Complete DC-8 MM R36 Vol 3

AIR TRANSPORT INTERNATIONAL
DC-8 MAINTENANCE MANUAL
VOLUME 3
ATA 36 THRU 71
This manual is the property of Air Transport International, Limited Liability Company. It is
issued for the use of Air Transport International, Limited Liability Company authorized
personnel.
Revision Number: 36
Issued: 04/06/11
All rights reserved, including the right to reproduce this publication. No part may be reproduced: stored in any retrieval
system: or transmitted in any part or form by any means electronic, photocopying, microfilm, microfiche, mechanical, or
otherwise, without prior written permission of Air Transport International, Limited Liability Company.
CHAPTER 36 - PNEUMATIC
36.01 – PNEUMATIC SYSTEM DECAY CHECK

TABLE OF CONTENTS
Page
Paragraph Page
A. GENERAL-------------------------------------------------------------------------- 36.01.1
RECURRING NON-ROUTINE JOB CARDS
Job Card Page

36.01-1 DC-8 PNEUMATIC SYSTEM DECAY CHECK----------------------------- 36.01.2
Revision 34 04-28-10 36.01-i

INTENTIONAL
BLANK
36.01-ii 04-28-10 Revision 34

36.01 PNEUMATIC SYSTEM DECAY CHECK
1. General
a. Non-routine Job Card DC8-36.01-1 “DC-8 Pneumatic System Decay Check” is

applicable to the DC-8 pneumatic ducting along the wing leading edge.
b. This Non-routine inspects for leakage in pneumatic ducting near the wing fuel tank.
Failures are found via performance of a Manifold Pressure Decay Check.
c. The following check is based on DC-8 Operation Manual (OM) procedure 2-42 reflecting
all DC-8 Series airplanes; differences for the DC-8-70 Series airplanes are specifically
noted in each applicable procedural step.
d. Accomplish Non-routine Job Card DC8-36.01-1 every 200 days.
Revision 34 04-28-10 36.01.1

36.01 PNEUMATIC SYSTEM DECAY CHECK (cont’d)
ATI RECURRING NON-ROUTINE ATI-001
A/C NUMBER TAT TAC POS DATE STATION JOB CARD NUMBER
DC8-36.01-1
JOB TITLE
DC-8 PNEUMATIC SYSTEM DECAY CHECK
Job Card Reviewed By: Date:
Page 1 of 5
References
Boeing Report MDC-02K9030, ALI 30-1 “DC-8 Pneumatic System Decay Check”
FAA AD 2010-21-03
DC-8 Operation Manual (OM), Procedure 2-42
Tools Needed
If the manifold pressure decay check is performed using ground air, a ground cart capable of supplying
40 PSIG is required.
Mechanic Inspector
Procedure
NOTE: The manifold pressure decay check may be accomplished
with either ground or engine pneumatic pressure. Each
manifold may be individually checked, or, if desirable,
both sides may be simultaneously checked.
1. Circuit Breaker “ANIMAL COMPT HEAT SHUTOFF
VALVE” DC Bus No. 1 (if installed) ....................... PULLED
2. All operable low-pressure pneumatic shutoff switches “LOW

PRESS PNEU SYSTEM” (on side being checked) ........HIGH
3. Pneumatic crossfeed switch “PNEU X-FEED”............ CLOSE
4. All cabin compressor switches “CABIN COMPRESSORS” (on

side being checked) [Not applicable to DC-8 airplanes with Air
Cycle packs] ...................................................................... OFF
5. Freon compressor switch “FREON COMPRESSORS” (on side

being checked) [Not applicable to DC-8 airplanes with Air
Cycle packs] ...................................................................... OFF
6. AC pack off switches “L PACK” and “R PACK” [Applicable to

DC-8 airplanes with Air Cycle packs]............................... OFF
7. Rain removal lever “RAIN REMOVAL”(on side being

checked).............................................................................. OFF
8. All engine anti-icing switches “ENGINES 1 2 3 4 ANTI-

ICE” (on side being checked)............................................ OFF
9. Scoops anti-icing switch “SCOOPS ANTI-ICE”.............. OFF
10. Airfoil de-icing switch “AIRFOIL DE-ICE” .................... OFF
36.01.2 04-06-11 Revision 36

DC8-36.01-1
JOB TITLE
Page 2 of 5
Mechanic Inspector
Procedure
11. Adjust ground air pressure or both throttles (related to side
being checked) until associated manifold pressure reads
between 30 to 40 psig. Maintain the resulting ground air
pressure or engine power setting for the balance of the test. The
position of the throttles on the opposite side is optional. If
desired manifold pressure cannot be attained with reasonable
power setting, immediately discontinue test as this indicates
either leaking or failed shutoff relief valves, or an excessive
leakage from the manifold.
12. Note the manifold air temperature.
13. All operable low-pressure pneumatic shutoff switches “LOW

PRESS PNEU SYSTEM” (on side being checked) .......... OFF
14. Check the time for the manifold pressure decay from 30 to 20
psig.
15. Should the period for the pressure decay occur in a shorter time
than that given in Figure 36.01-1 (for DC-8-61, 71, 63, &-73
Series airplanes) or Figure 36.01-2 (for DC-8-30, -40, 50, -62,
& -72 Series airplanes), it is possible that one or more of the
shutoff or relief valves is leaking, failed open, or there is an
excessive manifold leakage.
16. Momentarily crack the RAIN REMOVAL lever on the side

being checked to depressurize that manifold.
Revision 36 04-06-11 36.01.3

DC8-36.01-1
JOB TITLE
Page 3 of 5
Mechanic Inspector
Procedure
CAUTION: WINDSHIELD RAIN REMOVAL LEVERS MUST
BE IN THE OFF POSITION WHEN THE
MANIFOLD IS DEPRESSURIZED. IF THE
LEVERS ARE LEFT IN THE ON POSITION, RAIN
OR CONDENSATION MIGHT ENTER THE
CABIN COMPRESSORS THROUGH THE RAIN
REMOVAL SYSTEM AND CAUSE DAMAGE TO
THE COMPRESSORS WHEN THEY ARE
STARTED. IF PRESSURE DOES NOT DECAY
TO ZERO IMMEDIATELY (ENGINE BLEED OR
CROSSFEED VALVE NOT CLOSED), CLOSE
THE RAIN REMOVAL VALVE BY MOVING
THE LEVER TO THE OFF POSITION
IMMEDIATELY TO PREVENT OVERHEAT
DAMAGE TO THE WINDSHIELD.
17. With the RAIN REMOVAL lever OFF, check for pressure
buildup in the manifold being checked. If the manifold
pressure increases to 5 psig within 30 seconds, the decay check
is invalid due to excessive leakage into the manifold from the
crossfeed valve and/or pneumatic shutoff valve at the engine(s).
18. Repeat above test on opposite side of manifold.
19. Circuit Breaker “ANIMAL COMPT HEAT SHUTOFF

VALVE” DC Bus No. 1 (if installed) ........................... RESET
20. Ensure the pneumatic system decay check passes.
NOTE:
PASS - The manifold being checked passes steps 11 and 17 and
meets the requirements of step 15.
FAIL - The manifold being checked fails at either steps 11, 15, or
17.
21. Ensure all job card sign offs are complete.
36.01.4 04-06-11 Revision 36

DC-8-61, -71, -63, & -73 SERIES DECAY GRAPH

Figure 36.01-1
Revision 36 04-06-11 36.01.5

DC-8-30, -40, -50, -62, & -72 SERIES DECAY GRAPH

Figure 36.01-2
36.01.6 04-06-11 Revision 36

CHAPTER 52- DOORS
TABLE OF CONTENTS
Page
52.01 LEFT HAND FORWARD ENTRY DOOR HINGE COVERS
MAINTENANCE POLICY--------------------------------------------------------- 52.01.1
52.02 RESERVED FOR FUTURE USE ------------------------------------------------- 52.02.1
52.03 LOWER CARGO COMPARTMENT DOORS DEACTIVATION----------- 52.03.1
52.05 NATIONAL AIRCRAFT SERVICE VENT DOOR (S.T.C. SA1614GL) --- 52.05.1
52.10 NASI FLIGHT DECK DOOR SYSTEM (STC ST01791CH) ----------------- 52.10.1
Revision 23 12-07-05 52-i

CHAPTER 52- DOORS
INTENTIONAL
BLANK
52-ii 12-07-05 Revision 23

CHAPTER 52 - DOORS
52.01 – LEFT HAND FORWARD ENTRY DOOR HINGE COVERS

MAINTENANCE POLICY
TABLE OF CONTENTS
Paragraph Page
1. GENERAL-------------------------------------------------------------------------- 52.01.1
2. PROCEDURE ---------------------------------------------------------------------- 52.01.1
FIGURES
52.01-1 LH FWD ENTRY DOOR JAMB HINGE COVERS ---------------------------- 52.01.2

52.01-2 LH FWD ENTRY DOOR HINGE COVERS ------------------------------------- 52.01.3
Revision 14 12-03-01 52.01-i

CHAPTER 52 - DOORS
INTENTIONAL
BLANK
52.01-ii 12-03-01 Revision 14

CHAPTER 52-DOORS
52.01 LEFT HAND FORWARD ENTRY DOOR HINGE COVERS MAINT. POLICY
1. General
a. This instruction applies to cargo configured aircraft with solid 9-G bulkhead or net and
smoke curtain installations.
b. The decorative hinge covers specified below may be permanently removed from the
aircraft when found damaged or missing.
Note: Hinge covers installed on doors aft of the smoke barrier must be maintained as
part of the Class "E" cargo compartment fire protection scheme.
2. Procedure
a. Remove any remaining portions of hinge cover.
b. Fill all vacated attachment holes with original fasteners. Reinstall all other hardware,
with the exception of figure 52.01-1, items 9, 10 or figure 52.01-2 items 16, 17.
c. Any combination of the above specified hinge covers may be deleted as necessary.
Revision 6 07-01-98 52.01.1

CHAPTER 52-DOORS
52.01 LH FORWARD ENTRY DOOR HINGE COVERS MAINT. POLICY(cont’d)
IPC Reference
25-21-0, figure 10
LH FWD. ENTRY DOOR JAMB HINGE COVERS

Figure 52.01-1
52.01.2 07-01-98 Revision 6

CHAPTER 52-DOORS
52.01 LH FORWARD ENTRY DOOR HINGE COVERS MAINT POLICY(cont’d)
IPC Reference
52-10-1, Figure 20
LH FWD. ENTRY DOOR HINGE COVERS

Figure 52.02-2
Revision 6 07-01-98 52.01.3

CHAPTER 52-DOORS
INTENTIONAL
BLANK
52.01.4 07-01-98 Revision 6

CHAPTER 52 - DOORS
52.02 RESERVED FOR FUTURE USE
1. This section is reserved for future use.
Revision 23 12-07-05 52.02.1

CHAPTER 52 - DOORS
INTENTIONAL
BLANK
52.02.2 12-07-05 Revision 23

CHAPTER 52 - DOORS
52.03 – LOWER CARGO COMPARTMENT DOORS DEACTIVATION

TABLE OF CONTENTS
Paragraph Page
1. GENERAL-------------------------------------------------------------------------- 52.03.1
2. PROCEDURE ---------------------------------------------------------------------- 52.03.1
FIGURES
52.03-1 DEACTIVATION STRAP ---------------------------------------------------------- 52.03.2
Revision 14 12-03-01 52.03-i

