Model 560XL Structural Repair Manual (Rev 16)

54-10-01 (Rev 15)

NACELLE UPPER/LOWER ENGINE COWL DOOR OUTBOARD EDGE DELAMINATION

1. General
A. Airplane Serialization.
(1) Airplanes -5001 and ON.
B. Damage Description.
(1) This procedure gives instructions for the repair of delamination damage on the outboard edges of the upper and lower
door bond assemblies (upper and lower cowl doors) of the upper and lower engine nacelle assemblies. Refer to Figure
201.
(2) The damage is typically limited to an area approximately 1.50 inches (38.10 mm) wide and 3.50-4.00 inches (88.90-
101.60 mm) long. It is located from the outboard edge of the part to approximately midway between the forward and center
hinge fitting attachments of the cowls and midway between the center and aft hinge fitting attachments of the cowls. Refer
to Table 201 for part numbers.
Table 201. Part Number List
PART NUMBER NOMENCLATURE
6652120-1 Upper Door Bond Assembly (LH)
6652120-2 Upper Door Bond Assembly (RH)
6652120-33 Upper Door Bond Assembly (LH)
6652120-34 Upper Door Bond Assembly (RH)
6652120-35 Upper Door Bond Assembly (LH)
6652120-36 Upper Door Bond Assembly (RH)
6652120-21 Lower Door Bond Assembly (LH)
6652120-22 Lower Door Bond Assembly (RH)
6652120-28 Lower Door Bond Assembly (RH)
6652120-29 Lower Door Bond Assembly (LH)
6652120-30 Lower Door Bond Assembly (RH)
C. Standard Practices.
(1) Before beginning a repair, refer to Chapter 51, Structures - General to review general procedures.
2. Preparation
A. Tools and Equipment
• None necessary.
B. Materials
(1) Table 202 lists the repair materials.
Table 202. List of Repair Materials
NAME NUMBER MANUFACTURER USE
Adhesive EA9309.3NA (Non- Dexter Hysol Repair adhesive.
Asbestos)
Adhesive EA9309.3NA (Non- Henkel Loctite Repair adhesive.
Asbestos)
Adhesive EA9339 Dexter Hysol Repair adhesive.
Adhesive EA9396 (High Temp) Dexter Hysol Repair adhesive.
Woven graphite fabric 3K-193-PW Fabric Development Inc Repair bond assemblies.
1217 Mill Street
Quackertown, PA 18951-
1127

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 Model 560XL Structural Repair Manual (Rev 16)
54-10-01 (Rev 15)

Woven graphite fabric ALS 3K-216-PW-ALS Textile Technologies Inc Repair bond assemblies.
2800 Turnpike Dr
Hatboro, PA 19040
C. Reference Material
• Chapter 51, Structures - General
• Chapter 51, Coin Tap Inspection
• Chapter 51, Vacuum Bagging for Composite Repairs
• Chapter 51, Fastener Installation and Removal
• Model 560XL Maintenance Manual, Chapter 71, Engine Cowling - Maintenance Practices
• Citation Standard Practices Manual, Chapter 20, Electrical Bonding and Grounding - Maintenance Practices
• Citation Standard Practices Manual, Chapter 20, Exterior Finish - Cleaning/Painting
• Citation Standard Practices Manual, Chapter 20, Exterior Finish Paint Thickness - Cleaning/Painting.
D. Prepare the Airplane for the Repair Procedure.
(1) Remove the upper and lower cowl doors from the airplane (Refer to the Model 560XL Maintenance Manual, Chapter 71,
Engine Cowling - Maintenance Practices).
3. Repair Procedure
A. Inspect for Damage.
(1) Coin tap test.
(a) Do a coin tap test to determine the full depth of the damaged area. Refer to Chapter 51, Coin Tap Inspection.
(b) Mark the damaged area with a permanent marker.
B. Remove the Damage.
(1) Remove fasteners common to the 6652100-3/-5 Fwd/Aft Outboard Fire Stop as necessary.
(2) Sand the area manually or with a flexible disk sander.
(a) Carefully scarf back damaged plies from the IML facesheet in the smallest area necessary to remove all detectable
damage. Refer to Figure 202.
NOTE: Maximum allowed size of the sand out area is 5.00 inches x 2.50 inches (127.00 mm x 63.50
mm). If the sand out area is more than these dimensions or if sanding operation does not
remove all damage, contact Cessna Customer Service. Refer to Figure 202.
(3) Carefully inspect the sanded surface for any evidence of moisture or contamination.
(a) If any evidence of the above is present, stop repair and contact Cessna Customer Service.
(b) If no evidence of damage remains, continue with repair.
(4) Sand back the paint and primer within the periphery of the repair lay-up to be installed. Refer to Figure 202.
C. Fabricate the Repair Parts.
NOTE: All repairs are typical for right and left cowls.
(1) Repair Preparation. Refer to Figure 202.
(a) Repair plies RP001 through RP004 will be sized 0.50 inch (12.70 mm) larger than the previous ply or cutout edge in
all directions. Refer to Figure 202.
(2) Repair Ply Details
Table 203. Ply Orientation
Repair Ply Material Orientation
RP001 Woven graphite fabric 0/90°
RP002 Woven graphite fabric +/-45°
RP003 Woven graphite fabric 0/90°
RP004 Woven graphite fabric ALS +/-45°
(3) Repair as follows. Refer to Figure 202.
(a) Lightly sand the repaired area to give a clean, bondable surface.

