearing installation

R Finch 463-12-8

C03-064 Conversion Coating, Chromated, Protect the surface

Iridite 14-2

C04-001 Solvent, Methyl-Ethyl-Ketone Clean the repair area

(MEK) Fed. Spec TT-M-261

C04-003 Solvent, Acetone Clean the repair area

(Fed. Spec. 0-A51)

REPAIR 006
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Code Description Use

R C04-035 Isopropyl Alcohol Clean the repair area

C04-222 Surfactant, APR2 Agent Use with C03-064

C10-182 Cloths, Cleaning Clean the repair area

C. Expendable Parts. None required.

D. SPD Identification.

SPD Description

9352M62P06 Oversize bearing 78-32-31-05-060B

9352M62P07 Oversize bearing 78-32-31-05-060C

GB520GC2 Standard size bearing 78-32-31-05-060

E. Referenced Procedures. None.

3. Dimensional Information. See figure 601.

4. Setup Information. None required.

5. Procedure.

A. Do the steps that follow to remove a worn or damaged bearing from the blocker door hinge
assembly.

CAUTION: BE CAREFUL NOT TO DAMAGE THE INSIDE DIAMETER OF THE HINGE WHEN
YOU REMOVE THE BEARING.

B. Grind a groove approximately 80% through the swaged lip of the bearing.

C. Use a press to remove the bearing from the hinge assembly.

D. Machine the hole diameter in the hinge. Refer to figure 601.

(1) If hole diameter C is less than 0.5940 inch (15.088 mm), hone the hole to remove all
scoring or non-uniformity from the hole to a diameter of 0.5935- 0.5940 inch (13.805-
15.088 mm). You can install a standard bearing. Refer to paragraph 5.E.

NOTE: If the diameter of hole C is more than 0.5940 inch (15.088 mm), it will be
necessary to use an oversize bearing.

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(2) If the diameter of hole C is more than 0.5940 inch (15.088 mm), do the steps that
follow:

(a) Ream the worn hole to the first oversize diameter for hole C. Refer to the
dimensional information in figure 601. Make sure the hole has a cylindrical
shape and a constant diameter. You must remove all evidence of wear from
the hole.

(b) If necessary, ream the hole to the next oversize diameter for hole C. Refer to
the dimensional information in figure 601. Make sure the hole has a cylindrical
shape and a constant diameter. You must remove all evidence of wear from
the hole.

(c) Make a record of the size of the hole.

(d) If the diameter of hole C does not clean up at 0.6140 inch (15.596 mm), you
must replace the hinge.

(e) Increase the diameters of features A, B, and D as applicable for the diameter of
hole C. Refer to figure 601.

(f) Remove all burrs, and break sharp edges to 0.005-0.015 inch (0.13-0.38 mm).

E. Prepare the hinge and the bearing.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

R (1) Use a clean cloth (C10-182) moist with solvent (C04-001, C04-003 or C04-035) to
clean the hinge. Use a clean, dry cloth to remove the solvent before it dries.

WARNING: DO NOT LET THE IRIDITE SOLUTION DRY IN THE BRUSH, CLOTH, OR
SPONGE BECAUSE SPONTANEOUS COMBUSTION CAN OCCUR. FULLY
CLEAN THE ITEMS IN WATER, OR WRING OUT AS MUCH SOLUTION AS
POSSIBLE AND STORE IN A FIREPROOF CONTAINER.

(2) Mix 3.0 oz/gallon (22.5 g/liter) of Iridite (C03-064) and 1.25 fl oz/gallon (10 cc/liter) of
surfactant (C04-222).

(3) Use a nylon brush, cellulose sponge, or clean cloth (C10-182) to apply the Iridite
solution to the hinge hole diameter. Keep the surface wet until you see a small color
change (usually 2-3 minutes).

REPAIR 006
PAGE 603
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R MM50060-01-A
Blocker Door Hinge Bearing Replacement
Figure 601 (Sheet 1)

REPAIR 006
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78-32-31 JUN 01/02
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R MM50061-02-A
Blocker Door Hinge Bearing Replacement
Figure 601 (Sheet 2)

REPAIR 006
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R (4) Flush the hinge with deionized water.

R (5) Air dry for 8 hours or oven dry at a maximum temperature of 135°F (57°C) for 1 hour or
R until dry.

R F. Install a replacement hinge bearing.

R (1) Get a replacement bearing. Use the applicable hole diameter from paragraph 5.D. to
R select the replacement bearing.

R (a) If the hole diameter is 0.5395-0.5940 inch (13.805-13.945 mm) install bearing
R 78-32-31-05-060.

R (b) If the hole diameter is 0.6035-0.6040 inch (15.329-15.341 mm) install bearing
R 78-32-31-05-060B.

R (c) If the hole diameter is 0.6135-0.6140 inch (15.583-15.596 mm) install bearing
R 78-32-31-05-060C.

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
R USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
R SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
R AND CLOTHING TO PROTECT YOURSELF.

R (2) Apply a layer of epoxy resin primer (C03-005) to the outer diameter of the replacement
R bearing.

R (3) Press fit the replacement bearing into the hole in the hinge with the ball installed. Make
R sure that the bearing is straight and not canted to the hinge bore during insertion. Turn
R the bearing so that the notch in the outer race is in the position shown in figure 601.

R G. Roll stake the replacement bearing in position.

R (1) Hold the bearing outer race in position on an anvil.

R (2) Install a roller staking tool into a drill press. Refer to NAS 0331, Method 200.

R (3) Put the roller staking tool on the bearing and align the pilot with the bearing inner race.
R Refer to figure 602.

R CAUTION: DO NOT LET THE BEARING OUTER RACE LIP BECOME WORK
R HARDENED DURING THE STAKING OPERATION.

R (4) Operate the drill press at a low speed (6-20 RPM) to stake the bearing outer race to the
R hinge.

REPAIR 006
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CF8-7246-00-C
Roller Staking Tool Use
Figure 602

REPAIR 006
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R H. Inspect the bearing installation for gaps and tool marks.

R (1) A maximum edge gap of 0.005 inch (0.13 mm) with a maximum depth of 0.007 inch
R (0.18 mm) is permitted between the swaged lip and the fitting chamfer. The edge gap
R can be more than 0.005 inch (0.13 mm) for up to 90° of the circumference. Installations
R outside of these limits can be accepted if an axial proof load is applied to the bearing
R outer race with the fitting restrained. If you apply a proof load, do the step that follows:

R (a) Use a proof load of 500 pounds (227 kg). The bearing must not shift more than
R 0.005 inch (0.13 mm) in the fitting under this axial load. Apply the proof load
R normal to the fitting on the bearing outer race surface that was swaged.

R (2) Examine the swaged outer race lip for tool gouges or fractures. Tool gouges and
R fractures are not permitted.

R (3) Examine the surface of the groove, toward the ball, for tool marks or gouges. Tool
R marks and gouges are not permitted. If there are tool marks or gouges, you must
R replace the bearing.

R (4) Make sure the installed bearings move freely. If you can move or turn the ball with your
R finger, the bearings can move freely.

R I. If necessary, touch up the epoxy resin primer (C03-005) on the swaged outer race lip.

REPAIR 006
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FAN REVERSER TRANSLATING COWL - REPAIR

1. Remove and Replace the Worn or Damaged Bumper(s) on the Translating Cowl.

A. This procedure gives the necessary instructions to remove and replace worn or damaged
bumper(s) on the translating cowl.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment. None required.

B. Consumable Materials.

Code No. Description Use

C03-005 Primer, Epoxy Touch up resin

C04-003 Solvent, Acetone Clean the repair area

C. Expendable Parts.

CSN Description

78-32-31-1-265 Nut

D. SPD Identification. None required.

E. Referenced Procedures. None required.

3. Dimensional Information. None required.

4. Setup Information. None required.

REPAIR 008
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5. Procedure.

A. Remove the worn/damaged bumper(s) (1-253, 78-32-31) from the translating cowl as follows:

(1) Manually open the translating cowl.

(a) Pull the brake handle out, away from the center drive unit (CDU), until a flat is
felt, to release the CDU brake. The brake handle will be at approximately 60
degrees.

(b) Install a 0.25 inch (6.4 mm) square drive handle into the external drive pod.
Turn the square drive handle to deploy the translating cowl until you have
sufficient access to the bumpers.

(2) Remove the bolts (1-255, 78-32-31), washers (1-260, 78-32-31) and nuts (1-265, 78-
32-31) that attach the worn/damaged bumper(s) to the translating cowl. If the bolts and
washers are not damaged, keep them to attach the new bumper(s). Discard the nuts.

(3) Remove and discard the worn/damaged bumper(s) from the translating cowl.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

B. Clean the area(s) where the bumper(s) were removed with solvent (C04-003).

WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU USE
THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU DO NOT
BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR SKIN OR INTO
YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES AND CLOTHING TO
PROTECT YOURSELF.

C. Apply epoxy primer (C03-005) on any bare metal where the bumper(s) were removed.

D. Attach the new bumper(s) (1-253, 78-32-31) to the translating cowl with three bolts (1-255, 78-
R 32-31), three washers (1-260, 78-32-31) and three new nuts (1-265, 78-32-31). Tighten the
R nuts to 24-27 lb in. (3.7-4.2 N·m) of torque. See figure 601.

E. Manually close the translating cowl.

(1) Install a 0.25 inch (6.4 mm) square drive handle into the external drive pod. Rotate the
square drive handle until the translating cowl is fully closed.

(2) Push the CDU brake handle in, toward the CDU, until it is fully against the retaining
bracket, to engage the CDU brake.

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CF8-7313-00-C
Translating Cowl Bumper Assembly
Figure 601

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FAN REVERSER TRANSLATING COWL - REPAIR

1. Locally Manufactured Bushings.

A. This procedure provides instructions to locally make bushings and to install the bushings into
the cowl guide.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment.

Description Manufacturer

Furnace capable of heating to 1100°F Local purchase

(593°C) and will support a vacuum,
dry hydrogen, inert gas, air or neutral
atmosphere

B. Consumable Materials.

Code No. Description Use

C02-005 Lubricant, Solid Dry Film, Lubricate the bushings

MIL-L-81329

C03-005 Primer, Epoxy Resin, Coat the bushings

Spray Type 463-12-8

C04-094 Chromic Acid Anodize the machined surfaces

--- Bar Stock, Stainless Steel, Make the bushings

AMS 5604, 17-4 PH SST

C. Expendable Parts. None required.

D. SPD Identification. None required.

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E. Referenced Procedures.

H1025

MIL-A-8625, Type I, Class I

MIL-H-6875

R AMS2700E

SPM 70-32-02

3. Dimensional Information. None required.

4. Setup Information. None required.

5. Procedure.

A. Rework the cowl guide support.

(1) Put the support in a holding fixture.

(2) Find the center-line of the drill-through hole from datums A and B. Refer to figure 601.

(3) Use a drill to increase the hole size to 0.2498-0.2503 in. (6.345-6.358 mm) at two
locations.

(4) Remove all burrs and break the sharp edges 0.005-0.015 in. (0.13-0.38 mm).

(5) After you machine the part, fluorescent-penetrant-inspect the part. Refer to Standard
Practices Manual, TASK 70-32-02-230-001 (70-32-02). No cracks are permitted.

(6) Anodize all machined surfaces with chromic acid (C04-094). Refer to MIL-A-8625,
Type I, Class I.

B. Rework the guide assembly.

(1) Put the part in a holding fixture.

(2) Find the center line of the drill-through hole from datums B and C. Refer to figure 602.

NOTE: You may have to remove the Teflon wear strip to accurately locate off of
datum C. Replace the wear strip when you have completed this repair.

(3) Increase the hole size to 0.2498-0.2503 in. (6.345-6.358 mm) at two locations with a
drill.

(4) Remove all burrs and break the sharp edges 0.005-0.015 in. (0.13-0.38 mm).

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MM50015-00-A
Cowl Guide Support
Figure 601

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1121960-00-A
Cowl Guide Assembly
Figure 602

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(5) After you machine the part, fluorescent-penetrant-inspect the part. Refer to Standard
Practices Manual, TASK 70-32-02-230-001 (70-32-02). No cracks are permitted.

(6) Anodize all machined surfaces with chromic acid (C04-094). Refer to MIL-A-8625,
Type I, Class I.

C. Locally make the press-fit bushings.

(1) Use 0.375 in. (9.53 mm) stainless steel bar stock (AMS 5604, 17-4 PH SST) and make
bushings A and B. Refer to figure 603.

NOTE: One bushing (A) and two bushings (B) are necessary.

(2) Heat treat the bushings to H1025. Refer to MIL-H-6875. Passivate. Refer to
R AMS2700E.

(3) Apply a layer of solid film lubricant (C02-005) to the inner surface of the bushings.

D. Press-fit the bushings into the guide assembly.

(1) Put the guide assembly in a holding fixture. You must have access to the entire length
of the drill-through holes.

WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
AND CLOTHING TO PROTECT YOURSELF.

(2) Apply a layer of epoxy resin primer (C03-005) to the outer surface of the bushings.

(3) Press the bushings into the drill-through holes. Make sure that the ends of the
bushings are not over the edges of the guide assembly.

(4) Clean the surfaces to remove unwanted primer.

(5) Remove all burrs caused by the pressing operation.

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MM50019-00-C
Locally Made Bushings
Figure 603

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E. Press-fit the bushing into the cowl guide assembly.

(1) Put the guide assembly in a holding fixture. You must have access to the entire length
of the drill-through hole.

WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
AND CLOTHING TO PROTECT YOURSELF.

(2) Apply a layer of epoxy resin primer (C03-005) to the outer surface of the bushing.

(3) Press the bushing into the drill-through holes. Make sure that the ends of the bushing
are not over the edges of the guide assembly.

(4) Clean the surfaces to remove unwanted primer.

(5) Remove all burrs caused by the pressing operation.

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FAN REVERSER TRANSLATING COWL - REPAIR

1. Translating Cowl Inner Flow Path Fiberglass Closure Ply Repair.

A. This procedure gives the instructions for the repair of a delaminated and/or missing fiberglass
ply on the translating cowl inner flow path around the acoustic screen.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

(3) Locally Manufactured Tools. None required.

