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Goodrich Aerostructures: Transmittal Letter

Goodrich Aerostructures has issued a complete reissue of the Component Maintenance Manual, Revision No. 33, dated April 15, 2019. The manual includes various updates such as revised measurement values, updated illustrations, and new nomenclature across multiple sections. Users are instructed to discard the old manual upon receipt of this new version.

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0% found this document useful (0 votes)

21 views237 pages

Goodrich Aerostructures: Transmittal Letter

Uploaded by

Alireza Samavati.H

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

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GOODRICH AEROSTRUCTURES

CAGE Code 51563

Goodrich Aerostructures
850 Lagoon Drive
Chula Vista, California 91910−2098
Phone: +1−800−735−7899
Email: 24−7@goodrich.com

TRANSMITTAL LETTER
HIGHLIGHTS

TO: COMPONENT MAINTENANCE MANUAL DISTRIBUTION

CONCERNING: Revision No. 33, Dated April 15, 2019

MANUAL UPDATE INSTRUCTIONS

This is a complete reissue of the manual. Discard the old manual upon receipt of this reissued manual.

Chapter/Section/Subject Page Description of Change

Title Page TL−1 Added title and RDN

Description and Operation 1 Revised conversion

Repair 2 6007 Replaced obsolete primer with new primer
and its’ manufacturer (CV17–2912)

Repair 3 6007 Revised measurement values

Repair 4 6016 — 6018 Revised measurement conversion
Repair 6 6002, 6004 Revised measurement values

Repair 7 6005 Revised text (CV18–0167)

6012
6031
6008, 6011 — 6012, Revised measurement values
6019

Assembly 7004 — 7005 Revised measurement values

Illustrated Parts List:
Introduction 10001 Added Note (CV18–2641 Rev A)
Numerical Index 10008 Revised text (CV18–0167)

Figure 1 10028 Added superseded part (CV17–2745)

10029 Revised nomenclature
Figure 5 10052 Updated illustration to add forward arrow
10054 Revised illustration

Page HL−1

Printed in U.S.A.
71−11−09 Apr 15/2019
Rohr, Inc., operating as Goodrich Aerostructures. U.S. Export Classification: EAR 9E991
Goodrich Proprietary − This document is subject to the controls and restrictions on the title page.
GOODRICH AEROSTRUCTURES

CAGE Code 51563

Goodrich Aerostructures
850 Lagoon Drive
Chula Vista, California 91910−2098
Phone: +1−800−735−7899
Email: 24−7@goodrich.com

Chapter/Section/Subject Page Description of Change

10058 Revised nomenclature

Page HL−2

CAGE Code 51563

Goodrich Aerostructures
850 Lagoon Drive
Chula Vista, California 91910−2098
Phone: +1−800−735−7899
Email: 24−7@goodrich.com

COMPONENT MAINTENANCE MANUAL

WITH ILLUSTRATED PARTS LIST

INLET COWL
ASSEMBLY
PART NUMBERS
277−1100−505
277−1100−507
RDN 117

TRANSMITTAL OF TECHNICAL DATA (EAR)

THESE COMMODITIES, TECHNOLOGY, OR SOFTWARE ARE CONTROLLED BY THE U.S. EXPORT
ADMINISTRATION REGULATIONS (EAR). DIVERSION CONTRARY TO U.S. LAW IS PROHIBITED

ECCN: 9E991

71−11−09 Page TL−1

Original Issue Oct 01/1993
Rev 33 Apr 15/2019
Printed in U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures. U.S. Export Classification: EAR 9E991
Goodrich Proprietary − This document is subject to the controls and restrictions on the title page.
GOODRICH AEROSTRUCTURES

CAGE Code 51563

Goodrich Aerostructures
850 Lagoon Drive
Chula Vista, California 91910−2098
Phone: +1−800−735−7899
Email: 24−7@goodrich.com

Goodrich Aerostructures Group Proprietary Information

The information contained in this document is Goodrich proprietary information and is

disclosed in confidence. It is the property of Goodrich and shall not be used, disclosed
to others or reproduced without the express written consent of Goodrich, including, but
without limitation, it is not to be used in the creation, manufacture, development, or
derivation of any repairs, modifications, spare parts, design, 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 the U.S. export control
laws. Unauthorized export or re−export is prohibited.

Copyright License:
Customer is authorized to copy these materials for its own use only, provided that all
copyright notices, proprietary legends, confidential markings, and other restrictive
notices appearing on the original materials are preserved on all such copies.

Caution Regarding Use of Materials:

It is customer’s sole responsibility to ascertain and ensure that all materials are current
and appropriate for the use to which they are put and Goodrich assumes no
responsibility whatsoever in that regard. Customer agrees to indemnify and save
harmless Goodrich against all claims and liability of whatever nature, including those of
third parties (including contractors and vendors to customer) where and by whomsoever
brought, resulting from customer’s use of materials or other information, consultation,
assistance, or training furnished or any other performance in connection with this
agreement by Goodrich or from the manufacture, sale, delivery, resale of any product by
customer. In no event shall Goodrich be liable for any special, incidental, indirect or
consequential or punitive damages.

71−11−09 Page TL−2

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

RECORD OF REVISIONS

REV. DATE REV. DATE

NO. ISSUE DATE INSERTED BY NO. ISSUE DATE INSERTED BY

Initial Oct 01/93 25 Oct 01/10

1 Jan 01/94 26 Apr 01/11
2 Apr 15/94 27 Oct 01/11
3 Apr 01/99 28 Apr 01/12
4 Oct 01/99 29 Oct 01/13
5 Apr 01/00 30 Oct 01/14
6 Oct 01/00 31 Dec 01/15
7 Apr 01/01 32 Oct 01/16
8 Oct 01/01 33 Apr 15/19
9 Oct 01/02
10 Apr 01/03
11 Oct 01/03
12 Apr 01/04
13 Oct 01/04
14 Apr 01/05
15 Oct 01/05
16 Apr 01/06
17 Oct 01/06
18 Apr 01/07
19 Oct 01/07
20 Apr 01/08
21 Oct 01/08
22 Apr 01/09
23 Oct 01/09
24 Apr 01/10

RETAIN THIS RECORD IN THE FRONT OF MANUAL OR CHAPTER. ON RECEIPT OF REVISIONS,

INSERT REVISED PAGES IN THE MANUAL AND ENTER REVISION NUMBER, DATE INSERTED,
AND INITIALS.

Page ROR−1

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

THIS PAGE INTENTIONALLY LEFT BLANK

Page ROR−2

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

RECORD OF TEMPORARY REVISIONS

DATE DATE
TEMPORARY INSERTED/ REMOVED/ DATE
REV. NO. ISSUE DATE INSERTED BY REMOVED BY INCORP.

Page RTR−1

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

THIS PAGE INTENTIONALLY LEFT BLANK

Page RTR−2

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

SERVICE BULLETIN LIST

DATE
SERVICE BULLETIN / INCORPORATED
REVISION NUMBER ISSUE DATE OR NO EFFECT TITLE

23−001 Apr 01/00

23−002 Apr 01/99

30−001 Apr 01/00

30−005 Apr 01/01

71−015 Apr 01/99

71−021 Apr 01/00

71–041 Oct 01/14

71–042 Oct 01/14

71–043 Oct 01/14

Page SBL−1

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THIS PAGE INTENTIONALLY LEFT BLANK

Page SBL−2

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

LIST OF EFFECTIVE PAGES

SECTION PAGE DATE SECTION PAGE DATE

TRANSMITTAL LETTER HL−1 Apr 15/2019 5002 Oct 01/2016

HL−2 Apr 15/2019
Repair General 6001 Oct 01/2016
Title Page TL−1 Apr 15/2019 6002 BLANK
Legal Notice TL−2 Apr 15/2019
Repair No. 1 Stencil And 6001 Oct 01/2016
Record of Revisions ROR−1 Apr 15/2019 Marking Replacement 6002 Oct 01/2016
ROR−2 BLANK 6003 Oct 01/2016
6004 Oct 01/2016
RECORD OF RTR−1 Apr 15/2019 6005 Oct 01/2016
TEMPORARY RTR−2 BLANK 6006 Oct 01/2016
REVISIONS 6007 Oct 01/2016
6008 BLANK
SERVICE BULLETIN SBL−1 Apr 15/2019
LIST SBL−2 BLANK Repair No. 2 Leading 6001 Oct 01/2016
Edge Protector Repair 6002 Oct 01/2016
EFFECTIVE PAGES LEP−1 Apr 15/2019 6003 Oct 01/2016
LEP−2 Apr 15/2019 6004 Oct 01/2016
LEP−3 Apr 15/2019 6005 Oct 01/2016
LEP−4 Apr 15/2019 6006 Oct 01/2016
6007 Apr 15/2019
CONTENTS TOC−1 Apr 15/2019 6008 Apr 15/2019
TOC−2 BLANK 6009 Oct 01/2016
6010 Oct 01/2016
Introduction INTRO−1 Oct 01/2016
INTRO−2 Oct 01/2016 Repair No. 3 Repair Of 6001 Oct 01/2016
INTRO−3 Oct 01/2016 Inlet Cowl Outer Barrel 6002 Oct 01/2016
INTRO−4 Oct 01/2016 Frame Structure 6003 Oct 01/2016
6004 Oct 01/2016
Description and 1 Apr 15/2019 6005 Oct 01/2016
Operation 2 Oct 01/2016 6006 Oct 01/2016
6007 Apr 15/2019
Disassembly 3001 Oct 01/2016 6008 Oct 01/2016
3002 Oct 01/2016 6009 Oct 01/2016
3003 Oct 01/2016 6010 Oct 01/2016
3004 BLANK 6011 Oct 01/2016
6012 Oct 01/2016
Cleaning 4001 Oct 01/2016 6013 Oct 01/2016
4002 Oct 01/2016 6014 BLANK
4003 Oct 01/2016
4004 BLANK Repair No. 4 Non− 6001 Oct 01/2016
Autoclave Outer Barrel 6002 Oct 01/2016
Check 5001 Oct 01/2016 Frame Structure 6003 Oct 01/2016

Page LEP−1

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

LIST OF EFFECTIVE PAGES

SECTION PAGE DATE SECTION PAGE DATE

6004 Oct 01/2016 6007 Oct 01/2016

6005 Oct 01/2016 6008 Oct 01/2016
6006 Oct 01/2016
6007 Oct 01/2016 Repair No. 7 − 6001 Oct 01/2016
6008 Oct 01/2016 REPLACE INLET COWL 6002 Oct 01/2016
6009 Oct 01/2016 INNER BARREL 6003 Oct 01/2016
6010 Oct 01/2016 6004 Oct 01/2016
6011 Oct 01/2016 6005 Apr 15/2019
6012 Oct 01/2016 6006 Apr 15/2019
6013 Oct 01/2016 6007 Oct 01/2016
6014 Oct 01/2016 6008 Apr 15/2019
6015 Apr 15/2019 6009 Oct 01/2016
6016 Apr 15/2019 6010 Oct 01/2016
6017 Apr 15/2019 6011 Apr 15/2019
6018 Apr 15/2019 6012 Apr 15/2019
6019 Oct 01/2016 6013 Oct 01/2016
6020 Oct 01/2016 6014 Oct 01/2016
6021 Oct 01/2016 6015 Oct 01/2016
6022 Oct 01/2016 6016 Oct 01/2016
6023 Oct 01/2016 6017 Oct 01/2016
6024 Oct 01/2016 6018 Oct 01/2016
6025 Oct 01/2016 6019 Apr 15/2019
6026 BLANK 6020 Oct 01/2016
6021 Oct 01/2016
Repair No. 5 Insulation 6001 Oct 01/2016 6022 Oct 01/2016
Blanket Inner Barrel 6002 Oct 01/2016 6023 Oct 01/2016
Acoustic Panel Backskin 6003 Oct 01/2016 6024 Oct 01/2016
Replacement 6004 Oct 01/2016 6025 Oct 01/2016
6005 Oct 01/2016 6026 Oct 01/2016
6006 Oct 01/2016 6027 Oct 01/2016
6007 Oct 01/2016 6028 Oct 01/2016
6008 Oct 01/2016 6029 Oct 01/2016
6009 Oct 01/2016 6030 Oct 01/2016
6010 Oct 01/2016 6031 Apr 15/2019
6011 Oct 01/2016 6032 Oct 01/2016
6012 BLANK 6033 Oct 01/2016
6034 Oct 01/2016
Repair No. 6 Replace 6001 Oct 01/2016 6035 Oct 01/2016
Single Lip Skin Segment 6002 Apr 15/2019 6036 Oct 01/2016
6003 Oct 01/2016 6037 Oct 01/2016
6004 Apr 15/2019 6038 Oct 01/2016
6005 Oct 01/2016 6039 Oct 01/2016
6006 Oct 01/2016 6040 Oct 01/2016

Page LEP−2

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Document Part No. 277−1100

LIST OF EFFECTIVE PAGES

SECTION PAGE DATE SECTION PAGE DATE

6041 Oct 01/2016 10020 Oct 01/2016

6042 Oct 01/2016 10021 Oct 01/2016
6043 Oct 01/2016 10022 Oct 01/2016
6044 Oct 01/2016 10023 Apr 15/2019
6045 Oct 01/2016 10024 Apr 15/2019
6046 BLANK 10025 Apr 15/2019
10026 Apr 15/2019
Assembly (Includes 7001 Oct 01/2016 10027 Apr 15/2019
Storage) 7002 Oct 01/2016 10028 Apr 15/2019
7003 Oct 01/2016 10029 Apr 15/2019
7004 Apr 15/2019 10030 Apr 15/2019
7005 Apr 15/2019 10031 BLANK
7006 Oct 01/2016 Figure 2 10032 Oct 01/2016
7007 Apr 15/2019 10033 Oct 01/2016
7008 BLANK 10034 BLANK
10035 Apr 15/2019
Fits and Clearances 8001 Oct 01/2016 10036 Apr 15/2019
8002 Oct 01/2016 10037 BLANK
Figure 3 10038 Oct 01/2016
Special Tools, Fixtures 9001 Oct 01/2016 10039 Oct 01/2016
and Equipment 9002 Oct 01/2016 10040 BLANK
9003 Oct 01/2016 10041 Apr 15/2019
9004 Oct 01/2016 10042 Apr 15/2019
10043 Apr 15/2019
Introduction 10001 Apr 15/2019 Figure 4 10044 Oct 01/2016
10002 Apr 15/2019 10045 Oct 01/2016
10003 Apr 15/2019 10046 Oct 01/2016
10004 Apr 15/2019 10047 Apr 15/2019
10005 Apr 15/2019 10048 Apr 15/2019
10006 BLANK 10049 Apr 15/2019
Numeric Index 10007 Apr 15/2019 10050 Apr 15/2019
10008 Apr 15/2019 10051 BLANK
10009 Apr 15/2019 Figure 5 10052 Apr 15/2019
10010 Apr 15/2019 10053 Oct 01/2016
10011 Apr 15/2019 10054 Apr 15/2019
Figure 1 10012 Oct 01/2016 10055 Oct 01/2016
10013 Oct 01/2016 10056 Oct 01/2016
10014 Oct 01/2016 10057 Apr 15/2019
10015 Oct 01/2016 10058 Apr 15/2019
10016 Oct 01/2016 10059 Apr 15/2019
10017 Oct 01/2016 Figure 6 10060 Oct 01/2016
10018 Oct 01/2016 10061 Oct 01/2016
10019 Oct 01/2016 10062 BLANK

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Document Part No. 277−1100

LIST OF EFFECTIVE PAGES

SECTION PAGE DATE SECTION PAGE DATE

10063 Apr 15/2019

10064 Apr 15/2019
10065 BLANK

Page LEP−4

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

TABLE OF CONTENTS

SUBJECT TITLE PAGE

INTRODUCTION INTRO−1
DESCRIPTION AND OPERATION 1
TESTING AND FAULT ISOLATION N/A
SCHEMATICS AND WIRING DIAGRAMS N/A
DISASSEMBLY 3001
CLEANING 4001
CHECK 5001
REPAIR GENERAL 6001
REPAIR NO. 1 STENCIL AND MARKING REPLACEMENT 6001
REPAIR NO. 2 LEADING EDGE PROTECTOR REPAIR 6001
REPAIR NO. 3 REPAIR OF INLET COWL OUTER BARREL FRAME STRUCTURE 6001
REPAIR NO. 4 NON−AUTOCLAVE OUTER BARREL FRAME STRUCTURE 6001
REPAIR NO. 5 INSULATION BLANKET INNER BARREL ACOUSTIC PANEL BACKSKIN 6001
REPLACEMENT
REPAIR NO. 6 REPLACE SINGLE LIP SKIN SEGMENT 6001
REPAIR NO. 7 – REPLACE INLET COWL INNER BARREL 6001
ASSEMBLY 7001
FITS AND CLEARANCES 8001
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT 9001
ILLUSTRATED PARTS LIST 10001
SPECIAL PROCEDURES N/A
REMOVAL N/A
INSTALLATION N/A
SERVICING N/A
STORAGE N/A
REWORK N/A

Page TOC−1

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

THIS PAGE INTENTIONALLY LEFT BLANK

Page TOC−2

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

TASK 71−11−09−800−801
1. Introduction

A. This manual gives maintenance instructions and Illustrated Parts List for the Inlet Cowl
Assembly, Part Number 277−1100. Dash number applications are found by going to Figure 1
of the Illustrated Parts List.

B. Cautions, Warnings and Dangers

NOTICE!! Carefully read and obey all CAUTION and WARNING statements in this manual. Refer
to the descriptions of these statements that follow:
− A "CAUTION" statement is given to prevent damage to equipment.

− A "WARNING" statement is given to prevent personal injury or illness

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INCLUDE MANUFACTURER’S
INSTRUCTIONS, THE MATERIAL SAFETY DATA SHEET (MSDS), AND
GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU OR
MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS
GIVES INSTRUCTIONS ON HOW TO SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW TO SAFELY
USE, KEEP, AND DISCARD CHEMICALS.
CADMIUM − Obey the warnings below before you touch or do maintenance on parts that are cadmium
plated. The Occupational, Safety, and Health Administration (OSHA) sets mandatory limits on exposure
to cadmium dust (29 CFR 1910.1027).
WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT IS SWALLOWED CAN
CAUSE KIDNEY OR REPRODUCTIVE SYSTEM DISEASE. AFTER YOU TOUCH
CADMIUM PLATED PARTS, WASH YOUR HANDS BEFORE YOU EAT OR SMOKE.
GET SAFETY INSTRUCTIONS FROM YOUR EMPLOYER. OBEY GOVERNMENT
AND OSHA REGULATIONS WHEN YOU DISCARD PARTS THAT CONTAIN
CADMIUM.
WARNING: DO NOT INHALE CADMIUM PARTICLES, FUMES, OR DUST. THESE PARTICLES,
FUMES, OR DUST CAN CAUSE LUNG OR KIDNEY DISEASE. IF MAINTENANCE
PROCEDURES CREATE CADMIUM PARTICLES, FUMES, OR DUST, TELL YOUR
EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION, AND/OR PROCEDURES
TO PREVENT EXPOSURE TO PERSONNEL.

The Occupational, Safety, and Health Administration (OSHA) has an applicable DANGER warning (29
CFR 1910.1027 (m)(3)(ii)) as follows:

DANGER: CONTAINS CADMIUM. CANCER HAZARD. AVOID CREATING DUST. CAN CAUSE
LUNG AND KIDNEY DISEASE.

Page INTRO−1

Printed in U.S.A.
71−11−09 Oct 01/2016
Rohr, Inc., operating as Goodrich Aerostructures. U.S. Export Classification: EAR 9E991
Goodrich Proprietary − This document is subject to the controls and restrictions on the title page.
GOODRICH AEROSTRUCTURES

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

ASBESTOS − Obey the warning below before you touch or do maintenance on parts that contain
asbestos. Some old assembly components may contain asbestos. The Occupational, Safety, and
Health Administration (OSHA) sets mandatory limits on exposure to asbestos dust (29 CFR 1910.1001).
WARNING: DO NOT BREATHE ASBESTOS DUST. THIS DUST CONTAINS ASBESTOS FIBERS
THAT CAN CAUSE CANCER AND LUNG DISEASE. DO NOT USE COMPRESSED
AIR TO CLEAN PARTS OR ASSEMBLIES THAT POSSIBLY CONTAIN ASBESTOS
DUST. IF MAINTENANCE PROCEDURES EXPOSE PERSONNEL TO ASBESTOS
DUST, TELL YOUR EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION,
AND/OR PROCEDURES TO PREVENT EXPOSURE TO PERSONNEL. OBEY
GOVERNMENT AND OSHA REGULATIONS WHEN YOU DISCARD PARTS THAT
CONTAIN ASBESTOS.

The Occupational, Safety, and Health Administration (OSHA) has an applicable DANGER warning (29
CFR 1910.1001 (j)(4)(ii)) as follows:
DANGER: CONTAINS ASBESTOS FIBERS. AVOID CREATING DUST. CANCER AND LUNG
DISEASE HAZARD.

BERYLLIUM or BERYLLIUM COPPER ALLOYS − Obey the warning below before you touch or do
maintenance on parts that contain beryllium. Bronze bearings and bushings may contain beryllium or
beryllium copper alloys. The Occupational, Safety, and Health Administration (OSHA) sets mandatory
limits on exposure to dust or fumes from beryllium or beryllium copper alloys (29 CFR 1910.1000).
WARNING: DO NOT BREATHE BERYLLIUM PARTICLES OR DUST. THESE PARTICLES OR
DUST CAN CAUSE CANCER OR LUNG DISEASE. IF MAINTENANCE
PROCEDURES MAKE BERYLLIUM PARTICLES OR DUST, TELL YOUR EMPLOYER
TO SUPPLY RESPIRATORS, VENTILATION, AND/OR PROCEDURES TO PREVENT
EXPOSURE TO PERSONNEL. OBEY GOVERNMENT AND OSHA REGULATIONS
WHEN YOU DISCARD PARTS THAT CONTAIN BERYLLIUM. READ AND OBEY THE
NEWEST APPLICABLE MATERIAL SAFETY DATA SHEET (MSDS) THAT IS
AVAILABLE FROM BRUSH WELLMAN INC. (REFER TO THE ADDRESS BELOW).
The newest MSDS for beryllium is available from:
Brush Wellman Inc. Product Stewardship Tel.: (800) 862−4118 Fax: (419)
Department 14710 W. Portage River S. Road 862−4414 www.brushwellman.com
Elmore, Ohio 43416−9502 USA
CERAMIC FIBERS − Obey the warning below before you do maintenance on parts that contain ceramic
fibers. Heat resistant cloth and foil covered heat shields and thermal blankets may contain ceramic
fibers. The Occupational, Safety, and Health Administration (OSHA) and the Refractory Ceramic Fibers
Coalition (RCFC) have a voluntary personnel protection program (PSP 2002, Feb. 11, 2002). This
program gives limits on personnel exposure to ceramic fibers.

Page INTRO−2

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

WARNING: DO NOT BREATHE CERAMIC FIBER DUST. THIS DUST CONTAINS CERAMIC
FIBERS THAT MAY CAUSE CANCER. DO NOT USE COMPRESSED AIR TO CLEAN
PARTS OR ASSEMBLIES THAT POSSIBLY CONTAIN CERAMIC FIBERS. IF
MAINTENANCE PROCEDURES EXPOSE PERSONNEL TO CERAMIC FIBERS,
TELL YOUR EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION, AND/OR
PROCEDURES TO PREVENT EXPOSURE TO PERSONNEL. OBEY GOVERNMENT
AND OSHA REGULATIONS WHEN YOU DISCARD PARTS THAT CONTAIN
CERAMIC FIBERS. READ AND OBEY THE NEWEST APPLICABLE MATERIAL
SAFETY DATA SHEET (MSDS).
CHROMATES (HEXAVALENT CHROMIUM) − Obey the warnings below before you touch or do
maintenance on parts that contain hexavalent chromium. Stainless steel parts often contain hexavalent
chromium. The Occupational Safety and Health Administration (OSHA) sets mandatory limits on
exposure to chromium dust (29 CFR 1910.1000).