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 Model 560XL Structural Repair Manual (Rev 16)
54-10-01 (Rev 15)

(b) Vacuum dust or contaminants.

CAUTION: Do not wet area or allow solvent to seep between plies.
(c) Clean the edges with a cloth dampened with Methyl Propyl Ketone (MPK).
(d) Thoroughly wet out repair plies RP001 through RP004 with EA9396 (or equivalent) adhesive. Refer to Figure 202.
(e) Lay-up repair plies RP001 through RP004,
1 Maintain 0.50 inch (12.70 mm) overlap.
2 Maintain ply orientation. Refer to Table 203.
(f) Vacuum bag the lay-up and cure at room temperature for 24 hours or 1 hour at 150°F (65.55°C). Refer to Chapter 51,
Vacuum Bagging for Composite Repairs.
(g) After cure, visually inspect the repair for voids, resin cracks, delamination or bridging in material buildup that might
affect operation.
(h) If problems are found, report them to Cessna Customer Service for disposition.
(i) Back drill and counter sink the repair layup to fit existing fastener holes common to the 6652100-3/-5 Fire Stop. Refer
to Figure 202.
D. Install the Repair
(1) Install existing type and size fasteners (CR3522-4 rivets) of suitable length common to the 6652100-3/-5 Fire Stop. Refer
to Chapter 51, Fastener Installation and Removal.
(2) Do an electrical bond check of the of ALS ply (RP004). Refer to the Citation Standard Practices Manual, Chapter 20,
Electrical Bonding and Grounding - Maintenance Practices.
(3) Use a milli-ohm meter and measure the resistance from the center of the lower surface repair to an existing conductive
surface.
NOTE: Resistance measurements must meet the specifications called out in the Citation Standard
Practices Manual, Chapter 20, Electrical Bonding and Grounding - Maintenance Practices.
NOTE: If repaired area does not meet resistance measurement requirements, contact Cessna Customer
Service.
(4) Smooth and finish the exterior surface as required to obtain aerodynamic smoothness and contour.
(5) Clean and paint. Refer to the Citation Standard Practices Manual, Chapter 20, Exterior Finish - Cleaning/Painting.
(6) Do a check of the paint thickness. Refer to the Citation Standard Practices Manual, Chapter 20, Exterior Finish Paint
Thickness - Cleaning/Painting.
E. Put the Airplane Back to its Initial Condition.
(1) Install the upper and lower cowl doors on the airplane (Refer to the Model 560XL Maintenance Manual, Chapter 71, Engine
Cowling - Maintenance Practices).

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 Model 560XL Structural Repair Manual (Rev 16)
54-10-01 (Rev 15)

Figure 201 : Sheet 1 : DAMAGED AREA

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 Model 560XL Structural Repair Manual (Rev 16)
54-10-01 (Rev 15)

Figure 202 : Sheet 1 : REPAIR INSTALLATION

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 Model 560XL Structural Repair Manual (Rev 16)
54-10-01 (Rev 15)

Figure 202 : Sheet 2 : REPAIR INSTALLATION

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 Model 560XL Structural Repair Manual (Rev 16)
54-10-02 (Rev 15)