(4) Equipment.

Description Manufacturer

Heating blanket, Local purchase

Capable of heating part to 250°F (121.1°C)

Heat lamp Local purchase

B. Consumable Materials.

Code No. Description Use

C01-106 Adhesive, Epoxy Resin, Bond the glass fabric

EA 956

R C01-108 Fibers, Milled Glass Bond the glass fabric

C01-147 Adhesive, Liquid, Structural, Bond the glass fabric

EA 9396 A/B

C04-001 Solvent, Methyl-Ethyl- Clean the repair area

Ketone (MEK)

C10-003 Fabric, Glass, SAE-AMS-, Alternative repair material

C-9084, Type VIII or VIIIA to C10-122

C10-039 Tape, Mylar Protect the repair area

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Code No. Description Use

C10-108 Brush, Natural Bristle, Disposable Apply the adhesive

C10-122 Fabric, Glass, AMS3824A, Repair material

Style 120, Finish 538

C10-134 Cloth, Breather/Bleeder Vacuum bagging

C10-137 Film, Vacuum Bag Vacuum bagging

C10-140 Gloves, Nylon Film/Polyethylene, Mix and apply the adhesive

Disposable

C10-141 Abrasive Paper, 120-180 Grit Prepare the repair area

C10-182 Cloths, Cleaning Clean the repair area

--- Release Cloth Vacuum bagging

--- Separator Film Vacuum bagging

C. Expendable Parts. None required.

D. SPD Identification. None required.

E. Referenced Procedures. None required.

3. Dimensional Information. None required.

4. Setup Information. None required.

R 5. Removal and Replacement of the Fiberglass Closure Ply. Refer to figure 601 and figure 602.

A. Do a visual inspection to find areas where the fiberglass ply is damaged or delaminated. With a
felt-tip marker, make a line around each damaged or delaminated area.

(1) It is not necessary to replace the forward fiberglass ply at station 215.8, if it is damaged
or delaminated. Make sure the screen is bonded and extends under the blocker door
fairings and spacers. Make sure the gap between the fairings/spacers and screen is
filled with sealant.

B. Do a tap test to find out if the delaminated area extends farther than the visual indication of the
damage. If it does, use the felt-tip marker to adjust the line around the damaged area.

(1) Use a 0.5-1.0 oz (14-28 g) aluminum mallet to lightly hit the surface of the closure ply.

NOTE: If you hear a solid “click” sound, there are no voids. If you hear an empty
sound, the area is delaminated.

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R MR60042-00-A
R Fiberglass Closure Ply
R Figure 601

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R MR60109-00-A
R Fiberglass Closure Ply
R Figure 602 (Sheet 1 of 5)

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R MR60110-00-A
R Fiberglass Closure Ply
R Figure 602 (Sheet 2 of 5)

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R MR60111-00-A
R Fiberglass Closure Ply
R Figure 602 (Sheet 3 of 5)

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R MR60112-00-A
R Fiberglass Closure Ply
R Figure 602 (Sheet 4 of 5)

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R MR60113-00-A
R Fiberglass Closure Ply
R Figure 602 (Sheet 5 of 5)

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R C. Use a scraper or chisel to carefully cut through the damaged or delaminated ply of fiberglass,
R for the full width of the ply. Be careful not to damage the graphite or acoustic screen below. If
R damage does occur, repair it with a repair that is applicable to the new damage. If
there are damaged areas close together, remove the damaged pieces of the closure ply in
strips, along with the undamaged strip between the damaged areas.

D. Use 180-grit aluminum oxide abrasive paper (C10-141) to carefully remove surface resin and all
remaining unwanted ply material from the areas where the fiberglass was removed. Make sure
you do not damage the graphite fibers or stainless steel mesh when you remove the resin.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID IN AN
AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF YOU GET THE
SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER.
GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED. SOLVENTS
ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

E. Clean the surface with solvent (C04-001).

(1) Use a clean cloth (C10-182) wet with solvent (C04-001) to clean the bonding surface.
Use a clean dry cloth to remove the solvent before it dries.

F. Apply Mylar tape (C10-039) to the surface adjacent to the repair area so the resin does not
bleed into the acoustic screen. This operation is very important to prevent blockage of the
acoustic screen and/or unsatisfactory appearance caused by resin bleed out.

G. Cut a piece of glass fabric (C10-122 or C10-003) to the correct size for the repair area. The
new fiberglass ply should be the same size and shape as the piece that you replace, but with
an overlap of 0.5-1.0 inch (12.7-25.4 mm) with the remaining ply.

WARNING: ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR EYES OR ON

YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. WEAR CLEAN NYLON FILM OR
POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN YOU MIX OR APPLY
THE ADHESIVE.

H. Soak a single layer of glass fabric (C10-122 or C10-003) with epoxy resin adhesive (C01-106)
or structural liquid adhesive (C01-147).

R NOTE: Choose one of the two adhesives, and use the same adhesive to do all of the repair.
R Do not use two different adhesives for different parts of this repair.

I. Put the ply between two layers of separator film (Mylar, PVC, etc.) and push out all unwanted
adhesive.

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WARNING: THIS MATERIAL/COMPOUND IS POISONOUS AND GIVES OFF FUMES. MAKE

SURE YOU USE IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
GAS. DO NOT GET ON YOUR SKIN OR INTO YOUR EYES OR MOUTH. MAKE
SURE YOU USE GLOVES AND CLOTHING TO PROTECT YOURSELF.

J. Mix epoxy resin adhesive (C01-106) or structural liquid adhesive (C01-147) with milled glass
R fibers (C01-108) to form a lightly thickened liquid. Use an acid brush (C10-108) to apply the
adhesive to all surfaces on the bondment that receive replacement fiberglass plies.

R NOTE: Make sure you use the same adhesive for this step that you used in step H.

K. Remove one layer of separator film from the fiberglass ply. Install the ply so that the other layer
of the separator film is turned up. Push the ply tightly into position. Carefully remove the
second layer of separator film.

L. Put a layer of release cloth over all the replaced fiberglass. Put a layer of breather cloth (C10-
134) over the applicable acoustic bay or bays. Apply a vacuum bag (C10-137) to the
area and apply full vacuum (20 inch Hg. min). Cure at room temperature for 2 hours followed
by 2 hours at 170°-190° F (76.7°-87.8°C).

M. Remove all bagging material. Use abrasive paper (C10-141) lightly to remove unwanted
adhesive from the repair area.

WARNING: ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR EYES OR ON

YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. WEAR CLEAN NYLON FILM OR
POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN YOU MIX OR APPLY
THE ADHESIVE.

N. Use epoxy resin adhesive (C01-106) or structural liquid adhesive (C01-147) to fill all remaining
pin holes before you apply the necessary finishes.

O. Do a visual inspection to make sure the repair area is fully bonded.

R P. Do a tap test to make sure there is no more delamination. If there is more delamination, do this
R repair again, or contact MRAS Customer Support for assistance.

(1) Use a 0.5-1.0 oz (14-28 g) aluminum mallet to lightly hit the surface of the repair area.

NOTE: If you hear a solid “click” sound, there are no voids. If you hear an empty
sound, the area is delaminated.

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R FAN REVERSER TRANSLATING COWL - REPAIR

R 1. Translating Cowl Main Air Seal Repair.

R A. This repair gives the instructions to remove and replace the translating cowl main air seal (bulb
R seal) from the translating cowl inner bondment.

R SB 78-5037 * * * (FAN REVERSER - TRANSLATING COWL P-SEALS)

R B. This repair gives the instructions to remove and replace the P-seals from the translating cowl
R inner bondment.

R END SB 78-5037

R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools. None required.

R (3) Locally Manufactured Tools. None required.

R (4) Equipment. None required.

R B. Consumable Materials.

R Code No. Description Use

R C01-073 Adhesive, Silicone Bond the seal plug material

R C03-005 Primer, Epoxy Resin Primer for bare metal surfaces

R C04-014 Alcohol, Denatured Clean the mating surfaces

R C04-035 Alcohol, Isopropyl Clean the mating surfaces

R C10-182 Cloths, Cleaning Clean the repair area

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R Pre SB 78-5037 * * * (FAN REVERSER - TRANSLATING COWL P-SEALS)

R C. Expendable Parts.

R Part. No. Description

R D52B2410-11 Bulb Seal

R D52B1400-15 Seal Plug

R End Pre SB 78-5037

R SB 78-5037 * * * (FAN REVERSER - TRANSLATING COWL P-SEALS)

R C. Expendable Parts.

R Part. No. Description

R D52B2410-13 Bulb Seal

R D52B9001-11 P-Seal, Long

R D52B9001-13 P-Seal, Short

R D52B1400-15 Seal Plug

R End SB 78-5037

R D. SPD Identification. None required.

R E. Referenced Procedures. None required.

R 3. Dimensional Information. None required.

R 4. Setup Information. None required.

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R Pre SB 78-5037 * * * (FAN REVERSER - TRANSLATING COWL P-SEALS)

R 6. Replace the Translating Cowl Main Air Seal (Bulb Seal).

R A. Remove the bulb seal.

R (1) Remove the bolts that attach the bulb seal and the seal retainers to the inner
R bondment. Keep the bolts for use at installation. See figure 601.

R CAUTION: MAKE SURE YOU DO NOT DAMAGE THE END SEAL WHEN YOU REMOVE
R THE BULB SEAL.

R (2) Use the razor blade or knife to cut the plug that connects the bulb seal to the end seal.

R (3) Remove the bulb seal and the seal retainers.

R B. Install the replacement bulb seal.

R (1) Put the bulb seal that was removed adjacent to the replacement bulb seal (D52B2410-
R 11). Align the bolt holes in the two seals.

R (2) Use a razor blade or sharp knife to cut off unwanted seal material from each end of the
R replacement bulb seal so that it is the same length as the removed bulb seal. Discard
R the removed bulb seal.

R (3) Get two new seal plugs.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (4) Use a clean lint-free cotton cloth (C10-182) made moist with solvent (C04-014 or C04-
R 035) to clean the inner bondment. Immediately wipe the surface with a dry, clean lint-
R free cloth. Do not let the solvent dry on the surface. Do this again until the inner
R bondment is clean. Let the inner bondment dry for a minimum of 15 minutes.

R (5) Use a clean lint-free cotton cloth (C10-182) made moist with solvent (C04-014 or C04-
R 035) to clean the seal plugs, the end seal, and the ends of the replacement bulb seal.
R Do this to make sure you get a good bond when you install the seal.

R (6) Put the replacement bulb seal in the inner bondment and align the bolt holes.

REPAIR 013
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MR60036-02-A
Translating Cowl Main Air Seal (Bulb Seal) Pre SB 78-5037
Figure 601

REPAIR 013
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R (7) Install the replacement bulb seal and seal retainers on the inner bondment with the
R bolts. Hand tighten the bolts.

R WARNING: SILICONE RUBBER ADHESIVE IS AN IRRITANT. DO NOT GET THE

R MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN
R TO THE AIR. DO NOT BREATHE THE FUMES.

R (8) Apply a layer of adhesive (C01-073) to each seal plug, the inner surface of each end of
R the bulb seal, and the inner surface of each end of the end seal.

R (9) Install one end of the seal plug into the mating end of the bulb seal. if necessary, cut
R the end of the bulb seal to get a butt joint. Install the other end of the seal plug into the
R mating end of the end seal. Do this at each end of the bulb seal.

R (10) Let the adhesive cure at 75° - 85 °F (17.33° - 29.44 °C) for 24 hours.

R (11) Tighten the bolts to 22 - 27 lb in. (2.49 - 3.05 N⋅m) of torque.

R END Pre SB 78-5037

R SB 78-5037 * * * (FAN REVERSER - TRANSLATING COWL P-SEALS)

R 6. Replace the Translating Cowl Main Air Seal (Bulb Seal) and P-Seals.

R A. Remove the bulb seal and the P-seals.

R NOTE: The P-seals do not extend to the two bottom or the two top holes in the inner
R bondment.

R (1) At each end of the inner bondment, remove the two screws that attach the bulb seal
R and the seal retainers to the inner bondment. Keep the screws for use at installation.
R See figure 602.

R (2) Remove the screws that attach the bulb seal, the P-seals, and the seal retainer to the
R inner bondment. Keep the screws for use at installation. See figure 602.

R CAUTION: MAKE SURE YOU DO NOT DAMAGE THE END SEAL WHEN YOU REMOVE
R THE BULB SEAL.

R (3) Use the razor blade or knife to cut the plug that connects the bulb seal to the end seal.

R (4) Remove the bulb seal, the P-seals, and the seal retainers.

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MR60035-02-A
Translating Cowl Main Air Seal (Bulb Seal) Post SB 78-5037
Figure 602

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R B. Install the replacement bulb seal and P-seals, as necessary.

R (1) Put the bulb seal that was removed adjacent to the replacement bulb seal (D52B2410-
R 13). Align the screw holes in the two seals.

R (2) Use a razor blade or sharp knife to cut off unwanted seal material from each end of the
R replacement bulb seal so that it is the same length as the removed bulb seal. Discard
R the removed bulb seal.

R (3) Get two new seal plugs.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (4) Use a clean lint-free cotton cloth (C10-182) made moist with solvent (C04-014 or C04-
R 035) to clean the inner bondment. Immediately wipe the surface with a dry, clean lint-
R free cloth. Do not let the solvent dry on the surface. Do this again until the inner
R bondment is clean. Let the inner bondment dry for a minimum of 15 minutes.

R (5) Use a clean lint-free cotton cloth (C10-182) made moist with solvent (C04-014 or C04-
R 035) to clean the seal plugs, the end seals, and the ends of the replacement bulb seal.
R Do this to make sure you get a good bond when you install the seal.

R (6) Put the replacement bulb seal in the inner bondment and align the screw holes.

R (7) At one end of the inner bondment, install the two screws that attach the bulb seal and
R the seal retainer to the inner bondment.

R NOTE: The P-seals do not extend to the two bottom or the two top holes in the inner
R bondment.

R (8) Starting from the third screw hole at the end of the inner bondment, install the screws
R that attach the bulb seal, the short P-seal (D52B9001-13), and the seal retainer on the
R inner bondment.