WARNING: DO NOT GET HEXAVALENT CHROMIUM ON YOUR SKIN. REPEATED SKIN

CONTACT CAN CAUSE DERMATITIS AND SKIN ULCERS. DIRECT EYE CONTACT
WITH HEXAVALENT CHROMATE DUSTS CAN CAUSE EYE DAMAGE. AFTER YOU
TOUCH HEXAVALENT CHROMIUM PARTS. CLEAN YOUR HANDS BEFORE YOU
EAT OR SMOKE. GET SAFETY INSTRUCTIONS FROM YOUR EMPLOYER. OBEY
GOVERNMENT AND OSHA REGULATIONS WHEN YOU DISCARD PARTS THAT
CONTAIN HEXAVALENT CHROMIUM.
WARNING: DO NOT BREATHE HEXAVALENT CHROMIUM PARTICLES, FUMES OR DUST.
THESE PARTICLES, FUMES OR DUST CAN CAUSE CANCER OR LUNG DISEASE.
IF MAINTENANCE PROCEDURES MAKE HEXAVALENT CHROMIUM PARTICLES,
FUMES OR DUST, TELL YOUR EMPLOYER TO SUPPLY RESPIRATORS,
VENTILATION AND/OR PROCEDURES TO PREVENT EXPOSURE TO
PERSONNEL.
CRYSTALLINE SILICA (Quartz) − Obey the warning below before you touch or do maintenance on
parts that contain crystalline silica. Primers, sealants, static conditioners, and fillers may contain
crystalline silica. The Occupational, Safety, and Health Administration (OSHA) sets limits on exposure to
crystalline silica dust (29 CFR 1910.1000 Table Z−3).
WARNING: DO NOT BREATHE CRYSTALLINE SILICA PARTICLES OR DUST. THESE
PARTICLES OR DUST CAN CAUSE SILICOSIS AND OTHER LUNG DISEASE. IF
MAINTENANCE PROCEDURES MAKE CRYSTALLINE SILICA PARTICLES OR
DUST, TELL YOUR EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION
AND/OR PROCEDURES TO PREVENT EXPOSURE TO PERSONNEL.
LEAD − Obey the warnings below before you touch or do maintenance on parts that contain lead.
Soldered components and high temperature dry lubricants may contain lead. The Occupational, Safety,
and Health Administration (OSHA) sets limits on exposure to lead (29 CFR 1910.1025).

Page INTRO−3

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

WARNING: DO NOT GET LEAD IN YOUR MOUTH. LEAD THAT IS SWALLOWED CAN CAUSE
REPRODUCTIVE OR BLOOD SYSTEM DISEASE. AFTER YOU TOUCH LEAD
PARTS, CLEAN YOUR HANDS BEFORE YOU EAT OR SMOKE. GET SAFETY
INSTRUCTIONS FROM YOUR EMPLOYER. OBEY GOVERNMENT AND OSHA
REGULATIONS WHEY YOU DISCARD PARTS THAT CONTAIN LEAD.

WARNING: DO NOT BREATHE LEAD PARTICLES, FUMES OR DUST. THESE PARTICLES,

FUMES OR DUST CAN CAUSE REPRODUCTIVE OR BLOOD SYSTEM DISEASE. IF
MAINTENANCE PROCEDURES MAKE LEAD PARTICLES, FUMES OR DUST, TELL
YOUR EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION AND/OR
PROCEDURES TO PREVENT EXPOSURE TO PERSONNEL.

Page INTRO−4

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

TASK 71−11−09−870−801
1. Description and Operation (See Figure 1)

A. The inlet cowl assembly directs the air inlet flow to the engine fan section. This assembly has
two−section composite graphite outer barrel around an inner barrel. The inner barrel has three
aluminum alloy, bonded−honeycomb, acoustic−panel assemblies. A titanium bulkhead aft of
the inlet cowl serves as a fireshield between the inlet cowl and the engine fan case. The inlet
cowl lip, attached to both outer and inner barrels, separates the airstream to provide a smooth
airflow to the fan and over the nacelle external surface.

B. Three access panels located on the aft bulkhead of the inlet assembly, two access panels on
the upper outer barrel, and one access door on the inner barrel give access to internal
components. These components are the anti−ice ducting for the lip assembly, an electrical
harness and electrical connector, and an interphone jack.

C. Externally, two hoist points are located on the top of the cowl for attachment of a hand sling
and a grounding receptacle located in the anti−ice air exit duct.

D. Bleed air from the engine is routed through the anti−ice shutoff and regulating valve, the
ducting and the three outlet nozzle to the inlet cowl leading edge. The airflow is in a clockwise
direction. the anti−ice air flows out of the Inlet Cowl through the exhaust duct at the bottom of
the Inlet Cowl.

E. Pertinent Data. (See Table 1)

Diameter: 122.8 in. (3119 mm)

Length: 64 in. (1626 mm)

Weight: 552 lb (250 kg)

Pertinent Data
Table 1

Page 1

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

ANTI−ICE
ACCESS DOOR
ATTACH
RING

ATTACH
BOLT HOLE

INDEX PIN

PRESSURE
RELIEF DOOR INDEX PIN

INTERPHONE AND
GROUND JACKS
CEC−006−00

FIGURE 1 INLET COWL ASSEMBLY

Page 2

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Document Part No. 277−1100

TASK 71−11−09−040−801
1. Disassembly

General
Disassemble the inlet cowl only to the extent necessary to do required maintenance. Refer to
the Check section to determine the condition of components or most probable cause of
malfunction.

A. Disassembly Tools (See Table 301)

DESCRIPTION DESIGNATION MANUFACTURE

Wrench, spanner RSE 1243 V51563
Rohr Inc.
DBA Goodrich Aerostructures 850
Lagoon Dr Chula Vista, CA 91910
(619) 691−2006
www.parts.asg.goodrich.com
Screwdriver Commercially Available
Disassembly Tools
Table 301

B. Disassembly Procedures

CAUTION: PROTECT THE HARNESS ASSEMBLY CONNECTORS FROM DAMAGE

DURING REMOVAL.

(1) Electrical Installation (See IPL Figure 2)

(a) Remove bolts (90) and clamps (100).

(b) Remove bolt (120), nuts (70, 170 and 180), washers (60, 130, 140 and 150),
connector (80) and ground jack wire assembly (10).

(c) Remove screws (30), plate (50) and retainer (40).

(2) Upper Outer Barrel Access Panels (See IPL Figure 3)

(a) Remove screws (30) and access panel (40).

(b) Remove screws (30) and access panel (50).

(3) Anti−ice Supply Tube Assembly (See IPL Figure 1)

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(a) Pre SB 30−001

1) Remove the bolts (230), washers (240) and retainer (330).

2) Remove the screws (180), nut (340), seal (350), back up seal (360), two face
seals (370), face seal (380) and tube assembly (390).

(b) Post SB 30−001 Pre SB 30−005

1) Remove the bolts (230), washers (240) and retainer (330).

2) Remove the screws (180), nut (340), packing seal (355), face seal (385) and
tube assembly (390).

(c) Post SB 30−005

1) Remove the bolts (230), washers (240) and retainer (330).

2) Remove the screws (180), nut (340), packing seal assembly (387) and tube
assembly (390).

(4) Exhaust Duct Assembly (See IPL Figure 1)

(a) Remove bolts (200 and 210), washers (250) and duct assembly (400).

(5) Pressure Relief Door Assembly (See IPL Figure 3)

(a) Remove bolt (70), nut (100), washers (80), pin (280), sleeves (−275), springs (−
285) and door assembly (150).

(b) Remove pins (60), collars (90), strip (110) and bracket (120).

(d) Door Assembly (150)

1) Remove pins (210), nuts (240), washers (220) and latch (250).

2) Remove bolt (160), nut (180), washer (170) and lanyard (190).

3) Remove pins (200), collars (230) and bracket (260).

4) Remove pins (300), collars (330), spacer (310) and hinge half (390) from
splice (400).

(6) Lower Outer Barrel (See IPL Figure 4)

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(a) Remove nuts (120), screws (130) and clips (110).

(b) Remove Screws (290, 300) and plate (280).

(7) Inner Barrel Assembly (See IPL Figure 5)

(a) Remove screws (10), nuts (20) and pin (30).

(8) Lip Assembly (See IPL Figure 6)

(a) Remove bolts (40), washers (50) and nozzle assembly (60).

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TASK 71−11−09−100−801
1. Cleaning

A. Cleaning Materials.

NOTE: YOU CAN USE ALTERNATIVE MATERIALS WITH THE SAME

PROPERTIES TO REPLACE THE ITEMS SHOWN IN TABLE 401.

DESCRIPTION DESIGNATION MANUFACTURER

Blanket, Heat 0°−250°F (−17,8°−121,1°C) V61426

10W/Sq. In. (10W/645 Sq. Atacs Products, Inc.
mm) 850 South Cambridge Street
Seattle, WA 98108−4748
Phone: (206) 433−9000
www.atacs.com
Cheesecloth Commercially Available
Cloth, Breather RC3000−10 V0F451
Richmond Aircraft Products, Inc.
13503 Pulmice St
Norwalk, CA 90650−5250
Phone: (562) 404−2440
www.richmondaircraft.com

Cloth, Lint−Free Cotton Commercially Available

Fabric, Fiberglass Type 181 Commercially Available
Film, Parting Nonporous V0F451
Richmond Aircraft Products, Inc.
Solvent Isopropyl Alcohol 99 percent Commercially Available
pure or
MIBK/MEK Blend (60% Methyl V5E821
Isobutyl Ketone/40% Methyl Univar U.S.A., Inc.
Ethyl Ketone or 532 E. Emaus Street
Middletown, PA 17057−2200
Phone: (717) 944−7471
www.univarusa.com
Turco 6646 V71410
Henkel Corporation

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DESCRIPTION DESIGNATION MANUFACTURER

Cleaning Materials
Table 401

B. Cleaning Procedures.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER
ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Remove the unwanted material with a clean lint−free cloth and solvent. Remove the
solvent with a clean lint−free cloth before the solvent becomes dry. (See Table 401)

NOTE: PARTS MUST BE FREE OF CORROSION, DIRT, GREASE, OIL, AND

OTHER UNWANTED MATERIALS.

C. Cleaning Procedures − Hydraulic Decontamination.

(1) Open up the contaminated area.

(2) Saturate cheesecloth with the solvent and apply to the contaminated surface.

(3) Cover the saturated cheesecloth and contaminated surface with a plastic sheet to
reduce evaporation. Keep covered for approximately four hours.

(4) Remove the cheesecloth. Remove the solvent with a clean lint−free cloth before the
solvent becomes dry.

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(5) Do a test for the presence of Skydrol as follows:

(a) Apply one layer of fiberglass cloth and one layer of breather cloth on the cleaned
area.

(b) Cover breather cloth with nonporous parting film, heat blanket, three layers of
fiberglass cloth, a layer of breather cloth and a vacuum bag. Pull 20−in. HG (0,69
Kg/sq.cm) vacuum.

(c) Increase temperature to 150°−160°F (66°−71°C). Maintain temperature for 60

minutes.

(d) Remove vacuum bag, breather cloth, fiberglass cloth, heat blanket, nonporous
parting film, breather cloth and fiberglass cloth.

(e) Inspect for evidence of Skydrol on breather cloth. If Skydrol remains, repeat Steps
1.C.(2) to 1.C.(5).

(6) Bake dry at 150°−160°F (66°−71°C) for 60 minutes.

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TASK 71−11−09−200−801
1. Check

General.
Do a check of parts in accordance with the general instructions and data specified in this
section.

A. Nondestructive Check Data. (See Table 501.)

IPL NOMEN− METHOD INSTRUCTIONS REQUIREMENTS AND

FIG./ITEM CLATURE DISPOSITION

All Screws and Visual Do a check for corrosion, Replace if defective.

bolts wear, or stripped or Remove corrosion.
crossed threads.
*Flourescent Do a check for cracks at No cracks allowed.
Penetrant thread roots. Replace if defective.
All Nuts Visual Do a check for burrs, Replace if defective.
corrosion, wear, stripped
or crossed threads.

*Flourescent Do a check for cracks. No cracks allowed.

Penetrant Replace if defective.
2−10 Wire assembly Visual Do a check for Replace and/or repair as
discoloration due to required.
excessive heat, and for
broken, loose or frayed
wires.

2−80 Connectors Visual Do a check for damage to Replace and/or tighten

shell or threads, and defective or loose parts.
loose, bent or missing
connector pins.

1−390 Anti−ice tube Visual Do a check for dents, Replace defective tubes.
assembly holes and cracks. Tighten packing nut or
Borescope Do a check of seals for replace seals if leak
leakage. persists.
1−350, Seals Visual Do a check for scratches, No cracks allowed.
360, cracks or cuts. Replace defective parts.
370
380

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IPL NOMEN− METHOD INSTRUCTIONS REQUIREMENTS AND

FIG./ITEM CLATURE DISPOSITION

All Pins Visual Do a check for cracks, No cracks, wear or

corrosion or wear. distortion allowed.
Replace defective parts.
1−400 Exhaust duct Visual Do a check for dents, Replace and/or repair
assembly holes and cracks. Check defective parts.
seals and gaskets for
leakage.

1−480, Aft bulkhead Visual Do a check for cracks and No cracks and/or
490, panel assy, punctures, loose or punctures allowed.
500 access missing fasteners. Replace all loose or
missing fasteners.
Bulkhead assy Visual, Do a check for cracks and No cracks allowed.
forward borescope loose or missing Replace all loose and/or
fasteners. missing fasteners.

All Brackets Visual Do a check for cracks, Replace defective parts.

wear and distortion. Do a Tighten and/or replace
check for loose or missing loose or missing
fasteners. fasteners.
*Fluorescent Do a check for cracks. No cracks allowed.
Penetrant Replace defective parts.

* See GE Standard Practices Manual, GEK 9250

Nondestructive Check Data
Table 501

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TASK 71−11−09−300−801
1. Repair General
TASK 71−11−09−300−801
2. Removed

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TASK 71−11−09−300−802
1. Repair No. 1
TASK 71−11−09−300−802
2. General

A. For all inlet cowl access doors, the actual markings are to be centered on the external
surfaces of the doors. All other markings are placed immediately adjacent to the items on the
inlet cowl for which stenciling is required.

B. All letters and numerical figures are to be black in order to contrast with the surrounding
surface of the inlet cowl. Lines and letters are to be centered under the top line of each
marking. Letters are to be No. 3 Alternate Gothic style. Space height between lines is to be
the same as the letter height.
TASK 71−11−09−300−802
3. Repair Instructions

A. Remove the old stencil. (See Figure 601.)

CAUTION: DO NOT DAMAGE THE BASE FINISH.

(1) Lightly sand off the old stencil message using abrasive aluminum oxide paper (See
Table 602).

NOTE: SEE REPAIR NO. 2 SURFACE FINISH REPAIR−COMPOSITE AS

NECESSARY.

(2) Polish area with rubbing compound.

(3) Remove the unwanted material with a clean lint−free cloth and solvent. Remove the
solvent with a clean lint−free cloth before the solvent becomes dry. (See Table 602)

B. Prepare and apply new stencil.

(1) Cut the stencil. (See Table 601)

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(2) Locate the stencil on the cowl and spray paint through stencil (See Figure 601).

(3) Allow paint to dry.

NOTE: DRYING TIME:

DUST FREE...........30 MINUTES MAX

TACK FREE............3 HOURS MAX

DRY THROUGH..........6 HOURS MAX

TASK 71−11−09−300−802
4. Marking

A. Marking Locations.

NOTE: ITEM NUMBERS REFER TO FIGURE 601.

ITEM NO. LETTER HEIGHT MARKING

1 1/4 INSPECTION ACCESS

2 1/4 UPPER CENTER

3 1/4 LOWER LEFT
4 1/2 HOIST POINT
5 1/4 ANTI−ICE DUCT ACCESS
6 1/4 UPPER LEFT

7 1/2 NO STEP
8 1/2 PHONE JACK
9 1/4 LOWER RIGHT

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ITEM NO. LETTER HEIGHT MARKING

10 1/2 GROUND JACK

Marking Locations
Table 601
TASK 71−11−09−300−802
5. Material and Equipment

NOTE: YOU CAN USE ALTERNATIVE MATERIALS WITH THE SAME PROPERTIES TO
REPLACE THE ITEMS SHOWN IN TABLE 602.

DESCRIPTION DESIGNATION MANUFACTURER

Cloth, Lint−Free Cotton Commercially Available

Compound, Rubbing Commercially Available
Flat Black Flat 3121 V9D157
Pro Line Paint Company
2646 Main Street
San Diego, CA 92113
619−231−2313
Paper, Abrasive 400, 600 Grit Aluminum Oxide Commercially Available

Spatula Metal or Plastic Commercially Available

Solvent Isopropyl Alcohol 99 percent Commercially Available
pure or

MIBK/MEK Blend (60% Methyl V5E821

Isobutyl Ketone/40% Methyl Univar U.S.A., Inc.
Ethyl Ketone or 532 E. Emaus Street
Middletown, PA 17057−2200
Phone: (717) 944−7471
www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583−9300
www.aerospace.henkel.com
Tape, Teflon 2−In. (50.8 mm) Wide Commercially Available

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DESCRIPTION DESIGNATION MANUFACTURER

Template Commercially Available

Topcoat, Epoxy − Flat 463−3−8, Flat Black V0KXA5
Temperature control Akzo Nobel Aerospace Coatings
East Water St.
Waukegan, IL 60085−5563
Phone: (847) 625−4200
Fax: (847) 625−3200
www.anac.com

Repair Materials and Equipment

Table 602

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7 4
1
6

1
9 C2C−1060−01

FIGURE 601 ENGINE INLET COWL MARKING LOCATIONS

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1 4
2

1
3 8 10
C2C−1061−01

FIGURE 601 ENGINE INLET COWL MARKING LOCATIONS

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PHONE
JACK 0.38

2.75

3.20

(0.25)
0.25
2 PL 4.05

GROUND
JACK
1.25
0.50
TYP

DIAGRAM OF MARKING FOR

C2C−1094−00

PHONE JACK AND GROUND JACK

SCALE: NONE

FIGURE 601 ENGINE INLET COWL MARKING LOCATIONS

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TASK 71−11−09−300−803
1. Repair No. 2
TASK 71−11−09−300−803
2. General

A. This repair installs edge protectors which are 18−inch (457 mm) in length.

B. For larger areas, butt splice two sections together. For smaller areas, cut the length to size.

C. If there is damage to the composite surfaces, refer to CF6−80E1 A330 Structural Repair
Manual Section 54−10−00.
TASK 71−11−09−300−803
3. Repair Instructions

A. Surface Preparation

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE)

WHEN YOU DO THIS TASK. BEFORE YOU USE PPE, READ,
UNDERSTAND AND OBEY ALL INSTRUCTIONS FOR ITS USE. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, YOUR EMPLOYER AND GOVERNMENT
REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE PPE. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

(1) Use a putty knife and remove all aerodynamic sealant between the lip skin and the outer
barrel panel in the damaged area.

(2) Make sure there is a minimum gap 0.040−inch (1.02 mm) between the lip skin trailing
edge and the outer barrel leading edge (See Figure 601).

(3) If the gap is less than 0.040−inch (1.02 mm), proceed as follows:

CAUTION: DO NOT CUT INTO LIP SKIN ASSEMBLY BELOW THE OUTER
BARREL LEADING EDGE.

(a) Grind or cut the outer barrel leading edge. Maintain a minimum 2D edge distance
around fasteners.

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(4) Remove the unwanted material with a clean lint−free cloth and solvent. Remove the
solvent with a clean lint−free cloth before the solvent becomes dry. (See Table 601)

(5) Mask the area 1.0−inch (25.4 mm) around the repair area with Teflon tape (See Table
601).

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE)

(6) Use 240−grit abrasive paper (See Table 601) and rough the repair area between the
tape and the lip skin.

(7) Use 240−grit abrasive paper and break the corner of the outer barrel leading edge to a
0.020−inch (0.51 mm) radius (See Figure 601).

(8) Remove the unwanted material with a clean lint−free cloth and solvent. Remove the
solvent with a clean lint−free cloth before the solvent becomes dry. (See Table 601)

B. Repair Material Preparation

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(1) Cut the edge protector(s) to fit the repair edge. Butt the edge protector(s) to the outer
barrel leading edge and gently bend to form around the contour.

(2) Use 400−grit abrasive paper (See Table 601) and rough the mating surface of the edge
protector (See Table 601).

(3) Remove the unwanted material with a clean lint−free cloth and solvent. Remove the
solvent with a clean lint−free cloth before the solvent becomes dry. (See Table 601)

(4) Use 0.063−inch (1.60 mm) thick Aluminum sheet (See Table 601) and make 1.0−inch
(25.4 mm) wide x 40.0−inch (1016.0 mm) long strips.

NOTE: THE STRIPS WILL BE USED TO CLAMP THE EDGE PROTECTORS

TO THE OUTER BARREL WHILE THE ADHESIVE CURES. MAKE A
SUFFICIENT NUMBER OF STRIPS TO COVER ALL OF THE EDGE
PROTECTOR(S).

(5) Cover the mating side of the aluminum strips with Teflon tape (See Figure 602).

C. Edge Protector Bonding

(1) Mix the adhesive (See Table 601). Refer to the instructions of the manufacturer.

(2) Apply the adhesive to the repair surface and the mating surface of the edge protector(s).
Refer to the instructions of the manufacturer.

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(3) Butt the edge protector(s) to the leading edge of the outer barrel (See Figure 602).

(4) Remove excess adhesive with a clean cotton cloth moist with solvent. Remove the
solvent with a clean lint−free cloth before the solvent becomes dry. (See Table 601)

(5) Put the aluminum strips over the edge protector(s) and apply Teflon tape axially over the
aluminum strips (See Figure 602).

(6) Put a cargo strap around the inlet cowl and over the aluminum strips. Lightly snug the
cargo strap to the inlet cowl (See Figure 602).

(7) Use a putty knife and push the edge lip of the edge protector aft against the outer barrel
leading edge.

CAUTION: DO NOT OVER TIGHTEN THE CARGO STRAP. DAMAGE TO THE INLET
COWL CAN OCCUR.

(8) Tighten the cargo strap against the inlet cowl.

(9) Dry the adhesive. Refer to the instructions of the manufacturer.

(10) Remove the cargo strap, aluminum strip(s) and Teflon tape.

D. Surface Finish Application

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WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE)

(1) Use 240−grit abrasive paper and remove the excess adhesive to make an aerodynamic
surface. Use 400−grit abrasive paper and rough the surface of the edge protector(s).

(2) Fill the gap between the edge protector(s) and lip skin with the sealant. Use the sealant
to fill any area around the edge protector(s) not filled by adhesive. Refer to the
instructions of the manufacturer.

(3) Use a putty knife and form the sealant to make an aerodynamic surface.

(4) Mix the epoxy primer (See Table 601). Refer to the instructions of the manufacturer.

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(5) Remove the unwanted material with a clean lint−free cloth and solvent. Remove the
solvent with a clean lint−free cloth before the solvent becomes dry. (See Table 601)

(6) Mask the repair area and the lip skin prevent over spray on the surrounding surface.

(7) Apply one coat of the epoxy primer to the masked repair area. Refer to the instructions
of the manufacturer.

NOTE: A COAT OF EPOXY PRIMER SHALL BE 0.0005 TO 0.001−INCH

(0.013 TO 0.025 MM) THICK.

(8) Dry the primer. Refer to the instructions of the manufacturer.

(9) Apply the anti−static and top coat. Refer to the requirements of the Airline Manufacturer.

(10) Remove all masking materials.

TASK 71−11−09−300−803
4. Repair Materials and Equipment

NOTE: YOU CAN USE ALTERNATIVE MATERIALS WITH THE SAME PROPERTIES TO
REPLACE THE ITEMS SHOWN IN TABLE 601.

DESCRIPTION DESIGNATION MANUFACTURER

Adhesive, Epoxy Paste EA934NA V33564

Henkel Corporation
2850 Willow Pass Rd.
P.O. Box 312
Baypoint, CA 94565−0031
Phone: (800) 257−7522
www.aerospace.henkel.com
Cloth Lint−Free, Cotton Commercially Available
Knife Putty Commercially Available

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DESCRIPTION DESIGNATION MANUFACTURER

Lamp, Heat 75°−200°F (25°−95°C) Commercially Available

Paper, Abrasive 240−Grit, Silicon Carbide Commercially Available
Paper, Abrasive 400−Grit, Aluminum Oxide Commercially Available
Primer, Epoxy Base Curing EEAY051 V83574
Solution Reducer or PRC−DeSoto International, Inc. DBA
02Y040A PPG Aerospace Div
ASC−Los Angeles
24811 Avenue Rockefeller Valencia,
CA 91355−3468
P.O. Box 1800
Phone: (661) 678−4209
www.ppgaerospace.com

Protector, Edge S700E1474−2 V51563

Goodrich Corporation
850 Lagoon Drive
Chula Vista, CA 91910−2098
Sealant DC 93−006 (Two Part) V5D028
Sealant and Catalyst Dow Corning Corporation
3901 South Saginaw Road
Midland, MI 48686
Phone: (989) 496−4400
www.dowcorning.com
Sheet, Aluminum 0.063−inch (1.60 mm) Commercially Available
CLAD 2024−T3
Solvent Isopropyl Alcohol 99 percent Commercially Available
pure or
MIBK/MEK Blend (60% Methyl V5E821
Isobutyl Ketone/40% Methyl Univar U.S.A., Inc.
Ethyl Ketone or 532 E. Emaus Street
Middletown, PA 17057−2200
Phone: (717) 944−7471
www.univarusa.com

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DESCRIPTION DESIGNATION MANUFACTURER

Turco 6646 V71410

Henkel Corporation
32100 Stephenson Hwy
Madison Heights, MI 48071
Phone: (248) 583−9300
www.aerospace.henkel.com
Spatula Metal or Plastic Commercially Available

Strap Cargo Commercially Available

Tape, Masking 2.0−inch (50.8 mm) Commercially Available
Tape, Teflon 1.0−inch (25.4 mm) Commercially Available

Template Commercially Available

Repair Materials and Equipment
Table 601

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1.0 IN. 1.0 IN.