ENGINE NACELLE COWL LOWER DOOR LEADING EDGE REPAIR

1. General
A. Airplane Serialization.
(1) Airplanes -5001 and On.
B. Damage Description.
(1) The leading edge of the LH and RH lower cowl doors becomes eroded when the door is exposed to the slipstream. (Refer
to Figure 201) for damage location.
(2) This repair covers damage to the leading edge of the LH and RH lower cowl doors only. The damage must not extend
more than 0.20 inch (5.08 mm) aft of the leading edge. If the damage is greater than 0.20 inch (5.08 mm), or if the existing
plies do not match the original plies, contact Cessna Customer Care for further repair definition.
(3) This repair can only be accomplished one time in any given location using this standard repair. (Refer to Figure 201) for
the general locations of the damage and ply lay-up. Refer to Table 202 for the list of materials. At the latch locations,
additional ply build-up is added to the lay-up. Refer to Table 201 for cowl door part numbers.
Table 201. Part Number List
PART NUMBER NOMENCLATURE
6652120-21 (LH) Cowl Door Bond Assembly (Airplanes -5001 thru -5074)
6652120-29 (LH) Cowl Door Bond Assembly (Airplanes -5075 and On)
6652120-22 (RH) Cowl Door Bond Assembly (Airplanes -5001 thru -5020)
6652120-28 (RH) Cowl Door Bond Assembly (Airplanes -5021 thru -5074)
6652120-30 (RH) Cowl Door Bond Assembly (Airplanes -5075 and On)
C. Repair Definition
(1) The damaged LH and RH lower cowl door leading edge is to be repaired by removing the damaged plies and overlying
repair plies.
(2) This repair is a two-step process. It is necessary to first repair the outside surface with Step 1, allow that portion of the
repair to cure, and then repair the inner surface with Step 2.
NOTE: If the damage is only to the outer plies (P15-P17, P29, P30), then only Step 1 needs to be performed.
If the damage is only to the inner plies (P19-P23, P44/P29, P45/P28), then only Step 2 needs to be
performed.
D. Standard Practices.
(1) Before beginning a repair, refer to Chapter 51, Structures - General to review general procedures.
2. Preparation
A. Tools and Equipment
• None necessary.
B. Materials
(1) Table 202 lists the repair materials.
Table 202. Repair Materials
NAME NUMBER MANUFACTURER USE
Adhesive EA9396 Loctite Aerospace Repair adhesive.
2850 Willow Pass Road
Pittsburg, KS 67277-7704
Syntactic Foam Adhesive EC3524 3M Co. To fabricate the repair ply.
St. Paul, MN 55144
Woven Graphite Fabric with 3K-216-PW-ALS Textile Technologies Inc. Repair fabric.
Aluminum (NOTE 1) 2800 Turnpike Dr.
Hatboro,, PA 19040

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 Model 560XL Structural Repair Manual (Rev 16)
54-10-02 (Rev 15)

Woven Graphite Fabric 3K-193-PW Fabric Development Inc. Repair fabric.

(NOTE 1) 1217 Mill Street
Quackertown,, PA 18951-
1127
Woven Graphite Fabric 6K-370-5H Fabric Development Inc. Repair fabric.
(NOTE 1) 1217 Mill Street
Quackertown,, PA 18951-
1127
Woven Fiberglass 120 Hexcel Repair fabric.
(NOTE 1) Dublin, CA 94568-2898
Bondable Tedlar 100BG30TR E I Du Pont De Nemours Co Repair the leading edge.
(NOTE 1) Inc.
1251 Brandywine Bldg
Wilmington, DE
NOTE 1:
Available from Cessna Aircraft Company.
C. Reference Material
• Chapter 51, Structures - General.
• Chapter 51, Vacuum Bagging For Composite Repairs.
• Model 560XL Maintenance Manual, Chapter 71, Engine Cowling - Maintenance Practices
• Citation Standard Practices Manual, Chapter 20, Electrical Bonding and Grounding - Maintenance Practices
• Citation Standard Practices Manual, Chapter 20, Exterior Finish - Cleaning/Painting
• Citation Standard Practices Manual, Chapter 20, Exterior Finish Paint Thickness - Cleaning/Painting.
D. Definition of repair location and terminology used in this repair.
(1) All repairs are typical for right and left cowls.
(2) The composite structure is made up of plies identified by ply number. These plies are individually identified and each
name is retained throughout this repair.
(a) Plies as manufactured are named Pnn.
(b) Repair plies are named RPnn.
(3) Ply orientation is the direction of the "threads" of the woven fabric in relation to the edge of the cowl door. (Refer to Figure
203).
(a) Ply orientation 0/90º indicates the "threads" are perpendicular and parallel to the edge.
NOTE: A tolerance of +10 or -10 degrees is permissible.
(b) Ply orientation +/-45º indicates the "threads" are at 45 degree angles to the edge.
(c) If ply orientation is listed as optional, there is either no "thread" or orientation is not critical.
(4) Table 203 lists the original ply configuration and lay-up.
Table 203. Original Ply Configuration and Lay-up
PLY MATERIAL ANGLE - (0º = FORWARD, 90º =
OUTBOARD)
(P15) Woven graphite 3K-70-PW-ALS +/-45º
(P16) Woven Graphite 3K-70-PW 0/90º
(P17) Woven Graphite 3K-135-8H +/-45º
(P18) Syntactic Foam N/A
(P19) Woven Graphite 3K-135-8H +/-45º
(P20) Woven Graphite 3K-70-PW 0/90º
(P21) Woven Graphite 3K-70-PW +/-45º

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 Model 560XL Structural Repair Manual (Rev 16)
54-10-02 (Rev 15)