R NOTE: There is approximately 1.0 inch (25.4 mm) of clearance between the short P-
R seal and the adjacent long P-seal. However, the seal retainers are positioned
R against one another.

R (9) Install the screws that attach the bulb seal, the long P-seals (D52B9001-11), and the
R seal retainers on the inner bondment.

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R (10) At the opposite end of the inner bondment, install the screws that attach the bulb seal,
R the short P-seal, and the seal retainer on the end of the inner bondment.

R (11) Install the two remaining screws that attach the bulb seal and the seal retainer to the
R inner bondment.

R WARNING: SILICONE RUBBER ADHESIVE IS AN IRRITANT. DO NOT GET THE

R MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN
R TO THE AIR. DO NOT BREATHE THE FUMES.

R (12) Apply a layer of adhesive (C01-073) to each seal plug, the inner surface of each end of
R the bulb seal, and the inner surface of each end of the end seal.

R (13) Install one end of the seal plug into the mating end of the bulb seal. if necessary, cut
R the end of the bulb seal to get a butt joint. Install the other end of the seal plug into the
R mating end of the end seal. Do this at each end of the bulb seal.

R (14) Let the adhesive cure at 75° - 85 °F (17.33° - 29.44 °C) for 24 hours.

R (15) Tighten the screws to 22 - 27 lb in. (2.49 - 3.05 N⋅m) of torque.

R END SB 78-5037

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FAN REVERSER TRANSLATING COWL - REPAIR

R 1. Fan Thrust Reverser Translating Cowl Screen Replacement.

R A. The aft portion of the wire screen on the translating cowl acoustic area is subject to erosion. In
R order to prevent erosion damage of the underlying open weave skin and core it is necessary to
R replace the screen when it becomes worn. To improve erosion resistance, a stainless steel
R wire screen has been chosen for the replacement. Partial replacement is acceptable;
R however, it is recommended that only whole acoustic areas are repaired.

R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools. None required.

R (3) Locally Manufactured Tools.

R Description Figure No.

R Teflon spatula 604

R (4) Equipment.

R Description Manufacturer

R Dual action Local purchase

R (random orbital) sander

R Teflon squeegee Local purchase

R Vacuum bag fittings Local purchase

R Vacuum gage Local purchase

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B. Consumable Materials:

Code No. Description Use

C01-134 Adhesive, Sprayable, EC 3964, 3M Bond the screen

C03-059 Polyurethane Paint, Gray Glossy, Paint the area

Sikkens 643-18-82 around the screen

C03-062 Thinner, Epoxy Paint, Sikkens TL 52 Thinner for C03-059

C03-063 Primer, Epoxy (Green) 515X349 Prime the area around the
Base, 910X533-Activator, screen
PRC Desoto International, Inc.

R DELETED

C04-003 Solvent, Acetone Clean the repair area

R C04-035 Solvent, Isopropyl Alcohol Clean the repair area

C10-010 Scotch Brite Pads Make the primer rough

C10-040 Tape, Teflon, 1.0 x 0.002 inch Surface protection

C10-048 Bleeder Cloth, Osnaburg, Vacuum bag, air bleeder

6.5 oz/sq. yd. - 40 inch wide

C10-054 Gun, Heat Make the adhesive soft

C10-055 Heat Blankets, Controllers, and Cure the adhesive

Lamps

C10-119 Wire mesh, 304L, Stainless Steel Screen replacement

C10-121 Abrasive Paper, 320 Grit Make the repair area smooth

C10-130 Cloth, Glass fiber, Pre-impregnated, Seal the screen

R MXB 7740/120 or E773FR/120
R (A50TF273)

C10-131 Peel Ply, Style 52006/51789, SRB Release for glass fiber
Precision Fabrics cloth

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R Code No. Description Use

R C10-132 Film, Polymer, FEP, Perforated, Release film

R 0.001 thick, A4000P3.
R Airtech International

R C10-133 Film, Polymer, FEP, Unperforated, Release film

R 0.001 in. (0.025 mm) thick, A4000,
R Airtech International.

R C10-134 Cloth, Bleeder/Breather, Vacuum bag, air bleeder

R N10 Polyester Felt,
R Airtech International
R (Alternative to C10-048)

R C10-136 Tape, Flashbreaker, No. 855 Masking

R 0.002 in. (0.051 mm) thick. - 3M

R C10-137 Film, Vacuum Bag, Wrightlon 6400 Vacuum bag material

R Airtech International

R C10-138 Tape, Sealant, Vacuum Bag GS-213 Vacuum bag sealant

R Airtech International

R C10-140 Gloves, Film Nylon/Polyethylene, Mix and apply the

R Disposable adhesive

R C10-141 Abrasive Paper, 120-180 Grit Prepare the surface

R C10-142 Film, Polyester (Mylar) Surface protection

R 0.002-0.004 in. (0.051-0.102 mm)
R thick

R C. Expendable Parts. None required.

R D. SPD Identification. None required.

R E. Reference Data.

R 78-32-31 Repair 002

R 3. Dimensional Information. None required.

R 4. Setup Information. None required.

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5. Procedure.

A. This procedure is to replace the screen on the acoustic areas on the inside of the translating
cowl. Refer to figure 601 and figure 602. It is recommended that you do the repair on whole
acoustic areas. A whole area or part of an area can be cured at one time, depending on the
size of the heat blankets available. This repair is not applicable if the open weave skin is
significantly worn. Before you do this repair, disassemble the translating cowl from the fixed
structure, and put it in a supporting cradle with the inner surface facing up.

B. Do the steps that follow to prepare the repair area.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

(1) Clean in and around the repair area with clean, dry, lint-free, white cotton cloths moist
R with solvent (C04-0035 or C04-003). Clean until a clean area of the cloth stays clean.
Let the surface air dry for a minimum of 15 minutes.

CAUTION: MAKE SURE YOU REMOVE ALL OF THE OLD WIRE SCREEN FROM THE
AREA TO BE REPAIRED, TO PREVENT THE POSSIBILITY OF GALVANIC
CORROSION WITH THE NEW SCREEN.

CAUTION: BE CAREFUL NOT TO REMOVE THE FIBERS OF THE PERFORATED SKIN

MATERIAL WHEN YOU USE ABRASIVE PAPER.

(2) Use tweezers or needle-nose pliers carefully to remove all loose screen material from
the acoustic panel in the area to be repaired. Use a dual action (random orbital) sander
with 120 grit abrasive paper (C10-141) to remove the remaining screen.

WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE. WEAR
GOGGLES. DO NOT POINT COMPRESSED AIR IN THE DIRECTION OF
YOUR SKIN.

(3) Blow out any screen material remaining in the skin openings with clean, dry, oil free,
shop air.

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R MR60115-00-A
R Translating Cowl
R Figure 601

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R MR60091-01-A
R Inner Bondment Wire Mesh Acoustic Areas
R Figure 602

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C. Examine the skin for signs of wear or missing material. If you find areas of missing or damaged
open weave, refer to Repair 002.

D. Identify the area of screen that you will replace. Refer to figure 603. The area should be at
least 1.0 in. (25.4 mm) smaller than working area of the heat blanket . You must try to
replace the screen on each acoustic area in a maximum of three pieces. For the heat blanket
to operate at the edge of the translating cowl, the heat blanket must hang over the trailing edge.
This is permitted.

E. Prepare the surface for application of the stainless steel wire mesh screen (C10-119).

(1) Use Mylar film (C10-142) and Teflon tape (C10-040) to cover the surfaces adjacent to
the repair area.

(2) Use 120-180 grit abrasive paper (C10-141) to make the repair area lightly rough.
Include all of the area to which the screen will be bonded plus an extra 1.0 in.
(25.4 mm) all around.

(3) Cut a sufficient quantity of the wire mesh screen material (C10-119) to apply over the
perforated skin repair area. The gap between the bonded areas of the screen can be a
maximum of 0.060 in. (1.52 mm).

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

(4) Clean the repair area and the replacement wire mesh screen with a clean, dry, lint free,
R white cotton cloth moist with solvent (C04-0035 or C04-003). Clean until a clean a cloth
stays clean. Let the area dry for a minimum of 15 minutes.

WARNING: SPRAYABLE ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN

YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR.
WEAR CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES
(C10-140) WHEN YOU MIX OR APPLY THE ADHESIVE.

CAUTION: IF THE ADHESIVES HAVE BEEN STORED BELOW ROOM TEMPERATURE,

MAKE SURE THE ADHESIVE REACHES ROOM TEMPERATURE BEFORE
YOU OPEN THE CONTAINER.

(5) Let the adhesive reach room temperature. After the adhesive reaches room
temperature, fully mix the adhesive on a mechanical shaker for 5 minutes.

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R MR6011400-A
R Typical Screen Areas to be Replaced in One Cure
R Figure 603

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R (6) Shake the container while you spray a 0.0016-0.0020 in. (0.041-0.051 mm) thick layer
of sprayable adhesive, (C01-134) onto the prepared skin. Apply as many layers
as necessary to get the correct thickness. Let the surface dry for 15-20 minutes
before each subsequent layer.

R NOTE: If desired, you can increase the adhesive thickness to get adhesive “bleed-
R through” on the solid areas of the acoustic skin. Adhesive bleed-through is
R acceptable if the openings in the skin do not become blocked. Bleed-
R through is desirable because it increases the bond adhesion of the wire
R mesh.

(7) After you apply the last layer, let the surface dry for 30 minutes, then cover the sprayed
area with FEP release film (C10-133).

(8) Pre-cure the adhesive at 140°-160°F (60°-71°C) for 60 minutes with heat lamps or
heat blankets (C10-055). Use a minimum of two thermocouples, attached to the skin
next to the repair area with Teflon tape (C10-040), to monitor the temperature.

CAUTION: YOU MUST BOND THE WIRE MESH CLOTH REPLACEMENT SCREEN WITHIN 48
HOURS AFTER THE ADHESIVE PRE-CURE.

F. Apply the wire mesh as follows:

(1) Use a Teflon spatula (figure 604) to apply the screen to the open weave skin. Start at
the center and work outwards. Make sure that the screen has no wrinkles and is in full
contact with the skin. If necessary, you can use a hot air gun (C10-054) to tack the wire
mesh in position.

(2) When the screen is in full contact with the adhesive and there are no bubbles or
wrinkles, work around the edge of the screen with the Teflon spatula. Apply gentle heat
with the hot air gun (C10-054). Be careful not to apply too much heat. If you apply too
much heat, it will cure the adhesive.

CAUTION: IF AN EDGE WILL BE JOINED TO ANOTHER PIECE OF WIRE MESH AT A

SUBSEQUENT BONDING OPERATION, DO NOT APPLY THE PRE-
IMPREGNATED GLASS FIBER (PREPREG) (C10-130) UNTIL THE
ADJOINING SCREEN IS BONDED.

(3) Apply a 1.0 in. (25.4 mm) wide strip of pre-impregnated glass fiber (prepreg) (C10-130)
across the edges of the screen as shown in figure 605. Make sure that the prepreg
glass fiber is smooth and is not wrinkled or creased. Press the prepreg glass fiber
firmly into position with the Teflon spatula (figure 604).

(4) Apply Teflon tape (C10-040) or flashbreaker tape (C10-136) along the two edges of the
prepreg glass fiber to within 0.1 in. (3 mm) of the edge. Apply tape until you have
masked an area larger than the area to be covered by the vacuum bag. Refer to figure
606. If necessary, adjust the Mylar film and tape that you applied in step 5.E.(1).

(5) Cut a piece of peel ply, (C10-131), to cover an area 0.5 in. (13 mm) larger than the
glass fiber prepreg, (C10-130) and place it centrally over the wire mesh and prepreg.

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R MM50071-00-A
R Teflon Spatula
R Figure 604

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R MR60109-00-A
R Placement of Repair Material
R Figure 605 (Sheet 1 of 5)

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R MR60110-00-A
R Placement of Repair Material
R Figure 605 (Sheet 2 of 5)

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R MR60111-00-A
R Placement of Repair Material
R Figure 605 (Sheet 3 of 5)

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R MR60112-00-A
R Placement of Repair Material
R Figure 605 (Sheet 4 of 5)

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R MR60113-00-A
R Placement of Repair Material
R Figure 605 (Sheet 5 of 5)

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R MM50075-00-A
R Stacking Sequence of Vacuum Bag
R Figure 606

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R G. Make and install the vacuum bag as follows:

R (1) For the aft acoustic areas, cut two pieces of bagging film (C10-137). For the forward
R acoustic areas, cut the first piece only.

R (a) Cut the first piece to go over the repair area and the full surface of the heat
R blanket (C10-055), plus an additional 10.0 in. (25.4 cm) on all sides. Refer to
R figure 606.

R (b) The width of the second piece should equal the first piece. The length of the
R second piece must be equal to the amount of overhang of the first piece, plus
R 18.0 in. (45.7 cm) more. Refer to figures 606 and 607.

R (2) Cut bleeder cloth (C10-048 or C10-134) and a piece of perforated FEP film (C10-132)
R 1.0 in. (25.4 mm) smaller all around than the first piece of bagging film. For aft acoustic
R areas only, cut two pieces of bleeder cloth, (C10-048 or C10-134) and a piece of
R perforated FEP film (C10-132) 1.0 in. (25.4 mm) smaller all around than the second
R piece of bagging film. Refer to figure 606 .

R (3) Make two vacuum fitting cushions from 12.0 in. (30.5 cm) square pieces of bleeder
R cloth, (C10-048) or (C10-134) folded to 4.0 in. (10.2 cm) square, 9-ply thick cushions.

R (4) Attach the vacuum bag sealant tape (C10-138) around the edges of the vacuum
R bagging film. Do not remove the backing from the sealant tape.

R (5) Install the vacuum fitting stems in opposite corners of the bag and positioned well clear
R of the edge of the repair area. Refer to figure 608.

R (6) Attach the vacuum fitting cushions to the vacuum bag over the vacuum bag fittings with
R Teflon tape (C10-040).

R (7) Put the perforated FEP film (C10-132) in the center over the peel ply (C10-131) and
R attach it lightly in position with Teflon tape (C10-040).

R (8) Put two plies of bleeder cloth over the repair area. Let the remaining material hang
R over the trailing edge of the translating cowl 1.0 in. (25.4 mm) more than the heat
R blanket will when it is in the correct position over the repair area.