(25.4 mm) (25.4 mm)
TEFLON TAPE

OUTER
0.040 IN. BARREL
(1.016 mm)
LIPSKIN MINIMUM
GAP

REMOVE ALL BREAK CORNER

AERODYNAMIC 0.020 IN.
SEALANT (0.508 mm)
RADIUS

MCC−094−00

PREPARATION FOR INSTALLATION OF OUTER BARREL EDGE PROTECTOR STRIP FIGURE 601

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CARGO STRAP (ALL AROUND INLET)

METAL CLAMPING STRIP
TEFLON TAPE
STRIPS OF TEFLON
TAPE (TYPICAL)
EDGE PROTECTOR (AXIAL DIRECTION)
P/N − S700E1474−2
OUTER BARREL
LIPSKIN

1.0 in. WIDE TEFLON TAPE

EA9394
BOTH FAYING
SURFACES

CEC−007−00

PREPARATION FOR INSTALLATION OF OUTER BARREL EDGE PROTECTOR STRIP FIGURE 601

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TASK 71−11−09−300−804
1. Repair No. 3
TASK 71−11−09−300−804
2. General

A. This repair assumes the outer barrel panel has been removed.

B. This repair describes a single frame repairs. All three frames may be repaired and the
moisture barrier is recommended on all three frames.

C. Repair to frame caps uses precured flat laminations of unidirectional carbon tape. The basic
element is a fiberglass cloth sandwiched between two layers of 0.005−inch thick unidirectional
carbon−epoxy tape. The glass stops the carbon tape from splitting when laminates are
pushed into the contour.
TASK 71−11−09−300−804
3. Repair Instructions

A. Inspect damage area. (See Figure 601)

(1) Determine the extent of the damage.

B. Remove all damage. (See Figure 601)

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE)

(1) Cut out damaged area of frame to the length required to accomplish required repairs.

(2) Cut away or remove damaged or disbonded part of aluminum honeycomb core. Sand off
adhesive fillets and remove adhesive down to original fiberglass layer. Fiberglass layer
must not be damaged. If damaged, you must replace the layer.

(3) Taper ends off frame caps 45 degrees toward outer surface at the cut off line. Smooth
edges of cut off using 180−grit or finer abrasive paper. Sand outer surface of frame cap
six inches beyond cut off using 180−grit abrasive paper. Sand surfaces to smooth matte
finish for bonding.

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(4) Remove the unwanted material with a clean lint−free cloth and solvent. Remove the
solvent with a clean lint−free cloth before the solvent becomes dry. (See Table 601)

C. Remove moisture from the repair area.

NOTE: DO THIS PROCEDURE IF THERE IS EVIDENCE OF MOISTURE IN

THE REPAIR AREA.

(1) Put five plies of fiberglass fabric bleeder cloth above and all around the repair area.

(2) Put a sheet of silicone rubber above the fiberglass fabric.

(3) Put a heat blanket above the sheet of silicone rubber.

(4) Put two plies of breather cloth above the heat blanket.

(5) Put a sheet of 4 mil nylon bagging film above the repair area. The sheet must be 2.0 in.
(51 mm) larger than the repair area all around.

(6) Put the vacuum probes under the nylon bagging film. Seal the probes to the bagging film
with tacky tape bag sealant. Seal the edges of the bagging film to the structure with the
sealant.

(7) Connect the vacuum hose to the vacuum source. Connect the heat blanket to an
electrical source.

(8) Apply a steady vacuum pressure of 22 in. of mercury (74, 5 kPa) and heat the area for
two hours at 150° to 170°F (66° to 77°C).

NOTE: REPEAT STEPS C.(1) THROUGH C.(8) UNTIL THERE IS NO

EVIDENCE OF MOISTURE OR OTHER CONTAMINATION.

(9) Disconnect the heat blanket and the vacuum source. Remove the bagging material.

D. Trim repair core plug. (See Table 601 for core material)

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(1) Trim aluminum honeycomb repair core plug to length of the cutout for a close fit.

E. Make frame cap repair element.

(1) Lay out two graphite tapes with fiber in the lengthwise direction and one prepreg glass
fabric strip at least 2 in. (50.8 mm) longer and the same width as the removed cap
material for each ‘cap repair element’.

(2) Lay up two graphite tapes with one prepreg glass fabric strip sandwiched in between,
i.e., tape−glass−tape, for each cap repair element. (Two cap repair elements are
required for each frame repair).

(3) Vacuum bag and place both repair elements (tape−glass−tape) flat in autoclave and
cure at 70 psi (482.6 kPa) and 345°−355°F (173.9°−179.4°C) for 120−180 minutes.

NOTE: IF TOOLING IS AVAILABLE, INDIVIDUAL GRAPHITE TAPES (4 PER

FRAME REPAIR) CAN BE CURED TO THE OUTER BARREL
RADIUS AND WOULD NOT REQUIRE THE GLASS FABRIC.

F. Prepare fiberglass fill plies.

(1) Use prepreg glass fabric and cut sufficient plies to provide a level surface between the
aluminum honeycomb repair core plug and the original frame cap surface. (See Figure
602)

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(2) Lay up the required number of plies. Bag and apply vacuum at 22 in. of mercury (74.5
kPa). Put into autoclave while under vacuum. Apply 40 to 50 psi (275.8−344.7 kPa)
positive pressure. When autoclave pressure reaches 15 psi (103.4 kPa), vent the
vacuum bag to the atmosphere.

(3) Heat to 240° to 260°F (115° to 127°C) at a rate of 2° to 8°F (1° to 5°C) per minute. Keep
at temperature for 90 to 105 minutes. Cool down to 160°F (71°C) before you release the
autoclave pressure.

G. Install aluminum honeycomb repair core plug.

(1) Use foaming adhesive in accordance with manufacturer’s instructions.

(2) Apply foaming adhesive at the mating areas of the original honeycomb.

(3) Apply supported film adhesive between core plug and outer barrel.

(4) Insert repair core plug.

(5) Apply one or more plies of supported film adhesive on open honeycomb cells.

H. Install pre−cured fill plies. (See Figure 602)

(1) Cut and fit the pre−cured fiberglass fill plies to the area.

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(2) Make sure the fill plies will be flush with the outer frame cap outer surface. Use abrasive
paper to sand down to the correct thickness, if necessary.

(3) Fit the fill plies into position.

I. Install repair elements. (See Figure 602)

(1) Place supported film adhesive over the entire repair length including at least one inch
(25.4 mm) beyond the cut off line at each end.

(2) Place the first cap repair element in the location shown with the one inch (25.4 mm)
overlap at each end.

(3) Place another layer of supported film adhesive between the first and second cap repair
elements.

(4) Install the second cap repair element with length as shown.

J. Prepare repair elements and fill plies for curing.

(1) Vacuum bag repair area for autoclave cure.

(2) Install adequate tooling to stabilize the outer barrel panel during the cure cycle.

K. Cure repair parts.

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(1) Load into autoclave and apply a minimum of 10 inches (250 mm) of mercury (33.9 kPa)
vacuum.

(2) Apply 35 psig (241.3 kPa) pressure before autoclave temperature reaches 200°F
(93.3°C).

(3) Vent bag to atmosphere when autoclave pressure records 15 to 20 psig (103.4 to 137.9
kPa).

(4) Heat at 1° to 10°F (0.5° to 5.5°C) per minute.

(5) Cure at 345° to 365°F (174° to 185°C) for 120 minutes at 35 psig (241.3 kPa).

(6) Remove vacuum bag and materials.

L. Inspect the repair.

(1) Do an inspection and a tap test of the repair area to make sure the requirements of this
repair are done.

M. Install fiberglass fabric moisture barrier over complete repair area as well as any remaining
undamaged frames. (See Figure 603)

(1) Place a sheet of fiberglass on a sheet of nonporous parting film that is large enough to
cover the frame and extend at least 0.5 inch (12.7 mm) on each side of the frame.

(2) Cover with another sheet of nonporous parting film after coating with adhesive. Use a
roller to thoroughly soak fiberglass fabric with adhesive, to remove trapped air and to
remove excessive adhesive.

(3) Fit fiberglass fabric sheet over complete frame, tucking in the corner at the core to outer
skin joint on both sides of the frame.

(4) Cover the fiberglass fabric sheet with a sheet of porous parting film approximately 2
inches (50.8 mm) larger than the fiberglass. Cover the parting film with three layers of
bleeder cloth.

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(5) Cover the entire porous parting film with a vacuum bag approximately 2 inches (50.8
mm) larger, place a vacuum connector under the bag and seal edges with bag sealant.
Apply 20 inches (508 mm) of mercury (67.7 kPa) vacuum inside bag.

(6) Use heat lamps and cure at approximately 150°F (65.5°C) for 1 hour.

(7) Remove vacuum bag and materials.

N. Inspect for integrity of sealing against moisture around complete repair area.
TASK 71−11−09−300−804
4. Repair Materials and Equipment

NOTE: YOU CAN USE ALTERNATIVE MATERIALS WITH THE SAME PROPERTIES TO
REPLACE THE ITEMS SHOWN IN TABLE 601. .

DESCRIPTION DESIGNATION MANUFACTURER

Adhesive, Foaming FM410−1 V0V7G8

Cytec Industries Inc.
5 Garret Mountain Plz
West Paterson, NJ 07242−3317

Adhesive EA9396 A/B V33564

Henkel Corporation
2850 Willow Pass Rd.
P.O. Box 312
Baypoint, CA 94565−0031
Phone: (800) 257−7522
www.aerospace.henkel.com

Adhesive, Epoxy Film EA9689 V33564

Henkel Corporation

Blanket, Heat 0°−250°F 10W/Sq.In V61426

(−18°−121°C 10W/ Atacs Products, Inc.
(645 mm sq) 850 South Cambridge Street
Seattle, WA 98108−4748
Phone: (206) 433−9000
www.atacs.com

Brush Nylon Bristle Commercially Available

Cloth, Bleeder Fiberglass Commercially Available

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DESCRIPTION DESIGNATION MANUFACTURER

Cloth, Breather RC3000−10 V0F451

Richmond Aircraft Products, Inc.
13503 Pulmice St
Norwalk, CA 90650−5250
Phone: (562) 404−2440
www.richmondaircraft.com
Cloth, Lint−Free Cotton Commercially Available

Clothing, Protective Commercially Available

Connector, Vacuum 1/8−In. (3,2 mm) Commercially Available
Diameter
Container Metal or Plastic Commercially Available

Cover, Container Metal or Plastic Commercially Available

Fabric, Fiberglass Type 181 Commercially Available

Film, Bagging 4 Mil (0.1 mm) Nylon V0F451

Richmond Aircraft Products, Inc
Film, Parting Non−Pourous, Porous V0F451
Richmond Aircraft Products, Inc.

Gauge, Vacuum 0−20−In.−Of−Mercury Commercially Available

(0 to 67.7 kPa)
Glasses, Safety Commercially Available
Gloves Neoprene or Polyvinyl Commercially Available
Chloride
Graphite Tape AS−4/3501−5A V0CZA6
2 in. (50.8 mm) wide Hercules Aerospace Co.
5000 S 8400 W
P.O. Box 98
Magna, UT 84044−0098
Honeycomb Core 0.842 height x 2 wide V0WL95 Alcore, Inc.
(1/8 hex cell x 1502 Quarry Drive
0.0020 Thick) 5052 Edgewood, MD 21040−1047
or 5056 Al alloy Phone (410) 676−7100
foil, Non−perforated, www.alcore.com
Core density 8.1 lb/
cu. ft.

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DESCRIPTION DESIGNATION MANUFACTURER

Honeycomb Core 0.842 height x 2 wide V52331

Hose, Vacuum 1/8−In. (3.2 mm) Commercially Available

Diameter

Knife, Utility Commercially Available

Lamp, Heat 180°−200°F Commercially Available
(82.2°−93.3°C)

Mask, Dust Regulatory Agency Commercially Available

Approved
Paper, Abrasive 159, 320−Grit Commercially Available
Aluminum Oxide
Prepreg Glass Fabric CYCOM 985−1/120 V0V7G8
Cytec Industries Inc.
5 Garret Mountain Plz
West Paterson, NJ 07242−3317
phone: (973) 357−3100
www.cytec.com
Probe, Temperature 0° − 250°F Commercially Available
(−17.8° − 121°C)
Pump, Vacuum 0−30 In.−of−Mercury Commercially Available
(0−101.6 kPa)

Roller Steel or Plastic Commercially Available

2−Inch (50.8 mm) Dia

Rubber, Sheet 0.062−0.125−Inch V85471

(1.6−3.2 mm) Boyd Corporation
Silicone 13885 Ramona Avenue
Chino, CA 91710−5426
www.boydcorp.com

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DESCRIPTION DESIGNATION MANUFACTURER

Sealant, Bag Tacky Tape V53309

Schnee−Morehead
Chemicals, Inc.
111 North Nursery Road
P.O. Box 1305
Irving, TX 75060−3153
Solvent Isopropyl Alcohol 99 Percent Commercially Available
Pure
or

MIBK/MEK Blend (60% Methyl V5E821

Isobutyl Ketone/40% Methyl Univar U.S.A., Inc.
Ethyl Ketone) 532 E. Emaus Street
or Middletown, PA 17057−2200
Phone: (717) 944−7471
www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583−9300
www.aerospace.henkel.com
Repair Materials and Equipment
Table 601

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A DAMAGE
A

24 INCH MAX.

CUTOUT CUTOUT

INNER BARRIER INNER CAP (4)

OUTER BARRIER OUTER BARREL SKIN

CORE
SIDE VIEW
SECTION A−A

C2C−081−00

FIGURE 601 FRAME DAMAGE CLEAN UP

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GLASS CLOTH DUST COVER

B B

.075 .075 1.0

INCH INCH INCH

GLASS CAP REPAIR

CLOTH TOP VIEW ELEMENT (2)
DUST
COVER INNER CAP
(4) GLASS
FILL PLIES INNER BARRIER

CORE REPAIR PLUG

OUTER BARRIER OUTER BARREL SKIN

CORE
SIDE VIEW
SECTION B−B

C2C−082−00

FIGURE 602 INSTALLATION OF REPAIR PLIES

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HEAT BLANKET
BREATHER CLOTH (2)
BREATHER CLOTH (2)

NONPOROUS PARTING
VACUUM BAG FILM
BLEEDER CLOTH (3)
VACUUM
HOSE

POROUS PARTING
FILM
CAP REPAIR ELEMENT (2)
GLASS
CLOTH
GLASS FILL
CLOTH PLIES
DUST
CORE REPAIR
COVER
PLUG

BAG SEAL OUTER BARRIER TEMPERATURE

PROBE

C2C−083−00

FIGURE 603 HEAT BLANKET INSTALLATION

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TASK 71−11−09−300−805
1. Repair No. 4
TASK 71−11−09−300−805
2. General

A. This repair applies to frame damage up to 60−inches (1524 mm) in length.

B. This repair applies to outer barrel panels that you have removed from the inlet cowl.

C. This repair gives a single or multiple frame repairs. All three frames can be repaired at one
time. We recommend that you apply the moisture barrier on all three frames, whether you
repair them or not.

D. This repair replaces a section of carbon tape cap element and damaged core with
replacement core and five (5) plies of graphite fabric.
TASK 71−11−09−300−805
3. Repair Instructions

A. Examine damage area (See Figure 601)

(1) Install adequate fixture(s) to stabilize outer barrel panel.

(2) Visually examine and do a tap test on all frames to determine the extent of damage. Put
marks on the panel where you will cut out the damaged frame.

NOTE: ENSURE THE MAXIMUM LENGTH OF DAMAGE DOES NOT

EXCEED 60−INCHES (1524 MM) FOR ANY ONE FRAME. IF
DAMAGE EXCEEDS THIS LIMIT, CONTACT YOUR LOCAL
REPRESENTATIVE FROM GOODRICH AEROSTRUCTURES,
FORMALLY ROHR, FOR DISPOSITION.

(3) Determine the distance from the marks to apply tape according to the following formula:
(See Figure 602)

(a) Add 1−inch (25.4 mm) from the marks for first repair ply.

(b) Add 0.75−inch (19.05 mm) more from the marks for each additional repair ply,
including the fiberglass moisture barrier.

(c) Add 2−inches (50.8 mm) more from the marks.

(4) Apply 2−inch (50.8 mm) wide teflon tape around the repair area at the distance you
found in step A.(3).

(5) Make lay−up templates for the ply lay−ups. See figure 602 for the dimensions of each
ply lay−up.

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B. Remove all damage (See Figure 601)

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE)

(1) Cut out the section of the damaged frame as necessary.

(2) Cut away and remove the damaged or disbonded part of the aluminum honeycomb
core. Remove the adhesive on the graphite fabric under the core to a smooth finish. Use
180−grit or finer abrasive paper. Be careful that you do not damage the fibers of the
graphite fabric.

(3) Taper the ends of the cut frame caps to 45 degrees at the cut off line. Make the edges of
frame cut off areas smooth with 180−grit or finer abrasive paper. Remove the outer
surface of the frame cap 6.0−inches (152.4 mm) beyond the cut off line. Use 180−grit or
finer abrasive paper. Make the surfaces smooth to a matte finish for bonding. (See
Figure 601)

(4) Remove the unwanted material with a clean lint−free cloth and solvent. Remove the
solvent with a clean lint−free cloth before the solvent becomes dry. (See Table 601)

C. Remove moisture from the repair area

NOTE: DO THE FOLLOWING PROCEDURE IF THERE IS EVIDENCE OF

MOISTURE IN THE REPAIR AREA.

(1) Put five plies of the fiberglass fabric bleeder cloth above and all around the repair area.

(2) Put a sheet of silicone rubber above the fiberglass fabric.

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(3) Put a heat blanket above the silicone rubber.

(4) Put two plies of breather cloth above the heat blanket.

(5) Put a sheet of 4−mil nylon bagging film above repair area. The sheet must be 2.0−
inches (50.8 mm) larger than the repair area all around.

(6) Put the vacuum probes under the nylon bagging film. Seal the probes to the bagging film
with tacky tape bag sealant. Seal the edges of the bagging film to the structure with bag
sealant.

(7) Connect the vacuum hose to the vacuum source. Connect the heat blanket to an
electrical source.

(8) Apply a steady vacuum pressure of 22−inches of mercury (74.53 kPa) and heat the area
at 150° to 170°F (66° to 77°C) for two hours.

NOTE: REPEAT STEPS C.(1) THROUGH C.(8) UNTIL THERE IS NO SIGN

OF MOISTURE OR OTHER CONTAMINATION.

(9) Disconnect the heat blanket and the vacuum source. Remove bag sealant, vacuum
hose, heat probe, bagging film, breather cloth, rubber sheet, and bleeder cloth.

D. Cut repair core plug

(1) Cut the aluminum honeycomb repair core plug to the same length and height of the cut
out section. The repair core must be cut so that the ribbon direction matches that of the
remaining core.

E. Prepare the graphite fabric and the fiberglass fabric

NOTE: DETERMINE THE WARP DIRECTION AND LAY−UP OF THE OUTER

BARREL PANEL. THIS DATA CAN BE FOUND IN THE SRM.

(1) Cut a sheet of graphite fabric large enough so that you can cut all repair plies and fill
plies from it.

(2) Cut a sheet of the fiberglass fabric large enough that you can cut the moisture barrier
from it.

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(3) Mix the epoxy composite repair adhesive. Refer to the instructions of the manufacturer.

(4) Put a sheet of graphite fabric on a sheet of nonporous parting film. Use a brush or
spatula to apply a layer of adhesive on the fabric. Put another sheet of nonporous
parting film on the fabric. Apply adhesive with a spatula and soak the sheet thoroughly.
Use the spatula to remove air trapped in the fabric.

(5) Prepare the fiberglass fabric by repeating step E.(4).

F. Prepare the repair area for the aluminum honeycomb core plug (See Figure 602)

(1) Mix the structural paste adhesive. Refer to the instructions of the manufacturer.

(2) Apply structual paste adhesive at the areas that touched the original honeycomb and at
the inner surface of the outer barrel. Refer to the instructions of the manufacturer.

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G. Install core plug with the ribbon direction matching that of the remaining core (See Figure 602)

(1) Apply structural paste adhesive. Refer to the instructions of the manufacturer.

(2) Use a brush to coat the ends and sides of the repair plug with the adhesive.

(3) Install the repair core plug with the ribbon direction matching that of the remaining core.

H. Cut the repair and fill plies (See Figure 602)

(1) Cut the five repair plies and fill plies from the prepared graphite fabric with the templates
made in step A.(5). Make sure the warp direction of the fill plies match that of each
repair ply.

(2) Remove bottom ply of nonporous parting film from first graphite fill ply. Install the fill ply
on top of the honeycomb core. Remove all wrinkles and trapped air from the fill ply with
a brush. Remove the nonporous parting film from top of fill ply.

(3) Repeat step H.(2) for the remaining graphite fill plies. Make sure the top fill ply is flush
with the outer frame cap outer surface. Remove all wrinkles and trapped air from top fill
ply with a brush. Remove the nonporous parting film from top ply.

I. Install Graphite Fabric repair elements (See Figure 602)

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(1) Remove the nonporous parting film from the bottom of repair ply No. 1. Install the repair
ply on the frame cap surface with the cut out and fill plies in the center. Remove all
wrinkles and trapped air from the repair ply with a brush. Remove the nonporous parting
film from the top of the graphite repair ply.

(2) Remove the nonporous parting film from the bottom of the subsequent repair ply. Install
the repair ply with the previous repair ply in the center. Remove all wrinkles and trapped
air with a brush. Remove the nonporous parting film from the top of the repair ply.

(3) Repeat step I.(2) for all five (5) repair plies.

J. Install the fiberglass fabric as a moisture barrier over complete repair area (See Figure 603)

(1) Cut the moisture barrier from the prepared fiberglass fabric. Make sure it is large enough
to cover the frame(s) being repaired and any adjacent frames. Make sure it extends at
least 0.5−inch (12.7 mm) on each side of all frame(s) covered.

(2) Remove the nonporous parting film from bottom of the fiberglass ply. Put the fiberglass
ply over the repair area. Remove wrinkles and trapped air with a brush. Remove the
nonporous parting film from the top of the fiberglass ply.

K. Prepare repair area for curing (See Figure 604)

NOTE: ONE SHEET OF BLEEDER PLY IS NECESSARY FOR EACH

REPAIR LAYER.

NOTE: IF THE REPAIR AREA IS LARGER THAN 36−INCHES (914.4 MM),

TWO VACUUM CONNECTIONS AT OPPOSITE CORNERS OF THE
BAG ARE NECESSARY. THIS IS TO MAKE SURE THERE IS
CORRECT VACUUM PRESSURE OVER THE REPAIR AREA.

NOTE: INSULATION CAN POSSIBLY BE NECESSARY AROUND THE

OUTSIDE SURFACE OF THE OUTER BARREL. THIS IS TO KEEP
THE TEMPERATURE EVEN AND CONSTANT, WHICH IS
NECESSARY FOR CORRECT BONDING.

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(1) Put a sheet of porous parting film over the moisture barrier. Make sure the parting film is
approximately 2−inches (50.8 mm) larger all around than the moisture barrier. Put six
layers of bleeder cloth over the parting film. Put a sheet of nonporous parting film over
the bleeder cloth. Put a silicone rubber sheet over the parting film.

(2) Put one ply of breather cloth over the rubber sheet. Put a heat blanket over the breather
cloth. Put two plies of breather cloth over the heat blanket. Put a vacuum bag on the
heat blanket and rubber sheet. Make sure the vacuum bag is approximately 2−inches
(50.8 mm) larger all around than the heat blanket and rubber sheet. Put a minimum of
three temperature probes at the edge of the bond area. Put a vacuum connector under
the vacuum bag. Seal the edges of the vacuum bag with bag sealant.