(P22) Woven Fiberglass Optional

(P23) Bondable Tedlar Optional
(P27) Woven Graphite 3K-135-8H 0/90º
(P28) Woven Graphite 3K-135-8H +/-45º
(P29) Woven Graphite 3K-135-8H +/-45º
(P30) Woven Graphite 3K-135-8H 0/90º
(P44) Woven Graphite 3K-135-8H +/-45º
(P45) Woven Graphite 3K-135-8H 0/90º
E. Prepare the Airplane for the Repair Procedure.
(1) Remove the lower engine cowl door(s) from the airplane. Refer to the Model 560XL Maintenance Manual, Chapter 71,
Engine Cowling - Maintenance Practices.
3. Repair Procedure
A. Step One - Repair of the Outer Plies.
(1) Remove the two cowling latches from the leading edge of the lower cowl skin. Refer to the Model 560XL Maintenance
Manual, Chapter 71, Engine Cowling - Maintenance Practices).
NOTE: Sand by using a flexible disc sander or by hand.
(2) Sand back paint and primer 1.00 inch (25.40 mm) along the entire leading edge.
(3) Sand back paint and primer, P15, P16, and P17 along the damaged leading edge, fairing back the plies as shown
inFigure 202 and Figure 201, Step One: Repair Ply Lay-Up.
(4) Paint and primer should be sanded to 1.00 inch (25.40 mm) back from the sanded portion of P15.
(5) Make sure that all of the damage has been sanded away.
(6) Fabricate repair plies RP04 and RP05 from Woven Graphite Fabric, 6K-370-5H. Refer to Table 204 for ply configuration
and orientation.
(a) Size ply RP05 to butt splice against ply P17 (Refer to Figure 201), outer repair ply installation.
(b) Size ply RP04 to overlap ply P17 by 0.75 inch (19.05 mm).
(c) The ply orientation will be +/-45º.
(7) Fabricate repair plies RP02 and RP03 from Woven Graphite Fabric, 3K-193-PW.
(a) Size ply RP03 to overlap ply P16 by 0.50 inch (12.70 mm).
(b) Size ply RP02 to overlap ply RP03 by 0.50 inch (12.70 mm).
(c) The ply orientation will be 0/90º.
(8) Fabricate repair ply RP01 from Woven Graphite Fabric, 3K- 216-PW-ALS.
(a) Size ply RP01 to overlap existing ply P15 by 0.075 inch (1.905 mm).
(b) Ply orientation to be +/-45º.
(9) Table 204 lists the repair ply details for Step One.
Table 204. Repair Ply and Orientation for Step One
Repair Ply Material Orientation
RP01 3K-216-PW-ALS +/-45º
RP02 3K-193-PW 0/90º
RP03 3K-193-PW 0/90º
RP04 6K-370-5H +/-45º
RP05 6K-370-5H +/-45º
(10) Fill the removed area of syntactic foam (P18) with EC3524 syntactic foam adhesive.
NOTE: It is permissible to substitute 2 plies of Woven Graphite Fabric, 3K-193-PW in place of the syntactic
foam.

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 Model 560XL Structural Repair Manual (Rev 16)
54-10-02 (Rev 15)

(11) Allow the foam to cure for 24 hours at room temperature.

(12) Thoroughly wet out the repair plies RP01, RP02, RP03, RP04, and RP05 with EA9396.
(13) Apply the repair plies as shown in Figure 201, Step One: Repair Ply Lay-up.
(14) Plug the holes for the cowling latches if required for vacuum bagging.
(15) Vacuum bag the repair plies. Refer to Chapter 51, Vacuum Bagging For Composite Repairs.
(a) Allow the repair plies to cure.
(b) Let the adhesive (EA9396) cure for a minimum of 24 hours at room temperature or 1 hour at 150°F (65.55°C).
B. Step Two - Repair of the Inner Plies.
NOTE: Sand by using a flexible disc sander or by hand.
(1) Sand back P23, P22, P21, P45/P27, P44/P28, P20, and P19 along the damaged leading edge, fairing back the plies as
shown in Figure 201 and Figure 201, inner repair ply installation.
(2) Table 205 lists the repair ply details for Step Two.
Table 205. Repair Ply and Orientation for Step Two
Repair Ply Material Orientation
RP06 6K-370-5H +/-45º
RP07 6K-370-5H +/-45º
RP08 3K-193-PW 0/90º
RP09 6K-370-5H +/-45º
RP10 6K-370-5H 0/90º
RP11 3K-193-PW +/-45º
RP12 3K-193-PW +/-45º
RP13 3K-216-PW-ALS +/-45º
RP14 120 Optional
RP15 Bondable Tedlar Optional
(3) Make sure that all of the damage has been sanded away.
(4) Fabricate repair plies RP06 and RP07 from Woven Graphite Fabric, 6K-370-5H. Size ply RP06 to butt splice against ply
P19. Size ply RP07 to overlap ply P19 by 0.75 inch (19.05 mm). Ply orientation to be +/-45º.
(5) Fabricate repair ply RP08 from Woven Graphite Fabric, 3K-193-PW. Size ply RP08 to overlap ply P20 by 0.50 inch (12.70
mm). Ply orientation to be 0/90º.
(6) Fabricate repair ply RP09 from Woven Graphite Fabric, 6K-370-5H. Size ply RP09 to overlap ply P28/P44 by 0.75 inch
(19.05 mm). Ply orientation to be +/-45º.
(7) Fabricate repair ply RP10 from Woven Graphite Fabric, 6K-370-5H. Size ply RP10 to overlap ply P27/P45 by 0.75 inch
(19.05 mm). Ply orientation to be 0/90º.
(8) Fabricate repair plies RP11 and RP12 from Woven Graphite Fabric, 3K-193-PW. Size ply RP11 to overlap ply P21 by
0.50 inch (12.70 mm). Size ply RP12 to overlap ply RP11 by 0.50 inch (12.70 mm). Ply orientation to be +/-45º.
(9) Fabricate repair ply RP14 from Woven Glass Fabric, Style 120 to overlap ply RP12.
(10) Fabricate repair ply RP15 of Bondable Tedlar to cover the repaired area and overlap the existing ply of Tedlar by 0.50 inch
(12.70 mm).
(11) Thoroughly wet out the repair plies RP06, RP07, RP08, RP09, RP10, RP11, and RP012 with adhesive (EA9396) and
apply as shown in Figure 201, Step Two: Repair Ply Lay-Up.
(12) Plug the holes for the cowling latches if required for vacuum bagging.
(13) Vacuum bag the repair plies. Refer to Chapter 51, Vacuum Bagging For Composite Repairs and allow it to cure.
(14) Let the EA9396 adhesive to cure for a minimum of 24 hours at room temperature or 1 hour at 150°F (65.55°C).
C. Step Three - Final Repair (Refer to Figure 201).
NOTE: The following steps must be performed to finish the repair.