CHAPTER 52 - DOORS
INTENTIONAL
BLANK
52.03-ii 12-03-01 Revision 14

CHAPTER 52-DOORS
52.03 LOWER CARGO COMPARTMENT DOORS DEACTIVATION
1. General: The lower cargo doors on the DC-8 aircraft are subjected to ongoing abuse and are
often damaged to the point where they can no longer be opened or closed without jumping
out of the tracks they are designed to ride in. The operating mechanisms of these doors can
be damaged, the door closed and locked, and the aircraft can then continue to operate safely
with the door deactivated. This section describes the procedure which will ensure the safe
operation of the aircraft with a lower cargo door deactivated. This procedure should not be
used to deactivate a door with major structural damage. Its purpose is to allow for operating
mechanism damage only.
2. Procedure
a. If it is determined a lower cargo door should be deactivated, a logbook discrepancy

should be initiated (if not already accomplished by a flight crew.)
b. Verify that the affected door can be closed and secured in the locked configuration. The
handle should be stowed.
c. In order to ensure that the door is not inadvertently opened at down line stations, a sheet
metal strap will be installed over the stowed handle. This strap should be manufactured
from approximately 0.050" x 0.75" wide 2024T3 aluminum. It will be installed by
removing two of the existing countersunk screws adjacent to the door handle. After
removing the existing screws, the strap is to be installed by replacing the removed screws
with button head type screws. This will effectively make it impossible for anyone except
a qualified mechanic to open the affected door. For the purposes of this procedure, it will
be necessary to only pick up two of the screw hold locations to secure the strap and make
it impossible to unlatch the stowed handle (unless the strap is removed).
d. The logbook discrepancy should be cleared using the standard "Carry-over" procedure of
the GMM. This maintenance manual procedure should be referenced in the carry-over
item for the deactivation procedure.
e. In the case of a lower cargo door which becomes inoperative at a through-stop or other
location where the capability to manufacture and install the above-described sheetmetal
strip does not exist, the aircraft may continue the flight, or a series of flights until this
strap can be installed by substituting speed tape for the strap. The speed tape should be
removed at the first opportunity and replaced with the strap as described above. The tape
is not to be used for the purpose of holding the handle stowed, only to make the door
handle inaccessible to ground crews who may disturb a deactivated door. The tape
serves the purpose of a temporary "placard" only.
Revision 6 07-01-98 52.03.1

CHAPTER 52-DOORS
52.03 LOWER CARGO COMPARTMENT DOORS DEACTIVATION (cont’d)
**Note: This strap is intended to be installed with "Button head" type fasteners. It will be
necessary to add the thickness of the manufactured strap to the original length of
the removed fasteners in order to determine proper grip length for the strap
fasteners. It is acceptable to countersink the strap holes in order to use
countersunk hardware. Countersinking the strap will be considered optional.
DEACTIVATION STRAP
Figure 52.03-1
52.03.2 07-01-98 Revision 6

CHAPTER 52 - DOORS
Revision 23 12-07-05 52.04.1

CHAPTER 52 - DOORS
INTENTIONAL
BLANK
52.04.2 12-07-05 Revision 23

CHAPTER 52 - DOORS
52.05 – NATIONAL AIRCRAFT SERVICE VENT DOOR (STC SA1614GL)

TABLE OF CONTENTS
Paragraph Page
1. GENERAL-------------------------------------------------------------------------- 52.05.1
2. DOOR MAINTENANCE--------------------------------------------------------- 52.05.1
3. WIRING DIAGRAMS ------------------------------------------------------------ 52.05.13
FIGURES
52.05-1 “HOOK” STYLE DOOR TENSION ADJUSTMENT ------------------------ 52.05.5

52.05-2 “CAM LATCH” STYLE DOOR ADJUSTMENTS --------------------------- 52.05.7
52.05-3 “CAM LATCH” STYLE DOOR TORQUE STOP ADJUSTMENT -------- 52.05.8
52.05-4 VENT DOOR MANUAL BRACKET ------------------------------------------- 52.05.12
52.05-5 “HOOK” STYLE VENT DOOR WIRING DIAGRAM----------------------- 52.05.13
52.05-6 VENT DOOR WIRING DIAGRAM SB-92-01R1 ----------------------------- 52.05.14
52.05-7 VENT DOOR WIRING DIAGRAM SB-92-03R1 ----------------------------- 52.05.15
52.05-8 “HOOK” STYLE VENT DOOR IPC -------------------------------------------- 52.05.16
52.05-9 “HOOK” STYLE DOOR LOCK ASSEMBLY IPC --------------------------- 52.05.19
52.05-10 “CAM LATCH” STYLE VENT DOOR IPC ----------------------------------- 52.05.21
52.05-11 “CAM LATCH” STYLE DOOR LOCK ASSEMBLY IPC------------------- 52.05.26
52.05-12 LOGIC CONTROL INSTALLATION ------------------------------------------ 52.05.28
TABLES
52.05-1 “HOOK” STYLE DOOR TROUBLESHOOTING CHART------------------ 52.05.2
52.05-2 “CAM LATCH” STYLE DOOR TROUBLESHOOTING CHART --------- 52.05.3
52.05-3 “HOOK” STYLE DOOR ADJUSTMENT CHART --------------------------- 52.05.4
52.05-4 “CAM LATCH” STYLE DOOR ADJUSTMENT CHART ------------------ 52.05.6
Revision 14 12-03-01 52.05-i

CHAPTER 52 - DOORS
INTENTIONAL
BLANK
52.05-ii 12-03-01 Revision 14

CHAPTER 52 - DOORS
52.05 NATIONAL AIRCRAFT SERVICE VENT DOOR (S.T.C. SA1614GL)
1. General
a. This section is the reference for fuselage structural repair of the DC-8 with the National
Aircraft Service, Inc., Vent Door Installation. Company aircraft may have one of two
different models of door installed. The first model incorporates a “Hook Style”
mechanism for locking the vent door closed, and requires hook tension tests at every “B”
check, and overcenter tension tests at “C” check intervals. The second model has a “Cam
Latch” style locking mechanism, an outside handle for backup manual operation, and
requires no interval checks. Both types are covered in this section. Use the DACO DC-8
Structural Repair Manual, 51-00-00 General, for typical repair and fastener information.
b. There have been two Service Bulletins issued for the doors; however, the bulletins are
not mandatory and may not have been incorporated on some aircraft. SB-92-01R1
incorporated the “Cam Latch” type door and SB-92-03R1 incorporated a new blocking
mechanism which prevents the cargo door from being unlocked until the vent door is
fully open.
c. The Vent Door System is designed to indicate a properly closed and latched cargo door,
and prevent significant pressurization when the cargo door is improperly closed and
locked. This is accomplished by installing a blocking mechanism to the cargo door
torque tube, preventing the closure of the vent door until the cargo door is properly
closed and locked. Also, a sequence switch is installed on the lock pin walking beam and
lower inboard cargo door. Additionally, the vent door close sequence is wired through
the cargo door “A” system warning light relay, preventing any closure of the vent door
until the cargo door is properly closed and locked. The torque tube blocking mechanism
and the walking beam switch stricker both perform a secondary locking system for the
cargo door, in as much as they physically restrain the cargo door torque tube and the
walking beam in the locked position as long as the vent door is closed. The vent door is a
ground operation only, powered through the ground control relay.
c. The Vent door Warning System consists of position indicating lights, (open, in-transit,
closed) located at the control switch just forward of the cabin entry door, and a press to
test type engraved warning light on the flight engineers panel, next to the cargo door “A”
and “B” warning system lights.
d. Effectivity:
(1) “Hook” Style Door – 41CX, 799AL

(2) “Cam” Style Door – 71CX, 604BX
2. Door Maintenance
Note: If difficulty in operating vent door is experienced, check for proper operation of cargo
door before performing any of the following steps.
Revision 30 10-07-08 52.05.1

CHAPTER 52 - DOORS
52.05 NATIONAL AIRCRAFT SERVICE VENT DOOR (S.T.C. SA1614GL)(cont’d)
a. “Hook” Style Door Troubleshooting
1. VENT DOOR (a) Verify cargo door is fully closed and locked.
ACTUATOR WILL (b) Verify cargo door “A” warning system light is extinguished,
RUN IN THE and working properly.
OPEN DIRECTION (c) Inspect for proper operation of vent door sequence switches
ONLY. with Volt/Ohm meter. (Lock pin walking beam switch, located on
torque tube lock; and sill locating switch, located on cargo door,
lower center.)
(d) Inspect wire connections and grounds lugs to sequence
switches for security..
(e) Check for stuck “Closed Limit” switch.
2. VENT DOOR (a) Check for obstruction in vent door(foreign matter, ice, etc.)
CLOSES (b) Check for obstruction in torque tube lock.
PARTIALLY. (c) If no obstruction is found and vent door will not fully close,
remove electric actuator and close manually with manual brace
installed.
(d) If vent door will not close manually, remove control cables at
upper attachment to check for binding before performing
adjustment procedures.
3. VENT DOOR (a) Check warning light press to test, first.
CLOSES AND (b) Operate warning switches on door, hook, and torque tube lock
WARNING LIGHT manually, while monitoring warning light.
REMAINS ON. (c) Check for loose wire connection on warning switches, or loose
ground wires.
4. VENT DOOR (a) Check for stuck “Open Limit” switch.
WILL NOT OPEN. (b) Check for obstruction on torque tube lock and vent door lock
mechanism.
(c) If no obstruction is found, remove electric actuator and open
vent door with manual brace installed.
5. VENT DOOR (a) Remove control cable at upper and lower attachments and
HESITATES, check each cable for binding.
OPERATES SLOW (b) Manually operate vent door with control cables removed and
OR SLUGGISH. check for stiffness or binding. Replace bolts and bushings as
necessary and lube.
(c) Manually operate torque tube lock by hand with control cables
disconnected and check for binding. Lubricate as necessary.
(d) If no binding is found check voltage and amps at actuator
plug, 24 volts minimum, 2.0 amps minimum.
(e) If voltage and amps are correct, replace electric actuator.
“HOOK” STYLE DOOR TROUBLESHOOTING CHART
Table 52.05-1
52.05.2 07-01-98 Revision 6

CHAPTER 52 - DOORS
b. “Cam Latch” Style Door Troubleshooting
1. VENT DOOR (a) Verify cargo door is fully closed and locked.
ACTUATOR (b) Inspect for proper operation of vent door sequence switches
WILL RUN IN with volt/ohm meter. (Lock pin walking beam switch, located on
THE OPEN torque tube lock; and sill locating switch, located on cargo door,
DIRECTION lower, center.)
ONLY. (c) Inspect wire connections and ground lugs to sequence switches.
(e) Check for stuck “Closed Limit” switch.
2. VENT DOOR (a) Check for obstruction in vent door(foreign matter, ice, etc.)
CLOSES (b) Check for obstruction in torque tube lock.
PARTIALLY. (c) If no obstruction is found and vent door will not fully close,
disconnect electric actuator, rotate jack-screw clockwise until
actuator reaches its fully retracted position, reconnect actuator and
operate manually.
(d) If vent door will not close manually, remove control cables at
upper attachment to check for binding before performing
adjustment procedures.
3. VENT DOOR (a) Check warning light press to test, first.
CLOSES AND (b) Check position indication at vent door control:
WARNING (1) Green (closed) indication on vent door control with
LIGHT REMAINS warning light on at Flight Engineers panel is the torque tube
ON. lock warning switch function.
(2) Amber (in-transit) indication on vent door control with
warning light on at FE’s panel is the torque tube lock warning
switch function.
(c) Inspect wire connection and ground lugs to warning switches.
4. VENT DOOR (a) Check for stuck “Open Limit” switch.
WILL NOT OPEN. (b) Check for obstruction on torque tube lock and vent door lock
mechanism.
(c) If no obstruction is found, open vent door manually.
5. VENT DOOR (a) Remove control cable at upper and lower attachments and
HESITATES, check each cable for binding.
OPERATES (b) Manually operate vent door with control cables removed and
SLOW OR check for stiffness or binding. Replace bolts and bushings as
SLUGGISH. necessary and lube.
(c) Manually operate torque tube lock by hand with control cables
disconnected and check for binding. Lubricate as necessary.
(d) If no binding is found check voltage and amps at actuator plug,
24 volts minimum, 2.0 amps minimum.
(e) If voltage and amps are correct, replace electric actuator.
“CAM LATCH” STYLE DOOR TROUBLESHOOTING CHART
Table 52.05-2
Revision 6 07-01-98 52.05.3