L. Cure repair plies

(1) Apply 22−inches of mercury (74.50 kPa) pressure inside the vacuum bag. Turn on the
heat blanket and raise temperature of the repair area to 190° to 210°F (88° to 99°C) for
220 minutes.

(2) After the repair cools down to a minimum of 100°F (37.8°C), remove the bag sealant,
vacuum bag, heat blanket, rubber sheet, bleeder cloth, breather plies, and parting film.

M. Examine repair

(1) Do a visual inspection and a tap test of the repair to check for disbonds and voids.

N. Prepare surface for painting

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE)

CAUTION: USE OF PAINT REMOVER COMPOUNDS ON GRAPHITE/ARAMID/EPOXY

STRUCTURES IS PROHIBITED. THE COMPOUNDS ATTACK THE EPOXY
BONDING ADHESIVE IN THE STRUCTURE AND WILL DEGRADE THE
INTEGRITY OF THE PARENT COMPOSITE MATERIALS.

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CAUTION: DO NOT CUT OR BREAK FIBERS FROM EXPOSED GRAPHITE PLY.

(1) Air−wet the surface of the moisture barrier. Rub all around edge of the moisture barrier
to a featheredge with 180−grit or finer abrasive paper. Make sure the surface is smooth
enough to paint.

(2) Rub graphite/aramid/epoxy structures with 180−grit or finer abrasive paper to a smooth,
dull matte finish with all gloss removed.

(3) Remove surface finishes and filler material from areas to be painted. Rub the material
from rivet heads to a featheredge of a minimum blend ratio of 10 to 1.

(4) Remove the unwanted material with a clean lint−free cloth and solvent. Remove the
solvent with a clean lint−free cloth before the solvent becomes dry. (See Table 601)

(5) Put a cover around the repair area to protect adjacent surfaces from paint over−spray.

O. Apply the epoxy primer (green)

(1) Mix the green epoxy primer base and converter. Use thinner as necessary to get the
correct spray consistency. Refer to the instructions of the manufacturer.

(2) Apply a cross coat of primer 0.0005 − 0.0007−inches (0.5 − 0.7 mil) thick. Refer to the
instructions of the manufacturer.

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(3) Dry the paint. Refer to the instructions of the manufacturer.

(4) Remove the cover from around the repair area.

P. Do water break test

NOTE: THIS PROCEDURE WILL MAKE SURE NO CONTAMINATION

EXISTS ON THE SURFACES TO BE BONDED. DO THIS TEST
WHEN THE SURFACES ARE CLEAN.

CAUTION: BE CAREFUL WHEN EXPOSING WATER TO A SURFACE ADJACENT TO

HONEYCOMB MATERIAL. IF WATER BECOMES CAUGHT IN THE
HONEYCOMB, IT WILL BE NECESSARY TO REMOVE THE WATER
BEFORE PROCEEDING WITH THE REPAIR.

(1) Fill a clean polyethylene bottle that has a small spray nozzle with a sufficient amount of
distilled water for the test.

(2) Spray the water on the clean surface until a thin layer of water is on all the surface.

(3) If the surface is clean, there will be an unbroken layer of water for 30 seconds. If the
surface has contamination, the water will separate into sections or beads.

(4) If you find the surface has contamination, repeat the cleaning procedure and do another
water break test.

(5) After you do a successful water break test, clean the water off the surface with a clean
dry cloth.

(6) Force air−dry the area at 150°F (65.5°C) for 30 minutes. Let the area cool to ambient
temperature before you continue with the repair.

(7) If moisture exists in the honeycomb panel after the end of water break test, remove the
moisture from the honeycomb panel. Refer to step C. of this repair.

Q. Prepare surface for ablative material

NOTE: APPLY ABLATIVE MATERIAL TO THE INNER SURFACE OF THE

OUTER BARREL. MAKE SURE IT IS ON THE REPAIR AND ALL
ADJACENT AREAS. (SEE FIGURE 605).

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CAUTION: TO PREVENT CONTAMINATION OF OTHER REPAIR FACILITIES BY

SILICONE MATERIALS, MAKE SURE THE REPAIR FACILITY FOR THIS
REPAIR IS ISOLATED. ANY REPAIR FACILITIES THAT APPLIES THE
MATERIALS USED IN THIS REPAIR AND/OR ANY RELATED SILICONE
MATERIALS MUST BE IDENTIFIED "RESERVED FOR SILICONE
APPLICATION ONLY".

(1) Remove the unwanted material with a clean lint−free cloth and solvent. Remove the
solvent with a clean lint−free cloth before the solvent becomes dry. (See Table 601)

WARNING: DO NOT POINT COMPRESSED AIR IN THE DIRECTION OF PERSONNEL.

THIS CAN CAUSE INJURY TO THE EYES OR BLINDNESS. THIS CAN
CAUSE LOOSE PARTICLES TO BECOME EMBEDDED UNDER THE
SKIN.

(2) Blow air throughout the repaired area and around adjacent surfaces to make sure the
surface is fully clean. Air must be dry, oil−free, compressed air at 30 psi maximum
(206.8 kPa). Clean surfaces with dry cotton clothes as necessary.

NOTE: THE SURFACE MUST BE PRIMED WITHIN 12 HOURS OF SURFACE

PREPARATION. SURFACES THAT HAVE EXCEEDED THE 12−
HOUR LIMITATION MUST BE RE−CLEANED PER STEP Q.

NOTE: USE LINT−FREE GLOVES WHEN YOU TOUCH THE PARTS.

R. Prime surface for adhesion

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(1) Put a small quantity of RTV prime coat into a polyethylene container. Visually examine
the primer. Satisfactory siliocne primer will be clear. Unsatisfactory primer will be cloudy.

NOTE: NEVER PUT RTV PRIME COAT BACK INTO ITS ORIGINAL
CONTAINER. DISCARD UNUSED PRIMER IN AN APPROVED
WASTE CONTAINER.

(2) Apply a very thin layer of RTV prime coat to the prepared surface. If you use red RTV
prime coat, you can make an estimate of the layer thickness by its color: the thicker the
primer, the darker the red color. Too thick a layer is chalky. Remove too thick primer with
a clean cotton cloth.

NOTE: IF YOU REMOVED PRIMER BECAUSE IT WAS TOO THICK, IT IS

POSSIBLE THAT YOU DO NOT NEED TO APPLY MORE PRIMER.
MAKE SURE THE ENTIRE SURFACE IS WET WITHOUT RUNS OR
PUDDLES. MAKE SURE THE PRIMER IS NOT CHALKY.

(3) RDry the primer. Refer to the instructions of the manufacturer.

S. Apply ablative material (See Figure 605)

(1) Mix ablative material. Refer to the instructions of the manufacturer.

(2) Initial equipment adjustments are:

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COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

(a) Spray pot pressure; 25 ± 5 psi (172.3 ± 34.4 kPa).

(b) Atomization pressure; 30 ± 10 psi (206.8 ± 68.9 kPa).

(3) Put Heptane solvent through the fluid hose and spray gun immediately before the
ablative material. This prevents the equipment from becoming clogged at start up.

(4) Apply a test pattern spray on a test sheet. The distance from the nozzle to the substrate
must be 8−12−inches (203.2−304.8 mm). The spray material must be smooth and flat
on the paper. If the material does not apply correctly, adjust the spray gun equipment.
For example, adjust the fluid needle to change the wetness of the material. Adjust the
spray pattern to change the width of the fan pattern.

(5) Once you have correctly adjusted the spray pattern, apply the ablative material as
follows: Apply the first layer approximately 0.005 − 0.010−inches (0.127 − 0.254 mm)
thick. Apply subsequent layers 0.020 − 0.030−inches (0.508 − 0.762 mm) thick. Let the
solvent dry between layers for approximately 2 to 3 minutes or until the material has a
matte finish when seen from a 45 degree angle. Drying time can vary with weather
conditions and material thickness. Apply the layers with an approximately 50 percent
overlap. Each layer must be applied without stopping. The total thickness of all layers
must be between 0.500 ± 0.030−inches (12.7 mm ± 0.762 mm).

(6) Let the layers cure at 75°± 5°F (23.9°± 2.8°C), at a relative humidity of 30%, for 48
hours minimum. For a faster cure, let the layers cure for 8 hours at 75°± 5°F (23.9°±
2.8°C) followed by 10 hours at 120° to 150°F (48.8° to 65.6°C).

(7) Carefully remove the teflon tape from around the repair area.

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(8) Clean the repair area with a clean, lint−free cloth and the solvent. Remove the solvent
with a clean lint−free cloth before the solvent becomes dry.

T. Apply the sealant. (See Figure 606)

(1) Apply RTV prime coat by brush to the panel adjacent to the edge of the ablative
material. Let dry for a minimum of 60 minutes. Refer to the instructions of the
manufacturer.

NOTE: APPLY THE SEALANT IN 24 HOURS AFTER THE PRIMER HAS

DRIED. IF MORE THAN 24 HOUR, CLEAN THE SURFACE WITH
THE SOLVENT, DRY THE SURFACE WITH A CLEAN CLOTH, AND
APPLY THE PRIMER AGAIN.

(2) Mix the silicone sealant. Refer to the instructions of the manufacturer.

(3) Apply the sealant to the edges you can see of the ablative material. Refer to the
instructions of the manufacturer.

NOTE: DISTILLED WATER OR A SOLUTION OF ISOPROPYL ALCOHOL IN

DISTILLED WATER CAN BE USED TO MAKE SURE THE TOOLS
MOVE FREELY AND TO MAKE THE EDGES OF THE SEALANT
SMOOTH.

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Document Part No. 277−1100

(4) Make the edges of the sealant around the ablative material smooth. Use a non−metallic
scraper or spatula. (See Figure 606)

(5) Dry the sealant before you apply the ablative material topcoat. Refer to the instructions
of the manufacturer.

U. Apply the ablative material topcoat

(1) Mix the ablative material topcoat part "A" by itself for 30 minutes in an explosive proof
container. After you mix part "A" slowly add the applicable amount of part "B". Refer to
the instructions of the manufacturer.

NOTE: THE LIFE OF THE ABLATIVE MATERIAL TOPCOAT IS 60 MINUTES

AT 50° TO 90°F (9.99° TO 32.22°C) IN A CLOSED CONTAINER. FOR
SPRAY APPLICATIONS, USE THE FLUID NEEDLE TO ADJUST THE
WETNESS OF THE MATERIAL. THE NOZZLE TO SUBSTRATE
DISTANCE MUST BE 8 − 12−INCHES (203.2 − 304.8 MM). APPLY
THE MATERIAL IN MULTIPLE COATS AS NECESSARY TO
PREVENT RUNS, SAGS, AND PUDDLES. THE FIRST COAT MUST
BE 0.005−INCHES (0.127 MM) THICK. APPLY SUBSEQUENT
COATS 0.005 − 0.010−INCHES (0.127 − 0.254 MM) THICK. WAIT 2
TO 3 MINUTES BETWEEN COATS FOR SOLVENT TO DRY. AVOID
LONG DELAYS IN EXCESS OF 6 MINUTES BETWEEN COATS.
SPRAY POT PRESSURE MUST BE 20 ± 3 PSI (137.8 ± 20.6 KPA)
AND ATOMIZING SPRAY GUN PRESSURE MUST BE 40 ± 3 PSI
(275.7 ± 20.6 KPA).

(2) Apply a layer of ablative material topcoat 0.015 − 0.020−inches (0.381 − 0.508 mm)
thick on the ablative material. Refer to the instructions of the manufacturer.

(3) Dry the topcoat. Refer to the instructions of the manufacturer.

(4)
Visually examine the repair to make sure you did all of the requirements of this repair
procedure.
TASK 71−11−09−300−805

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CAUTION: WHEN YOU REMOVE THE PANEL FROM THE SUPPORT FIXTURE(S), DO NOT
LET THE PANEL BEND TOO MUCH. THIS COULD CAUSE DAMAGE TO THE
ABLATIVE MATERIAL.

4. Materials and Equipment

NOTE: YOU CAN USE ALTERNATIVE EQUIPMENT WITH THE SAME PRECISION TO
REPLACE THE ITEMS SHOWN IN TABLE 601.

NOTE: YOU CAN USE ALTERNATIVE MATERIALS WITH THE SAME PROPERTIES TO
REPLACE THE ITEMS SHOWN IN TABLE 601.

DESCRIPTION DESIGNATION MANUFACTURER

Adhesive, Epoxy Composite EA9390 (Two Part) V33564

Repair Henkel Corporation
2850 Willow Pass Rd.
P.O. Box 312
Baypoint, CA 94565−0031
Phone: (800) 257−7522
www.aerospace.henkel.com

Adhesive, Structural Paste EA9394 (Two Part) V33564

Henkel Corporation
Blanket, Heat 0°−250°F 5W/Sq.In V61426
(−18°−121°C5said tW/ Atacs Products, Inc.
(645 mm sq) 850 South Cambridge Street
Seattle, WA 98108−4748
Phone: (206) 433−9000
www.atacs.com
Brush Nylon Bristle Commercially Available

Cloth Lint−Free, Cotton Commercially Available

Cloth, Bleeder Fiberglass Commercially Available
Cloth, Breather RC3000−10 V0F451
Richmond Aircraft Products, Inc.
13503 Pulmice St
Norwalk, CA 90650−5250
Phone: (562) 404−2440
www.richmondaircraft.com
Clothing, Protective Commercially Available

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COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

DESCRIPTION DESIGNATION MANUFACTURER

Cloth, Wipe Cheesecloth Commercially Available

Connector, Vacuum 1/8−In. (3,2 mm) Commercially Available
Diameter
Container w/cover Polyethylene Mixing Cups Commercially Available
Fabric, Fiberglass Type 181 Commercially Available

Fabric, Carbon AH370−5H V2B975

Hexcel Corp
1913 N King St
Seguin, TX 78155−2197
Phone: (830) 401−8130
www.hexcel.com

Film, Bagging 4 Mil (0.1 mm) Nylon V0F451

Richmond Aircraft Products, Inc
Film, Parting Non−Pourous, Porous V0F451
Richmond Aircraft Products, Inc.

Gauge, Vacuum 0−30−In.−Of−Mercury Commercially Available

(0 to 101.6 kPa)
Glasses, Safety Commercially Available

Gloves Neoprene or Polyvinyl Commercially Available

Chloride
Honeycomb Core 1.0 height x 2 wide V0WL95
(1/8 hex cell x Alcore, Inc.
0.0020 Thick) 5052 1502 Quarry Drive
or 5056 Al alloy Edgewood, MD 21040−1047
foil, Non−perforated, Phone (410) 676−7100
Core density 8.1 lb/ www.alcore.com
Cu. Ft. RMS026,
Type 1 Grade 2

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COMPONENT MAINTENANCE MANUAL

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DESCRIPTION DESIGNATION MANUFACTURER

Honeycomb Core 1.0 height x 2 wide V52331

(1/8 hex cell x Hexcel Corporation
0.0020 Thick) 5052 11711 Dublin Blvd
or 5056 Al alloy Dublin, CA 94568−2832
foil, Non−perforated, Phone: (203) 696−0666
Core density 8.1 lb/ Fax: (203) 316−5139
Cu. Ft. RMS026, www.hexcel.com
Type 1 Grade 2
Hoses 3/8−inch (9.5 mm) Diameter Commercially Available
Nylon or Teflon Lined

Hose, Vacuum 1/8−In. (3.2 mm) Diameter Commercially Available

Knife, Utility Commercially Available

Lamp, Heat 180° − 200°F Commercially Available

(82.2° − 93.3°C)
Mask, Dust Regulatory Agency Commercially Available
Approved
Material, Ablative MI−15 Type I Lockheed Martin
Thermal Protection Products
P.O. Box 29304
New Orleans, LA 70189
Material, Ablative MI−15 Topcoat Lockheed Martin
Thermal Protection Products
Pad, Abrasive Scotchbrite V52152
Minnesota Mining and
Manufacturing Co.
Industrial Tape and
Specialties Division
3M Center
St. Paul, MN 55144−1000)
Paper, Abrasive 180−320−Grit Commercially Available
Silicone Carbide
Paper Kraft Commercially Available

Page 6017

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

DESCRIPTION DESIGNATION MANUFACTURER

Pressure Pot Binks, 15 gal V07334

(56.8 L) with ITW Industrial Finishing
dual regulator DBA Binks Devilbiss
195 Internationale Blvd.
Glendale Heights, IL 60139
Primer, Epoxy Green 10−P4−2 Base EC−117 V0KXA5
Converter TR−19 thinner Akzo Nobel Aerospace
Coatings
East Water St.
Waukegan, IL 60085−5563
Phone: (847) 625−4200
Fax: (847) 625−3200
www.anac.com

Prime Coat, RTV DOW CORNING®PR−1200 V5D028

Dow Corning Corporation
3901 South Saginaw Road
Midland, MI 48686
Phone: (989) 496−4400
www.dowcorning.com
Probe, Temperature 0° − 250°F Commercially Available
(−17.8° − 121°C)
Pump, Vacuum 0−30 In.−of−Mercury Commercially Available
(0−101.6 kPa)
Rubber, Sheet 0.062−0.125−Inch V85471
(1.6−3.2 mm) Silicone Boyd Corporation
13885 Ramona Avenue
Chino, CA 91710−5426
www.boydcorp.com

Scraper Plastic Commercially Available

Sealant RTV 88/9910 V01139
Momentive Performance Materials
Inc. (704) 992−4107
187 Danbury Road
Wilton, CT 06897−4122

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COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

DESCRIPTION DESIGNATION MANUFACTURER

Sealant, Bag Tacky Tape V53309 Schnee−Morehead

Chemicals, Inc.
111 North Nursery Road
P.O. Box 1305
Irving, TX 75060−3153
Sealant, Silicone Paste, DC 93−006−6 (Two Part) Sealant V5D028
Gray and Catalyst Dow Corning Corporation

Solvent Isopropyl Alcohol 99 Percent Pure Commercially Available

or
MIBK/MEK Blend (60% Methyl V5E821
Isobutyl Ketone/40% Methyl Ethyl Univar U.S.A., Inc.
Ketone) 532 E. Emaus Street
or Middletown, PA 17057−2200
Phone: (717) 944−7471
www.univarusa.com

Turco 6646 V71410

Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583−9300
www.aerospace.henkel.com
Solvent Heptane Commercially Available
Spatula Metal or Plastic Commercially Available
Spray Bottle Polyethylene Commercially Available
Spray Gun Binks Model 7 Nozzle, Fluid No. 36 V07334
Needle, Fluid No. 36SS Air Cap ITW Industrial Finishing
No. 36SD
Tape, Masking 1 or 2−Inch Wide (25.4 or 50.8 Commercially Available
mm)
Tape, Teflon 1 or 2−Inch Wide (25.4 or 50.8 Commercially Available
mm)
Water Distilled or Deionized Commercially Available
Repair Materials and Equipment
Table 601

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FIGURE 601 FRAME DAMAGE CLEAN UP

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FIGURE 602 CORE PLUG

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FIGURE 603 MOISTURE BARRIER

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FIGURE 604 HEAT BLANKET INSTALLATION

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FIGURE 605 ABLATIVE MATERIAL APPLICATION

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FIGURE 606 RTV SEALANT INSTALLATION

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TASK 71−11−09−300−806
1. Repair No. 5
TASK 71−11−09−300−806
2. General Information

A. This repair assumes the outer barrel panel(s) has been removed.

B. This repair applies to the insulation blanket bonded to the backskin of the inner barrel
assembly to be removed from the inlet cowl.
TASK 71−11−09−300−806
3. Repair Instructions

A. Remove Bonded Insulation Blanket (See Figure 601)

(1) Install adequate fixture(s) to stabilize inner barrel.

CAUTION: BE CAREFUL NOT TO DAMAGE COMPOSITE STRUCTURE WHEN

REMOVING INSULATION BLANKET.

(2) Use a rounded edge spatula to loosen edges of insulation blanket from inner barrel
structure. Carefully remove insulation blanket from structure.

CAUTION: BE CAREFUL NOT TO OVERSOAK COMPOSITE SURFACE WITH

SOLVENT.

CAUTION: DO NOT PULL OFF EXCESS BOND MATERIAL OR DAMAGE TO

STRUCTURE CAN OCCUR. BE CAREFUL NOT TO DAMAGE
COMPOSITE WHEN SCRAPING SURFACE OF STRUCTURE.

(3) Apply the solvent to bond material residue and allow to soak for approximately 3
minutes. Use a rounded edge spatula or equivalent to carefully remove softened excess
bond material from barrel surfaces. Use a clean, lint−free cloth to dry surface
completely.

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(4) Remove the bond residue with a clean, lint−free cloth and the aviation solvent. Remove
the solvent with a clean lint−free cloth before the solvent becomes dry.

(5) Make sure that all bond residue is removed, surface is clean, and that there is no
damage to composite structure.

B. Inner Barrel Surface Preparation

(1) Lightly abrade faying surface of the inner barrel backskin with 150 to 240−grit abrasive
paper. Do not damage graphite fibers when abrading composite material; remove
surface gloss only. Use a vacuum to remove debris.

(2) Clean faying and adjacent surfaces with a clean lint−free cloth and solvent. Remove the
solvent with a clean lint−free cloth before the solvent becomes dry. Force air dry surface
for 30 minutes minimum at 150° − 180°F (65.6° − 82.2°C). (See Table 601)

NOTE: DURING BONDING PROCESS WEAR CLEAN, LINT−FREE GLOVES

WHEN HANDLING CLEANED PARTS AND ADHESIVE MATERIAL.

NOTE: APPLY THE PRIMER IN 12 HOURS AFTER THE SURFACE IS

PREPARED. IF MORE THAN 12 HOURS, REFER TO STEP B TO
CLEAN THE SURFACE AGAIN

C. Prime Faying Surfaces for Bonding

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Document Part No. 277−1100

CAUTION: TO PREVENT CONTAMINATION OF OTHER REPAIR FACILITIES BY

(1) Put a small quantity of the RTV prime coat into a polyethylene container.

NOTE: VISUALLY EXAMINE THE PRIMER. SATISFACTORY RTV PRIME

COAT WILL BE CLEAR. UNSATISFACTORY PRIMER WILL BE
CLOUDY.

NOTE: NEVER PUT RTV PRIME COAT BACK INTO ITS ORIGINAL
CONTAINER. DISCARD UNUSED PRIMER IN AN APPROVED
WASTE CONTAINER.

(2) Apply a thin layer of RTV prime coat to the prepared surface with a clean, lint−free cloth.
Refer to the instructions of the manufacturer.

NOTE: IF YOU USE RED RTV PRIME COAT, YOU CAN MAKE AN
ESTIMATE OF THE LAYER THICKNESS BY ITS COLOR: THE
THICKER THE PRIMER, THE DARKER THE RED COLOR. TOO
THICK A LAYER IS CHALKY. REMOVE TOO THICK PRIMER WITH
A CLEAN, LINT−FREE CLOTH.

NOTE: IF YOU REMOVED PRIMER BECAUSE IT WAS TOO THICK, IT IS

POSSIBLE THAT YOU DO NOT NEED TO APPLY MORE PRIMER.
MAKE SURE THE ENTIRE SURFACE IS WET WITHOUT RUNS OR
PUDDLES. MAKE SURE THE PRIMER IS NOT CHALKY.

(3) Dry the primer. Refer to the instructions of the manufacturer.

D. Silicone Sealant Faying Surface Application (See Figure 601 and 603)

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Document Part No. 277−1100

NOTE: APPLY THE SEALANT IN 24 HOURS AFTER THE PRIMER HAS

DRIED. IF MORE THAN 24 HOURS, CLEAN THE SURFACE WITH
THE SOLVENT, DRY THE SURFACE WITH A CLEAN CLOTH, AND
APPLY THE PRIMER AGAIN.

(1) Mix the silicone sealant paste. Refer to the instructions of the manufacturer.

(2) Apply the silicone sealant paste to the faying surfaces within 24 hours of the RTV prime
coat application. Each faying surface shall have 0.010 − 0.015 in (0.25 − 0.38 mm) of
adhesive for a total bondline thickness of 0.020 − 0.030 in (0.51 − 0.76 mm). Apply the
silicone sealant paste with a serrated tool to control the application thickness. Squeeze
out is acceptable but not required.

NOTE: THE LOCAL ABSENCE OF ADHESIVE, WHERE THE TEETH OF

THE SERRATED TOOL MAKE CONTACT WITH THE SURFACE, IS
ACCEPTABLE. THE AREA SHALL BE NO WIDER THAN THE
TOOTH, WHICH IS APPROXIMATELY 0.031 (0.78 MM) OF AN INCH
OR LESS.

NOTE: DEMINERALIZED WATER, DEMINERALIZED ICE WATER OR A

SOLUTION OF ISOPROPYL ALCOHOL IN DEMINERALIZED WATER
CAN BE USED TO MAKE SURE THE TOOLS MOVE FREELY AND
TO MAKE THE EDGES OF THE SEALANT SMOOTH.