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 Model 560XL Structural Repair Manual (Rev 16)
54-10-02 (Rev 15)

(1) Fabricate repair ply RP13 from Woven Graphite Fabric, Style 3K-216-PW-ALS. Size ply RP13 to wrap around the leading
edge and extend 0.50 inch (12.70 mm). Ply orientation to be +/-45º.
NOTE: Ply RP13 should extend the entire length of the leading edge to protect from further erosion.
(2) Thoroughly wet out the repair ply RP13 with EA9396 adhesive and apply.
(3) Plug the holes for the cowling latches if required for vacuum bagging.
(4) Vacuum bag the repair plies. Refer to Chapter 51, Vacuum Bagging For Composite Repairs and allow it to cure.
(5) Let the EA9396 adhesive to cure for a minimum of 24 hours at room temperature or 1 hour at 150°F (65.55°C).
(6) Do an electrical bond check. Refer to the Citation Standard Practices Manual, Chapter 20, Electrical Bonding and
Grounding - Maintenance Practices. Verify the electrical conductivity of the repair using a milli-ohm meter to measure the
resistance from the center of each repair patch to an existing conductive surface, and the center of each repair patch to the
center of any adjacent repair patches.
NOTE: The resistance measurements must meet the specifications called out in the Maintenance Manual.
NOTE: If repaired area does not meet resistance measurement requirements, contact Cessna Customer
Service.
(7) Smooth and finish the exterior as required to obtain aerodynamic smoothness and contour.
(8) Clean and paint. Refer to the Citation Standard Practices Manual, Chapter 20, Exterior Finish - Cleaning/Painting.
(9) Do a check of the paint thickness. Refer to the Citation Standard Practices Manual, Chapter 20, Exterior Finish Paint
Thickness - Cleaning/Painting.
D. Put the Airplane Back to its Initial Condition.
(1) Install the cowl latches. (Refer to the Model 560XL Maintenance Manual, Chapter 71, Engine Cowling - Maintenance
Practices).
(2) Install the lower engine cowl doors on the airplane. Refer to the Model 560XL Maintenance Manual, Chapter 71, Engine
Cowling - Maintenance Practices.

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 Model 560XL Structural Repair Manual (Rev 16)
54-10-02 (Rev 15)

Figure 201 : Sheet 1 : Repair Procedure

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 Model 560XL Structural Repair Manual (Rev 16)
54-10-02 (Rev 15)

Figure 201 : Sheet 2 : Repair Procedure

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 Model 560XL Structural Repair Manual (Rev 16)
54-10-02 (Rev 15)

Figure 201 : Sheet 3 : Repair Procedure

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 Model 560XL Structural Repair Manual (Rev 16)
54-10-02 (Rev 15)

Figure 201 : Sheet 4 : Repair Procedure

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 Model 560XL Structural Repair Manual (Rev 16)
54-10-02 (Rev 15)

Figure 202 : Sheet 1 : Step One: Ply Sanding

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 Model 560XL Structural Repair Manual (Rev 16)
54-10-02 (Rev 15)

Figure 203 : Sheet 1 : Material Direction Definition

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 Model 560XL Structural Repair Manual (Rev 16)
54-10-03 (Rev 16)