CHAPTER 52 - DOORS
52.05 NATIONAL AIRCRAFT SERVICE VENT DOOR (S.T.C. SA1614GL)(CONT’D)
c. “Hook” Style Vent Door Adjustments
(1) Remove electric actuator and install Manual Brace (NAVD86-1) as alignment for
steps 2 through 4).
NOTE: Yoke has 3/8 bolt holes, and the bold through the yoke and the hook is 5/16,
allowing 1/16 play in yoke when hooks are unlocked.
1. HOOK (a) Adjust yokes to pull hooks into fully locked position. Hooks will
ADJUSTMENT not have any play when fully locked, and a small amount of force with
(WITH MANUAL one hand pushing actuator bracket up should be required to operate
BRACE) quick disconnect.
2. TORQUE TUBE (a) Remove bolts at rod end to torque tube lock.
LOCK (b) Hold torque tube lock assembly in fully locked position.
ADJUSTMENT (c) Adjust rod ends to align with bolt holes in torque tube lock.
(WITH MANUAL
BRACE)
3. CLOSED LIMIT (a) Check that hooks are fully locked with no play in hooks or linkage.
SWITCH (b) Adjust closed limit switch to actuate and compress .020 to .030
ADJUSTMENT inches overtravel.
(WITH MANUAL (c) Release quick disconnect and manually lock and unlock hooks to test
BRACE) switch. After point where switch is actuated, switch actuator must
continue to travel and compress switch .020 to .030 inches further to
fully lock hooks.
4. ELECTRIC (a) Remove manual brace and install electric actuator. Actuator must be
ACTUATOR fully retracted.
CLOSED (b) Push actuator bracket up to hold hooks in fully locked position.
ADJUSTMENT (c) Adjust actuator rod end to align with quick disconnect, then further
adjust rod end one and one half turns in (shorter), and tighten jam nut.
(d) Extend actuator to connect actuator at quick disconnect.
(e) Open and close vent door. Hooks should fully lock with no play,
and torque tube lock should be fully locked.
5. OPEN LIMIT (a) Open door and open limit switch should actuate at full open position.
SWITCH (b) Measure the distance the electric actuator has extended, then push
ADJUSTMENT quick disconnect and fully extend actuator. Again measure the distance
(WITH ELECTRIC the electric actuator has extended. The fully extended measurement
ACTUATOR) should be .125 to .250 inches longer.
(c) Adjust open limit micro switch if necessary, and repeat step (b).
(d) The torque tube lock when fully open should allow the torque tube
to rotate, and the key on the torque tube should not rub on the torque
tube lock.
“HOOK” STYLE DOOR ADJUSTMENT CHART
Table 52.05-3
52.05.4 07-01-98 Revision 6

CHAPTER 52 - DOORS
“HOOK” STYLE DOOR OVER CENTER TENSION ADJUSTMENT

Figure 52.05-1
Revision 6 07-01-98 52.05.5

CHAPTER 52 - DOORS
d. “Cam Latch” Style Door Adjustments
Note: Full operational check must be performed after any adjustments.

1. VENT DOOR OPEN (a) Adjust open limit switch to illuminate open L.E.D. when Vent Door
LIMIT SWITCH is open 5½ inches(Measured at bottom of Vent Door.
ADJUSTMENT (b) If Vent Door will not open 5½ inches, remove open limit switch and
operate open switch at logic control to run NAVD33 actuator to fully
extended position.
(c) Shorten rod assembly NAVD189-1A until vent door is open 5¾
inches, and adjust open limit switch per paragraph (a).
2. VENT DOOR (a) Disconnect rod assemblies(NAVD190-1) at cam latches (NAVD185-
ADJUSTMENT 1) and tape cam latches in the open position.
CLOSED (Note: (b) Close Vent Door with logic control switch. (Vent Door will close
Check latch clearance and start to open again as linkage at the top of the Vent Door travels over
per Figure 52.05-2 center.) When Vent Door has closed and opened ¼ inch, release close
prior to adjustment) switch. If Vent Door has traveled more than ¼ inch open, tap switch
open and closed until ¼ inch open (past closed) is obtained.
(c) Measure and record extended portion of electric actuator.
(d) Reconnect rod assemblies(NAVD190-1 to cam latches (NAVD185-
1) and adjust closed limit switch to maximum depressed position and
back off 1/16 if an inch.
NOTE: IMPORTANT, check cam latch engagement per Figure 52.05-2.
(e) Open and close Vent Door with logic control switch. Extended
portion of electric actuator should be within 1/32 inch of previous
measurement in paragraph (c), this final measurement is adjusted by the
closed limit/warning switch (NAVD53) adjustment only.
3. TORQUE TUBE (a) Open vent door and check for open indication on vent door control,
LOCK and adjust control cables as follows:
ADJUSTMENT (1) Loosen jam nuts on control cable conduit fittings, push key
(Reference Figure assembly(NAVD199) to obtain clearance as indicated by Note 1 in
52.05-2) Figure 52.05-3.
NOTE: Cargo door (2) Finger tighten conduit jam nuts prior to tightening with a wrench
must be unlocked for to maintain even travel on control cables.
step (a) and unlocked (3) Close and open vent door and re-inspect for clearance per Note 1
for step (b). in Figure 52.05-3
(b) Close vent door and check for closed indication on vent door control
and adjust switches as follows:
(1) Adjust actuator(NAVD199-3) to actuate warning switch
(NAVD207) with .100 to .150 overtravel.
(2) Adjust sequence switch (NAVD208) to actuate when clearance
between Beam Lock (NAVD206) and Beam Stop (NAVD199-2) is
.010 to .030. (Walking beam should travel approximately .100 after
sequence switch has actuated.)
“CAM LATCH” STYLE DOOR ADJUSTMENT CHART
Table 52.05-4
52.05.6 07-01-98 Revision 6

CHAPTER 52 - DOORS
CAM LATCH CLEARANCE
CAM LATCH ENGAGEMENT
“CAM LATCH” STYLE DOOR ADJUSTMENTS

Figure 52.05-2
Revision 6 07-01-98 52.05.7

CHAPTER 52 - DOORS
“CAM LATCH” STYLE DOOR TORQUE STOP ADJUSTMENT

Figure 52.05-3
52.05.8 07-01-98 Revision 6

CHAPTER 52 - DOORS
e. “Hook” Style Door Functional Test
(1) Lock cargo door, close vent door, open vent door, and unlock cargo door three
times. Monitor warning light for proper operation.
(2) Verify each switch as follows with vent door halt open(in-transit position) for steps
(3) through (5).
(3) Hold vent door, vent door hook, and torque tube lock warning switches in closed
position. Release and close each switch one at a time. Warning light should
illuminate and extinguish as each switch is cycled.
(4) Close vent door hook warning/limit switch, and vent door closed position indicator
should illuminate. Open vent door hook warning/limit switch, closed position
indicator should extinguish, and in-transit indicator should illuminate.
(5) Close vent door open limit switch, and in-transit indicator should extinguish, and
vent door open indicator should illuminate.
(6) Open vent door fully, unlock cargo door and place vent door control switch in
closed position. Vent door should not actuate.
(7) With cargo door locked, close and open vent door. Actuator should shut off as vent
door closed and open indicators illuminate, in closed and open positions.
(8) Open vent door and check for clearance between (NAVED39) Key on torque tube,
and (NAVD15) Torque Tube Lock, when torque tube is rotated to unlock cargo
door.
(9) With cargo door locked, close vent door and check:
(a) Full engagement of vent door hooks.
(b) Full down and locked position of torque tube lock.
(c) Lock pin walking beam/Torque Tube Lock, (NAVD15) will not allow walking
beam to move.
(d) Cargo door can not be unlocked.
(10) With vent door still closed and locked, check operation of actuator manual override
system.
(a) Refer to placards on vent door and manually open and close vent door.
(b) After completing this test repeat Functional Test one time.
Revision 6 07-01-98 52.05.9

CHAPTER 52 - DOORS
f. “Cam Latch” Style Door Functional Test
(1) Lock cargo door, close vent door, open vent door, and unlock cargo door three
times. Monitor warning light for proper operation.
(2) Verify each switch as follows with vent door halt open(in-transit position) for steps
(3) through (5).
(3) Hold vent door latch warning/limit switch and torque tube lock warning switches in
closed position. Release and close each switch one at a time. Warning light should
illuminate and extinguish as each switch is cycled.
(4) Close vent door latch warning/limit switch, and vent door closed position indicator
should illuminate. Open vent door latch warning/limit switch, closed position
indicator should extinguish, and in-transit indicator should illuminate.
(5) Close vent door open limit switch, and in-transit indicator should extinguish, and
vent door open indicator should illuminate.
(6) Open vent door fully, unlock cargo door and place vent door control switch in
closed position. Vent door should not actuate.
(7) With cargo door locked, close and open vent door. Actuator should shut off as vent
door closed and open indicators illuminate, in closed and open positions.
(8) Open vent door and check for clearance between Torque Stop(NAVD198) and Key
Assembly(NAVED199) per Note 1 on Figure 52.05-3.
(9) With cargo door locked, close vent door and check:
(a) Full engagement of vent door latches(Ref. Figure 52.05-2.
(b) Full down and locked position of torque tube lock.
WARNING: DO NOT ROTATE “T” HANDLE WHILE PERFORMING
THIS TEST, DAMAGE MAY OCCUR.
(c) Lock pin walking beam, Beam Lock(NAVD206) will not allow walking beam
to move more than 3/16 inch.
(10) With vent door still closed and locked, check operation of actuator manual override
system.
(a) Refer to placards on vent door and manually open and close vent door.
(b) After completing this test repeat Functional Test per paragraph (7) above.
52.05.10 07-01-98 Revision 6

CHAPTER 52 - DOORS
g. Manual Vent Door Operation
WARNING: ELECTRIC ACTUATOR MUST BE REPLACED WITH
MANUAL BRACE WHEN MANUALLY CLOSING VENT
DOOR.
Open:
(1) Remove two oval access covers secured by 4 flat head screws each.
(2) Looking through upper access hole, identify spring loaded quick disconnect pin.
(3) With right hand through upper access hole, push quick disconnect pin forward to
fully compress spring and release actuator. Hold compressed through step 4.
(4) Slide screwdriver at an upward angel three inches into the slot at top of lower
access hole. The end of the screwdriver should rest on top of the bracket welded to
the two vertical rods. Using the screwdriver as a lever, raise the handle to force the
bracket downward and open the door.
(5) Pull vent door open just enough to unlock cargo door. DO NOT FORCE vent door
beyond stop when open approximately 45 degrees.
Close:
(To close see placard on inside of vent door before proceeding with steps 6 through 9.)
(6) Push vent door closed.
(7) Push quick disconnect pin forward and hold through step 8.
(8) Slide screwdriver at a downward angle three inches into the slot at top of lower
access hole. The end of the screwdriver should be below the bracket welded to the
two vertical rods. Using the screwdriver as a lever, push the handle down to force
the bracket upward and latch the door.
(9) Release quick disconnect pin when it will pass through bushing in link. Verify
disconnect has returned to fully locked position.
h. Manual Brace Installation
WARNING: ELECTRIC ACTUATOR MUST BE REPLACED WITH
MANUAL LINK TO MANUALLY CLOSE VENT DOOR.
(1) Pull vent door C/b.
Revision 11 11-01-00 52.05.11

CHAPTER 52 - DOORS
(2) Remove grill assembly.
(3) Remove electric actuator.

(a) Remove upper mount bolt.
(b) Disconnect wire at plug.
(c) Remove and stow actuator.
(4) Install manual brace per Figure 52.05-4. (VENT DOOR MUST BE PARTIALLY
OPEN.) Install manual brace with upper mount bolt. Next close vent door and
verify disconnect has returned to fully locked position.
(5) Vent door may be manually operated from outside now.
VENT DOOR MANUAL BRACKET

FIGURE 52.05-4
52.05.12 11-01-00 Revision 11

CHAPTER 52 - DOORS
3. Wiring Diagrams
“HOOK” STYLE VENT DOOR WIRING DIAGRAM

FIGURE 52.05-5
Revision 11 11-01-00 52.05.13

CHAPTER 52 - DOORS
VENT DOOR WIRING DIAGRAM SB-92-01R1

Figure 52.05-6
52.05.14 11-01-00 Revision 11

CHAPTER 52 - DOORS
VENT DOOR WIRING DIAGRAM FOR SB-92-03R1

Figure 52.05-7
Revision 11 11-01-00 52.05.15

CHAPTER 52 - DOORS
“HOOK” STYLE VENT DOOR

Figure 52.05-8 (1 OF 3)
52.05.16 11-01-00 Revision 11

CHAPTER 52 - DOORS
INDEX UNITS PER

NO. PART NUMBER DESCRIPTION ASSEMBLY
NAVD01 VENT DOOR ASSEMBLY
1 NAVD03 FRAME 1
2 NAVD02 VENT DOOR 1
3 NAVD82-1 STIFFENER 1
4 NAVD82-2 STIFFENER 1
5 NAVD38 HINGE 1
6 NAVD73-3 PLUG ASSEMBLY 1
7 NAVD73-4 PLUG ASSEMBLY 1
8 NAVD04-1 BRACKET ASSEMBLY 1
NAVD76 SHIM
11 NAVD12-1 HOOK ASSEMBLY 1
12 NAVD12-2 HOOK ASSEMBLY 1
NAVD81 SHIM (81=.125F, 81-1=.100T, 81-2=.080T,
81-3=.050T, 81-4=.020T, 81-5=.063T
81-6=.032T, 81-7=.016T
14 NAVD05 BRACKET ASSEMBLY 1
NAVD162 SHIP
15 NAVD13-1 ACTUATOR ASSEMBLY 1
16 NAVD09-1 LINK ASSEMBLY 2
17 NAVD60 BRACKET 1
18 NAVD30 MOUNT ASSEMBLY 1
19 NAVD33 LINEAR ACTUATOR 1
20 NAVD29 LINK ASSEMBLY 1
21 NAVD68 BRACKET 1
22 NAVD77 BRACKET 1
23 NAVD67 BRACKET 1
24 NAVD53 SWITCH 1
25 NAVD78 SWITCH 1
26 NAVD54 SWITCH 1
27 NAVD69 ACTUATOR 1
28 NAVD66 CONTROL 2
“HOOK” STYLE VENT DOOR IPC
Figure 52.05-8 (2 OF 3)
Revision 11 11-01-00 52.05.17