R CAUTION: DO NOT PUT THE THERMOCOUPLES DIRECTLY ON FEP FILM. IF THE

R THERMOCOUPLES ARE PUT DIRECTLY ON THE PERFORATED FEP FILM,
R IT CAN CAUSE WRINKLES AND DISBONDS IN THE SCREEN.

R (9) Use Teflon tape (C10-040) to attach a minimum of five thermocouples to the bleeder
R cloth. Put the thermocouples in different areas the repair surface to get correct
R temperature monitoring.

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R 1118207-00-A
R Arrangement of Vacuum Bag with Heater Blanket Support
R for Repair of Aft Acoustic Areas Only
R Figure 607

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R 1118208-00-A
R Vacuum Fitting Installation
R Figure 608 (Sheet 1 of 2)

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R MM50076-00-A
R Vacuum Fitting Installation (Alternative)
R Figure 608 (Sheet 2 of 2)

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R (10) Place two more plies of bleeder cloth over the thermocouples. Let the remaining
R material hang over the trailing edge of the translating cowl 1.0 in. (25.4 mm) more than
R the heat blanket will when it is in the correct position over the repair area.

R (11) Put the heat blanket over the repair area. Make sure that the active area of the blanket
R is fully over the replacement screen area and the prepreg glass plies at the edge. The
R heat blanket will hang over the trailing edge of the translating cowl.

R (12) On one edge at a time, peel off the backing paper from the sealant and push the
R vacuum bag edge onto the tape around the repair area. Put at least two tucks or "ears"
R in each edge to avoid local stretching which can cause tears in the bag. Refer to figure
R 609. Put the second piece of bagging film with its two pieces of bleeder cloth on the
R outside of the translating cowl trailing edge to support the heat blanket. The heat
R blanket should not be folded over the trailing edge. Refer to figure 603. Use a Teflon
R spatula (figure 604) to push down the sealant. Make sure you seal around the
R thermocouple wires.

R NOTE: If the thermocouple wires have a fabric insulation, you must remove it
R locally to prevent leaks where the wires pass under the sealant tape.

R (13) Connect one vacuum fitting to the vacuum line from the controller (C10-055) and attach
R a vacuum gage to the other fitting.

R CAUTION: SOME TYPES OF VACUUM PUMPS ARE NOT DESIGNED FOR

R CONTINUOUS OPERATION AT A PARTIAL VACUUM. REFER TO THE
R MANUFACTURER’S INSTRUCTIONS.

R (14) Evacuate the vacuum bag to 20-26 in. Hg. Examine the bag for leaks. Repair all leaks.

R (a) To repair a leak, use a Teflon spatula to apply more pressure to the sealant in
R the area of the leak.

R H. Cure the assembly as follows:

R (1) Cure the adhesive at 285°-295°F (141°-146°C) for three hours with the heat blanket
R and controller, (C10-055). Use the thermocouples to monitor the temperature.

R WARNING: HOT PARTS CAN CAUSE SKIN DAMAGE OR SERIOUS BURNS, IF YOU DO
R NOT PROTECT YOUR HANDS. USE APPROVED PROTECTIVE GLOVES
R WHEN YOU TOUCH HOT PARTS.

R (2) Let the repair cool to ambient temperature, then remove the bagging materials, tape,
R and peel ply.

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R MM50077-00-A
R Formation of Tuck or Ear in Edge of Vacuum Bag
R Figure 609

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I. Make an inspection of the completed repair as follows:

(1) Examine the screen to make sure that the surface is smooth and equal, and that there
are no wrinkles or unbonded areas.

(2) Examine the glass fiber prepreg for runs, bubbles or blisters in the surface layer. If
necessary, use abrasive paper to make the surface smooth.

J. To replace subsequent areas of screen, do steps 5.E. through 5.I. again.

WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU USE
THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU DO NOT
BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR SKIN OR IN YOUR
EYES OR MOUTH. MAKE SURE YOU USE GLOVES AND CLOTHING TO PROTECT
YOURSELF.

K. Apply green epoxy primer (C03-063) over the repaired area around the edge of the screen as
follows.

(1) Mask the screen and the surrounding unrepaired area to prevent overspray.

(2) Use 320 grade abrasive cloth (C10-121) to make the surface lightly rough.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

(3) Clean the area with clean, dry, lint free, white cotton cloths moist with (C04-0035 or
R C04-003). Clean until a clean area of the cloth stays clean. Let the surface dry for a
minimum of 15 minutes.

(4) Perform a water break test.

(a) Pour a stream of water over the prepared area. If drops form, dry the surface,
and do steps 5.K.(2) and 5.K.(3) again.

(5) Let the surface dry.

(6) Examine the green epoxy primer (C03-063) for expiration date and batch number.

(7) Shake the two component parts of the primer in a paint shaker, then mix the primer
base and catalyst in a one-to-one ratio.

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(8) Let the mixture sit for 30 minutes before you use it.

NOTE: The pot life of the mixture is eight hours maximum.

(9) Stir the green epoxy primer fully and apply it to the prepared area.

(10) Alternative Procedure Available. Cure the green epoxy primer for three hours at
ambient temperature.

(10).A. Alternative Procedure. Cure the green epoxy primer for 15 minutes at ambient
temperature, then cure it for 30 minutes at 145°-150°F (63°-65°C).

(11) Under good lighting conditions, check the primer surface for equality of coverage,
discrepancies and smoothness of the paint film. If the primed surface is unacceptable,
apply a second layer (steps 5.K.(2) through 5.K.(10)).

(12) The completed dry film thickness of the primer must be 0.0006-0.0018 inch (0.015-
0.046 mm).

(13) Use very fine Scotch Brite pads (C10-010) on the primed surface until it has a smooth,
dull appearance.

WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
HIGHLY FLAMMABLE.

(14) Clean the primed area with clean, dry, lint free, white cotton cloths moist with solvent
R (C04-0035 or C04-003). Clean until a cloth stays clean. Let the surface dry for a
minimum of 15 minutes.

WARNING: THIS PAINT IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU USE THE
PAINT IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU DO NOT BREATHE
THE FUMES. DO NOT GET THE PAINT ON YOUR SKIN OR IN YOUR EYES OR
MOUTH. MAKE SURE YOU USE GLOVES AND CLOTHING TO PROTECT
YOURSELF.

L. Paint the area as follows:

(1) Make sure the polyurethane paint (C03-059) is within its shelf life.

NOTE: Color #26306 matches OEM requirements.

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R (2) Mix the paint. Refer to the manufacturer’s instructions.

R (3) Let the mixture stand for 30 minutes before you use it. If necessary, you can thin the
R paint with reducer (C03-062) to a maximum of 25 percent of the total volume of the
R mixture.

R (4) Spray apply one to two equal layers to the area.

R (5) Alternative Procedure Available. Let the paint air dry for seven hours at ambient
R temperature.

R (5).A. Alternative Procedure. Let the paint air dry for two hours at ambient temperature, then
R cure at a temperature of 180°-200°F (85°-95°C) for two hours.

R (6) The dry film thickness of the top layer must be 0.0015-0.0020 inch (0.038 - 0.051 mm).

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 FAN REVERSER
CF6-80E1 CMM

THIS PAGE INTENTIONALLY BLANK

 COMPONENT
MAINTENANCE
MANUAL

533A & 683L SERIES

FAN REVERSER TRANSLATING COWL - REPAIR

R 1. Replace the Damaged or Worn Wear Strips on the Cowl Guide Hook Fitting.

R A. This procedure gives the instructions to replace the wear strip in the translating cowl guide, with
R the guide removed from the translating cowl.

R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools. None required.

R (3) Locally Manufactured Tools. None required.

R (4) Equipment.

R Description Manufacturer

R Oven, Air Circulating, Local purchase

R 330°-350°F (166°-177°C)

R Pump, Vacuum, Local purchase

R 20 in. Hg minimum

R B. Consumable Materials.

R Code No. Description Use

R C01-097 Tape, Brown Ceramic Filled Replacement wear strip

R TFE, Etched One Side,
R 0.032 in. (0.81 mm) thick

R C01-126 Netting, Dacron Polyester, Support the adhesive

R D117 repair

R C01-155 Adhesive, Epoxy Resin Bond the wear strip

R C03-005 Primer, Epoxy Resin, Touch up

R Spray Type, Finch 463-12-8

R C03-007 Primer, Epoxy Adhesive, BR-127 Primer for the cowl guide

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R Code No. Description Use

R C04-001 Solvent, Methyl-Ethyl-Ketone Clean the repair area

R (MEK)

R C04-003 Solvent, Acetone Clean the repair area

R C04-035 Isopropyl Alcohol Clean the repair area

R C04-150 Pasa-Jell 105 Clean the repair area

R C10-040 Tape, Teflon Surface protection

R C10-108 Brush, Disposable, Natural Apply the adhesive

R Bristle

R C10-133 Film, Polymer Protection of clean surfaces

R C10-134 Cloth, Breather/Bleeder Air bleed from vacuum bag

R C10-136 Tape, Flashbreaker No. 855, Attach vacuum fitting cushions

R 0.002 in. (0.051 mm) thick

R C10-137 Film, Vacuum Bag Vacuum bag film

R C10-138 Tape, Sealant, Vacuum Bag Vacuum bag sealant

R C10-139 Gloves, White Cotton, Protect the cleaned doubler

R Disposable

R C10-140 Gloves, Film Nylon/ Mix and apply the adhesive

R Polyethylene, Disposable

R C10-141 Abrasive Paper, 120-180 Grit Surface preparation

R C10-182 Cloths, Cleaning Clean the repair area

R --- Adhesive, Epoxy Film, AF191 Wear strip adhesive

R --- Rubber, Liquid, Aircast 3700 Make a pressure pad

R C. Expendable Parts. None.

R D. SPD Identification. None.

R 3. Dimensional Information. None.

R 4. Setup Information. None.

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R 5. Procedure.

R A. Prepare the guide for installation of the wear strip.

R (1) Cut the wear strip tape, peel it back, and remove the worn or damaged rub strip from
R the inner surfaces of the guide

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID
R IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF
R YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT
R AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR EYES
R BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY
R FLAMMABLE.

R (2) Use a clean cloth (C10-182) moist with solvent (C04-001, C04-003, or C04-035) to
R clean the guide. Rub across the surface in one direction only. Immediately dry the
R surface with a clean dry cloth. Do not let the solvent dry on the surface. Continue to rub
R and dry the surface until the cloth stays clean.

R (3) Mask the lug area of guide with Teflon tape (C10-040) to protect the surface when you
R use abrasive paper and Pasa-Jell. Refer to figure 601.

R (4) Use 120-180 grit abrasive paper (C10-141) to remove the old adhesive and make the
R wear strip interface area of the guide lightly rough.

R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

R PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
R SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE. WEAR
R GOGGLES. DO NOT POINT COMPRESSED AIR IN THE DIRECTION OF
R YOUR SKIN.

R (5) Remove unwanted material with clean, dry oil free filtered shop air.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID
R IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF
R YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT
R AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR EYES
R BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY
R FLAMMABLE.

R (6) Use a clean cloth (C10-182) moist with solvent (C04-001, C04-003, or C04-035) to
R clean the guide. Rub across the surface in one direction only. Immediately dry the
R surface with a clean dry cloth. Do not let the solvent dry on the surface. Continue to rub
R and dry the surface until the cloth stays clean.

R NOTE: Wear clean white gloves (C10-139) when you touch the cleaned surfaces.

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R MR60071-00-A
R Cowl Guide Wear Strip Replacement
R Figure 601

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R WARNING: PASA-JELL IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR EYES

R OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. WEAR CLEAN
R NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN
R YOU USE PASA-JELL.

R (7) Brush the repair surface with Pasa-Jell 105 (C04-150) paste. Apply as many times as
R necessary during the exposure period to keep the Pasa-Jell from drying on the surface.
R After 8-10 minutes, use a sponge and clean water to remove the Pasa-Jell. Do not rub
R the surfaces.

R (8) Do step (7) again. Then, flush the surface fully with tap water or deionized water until
R the surface can pass an acid free test. Make sure that chromate disposal provisions
R have been made for this water.

R (a) Touch the surface being tested with moist blue or neutral litmus paper. If the
R color of the paper changes to pink, acid is present. If acid is present, flush the
R surface with water and touch the surface again with litmus paper. If the litmus
R paper does not change color, there is no acid present, and the surface passes
R the test.

R (9) Check for a water break-free surface. A water break-free surface can keep a
R continuous water film on vertical surfaces for at least 15 seconds. If the guide does not
R have a water break-free surface, do steps (7) and (8) again.

R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

R PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
R SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE. WEAR
R GOGGLES. DO NOT POINT COMPRESSED AIR IN THE DIRECTION OF
R YOUR SKIN.

R (10) Remove the Teflon tape from the guide and dry the surface with clean, filtered, oil-free
R shop air.

R (11) To protect the surfaces of the guide from contamination, put the guide in a polyethylene
R bag until you are ready to apply the epoxy adhesive primer. You must apply the epoxy
R adhesive primer within 16 hours after you clean the guide.

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
R USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
R SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
R AND CLOTHING TO PROTECT YOURSELF.

R (12) Apply a layer of epoxy adhesive primer (C03-007) to the cowl guide bond surface. The
R cured epoxy adhesive primer thickness must be 0.00006-0.00016 in. (0.0015-0.0041
R mm).

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R (13) Cure the primer for 1 hour at ambient temperature, then cure at 240°-260° F (116°-
R 127°C) for 1 hour.

R (14) After the cure is complete, put each part in a separate, clean polyethylene bag. Use
R heat to seal the bag. Do not remove the parts until you are ready to attach the wear
R strip.

R B. Prepare the wear strip (C01-097) for installation.

R NOTE: The thickness of the ceramic-filled TFE tape (C01-097) for the guide is 0.032 in.
R (0.81 mm).

R (1) Cut the tape to the correct width and length. Refer to figure 601.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID
R IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF
R YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT
R AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR EYES
R BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY
R FLAMMABLE.