(3) Bond insulation blanket to the inner barrel backskin surface within five to ten minutes
after the sealant application.

(a) Put the insulation blanket on the inner barrel backskin surface, between the radials
located at 300°30’ and 350°30’. Make sure the aft edge of the insulation blanket is
4.4 inches (111.76 mm) from the aft edge of the inner barrel and 1.00 in. (25.4
mm) overlap at the edge of the closure.

(b) Assemble items in such a manner to prevent air entrapment between the bonding
surfaces.

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CAUTION: DO NOT LIFT OR DELAMINATE THE EDGES OF THE BONDED HEAT

SHIELD UNTIL FULL CURE IS ATTAINED.

(4) Cure the repair area as follows:

Apply mechanical pressure and cure at 75° F +/− 15° F for a minimum of 24 hours
before the part is handled.
or

(a) Use the vaccum bag process and cure the repair area at 110° F +/− 10° F for a
minimum of two hours before the part is handled. (Refer to the GE SPM 70−46−
03, Vaccum Bagging of Thermosetting Composite Repairs).

(5) Dry the sealant prior to handling. Refer to the instructions of the manufacturer.

NOTE: RECOMMENDED RELATIVE HUMIDITY IS 50% OR GREATER

DURING THE CURE. RELATIVE HUMIDITY LESS THAN 50% WILL
REQUIRE LONGER CURE TIMES.

E. Prime Edge Seal Surfaces for Bonding (See Figure 602)

(1) Put a small quantity of silicone primer into a polyethylene container.

NOTE: VISUALLY EXAMINE THE PRIMER. SATISFACTORY RTV PRIME

COAT WILL BE CLEAR. UNSATISFACTORY PRIMER WILL BE
CLOUDY.

NOTE: NEVER PUT RTV PRIME COAT BACK INTO ITS ORIGINAL
CONTAINER. DISCARD UNUSED PRIMER IN AN APPROVED
WASTE CONTAINER.

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Document Part No. 277−1100

(2) Apply a thin layer of silicone primer to the prepared surface with a clean, lint−free cloth.
Refer to the instructions of the manufacturer.

NOTE: IF YOU REMOVED PRIMER BECAUSE IT WAS TOO THICK, IT IS

POSSIBLE THAT YOU DO NOT NEED TO APPLY MORE PRIMER.
MAKE SURE THE ENTIRE SURFACE IS WET WITHOUT RUNS OR
PUDDLES. MAKE SURE THE PRIMER IS NOT CHALKY.

(3) Dry the primer. Refer to the instructions of the manufacturer.

F. Silicone Sealant Edge Seal Application (See Figure 603)

NOTE: APPLY THE SEALANT IN 24 HOURS AFTER THE PRIMER HAS

DRIED. IF MORE THAN 24 HOURS, CLEAN THE SURFACE WITH
THE SOLVENT, DRY THE SURFACE WITH A CLEAN CLOTH, AND
APPLY THE PRIMER AGAIN.

(1) Mix silicone sealant paste. Refer to the instructions of the manufacturer.

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Document Part No. 277−1100

(2) Fillet seal the edge of the insulation blanket.

(3) Apply the silicone sealant paste to the faying surfaces. The silicone sealant paste shall
be applied to form a bead that is 0.125 − 0.375−inch (3.18 − 9.53 mm) wide. The
silicone sealant paste shall be 0.090 − 0.150−inch (2.29 − 3.81 mm) thick at the center
of the seam, feathered out to the edges from the center of the bead.

CAUTION: DO NOT LIFT OR DELAMINATE THE EDGES OF THE BONDED HEAT

SHIELD UNTIL FULL CURE IS ATTAINED.

(4) Dry the silicone sealant paste. Refer to the instructions of the manufacturer.
TASK 71−11−09−300−806
4. Material and Equipment

NOTE: YOU CAN USE ALTERNATIVE MATERIALS WITH THE SAME PROPERTIES TO
REPLACE THE ITEMS SHOWN IN TABLE 601.

DESCRIPTION DESIGNATION MANUFACTURER

Clothing, Protective Commercially Available

Containers, W/Covers Polyethylene Commercially Available

Mixing Cups
Gauge, Vacuum 0−30−In.−of−Mercury Commercially Available
(0−01.6 kPa)

Gloves, Fabric JOH Contamination Control V8M556

Plasco Gloves Inc
1919 Commerce Rd
Springfield, OH 45501
Mask, Dus Regulatory Agency Approved Commercially Available
Paper, Abrasive 150−240 Grit Silicone Carbide Commercially Available
Prime Coat, RTV DOW CORNING®PR−1200 V5D028
Dow Corning Corporation
3901 South Saginaw Road
Midland, MI 48686
Phone: (989) 496−4400
www.dowcorning.com
Roller Plastic or Rubber 2−In. (50,8 Commercially Available
mm) Dia
Scraper, Plastic Serrated Edge Commercially Available

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DESCRIPTION DESIGNATION MANUFACTURER

Sealant, Silicone Paste, Red DC 90−006−2 Sealant and V5D028

Catalyst Dow Corning Corporation

Solvent, Aviation SkyKleen 1000 V1CHP6

Solutia Inc.
Specialty Chemicals Division
575 Maryville Center Drive
St. Louis, MO 63166−6760
Phone: (314) 674−6661

Solvent Isopropyl Alcohol 99 Percent Commercially Available

Pure
MIBK/MEK Blend (60% Methyl V5E821
Isobutyl Ketone/40% Methyl Univar U.S.A., Inc.
Ethyl Ketone 532 E. Emaus Street
or Middletown, PA 17057−2200
Phone: (717) 944−7471
www.univarusa.com

Turco 6646 V71410

Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583−9300
www.aerospace.henkel.com
Spatual Rounded Edge Commercially Available
Water Demineralized Commercially Available
Repair Materials and Equipment
Table 601

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INLET STA
141.200
INLET STA
16.886

PANEL SPLIT
INLET RADIAL 355

INLET RADIAL
NEW
350 30’
INSULATION
BLANKET

A A B B
INLET RADIAL 325 30’

INLET RADIAL 300 30’

INNER
CEC−102−00

BARREL
BACKSKIN

FIGURE 601 INSULATION BLANKET ON INNER BARREL BACKSKIN LOOKING INBOARD

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Document Part No. 277−1100

REPAIR NO. 5 INSULATION BLANKET INNER BARREL ACOUSTIC PANEL BACKSKIN

REPLACEMENT

NEW INSULATION
INSTALLATION
EXISTING
PANEL CLOSURE
PLY LAY−UP
1.00 INCH INNER
(25.4 mm) BARREL
OVERLAP PANEL

SILICONE
SEALANT FILLET

A−A AIR WETTED

FWD EDGE
SURFACE
OF PANEL

NAC STA
141.200
4.40 INCH
(111.76 mm)
NEW INSULATION
INSTALLATION
SILICONE
SEALANT FILLET
AFT
PANEL
EDGE

INNER
BARREL
BACKSKIN
CEC−103−00

AIR WETTED
B−B
SURFACE

FIGURE 602 INSULATION BLANKET EDGE DETAILS

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Document Part No. 277−1100

PLASTIC SCRAPER

NEW
INSULATION
SEALANT BLANKET

45°

INNER BARREL
BACKSKIN
CEC−104−00

FIGURE 603 SILICONE SEALANT FILLET SEAL APPLICATION

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COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

TASK 71−11−09−300−807
1. Repair No. 6
TASK 71−11−09−300−807
2. General Information

A. Do the repair by access through the Aft bulkhead access panels or by removal of the outer
barrel half.

B. If the access through the Aft Bulkhead in not sufficient, remove the outer barrel panel(s).
TASK 71−11−09−300−807
3. Repair instructions

A. Remove the NAS1079D6 rivets with 0.185−inch (4.69 mm)(No. 13) diameter drill that attach
the damaged lip skin segment to the adjacent lip segments. (Ref. SRM 54−04−01)

B. Remove the collars, bolts and pins that attach the damaged lip skin segment to the outer cap
angle of the forward bulkhead assembly.

C. Remove the collars and pins that attach the damaged lip skin segment to the inner cap angle
of the forward bulkhead assembly.

D. Remove the damaged lip skin segment from the inlet cowl assembly.

E. Make a mark of the position of the shims and fillers for the installation of the new lip skin
segment.

F. Remove the splice plates from the inlet cowl assembly.

G. Trim The New Lip Skin Segment

(1) Put the new lip skin segment on the inlet cowl and attach with a clamp.

(2) Make a mark for the trim lines on the new lip skin segment at the splice plates. make
sure there is a 0.030 to 0.120−inch (0.762 to 3.048 mm) gap at the two splice locations.

(3) Remove the new lip skin segment and trim to marked lines.

H. Make Rivet Holes In New Lip Skin Segment (See Figure 601)

(1) Cover the holes in the anti−ice spray tube with masking tape to prevent the entry of
metal chips and unwanted material into the tube.

(2) Put the new splice plates on each side of the lip skin segments that remain on the inlet
cowl.

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(3) Use the rivet holes in the lip skin segments as a template. Use a 0.189−inch (4.800 mm)
diameter (No. 12) drill to make the holes in the new splice plates for the NAS1097D6
rivets.

(4) Install temporary fasteners to attach the new splice plates on the lip skin segments.

(5) Layout the rivet holes in the new splice plates and lip skin segment to align with the rivet
holes made in paragraph ‘C’.

(6) Use a 0.205−inch (5.22 mm) diameter (No. 5) drill to make the holes through the new lip
skin segment and splice plate for the CR3552−6−3 rivets. Install temporary fasteners.

NOTE: TOTAL NUMBER OF RIVETS CAN CHANGE FROM SPLICE PLATE

TO SPLICE PLATE.

(7) Use the fastener holes in the inner and outer cap angles of the forward bulkhead as a
template for the rivet holes in the new lip skin segment. Use a 0.166−inch (4.21 mm)
diameter (No. 19) drill to make the holes.

(8) Countersink the rivet holes on the new lip skin segment where the lip skin attaches to
the inner cap angle for the HL633−5 pins. (Ref. SRM 54−04−09)

(9) Countersink the rivet holes on the new lip skin segment where the lip skin attaches to
the outer cap angle for the HL41−5 pins. (Ref. SRM 54−04−09)

(10) Countersink the rivet holes on the new lip segment where the lip skin attaches to the
splice plates for rivets CR3552−6−3. (Ref. SRM 54−04−10)

(11) Remove the new lip skin segment and new splice plates, remove rough edges from
around the holes.

(12) Remove unwanted material from inner area of the inlet cowl lip.

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Document Part No. 277−1100

(13) Clean the new lip skin, splice plates and lip skin area with a clean lint−free cloth and
solvent. Remove the solvent with a clean lint−free cloth before the solvent becomes dry.
(See Table 601)

(14) Apply chemical conversion coating to the cut edges of the new lip skin segment and all
the new rivet holes. Allow chemical conversion costing to dry. (Ref. SRM 54−02−03)

I. Install the new splice plates and new lip skin segment on the inlet cowl. (See Figure 601)

(1) Mix the epoxy primer. Refer to the instructions of the manufacturer.

(2) Put the new splice plates on the lip skin segments on the inlet cowl and attach with
NAS1097D6 rivets made moist with epoxy primer. (See Table 601)

(3) Remove the masking tape from the anti−ice spray tube. (See Table 601)

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Document Part No. 277−1100

CAUTION: DO NOT PRELOAD THE NEW LIP SKIN SEGMENT. NO MORE THAN TEN
(10) LBS OF FORCE MUST BE NECESSARY TO POSITION THE NEW LIP
SKIN SEGMENT AGAINST THE INLET COWL BARREL ASSEMBLY
WHEN ONE SIDE IS ATTACHED WITH A CLAMP.

(4) Put the new lip skin segment in position on the inlet cowl assembly and install temporary
fasteners.

(5) Install the CR3552−6−3 rivets made moist with the epoxy primer where the new lip skin
segment is attached at the splice plates. Remove the unwanted rivet stems. (See Table
601)

(6) Install the pins and collars that attach the new lip skin segment to the inner cap angle of
the forward bulkhead assembly. (See Table 601)

(7) Install the pins, bolts and collars that attach the new lip skin segment to the outer cap
angle of the forward bulkhead assembly. (See Table 601)

J. Close access

(1) Install the access panels on the aft bulkhead and the outer barrel panel(s) if the panel(s)
where removed.

K. Apply Aerodynamic Sealant to the Inlet Cowl Lip Skin Area

(1) Remove the remaining sealant from the lip skin repair area.

(2) Taper the ends of the sealant that stays for a minimum of 1.00−inch (2.54 mm) overlap
with new sealant.

(3) abrade the ends of the sealant that stays to have a better bond with the new sealant.

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Document Part No. 277−1100

(4) Remove the unwanted material with a clean lint−free cloth and solvent. Remove the
solvent with a clean lint−free cloth before the solvent becomes dry. (See Table 601)

(5) Put masking tape on the two side of the gap where the sealant is applied. (See Table
601)

(6) Mix the sealant. Refer to the instructions of the manufacturer.

(7) Put the sealant in the gap, push the sealant into the area and smooth with a spatula.
The sealant must flush to the surface or 0.010−inch (0.254 mm) below the surface.

NOTE: DO NOT LET THE SEALANT TO BE ABOVE THE SURFACE.

(8) Dry the sealant. Refer to the instructions of the manufacturer. Remove masking tape.
TASK 71−11−09−300−807
4. Material and Equipment

NOTE: YOU CAN USE ALTERNATIVE MATERIALS WITH THE SAME PROPERTIES TO
REPLACE THE ITEMS SHOWN IN TABLE 601.

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Document Part No. 277−1100

DESCRIPTION DESIGNATION MANUFACTURER

Coating, Chemical Alodine 1000L V71410

Conversion Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583−9300
www.aerospace.henkel.com
Cloth Lint−Free, Cotton Commercially Available

Gloves Neoprene or Polyvinyl Commercially Available

Chloride
Hi−Lok Pin Hi−Lok Collar HL633−5−4, −5, −6 V73197
HL41−5−3, −4 Hi−Shear Corporation
2600 Skypark Dr
Torrance, CA 90505
Phone: (310) 326−8110
Primer, Epoxy Yellow V0KXA5
10P20−13 Base Akzo Nobel Aerospace Coatings
EC−213 Curing Solution
TR−144 or TR−49 Thinner
Respirator Regulatory Agency Approved Commercially Available

Rivet, Blind Coutersink CR3552−6−3 V05693

Cherry Textron Inc
1224 E. Warner St.
Santa Ana, CA 92705−5484
Phone: (714) 545−5511
www.cherryaerospace.com
Rivet, Solid Shank NAS1097D6 Commercially Available
Solvent Isopropyl Alcohol Commercially Available
99 Percent Pure
or
MIBK/MEK Blend (60% V5E821
Methyl Isobutyl Ketone/ Univar U.S.A., Inc.
40% Methyl Ethyl Ketone) 532 E. Emaus Street
or Middletown, PA 17057−2200
Phone: (717) 944−7471
www.univarusa.com

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COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

DESCRIPTION DESIGNATION MANUFACTURER

Solvent Turco 6646 V71410

Henkel Corporation

Tape, Masking 2−inch (50.8 mm) Wide Commercially Available

Sealant, Silicone DOW CORNING® 93−006−1/− V5D028
6 Dow Corning Corporation
or DC93−006RF−1/−6 (ALT) 3901 South Saginaw Road
Grey Midland, MI 48686
Phone: (989) 496−4400
www.dowcorning.com
Repair Materials and Equipment
Table 601

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Document Part No. 277−1100

FIGURE 601 REPLACE DAMAGED LIP SKIN SEGMENT

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TASK 71−11−09−300−810
Repair No. 7
1. Repair Instructions

A. This repair provides instructions to remove and replace damaged inlet cowl acoustic panel
segments. Carefully dismantle and remove the inlet cowl (277−1100) from the aircraft at the
engine attach interface using proper ground handling equipment/tools (RSE1021 and
RSE1236) and appropriate ground transportation and restraints. Remove and keep the
2750308−30 bolt, 277−1011−501 spacer, VN936NP8 washer and NAS1805−8 nuts for
installation. Refer to A330 CF6−80E1 AMM and CMM 71−11−09 Disassembly section for
additional removal instructions. Refer to A330 CF6−80E1 SRM 54−10−00 Structural
Identification and A330 CF6−80E1 CMM 71−11−09 Illustrated Parts List for inlet cowl parts
identification. See Figures 901 and 902, Special Tools, Fixtures and Equipment.

NOTE: TO MAINTAIN CORRECT ALIGNMENT OF INLET COWL, THE INNER

BARREL, WHICH IS THE PRIMARY STRUCTURE, MUST BE REPLACED
ONE SEGMENT AT A TIME USING SUITABLE SHOP TOOLING AIDS AND
THE INLET COWL ATTACH RING/FAN CASE INTERFACE PLANE TOOL.
SEE FIGURE 610.

B. Prepare the inlet cowl assembly for inner barrel replacement. See Figure 601.

(1) Use inlet cowl sling RSE1236 (See Figure 902, Special Tools, Fixtures and Equipment)
or equivalent tool to rotate the inlet cowl to the vertical position and place it facedown
with the inlet lip on a padded surface.

(a) Disconnect chain to separate front and rear harnesses on the sling and use two
cranes to control rotation.

(b) Position lead−shot bags or sandbags where the lip skin of the inlet cowl is to be
placed face−down.

(c) The inlet cowl attach ring at the aft end should be in a horizontal position to
provide access to the interior surface area of the inner barrel.

(2) Make a shop aid alignment tool and install it at the inlet cowl attach ring/fan case
interface plane.

(a) Use suitable bolts, nuts and washers to match existing hole sizes in each of the
three attach ring segments.

(b) Torque fasteners per SRM and Industry Standard requirements. See Figure 610.

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CAUTION: TO PREVENT STRUCTURE MISALIGNMENT DURING REWORK, DO NOT

MOVE OR SHIFT THE INLET COWL UNTIL THE WORK IS COMPLETE.

(3) Check the perimeter of attach ring and shop aid tool interface for gaps. Use a 0.002 inch
(0,0508 mm) thick feeler gauge and record the size and location of gaps that exist.

CAUTION: TO PREVENT DISTORTION OF THE SHOP AID INTERFACE PLANE

TOOL AND PREVENT DAMAGE TO THE INLET COWL INTERFACING
STRUCTURE, DO NOT PLACE ANY LOAD ON THE TOOL.

(4) Remove the shop aid tool from the inlet cowl assembly. Keep it for later use.

2. Replace the inlet cowl inner barrel lower acoustic panel assembly.

A. Remove the lower outer barrel assembly (277−1130) to get access to inner barrel assembly.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE)

CAUTION: REMOVE THE SURFACE FINISH ONLY. DO NOT TAPER OR BREAK THE
GRAPHITE FIBERS FROM THE TOP SURFACE OF THE OUTER SKIN
PLY.

(1) Remove the surface finish to expose the heads of rivets which attach the lower outer
barrel assembly to the forward bulkhead and to the splice plates at radials 90 and 270
degrees. Use 150−grit or finer silicon carbide abrasive paper. See Table 601.

NOTE: SURFACE PRIMER TOP COAT IS GRAY, MIDDLE COAT IS BLACK,

AND FIRST COAT IS YELLOW.

NOTE: REFER TO THE A330 CF6−80E1 SRM 54−04−01 FASTENER

REMOVAL AND INSTALLATION.

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WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE)

CAUTION: MAKE SURE NOT TO DAMAGE THE OUTER BARREL DURING THE
FASTENER SURFACE REMOVAL PROCESS.

CAUTION: DO NOT ALLOW BLIND RIVETS TO SPIN IN COMPOSITE SKIN WHEN

YOU DRILL THEM OUT. REFER TO THE A330 CF6−80E1 SRM 54−04−01
FASTENER REMOVAL AND INSTALLATION.

(2) Remove the anti−ice duct overboard discharge access panel to get access to the inside
of the outer barrel. Keep the attach hardware for installation. See Figure 606.

(3) Drill out CR3522−5 rivets which attach the lower outer barrel assembly to the forward
bulkhead. Use a 0.1570−inch diameter No. 22 drill for the CR3522−5 blind rivets.

(4) Drill out rivets which attach lower outer barrel assembly to the splice plate at radial 90
degree and at radial 270 degree. Use No. 22 drill for CR3522−5 blind rivets.

(5) Drill out MS21141U05 blind rivets which attach aft bulkhead webs to lower outer frame
using No. 5/32−inch drill.

(6) Drill out MS20427M5 blind rivets which attach left and right bulkhead stiffener splice
angles to upper outer barrel and to upper outer frame. Drill out MS20427M5 blind rivets
which attach splice angles to upper outer frame and to aft bulkhead web using No. 22
drill. See Figures 608 and 609.

(7) Drill out MS20427M5 rivets which attach left and right frame splice plates to upper outer
frame using No. 22 drill.

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(8) Remove the lower outer barrel segment (277−1130) from inlet cowl assembly. Leave
splice plates attached to outer barrel panel assembly, where practicable. Place lower
outer barrel segment with forward end down on a smooth flat surface and keep it for
installation.

NOTE: COVER ANY OPENINGS IN FORWARD BULKHEAD OF THE INLET

COWL TO PREVENT ENTRANCE OF FOREIGN MATTER AND TO
MAKE THE INLET COWL VERMIN−PROOF.

CAUTION: BE CAREFUL NOT TO DAMAGE THE OUTER GRAPHITE

FABRIC/STRUCTURE WHEN YOU REMOVE THE SEALANT AND FILLER
MATERIAL.

(9) Remove all sealant and filler material between inlet lip skin and outer barrel lower half.
Smooth the surface with 150−grit abrasive paper. Vacuum and remove remaining
sanding debris with a cloth moistened with solvent. Wipe dry before solvent evaporates.

B. Remove aft bulkhead lower sections. See Figure 607.

NOTE: REFER TO THE A330 CF6−80E1 SRM 54−04−01, FASTENER REMOVAL

AND INSTALLATION.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE)

(1) Remove MS21141U05 blind rivets which attach lower web sections to lower inner frame
(Ref 277−1100). Use a No. 5/32−inch drill. See Figure 607.

(2) Remove aft bulkhead lower web sections and keep them for installation.

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(3) Remove all sharp edges and burrs from structure assembly after fastener removal in
accordance with A330 CF6−80E1 SRM 54−02−01 Damage Clean−up.

C. Remove the lower engine attach ring segment with brackets attached. Remove the HL930−6
Pins and HL585DU( )AW Collars that attach to the Aft Engine Attach Brackets to the Aft Ring.
Retain Lower Engine Attach Ring Segment and Aft Engine Attach Brackets for reinstallation.
(Ref 277−1123 and 277−1124). See Figures 603 and 604.

(1) Remove collars and fastener pins which attach two lower attach ring splices to upper
and lower attach ring segments and to inner barrel acoustic panel Assemblies.

(2) Remove splice angles which attach upper and lower attach ring segments. Remove
splice angles and aft ring segments and keep for installation.

NOTE: TAP THE SPLICES LIGHTLY TO RELEASE FROM CURED LIQUID

SHIM UNDER FILLERS.

(3) Remove collars, fasteners pins, and rivets which attach lower segment of attach ring,
brackets and shims to inner barrel lower acoustic panel assembly. Remove attach ring
lower segment, attach ring brackets and shims as a unit. Tap brackets lightly to release
from cured liquid shim under fillers. Use 150−grit abrasive paper to remove gloss from
exposed surface of liquid shim and leave with a dull matte finish. Keep the attach ring,
brackets, and fillers for installation.

NOTE: A FILLER MAY BE INSTALLED BETWEEN THE ATTACH RING AND

THE ACOUSTIC PANEL AFT LAND. KEEP THE FILLERS FOR
INSTALLATION WITH THE ATTACH RING OR REPLACE FILLERS.

NOTE: MEASURE AND RECORD GAPS AROUND THE ENTIRE PANEL

BEFORE YOU REMOVE THE DAMAGED PANEL.

D. Remove the damaged inner barrel lower acoustic panel assembly (277−1121) from the inlet
cowl.

(1) Remove collars, sleeves, pins, rivets, outer splices, shims and inner splices, which
attach inner barrel lower acoustic panel to inner barrel upper acoustic panels. Keep the
pins and sleeves for use for fit up of replacement panel or replace fasteners if damaged
during the fastener removal process.

(2) Remove collars and pins which attach inner barrel lower acoustic panel to forward
bulkhead assembly. See Figure 605.