CHAPTER 52 - DOORS
29 AN4-13 BOLT 2
AN90-10 WASHER 2
AN310-4 NUT 2
MS24665-4 COTTER PIN 2
30 AN5-33 BOLT 1
AN960-516 WASHER 1
AN310-5 NUT 1
31 NAS1104-18D BOLT 2
AN960-10L WASHER 2
AN320-4 NUT 2
32 AN4-13 BOLT 1
AN960-416 WASHER 1
AN310-4 NUT 1
33 AN4-21 BOLT 1
AN960-416 WASHER 1
AN310-4 NUT 1
34 AN4-25 BOLT 1
AN960-416 WASHER 1
AN310-4 NUT 1
35 AN4-24 BOLT 1
AN960-416 WASHER 1
AN310-4 NUT 1
36 AN4-10 BOLT 2
AN960-416 WASHER 2
AN310-4 NUT 2
37 NAVD41 SEAL 1
38 NAVD150 BRACKET-RECEPTACLE 1
39 AN3-16 BOLT 1
AN960-10 WASHER 1
AN310-3 NUT 1
“HOOK” STYLE VENT DOOR IPC

Figure 52.05-8 (3 OF 3)
52.05.18 11-01-00 Revision 11

CHAPTER 52 - DOORS
“HOOK” STYLE DOOR LOCK ASSEMBLY

Figure 52.05-9 (1 OF 2)
Revision 11 11-01-00 52.05.19

CHAPTER 52 - DOORS
INDEX UNITS PER

NAVD14 LOCK ASSEMBLY 1
1 NAVD22 SUPPORT ASSEMBLY 1
2 NAVD15 LOCK BEARING ASSEMBLY 1
3 NAVD35 HINGE 1
4 NAVD66 CONTROL CABLE 2
5 NAVD62 ROD END 2
6 NAVD70 SPACER 1
7 NAVD145 SPACER 1
8 NAVD51 SWITCH 1
9 NAVD52 SWITCH 1
10 AN515-6R16 SCREW 2
AN960-6 WASHER 2
MS21042-06 NUT 2
11 6-32 FLAT HEAD STAINLESS SCREW 2
AN960-6 WASHER 2
MS21042-06 NUT 2
12 MS20426AD6 RIVET 1
13 NAVD39-1 KEY ASSEMBLY 1
14 NAVD45-1 WASHER STRIP ASSEMBLY 1
15 AN509-10R SCREW 4
16 AN509-10R SCREW 8
AN960-10 WASHER 8
MS21042-3 NUT 8
17 AN4-11 BOLT 2
AN960-416 WASHER 2
AN310-4 NUT 2
18 NAVD43 BRACKET ASSEMBLY 1
“HOOK” STYLE DOOR LOCK ASSEMBLY

Figure 52.05-9 (2 OF 2)
52.05.20 11-01-00 Revision 11

CHAPTER 52 - DOORS
52.05 NATIONAL AIRCRAFT SERVICE VENT DOOR(S.T.C. SA1614GL)(cont’d)
“CAM LATCH” STYLE DOOR IPC

Figure 52.05-10 (1 OF 5)
Revision 11 11-01-00 52.05.21

CHAPTER 52 - DOORS

Figure 52.05-10 (2 OF 5)
52.05.22 11-01-00 Revision 11

CHAPTER 52 - DOORS
INDEX UNITS PER

VENT DOOR ASSEMBLY
-1 NAVD33 LINEAR ACTUATOR 1
-2 NAVD173-1 MOUNT ASSEMBLY 1
-3 NAVD189-2 ROD ASSEMBLY 1
-4 NAVD175-2 ACTUATOR ASSEMBLY 1
-5 NAVD176 HANDLE 1
-6 NAVD177 SHAFT 1
-7 NAVD178-1 ACTUATOR BRACKET ASSEMBLY 1
-8 NAVD188-1 BRACKET ASSEMBLY 1
-9 NAVD180-1 BRACKET ASSEMBLY 1
-10 NAVD181-1 LINK ASSEMBLY 1
-11 NAVD182-1 LINK ASSEMBLY 1
-12 NAVD183 ADAPTER BLOCK 1
-13 NAVD184 PIN 1
-14 NAVD66 CONTROL CABLE 2
-15 NAVD38 HINGE 1
-16 NAVD190-1 ROD ASSEMBLY 2
-17 NAVD185-1 CAM LATCH ASSEMBLY 2
-18 NAVD186 BLOCK 1
-19 NAVD179 STRIKER BRACKET 1
-20 NAVD53 SWITCH 1
-21 AN525-624 SCREW 2
AN960-6L WASHER AR
MS21042-06 NUT 2
-22 NAVD174 STRIKER BLOCK 1
-23 AN525-624 SCREW 2
AN960-6L WASHER AR
MS21042-06 NUT 2
-24 NAVD67 BRACKET 1
-25 DELETED
-26 DELETED
-27 NAVD54 SWITCH 1
-28 MS20426DD-12 RIVET AR
Figure 52.05-10 (3 OF 5)
Revision 11 11-01-00 52.05.23

CHAPTER 52 - DOORS
INDEX UNITS PER

-29 AN509-8R16 SCREW 4
-30 NAVD02-1 DOOR ASSEMBLY 1
-31 NAVD82-1 STIFFENER 2
-32 NAVD69 ACTUATOR 1
-33 NAVD79 SHIM 1
-34 NAVD41 SEAL 1
-35 NAVD73-3 PLUG ASSEMBLY 1
-36 AN4-17 BOLT 1
AN960-414 WASHER AR
AN310-4 NUT 1
AN380-2-2 COTTER PIN 1
-37 AN4-11 BOLT 2
AN960-414L WASHER AR
AN310-4 NUT 2
-38 AN4-32 BOLT 4
AN960-414 WASHER AR
AN310-4 NUT 4
-39 AN4-12A BOLT 1
MS21042-4 NUT 1
-40 AN4-11A BOLT 1
MS21042-4 NUT 1
-41 AN4-47A BOLT 1
AN960-414 WASHER AR
MS21042-4 NUT 1
-42 AN4-44A BOLT 1
AN960-414 WASHER AR
MS21042-4 NUT 1
-43 AN4-12 BOLT 2
AN960-414 WASHER AR
AN310-4 NUT 2
-44 AN509-10R26 SCREW AR
MS21042-3 NUT AR
-45 MS20426DD-6 RIVET AR
Figure 52.05-10 (4 OF 5)
52.05.24 11-01-00 Revision 11

CHAPTER 52 - DOORS
INDEX UNITS PER

-46 NAS517-4-11 SCREW 1
MS21042-4 NUT 1
-47 NAS517-4-16 SCREW 1
MS21042-4 NUT 1
MS21042-3 NUT AR
MS21042-3 NUT AR
AN960-10 WASHER AR
MS21042-3 NUT AR
-51 AN509-10R27 SCREW 2
MS21042-3 NUT 2
-52 AN509-10R29 SCREW 3
AN960-10 WASHER AR
MS21042-3 NUT 3
-53 AN525-10R16 SCREW 2
AN960-10 WASHER AR
MS21042-3 NUT 2
-54 NAVD192 SHIM-STOP 1
-55 NAVD191 SPRING 1
-56 AN394-55 PIN 1
-57 NAVD193 BOLT 2
AN960-616C WASHER AR
AN320-6 NUT 2
-58 NAVD80 PLATE 1
-59 NAVD03 FRAME 1
-60 NAVD150 BRACKET RECEPTACLE 1
Figure 52.05-10 (5 OF 5)
Revision 11 11-01-00 52.05.25

CHAPTER 52 - DOORS
“CAM LATCH” STYLE DOOR LOCK ASSEMBLY IPC

Figure 52.05-11 (1 OF 2)
52.05.26 11-01-00 Revision 11

CHAPTER 52 - DOORS
INDEX UNITS PER
LOCK ASSEMBLY
-1 NAVD201-1 HOUSING 1
-2 NAVD201-2 BRACKET 1
-3 NAVD199-1 KEY 1
-4 NAVD199-3 ACTUATOR 1
-5 NAVD199-2 BEAM STOP 1
-6 NAVD204 STUD 2
-7 NAVD203 SPRING 2
-8 NAVD205 CLIP 1
-9 NAVD202-1 SUPPORT 1
-10 NAVD202-3 GUIDE 1
-11 NAVD202-2 GUIDE 1
-12 NAVD210 SHIM 1
-13 NAVD198 TORQUE STOP 1
-14 NAVD206 BEAM LOCK 1
-15 NAVD208 SEQUENCE SWITCH 1
-16 NAVD207 WARNING SWITCH 1
-17 NAVD66 CONTROL CABLE 2
-18 NAS517-3-6 SCREW 6
MS21042-3 NUT 6
-19 AN3-10-A BOLT 8
AN960-10PD WASHER 8
-20 6-32 STAINLESS STEEL SCREW 1 3/8 2
LONG
-21 6-32 STAINLESS STEEL SCREW 1 3/8 2
LONG
-22 NAS517-4-33 SCREW 2
MS21042-3 NUT 2
-23 AN509-10R22 SCREW 2
MS21042-3 NUT 2
-24 AN3-17A BOLT 2
AN960-10PD WASHER 2
-25 AN3-7A BOLT 2
AN960-10PD WASHER 2
-26 AN509-10R17 SCREW 2
AN960-10PD WASHER 2
MS21042-3 NUT 2
“CAM LATCH” STYLE DOOR LOCK ASSEMBLY IPC
Figure 52.05-11 (2 OF 2)
Revision 11 11-01-00 52.05.27

CHAPTER 52 - DOORS
INDEX UNITS PER

LOGIC CONTROL INSTALLATION
-1 NAVD84 CONTROL PANEL 1
-2 NAVD97, (-1), (-2) CONTROL PANEL MOUNT 1
-3 NAVD141, (-1), (-2) MOUNT DOUBLER 1
-4 NAVD144 NUT PLATE 1
-5 CR3212-5-3 CHERRY MAX RIVET 20
-6 AN509-8R11 SCREW 4
-7 NAVD146 PLACARD 1
LOGIC CONTROL INSTALLATION

Figure 52.05-12
52.05.28 11-01-00 Revision 11

CHAPTER 52 - DOORS
Revision 23 12-07-05 52.06.1

CHAPTER 52 - DOORS
INTENTIONAL
BLANK
52.06.2 12-07-05 Revision 23

CHAPTER 52 - DOORS
Revision 23 12-07-05 52.07.1

CHAPTER 52 - DOORS
INTENTIONAL
BLANK
52.07.2 12-07-05 Revision 23

CHAPTER 52 - DOORS
Revision 23 12-07-05 52.08.1

CHAPTER 52 - DOORS
INTENTIONAL
BLANK
52.08.2 12-07-05 Revision 23

CHAPTER 52 - DOORS
Revision 23 12-07-05 52.09.1

CHAPTER 52 - DOORS
INTENTIONAL
BLANK
52.09.2 12-07-05 Revision 23

CHAPTER 52- DOORS
52.10 – NASI FLIGHT DECK DOOR SYSTEM (STC ST01791CH)

TABLE OF CONTENTS
Paragraph Page
1. GENERAL-------------------------------------------------------------------------- 52.10.1
2. FLIGHT DECK DOOR REMOVAL & INSTALLATION ------------------ 52.10.5
3. FLIGHT DECK DOOR RIGGING & ADJUSTMENTS--------------------- 52.10.6
4. FLIGHT DECK DOOR INSPECTION ----------------------------------------- 52.10.7
5. ILLUSTRATED PARTS LIST -------------------------------------------------- 52.10.8
FIGURES
52.10-1 DOOR ASSEMBLY (COMPONENT LOCATION) -------------------------- 52.10.2