R CAUTION: WEAR CLEAN WHITE GLOVES WHEN YOU TOUCH THE TAPE (C01-097).
R MAKE SURE YOU DO NOT USE TOO MUCH PRESSURE WHEN YOU
R CLEAN THE TAPE. TOO MUCH PRESSURE WILL REMOVE THE ETCHED
R SURFACE.

R (2) Clean the etched surface (the darker surface) of the tape with a clean cloth (C10-182)
R moist with solvent (C04-001, C04-003, or C04-035). Rub across the surface in one
R direction only. Immediately dry the surface with a clean dry cloth. Do not let the solvent
R dry on the surface. Continue to rub and dry the surface until a cloth stays clean.

R NOTE: Clean the tape within eight hours before the bonding procedure.

R C. (Alternative procedure available.) Use a vacuum bag and an oven to bond the parts.

R (1) Cast liquid rubber into a complete cowl guide assembly to make a rubber pressure pad,
R or make the tools shown in figure 601.

R (2) Cut the epoxy film adhesive (AF191) to the correct length and width. Refer to figure
R 601.

R (3) Put the adhesive in a new, clean polyethylene bag. Seal the bag. Do not open the bag
R until you are ready to start the installation. You must use the adhesive film in less than
R 14 days after you seal it in the bag.

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R WARNING: WEAR THERMAL OR INSULATED GLOVES TO PREVENT HAND INJURY

R WHEN YOU TOUCH HOT OR COLD PARTS.

R (4) Remove the prepared guide from its polyethylene bag. Put the guide in a clean dust
R free oven heated to 140°-160°F (60°-71°C) for 10 minutes.

R (5) Remove the prepared adhesive film from its polyethylene bag. Remove the protective
R backing from the adhesive film. Remove the preheated guide from the oven and
R immediately install the adhesive with the exposed side down, and the plastic film side
R up. Align the adhesive to the proper location on the guide. Refer to figure 601.

R (a) Use an acrylic squeegee to make the adhesive film smooth on the bond area of
R the guide.

R (6) Remove the plastic film from the exposed side of the film adhesive. Attach the etched
R surface of the ceramic-filled TFE tape (C01-097) to the adhesive film in the correct
R position while the adhesive is warm. Refer to figure 601. Push the tape into position
R against the adhesive.

R (a) If the adhesive on the guide is not tacky enough to stick to the tape, you can
R heat the adhesive slightly with a heat gun just before you install the tape. Use a
R continuous motion with the heat gun, at a distance of 8.0-12.0 in. (203-305
R mm), to prevent staging of the adhesive.

R (7) Stretch the rubber pressure pad and install it into the cowl guide, or use the shop tools
R shown in figure 601 to keep pressure on theTFE tape. Make sure the teflon has not
R moved out of position.

R (8) Attach two thermocouples, one at each end of the guide. Mount the thermocouples on
R the metallic surface.

R (9) Cut the bagging film (C10-137) to cover the repair area. Make the bagging film large
R enough to enclose the part and include sufficient extra material to connect the vacuum
R line.

R (10) Cut a piece of bleeder cloth (C10-134) and a piece of film (C10-133) 1.0 in. (25 mm)
R smaller all around than the bagging film.

R (11) Make two vacuum fitting cushions from pieces of bleeder cloth (C10-134), 12.0 in. (30.5
R cm) long and 12.0 in. (30.5 cm) wide. Fold the bleeder cloth into 4.0 in. (10.2 cm)
R square, 9 ply thick cushions.

R (12) Attach the vacuum bag sealant tape (C10-138) around the edge of the vacuum bag. Do
R not remove the backing paper from the sealant tape.

R (13) Install the vacuum bag stems in the bag 180 degrees apart and positioned away from
R the repair area. Refer to figure 602.

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R 1093873-00-A
R Vacuum Fitting Installation
R Figure 602 (Sheet 1 of 2)

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R MM50076-00-A
R Vacuum Fitting Installation
R Figure 602 (Sheet 2 of 2)

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R (14) Attach vacuum fitting cushions to the vacuum bag. Use tape (C10-136). Put the
R cushions over the vacuum bag fittings.

R (15) Put the film (C10-133) over the part and attach in position lightly with tape (C10-136).
R Make sure there are no creases in the film on the wear strip tape surface.

R (16) Put the bleeder cloth over the film.

R (17) Do one edge at a time. Remove the backing paper from the sealant and push on the
R vacuum bag edge along the edges of the repair area. Put two folds in each edge to
R prevent local stretching which will cause tears in the bag. Use a spatula to push down
R the folds. Refer to figures 603 and 604.

R (18) Remove the air from the bag to a vacuum of 20 inches (60 kPa) of mercury (minimum).
R Examine the bag for leaks. Repair all leaks.

R (a) To repair a leak, use an acrylic spatula to apply more pressure to the sealant in
R the area of the leak.

R (19) Keep the vacuum applied and the vacuum lines connected until the part is ready to be
R cured.

R (20) Install the bagged part in the air circulating oven and attach the vacuum lines and
R thermocouples.

R (21) With the vacuum at 16-20 in. Hg, increase the oven temperature to 330°F (166°C) at a
R rate of 2°-8F° (or equivalent) per minute. Cure at 330°-350°F (166°-177°C) for 60-90
R minutes.

R (22) Decrease the temperature of the guide to ambient temperature, then release the
R vacuum and remove the bag from the oven.

R (23) Remove the vacuum bagging materials and the pressure pad.

R D.A. (Alternative method). Bond the parts with paste adhesive (C01-155).

R (1) Cast liquid rubber into a complete cowl guide assembly to make a rubber pressure pad,
R or make the tools shown in figure 601.

R (2) Cut the dacron netting (C01-126) to the approximate length and width. Refer to figure
R 601.

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R MM50077-00-A
R Formation of Folds in the Vacuum Bag
R Figure 603

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R MM50071-01-A
R Acrylic Spatula
R Figure 604

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R WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL

R IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA OPEN TO THE AIR.
R WEAR CLEAN NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES
R (C10-140) WHEN YOU MIX OR APPLY THE ADHESIVE.

R (3) Prepare the epoxy adhesive (C01-155) as follows. Mix no more than 0.5 lb (225 g) in
R one mixture.

R (a) Prepare the adhesive in a clean metal or uncoated paper container.

R (b) Make an estimate the quantity of adhesive that you will use.

R (c) Weigh out sufficient quantities of each of the components as follows:

R - Resin - (thixotropic gray material) 100 parts by weight

R - Catalyst - (thin black paste) 17 parts by weight

R (d) Mix the resin and catalyst until you can see no streaks of the two components.

R NOTE: The pot life of the adhesive will be approximately 90 minutes.

R (4) Apply a thin layer of adhesive, approximately 0.007 in. (0.18 mm) thick, to the bonding
R surface of the guide. Apply the adhesive with a stiff bristle brush (C10-108) or wooden
R spatula. Make sure you cover all of the bonding surface. Rub the adhesive onto the
R surface. Make the adhesive smooth so that no air is caught in the adhesive.

R (5) Push the dacron netting (C01-126) into the adhesive layer on the guide.

R (6) Remove all wrinkles from the netting and make it smooth. Apply a second thin, equal
R layer of adhesive over the netting.

R 7) Put the etched side of the wear strip (C01-097) against the adhesive. Stretch the
R rubber pressure pad and install it into the cowl guide. Make sure the teflon has not
R moved out of position. Or, use the shop tools shown in figure 601 to keep pressure on
R the tape during the oven cure.

R (8) Cure the guide in an oven for 1 hour at 200°-220°F (93°-104°C).

R E. Make an inspection of the guide.

R (1) Examine the bond line for full adhesion on all surfaces. No voids or separations are
R permitted. No unwanted adhesive is permitted on the tape surface.

R (2) Examine the wear strip to see that it is in the correct position. Look for cuts or tears on
R the wear strip. No cuts or tears are permitted, except for the acceptable cuts in the
R three corners. Refer to figure 601.

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R (3) If necessary, apply masking material to the wear strip, and do the steps that follow to
R apply a layer of epoxy resin primer (C03-005) to the guide.

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE

R SURE YOU USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW.
R MAKE SURE YOU DO NOT BREATHE THE FUMES. DO NOT GET
R THE PRIMER ON YOUR SKIN OR IN YOUR EYES OR MOUTH.
R MAKE SURE YOU USE GLOVES AND CLOTHING TO PROTECT
R YOURSELF.

R (a) Fully mix the primer (C03-005) base material and catalyst in the manufacturer's
R containers.

R (b) Move the base material to a different container. Add the catalyst until you have
R a 1-to-1 ratio with the base. Mix the two components continuously while you
R add the catalyst.

R (c) Let the primer stand for a minimum of 15 minutes at an ambient temperature of
R 50°-100°F (88°-99°C)

R NOTE: The primer has a pot life of 8 hours.

R (d) Apply an equal layer of primer to the applicable area.

R (e) Cure the primer at ambient temperature for 1-3 hours or air cure for 5-10
R minutes, and then cure at 190°-210°F (88°-99°C) for 15-20 minutes.

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 COMPONENT
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MANUAL

683L SERIES

FAN REVERSER TRANSCOWL - REPAIR

1. Replacement of the Tee Hinge Wear Strip.

A. This procedure gives the instructions for the replacement of worn or damaged translating cowl
tee hinge wear strips.

2. Tools, Equipment, and Materials.

NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

A. Tools and Equipment.

(1) Special Tools. None required.

(2) Standard Tools. None required.

R (3) Locally Manufactured Tools. Refer to figure 602, 604, and 605.

(4) Equipment.

Description Manufacturer

Autoclave that can heat a part Local purchase

to 350°-360°F (177°-182°C)

Oven that can heat a part Local purchase

to 175°-200°F (79°-93°C)

B. Consumable Materials.

Code Description Use

C01-007 Adhesive, Silicone Rubber, Seal the tee hinge

RTV-106 (Red)

C01-115 Adhesive Sealant, Seal the tee hinge

MIL-S-81733

C01-126 Fabric Netting, Dacron Adhesive support

Polyester

C01-155 Adhesive, Paste, Bond the wear strips

Two Part, EA 9394

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683L SERIES

Code Description Use

C01-165 Adhesive, Film, Supported, Bond the wear strips

AF-191K, Class B
0.08 psf wt (0.391 kg/m sq)

C01-166 Primer, Adhesive, Bond the wear strips

EC-3917

C04-001 Solvent, Methyl-Ethyl- Clean the repair area

Ketone (MEK)

C04-003 Solvent, Acetone Clean the repair area

C10-021 Tape, Plastic Protection for the repair area

C10-040 Tape, Teflon, 1.0 X Hold the repair parts

0.002 inch thick, in position
R Scotch Brand 5490

C10-048 Bleeder Cloth, Osnaburg, Bleeder ply for

6.5 oz/sq yd, 40 inch wide vacuum bagging

C10-108 Brush, Natural Bristle, Apply the adhesive

Disposable, Cat. No.
7237T4 or 7798T2

C10-137 Film, Vacuum Bag Vacuum bag cure

C10-140 Gloves, Nylon Film/Polyethylene, Mix and apply the adhesive

Disposable

C. Expendable Parts. None required.

D. SPD Identification.

SPD No. Description

3046M82P04 Brown Ceramic Filled TFE (Teflon) Tape,

etched one side

E. Referenced Procedures.

SPM 70-21-04

3. Dimensional Information. None required.

4. Setup Information. None required.

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R 5. Procedure.

R A. Do the steps that follow to remove the right or left translating cowl tee hinge (1-550, 78-32-31)
R for repair.

R (1) Remove the screws (1-565, 78-32-31) that attach the tee hinge pin retainer (1-560,
R 78-32-31) to the translating cowl. Remove the pin retainer. Keep the screws and the
R retainer for use at installation.

R (2) Remove the tee hinge pin (1-570, 78-32-31) and the hinge pin seal (1-575, 78-32-31)
R that attach the tee hinge to the translating cowl. Keep the pin and the seal for use at
R installation.

R (3) Remove the tee hinge to be repaired.

R B. Use a scraper to remove the damaged wear strips and remaining adhesive from the tee hinge.

R C. Prepare the bonding surfaces of the tee hinge as follows:

R (1) Apply plastic tape (C10-021) or masking tape to the lug area of the tee hinge to protect
R the area during grit blasting. See figure 601.

R CAUTION: DO NOT OVER BLAST THE BONDING SURFACE. TO DO SO CAN CAUSE

R DAMAGE TO THE PARENT METAL.

R (2) Dry grit blast the bonding surfaces. Refer to Standard Practices Manual, 70-21-04. Use
R 120-220 grit aluminum oxide at 40-70 psi (345-483 kPa). Grit blast to an equal matte
R finish, but do not over blast.

R (3) Remove the plastic tape or masking tape from the hinge.

R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

R PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
R SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE. WEAR
R GOGGLES. DO NOT POINT COMPRESSED AIR IN THE DIRECTION OF
R YOUR SKIN.

R (4) Use dry shop air to remove unwanted material from the bonding surface.

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R MR60123-01-A
R Surface Protection for Grit Blasting
R Figure 601

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 COMPONENT
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683L SERIES

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (5) Use a clean cloth moist with solvent (C04-001 or C04-003) to clean the grit blasted
R surfaces until a cloth stays clean. Let the surfaces dry.

R NOTE: Wear clean cotton gloves when you touch the cleaned surfaces.

R (6) Apply EC-3917 primer (C01-166) to the tee hinge.

R NOTE: The shelf life of the primer is 6 months when stored in its original container
R at or below 0°F (-18°C).

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE

R SURE YOU USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW.
R MAKE SURE YOU DO NOT BREATHE THE FUMES. DO NOT GET
R THE PRIMER ON YOUR SKIN OR IN YOUR EYES OR MOUTH.
R MAKE SURE YOU USE GLOVES AND CLOTHING TO PROTECT
R YOURSELF.

R (a) Get the primer (C01-166) from cold storage and let it sit at ambient temperature
R for 2 hours.

R (b) Stir the primer before and during the spray application. The thickness of the
R cured film must be 0.06 to 0.16 mils (0.015-0.041 mm).

R 1 Spray a separate 4.0 x 4.0 in. (10.2 x 10.2 cm) panel along with the tee
R hinge. Cure the panel and use it to measure the cured film thickness of
R the primer.