LOWER COWL DOOR TEARS AT OIL ACCESS DOOR - REPAIR

1. General
A. Airplane Serialization.
(1) Airplanes -5001 and On.
B. Damage Description.
(1) This procedure gives instructions for the repair of tears on the LH and RH lower cowling door just aft of the cowl oil access
door cutout. The tear is typically limited to approximately 1.00 inch (25.40 mm) long. (Refer to Figure 201) for damage
location.
(2) Refer to Table 201 for part numbers.
Table 201. Part Number List
PART NUMBER NOMENCLATURE
6652120-21 (LH) Lower Cowl Door Bond Assembly (Airplanes -5001 thru -
5074)
6652120-29 (LH) Lower Cowl Door Bond Assembly (Airplanes -5075 and
On)
6652120-22 (RH) Lower Cowl Door Bond Assembly (Airplanes -5001 thru -
5020)
6652120-28 (RH) Lower Cowl Door Bond Assembly (Airplanes -5021 thru -
5074)
6652120-30 (RH) Lower Cowl Door Bond Assembly (Airplanes -5075 and
On)
6652120-7 Cowl Oil Access Door
6652100-21 Oil Access Door Lower Hinge
C. Repair Definition
(1) The damaged LH and RH lower cowl door is to be repaired by removing the damaged plies, laying-up repair plies, and
installing a stainless steel doubler under the oil door hinge. Read all of the directions before you begin the repair and
contact Cessna Customer Service if the repair cannot be completed as shown in the directions.
(2) This repair is a two-step process. It is necessary to first repair the outside surface with Step 1, allow that portion of the
repair to cure, and then repair the inner surface with Step 2.
NOTE: It is acceptable to install this repair on an individual cowl or both cowls.
NOTE: (Refer to Figure 202) and Table 203 for original ply configuration and lay-up.
D. Standard Practices.
(1) Before beginning a repair, refer to Chapter 51, Structures - General to review general procedures.
2. Preparation
A. Tools and Equipment
• None necessary.
B. Materials
(1) Table 202 lists the repair materials.
Table 202. Repair Materials
NAME NUMBER MANUFACTURER USE
Adhesive EA9396 Loctite Aerospace Repair adhesive.
2850 Willow Pass Road
Pittsburg, KS 67277-7704
Syntactic Foam Adhesive EC3524 3M Co. To fill the removed area of
St. Paul, MN 55144 syntactic foam (P18).

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 Model 560XL Structural Repair Manual (Rev 16)
54-10-03 (Rev 16)

Woven Graphite Fabric with 3K-216-PW-ALS Textile Technologies Inc. Repair fabric.
Aluminum (NOTE 1) 2800 Turnpike Dr.
Hatboro,, PA 19040
Woven Graphite Fabric 3K-193-PW Fabric Development Inc. Repair fabric.
(NOTE 1) 1217 Mill Street
Quackertown,, PA 18951-
1127
Woven Graphite Fabric 6K-370-5H Fabric Development Inc. Repair fabric.
(NOTE 1) 1217 Mill Street
Quackertown,, PA 18951-
1127
Woven Fiberglass 120 Hexcel Repair fabric.
(NOTE 1) Dublin, CA 94568-2898
Bondable Tedlar 100BG30TR E I Du Pont De Nemours Co Repair the door tear.
(NOTE 1) Inc.
1251 Brandywine Bldg
Wilmington, DE
Stainless Steel (annealed 1/4 Purchase Locally Used to make the doubler
to 1/2 hard), 0.020 inch and shim.
(0.508 mm)
NOTE 1:
Available from Cessna Aircraft Company.
C. Reference Material
• Chapter 51, Structures - General
• Chapter 51, Coin Tap Inspection
• Chapter 51, Vacuum Bagging For Composite Repairs
• Chapter 51, Fastener Installation and Removal
• Model 560XL Maintenance Manual, Chapter 71, Engine Cowling - Maintenance Practices
• Citation Standard Practices Manual, Chapter 20, Electrical Bonding and Grounding - Maintenance Practices
• Citation Standard Practices Manual, Chapter 20, Fuel, Weather, Pressure, and High-Temperature Sealing -
Maintenance Practices
• Citation Standard Practices Manual, Chapter 20, Exterior Finish - Cleaning/Painting
• Citation Standard Practices Manual, Chapter 20, Exterior Finish Paint Thickness - Cleaning/Painting.
D. Definition of repair location and terminology used in this repair.
(1) All repairs are typical for right and left cowls.
(2) The composite structure is made up of plies identified by ply number. These plies are individually identified and each
name is retained throughout this repair.
(a) Plies as manufactured are named Pnn.
(b) Repair plies are named RPnn.
(3) Ply orientation is the direction of the "threads" of the woven fabric in relation to the edge of the cowl door.
(a) Ply orientation 0/90º indicates the "threads" are perpendicular and parallel to the edge.
NOTE: A tolerance of +10 or -10 degrees is permissible.
(b) Ply orientation ±45º indicates the "threads" are at 45 degree angles to the edge.
(c) If ply orientation is listed as optional, there is either no "thread" or orientation is not critical.
(4) Table 203 lists the original ply configuration and lay-up.
Table 203. Original Ply Configuration and Lay-up
PLY MATERIAL ANGLE - (0º = FORWARD, 90º =
OUTBOARD)

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 Model 560XL Structural Repair Manual (Rev 16)
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(P15) Woven graphite 3K-70-PW-ALS ±45º