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(3) Move the inner barrel lower acoustic panel aft and outboard to remove from inlet cowl.
Rotate right side of panel as required to clear upper right attach ring segment.
Determine if the damaged inner barrel is repairable. Keep the part for repair or scrap the
segment if it is not repairable.

(4) Use 150−grit aluminum oxide abrasive paper and remove sealant and cured liquid shim
from faying surfaces of inner barrel upper acoustic panels, inner barrel outer splices,
inner splices, shims and angle splices for aft bulkhead inner frames. Keep the hardware
for installation.

E. Make a template of the damage area. Trim the replacement inner barrel lower acoustic panel
to fit the inlet cowl assembly. Record the fastener locations from the interfacing structure.

NOTE: MEASURE THE AREA WHERE THE INNER BARREL LOWER ACOUSTIC
PANEL IS TO BE INSTALLED. USE A TRANSFER TEMPLATE AND
TRANSFER THE TRIM DIMENSIONS TO THE NEW INNER BARREL
SEGMENT AND TRIM TO FIT.

(1) Put the replacement inner barrel lower acoustic panel between inner barrel upper panels
and temporarily secure in place using shop aids to ensure gaps are properly maintained.
Check aerodynamic smoothness steps and gaps in accordance A330 CF6−80E1 SRM
54−07−00 for compliance. Install aft bulkhead inner frame splice angles on panels with
pins and sleeves retained from removal procedure. Use temporary fasteners through
free legs of aft bulkhead inner frames on panels and splice angles. Clamp splice angles
to free leg of aft bulkhead lower inner frame on the lower acoustic panel.

NOTE: THE FORWARD END OF THE REPLACEMENT PANEL WILL REST

INSIDE THE TRAILING EDGE OF THE INLET LIP UNTIL IT IS
TRIMMED FOR BUTT SPLICE ATTACHMENT TO THE FORWARD
BULKHEAD ANGLES.

(2) Make sure the aft corners of the panel match the aft corners of the upper panels and do
not extend beyond the aft vertical surfaces of the upper attach ring segments See Figure
605.

(3) Install the shop aid alignment tool on inlet cowl attach ring upper segments. Use two
NAS567−45 bolts, AN960C716 washers, and AN315−7R nuts in each segment of attach
ring. Torque NAS567−45 bolts to 270 to 300 lb−in (30,5 to 33,9 N.m). Use NAS566−45
bolts, AN960D616 washers, and AN315−6R nuts in remaining holes. Torque NAS566−
45 bolts 96 to 114 lb−in (10,8 to 12,9 N.m). See Figure 610.

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CAUTION: MISMATCH ALIGNMENT AND GAP AT INNER BARREL FORWARD AND

AFT EDGES ARE CRITICAL FOR AERODYNAMIC SMOOTHNESS
REQUIREMENTS OF INLET COWL ASSEMBLY. REFER TO THE A330
CF6−80E1 SRM 54−07−00 FOR AERODYNAMIC SMOOTHNESS
REQUIREMENTS.

(4) Hold the forward land of panel firmly against inner surface of the inlet lip. Make sure the
gap between aft corners of panel and face of shop aid tool interface plane is 00.060 to
0.120 inch (1,524 to 3,048 mm) and gap at center of panel is based on previous
measurements.

NOTE: THE THICKNESS OF THE FORWARD LAND OF PANEL WHICH

EXTENDS OVER INLET LIP CAUSES THE CENTER OF THE AFT
EDGE OF THE PANEL TO BE MOVED 0.102 INCH (2,591 MM) FROM
THE INTERFACE PLANE WHEN THE AFT BULKHEAD INNER
FRAMES OF THE PANELS ARE ALIGNED AT THE SPLICE POINTS.
THE CENTER OF THE FORWARD EDGE OF PANEL IS ALSO
MOVED FORWARD.

(5) Hold the forward land of panel firmly against the inner surface of the inlet lip. Mark a line
on the inlet lip at the forward edge of the panel. Mark reference lines at the center of the
panel and lip and at four equally spaced points between the center and corners of panel.

(6) Remove the shop aid tool from the attach ring upper segments. Remove the splice
angles from the aft bulkhead inner frames and remove the replacement inner barrel
panel from the inlet cowl assembly.

(7) Measure the distance the forward land extends over inlet lip at center mark and at each
reference point on each side out to corner.

(8) Make a fairing strip straight edge from aluminum stock. Place the fairing strip on the
inner surface of the forward land of the replacement panel, align forward edge of strip
with measurements at corners, center and intermediate points and clamp to land. Mark
forward edge trim line for inner barrel along forward edge of fairing strip.

(9) Remove the fairing strip and trim the inner barrel forward land to the trim line mark.
Smooth the edge of the land and break sharp corners.

F. Install the replacement inner barrel lower acoustic panel assembly (277−1120) to the inlet
cowl assembly (277−1100).

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(1) Put the replacement inner barrel lower panel centered between the upper panels. Install
the inner splices on the panels using the pins and collars which were removed from the
original installation. Install the aft bulkhead inner frame splice angles on the aft bulkhead
inner frames of panels using fasteners which were removed from the original installation.
Insert the fasteners through the panel, frames, and splice angles. Use temporary
fasteners through the splice angles and the free legs of the frames. See Figures 603,
604 and 605.

CAUTION: LIMIT THE TORQUE OF HI−LOK COLLARS TO 19−23 IN−LBS FOR 5/32
INCH COLLARS AND 26−30 IN−LBS FOR 3/16 INCH COLLARS. IF HI−
LOK NUT DOES NOT SNAP OFF, CAREFULLY REMOVE THE NUT
PORTION OF THE COLLAR PER INDUSTRY STANDARD PRACTICES.

(2) Install the shop aid alignment tool on the inlet cowl attach ring upper segments and
torque the bolts. See Figure 610.

(3) Install the lower attach angle (and filler if used on original installation) on the shop aid
alignment tool. Use two NAS567−45 bolts, AN960C716 washers, and AN315−7R nuts.
Torque the NAS567−45 bolts 270 to 300 lb−in (30,5 to 33,9 N.m). Use NAS566−45
bolts, AN960D616 washers, and AN315−6R nuts in the remaining holes. Torque the
NAS566−45 bolts 90 to 114 lb−in (10,2 to 12,9 N.m).

NOTE: REMOVE SCREWS, NUTS AND INDEX PIN (277−1125) FROM THE
LOWER ATTACH RING SEGMENT IF IT INTERFERES WITH
INSTALLATION OF THE ATTACH RING SEGMENT. KEEP THE
HARDWARE FOR INSTALLATION.

(4) Hold forward land of panel firmly against forward bulkhead angles and aft land firmly
against lower attach ring. Make sure the gap between forward edge of panel forward
land and inlet lip is 0.060 to 0.120 inch (1,524 mm to 3.048 mm). Make sure the gap
between aft edge of aft land of panel and face of shop aid alignment tool is 0.010 to
0.070 inch (0,254 to 1,778 mm). Insert the “GO” pin of through ring of shop aid
alignment tool to get correct position of panel aft land and to hold land in contact with
attach ring segment. See Figure 610.

(5) Install inner splices, outer splices and shims. Use pins and collars removed from original
installation through panels splices, and shims. Use temporary fasteners through outer
splices, aft bulkhead land, and attach ring segment Use temporary fasteners through
panels inner splices, outer splices, forward land, and forward bulkhead angles.

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WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE)

(6) Use a 0.1890−inch (4,801 mm) diameter (No. 12) drill and back−drill Hi−Lok holes in
lower attach ring segment (and filler between attach ring and panel land if it existed on
original assembly) through aft land of panel. Work outboard from center of panel and
install temporary fasteners. Countersink inner skin of panel for rivets in accordance with
A330 CF6−80E1 SRM 54−04−09 and SRM 54−04−01.

(7) Install attach ring splices on panels with temporary fasteners through the panels and
upper attach ring segments.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE)

(8) Use 0.1910−inch (4,851 mm) diameter (No. 11) drill and back−drill existing pin holes in
splices through panel. Install temporary fasteners.

(9) Use a No.11 or 19 drill and back−drill existing pin holes in forward bulkhead angles
through forward land of panel. Install temporary fasteners in holes.

(10) Use a 0.1910−inch (4,851 mm) diameter (No. 11) drill and back−drill existing pin holes in
splices through outer skin of panel. Drill mating pin holes in splices through inner skin of
panel and core. Align holes through inner skin, outer skin, and core.

(11) Use a No. 16 drill and back−drill existing rivet holes in splices through outer skin only at
aft end of panel.

(12) Check for gaps between shims under attach brackets, attach ring splices and the outer
skin of panel. If gap exceeds 0.030 inch (0,762 mm), use additional laminated shims to
close gap. Peel fillers to the thickness required.

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(13) Remove the shop aid alignment tool, lower attach ring, inner barrel lower panel, splices,
fillers, and angle splices. Deburr rivet and pin holes, and clean drill chips from structure.

(14) Treat exposed untreated reworked surfaces of panel with chemical conversion coating
and prime with epoxy primer. See Table 601.

G. Install replacement inner barrel lower acoustic panel assembly.

(1) Put the replacement panel between panels and install inner splices, outer splices, shims
and aft bulkhead lower inner frame angle splices. Use temporary pins, and collars which
were removed from original structure. Use other temporary fasteners through angle
splices and free legs of aft bulkhead inner frames on panels. Install temporary fasteners
through forward land of panel and forward bulkhead angles. Install temporary fasteners
through outer splices at forward ends of panels.

(2) Install shop aid alignment tool and torque bolts. Install lower attach ring segment (and
filler between attach ring and panel land if it existed on original assembly) on the shop
aid alignment tool. Position attach ring splices and install temporary fasteners through
attach ring segments, splices, attach brackets, and aft land of panel.

(3) Use epoxy primer and wet−install new pins through the forward land of the inner barrel
panel and forward bulkhead assembly. Install collars on the pins.

(4) Use epoxy primer and wet−install new fasteners through panels, inner splices, outer
splices. Install pins and collars.

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(5) Install rivets through splices and outer skin of panels.

(6) Remove the attach ring splices and lower attach ring segment from the panel and shop
aid alignment tool.

(7) Clean mating surfaces of splices shims, lower attach ring segment attach brackets and
panels with solvent. Wipe dry before solvent evaporates. Brush or spray surfaces which
will contact liquid shim with polyvinyl alcohol to serve as a release agent. Apply polyvinyl
alcohol to all surfaces of bolts, washers, and nuts used to attach lower ring segment to
shop aid alignment tool. Apply masking tape to surfaces adjacent to liquid shim areas to
protect surfaces from excess liquid shim squeeze−out.

(8) Mix one part−by−weight (pbw) of Part B epoxy adhesive catalyst with three pbw of Part
A epoxy adhesive base in a stainless steel container.

NOTE: THE USEFUL LIFE OF AN EIGHT−OUNCE MIX OF LIQUID SHIM IS

1.5 HOURS AT ROOM TEMPERATURE, 65°F TO 75°F (18,3°C TO
23,8°C).

(9) Use a brush and apply liquid shim mix to the mating surfaces of the attach ring segment
panels, brackets, splices and shims and existing cured liquid shim surfaces.

Page 6011

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(10) Put the attach ring segment on panel with shims in place under brackets and attach to
shop aid alignment tool with NAS567−45 and NAS566−45 bolts. Position splices on
panels and install temporary fasteners (clecos) through panels. Clamp splices to shop
aid alignment tool and legs of attach ring segments.

(11) Remove excess liquid shim with clean wipers dampened with solvent. Remove masking
tape. Cure liquid shim 24 hours at room temperature, 65°F to 75°F (18,3°C to23,8°C),
or two hours at 150°F to 200°F (65,5°C to 93,3°C).

(12) Insert HL930 pins through panel, shims, and attach brackets and install HL585 collars.
Wet−install pins with epoxy primer. See Figures 603, 604, and paragraph 1.C.

(13) Insert pins through panels, and attach ring splices, and install collars. Wet−install the
pins with epoxy primer.

(14) Wet−install pins with epoxy primer rivets through aft land of panel and lower attach ring
segment.

(15) Remove shop aid alignment tool and install rivets through attach ring segments and
attach ring splices.

(16) Install index pin, bolts, and nuts on lower attach ring segment, if it was removed.

Page 6012

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

(17) Mix 100 pbw of sealant base with 12 pbw of sealant catalyst in a stainless steel
container. See Table 601.

NOTE: THE SEALANT MIXTURE IS USABLE FOR TWO HOURS AT ROOM

TEMPERATURE, 70°F TO 80°F (21,1°C TO 26,6°C).

(18) Scuff sand the epoxy primer on the outer skin of panels and outer splices along edges of
splices. Use 320−grit abrasive paper. Clean skins and splices with wiper moistened with
solvent. Wipe dry before solvent evaporates.

(19) Apply a filler of sealant mix along edges of outer splices and between joints of splices.
Cure the sealant for 24 hours at room temperature.

H. Install the aft bulkhead lower panels to the inner frame on the inner barrel lower acoustic
panel. See Figure 607.

(1) Install the lower outer barrel assembly on the inlet cowl with temporary fasteners
through the right splice plate, the left splice plate, forward bulkhead, and upper sections
of the aft bulkhead of the inner barrel assembly.

(2) Install the lower sections of the aft bulkhead webs on the lower outer barrel with
temporary fasteners through the aft bulkhead outer frame (which was left installed on
the outer barrel).

(3) Clamp the aft bulkhead webs to the leg of the aft bulkhead lower inner frame.

Page 6013

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Document Part No. 277−1100

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE)

(4) Drill the MS21141 blind fastener holes in the aft bulkhead webs through the leg of lower
inner frame of the panel using a 5/32−inch diameter drill.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE)

(5) Use a 0.194−inch (4,928 mm) diameter (No. 10) drill for the screw holes at the ends of
webs and at the starter duct bracket.

(6) Remove the aft bulkhead webs from the inlet cowl assembly.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE)

(7) Drill attach rivet holes in the inner frame for nutplates using 0.098−inch (2,489 mm)
diameter (No. 40) drill.

(8) Remove burrs from rivet and screw holes in the inner frame and install nutplates with
rivets. Remove all drill chips and other debris from inside of the inlet cowl inner and the
outer barrels. Remove protective covers from the forward bulkhead.

(9) Position the aft bulkhead lower web sections and reinstall MS21141U05 blind rivets
through the webs and the aft bulkhead lower outer frame. Use the same production type
fasteners at intersection of radial stiffener angles.

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Document Part No. 277−1100

NOTE: INSTALLATION OF RIVETS BETWEEN THE LOWER ACCESS

DOORS AND THE UPPER ENDS OF LOWER OUTER FRAME MAY
BE DEFERRED IF THE UPPER LEFT AND/OR UPPER RIGHT INNER
BARREL PANELS WILL BE REPLACED.

(10) Install HL48−5 pins and HL86−5 collars through webs and aft bulkhead inner frame and
at intersection of radial stiffener angles.

I. Complete the installation of the lower outer barrel.

(1) Wet−install fasteners through the forward land of the lower outer barrel assembly and
inlet cowl forward bulkhead angles, using polyamide epoxy primer. See Table 601.

(2) Wet−install rivets through the lower outer barrel assembly and splice plates, using
polyamide epoxy primer.

NOTE: INSTALLATION OF RIVETS MAY BE DEFERRED IF THE UPPER

LEFT AND/OR UPPER RIGHT INNER BARREL PANELS WILL BE
REPLACED.

(3) Wet−install CR3522−5 blind rivets through upper outer barrel, splice angles, and upper
outer frame. Install blind rivets through aft bulkhead upper and lower webs and aft
bulkhead upper and lower outer frames. See Figure 609.

Page 6015

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

(4) Install CR3522−5 blind rivets through aft bulkhead upper outer frame and outer frame
splice plates. See Figure 608.

(5) Repair surface finish of inlet cowl outer barrel in accordance with instructions in A330
CF6−80E1 SRM 54−10−00, Repair No.1.

3. Replace the inlet cowl inner barrel upper left acoustic panel assembly.

A. Remove the outer barrel upper assembly to get access to the upper left panel of the inner
barrel assembly.

CAUTION: REMOVE SURFACE FINISH ONLY. DO NOT TAPER OR BREAK

GRAPHITE FIBERS FROM THE TOP SURFACE OF THE OUTER SKIN
PLY.

(1) Remove surface finish to expose heads of rivets which attach the upper outer barrel
assembly to the inlet cowl forward bulkhead. Remove surface finish from rivets which
attach the splice plates to the lower outer barrel assembly at the 90 and 270 inlet cowl
radials. Use 150−grit or finer silicon carbide abrasive paper. See Table 601.

NOTE: SURFACE PRIMER TOP COAT IS GRAY, THE MIDDLE COAT IS

BLACK, AND FIRST COAT IS YELLOW.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE)

CAUTION: DO NOT ALLOW BLIND RIVETS TO SPIN IN THE COMPOSITE SKIN

WHEN DRILLING OUT.

(2) Drill out rivets which attach upper outer barrel assembly to inlet cowl forward bulkhead.
Use 0.1570−inch (3,988 mm) diameter (No. 22) drill for CR3522−5 blind rivets.

(3) Drill out rivets which attach splice plates to lower outer barrel.

(4) Drill out fasteners which attach aft bulkhead webs to aft bulkhead upper outer frame.

(5) Remove HL48−5 pins and HL86−5 collars and MS21141U05 blind rivets which attach
aft bulkhead webs and stiffeners to aft bulkhead upper outer frame. See Figure 607.

Page 6016

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(6) Remove all filler material applies between inlet lip and outer barrel upper half and
between outer barrel upper and lower Halves. Smooth surface with 150−grit abrasive
paper. Remove sanding debris with a cloth wiper moistened with solvent. Wipe dry
before solvent evaporates.

B. Remove aft bulkhead upper left sections.

NOTE: DISCONNECT THE ANTI−ICE DUCT (277−1150) ATTACHMENT AND

COMPONENT PARTS (AS REQUIRED) AT AFT BULKHEAD AND KEEP
THE HARDWARE FOR INSTALLATION.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE)

(1) Remove HL48−5 pins and HL86−5 collars which attach aft bulkhead upper left web
sections to aft bulkhead upper left inner frame. See Figure 607.

(2) Remove HL48−5 pins and HL86−5 collars and MS21141U05 blind rivets which attach
stiffener angles to aft bulkhead webs and aft bulkhead upper left inner frame.

(3) Remove aft bulkhead upper left web sections and Keep the for installation.

C. Remove attachment ring upper left segment with brackets attached.

(1) Remove collars and pins which attach splices to upper and lower attach ring segments
and to inner barrel acoustic panel assemblies.

(2) Remove rivets which attach upper and lower left attach ring splices to lower and upper
attach ring segments. Remove splices and keep them for installation.

Page 6017

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NOTE: TAP THE SPLICES LIGHTLY TO RELEASE FROM CURED LIQUID

SHIM UNDER FILLERS.

(3) Remove collars, pins, and rivets which attach upper left segment of attach ring, brackets
and shims to lower inner barrel acoustic panel assembly. Remove attach ring upper left
segment, brackets and shims as a unit and keep for installation. Tap brackets lightly to
release from cured liquid shim under fillers. Use 150−grit abrasive paper to remove
gloss from exposed surface of cured liquid shim and leave with a dull matte finish. Keep
the attach ring, brackets, and fillers for installation.

NOTE: A FILLER MAY BE INSTALLED BETWEEN THE ATTACH RING AND

THE ACOUSTIC PANEL AFT LAND. YOU MUST KEEP THE FILLER
FOR INSTALLATION WITH THE ATTACH RING.

D. Remove upper left acoustic panel assembly from inlet cowl inner barrel.

(1) Remove collars, pins, rivets, outer splices, shims and inner splices which attach inner
barrel acoustic panel to inner barrel acoustic panels. Keep the pins and collars for use in
fitting replacement panel.

(2) Remove collars and pins which attach inner barrel upper left acoustic panel to forward
bulkhead assembly.

(3) Move the inner barrel panel aft as required to remove from inlet cowl inner barrel
assembly. Rotate lower side of panel to clear lower attach ring segment.

(4) Use 150−grit aluminum oxide abrasive paper and remove sealant and cured liquid shim
from faying surfaces of inner barrel panels inner barrel outer splices, inner barrel inner
splices and shims. Keep the splices and shims for installation.

E. Trim the replacement inner barrel upper left acoustic panel to fit existing inlet cowl assembly.

(1) Put the replacement inner barrel upper left panel between the inner barrel upper right
panel and the inner barrel lower panel.

NOTE: THE FORWARD END OF THE REPLACEMENT PANEL REQUIRES

FINAL TRIM AND WILL REST INSIDE THE TRAILING EDGE OF THE
INLET LIP UNTIL IT IS TRIMMED FOR BUTT−SPLICE
ATTACHMENT TO THE FORWARD BULKHEAD ANGLES.

(2) Make sure the aft corners of panel match aft corners of panels and do not extend
beyond aft vertical surfaces of upper right and lower attach ring segments.

Page 6018

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(3) Install the shop aid alignment tool on the inlet cowl attach ring upper right and lower
segments. Use two NAS567−45 bolts, AN960C716 washers, and AN315−7R nuts in
each segment of attach ring. Torque NAS567−45 bolts to 270 to 300 lb−in (30,5 to 33,9
N.m). Use NAS566−45 bolts, AN960D616 washers, and AN315−6R nuts in remaining
holes. Torque NAS566−45 bolts to 96 to 114 lb−in (10,8 to 12,9 N.m).

WARNING: MISMATCH ALIGNMENT AND GAP AT INNER BARREL FORWARD AND

AFT EDGES ARE CRITICAL FOR AERODYNAMIC SMOOTHNESS
REQUIREMENTS OF THE INLET COWL ASSEMBLY.

(4) Hold the forward land of the panel firmly against the inner surface of the inlet lip. Make
sure the gap between the aft corners of the panel and face of the shop aid alignment
tool interface plane tool is 0.060 to 0.120 inch (1,524 to 3,048 mm) and gap at center of
panel is correct in accordance with previous measurement records.

(5) Hold the forward land of the panel firmly against the inner surface of the inlet lip and
mark a line on the inlet lip at the forward edge of the panel. Mark reference lines at the
center of the panel and lip and at four equally spaced points between the center and
each corner of the panel.

(6) Remove the shop aid alignment tool from the attach ring upper right and lower
segments. Remove the splice angles from the aft bulkhead inner frames and remove the
replacement inner barrel panel from the inlet cowl.

(7) Measure the distance the inner barrel land extends over the inlet lip at the center mark
and at each reference point on each side out to the corner. Subtract 0.13 inch (3,3 mm)
from the center measurement and transfer to the center reference line on the inside of
forward land of the replacement inner barrel panel. Subtract 0.10 inch (0,254 mm) from
measurement at next reference line out from center on each side and transfer to inner
barrel forward land. Subtract 0.08 inch (2,032 mm), 0.05 inch (1,270 mm) and 0.025
inch (0,635 mm) progressively from measurements at remaining reference lines and
transfer to inner barrel forward land at appropriate location. At each corner measure and
transfer the dimensions to the inner barrel forward land as required.

(8) Make a fairing strip straight−edge from aluminum stock. Place fairing strip on inner
surface of inner barrel forward land, align forward edge of strip with transferred
measurements at corners, center, and intermediate points and clamp to land. Mark the
forward edge trim line for the inner barrel along the forward edge of the fairing strip.

(9) Remove fairing strip and trim inner barrel forward land to trim line mark. Smooth the
edge of the land and break sharp corners.

F. Fit the replacement inner barrel upper left acoustic panel assembly (277−1120) to the inlet
cowl assembly (277−1100).

Page 6019

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Document Part No. 277−1100

(1) Position the replacement inner barrel panel centered between the panels.

(2) Remove fairing strip and trim inner barrel forward land to the trim line mark. Smooth the
edge of the land and break sharp corners.

(3) Install shop aid alignment tool on inlet cowl attach ring upper segments and torque bolts.

(4) Install upper left attach ring (and filler if used on original installation) on shop aid
alignment tool. Use two NAS567−45 bolts, AN960C716 washers, and AN315−7R nuts.
Torque NAS567−45 bolts to 270 to 300 lb−in (30,5 to 33,9 N.m). Use NAS566−45 bolts,
AN960D616 washers, and AN315−6R nuts in remaining holes. Torque NAS566−45
bolts to 96 to 114 lb−in (10,8 to 12,9 N.m).

(5) Hold forward land of panel firmly against forward bulkhead angles and aft land firmly
against upper left attach ring. Make sure the gap between forward edge of panel forward
land and inlet lip is 0.060 to 0.120 inch (1,524 to 3,048 mm). Make sure the gap
between aft edge of aft land of panel) and face of shop aid alignment tool is 0.010 to
0.070 inch (0,254 to 1,778 mm). Insert the "GO" pin of shop aid alignment tool through
ring of tool to get the correct position of panel aft land, and to hold land in contact with
attach ring segment.