R (c) Let the primer air dry at ambient temperature for a minimum of 30 minutes.
R Remove the plastic tape or masking tape and cure at 240°-260°F (116°-127°C)
R for 1 hour within 24 hours of the primer application.

R (7) Put a new, clean polyethylene film on the tee hinge to protect it from contact or
R contamination until you are ready to install the wear strips.

R NOTE: The wear strips must be bonded to the clean, grit blasted area within eight
R hours after grit blasting.

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R D. Prepare the SPD wear strip material (P/N 3046M82P04) as follows:

R NOTE: The SPD material must be kept in a light-free container, which restricts free airflow,
R to prevent possible deterioration of the etched surface.

R (1) Cut the SPD wear strip material to the correct length and width (if necessary). See
R figure 602.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R CAUTION: MAKE SURE YOU DO NOT APPLY TOO MUCH PRESSURE WHEN YOU
R CLEAN THE SURFACE. TOO MUCH PRESSURE CAN PARTIALLY
R REMOVE THE ETCHED SURFACE AND SUBSEQUENTLY REDUCE
R THE STRENGTH OF THE ADHESIVE BOND.

R (2) Use a clean, white cloth moist with solvent (C04-001 or C04-003) to clean the SPD
R wear strip material. Clean all the surfaces that will be bonded (etched surfaces).
R Dry the surfaces with a clean, dry cloth before the solvent dries. Clean the wear strip
R again until the surfaces are free of unwanted material.

R NOTE: SPD wear strip segments must be bonded as soon as possible after the
R cleaning operation. The SPD wear strip segments must be bonded within
R 36 hours after cleaning. If possible, clean the SPD wear strip material
R immediately before application and bonding.

R NOTE: The dark side of the teflon is the etched side that will be bonded to the
R hinge.

R E. Use one of the procedures that follow to prepare the adhesive and bond the SPD wear strips to
the tee hinge:

R (1) Autoclave and vacuum bag bonding method with epoxy film adhesive: (Refer to step
R (1).A. for an alternative procedure.)

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R (a) Get the epoxy film adhesive (C01-165) from cold storage. Let the adhesive
R warm to ambient temperature before you remove the adhesive from the sealed
R container.

R NOTE: A full roll of adhesive needs approximately four hours to warm to

R ambient temperature. The shelf life of the adhesive is six months if
R it is stored at 0°F (-18°C) or below. The shelf life is reduced to
R approximately five days (accumulated time out of freezer) if the
R material is stored at ambient temperature.

R (b) Cut strips of epoxy film adhesive to the correct length and width. See figure
R 602. Do not remove the protective sheets from the adhesive strips

R (c) Put the epoxy film adhesive strips in a new, clean plastic bag and seal the bag
R until you are ready to start the adhesive and wear strip installation procedure.

R (d) Remove the protective backing sheet from one side of the epoxy film adhesive
R strips. If the adhesive is not tacky enough to bond to the tee hinge, you can
R heat the adhesive lightly with a heat gun just before you install it on the hinge.
R Use a continuous motion with the heat gun, at a distance of 8.0-12.0 in. (203-
R 305 mm). Be careful not to apply too much heat. If you apply too much
R heat, it will cure the adhesive.

R (e) Remove the tee hinge from the plastic bag and immediately install the adhesive
R strips. The exposed side of the adhesive strips must be next to the hinge, and
R the side with the remaining protective backing sheet must be up. Put the
R adhesive strips in position. See figure 602. Use a Teflon squeegee to push the
R adhesive strips down onto the hinge bonding areas. Use the squeegee
R to make the adhesive strips smooth.

R (f) Remove the remaining protective backing sheet from the epoxy film adhesive
R strips. If the adhesive is not tacky enough to bond to the SPD wear strip
R segments, you can heat the adhesive lightly with a heat gun just before you
R install the wear strip segments. Use a continuous motion with the heat gun,
R at a distance of 8.0-12.0 in. (203-305 mm). Be careful not to apply too much
R heat. If you apply too much heat, it will cure the adhesive.

R (g) Install the SPD wear strip segments, with the etched (dark) surfaces down, on
R the adhesive strips. Put the wear strip segments in the correct positions. See
R figure 602.

R (h) Push the wear strip segments into position by pushing the segments
R against the adhesive.

R (i) Wrap 1-inch (25.4 mm) strips of Teflon tape (C10-040) around the sides of the
R hinge to hold the wear strip segments in position against the tee hinge.

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R MR50154-00-A
R Fan Reverser Translating Cowl Tee Hinge
R Figure 602 (Sheet 1)

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R MR60124-00-A
R Fan Reverser Translating Cowl Tee Hinge
R Figure 602 (Sheet 2)

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R (j) Attach a thermocouple to each end of the hinge.

R (k) Make and install a vacuum bag (C10-137) around the hinge. Use bleeder cloth
R (C10-048) to protect the bag from sharp corners, to bridge, and to provide an
R evacuation path for the bag. Refer to figure 602 and figure 604 for possible tool
R set-ups.

R (l) Install two vacuum bag fittings in the vacuum bag.

R (m) Seal the vacuum bag and attach the vacuum lines.

R (n) Evacuate the bag to 20 inches of mercury (HG) (67 kPa) minimum. Examine
R the bag for leaks and repair as necessary.

R (o) Install the bagged hinge in the autoclave and attach the thermocouples.

R NOTE: The autoclave must be able to increase the temperature of the part
R to 330°-350°F (166°-177°C). Use the thermocouples attached to
R the part to measure the temperature. The recommended heat-up
R rate is 2° to 8°F (1.0° to 4.3°C) a minute.

R (p) Start the autoclave heat-up and pressurization. When the autoclave pressure
R is 10 psi (69 kPa), vent the vacuum lines to the atmosphere. Continue to
R Pressurize the autoclave to 40-50 psi (276-345 kPa) pressure. Increase the
R temperature of the hinge to 330°-350°F (166°-177°C).

R (q) Hold the hinge temperature at 330°-350°F (166°-177°C) under 40-50 psi (276-
R 345 kPa) autoclave pressure for 60-90 minutes.

R (r) Cool the hinge to 150°F (66°C) or lower before you release the autoclave
R pressure.

R WARNING: WEAR THERMAL OR INSULATED GLOVES TO PREVENT HAND

R INJURY WHEN YOU TOUCH HOT OR COLD PARTS.

R (s) Remove the bagged hinge from the autoclave. Remove the vacuum bag
R fittings, the vacuum bag, the bleeder cloth, the thermocouples, and the Teflon
R tape from the hinge.

R (1).A. Alternative (oven cure) bonding method with epoxy adhesive:

R (a) Cut strips of fabric netting (C01-126) to the same dimensions as the wear strip
R segments. See figures 602 and 603.

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R CF8-7244-00-A
R Hold the Tee Hinge Wear Strip in Position with Clamps
R Figure 603

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R MR60125-00-A
R Use of Silicone Rubber Intensifiers with Autoclave Cure
R Figure 604

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R WARNING: EPOXY RESIN ADHESIVE IS AN IRRITANT. DO NOT GET THE

R MATERIAL IN YOUR EYES OR ON YOUR SKIN. USE IN AN AREA
R OPEN TO THE AIR. WEAR CLEAN NYLON FILM OR
R POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN YOU MIX
R OR APPLY THE ADHESIVE.

R (b) Mix the epoxy adhesive (C01-155) by weight, 100 parts A (resin) with 17
R parts B (catalyst). Mix fully until you can see no streaks of the two
R components.

R NOTE: The pot life of a 4.66 ounce (133 gram) batch of mixed epoxy is
R approximately 40 minutes.

R (c) Use a stiff bristle brush (C10-108) with a scrubbing action to apply a thin equal
R layer, approximately 0.007 inch (0.178 mm), of epoxy adhesive (C01-155) to
R the bonding surfaces of the tee hinge. Make sure the surface is fully wet with
R the adhesive. Make the surface smooth so that no air is caught in the
R adhesive.

R (d) Lay the applicable, previously cut pieces of fabric netting (C01-126) in the wet
R epoxy adhesive. Use a tongue depressor, or equivalent, to push the netting
R into the adhesive until it is fully soaked. Remove all wrinkles and make
R the fabric netting smooth.

R (e) Put the SPD wear strip segments in position, with the etched surface down,
R onto the hinge. Refer to figure 602. Use clean aluminum bars the same length
R as the tee hinge, and clamps as necessary, to hold the wear strips in position.
R Refer to figure 603.

R NOTE: Use only sufficient clamp pressure to give good, even contact
R between the aluminum bar, wear strips, and the tee hinge bond
R surface. Do not use so much pressure that the adhesive squeezes
R out of the bond areas. Some adhesive will squeeze to the sides;
R this is permissible.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT

R ON PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK.
R USE THE FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT
R BREATHE THE FUMES. IF YOU GET THE SOLVENT ON YOUR
R SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET
R MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
R SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R (f) Use a non-metallic scraper and a clean cloth moist with solvent (C04-001 or
R C04-003) to remove unwanted epoxy adhesive.

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R WARNING: WEAR THERMAL OR INSULATED GLOVES TO PREVENT HAND

R INJURY WHEN YOU TOUCH HOT OR COLD PARTS.

R (g) Let the clamped hinge assembly cure at ambient temperature for 2 hours, then
R put the assembly in an oven and cure the adhesive for a minimum of one hour
R at 175° to 200°F (80° to 93°C).

R WARNING: WEAR THERMAL OR INSULATED GLOVES TO PREVENT HAND

R INJURY WHEN YOU TOUCH HOT OR COLD PARTS.

R (h) Remove the clamped hinge assembly from the oven. Remove the clamps and
R the aluminum bars.

R F. Visually inspect the tee hinge wear strips.

R (1) Examine the bond line for full adhesion on all surfaces. No voids or separations are
R permitted. No adhesive is permitted on the wear strips.

R (2) Porosity along the edges of the wear strips is also permissible if it does not extend
R 0.030 inch (0.76 mm) from the edges of the wear strips.

R (3) Look for cuts or tears in the wear strips. No cuts or tears are permitted.

R G. Do the steps that follow to install the right or left translating cowl tee hinge (1-550, 78-32-31)
R that was repaired:

R (1) Attach the tee hinge to the translating cowl assembly and install it in position in with the
R tee hinge pin (1-570, 78-32-31) and the hinge pin seal (1-575, 78-32-31).

R (2) Install the tee hinge pin retainer (1-560, 78-32-31) and attach in position with
R the screws (1-565, 78-32-31).

R (3) Seal the tee hinge as follows:

R NOTE: Seal the tee hinge immediately before you install the translating cowl. This
R lets the tee hinge stay in the normal operating position and gets the best
R seal.

R (a) Apply plastic tape (C10-021) or masking tape to both sides of each tee hinge to
R cover and protect the wear strips.

R (b) Turn the tee hinge to its correct position.

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(c) Apply a line of adhesive (C01-007 or C01-115) approximately 0.015 inch (0.38
mm) thick between the air seal and tee hinge. If you move the tee hinge during
adhesive application, the adhesive can flow between the stationary and
moveable sections of the tee hinge.

(d) Apply another line of adhesive to the opposite side of the hinge at the
bondment joint. Make sure all open areas of the tee hinge are sealed.

CAUTION: IF THE HINGE STAYS IN A FREE STATE FOR MORE THAN 15

MINUTES, THE SEAL WILL BE BROKEN UPON INSTALLATION AND
THE PURPOSE OF THIS SEAL WILL BE DEFEATED. IMMEDIATE
TRANSLATING COWL INSTALLATION IS NECESSARY TO BE
SURE OF A CORRECT SEAL.

(e) Let the tee hinge set approximately 5-6 minutes before you remove the plastic
(or masking) tape. Careful removal of the tape will result in a clean edge at the
air seal.

R (f) Position the Tee Hinge Alignment tool on the cowl guide. Rest the tool onto the
R tee hinge and adjust the tee hinge until it is aligned with the tool surface.
R Remove the tool and allow the sealant to cure. (Refer to Figure 605 sheets 1
R and 2)

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R
R Translating Cowl Tee-Hinge Alignment Tool
R Figure 605 (Sheet 1)

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R
R Tee-Hinge Alignment Tool
R Figure 605 (Sheet 2)

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 COMPONENT
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FAN REVERSER TRANSLATING COWL - REPAIR

R 1. Replacement of Translating Cowl Clevis/Longeron Assembly Fasteners.

R A. This procedure gives the instructions for replacing loose, damaged or missing fasteners that
R attach the clevis to the longeron assembly. If the installation holes in the clevis and longeron
R assemblies are damaged, this procedure gives the instructions for increasing the installation
R hole sizes up to 0.25 in. (6.4 mm). This repair can also be used to replace the clevis fittings
R and/or the longerons.

R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools.

R Description Manufacturer

R Cotter Pin Extraction Tool no. 26 Contact local C. S. Osborne & Co.
R distributor
R or
R Contact local McMaster Carr distributor

R Burraway, Type B, 0.25 in. (6.4 mm) Contact local Cogsdill distributor
R Diameter

R (3) Locally Manufactured Tools. None required.

R NOTE: MRAS recommends the use of a locally made fixture to control the
R dimensions given in figure 607 and the STA locations in figure 605.

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R (4) Equipment.

R Ref. No. Description Manufacturer Use

R 1 Drill bits, No. E Local purchase Make installation

R holes larger

R 2 Drill motor Local purchase Drill the repair holes

R B. Consumable Materials.

R Code No. Description Use

R C01-073 Compound, Sealing, Install the fasteners

R PR-1750 B-2

R C03-005 Primer, Epoxy Resin, Install the fasteners

R (Spray Type) Finch 463-12-8

R OR

R C03-077 Primer, Epoxy, Water- Install the fasteners

R Reducible

R C10-140 Gloves, Film Latex or Apply the primer

R Nylon/Polyethylene, Disposable

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R C. Expendable Parts.