52.10-2 BULKHEAD SUPPORT (COMPONENT LOCATION) --------------------- 52.10.3
52.10-3 FLIGHT DECK DOOR LUBRICATION --------------------------------------- 52.10.4
52.10-4 PLACARD--------------------------------------------------------------------------- 52.10.8
52.10-5 FLIGHT DECK DOOR ASSEMBLY ------------------------------------------- 52.10.9
52.10-6 DOOR FRAME ASSEMBLY ---------------------------------------------------- 52.10.16
Revision 18 06-16-03 52.10-i

CHAPTER 52- DOORS
INTENTIONAL
BLANK
52.10-ii 06-16-03 Revision 18

CHAPTER 52 - DOORS
52.10 NASI FLIGHT DECK DOOR SYSTEM (STC ST01791CH)
1. General
a. The flight deck door design incorporates a honeycomb panel and a layer of ballistic
material glued together and sandwiched between unidirectional fiberglass sheets with a
stainless steel frame. The door hinges on three sectional lift-off hinges, allowing the door
to open toward the cabin. The door handle, located opposite the hinge, is designed to
minimize the amount of torque and pull applied to the door handle. The spring loaded
dead bolt operates with rotation of the door knob/handle and is operable and key-lockable
with two intrusion resistant locks in the unlocked position for maintenance and general
use when not in flight service.
b. The two intrusion resistant locks are located opposite the upper and lower hinges on the
cockpit side of the door, connected by a linkage to the door knob/handle. They are
lockable with a small lock lever adjacent to the inner door handle. When the lock lever is
pulled out, a spring loaded lock is engaged as the door knob/handle is rotated to the fully
locked position. The lock can be released by pushing the lock lever back.
c. The decompression and ventilation grille is mounted in the lower half of the door and
consists of stainless steel louvers welded into stainless steel channels. A thin stainless
steel panel installed on the cockpit side of the grille and hinged at the top protects from
ballistic splatter and smoke. The panel can be opened 3 ½ inches (max) at the bottom for
normal venting of cockpit air. Panel is normally in the full down position. Cargo aircraft
with a smoke curtain installed I.A.W. FAR 25.857(e)(4) do not require the cockpit door
to be a smoke barrier. (Most McDonnell-Douglas DC-8 cargo conversions include a
cargo compartment smoke barrier/curtain.)
d. In the event of an emergency, the stop bar, held in place above the door with two quick
release pins, can be removed and used as a pry bar to aid in the removal of the door. For
a description of emergency door removal, reference the placard located in the illustrated
parts catalog section of this chapter.
Revision 18 06-16-03 52.10.1

CHAPTER 52 - DOORS
52.10 NASI FLIGHT DECK DOOR SYSTEM (STC ST01791CH) (cont’d)
DOOR ASSEMBLY (COMPONENT LOCATION)

Figure 52.10-1
52.10.2 06-16-03 Revision 18

CHAPTER 52 - DOORS
BULKHEAD SUPPORT (COMPONENT LOCATION)

Figure 52.10-2
Revision 18 06-16-03 52.10.3

CHAPTER 52 - DOORS
FLIGHT DECK DOOR LUBRICATION

Figure 52.10-3
52.10.4 06-16-03 Revision 18

CHAPTER 52 - DOORS
2. Flight Deck Door Removal & Installation
a. Flight Deck Door Removal – Reference placard, Figure 52.10-4.
(1) (Above door) completely remove quick release disconnect pins.
(a) Push button in center of quick disconnect pin and pull pins straight down.
(Pins will hang on lanyards.)
(2) Jerk lanyards straight forward to remove stop bar.

(3) Unlock and unlatch door (with door handle).
(4) Lift and pull door to remove as follows:
(a) Hold stop in right hand with ears up.

(b) Place end of stop bar under door removal lever point (at center hinge).
(c) Apply force down as required on stop bar to remove door from hinges.
(d) Grasp door, lift straps, and pull door in to remove.
b. Flight Deck Door Installation
(1) Align door in doorjamb with door hinge on forward side of doorjamb-mounted
hinge.
(2) Grasp lifting straps and lift door while pushing aft on hinge side and lower door
onto hinge pins.
(3) Push stop in above door and insert quick disconnect pins.
(a) Verify pins are fully engaged with button pushed out (When button in center
of pin is depressed, pin can be pulled out.)
(b) Verify lanyards are free and not stuck between stop and upper doorjamb.
(4) Perform Functional Test Procedure (paragraph 4.a.).
Revision 18 06-16-03 52.10.5

CHAPTER 52 - DOORS
3. Flight Deck Door Rigging & Adjustment
a. Flight Deck Door Rigging
(1) Close the cockpit door. (If door will not close due to female latch hitting on locking
pin of the male latch assembly, see 3.b. below.)
(2) Verify that when door is NOT locked and doorknob is in neutral position, the spring
loaded deadbolt is fully extended and the two female latches are both above and
clear of the male latch assembly pins.
(3) Turn knob and lock door. Check that the female latch engaged on the male latch
assembly pins (7/8 ± 1/8) and center housing lock pin automatically slides into the
locked position (when the lock pin is placed in the center lock position).
b. Flight Deck Door Adjustment
(1) With doorknob in the neutral position, loosen the two jamb nuts located at the end
of the two actuating rods at the female latches.
(2) Close the door. Verify that the doorknob is still in the neutral position and that both
female latches are “free” of the male latch pins. If either or both of the female
latches are hitting the male latch pins, adjust the appropriate actuating rod until the
female latch clears the male latch pin.
(3) Once the female latches are adjusted to clear the male latch pins, close and lock the
door. When fully engaged, the female latches travel down on the male latch pins
(7/8 ± 1/8).
NOTE: The female latches do not bottom out on the male latches.
(4) Check that the latch and lock assembly operate smoothly with no binding or
jamming and the center housing lock pin automatically slides into the locked
position (when the lock pin is placed up in the locked position).
(5) Once this adjustment has been made, open the door and verify that the female
latches clear the male latch pins when opening the door.
52.10.6 06-16-03 Revision 18

CHAPTER 52 - DOORS
4. Flight Deck Door Inspection
CAUTION: MANUAL LATCH CANNOT BE LOCKED BY PILOT OR COPILOT WHILE
SEATED.
a. Functional Test Procedure
NOTE: Minimum of two personnel is required for door operational functional testing
on the ground. One person must occupy the cockpit at all times during testing.
(1) From cockpit side of door:
(a) Close door. Release door lock lever and rotate doorknob while holding
lockout safety (below upper latch) to engage latches on latch pins.
NOTE: Latch engagement on pins is 7/8 ± 1/8.
(b) Visually verify upper and lower latches are engaged over latch pins.
(c) Visually verify lock lever has engaged slot in center cam and door handle
cannot be rotated.
(d) Push lock lever back (outb’d) and up to the unlock position.
(e) Rotate door handle to disengage upper and lower latches from latch pins and
disengage center dead bolt. Push door open.
(2) From cabin side of cockpit door:
(a) Close cockpit door. (Do not rotate doorknob.)
(b) Visually verify door remains closed with the center dead bolt engaged in
doorjamb. (Visually verified from cockpit side.)
(c) With the key, verify doorknob can be locked and door knob cannot be rotated.
(d) With the key, unlock the doorknob, rotate doorknob, and open the door.
b. Functional Test Procedure (71CX only)
(1) Close door, release door lock lever, and rotate door knob while holding lockout
safety (below upper latch) to engage door locks.
(a) Verify door locks are fully engaged. (Female latches engage male pins 7/8” ±
1/8”.)
(b) Rotate door knobs to disengage locks, set lock lever release to secure locks in
disengaged position, and open door.
(2) Close door, release door lock lever, and rotate door knob to engage door locks.
(a) Verify door locks are fully engaged.
(b) Pull emergency release pins from stop assembly above door and remove stop
assembly.
(c) Lift door off hinges and set aside.
Revision 22 05-20-05 52.10.7

CHAPTER 52 - DOORS
(3) Reinstall door on hinges.
(4) Reinstall stop assembly with emergency release pins and repeat steps (1)(a) and (b).
c. Emergency Door Removal Test Procedure
NOTE: Reference placard, Figure 52.10-4.
(1) (Above door) completely remove quick release disconnect pins.
(a) Push button in center of quick disconnect pins and pull pins straight down.
(Pins will hang on lanyards.)
(2) Jerk lanyards straight forward to remove stop bar.
(3) Unlock and unlatch door (with door handle).
(4) Lift and pull door to remove as follows:
(a) Hold stop in right hand with ears up.
(b) Place end of stop bar under door removal lever point (at center hinge).
(c) Apply force down as required to stop bar to remove door from hinges.
(d) Grasp door, lift straps, and pull door in to remove.
5. Illustrated Parts List
PLACARD
Figure 52.10-4
52.10.8 05-20-05 Revision 22

CHAPTER 52 - DOORS
FLIGHT DECK DOOR ASSEMBLY

Figure 52.10-5 (1 of 7)
Revision 18 06-16-03 52.10.9

CHAPTER 52 - DOORS

Figure 52.10-5 (2 of 7)
52.10.10 06-16-03 Revision 18

CHAPTER 52 - DOORS

Figure 52.10-5 (3 of 7)
Revision 18 06-16-03 52.10.11

CHAPTER 52 - DOORS

Figure 52.10-5 (4 of 7)
52.10.12 06-16-03 Revision 18

CHAPTER 52 - DOORS

Figure 52.10-5 (5 of 7)
Revision 23 12-07-05 52.10.13

CHAPTER 52 - DOORS
Find Number Part Number Description Quantity

-1 Door Assy.
1 NAS632-3-6 Screw 1
2 NASI03-219 Spring 1
3 MS21042-3 Nut 1
4 NASI01-03-1 Door Panel Assy. 1
5 NASI03-69 Mount, Handle, Ext. 1
6 NASI03-31 Center Housing Assy. 1
7 NASI03-37 Cam, Center Housing 1
8 NASI03-41 Spring, Center Housing 1
9 NASI03-39 Link, Center Housing 1
10 NASI03-35-1 Center Housing, Front 1
11 NASI03-61 Handle Assy., Ext. 1
12 NASI03-71 Handle, Int. 1
13 NASI03-73 Cover, Handle, Int. 1
14 NASI03-75 Retaining Ring, Handle, Int. 1
15 NASI03-23-1 Link Assy., Bottom 1
16 NASI03-19-1 Link Assy., Top 1
17 NASI03-217-1 Cover – Upper 1
18 NASI03-218-1 Cover – Lower 1
19 NASI03-15 Latch, Female 2
20 NASI03-17 Guide, Latch 2
21 NASI03-07 Hinge Leaf, Lift-Off, Female 3
22 NAS1581F3T9 Screw 2
23 HL19PB6-12 Hi-Lok 2
24 AN509-10R8 Screw 4
25 HL19PB6-7 Hi-Lok 2
26 AN509-10R17 Screw 6
27 AN509-10R15 Screw 12
28 DP1085-20 Dimple Washer 6
29 AN960-10 Washer 6
30 AN960-10L Washer 4
31 NAS103-77 Washer, Handle, Int. 1
32 90295A187 Washer 1
33 MS21042-3 Nut 12
34 MS21042-4 Nut 1

Figure 52.10-5 (6 of 7)
52.10.14 12-07-05 Revision 23

CHAPTER 52 - DOORS
Find Number Part Number Description Quantity

35 NASI03-55 Deadbolt 1
36 NASI03-59 Spring, Deadbolt 1
37 NASI03-57 Cam, Deadbolt 1
38 NASI03-133 Backing Plate 3
39 NASI03-135 Shim 3
40 MS21042-3 Nut 12
41 NASI05-09-1 Vent Panel Assembly 1
42 N/A N/A N/A
43 N/A N/A N/A
44 NASI03-177 Bracket 1
45 AN960-3 Washer 12
46 MS35206-243 Screws 8

Figure 52.10-5 (7of 7)
Revision 23 12-07-05 52.10.15

CHAPTER 52 - DOORS
Find Number Part Number Description

1 NASI03-111 Channel Assembly
2 NASI03-89 Upper Filler
3 NASI03-91 Lower Filler
4 NASI03-119 Plate Assembly
5 NASI03-137 Trim Plate Assembly
6 NASI03-129 Stop Assembly
DOOR FRAME ASSEMBLY