(6) Install inner splices, outer splices, and shims. Use pins and collars (which were removed
from original installation) through panels , splices, and shims. Use temporary fasteners
through outer splices, aft bulkhead land, and attach ring segment. Use temporary
fasteners through panels inner splices, outer splices, forward land, and forward
bulkhead angles.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE)

(7) Use 0.1890−inch (4,801 mm) diameter (No. 12) drill and back−drill rivet holes in upper
left attach ring segment (and filler between attach ring and panel land if it existed on
original assembly) through aft land of panel. Work outboard from center of panel and
install temporary fasteners. Countersink inner skin of panel for rivets in accordance with
A330 CF6−80E1 SRM 54−04−09 and SRM 54−04−01.

(8) Install attach ring splices on panels with temporary fasteners through panels, upper right
attach ring segment and lower attach ring segment.

Page 6020

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Document Part No. 277−1100

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE)

(9) Use 0.1910−inch (4,851 mm) diameter (No. 11) drill and back−drill existing pin holes in
splice through panel. Install temporary fasteners.

(10) Use No. 11 and 19 drill and back−drill existing pin holes in forward bulkhead angles
through forward land of panel. Install temporary fasteners in holes.

(11) Use 0.1910−inch (4,851 mm) diameter (No. 11) drill and back−drill existing pin holes in
splices through outer skin of panel. Drill mating pin holes in splices through inner skin of
panel and core. Align holes through inner skin, outer skin, and core.

(12) Use a 5/32−inch drill and back−drill existing rivet holes through the outer skin only at
the aft end of the panel.

(13) Check for gaps between shims under attach brackets, attach ring splices, and the outer
skin of panel. If gap exceeds 0.030 inch (0,762 mm), use additional laminated shims to
close gap. Peel fillers to thickness required.

(14) Remove shop aid alignment tool, upper left attach ring, inner barrel lower panel, splices,
fillers, and angle splices. Deburr rivet and pin holes, and clean drill chips from structure.

(15) Treat exposed, untreated or reworked surfaces of the panel with chemical conversion
coating and prime with epoxy primer. See Table 601.

G. Install replacement inner barrel upper left acoustic panel assembly.

Page 6021

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

(1) Put the replacement panel between existing panels and install inner splices, and outer
splices, shims. Use temporary pins and collars which were removed from original
structure. Install temporary fasteners through forward land of panel and forward
bulkhead angles. Install temporary fasteners through outer splices at forward ends of
panels.

(2) Install the shop aid alignment tool and torque bolts. Install upper left attach ring segment
and filler between attach ring and panel land if it existed on original assembly on shop
aid alignment tool. Position attach ring splices and install temporary fasteners through
attach ring segments, splices, attach brackets and aft land of the panel.

(3) Use epoxy primer and wet−install new pins through forward land of inner barrel panel
and forward bulkhead assembly. Install collars on pins.

(4) Use epoxy primer and wet−install new pins through panels, inner splices and outer
splices. Install pins and collars.

(5) Install rivets through splices and outer skin of panels.

(6) Remove attach ring splices, upper left attach ring segment, and filler if used on the
original installation from panel and shop aid alignment tool.

Page 6022

COMPONENT MAINTENANCE MANUAL

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(7) Clean mating surfaces of splices, shims , upper left attach ring segment, attach
brackets, and panels with solvent. Wipe dry before solvent evaporates. Brush or spray
surfaces which will contact liquid shim with polyvinyl alcohol to serve as a release agent.
Apply polyvinyl alcohol to all surfaces of bolts, washers, and nuts used to attach upper
left ring segment to the shop aid alignment tool. Apply masking tape to surfaces
adjacent to liquid shim areas to protect surfaces from excess liquid shim squeeze−out.

(8) Mix in a stainless steel container one pbw of Part B epoxy adhesive catalyst with three
pbw of Part A epoxy adhesive base. Useful life of eight ounce mix of liquid shim is 1.5
hours at room temperature, 65°F to 75°F (18,3°C to 23,8°C). See Table 601.

(9) Brush apply liquid shim mix to mating surfaces of attach ring, panels, brackets, splices,
shims and existing cured liquid shim surfaces.

Page 6023

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

(10) Put the attach ring on panel with shims in place under brackets and attach to shop aid
alignment tool with NAS567−45 and NAS566−45 bolts. Position splices on panels and
install temporary fasteners through panels. clamp splices to shop aid alignment tool and
legs of attach rings.

(11) Remove excess liquid shim with clean wipers dampened with solvent. Remove masking
tape. Cure liquid shim 24 hours at room temperature, 65°F to 75°F (18,3°C to 23,8°C) or
two hours at 150°F to 200°F (65,5°C to 93,3°C).

(12) Insert pins through panel, shims, and attach brackets and install collars. Wet−install pins
with epoxy primer.

(13) Insert pins through panels, and attach ring splices, and install collars. Wet−install pins
with epoxy primer.

(14) Wet−install with epoxy primer rivets through aft land of panel and lower attach ring
segment.

(15) Remove the shop aid alignment tool and install rivets through attach rings and attach
ring splices.

Page 6024

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

(16) Install index pin, bolts and nuts on attach ring if they were removed.

(17) Mix 100 pbw of sealant base with 12 pbw of sealant catalyst in a metal container. See
Table 601.

NOTE: THE SEALANT MIXTURE IS USABLE FOR TWO HOURS AT ROOM

TEMPERATURE, 70°F TO 80°F (21,1°C TO 26,6°C).

(18) Scuff−sand with 320−grit abrasive paper and epoxy primer on outer skin of panels and
outer splices along edges of splices. Clean skins and splices with wiper moistened with
solvent. Wipe dry before solvent evaporates.

(19) Apply a fillet of sealant mix along edges of outer splices and between joints of splices.
Cure sealant 24 hours at room temperature.

Page 6025

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Document Part No. 277−1100

H. Install aft bulkhead upper left panels to aft bulkhead inner frame on upper left inner barrel
panel. See Figure 607.

(1) Install outer barrel upper assembly on inlet cowl with temporary fasteners through right
splice plate, left splice plate, forward bulkhead, and upper right section of aft bulkhead.

(2) Install upper left sections of aft bulkhead webs on outer barrel upper assembly with
temporary fasteners through aft bulkhead outer frame (which was left installed on outer
barrel).

(3) Clamp aft bulkhead webs to leg of aft bulkhead upper left inner frame.

(4) Drill the MS21141U05 blind fastener holes in aft bulkhead webs through leg of upper left
inner frame, using 5/32−inch diameter drill.

(5) Remove Aft Bulkhead Webs from Inlet Cowl Assembly.

(6) Drill attach rivet holes in aft bulkhead inner frame for nutplates using 0.098−inch (2,489
mm) diameter (No. 40) drill. Debur rivet and screw holes in aft bulkhead inner frame and
install nutplates with rivets. Remove all drill chips and other debris from the inside of
inlet cowl and outer barrels. Remove protective covers from the forward bulkhead.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE)

(7) Position aft bulkhead upper left web sections and install MS21141U05 blind fasteners
through the webs, aft bulkhead upper and lower outer frames. Use same production
type fasteners at intersections of radial stiffener angles.

Page 6026

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Document Part No. 277−1100

(8) Install new HL48−5 pins and HL86−5 collars through webs and aft bulkhead inner frame
and at intersection of radial stiffener angles.

I. Complete the installation of upper outer barrel.

NOTE: IF YOU ALSO WILL REPLACE THE INNER BARREL UPPER RIGHT
ACOUSTIC PANEL ASSEMBLY, YOU MAY WAIT TO DO THESE
PROCEDURES UNTIL AFTER YOU REPLACE THE UPPER RIGHT
ACOUSTIC PANEL ASSEMBLY.

(1) Wet−install rivets through forward land of upper outer barrel assembly and inlet cowl
forward bulkhead angles, using polyamide epoxy primer. See Table 601.

(2) Wet−install rivets through lower outer barrel assembly and splice plates using polyamide
epoxy primer.

(3) Wet−install CR3522−5 blind rivets through upper outer barrel, splice angles, and aft
bulkhead upper outer frame. Install blind rivets through aft bulkhead upper and lower
webs and aft bulkhead upper and lower outer frames. See to Figure 609.

(4) Install CR3522−5 blind rivets through aft bulkhead upper outer frame, and outer frame
splice plates. See Figure 608.

(5) Repair the surface finish of inlet cowl outer barrel in accordance with instructions in the
A330 CF6−80E1 SRM 54−10−00, Repair No.1.

Page 6027

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

(6) Apply aerodynamic silicone sealant to inlet cowl outer barrel.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY

ALL SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS),
AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY
INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND
DISCARD CHEMICALS.

(a) Clean the surfaces in and around gaps between the upper and lower outer barrel
panels at the 90 degree and 270 degree radials and at the aft edge of the inlet lip
with a cloth moistened with solvent. Wipe the cleaned area dry before the solvent
evaporates.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY

(b) Mask around gaps to protect surfaces from excess sealant.

Page 6028

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Document Part No. 277−1100

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY

(d) Mix one pbw of silicone sealant catalyst with ten pbw of silicone sealant base.

NOTE: THE SEALANT MIX IS USABLE FOR TWO HOURS AT ROOM

TEMPERATURE.

(e) Apply sealant mixture with plastic spatula to fill gaps around inlet lip and between
upper and lower outer barrel panels flush with air−wetted surfaces. Work trapped
air from sealant in gaps with spatula.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY

(f) Remove masking tape and fair sealant head with spatula to form an
aerodynamically smooth surface. Clean excess sealant from adjacent surfaces
with cotton wiper moistened with solvent.

(g) Cure the sealant for 48 hours at room temperature.

J. Replace the inlet cowl inner barrel upper right acoustic panel assembly.

(1) Replace the inner barrel upper right acoustic panel assembly. Use the instructions given
in step 2.D.

Page 6029

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Document Part No. 277−1100

K. Return the inlet cowl assembly to serviceable status or storage status, whichever existed prior
to inner barrel replacement.

(1) Install hoist plates on inlet cowl upper outer barrel.

(2) Attach the front sling to inlet cowl front hoist plates and rear sling to aft hoist plates. Use
the inlet cowl sling RSE1236. See Figure 902.

(3) Lift inlet cowl from the lip−down position on the padded work surface and rotate to the
horizontal position.

(4) Place inlet cowl on the RSE1021 inlet cowl dolly. See Figure 901

4. Materials and Equipment.

NOTE: YOU CAN USE ALTERNATIVE EQUIPMENT AND MATERIALS WITH THE
SAME PRECISION TO REPLACE THE ITEMS SHOWN IN TABLE 601.

DESCRIPTION DESIGNATION MANUFACTURER

Agent, Wetting Calsoft LAS 99 McKesson Chemical Corp

Agent, Wetting Surfactant Activol 1357 Harry Miller Corp
Alternate
Aluminum Stock Bare, 2024−T42 or −T3 Commercially Available
0.025 in. (0.64 mm),
0.028 in. (0.71 mm),
0.036 in. (0.91 mm), and
0.050 in. 1.27 mm) Thick
Bolt NAS566−45 Commercially Available
NAS567−45
2750308−30
Coating, Chemical Alodine 1000L or equivalent V71410
Conversion Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583−9300
www.aerospace.henkel.com

Cloth, Lint−Free Cotton Commercially Available

Container Stainless Steel Commercially Available

Page 6030

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

DESCRIPTION DESIGNATION MANUFACTURER

Dolly, Inlet Cowl Work RSE1021 Rohr Industries

Stand

Drill Size No.: Commercially Available

5/32 in.,
11,
12,
16

Pin, Hi−Lok HL48−5 Hi−Shear

Collar, Hi−Lok HL86−5 Hi−Shear
Pin, Hi−Lok−HL930−6 and Collar, Hi−Lok
HL585DU( )AW
Nut NAS1805−8 Commercially Available
AN3156R
Paper, Abrasive Aluminum Oxide 150, 320−Grit Commercially Available
Paper, Abrasive 150−Grit Silicon Carbide Commercially Available

Prime Coat, RTV DOW CORNING® PR−1200 V5D028

Dow Corning Corporation
3901 South Saginaw Road
Midland, MI 48686
Phone: (989) 496−4400
www.dowcorning.com
Primer, epoxy − Fluid Base 10P4−2 (Green) V0KXA5
Resistant Converter EC−117 Akzo Nobel Aerospace Coatings
Thinner TR−19 East Water St.
Retarder Thinner TR−20 Waukegan, IL 60085−5563
Phone: (847) 625−4200
Fax: (847) 625−3200
www.anac.com
Primer, epoxy − Fluid Lead and Cadmium Free V0KXA5
Resistant Base 10P4−3 Akzo Nobel Aerospace Coatings
Converter EC−117
Thinner TR−19
Retarder Thinner TR−20
Rivet MS20426AD5−( ) Commercially Available
MS20427M5

Page 6031

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

DESCRIPTION DESIGNATION MANUFACTURER

Rivet, Blind CR3522PR−5 V05693

CR3522−6 Cherry Textron Inc
1224 E. Warner St.
Santa Ana, CA 92705−5484
Phone: (714) 545−5511
www.cherryaerospace.com
Rivet, Blind MS21141−5 Commercially Available

Sealant, DC 93−006−6 (Two Part) V5D028

Silicone Paste, Sealant and Catalyst Dow Corning Corporation
Gray 3901 South Saginaw Road
Midland, MI 48686
Phone: (989) 496−4400
www.dowcorning.com
Adhesive, EA934NA V33564
Epoxy Paste Henkel Corporation
2850 Willow Pass Rd.
P.O. Box 312
Bay Point, CA 94565−0031
Phone: (925) 458−8000
www.aerospace.henkel.com

Shop Aid Alignment Tool, Not Applicable Develop locally

Engine Attach Flange
Sling, Inlet Cowl RSE1236 Rohr Industries
Solvent Isopropyl Alcohol 99 percent Commercially Available
pure
or
MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Univar U.S.A., Inc.
Ketone/40% Methyl Ethyl 532 E. Emaus Street
Ketone) Middletown, PA 17057−2200
or Phone: (717) 944−7471
www.univarusa.com
Turco 6646 V71410
Henkel Corporation
Spacer 277−1011−501 Commercially Available
Spatula Plastic Commercially Available

Page 6032

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

DESCRIPTION DESIGNATION MANUFACTURER

Tape Masking Commercially Available

Washer AN960C10L Commercially Available
AN960C716
AN960D616
VN936NP8
Repair Materials and Equipment
Table 601

Page 6033

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

INLET COWL
ASSY (277−1100)

INNER BARREL
ASSY (277−1120)
INLET RADIAL 270 O
FIGURE 604 AND
(90O RADIAL OPP.) FIGURE 605

OUTER BARREL AFT BULKHEAD

CEC−120−00

ASSY (277−1130) ASSY (277−1140)

FIGURE 609

FIGURE 601 INLET COWL ASSEMBLY (277−1100)

Page 6034

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

AFT FRAME
(277−1122)

INNER BARREL
ACOUSTIC PANEL
(277−1120)

AFT ENGINE
CEC−121−00

ATTACH FITTING
C (277−1123)

FIGURE 602 INLET COWL INNER BARREL ASSEMBLY AND ENGINE ATTACH BRACKETS (277−1120 AND 277−1123)

Page 6035

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

J
AFT ENGINE ATTACH
RING (277−1124)

INSULATION
BLANKET

INSULATION
BLANKET
(277D1101)

INNER BARREL
SPLICE TYPICAL
(3 PLACES)
(277−1120)
o o o
RDL114 , 236 , & 355

H
CEC−122−00

FIGURE 603 (SHEET 1) INLET COWL INNER BARREL CONFIGURATION (277−1120)

Page 6036

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

SPLICE STRAP SPLICE STRAP

(277−1120) (277−1120)
HL633−6 PIN
HL585DU6AW
COLLAR TYP

SPLICE STRAP
(277−1120)

H HL633−6 PIN
ENGINE ATTACH HL585DU6AW
RING (277−1124) AFT FRAME COLLAR TYP
(277−1122)
SPLICE STRAP SPLICE STRAP
(277−1120) (277−1120)
HL633−6 PIN
HL585DU6AW
COLLAR TYP

SPLICE STRAP
(277−1120)

HL633−6 PIN
ENGINE ATTACH
AFT FRAME
G HL585DU6AW
RING (277−1124) COLLAR TYP
(277−1122)

SPLICE STRAP SPLICE STRAP

(277−1120) (277−1120)
HL633−6 PIN
M
HL585DU6AW
COLLAR TYP

SPLICE STRAP
(277−1124) M HL633−6 PIN
HL585DU6AW
AFT FRAME COLLAR TYP
CEC−123−00

(277−1122)
ENGINE ATTACH
RING (277−1120)
BRACKET
(277−1123) TYP
F INLET COWL
(273−1100) TYP

FIGURE 603 (SHEET 2) INNER BARREL ASSEMBLY SPLICE DEFINITION (277−1120) (INLET RADIALS 114°, 236° AND 355°)

Page 6037

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

NAC STA
141.200

INLET COWEL ENGINE

ATTACH BRACKET
(277−1123 TYP)

HL930−6 PIN
HL585DU( )AW MS20426 AD5
TYP RIVET TYP

HL930−5 PIN
HL585DU5AW

AFT FRAME ENGINE ATTACH

(277−1122) RING (277−1124)
CEC−124−00

FIGURE 603 (SHEET 3) INNER BARREL ASSEMBLY

Page 6038

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

AFT ENGINE ATTACH

FITTING (277−1123)

HL41DU−6−( ) PIN
HL97DU ( ) AW COLLAR

SPLICE ANGLE
(277−1120)

HL930−6−( ) AW PIN
HL585 DU ( ) AW COLLAR

AFT ENGINE ATTACH

RING (277−1124)

BRACKET TYPICAL
(277−1123)
CEC−125−00

AFT ENGINE ATTACH AT

RDL 15O AND 195 O
K

FIGURE 604 LOWER INNER BARREL ASSEMBLY

Page 6039

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

INNER BARREL
INNER BARREL SPICE@ SEGMENT
236 DEGREE RDL (277−1120)

HL633−( ) PIN WITH

HL585DU−( ) AW
COLLAR

LIP SKIN
ASSEMBLY HL930−( ) PIN WITH
(277−1110) L HL585DU−( ) AW
COLLAR

2.19 OUTER SPLICE

STRAP (277−1120)

(1.272 CONST)

.180
.030
LL
INNER BARREL INNER BARREL
STRAP (277−1120) .130
2X PANEL (277−1120)
.015
CEC−126−00

FIGURE 605 INNER BARREL SPLICE AT FORWARD BULKHEAD

Page 6040

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

CEC−127−00

FIGURE 606 INNER BARREL ASSEMBLY

Page 6041

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

MS21141
BLIND HL48 PIN
FASTENER HL86 COLLAR

MS21141
BLIND M13701−02−2
FASTENER

UPPER INNER FRAME

NAS6303U4
NAS1149D0332
M13701−02−3
HL48 PIN
HL86 COLLAR

M13701−02−2

277−1140

MS21141
BLIND LOWER
FASTENER OUTER
CEC−128−00

FRAME

FIGURE 607 AFT BULKHEAD

Page 6042

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

277−1131
OUTER BARREL
277−1131
OUTER BARREL
MS20427M5
BLIND RIVETS
AFT FRAME
SPLICE STRAP

A
8X .74

1.02
.56

.050 + .030

A
277−1141 OUTER 3.12
AFT BHD FRAME
2X .45 + .03
FWD

SPLIT LINE
AFT FRAME
SPLICE STRAP

AFT OUTER
LL FRAME

MS20427M5 NAC STA 137.11

BLIND RIVETS NAC STA
137.240
CEC−129−00

VIEW A−A

FIGURE 608 AFT OUTER FRAME SPLICE STRAPS

Page 6043

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

AFT OUTER
FRAME

277−1110 1.98
LIP SKIN 60 EQ SPACES
2.06 STAGGERED
277−1130−501 SPLICE
A

1.21 .44 .77

CR3522−5
BLIND RIVETS
277−1130−505
OUTER BARREL MS20427M5
RIVETS AFT FRAME
SPLICE STRAP
VIEW LOOKING INBOARD

277−1130

277−1130−505 SPLICE
1.55
1.62 SPLICE
AFT
FORWARD AFT OUTER
BULKHEAD BULKHEAD FRAME
SECTION A−A
TYPICAL OUTER BARREL SPLICE
FWD
CEC−130−00

FIGURE 609 OUTER BARREL SPLICE TYPICAL

Page 6044

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

CEC−106−00

FIGURE 610 SHOP AID ALIGNMENT TOOL ENGINE ATTACH FLANGE

Page 6045

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

THIS PAGE INTENTIONALLY LEFT BLANK

Page 6046

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

TASK 71−11−09−500−801
1. Assembly (Includes Storage)

A. Assembly Materials and Equipment (See Table 701)

NOTE: YOU CAN USE ALTERNATIVE EQUIPMENT WITH THE SAME PRECISION
TO REPLACE THE ITEMS SHOWN IN TABLE 701.

NOTE: YOU CAN USE ALTERNATIVE MATERIALS WITH THE SAME

PROPERTIES TO REPLACE THE ITEMS SHOWN TABLE 701.

DESCRIPTION DESIGNATION MANUFACTURER

Anti−Seize, Copper Based LOCTITE® C5−A® V33564
Henkel Corporation
2850 Willow Pass Rd.
P.O. Box 312
Baypoint, CA 94565−0031
Phone: (800) 257−7522
www.aerospace.henkel.com
Cloth Lint−free, Cotton Commercially Available
Screwdriver Standard Commercially Available

Solvent Isopropyl Alcohol 99 Percent Commercially Available

Pure
or
MIBK/MEK Blend (60% V5E821
Methyl Isobutyl Ketone/40% Univar U.S.A., Inc.
Methyl Ethyl Ketone) 532 E. Emaus Street
or Middletown, PA 17057−2200
Phone: (717) 944−7471
www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583−9300
www.aerospace.henkel.com
Wrench, Spanner RSE 1243 Locally Manufactured
Tool drawings provided by
Goodrich, upon request

Page 7001

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

Assembly Materials and Equipment

Table 701

B. Assembly Procedures

WARNING: THE INLET COWL WEIGHS APPROXIMATELY 552 LBS (250 KG). MAKE
SURE THE COWL IS ADEQUATELY SUPPORTED DURING
DISASSEMBLY TO AVOID INJURY TO PERSONNEL.

(1) Lip Assembly (See IPL Figure 6)

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY

(a) Clean the threads of the bolts (40) with a clean lint−free cloth and the solvent.
Remove the solvent with a clean lint−free cloth before the solvent becomes dry.

(2) Apply a small amount of anti−seize compound to threads of bolts (40). Remove excess
compound with a clean dry cotton cloth. Refer to the instructions of the manufacturer.

(3) Install the nozzle assembly (60) with bolts (40) and washers (50).

(4) Torque bolts (40) to 20−25 lb−in. (2.3−2.8 Nm).

(5) Inner Barrel Assembly (See IPL Figure 5)

Page 7002

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

(a) Install pins (30) with screws (10) and nuts (20).

(b) Torque nuts (20) to 12−15 lb−in (1.4−1.7 Nm).

(6) Lower Outer Barrel (See IPL Figure 4)

(a) Install clips (70) with screws (50) and nuts (60).

(b) Torque nuts (60) to 1.7−2.3 lb−in (0.2−0.3 Nm).

(7) Pressure Relief Door Assembly (See IPL Figure 3)

(a) Install hinge half (390) on splice (400) with spacer (310), pins (300) and collars
(330).

(b) Install bracket (260) with pins (200) and collars (230).

(d) Torque nut (180) to 12−15 lb−in. (1.4−1.7 Nm).

(e) Install latch (250) with pins (210), nuts (240) and washers (220).

(f) Torque nuts (240) to 12−15 lb−in. (1.4−1.7 Nm).

(g) Install hinge half (370) with shims (130 and 140) and bolts (75).

(h) Torque bolts (75) to 20−25 lb−in. (2.3−2.8 Nm).

(i) Install bracket (120) with strip (110), pins (60) and collars (90).

(j) Install door assembly (150) with pin (280), sleeves (−275), springs (−285), bolt
(70), nut (100) and washers (80).

NOTE: INSTALL THE SPRINGS TO FORCE THE DOOR OPEN WHEN

UNLATCHED.

(k) Torque nut (100) to 12−15 lb−in. (1.4−1.7 Nm).

(8) Peening of Hinges

(a) Peening of hinges (both extruded and formed) shall be sufficient to resist a push−
out force, applied to the hinge pin of 20 pounds.

(9) Exhaust Duct Assembly (See IPL Figure 1)

Page 7003

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

(a) Install duct assembly (400) with bolts (200 and 210), washers (250).