R Part Number Description Manufacturer

R See table 601 to Fastener Hi Shear – Contact local distributor, or:

R find the correct Hi Shear Corporation
R fastener type Main Plant
R size 2600 Skypark Drive
R Torrance, CA 90509-2975 USA
R Telephone: (310) 326-8100
R Fax: (310) 784-4144
R or
R SPS Technologies – Contact local distributor,
R or:
R SPS Technologies
R Highland Avenue
R Jenkinstown, PA USA
R Telephone: (215) 572-3000
R Fax: (215) 572-3194

R See table 601 to Collar Hi Shear, or SPS Technologies

R find the correct
R collar to use with
R this repair

R See table 601 to Washer Standard

R find the correct
R washer to use with
R this repair

R D52B2000-19 Radius Filler Block Obtain from MRAS

R for the Mid-Clevis,
R Qty = 2

R D52B2000-21 Radius Filler Block Obtain from MRAS

R for the Mid-Clevis,
R Qty = 1

R D. SPD Identification. None required.

R E. Referenced Procedures.

R 78-32-31 Inspection

R CF6-80E1 Fan Reverser IPC (MR 99379) 78-32-31 Figure 5

R SPM 70-11-00

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R 3. Dimensional Information. Refer to table 601 and to figures 602 through 605.

R 4. Set-up Information. None required.

R 5. Procedure. Refer to figures 601 through 604.

R A. The clevis is attached to each longeron assembly with two fasteners (four total). The procedure
R that follows gives the instructions needed to replace loose or missing production fasteners. The
R following applies to this repair:

R (1) Do this procedure only if one or more production fasteners are loose, damaged or
R missing, or if a clevis will be replaced.

R (2) Make sure that the clevis pin hole diameter is not more than the CMM inspection limit of
R 0.393 in. (10.0 mm). Refer to 78-32-31 Inspection.

R (3) This procedure will increase the installation hole size. You must do this procedure
R on all four installation holes.

R (4) You must increase all of the installation holes to the same size.

R (5) Remove and replace one fastener at a time. Always have three fasteners installed and
R properly torqued. Refer to table 601 to find the correct fastener.

R B. To correctly replace the fasteners, it is recommended that you remove the

R longeron/clevis subassemblies (5-273 and 5-300, 78-32-31) from the translating cowl and
R perform this repair on a bench. Do the steps that follow to remove the translating cowl
R longeron/clevis subassemblies:

R (1) Remove the sealant to get access to the cotter pins (5-225 and 5-250, 78-32-31) that
R attach the longerons (5-278, 5-279, 5-318 and 5-319, 78-32-31) to the translating cowl
R inner bondment.

R (2) Use the cotter pin extraction tool (C. S Osborne Cotter Pin Extractor No. 26, UPC No.
R 68340) to remove the cotter pins (5-225 and 5-250, 78-32-31). Remove the nuts
R (5-220 and 5-245, 78-32-31), bolts (5-230 and 5-256, 78-32-31) and washers (5-215
R and 5-235, 78-32-31). Discard the cotter pins. Keep the nuts, bolts and washers for
R use at installation.

R (3) Remove the longeron/clevis subassemblies from the translating cowl inner bondment.
R Make sure the installed liquid shim packs stay attached to the inner bondment.

R C. Do the steps that follow to install all four of the new fasteners: Refer to table 601.

R (1) Remove the fastener, if installed, that you will replace.

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R Table 601
R Replacement Fasteners and Collars

R Installation Hole
R Size Fastener Collar Washer
R 0.250 – 0.254 in. HL48-8 A-286 High Temp Alloy MS21043-4 NAS1149C0432R
R (6.35 – 6.45 mm)

R NOTE 1: Nut 491B0700015-006 can be used as an alternative to the Hi-Shear collar listed.
R Torque the 491B0700015-006 nut to 60-80 lb in. (6.8-9.0 N·m).
R NOTE 2: Fastener 491B0700025-80X can be used as an alternative to HL20-8.

R (2) Use a No. E drill bit and a drill to increase the size of the installation hole in the clevis
R and longeron assembly to 0.250–0.254 in. (6.35–6.45 mm).

R (3) Chamfer the hole in the clevis to accommodate the fillet radius at the head of the
R Hi-Lok fastener. Use a Cogsdill Burraway tool to deburr the hole in the clevis and the
R hole in the longeron assembly.

R (4) Refer to table 601 to find the fastener and collar options for this repair.

R (5) When you install 0.25 in. (6.4 mm) Hi-Lok fasteners at the mid-clevis, it will be
R necessary to install radius filler blocks to keep the fastener head away from the fillet
R radius of the clevis (figure 604).

R WARNING: THIS PRIMER IS POISONOUS AND GIVES OFF FUMES. MAKE SURE YOU
R USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE YOU
R DO NOT BREATHE THE FUMES. DO NOT GET THE PRIMER ON YOUR
R SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE GLOVES
R AND CLOTHING TO PROTECT YOURSELF.

R (5) Apply epoxy resin primer (C03-077 or C03-005) to the fastener shank.

R (6) Wet install the new fastener through the installation hole in the clevis to the installation
R hole in the longeron assembly.

R (7) Install the washer and the collar/nut on the fastener and tighten according to
R manufacturer’s instructions.

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R (8) Do steps (1) through (7) for each fastener.

R (9) Fillet seal the joints common to the clevis and longerons with PR-1750 sealant
R (C01-073). Refer to figure 606.

R D. Do the steps that follow to install the translating cowl longeron/clevis subassemblies
R (5-273, 5-300, 78-32-31):

R WARNING: THIS COMPOUND IS POISONOUS AND GIVES OFF FUMES. MAKE SURE
R YOU USE THE PRIMER IN AN AREA WITH GOOD AIR FLOW. MAKE SURE
R YOU DO NOT BREATHE THE FUMES. DO NOT GET THE COMPOUND ON
R YOUR SKIN OR IN YOUR EYES OR MOUTH. MAKE SURE YOU USE
R GLOVES AND CLOTHING TO PROTECT YOURSELF.

R (1) Apply sealing compound (C01-073) to the faying surface of the liquid shim packs at the
R longeron/clevis installation area. Temporarily install two or three of the necessary
R fasteners (5-256, 5-230, 78-32-31) to hold the subassembly in position. Refer
R to figure 608.

R (2) Install the bolts (5-256, 5-230, 78-32-31), nuts (5-220, 5-245, 78-32-31), and washers
R (5-215, 5-235, 78-32-31). Refer to the CF6-80E1 Fan Reverser IPC (MR 99379),
R 78-32-31 Figure 5. Refer to figure 605.

R (3) Torque the nuts (5-220, 5-245, 78-32-31) to the minimum torque shown in the table
R below. If it is not possible to install the cotter pin, tighten the nut until a slot in the nut
R aligns with the hole in the bolt. Install the cotter pins (5-225, 5-250, 78-32-31).
R Refer to SPM 70-11-00.

R CSN THREAD SIZE TORQUE

R 5-220, 5-245 0.250-28 65-75 lb in. (7.3-8.5 N·m)

R (4) Apply a layer of sealing compound (C01-073) to the installed cotter pins.

R (5) Fillet seal all joints around the liquid shim packs and the longeron. Refer to figure 607.

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R MR60146-00-A
R Install the Clevis/Longeron Assembly Hi-Lok Fasteners
R Figure 601

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R MR60147-00-A
R Upper/Lower Clevis
R Figure 602

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R MR60148-00-A
R Mid Clevis
R Figure 603

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R MR60177-01-A
R Radius Fillers at the Mid Clevis Location
R Figure 604

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R MR60144-00-A
R Longeron/Clevis Installation Data (Refer to IPC MR 99379 78-32-31 Figure 5)
R Figure 605

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R MR50302-00-A
R Clevis Sealing - Mid Location Shown
R Figure 606

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R MR60145-00-A
R Longeron/Clevis Installation Area – Sealing of Shim Packs to Longerons
R Figure 607

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R MR60145-00-A
R Longeron Shimming Requirements
R Figure 608

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683L SERIES

FAN REVERSER TRANSLATING COWL - REPAIR

R 1. Fan Thrust Reverser Translating Cowl Screen Patch On-Wing/Under-Wing Repair.

R A. This procedure gives instructions to apply a wire mesh screen patch up to 300 sq in. (1,935 sq
R cm) to replace a missing section of screen while the reverser is still mounted on-wing or under-
R wing. Refer to figure 601 and figure 602.

R B. There is no limit to the number of patches that you can use on a reverser half if these two limits
R are followed:

R (1) The total patched area must not be larger than 1,000 sq in. (6,452 sq cm).

R (2) The acoustic blockage caused by adhesive applied to the edges of the repair area
R must be within the acoustic blockage limits given in the 78-32-31 Inspection section.

R C. The intent of this repair is to protect the acoustic skin when pieces of screen peel off the
R translating cowl while in service. Unprotected acoustic skin will erode over time. If more than
R 50% of the screen is lost, remove the translating cowl and do a full screen replacement. Refer
R to 78-32-31 Repair 014.

R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools. None required.

R (3) Locally Manufactured Tools.

R Description Figure No.

R Teflon spatula 603

R (4) Equipment.

R Description Manufacturer

R Sponge roller PADCO, Model

R 3818

R Vacuum bag fittings Local purchase

R Vacuum gage Local purchase

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R B. Consumable Materials:

R Code No. Description Use

R C01-106 Adhesive, Paste, Hysol EA 956 Bond the screen

R C04-035 Alcohol, Isopropyl Clean the repair area

R C10-040 Tape, Teflon, 1.0 x 0.002 inch Surface protection

R C10-048 Bleeder Cloth, Osnaburg, Vacuum bag, air bleeder

R 6.5 oz/sq. yd. - 40 inch wide

R C10-054 Gun, Heat Make the adhesive soft

R C10-119 Wire mesh, 304L, Stainless Steel Screen replacement

R C10-132 Film, Polymer, FEP, Perforated, Release film

R 0.001 thick, A4000P3.
R Airtech International

R C10-134 Cloth, Bleeder/Breather, Vacuum bag, air bleeder

R N10 Polyester Felt,
R Airtech International
R (Alternative to C10-048)

R C10-136 Tape, Flashbreaker, No. 855 Masking

R 0.002 in. (0.051 mm) thick. - 3M

R C10-137 Film, Vacuum Bag, Wrightlon 6400 Vacuum bag material

R Airtech International

R C10-138 Tape, Sealant, Vacuum Bag GS-213 Vacuum bag sealant

R Airtech International

R C10-140 Gloves, Film Nylon/Polyethylene, Mix and apply the

R Disposable adhesive

R C10-141 Abrasive Paper, 180 Grit Prepare the surface

R Local Purchase Film, Polyethylene Surface protection

R Local Purchase Lightweight Fiberglass Fabric Vacuum cure

R Local Purchase Air Weave Vacuum cure

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R C. Expendable Parts. None required.

R D. SPD Identification. None required.

R E. Reference Data.

R 78-32-31 Inspection

R 78-32-31 Repair 014

R 3. Dimensional Information. None required.

R 4. Setup Information. None required.

R 5. Procedure.

R A. This procedure gives instructions to apply a wire mesh screen patch up to 300 sq in. (1,935 sq
R cm) to replace a missing section of screen while the reverser is still mounted on-wing or under-
R wing. There is no limit to the number of patches that you can use on a reverser half. Refer to
R figure 601 and figure 602.

R B. Do the steps that follow to prepare the repair area.

R (1) Use tweezers or needle-nose pliers carefully to remove all loose screen around the
R area to be patched.

R (2) Use 180 grit abrasive paper (C10-141) to sand areas with screen loss. Use care not to
R damage the fibers.

R WARNING: IF YOU CLEAN WITH COMPRESSED AIR, IT CAN CREATE AIRBORNE

R PARTICLES THAT CAN GO INTO YOUR EYES OR GO THROUGH YOUR
R SKIN. DO NOT USE MORE THAN 30 PSIG (207 KPA) PRESSURE. WEAR
R GOGGLES. DO NOT POINT COMPRESSED AIR IN THE DIRECTION OF
R YOUR SKIN.

R (3) Use compressed air to remove remaining dust or other unwanted material.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE
R FLUID IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE
R FUMES. IF YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES,
R FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR
R EYES BECOME IRRITATED. SOLVENTS ARE VOLATILE, TOXIC, AND
R HIGHLY FLAMMABLE.

R (4) Clean the repair area with clean, dry, lint-free, white cotton cloths moist with Isopropyl
R alcohol (C04-035). Clean until a clean area of the cloth stays clean. Let the surface air
R dry for a minimum of 15 minutes.

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R C. Cut a sufficient quantity of the wire mesh screen material (C10-119) to apply over the repair
R area.

R WARNING: DO NOT GET SOLVENT ON YOUR SKIN OR IN YOUR EYES. PUT ON

R PROTECTIVE CLOTHING, GOGGLES, AND A FACE MASK. USE THE FLUID
R IN AN AREA WITH GOOD AIR FLOW. DO NOT BREATHE THE FUMES. IF
R YOU GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY
R WITH WATER. GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.
R SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE.

R D. Hang the piece of screen from one edge and flush it with Isopropyl alcohol to remove dirt and
R oils. Let the material dry in the air. Do not touch the cleaned screen with bare hands.

R WARNING: ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR EYES OR ON

R YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. WEAR CLEAN NYLON FILM OR
R POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN YOU MIX OR APPLY
R THE ADHESIVE.

R E. Make a mixture of EA 956 paste adhesive (C01-106).

R (1) Mix the adhesive in a clean container by weight, in a ratio of 100 parts A (base) to 58
R parts B (catalyst). Mix fully until you can see no streaks of the two components. To
R prevent too much heat buildup, do not mix more than 250 grams in a single mixture.

R NOTE: Heat buildup during or after mixing is normal. If a mixture is too large
R (> 250 grams), the heat buildup can reach a hazardous level that can
R cause uncontrolled decomposition of the adhesive mixture.

R F. Pour the adhesive mixture onto a piece of polyethylene film.

R G. Use a sponge roller to apply an equal layer onto the perforated skin surface.

R H. Let the adhesive dry until the surface is slightly tacky (about 45-60 minutes). When tacky, the
R adhesive will feel slightly sticky, but will not transfer onto your fingers when touched lightly.

R I. Apply the cleaned screen material to the slightly tacky adhesive surface.

R J. Put release film (C10-132) in position over the screen, and then apply light weight fiberglass
R fabric or Air Weave over the release film. Use a locally made Teflon spatula (figure 603) or
R similar tool to work all wrinkles out of the screen.