Figure 52.10-6
52.10.16 12-07-05 Revision 23

CHAPTER 53 - FUSELAGE
TABLE OF CONTENTS
Page
53.01 FUSELAGE CARGO COMPARTMENT LINER REPAIR -------------------- 53.01.1
53.02 RADOME AND ANTENNA FIBERGLASS PANEL --------------------------- 53.02.1
53.03 HONEYCOMB PANEL DELAMINATION LIMITS --------------------------- 53.03.1
Revision 14 12-03-01 53-i

INTENTIONAL
BLANK
53-ii 12-03-01 Revision 14

53.01 – FUSELAGE CARGO COMPARTMENT LINER REPAIR

TABLE OF CONTENTS
Paragraph Page
1. LIMITATIONS ----------------------------------------------------------------------- 53.01.1
2. AIR-TIGHT SEALING REQUIREMENTS -------------------------------------- 53.01.1
3. REPAIR MATERIALS AND TOOLS--------------------------------------------- 53.01.1
4. REPAIR PROCEDURE-------------------------------------------------------------- 53.01.2
FIGURES
53.01-1 LINER PATCH CRITERIA --------------------------------------------------------- 53.01.4
TABLES
53.01-1 PREPARED PATCHES ------------------------------------------------------------- 53.01.1
Revision 14 12-03-01 53.01-i

INTENTIONAL
BLANK
53.01-ii 12-03-01 Revision 14

53.01 FUSELAGE CARGO COMPARTMENT LINER REPAIR
1. Limitations. As to whether a panel may be patched or replaced, damage limitation is left up
to the discretion of maintenance supervision. This includes limitation on a number of
patches per panel. For ease of repair, precut, non-self-adhesive patches of various
dimensions and thickness' are referenced in this procedure. Sheet metal liners are to be
repaired with material equal to or greater in thickness than the original liner.
2. Air-Tight Sealing Requirements.
a. Repairs to cargo compartment linings should be made in such manner as to maintain the
cargo compartment air tight sealing. Gaps between spacers and floor panels should be
packed with PR-1422 sealant.
b. Seal all openings which would allow air passage into cargo compartments through lining
boundaries. Sealants exposed to view or gaps, voids, or joggles that are existing after
repairs are installed, should receive aluminized sealant.
3. Repair Materials and Tools
a. Prepared Patches.
Thickness Shape Size Part Number

0.016" round 6" GAP6R16
GILLFAB6167-016905
square 12" GAP12S16

GILLFAB6167-016907
0.030" square 12" GAP12S30

GILLFAB6167-030907
Sources:
Gelko Adhesive Corp. M.C. Gill Corp.

P. O. Box 242 4056 Easy Street
Palos Park, IL 60464 El Monte, CA 91731
Phone: 708-388-2816 Phone: 818-350-5880
PREPARED PATCHES
Table 53.01-1
b. Aviation snips.
c. Abrasive aluminum oxide sheets, 200 grit.
d. Power drill..
e. Drill bit, 0.204" to 0.209" diameter.
Revision 6 07-01-98 53.01.1

53.01 FUSELAGE CARGO COMPARTMENT LINER REPAIR (cont’d)
f. 1, 1, 1, Trichloroethan solvent
g. Wiping cloths
h. Monel rivets, P/N CR8M3-6-02, Cherry Aerospace
Grip range - 0.031” to 0.094;
i. Fastener gun P/N G784 with pulling head P/N Hg80B220
j. Nosepiece P/N 74C53, Cherry Aerospace
k. PR-1422 sealant, Product Research and Chemical Corp.
4. Repair Procedure (Refer to Figure 53.01-1)
a. Based upon the approximate shape of the damage, cut back the damaged panel area and
trim into a square or round shape with the cutting tool fitted to one of the patches in
Table 53.01-1, or to a patch fabricated from liner material equal to or greater in thickness
than the liner to be repaired. Remove as little material as necessary.
b. Smooth the edges of the ducts with aluminum oxide sheet abrasive.
c. For fiberglass liner material, remove the glossy panel surface by lightly abrading with an
aluminum oxide sheet to a minimum of one inch from all edges of the trimmed damaged
area. For metal liner, abrade the paint from this area.
d. Clean this area wit solvent and wipe dry with a clean cloth.
e. Select the appropriate repair patch as required by the thickness of the damaged liner
panel and the size and shape of the trimmed hole.
Note: The patch must overlap the edge of the prepared hole in the liner by a
minimum of two inches at all points around the repair.
f. Smooth the edges with an aluminum oxide sheet.
g. Lightly abrade the surface of the patch with an aluminum oxide sheet to a minimum of
one inch from all edges on the side that will interface with the repair mating surface of
the panel.
h. Clean this area with solvent and wipe dry with a clean cloth.
i. Place the patch over the mating repair surface of the damaged panel and hold in place.
j. Drill holes 0.204” to 0.209” in diameter around the prepared patch. Minimum edge
distance from both inner and outer edges is one inch. Rivet spacing is one inch for 0.016
inch thick liner and two inches for material 0.030 inch thick or greater.
53.01.2 07-01-98 Revision 6

k. Remove the patch, clean and de-bur the holes. Again clean the surfaces with solvent and
wipe dry.
l. Apply a 1/4 inch bead of PR-1422 sealant on the panel, around each drill hole, and on the
entire interfacing surface of the patch.
m. Place the patch over the repair area and press it into place, aligning the rivet holes.
n. Immediately install the patch using the CR8M3-6-02 rivets.
o. Remove excess sealant from around the patch with solvent and clean wiping cloths.
Revision 6 07-01-98 53.01.3

LINER REPAIR CRITERIA

Figure 53.01-1
53.01.4 07-01-98 Revision 6

53.02 – RADOME AND ANTENNA FIBERGLASS PANEL

TABLE OF CONTENTS
Paragraph Page
1. GENERAL----------------------------------------------------------------------------- 53.02.1
2. MATERIALS-------------------------------------------------------------------------- 53.02.1
3. INSPECTION / REPAIR LIMITS-------------------------------------------------- 53.02.1
4. MIXING INSTRUCTIONS – RESIN KITS -------------------------------------- 53.02.3
5. REPAIR PROCEDURES ------------------------------------------------------------ 53.02.3
6. REFINISHING ------------------------------------------------------------------------ 53.02.5
FIGURES
53.02-1 RADOME PATCH CRITERIA----------------------------------------------------- 53.02.6
Revision 14 12-03-01 53.02-i

INTENTIONAL
BLANK
53.02-ii 12-03-01 Revision 14

53.02 RADOME AND ANTENNA FIBERGLASS PANEL
1. General
a. This specification defines the requirements for inspection and minor repair of nose
radome and antenna fiberglass panels.
b. Any damage, however minor, may allow penetration of moisture or air which could cause
additional damage or impair radome and antenna panels performance.
c. The following specification is for antenna Panels, not for the antenna itself.
2. Materials
a. Solvent, Methyl Ethyl Ketons (MEK)
b. Tape, Shuretape (Permacell 670, Nashua 345 or Pelican 222)
c. Sheet - Mylar
d. Cloth - Fiberglass (181 Volan A)
e. Mold Release Film, Poly-Vinyl-Alcohol, Cellophane or other local supply.
f. Resin Kit, (Epocast 156 Resin with 947 Hardener.
Note: Ref. Paragraph 4.b. (1) for mixing and curing instruction.
g. Resin, (Epon 828 Resin)
h. Catalyst, (T-1)
Note: Ref. Paragraph 4.b. (2) for mixing and curing instructions of materials g and h.
i. Polyurethane Paint, Imron 508U White (ISA), Crown Metro 24-F2-11RS (UPS)
j. Red Grease Pencil - Local supply
k. Sandpaper, 80 grit - Local supply
3. Inspection / Repair Limits

a. Nicks, Dents, and Erosion, Paint Chipping
(1) Repair over unlimited area allowed where no penetration of the outer resin and
glass layer has occurred.
(2) Repair, per Paragraph 6.
b. Pinholes - Caused by Lightening or Static Discharges
(1) Usually found where paint appears to be chipped.
(2) Perform a thorough inspection of the inner surface of the radome, since pinhole
damage often indicates significant internal damage.
(3) Repair pinholes, using Class C techniques, per Paragraph 5.b.(1).
Revision 6 07-01-98 53.02.1

53.02 RADOME AND ANTENNA FIBERGLASS PANEL(cont’d)
c. Cracks
(1) Applicability. Hairline cracks or fracture marks on fiberglass surface must be
repaired at first available opportunity but not later than next Maintenance Check or
Overhaul, whichever comes first.
(2) Repairs
(a) Accomplish emergency repairs per Paragraph 5.a.

(b) Repair cracks not exceeding one inch, using Class C techniques - paragraph
5.b.(2).
(c) Repair cracks not exceeding three inches using class C techniques - Paragraph
5.b.(1).
(d) Cracks exceeding three inches in length require radome replacement.
(e) Cracks of any length in antenna access panels can be repaired using Class C
techniques providing that panel is not distorted.
d. Punctures, Ruptures or Holes
(1) Accomplish emergency repairs per Paragraph 5.a.

(2) Repair holes less than one inch in diameter (through two or more plies) or skin and
column puncture or rupture less than three inches in diameter using Class B
techniques - Paragraph 5.c.(1).
(3) Holes greater than one inch in diameter through two or more plies of material or
punctures and ruptures exceeding three inches in diameter require radome
replacement.
(4) Use Class B techniques to repair hole in antenna access panel.
e. Spongy or soft Areas (Delaminations)

(1) Check for soft or spongy areas by pressing inward on the radome surface using
fingertip pressure. Delamination can be detected by softly tapping with a blunt
object (e.g. a coin).
(a) Delamination of the skin between flutes and skin on fluted core radomes and
between dkin piles on all radomes less than one inch in diameter without
damage to core structure does not require repair.
(b) Soft spots less than one inch in diameter caused by impact where one set of
columns is ruptured and the outer skin ply has delaminated, but not ruptured, do
not require repair.
53.02.2 07-01-98 Revision 6

(2) Accomplish emergency repairs per Paragraph 5.a.
(3) Spongy or soft areas from one to six inches in diameter require Class B repairs.
(Ref. Paragraph 5.c. (1).) However, the repair need not be accomplished if the
radome or antenna access panel is replaced or repaired not later than next
Maintenance check or Overhaul, whichever comes first and also provided that the
spongy or soft area does not increase to over one foot in diameter (radome only) or
the outer skin rupture.
(4) Spongy or soft areas greater than one foot in diameter for radome and two feet in
diameter for antenna access panel require replacement or shop repair.
4. Mixing Instructions - Resin Kits
a. Epocast 156 with 947 Hardener
(1) Mix by weight 5 parts of 156 to 1 part 947. If no scale available, mix by volume 4
parts 156 to 1 part 947. Mix kit contents if 50 grams of material are needed.
(2) Pot life of mixture at 75° F for 1 hour. Room temperature cure (80°F) requires 16
hours.
b. Epon 828 with Curing Agent T-1
(1) Mix by weight in proportion of 100 parts 828 to 25 parts T-1.