(P16) Woven Graphite 3K-70-PW 0/90º
(P17) Woven Graphite 3K-135-8H ±45º
(P18) Syntactic Foam N/A
(P19) Woven Graphite 3K-135-8H ±45º
(P20) Woven Graphite 3K-70-PW 0/90º
(P21) Woven Graphite 3K-70-PW ±45º
(P22) Woven Fiberglass Optional
(P23) Bondable Tedlar Optional
E. Prepare the Airplane for the Repair Procedure.
(1) Remove the lower cowl door(s) from the airplane. Refer to the Model 560XL Maintenance Manual, Chapter 71, Engine
Cowling - Maintenance Practices.
(2) Remove the lower cowl oil access door by removing the fasteners common to the lower cowl door and the lower hinge.
Remove the fasteners per Model 500 Series Structural Repair Manual, Chapter 51-40-03,Fastener Installation and
Removal.
3. Repair Procedure
A. Inspect for Damage.
(1) Coin tap test.
(a) Do a coin tap test to determine the full extent of the damaged area. Refer to Chapter 51, Coin Tap Inspection.
(b) Mark the damaged area with a marker.
B. Step One - Repair of Outer Plies.
NOTE: Sand by using a flexible disc sander or by hand.
(1) Sand back the outer 2 plies P15 and P16 from the edge of the tear, fairing back the plies as shown in Figure 203.
(2) Paint and primer should be sanded to 1.0 inch (25.40 mm) back from the sanded portion of P15.
(3) Make sure that all of the damage has been sanded away.
(4) Cut and remove the syntactic foam from the damaged area.
(5) Fabricate repair plies RP02 and RP03 from Woven Graphite Fabric, Style 3K-193-PW. (Refer to Table 204) for ply
configuration and orientation.
(a) Size ply RP03 to overlap ply P16 by 0.50 inch (12.70 mm). (Refer to Figure 204) for outer repair ply installation.
(b) Size ply RP02 to overlap ply RP03 by 0.50 inch (12.70 mm).
(c) The ply orientation will be 0/90º.
(6) Fabricate repair ply RP01 from Woven Graphite Fabric, Style 3K- 216-PW-ALS.
(a) Size ply RP01 to overlap existing ply P15 by 0.075 inch (1.905 mm). (Refer to Figure 204) for outer repair ply
installation.
(b) Ply orientation to be ±45º.
(7) Table 204 lists the Outer Repair Ply Details.
Table 204. Repair Ply and Orientation for Step One
Repair Ply Material Orientation
RP01 Style 3K-216-PW-ALS ±45º
RP02 Style 3K-193-PW 0/90º
RP03 Style 3K-193-PW 0/90º
(8) Fill the removed area of syntactic foam (P18) with EC3524 syntactic foam adhesive.
NOTE: It is permissible to accelerate heat cure the syntactic foam per the manufacturer instructions.
(9) Allow the foam to cure for 24 hours at room temperature.