R K. Apply flashbreaker tape (C10-136) around the edge of the screen repair and rub it into the
R surface. Apply vacuum sealant tape (C10-138) on top of the flashbreaker tape.

R NOTE: Depending on the location of the patch, it might be possible to apply

R pressure to the repair by a means other than vacuum, such as a sand bag
R or other similar method. Alternative procedures are permitted if sufficient
R pressure is applied.

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R L. Apply vacuum bagging material over the sealant tape. Refer to figure 604 and figure 605.

R (1) Cut vacuum bagging film (C10-137) to fit over the repair area with an overlap.

R (2) Cut bleeder cloth (C10-048 or C10-134) and perforated FEP release film (C10-132)
R slightly smaller than the piece of bagging film.

R (3) Make two vacuum fitting cushions from 12.0 in. (30.5 cm) square pieces of bleeder
R cloth (C10-048 or C10-134) folded to 4.0 in. (10.2 cm) square, 9-ply thick cushions.

R (4) Attach the vacuum bag sealant tape (C10-138) around the edges of the vacuum
R bagging film. Do not remove the backing from the sealant tape.

R (5) Use Teflon tape (C10-040) to attach the vacuum fitting cushions to the vacuum bag
R over the fittings.

R M. Apply full vacuum and cure for two hours at ambient temperature, followed by one hour at
R 180°-200° F (82°-93° C). You can also cure the adhesive at ambient temperature for 5-7 days.

R N. Remove the bagging materials.

R WARNING: ADHESIVE IS AN IRRITANT. DO NOT GET THE MATERIAL IN YOUR EYES OR ON

R YOUR SKIN. USE IN AN AREA OPEN TO THE AIR. WEAR CLEAN NYLON FILM OR
R POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN YOU MIX OR APPLY
R THE ADHESIVE.

R O. Make a mixture of EA 956 paste adhesive (C01-106).

R (1) Mix the adhesive in a clean container by weight, in a ratio of 100 parts A (base) to 58
R parts B (catalyst). Mix fully until you can see no streaks of the two components. To
R prevent too much heat buildup, do not mix more than 250 grams in a single mixture.

R NOTE: Heat buildup during or after mixing is normal. If a mixture is too large
R (> 250 grams), the heat buildup can reach a hazardous level that can
R cause uncontrolled decomposition of the adhesive mixture.

R P. Seal the edges of the repair screen and the adjacent screen with a 1/8-1/4 in.(3.2-6.4 mm) wide
R band of EA 956.

R Q. Cure the adhesive. Refer to step Q.A. for an alternative cure.

R (1) Cure at ambient temperature for one hour.

R (2) Follow with a one hour cure at a thermocouple controlled temperature between 180°F
R and 200°F (82°C and 93°C). Use a heat lamp or a heat blanket.

R Q.A. (Alternative Procedure). Cure the adhesive for 24 hours at ambient temperature.

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R MR50317-00-A
R Inner Bondment Wire Mesh Acoustic Areas
R Figure 601

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R MR50316-01-A
R Screen Patch and Edge Sealing
R Figure 602

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R MM50071-00-A
R Teflon Spatula
R Figure 603

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R 1118208-00-A
R Vacuum Fitting Installation (Typical)
R Figure 604

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R MM50077-00-A
R Formation of a Tuck or “Ear” in the Edge of a Vacuum Bag (Typical)
R Figure 605

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FAN REVERSER TRANSLATING COWL - REPAIR

R 1. Fan Thrust Reverser Translating Cowl Re-Finishing.

R A. This procedure provides instructions to re-apply the exterior protective finishes and
R recommended markings to the Translating Cowl Assembly.

R 2. Tools, Equipment, and Materials.

R NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials.

R A. Tools and Equipment.

R (1) Special Tools. None required.

R (2) Standard Tools.

R Description Manufacturer

R Orbital sander Local purchase

R Fine dust vacuum Local purchase

R (3) Locally Manufactured Tools. None required.

R (4) Equipment.

R Description Manufacturer

R HVLP Spray equipment Devilbiss

R JGHV-531-33FX

R Paint Shaker Local purchase

R Zahn viscosity cup #2 Local purchase

R Paint Booth Local purchase

R B. Consumable Materials:

R Code No. Description Use

R C03-006 Chemical Conversion Coating Touch up bare Aluminum

R (Alternates: C03-008, C03-092)

R C03-009 Orange Epoxy Coating Access Opening, Stencils

R (Alternate: Orange Polyurethane
R per MIL-PRF-85285, Color 12197)

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R B. Consumable Materials (Continued):

R Code No. Description Use

R C03-010 Flat Black Epoxy Coating Stenciling

R (Alternate: C03-076)

R C03-060 Black Anti-Static paint Electrically Conductive Coating

R C03-063 Urethane Compatible Prime before Top Coat

R Corrosion Resistant Primer (Alternate: C03-017)
R Per BMS 10-79, Type II or III,
R Class A, Grade A

R C03-077 Epoxy Primer Prime Non-Top coated parts

R C04-003 Acetone Solvent wipe areas to be coated

R or taped (Alternate: C04-035)

R C04-035 Isopropyl Alcohol Solvent wipe areas to be coated

R or taped (Alternate: C04-003)

R C10-009 Paper, Greaseproof Mask off Acoustic Wire Mesh,

R (MIL-B-121 Type II, Grade A, T-Hinges, Seals and any areas
R Class 2 (Kraft)) that are not to receive coating

R C10-102 Masking Tape Mask off Acoustic Wire Mesh,

R T-Hinges, Seals and any areas
R that are not to receive coating

R C10-105 Abrasive Paper, 120 grit Lightly abrade surfaces to be

R re-finished

R C10-120 Abrasive Paper, 320 grit Lightly abrade filled surfaces to be

R re-finished (Alternate: C10-121)

R C10-141 Abrasive Paper, 180 grit Lightly abrade surfaces to be

R re-finished

R C10-182 Cloth (lint-free) Solvent wipe areas to be coated

R or taped

R Local Purchase Polyurethane Top Coat per Topcoat Inner flow surfaces
R MIL-PRF-85285, Type1
R Color #26306 or AR25

R Local Purchase Orange Reflective tape Lock-Out Plates

R Per ASTM D4956, CL.1, Type 1
R Scotchlite 1484 or CW84 (3M)

R Local Purchase 467-9 Composite Filler Putty Fill surface imperfections

R Akzo Nobel

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R C. Expendable Parts. None required.

R D. SPD Identification. None required.

R E. Referenced Procedures.

R 78-32-00 CLEANING

R 78-32-31 Repair 004

R SPM 70-21-04

R SPM 70-21-23

R SPM 70-43-08

R 3. Dimensional Information. None required.

R 4. Setup Information. None required.

R 5. Procedure.

R A. MRAS recommends that existing exterior coatings be removed without damaging the
R underlying composite skin. Recommended stripping processes are Plastic Bead blasting,
R Baking Soda blasting, Dry Ice blasting, or an equivalent blasting method as these types of
R blasting methods will remove primers and top coats without harming anodized surfaces. Refer
R to SPM 70-21-04. If a blasting method is used, MRAS recommends that the exterior coatings
R be removed down to the first primer layer. This primer layer is to be manually sanded away.
R Attempting to blast off all coating may result in perforations to the composite skins. If the
R Mateline filler requires replacement, repair according to 78-32-31 Repair 004 before
R proceeding.

R NOTE: MRAS recommends that the blasting be performed prior to Inspection, Rescreening,
R Repairs and Re-assembly.

R B. Mask off Acoustic Wire Mesh, T-Hinges, Seals and any areas that are not to receive coating
R using masking tape (C10-102) and Kraft paper (C10-009) as necessary.

R C. Lightly abrade all surfaces to be re-finished using #120 - #180 grit paper to remove any
R remaining old primer. Use an orbital sander when possible. Vacuum all dust from structure.

R D. Solvent wipe areas to be coated using Isopropyl Alcohol (C04-035) or Acetone (C04-003) using
R the two-cloth method. Refer to SPM 70-21-23 and 78-32-00 CLEANING.

R E. Fill surface imperfections in composite skins using 467-9 Composite Filler Putty. Mix, apply
R and cure according to manufacturer’s recommendations.

R F. Lightly abrade all filled surfaces using #180 - #320 grit paper. Use an orbital sander when
R possible. Vacuum all dust from structure.

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R G. Solvent wipe areas to be coated using Isopropyl Alcohol (C04-035) or Acetone (C04-003) using
R the two-cloth method. Refer to SPM 70-21-23 and 78-32-00 CLEANING.

R H. Apply Chemical Conversion Coating (Alodine; C03-006, C03-008 or C03-092) to any bare
R Aluminum areas. Refer to SPM 70-43-08.

R I. PRIMED, NON-TOPCOATED ALUMINUM AREAS:

R Mix Epoxy Resin Primer (C03-077) according to manufacturer’s instructions and apply to all
R Aluminum Non-Top Coated parts. Apply one box coat of primer to a dry film thickness of
R 0.0005 inch - 0.0010 inch (0,0127 mm – 0,0254 mm). Allow to cure according to
R manufacturer’s recommendations.

R J. PRIMED AND TOPCOATED AREAS:

R Mix Urethane Compatible Corrosion Resistant Primer (C03-063) BMS 10-79 Type II or III,
R Class A, Grade A or Epoxy Resin Primer MIL-PRF-23377 (C03-017) according to
R manufacturer’s instructions. Apply to the Inner and Outer Flow Path surfaces including the
R Upper and Lower Fairings. Refer to figure 601. Apply one box coat of primer to a dry film
R thickness of 0.0005 inch - 0.0018 inch (0,0127 mm – 0,0457 mm). Allow to cure according to
R manufacturer’s recommendations.

R NOTE: It is best practice to use a primer and top coat from the same manufacturer.

R K. ELECTRICALLY CONDUCTIVE (ANTI-STATIC) COATING:

R Mix Anti-Static Coating (C03-060) according to manufacturer’s instructions. Spray apply two
R cross coats of Anti-Static coating to the outer surface including Actuator Access covers. Refer
R to figure 601. Omit coating from Fairings. Allow fifteen (15) minutes between coats for solvent
R to flash off. Dry coating thickness is to be 0.0012 inch - 0.0025 inch (0,0305 mm – 0,0635 mm).
R Allow to cure according to manufacturer’s recommendations.

R L. Mix Urethane Compatible Corrosion Resistant Primer (C03-063) BMS 10-79 Type II or III,
R Class A, Grade A or Epoxy Resin Primer MIL-PRF-23377 (C03-017) according to
R manufacturer’s instructions. Apply to the Outer Flow Path surfaces with Anti-Static coating
R applied. Refer to figure 601. Apply one box coat of primer to a dry film thickness of 0.0005
R inch - 0.0018 inch (0,0127 mm – 0,0457 mm). Allow to cure according to manufacturer’s
R recommendations. A Pin Hole Filler that is compatible with the chosen paint system may be
R applied as necessary.

R NOTE: It is best practice to use a primer and top coat from the same manufacturer.

R M. TOP COAT OF INNER C-DUCT FLOWPATH:

R Mix Polyurethane Top Coat MIL- PRF-85285, Type 1, Color #26306 or AR25 according to
R manufacturer’s instructions. With wire mesh masking in place, apply two cross coats of
R Polyurethane Top Coat MIL- PRF-85285, Type 1, Color #26306 or AR25 to the Inner Flow Path
R surface of the Translating Cowl to a dry coating thickness of 0.002 inch - 0.005 inch (0,051 mm
– 0,127 mm) thick. Refer to figure 601.

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R N. EXTERIOR OUTER FLOWPATH TOPCOAT:

R Apply Exterior Surface Topcoat(s) per Airline Customer direction. A dry coating thickness of
R 0.002 inch - 0.005 inch (0,051 mm – 0,127 mm) is required. Include the three (3) Actuator
R Access covers and associated screw heads. Refer to figure 601.

R NOTE: It is best practice to use a primer and top coat from the same manufacturer.

R O. Mix Orange Paint (C03-009) according to manufacturer’s instructions. Apply one brush coat to
R the Inner Flange of the three Actuator Access Openings as shown in figure 603.

R P. EXTERIOR MARKINGS:
R After Top Coat is applied, apply Markings per Figure 602. All lettering (except CAUTION) is to
R be Flat Black Epoxy Coating (C03-010 or C03-076). The CAUTION shown in figure 602, Sheet
R 3, is to be Gloss Orange Color #12197 (C03-009). Characters are to be Capitalized Box Style
R lettering (No Serifs).

R NOTE 1: Airframer or FAA-PMA Approved Decals may be used instead of painted Markings on
R Non-Acoustic surfaces.

R NOTE 2: Aircraft Maintenance Manual (AMM) Chapter 11 data may differ with this Repair
R information. The Airline Customer should be consulted when a conflict occurs.

R Q. Solvent wipe the three (3) Lock-Out plates with Isopropyl Alcohol (C04-035) or Acetone (C04-
R 003). Re-apply Orange Reflective tape, Scotchlite 1484 or CW84 (3M) (ASTM-D4956, Class 1,
R Type 1, 0.625 inch (~16 mm) Wide) to the exterior surface of the three (3) Lock-Out plates as
R shown in figure 602 View E.

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R MR50317-00-A
R Translating Cowl Re-Finishing
R Figure 601

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R MR50316-01-A
R Translating Cowl Marking Locations
R Figure 602 (Sheet 1 of 5)

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R NOTE: There are three actuator access covers on the translating cowl.

R MR50316-01-A
R Translating Cowl Marking Locations
R Figure 602 (Sheet 2 of 5)

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R MR50316-01-A
R Translating Cowl Marking Locations
R Figure 602 (Sheet 3 of 5)

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R MR50316-01-A
R Translating Cowl Marking Locations
R Figure 602 (Sheet 4 of 5)

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R MR50316-01-A
R Translating Cowl Marking Locations
R Figure 602 (Sheet 5 of 5)

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R NOTE: Refer to Figure 602 View A for the three locations of the actuator access covers.

R MR50316-01-A
R Translating Cowl Actuator Access Opening Flange Re-Finishing
R Figure 603

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Printed in U.S.A. Middle River Aircraft Systems
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