(b) Torque bolts (200 and 210) to 20−25 lb−in. (2.3−2.8 Nm).

(10) Anti−ice Supply Tube Assembly (See IPL Figure 1)

(a) Pre SB 30−001

1) Install the nut (340), seal (350), back up seal (360), two face seals (370) and
face seal (380) on the tube assembly (390).

2) Move the tube assembly (390), seal (350), back up seal (360), two face
seals (370) and face seal (380) into the swirl−tube coupling. Loosely engage
the nut (340) on the swirl−tube coupling.

3) Attach the tube assembly (390) to the inlet cowl aft bulkhead with the screws
(180). Torque the screws (180) to 55 − 70 lb−in. (6.2 − 7.9 Nm).

4) Tighten the nut (340) with the RSE 1243 wrench. Torque the nut (340) to
120 − 240 lb−in. (1.35 − 2.71 daNm). See Special Tools, Figure 903.

5) Install the retainer (330) with washers (240) and bolts (230). Torque the bolts
(230) to 12 − 15 lb−in. (1.4 − 1.7 Nm).

(b) Post SB 30−001 Pre SB 30−005

1) Install the nut (340), packing seal (355) and face seal (385) on the tube
assembly (390).

2) Move the tube assembly (390), packing seal (355) and face seal (385) into
the swirl−tube coupling. Loosely engage the nut (340) on the swirl−tube
coupling.

3) Attach the tube assembly (390) to the inlet cowl aft bulkhead with the screws
(180). Torque the screws (180) to 55 − 70 lb−in. (6.2 − 7.9 Nm).

4) Tighten the nut (340) with the RSE 1243 wrench. Torque the nut (340) to
360 − 480 lb−in. (4.1 − 5.4 daNm). See Special Tools, Figure 903.

5) Install the retainer (330) with washers (240) and bolts (230). Torque the bolts
(230) to 12 − 15 lb−in. (1.4 − 1.7 Nm).

(c) Post SB 30−005

1) Install the nut (340) and the packing seal assembly (387) on the tube
assembly (390).

Page 7004

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

2) Move the tube assembly (390) and packing seal assembly (387) into the
swirl−tube coupling. Loosely engage the nut (340) on the swirl−tube
coupling.

3) Attach the tube assembly (390) to the inlet cowl aft bulkhead with the screws
(180). Torque the screws (180) to 55 − 70 lb−in. (6.2 − 7.9 Nm).

4) Tighten the nut (340) with the RSE 1243 wrench. Torque the nut (340) to
360 − 480 lb−in. (4.1 − 5.4 daNm). See Special Tools, Figure 903.

5) Install the retainer (330) with washers (240) and bolts (230). Torque the bolts
(230) to 12 − 15 lb−in. (1.4 − 1.7 Nm).

(11) Upper Outer Barrel Access Panels (See IPL Figure 3)

(a) Install access panel (50) with screws (30).

(b) Torque screws (30) to 20−25 lb−in. (2.3−2.8 Nm).

(c) Install access panel (40) with screws (30).

(d) Torque screws (30) to 20−25 lb−in. (2.3−2.8 Nm).

(12) Electrical Installation (See IPL Figure 2)

(a) Install jack end of wire harness assembly (10) with plate (50), retainer (40) and
screws (30).

(b) Torque screws (30) to 7−9 lb−in. (0.8−1.0 Nm).

(c) Install ground jack wire assembly (10) with connector (80), bolt (120), nuts (70,
170 and 180), washers (60, 130, 140 and 150).

(d) Torque nuts (70, 170 and 180) to 20−25 lb−in. (2.3−2.8 Nm).

(e) Install clamps (100) with bolts (90).

(f) Torque bolts (90) to 20−25 lb−in. (2.3−2.8 Nm).

TASK 71−11−09−500−801
2. Storage After Assembly

A. Apply a layer of the protective coating to the inlet cowl lip skin. (SeeTable 702)

Page 7005

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

NOTE: YOU MUST REMOVE THE TEMPORARY PROTECTIVE COATING

BEFORE THE OPERATION OF THE AIRCRAFT ENGINE. REMOVE
THE PROTECTIVE COATING FROM THE COMPONENT SURFACE.
REFER TO THE INSTRUCTIONS OF THE MANUFACTURER.

(1) Clean the inlet cowl lip skin. Make sure the lip skin is dry and free of dirt, chips, oil,
grease, or other unwanted materials. Refer to Cleaning Section.

(2) Make a mask onall painted surfaces, inner barrel, and electrical connectors of the inlet
cowl.Use the masking tape and kraft paper.

(3) Apply the protective coating to the inlet cowl lip skin.Refer to the instructions of the
manufacturer.

B. Put the covers on the open ends of the pneumatic ducts.

C. Put the covers on the open ends of the electrical plugs. Use the polyethylene sheets and
adhesive tape.

D. Put the unit in a clean, dry area.

CAUTION: DO NOT PUT TARPAULIN TYPE COVERS DIRECTLY ON THE INLET.

THE MOVEMENT OF THE COVER AGAINST THE ALUMINUM SURFACE
CAN CAUSE DAMAGE THROUGH THE OXIDE COATING OF THE
COMPONENT. THE MOISTURE FROM THE RAIN, OR CONDENSATION
FROM THE TEMPERATURE CHANGES BETWEEN THE COVER AND
INLET CAN CAUSE CORROSION ON THE ALUMINUM.

(1) When the inlet is in an open area where the temperature changes, put the inlet in a
shipping container. Use tarpaulin covers on the shipping container.

E. Storage Materials. (See Table 702.)

NOTE: YOU CAN USE ALTERNATIVE MATERIALS WITH THE SAME

PROPERTIES TO REPLACE THE ITEMS SHOWN TABLE 702.

Page 7006

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

DESCRIPTION DESIGNATION MANUFACTURER/SUPPLIER

Coating, Protective Spraylat V87354

1074 B1 (basecoat) Spraylat Corporation
SC 1090 (topcoat−white) 143 Sparks Ave
Pelham, NY 10803−1810
(914) 699−3030
www.spraylat.com
Cover, Tarpaulin Cloth, Plastic, or Rubber Commercially Available

Paper, Kraft Commercially Available

Polyethylene Sheet L−P−378, Type I Commercially available
Tape, Adhesive Cloth−backed PPP−T−60, Type IV Commercially available
Class 1

Tape, Masking Commercially available

Storage Materials
Table 702 dif

Page 7007

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

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Page 7008

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

TASK 71−11−09−220−801
1. Fits and Clearances

A. Torque Values (See Table 801)

NOTE: FASTENERS TIGHTENED FROM THE HEAD END MUST BE TIGHTENED

TO THE HIGH VALUE OF THE TORQUE RANGE.

IPL FIGURE AND ITEM TORQUE VALUE TORQUE VALUE

ITEM NUMBER NOMENCLATURE POUND−INCHES NEWTON−METER

1− 180 Screw 50 − 70 5.7 − 7.9

− 190 Bolt 50 − 70 5.7 − 7.9

− 200 Bolt 20 − 25 2.3 − 2.8

− 210 Bolt 20 − 25 2.3 − 2.8
− 220 Bolt 20 − 25 2.3 − 2.8
− 230 Bolt 12 − 15 1.4 − 1.7
− 340 Nut 120 − 240 13.6 −27.1

2− 30 Screw 7−9 0.8 − 1.0

− 70 Nut 20 − 25 2.3 − 2.8

− 90 Bolt 20 − 25 2.3 − 2.8

− 110 Screw 7−9 0.8 − 1.0

− 120 Bolt 20 − 25 2.3 − 2.8

− 160 Nut 7−9 0.8 − 1.0
− 170 Nut 20 − 25 2.3 − 2.8
− 180 Nut 20 − 25 2.3 − 2.
3− 30 Screw 20 − 25 2.3 − 2.
− 70 Bolt 12 − 15 1.4 − 1.7
− 75 Bolt 20 − 25 2.3 − 2.8
− 100 Nut 12 − 15 1.4 − 1.7
− 160 Bolt 12 − 15 1.4 − 1.7

Page 8001

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

IPL FIGURE AND ITEM TORQUE VALUE TORQUE VALUE

ITEM NUMBER NOMENCLATURE POUND−INCHES NEWTON−METER

− 180 Nut 12 − 15 1.4 − 1.7

− 240 Nut 12 − 15 1.4 − 1.7

4− 50 Screw 1.7 − 2.3 0.2 − 0.3
− 60 Nut 1.7 − 2.3 0.2 − 0.3

5− 10 Screw 12 − 15 1.4 − 1.7

− 20 Nut 12 − 15 1.4 − 1.7

6− 40 Bolt 20 − 2 2.3 − 2.8
Torque Values
Table 801

Page 8002

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

TASK 71−11−09−940−801
1. Special Tools, Fixtures and Equipment

NOTE: YOU CAN USE ALTERNATIVE EQUIPMENT WITH THE SAME PRECISION TO
REPLACE THE ITEMS SHOWN IN TABLE 901.

NOMENCLATURE USAGE
Inlet Cowl Dolly, To be used for storage, transport and as a work support fixture.
RSE1021 (See Figure 901)

Inlet Cowl Sling, To be used for lifting and shop handling.

RSE1236 (See Figure 902)
Wrench, Spanner − Anti−Ice To be used to torque the seal nut for the Anti−Ice Duct (See
Duct Seal Nut Figure 903)
RSE1243

Special Tools, Fixtures and Equipment

Table 901

Page 9001

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

INLET COWL

DOLLY
CEC−012−00

FIGURE 901 INLET COWL DOLLY

Page 9002

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

SLING

INLET COWL

C2C−002−00

FIGURE 902 INLET COWL SLING

Page 9003

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

SEAL NUT
RSE1243

CEC−082−00

FIGURE 903 ANTI−ICE DUCT SEAL NUT SPANNER WRENCH

Page 9004

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

NOTE: ALPHA CODE (I.E. “A”, “B”...”ZZ”), IF PRESENT, DOES NOT AFFECT
PHYSICAL OR FUNCTIONAL INTERCHANGEABILITY OF THE PART. IT
REPRESENTS THE DRAWING REVISION LEVEL FOR BETTER
TRACEABILITY ONLY.

Page 10001

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

Page 10002

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

Page 10003

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

Page 10004

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

Page 10005

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

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Page 10006

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

NUMERICAL INDEX

AIRLINE AIRLINE
PART NUMBER PART FIGURE− TTL PART NUMBER PART FIGURE− TTL
NUMBER ITEM REQ NUMBER ITEM REQ

Page 10007

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

NUMERICAL INDEX

AIRLINE AIRLINE
PART NUMBER PART FIGURE− TTL PART NUMBER PART FIGURE− TTL
NUMBER ITEM REQ NUMBER ITEM REQ

Page 10008

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

NUMERICAL INDEX

AIRLINE AIRLINE
PART NUMBER PART FIGURE− TTL PART NUMBER PART FIGURE− TTL
NUMBER ITEM REQ NUMBER ITEM REQ

Page 10009

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

NUMERICAL INDEX

AIRLINE AIRLINE
PART NUMBER PART FIGURE− TTL PART NUMBER PART FIGURE− TTL
NUMBER ITEM REQ NUMBER ITEM REQ

Page 10010

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

NUMERICAL INDEX

AIRLINE AIRLINE
PART NUMBER PART FIGURE− TTL PART NUMBER PART FIGURE− TTL
NUMBER ITEM REQ NUMBER ITEM REQ

Page 10011

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

AF
F

N
L
N E
N
K
K
V
N

P
AA J
C
X
D
T
S
530
AE 550
560 Q
P
B
N
AD
N
K
Q
540 R U P
N
N K

AJ A
N
K
30 N
CEC−083−01

INLET COWL ASSEMBLY FIGURE 1

IPL FIGURE 1 (SHEET 1 OF 11)

Page 10012

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

E 40 A 10

120
300

D
40 10
50

120
300
50

C
50 40
CEM−193−01

40 50

INLET COWL ASSEMBLY FIGURE 1

IPL FIGURE 1 (SHEET 2 OF 11)

Page 10013

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

50
G
F 50

100
50
50

100

100
50
50

100
50
100
50

50
H
50
CEM−194−00

120
50 50
50
120

INLET COWL ASSEMBLY FIGURE 1

IPL FIGURE 1 (SHEET 3 OF 11)

Page 10014

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

INLET COWL ASSEMBLY FIGURE 1

IPL FIGURE 1 (SHEET 4 OF 11)

Page 10015

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

INLET COWL ASSEMBLY FIGURE 1

IPL FIGURE 1 (SHEET 5 OF 11)

Page 10016

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

120 120 120 120 220 220

220
310 310 310 310 260 260
260
T
120 220
V 310 120 120 255
120 310 310 220
310 255
220
120 255
120 310
320 220
520
260
315 510 520
220 220 510
260 260 120
480 120 220
315 120 320 310 255
220 310
260 220
315 255
120 220 220 220 220
120 320 260 260 260 255 500
310 315 315 315
120 120 120 120
310 320 310 320 U
135 120
220 320 220 220 220 220
255 255 255 255 255
220
255 220
255
135
220
255
520
510

220
255

490

120 120
320 310
120 120 220 220 220 220 220
320 310 255 255 255 255 255
315 CEM−185−00

INLET COWL ASSEMBLY FIGURE 1

IPL FIGURE 1 (SHEET 6 OF 11)

Page 10017

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

160
165 160 160
165 165
150
152
7111090107−00

INLET COWL ASSEMBLY FIGURE 1

IPL FIGURE 1 (SHEET 7 OF 11)

Page 10018

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

270
Y

387
150

385
355
380 AB

150 270
Z 160 170
160 150 170

150
370 360 350 340
AC 280 270 270
280 270 270
AB 150

AA
390

180
270
CEM−195−01

INLET COWL ASSEMBLY FIGURE 1

IPL FIGURE 1 (SHEET 8 OF 11)

Page 10019

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

AD AC
230 330
240

200
250

410

430

400
460

420

210
295
315
317

210
315
317
120
CEC−084−00

210
295 470
315
317

INLET COWL ASSEMBLY FIGURE 1

IPL FIGURE 1 (SHEET 9 OF 11)

Page 10020

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

532

35 (24 LOCATIONS)

LWR OUTER
530 BARREL ASSY
REF REF
UPR OUTER 540
BARREL ASSY 532
AE

542
CEC−085−01

INLET COWL ASSEMBLY FIGURE 1

IPL FIGURE 1 (SHEET 10 OF 11)

Page 10021

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

AJ 190
(4 PL)
AG
AJ AK

AK AG
AH
190
(4 PL)
AG
AK

AH
AK

AK AJ

580
AK REF UPPER
PANEL OUTER
AF
570

REF LOWER
580 PANEL OUTER

600
CEM−023−04

F
590
AK W
D AH
TYPICAL 6 PLACES

INLET COWL ASSEMBLY FIGURE 1

IPL FIGURE 1 (SHEET 11 OF 11)

Page 10022

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

FIG.& AIRLINE UNITS

ITEM PART PART NOMENCLATURE EFF PER
NO. NUMBER NO. 1234567 CODE ASSY

− ITEM NOT ILLUSTRATED

Page 10023

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

FIG.& AIRLINE UNITS

ITEM PART PART NOMENCLATURE EFF PER
NO. NUMBER NO. 1234567 CODE ASSY

− ITEM NOT ILLUSTRATED

Page 10024

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

FIG.& AIRLINE UNITS

ITEM PART PART NOMENCLATURE EFF PER
NO. NUMBER NO. 1234567 CODE ASSY

− ITEM NOT ILLUSTRATED

Page 10025

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

FIG.& AIRLINE UNITS

ITEM PART PART NOMENCLATURE EFF PER
NO. NUMBER NO. 1234567 CODE ASSY

− ITEM NOT ILLUSTRATED

Page 10026

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

FIG.& AIRLINE UNITS

ITEM PART PART NOMENCLATURE EFF PER
NO. NUMBER NO. 1234567 CODE ASSY

− ITEM NOT ILLUSTRATED

Page 10027

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

FIG.& AIRLINE UNITS

ITEM PART PART NOMENCLATURE EFF PER
NO. NUMBER NO. 1234567 CODE ASSY

− ITEM NOT ILLUSTRATED

Page 10028

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

FIG.& AIRLINE UNITS

ITEM PART PART NOMENCLATURE EFF PER
NO. NUMBER NO. 1234567 CODE ASSY

− ITEM NOT ILLUSTRATED

Page 10029

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

FIG.& AIRLINE UNITS

ITEM PART PART NOMENCLATURE EFF PER
NO. NUMBER NO. 1234567 CODE ASSY

− ITEM NOT ILLUSTRATED

Page 10030

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

THIS PAGE INTENTIONALLY LEFT BLANK

Page 10031

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

A
90

100
(2 PLACES)
C
170
10
140
A 140 140

180

120

(BULKHEAD) 150
140

B CEM−187−01

ELECTRICAL INSTALLATION FIGURE 2

IPL FIGURE 2 (SHEET 1 OF 2)

Page 10032

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

300

80
40

60
50

60
30
70 30 (4 PLACES)
(4 PLACES)

C
CEM−188−01

ELECTRICAL INSTALLATION FIGURE 2

IPL FIGURE 2 (SHEET 2 OF 2)

Page 10033

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

THIS PAGE INTENTIONALLY LEFT BLANK

Page 10034

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

FIG.& AIRLINE UNITS

ITEM PART PART NOMENCLATURE EFF PER
NO. NUMBER NO. 1234567 CODE ASSY

− ITEM NOT ILLUSTRATED

Page 10035

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

FIG.& AIRLINE UNITS

ITEM PART PART NOMENCLATURE EFF PER
NO. NUMBER NO. 1234567 CODE ASSY

− ITEM NOT ILLUSTRATED

Page 10036

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

THIS PAGE INTENTIONALLY LEFT BLANK

Page 10037

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

C C B A
40
30

410

A D
A
10

20
B

30
CEM−200−04

INLET COWL OUTER BARREL ASSEMBLY (UPR) FIGURE 3

IPL FIGURE 3 (SHEET 1 OF 2)

Page 10038

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

D
400

110
60
90
300
330
75
310

270
320
350
140
270
70 210
120 340
80 220
240 250 130
270
80 150 340
100 260
200
190 230 290
330 370
300
330
160 270
170 390 320
180 350

280
CEM−201−00

INLET COWL OUTER BARREL ASSEMBLY (UPR) FIGURE 3

IPL FIGURE 3 (SHEET 2 OF 2)

Page 10039

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

THIS PAGE INTENTIONALLY LEFT BLANK

Page 10040

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

FIG.& AIRLINE UNITS

ITEM PART PART NOMENCLATURE EFF PER
NO. NUMBER NO. 1234567 CODE ASSY

− ITEM NOT ILLUSTRATED

Page 10041

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

FIG.& AIRLINE UNITS

ITEM PART PART NOMENCLATURE EFF PER
NO. NUMBER NO. 1234567 CODE ASSY

− ITEM NOT ILLUSTRATED

Page 10042

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

FIG.& AIRLINE UNITS

ITEM PART PART NOMENCLATURE EFF PER
NO. NUMBER NO. 1234567 CODE ASSY

− ITEM NOT ILLUSTRATED

Page 10043

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

360
C C
B
A E
A D
A A
A
120
B
110

80
100

C 110

10
50 60 70

30 130
CEM−202−02

INLET COWL OUTER BARREL ASSEMBLY (LWR) FIGURE 4

IPL FIGURE 4 (SHEET 1 OF 3)

Page 10044

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

150
150 140
210
160

170 210
210

230
190

180

260
D
220
(22 PLCS) CONFIG 1

250
19 PLCS

270 200

D
240
CONFIG 2
CEM−246−00

D
CONFIG 3

INLET COWL OUTER BARREL ASSEMBLY (LWR) FIGURE 4

IPL FIGURE 4 (SHEET 2 OF 3)

Page 10045

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

310
330
350
350

340

320

REF

280

E
CEM−247−00

290
300 300

INLET COWL OUTER BARREL ASSEMBLY (LWR) FIGURE 4

IPL FIGURE 4 (SHEET 3 OF 3)

Page 10046

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

FIG.& AIRLINE UNITS

ITEM PART PART NOMENCLATURE EFF PER
NO. NUMBER NO. 1234567 CODE ASSY

− ITEM NOT ILLUSTRATED

Page 10047

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

FIG.& AIRLINE UNITS

ITEM PART PART NOMENCLATURE EFF PER
NO. NUMBER NO. 1234567 CODE ASSY

− ITEM NOT ILLUSTRATED

Page 10048

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

FIG.& AIRLINE UNITS

ITEM PART PART NOMENCLATURE EFF PER
NO. NUMBER NO. 1234567 CODE ASSY

− ITEM NOT ILLUSTRATED

Page 10049

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

FIG.& AIRLINE UNITS

ITEM PART PART NOMENCLATURE EFF PER
NO. NUMBER NO. 1234567 CODE ASSY

− ITEM NOT ILLUSTRATED

Page 10050

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

THIS PAGE INTENTIONALLY LEFT BLANK

Page 10051

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

A A
A A
A A
A
A A

G A A
D
A A
E
A A

A A
F
150 A D A
A
A
140
B A
E F
B A
D
C C C A
C
A
C
A TO C
C B
170
C B
180
200 170
190
200 160
180
200
180
200

A 210
CEM−203−04

B 220 240
C 230
250

INLET COWL INNER BARREL ASSEMBLY FIGURE 5

IPL FIGURE 5 (SHEET 1 OF 5)

Page 10052

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

D 70
90
60
90
70
90 110

20
30

E
106
10 108
50
90

40
80
CEM−204−01

INLET COWL INNER BARREL ASSEMBLY FIGURE 5

IPL FIGURE 5 (SHEET 2 OF 5)

Page 10053

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

G
ENGINE ATTACH
RING (277−1124)

INSULATION
BLANKET

INSULATION
BLANKET
(277D1101)

INNER BARREL
SPLICE TYPICAL
(3 PLACES)
(277−1120)
o o o
RDL114 , 236 , & 355

K
CEM−252−01

INLET COWL INNER BARREL ASSEMBLY FIGURE 5

IPL FIGURE 5 (SHEET 3 OF 5)

Page 10054

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

92 94

110
(REF)
H 60
90

102 104

110
(REF)
J 60
90

98 96
CEC−101−00

110
(REF)
K 60
90

INLET COWL INNER BARREL ASSEMBLY FIGURE 5

IPL FIGURE 5 (SHEET 4 OF 5)

Page 10055

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

NAC STA
141.200

42
44
82
84

CEC−100−00

INLET COWL INNER BARREL ASSEMBLY FIGURE 5

IPL FIGURE 5 (SHEET 5 OF 5)

Page 10056

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

FIG.& AIRLINE UNITS

ITEM PART PART NOMENCLATURE EFF PER
NO. NUMBER NO. 1234567 CODE ASSY

− ITEM NOT ILLUSTRATED

Page 10057

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

FIG.& AIRLINE UNITS

ITEM PART PART NOMENCLATURE EFF PER
NO. NUMBER NO. 1234567 CODE ASSY

− ITEM NOT ILLUSTRATED

Page 10058

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

FIG.& AIRLINE UNITS

ITEM PART PART NOMENCLATURE EFF PER
NO. NUMBER NO. 1234567 CODE ASSY

− ITEM NOT ILLUSTRATED

Page 10059

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

H
180

190
H A B

220
F

E
210
C

200

A TO E
D
DETAILS
100 A, B,C, E
120 D

DETAILS
90 130 A
140 B
150 C
CEM−205−02

160 D
170 E

INLET COWL LIP ASSEMBLY FIGURE 6

IPL FIGURE 6 (SHEET 1 OF 2)

Page 10060

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

10 240

260
(4 LOCATIONS) G

40
50

60 70
10
30
250
(7 LOCATIONS)
F
260
270 (14 LOCATIONS)

280
270 (2 LOCATIONS)
CEM−206−03

280 G
(2 LOCATIONS)
H

INLET COWL LIP ASSEMBLY FIGURE 6

IPL FIGURE 6 (SHEET 2 OF 2)

Page 10061

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

THIS PAGE INTENTIONALLY LEFT BLANK

Page 10062

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

FIG.& AIRLINE UNITS

ITEM PART PART NOMENCLATURE EFF PER
NO. NUMBER NO. 1234567 CODE ASSY

− ITEM NOT ILLUSTRATED

Page 10063

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

FIG.& AIRLINE UNITS

ITEM PART PART NOMENCLATURE EFF PER
NO. NUMBER NO. 1234567 CODE ASSY

− ITEM NOT ILLUSTRATED

Page 10064

COMPONENT MAINTENANCE MANUAL

Document Part No. 277−1100

THIS PAGE INTENTIONALLY LEFT BLANK

Page 10065

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