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 Model 560XL Structural Repair Manual (Rev 16)
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(10) Thoroughly wet out the repair plies RP01, RP02, and RP03 with EA9396.
(11) Apply the repair plies as shown. (Refer to Figure 204).
(12) Plug open holes if required for vacuum bagging.
(13) Vacuum bag the repair plies. Refer to Chapter 51, Vacuum Bagging For Composite Repairs.
(a) Allow the repair plies to cure.
(b) Let the adhesive (EA9396) cure for a minimum of 24 hours at room temperature or 1 hour at 150°F (65.55°C).
C. Step Two - Repair of Inner Plies.
NOTE: Sand by using a flexible disc sander or by hand.
(1) Sand back the inner 3 plies P23, P21, and P20, fairing back the plies as shown. (Refer to Figure 205).
(2) Table 205 lists the Inner Repair Ply Details.
Table 205. Repair Ply and Orientation for Step Two
Repair Ply Material Orientation
RP04 Style 3K-193-PW 0/90º
RP05 Style 3K-193-PW ±45º
RP06 Style 3K-193-PW ±45º
RP07 Bondable Tedlar OPT
(3) Make sure that all of the damage has been sanded away.
(4) Fabricate repair ply RP04 from Woven Graphite Fabric, Style 3K-193-PW. Size ply RP04 to overlap ply P20 by 0.50 inch
(12.70 mm). Ply orientation to be 0/90º.
(5) Fabricate repair plies RP05 and RP06 from Woven Graphite Fabric, Style 3K-193-PW. Size ply RP05 to overlap ply P21
by 0.50 inch (12.70 mm). Size ply RP06 to overlap ply RP05 by 0.50 inch (12.70 mm). Ply orientation to be ±45º. (Refer to
Figure 206).
(6) Fabricate repair ply RP07 of Bondable Tedlar to cover the repaired area and overlap the existing ply of Tedlar P23 by
0.50 inch (12.70 mm).
(7) Thoroughly wet out the repair plies RP04, RP05, RP06, and RP07 with adhesive (EA9396) and apply as shown. (Refer to
Figure 206).
(8) Plug open holes if required for vacuum bagging.
(9) Vacuum bag the repair plies. Refer to Chapter 51, Vacuum Bagging For Composite Repairs and allow it to cure.
(10) Let the (EA9396) adhesive cure for a minimum of 24 hours at room temperature or 1 hour at 150°F (65.55°C).
D. Fabricate the Repair Doubler and Shim. (Refer to Figure 207).
(1) Fabricate a repair doubler from 0.20 inch (0.508 mm) thick 1/4 hard stainless steel or 1/2 hard stainless steel
approximately as shown.
(2) Size the repair strap to be approximately 9.50 inches (241.30 mm) long by 1.90 inches (48.26 mm) wide.
(3) The actual geometry of the repair doubler may vary to incorporate the size, number and type of fasteners shown.
(4) Maintain a 2D edge distance at all fastener locations and a 4D to 8D fastener spacing on all new fastener locations.
(5) Break all sharp edges 0.03 to 0.06 inch (0.76 to 1.52 mm) radius.
(6) Abrasive clean and epoxy prime. Refer to Chapter 51 - Protective Treatment of Metal.
(7) Fabricate a repair shim from 0.020 inch (0.508 mm) thick 1/4 hard stainless steel 1/2 hard stainless steel to fit between the
upper hinge and the oil access door.
(8) The actual geometry of the repair shim may vary to incorporate the size, number and type of fasteners shown.
(9) Maintain a 2D edge distance at all fastener locations and a 4D to 8D fastener spacing on all new fastener locations.
(10) Break all sharp edges 0.03 to 0.06 inch (0.76 to 1.52 mm) radius.
(11) Abrasive clean and epoxy prime. Refer to Chapter 51 - Protective Treatment of Metal.
(12) Fay-seal the doubler with MIL-S-8802 Type I, Class B sealant. Refer to the Citation Standard Practices Manual, Chapter
20, Fuel, Weather, Pressure, and High-Temperature Sealing - Maintenance Practices.

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 Model 560XL Structural Repair Manual (Rev 16)
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(13) Install the repair doubler between the lower door and the lower hinge as shown.
(14) Install using CR3522-4-5 blind fasteners at all locations. Install the fasteners wet with sealant per Model 500 Series
Structural Repair Manual, Chapter 51-40-03, Fastener Installation and Removal.
(15) Fay-seal the shim with MIL-S-8802 Type I, Class B sealant. Refer to the Citation Standard Practices Manual, Chapter 20,
Fuel, Weather, Pressure, and High-Temperature Sealing - Maintenance Practices.
(16) Install the repair shim and upper hinge half using CR3522-4-5 blind fasteners. Install the fasteners wet with sealant per
Model 500 Series Structural Repair Manual, Chapter 51-40-03, Fastener Installation and Removal.
E. Composite Finish Operation.
(1) Do an electrical bond check. Refer to the Citation Standard Practices Manual, Chapter 20, Electrical Bonding and
Grounding - Maintenance Practices. Verify the electrical conductivity of the repair using a milli-ohm meter to measure the
resistance from the center of each repair patch to an existing conductive surface, and the center of each repair patch to the
center of any adjacent repair patches.
NOTE: The resistance measurements must meet the specifications called out in the Maintenance Manual.
NOTE: If repaired area does not meet resistance measurement requirements, contact Cessna Customer
Service.
(2) Smooth and finish the exterior as required to obtain aerodynamic smoothness and contour.
(3) Clean and paint. Refer to the Citation Standard Practices Manual, Chapter 20, Exterior Finish - Cleaning/Painting.
(4) Do a check of the paint thickness. Refer to the Citation Standard Practices Manual, Chapter 20, Exterior Finish Paint
Thickness - Cleaning/Painting.
F. Put the Airplane Back to its Initial Condition.
(1) Install the lower cowl door(s) on the airplane. Refer to the Model 560XL Maintenance Manual, Chapter 71, Engine Cowling
- Maintenance Practices.

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 Model 560XL Structural Repair Manual (Rev 16)
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Figure 201 : Sheet 1 : Damage Locations

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 Model 560XL Structural Repair Manual (Rev 16)
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Figure 202 : Sheet 1 : Lower Cowl Door Original Lay-Up

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 Model 560XL Structural Repair Manual (Rev 16)
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Figure 203 : Sheet 1 : Outer Ply Sanding

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 Model 560XL Structural Repair Manual (Rev 16)
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Figure 204 : Sheet 1 : Outer Repair Ply Installation

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 Model 560XL Structural Repair Manual (Rev 16)
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Figure 205 : Sheet 1 : Inner Ply Sanding

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 Model 560XL Structural Repair Manual (Rev 16)
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Figure 206 : Sheet 1 : Inner Repair Ply Installation

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 Model 560XL Structural Repair Manual (Rev 16)
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Figure 207 : Sheet 1 : Repair Doubler

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