(2) Pot life of material is 15 minutes at 75°F. Pot life can be extended by spreading out
mixture on a horizontal surface.
(3) Cure, using heat lamp at 130°F for 1 hour. Room temperature cure requires
approximately 4 hours at 75°F.
5. Repair Procedures
a. Emergency Repairs. If minor damage occurs at station not equipped with radome repair
facilities, it is mandatory to patch damaged area with specified tape before dispatch.
Check condition of tape before each flight departure until authorized repair or
replacement is performed. Initiate carryover item per the General Maintenance Manual
to repair or replace at next opportunity. Placard inside of Flight Log cover to inspect tape
prior to dispatch.
Revision 6 07-01-98 53.02.3

b. Class C Repairs
(1) Pinholes
(a) Using sharp knife or similar tool, cut a cone shaped hole in skin to form funnel
for paste used in repair. Base of cone should be approximately 3/16 to 3/8 inch
diameter and hole through inner fiberglass ply approximately 1/16 to 1/8 inch
diameter. No sanding is required unless surface is very dirty or greasy.
(b) Mix Epocast 156 per Paragraph 4.a. and force filler into hole using a tongue
depressor or similar tool. Leave a small raised amount of filler on the outer ply
overlapping the conical hole.
(c) When the adhesive is tack free, block sand the area flush with the outer radome
surface and paint per Paragraph 6.a.
(2) Cracks
(a) Remove paint from area three inches in diameter larger than damaged area by
sanding.
(b) Clean with MEK.
(c) Cut patch of 181 Volan A approximately two inches larger than damaged area.
Impregnate cloth with Epon 828 and apply to damaged area. Ref. Paragraph
4.B for mixing instructions.
(e) Cover area with cellophane or other mold release film and tape firmly in place.
(f) Start from center and work excess resin from repair with a squeegee. Allow
time for resin to cure.
(g) Sand edges to fair-in with surface.
(f) Paint area, per Paragraph 6.a.
c. Class B Repairs
(1) Cracks, punctures, ruptures, holes, spongy or soft areas
(a) Remove paint from area approximately seven inches larger than damaged area
by sanding.
(b) Clean area with MEK.
(c) Apply three plies for 181 Volan A impregnated with Epon 828. Ref. Paragraph
4.B for mixing instructions. Lower ply must be approximately two inches
larger than damaged area and each successive ply must be two inches larger
than previously applied ply, so as to overlap on inch. (Ref. Figure 53.02-1).
53.02.4 07-01-98 Revision 6

(d) Cover repaired area with cellophane or other mold release film and tape firmly
in place.
(e) Starting from center, work air and excess resin from repair with squeegee.
Allow time for resin to cure.
(f) Sand edges of repair to fair-in with surface.
(g) Paint area per Paragraph 6.a.
6. Refinishing
a. Painting. Remove dirt and steins before refinishing. Clean with MEK if necessary.
b. Paint touch-up.
(1) Sand area lightly with 80 grit sandpaper.
(2) Clean area with MEK.
(3) Paint with polyurethane paint.
Note: Surface must be dry before painting. A lamp (mild heat) should be used to
remove condensation and to accelerate the paint curing time which is less
than 20 minutes at 120°F.
c. Erosion Shoe (Radome Only). Area exposed by removal of shoe must be painted per
decorative scheme using only polyurethane paint.
Revision 6 07-01-98 53.02.5

RADOME REPAIR CRITERIA

Figure 53.02-1
53.02.6 07-01-98 Revision 6

53.03 – HONEYCOMB PANEL DELAMINATION LIMITS

TABLE OF CONTENTS
Paragraph Page
1. GENERAL----------------------------------------------------------------------------- 53.03.1
2. LIMITATIONS ----------------------------------------------------------------------- 53.03.1
FIGURES
53.03-1 TYPICAL EXTERNAL VIEW OF A WING / FUSELAGE FILLET

PANEL --------------------------------------------------------------------------------- 53.03.2
Revision 14 12-03-01 53.03-i

INTENTIONAL
BLANK
53.03-ii 12-03-01 Revision 14

53.03 HONEYCOMB PANEL DELAMINATION LIMITS
1. General. This specification provides wing trailing edge, wing to fuselage fillet panel (upper
and lower) and belly wing to fuselage fillet panel delamination limits, to provide greater
planning flexibility for panel repairs and replacement.
2. Limitations. The following delamination is acceptable for service providing that the skin is
not cracked, and fasteners are not puling through the skin.
a. Line Limits - Total of all delaminated areas per panel does not exceed 40% of total
exterior area, and minimum distance between delaminated areas is 8 inches.
b. "C" Check Limits - Total of all delaminated areas per panel does not exceed 20% of
total exterior area, and minimum distance between delaminated areas is 12 inches.
c. "D" Check Limits - No delamination allowed.
Revision 6 07-01-98 53.03.1

53.03 HONEYCOMB PANEL DELAMINATION LIMITS(CONT’D)
TYPICAL EXTERNAL VIEW OF A WING/FUSELAGE

FILLET PANEL
Figure 53.03-1
53.03.2 07-01-98 Revision 6

CHAPTER 57 - WINGS
TABLE OF CONTENTS
Page
57.01 EXTERNAL FUEL LEAK TEMPORARY REPAIR / CLICK PATCH 57.01.1
INSTALLATION AND REMOVAL-------------------------------------------
57.02 HONEYCOMB PANEL DELAMINATION - REPAIR--------------------- 57.02.1
57.03 DC-8-70 PYLON (INBOARD OR OUTBOARD) REMOVAL AND
INSTALLATION ----------------------------------------------------------------- 57.03.1
Revision 26 11-08-06 57-i

CHAPTER 57 - WINGS
INTENTIONAL
BLANK
57-ii 11-08-06 Revision 26

CHAPTER 57 - WINGS
57.01 – EXTERNAL FUEL LEAK TEMPORARY REPAIR / CLICK PATCH

INSTALLATION AND REMOVAL
TABLE OF CONTENTS
Paragraph Page
1. GENERAL-------------------------------------------------------------------------- 57.01.1
2. MATERIALS----------------------------------------------------------------------- 57.01.1
3. LIMITATIONS -------------------------------------------------------------------- 57.01.1
4. INSTALLATION ------------------------------------------------------------------ 57.01.1
5. REMOVAL ------------------------------------------------------------------------- 57.01.4
FIGURES
57.01-1 CLICK PATCH PROCEDURES ------------------------------------------------ 57.01.3
Revision 14 12-03-01 57.01-i

CHAPTER 57 - WINGS
INTENTIONAL
BLANK
57.01-ii 12-03-01 Revision 14

CHAPTER 57 - WINGS
57.01 EXTERNAL FUEL LEAK TEMPORARY REPAIR / CLICK PATCH
INSTALLATION AND REMOVAL
1. General. Structural fasteners used to assemble the wet wings on heavy aircraft such as the
DC-8 are subject to continuous working as the wing structure flexes under flight loads, and
expands or contracts with temperature changes experienced during the course of operations
to high altitudes. Fasteners which penetrate the wet area of the wing structure are generally
sealed by use of a coating of sealant applied to the fasteners on the interior surface of the
wing. With age, this sealant looses its elasticity and adhesion characteristics, causing leaks
to develop in fasteners. Douglas has approved the Click Patch system of external fuel leak
repairs to provide an effective temporary repair of leaking fasteners. (See Douglas AOL 10-
1588.)
2. Materials
KA1 A1 CP 125 000 005 A1A1 aluminum flat patch
KA1 A1 CP 125 375 005 A2A1 aluminum medium hat patch
KA1 A1 CP 125 625 005 A2A1 aluminum large hat patch
3. Limitations. All Click Patches shall be removed at "C" Check in order to accomplish
permanent internal fastener leak repairs. Click Patches shall be inspected as a part of normal
maintenance while installed, concurrently with normal wing visual inspections to assure a no
leak condition.
4. Installation (REF. Figure 57.01-1)
(See the instruction card in the Click Patch Kit.)
a. Using the Scotch-Brite pad provided, buff the area to which the patch is to be bonded.
Mark the centerlines of the fastener to be sealed with a grease pencil or marker at 90
degrees, in order to align with the indexes on the patch. Make the marks beyond the
circumference of the patch to help align the patch during installation. Clean both the
buffed area of the wing and the patch with the solvent wipe provided.
b. Mix the adhesive. Using the stick provided, flatten one end of the two-part adhesive
packet to move the contents toward the opposite end. Tear off a strip from the flattened
end to open both compartments of the packet. Fold the packet in half lengthwise. Lay
the folded packet on the plastic mixing sheet provided and push out the entire contents
using the edge of the mixing stick. Press down hard to make sure all of both components
are removed. BE SURE ALL CONTENTS ARE REMOVED FROM THE PACKET.
THE MIX RATIO IS CRITICAL. Mix the hardener and resin together thoroughly.
Wipe the stick against the plastic sheet several times during the mixing to get all of the
clinging components mixed in. Mix until the color of the adhesive is uniform.
c. Apply the adhesive to the center of the patch, making a spot of adhesive in the center of
the metal patch approximately 5/8 inch in diameter. When applying a hat patch, the
adhesive is applied to the outer ring of the hat patch.
Revision 6 07-01-98 57.01.1

CHAPTER 57 - WINGS
INSTALLATION AND REMOVAL (CONT’D)
d. Peel off the protective ring exposing the foam tape around the outside of the patch.
Position the Click Patch by matching the index marks on the disk with the centerline
marks made earlier. Press down around the outer edge of the disk to adhere the foam
tape to the wing surface.
e. Activate the Click disk by pressing near the center until the "click" is felt. This
activation applies gluing pressure to the patch and extrudes the adhesive to a thin glue
line. For hat patches, press down a the inner edge of the gluing fixture, not the patch.
f. After the adhesive has cured (check the leftover adhesive on the mixing plate), remove
the fixture and discard it. The Click Patch is now bonded to the wing surface. The
adhesive bead may be trimmed and the patch pained if desired.
57.01.2 07-01-98 Revision 6

CHAPTER 57 - WINGS
Step 1: Abrade and solvent wipe

Prepare surface. substrate. Mark centerlines
Mark centerlines. where patch is to be installed.
Solvent wipe patch surface.
Step 2: Follow mixing instructions.

Mix adhesive and Apply approximately a 5/8”
apply to patch. diameter spot of adhesive to
center of patch. When
applying hat patches, adhesive
is applied to outer ring of hat
patch.
Step 3: Peel off the protective ring
Peel paper from outer exposing foam tape.
foam ring.
Step 4: Position Click Patch by

Position fixture and matching index marks on the
press down outer disk with the centerlines. Press
edge. down around outer edge of disk
to adhere foam tape to surface.
Step 5 Activate click disk by pressing

Press fixture center to near center until “click” is felt.
“click”. This activation applies pressure
to the patch and extrudes the
adhesive to a thin glue line.
For hat patches, press down at
inner edge of fixture, not on the
patch.
Step 6: After adhesive has cured
Peel off fixture after (check leftover adhesive on
adhesive is set. mixing plate), remove the
fixture and discard. Patch is
now bonded to surface.
Adhesive bead may be trimmed
and patch painted.
CLICK PATCH PROCEDURE
Figure 57.01-1
Revision 6 07-01-98 57.01.3

CHAPTER 57 - WINGS
5. Removal
a. Confirm that the aircraft has been properly grounded, and that there is no possibility of
igniting fuel or fuel vapors contained in the wing.
b. Apply heat to the Click Patch using a 350 degree F heat gun. Heat the patch until a tank
sealer's scraper can be inserted under the edge of the patch. BE CAREFUL NOT TO
SCRATCH THE WING SKIN. Work up one edge of the patch enough to grip with
pliers.
c. Maintaining heat on the patch, use pliers to peel the patch from the wing skin.
d. Mask off the patch area with aircraft window masking tape in preparation for removing
the residual adhesive from the wing surface.
e. Apply an approved paint removal gel to the area of the patch on the wing skin. Using the
same procedures as you would to remove paint, remove the residual adhesive. De-mask,
clean and neutralize the area as required.
f. Open a non-routine item to enter that tank and accomplish the permanent internal repair
of that fastener's fuel leak.
57.01.4 07-01-98 Revision 6

CHAPTER 57 - WINGS
57.02 – HONEYCOMB PANEL DELAMINATION REPAIR

TABLE OF CONTENTS
Paragraph Page
1. GENERAL-------------------------------------------------------------------------- 57.02.1
2. MATERIALS----------------------------------------------------------------------- 57.02.1
3. LIMITATIONS -------------------------------------------------------------------- 57.02.1
4. REPAIR ----------------------------------------------------------------------------- 57.02.1
Revision 14 12-03-01 57.02-i

CHAPTER 57 - WINGS
INTENTIONAL
BLANK
57.02-ii 12-03-01 Revision 14

CHAPTER 57 - WINGS
57.02 HONEYCOMB PANEL DELAMINATION REPAIR
1. General
a. Whenever possible, Honeycomb Panels should be repaired using SRM procedures, but
when delamination reaches the point of oil canning on panels larger than 2' x 2', the
following repair may be used to allow aircraft utilization until panel can be repaired or
replaced.
b. Any panels so repaired must be replaced during aircraft overhaul.
c. This repair applies to all wing Honeycomb Panels, wing to fuselage (including belly)
fillet panels and the Flap Scissors Brace Panels must be replaced during "C" Check if
total delamination area exceeds 200 square inches.
2. Materials
a. Chicago screw, 1011536

b. Screw, NAS 517-3
c. Washer, A3235-028-24A
d. Sealant, PR1436-G-B 1/2
e. MEK
f. Masking tape
3. Limitations. See DACO MM 53-53-09 for delamination limits.
4. Repair
a. Locate boundaries of delaminated area and mark locations of fasteners, starting at the
edges and using a 2 to 3 inch grid pattern. Fasteners are to be distributed evenly over
entire area.
b. Drill 5/16 inch holes through upper and lower skin.
c. Let water run out of drilled area and using an approved source of heat, dry area as much
as possible.
d. Coat shank of Chicago screw with PR1436 and insert in hole from back side.
Revision 6 07-01-98 57.02.1

CHAPTER 57 - WINGS
57.02 HONEYCOMB PANEL DELAMINATION REPAIR (CONT’D)
e. Apply PR1436 to washer and screw head and install from front side.
Note: Do not put sealant on screw thread. The sealant would hydraulic and prevent
the screw from being fully torqued.
f. Clean outer skin using MEK.
g. Mask off the grid pattern of screw heads, leaving heads and washers exposed within the
grid. Allow about 1/8 inch clearance from edge of tape to edge of washers.
h. Seal screw heads and washers using PR1436 and remove masking tape while sealant is
still wet.
i. Clean up using MEK.
57.02.02 08-01-00 Revision 10

CHAPTER 57 - WINGS
57.03 – DC-8-70 PYLON (INBOARD OR OUTBOARD) REMOVAL AND

INSTALLATION
TABLE OF CONTENTS
Paragraph Page
JOB CARDS
57.03-1 DC-8-70 PYLON (INBOARD OR OUTBOARD) REMOVAL AND

INSTALLATION ------------------------------------------------------------------ 57.03.1
FIGURES
57.03-1 PYLON STATION IDENTIFICATION, CFM56 ----------------------------- 57.03.2
57.03-2 PYLON HANDLING SLING---------------------------------------------------- 57.03.3
Revision 26 11-08-06 57.03-i

CHAPTER 57 - WINGS
INTENTIONAL
BLANK
57.03-ii 11-08-06 Revision 26

CHAPTER 57 - WINGS
57.03-1
JOB TITLE
DC-8-70 PYLON (INBOARD OR OUTBOARD) REMOVAL AND INSTALLATION
Job Card Reviewed By Date Page 1 of 7
Mechanic RII Insp.
A. REFERENCES
DACO Structural Repair Manual
DACO Maintenance Manual
B. PROCEDURE – GENERAL
1. This procedure is for removal and installation of a single DC-8-70 series
pylon, inboard or outboard. If more than one pylon must be removed at a
time, contact DACO Engineering prior to removal.
CAUTION: WHEN REMOVING PYLONS, IF RESISTANCE IS FOUND DUE

TO SEIZURE (BINDING) OF ATTACHING BOLTS, CORROSION,
OR MISALIGNMENT, THE AIRCRAFT WILL NEED TO BE
SHORED AND LEVELED PER THE DC-8 MAINTENANCE
MANUAL PRIOR TO PROCEEDING.
WARNING: TO AVOID INJURY TO PERSONNEL OR DAMAGE TO
EQUIPMENT, MAKE CERTAIN ADEQUATE PRECAUTIONS
ARE TAKEN WHILE PERFORMING ANY WORK IF
ELECTRICAL POWER IS APPLIED TO THE AIRCRAFT.
CAUTION: ELECTRICALLY GROUND THE AIRCRAFT.
2. It is recommended mechanics note size and type of existing attachments
prior to removal. Existing and/or identical type attachments are to be
used on installation.
3. The sequence of removals and installations outlined in this procedure is

intended as an aid for general references but may not be an exact
sequence of operations.
4. Seal all attachments in fuel tanks areas with PR 1422 sealant (or
equivalent). (See DACO SRM Chapter 51-1-12.)
Revision 26 11-08-06 57.03.1

CHAPTER 57 - WINGS
57.03-1
JOB TITLE
Mechanic RII Insp.
PYLON STATION IDENTIFICATION, CFM56

Figure 53.07-1
57.03.2 11-08-06 Revision 26

CHAPTER 57 - WINGS
57.03-1
JOB TITLE
Mechanic RII Insp.
PYLON HANDLING SLING

Figure 53.07-2
Revision 26 11-08-06 57.03.3

CHAPTER 57 - WINGS
57.03-1
JOB TITLE
Mechanic RII Insp.
C. ACCOMPLISHMENT INSTRUCTIONS:
1. Remove and retain engine, thrust reverser, and attach parts. (See DACO
Maintenance Manual 71-00, paragraph entitled “Remove Power Plant”.)
CAUTION: DO NOT REMOVE TWO OR MORE ENGINES FROM THE
AIRCRAFT AT ONE TIME WITHOUT FIRST SUPPORTING THE
TAIL SECTION AT MOORING FITTINGS. WEIGHTS MAY BE
ATTACHED TO THE FORWARD FUSELAGE IN LIEU OF
SUPPORTING THE AFT FUSELAGE. (SEE DACO
MAINTENANCE MANUAL 7-30-0, PARAGRAPH ENTITLED
“JACKING PROCEDURES”.)
2. Drain and purge the following fuel tanks. (See DACO Maintenance
Manual Chapter 12-13-1, paragraph entitled “Defuel Fuel Tanks”.)
Pylon Area Fuel Area
1 No. 1 Alternate
2 No. 1 Main and No. 2 Alternate
3 No. 4 Main and No. 3 Alternate
4 No. 4 Alternate
3. Defuel remaining fuel tanks as required to be within jacking limitations

and jack aircraft. Level aircraft and support at nose jack station and tail
mooring fitting. The wing need not be placed in a relaxed position but
should be supported at the wing jack points, including auxiliary jack
points. (See DACO Maintenance Manual Chapter 7-11-0, paragraph
entitled “Jacking Procedures”.)
4. Disable firex system by opening firex agent discharge and low pressure
warning circuit breakers. Placard circuit breaker panel.
5. Pull fire handle for the specific pylon to mid position. This is to activate
the systems shut-off valves on the forward spar. Placard fire handle.
6. Remove and retain fuel tank access doors 505A, 505B, 505C, 505D, and
560A on left and/or right wings (as required) internal piping and interfering
installations in tanks, as necessary for access. (See DACO Maintenance
Manual Chapter 6-11-2.)
7. Remove and retain access door and attaching parts on lower wing
leading edge on either side of pylon.
8. Remove and retain pylon upper fairing and fillers, and open pylon leading
edge access doors. Retain all attaching parts.
9. Remove and retain pylon aft fairing and attaching parts.
57.03.4 11-08-06 Revision 26

CHAPTER 57 - WINGS
Revision 26 11-08-06 57.03.5

CHAPTER 57 - WINGS
57.03-1
JOB TITLE
Mechanic RII Insp.
10. Pylons 2 and 3 – Remove and retain trough installation aft of pylons,
Station Yn 390 to Station Yn 490. Retain all attaching parts. (See Figure
57.03-1.)
11. Remove and retain all pylon vent and access doors and attaching parts.
12. Disconnect pneumatic ducts at pylon bleed air precooler. Remove and
retain precooler and check valve. Remove and retain ducting between
precooler and forward spar.
13. Disconnect control cables that run down to pylon. Put cable clamps at
pulleys on spar and on pylon. Disconnect cables at turnbuckles. Pull
cables through pulleys on tombstone fitting and keep with pylon. Pylons
2 and 3 – Loosen clamps and disconnect control cables that run through
hole in pylon bulkhead.
14. Disconnect and cap fuel lines at station Yn-290.000.
15. Pylons 2 and 3 – Remove and retain firex bottles, piping, and attaching
parts as required to remove pylon. Cap open piping. (See DACO
Maintenance Manual Chapter 26-20-1, paragraph entitled “Removal/
Installation Fire Extinguisher Agent Containers”.)
16. Disconnect and remove all piping extending from rear wing spar to
disconnects in aft end of pylon.
17. Disconnect generator cables. Remove wire clamps in pylon for hard wire
harness to allow pylon to move without damaging wires.
18. Disconnect firex line on pylon. Leave line attached on spar.
19. Verify hydraulic pressure to the pylon is zero. Disconnect hydraulic line at
pylon/spar fitting (drain hydraulic fluid in line). Plug line. Pylons 2 and 3 –
Remove and retain hydraulic lines in trough between aft spar and at
pylon. (See Figure 57.03-1.)
20. Position and attach a pylon handling sling, similar to the sling shown on
Figure 57.03-2, to the pylon.
NOTE: To simplify pylon reinstallation, it is recommended that prior to
removing pylon attach bolts, bolt patterns be reproduced in
plywood or other suitable material to receive the bolts as they
are removed.
57.03.6 11-08-06 Revision 26

CHAPTER 57 - WINGS
57.03-1
JOB TITLE
Mechanic RII Insp.
21. Remove and retain the following:
a. Attachments through pylon plank and pylon-to-wing attach angle both

inboard and outboard side.
b. Attachments through pylon plank and V-fittings at aft end of pylon.
c. Pylon aft attach brackets and attaching parts.
d. Attachments through pylon bulkhead installation and wing front spar

fitting.
e. Attachments through pylon bulkhead and tee doubler.
f. Engine control pulley brackets and attaching parts.
Loosen pylon from sealant and attach angle by slow up and down
movement.
22. Carefully lower pylon approximately inch; ensure all attachments to the
pylon area loose or have been removed. Then, lower pylon a maximum
of 18 inches.
NOTE: Use care to prevent damage to lines, cables, and conduits.
23. Lower pylon onto stand.
24. Inspect area under pylon and generate non-routine cards as applicable.
25. Raise pylon into position and reinstall, taking the same precautions used
in lowering the pylon.
CAUTION: ENSURE THAT DYNOMETER LOAD MEASUREMENT IS
NOT GREATER THAN THAT MEASURED IN STEP 20
BEFORE INSTALLING FASTENERS. EXERCISE EXTREME
CAUTION WHEN MOVING PYLON INTO POSITION.
26. Reinstall any shims removed during disassembly and check for gaps at
all mating surfaces.
27. Reinstall attachments, pylon attach brackets, and pulley brackets retained
previously. Tighten ¾-inch bolts to a torque of 83 to 115 inch-pounds and
tighten 5/16-inch bolts to a torque of 165 to 230 inch-pounds. Remove
pylon handling fixture.
NOTE: Visually inspect pylon attaching structure for possibly damage
caused by reinstallation.
28. Connect and/or install electrical wiring and generator cables.
29. Reconnect and/or install hydraulic piping.
30. Reconnect and/or install engine control cables.
Revision 26 11-08-06 57.03.7

CHAPTER 57 - WINGS
57.03-1
JOB TITLE
Mechanic RII Insp.
31. Reconnect fuel line at station Yn-290.000 using two new 13-05-226 O-
rings on each pylon.
32. Pylons 2 and 3 – Reinstall retained firex bottles and piping using retained
attaching parts. (See DACO Maintenance Manual Chapter 26-20-1,
paragraph entitled “Removal/Installation Fire Extinguisher Agent
Containers”.)
33. Reinstall and connect bleed air ducts, precooler, and check valve.
34. Inspect structure for debris and foreign objects. Reinstall retained vent
and access doors, piping and interfering installation. Remove debris from
fuel tanks and check for leaks. (See DACO SRM Chapter 51-1-12,
paragraph entitled “Tank Leak Pressure Testing”.)
35. Lower the aircraft. Reinstall retained wing leading edge covers, pylon
leading edge access doors, fairing, fillers, and trough installation. Fill gap
between upper planks and wing skin using CS2410 sealant and paint as
required. (See DACO Maintenance Manual Chapter 7-11-0, paragraph
entitled “Lower Instructions”.)
36. Reinstall retained engines and thrust reversers. (See DACO

Maintenance Manual Chapter 71-00, paragraph entitled “Install Power
Plant”.)
37. Make an entry in the aircraft logbook as to the accomplishment of this

non-routine job card.
57.03.8 11-08-06 Revision 26

CHAPTER 70 – ENGINE JOB CARDS
JOB CARDS
TABLE OF CONTENTS
Page
70.00 INTRODUCTION ----------------------------------------------------------------- 70.00.1
70.01 ENGINE GENERAL -------------------------------------------------------------- 70.01.1

70.02 ENGINE REMOVAL & INSTALLATION------------------------------------ 70.02.1
70.03 ENGINE INSPECTION ---------------------------------------------------------- 70.03.1
70.04 ENGINE FUEL & CONTROL -------------------------------------------------- 70.04.1
70.05 ENGINE CONTROLS ------------------------------------------------------------ 70.05.1
70.06 ENGINE INDICATING ---------------------------------------------------------- 70.06.1
Revision 10 08-01-00 70-i

INTENTIONAL
BLANK
70-ii 08-01-00 Revision 10

JOB CARDS
70.00 - INTRODUCTION
TABLE OF CONTENTS
Paragraph Page
1. PURPOSE------------------------------------------------------------------------------ 70.00.1
2. USE ------------------------------------------------------------------------------------- 70.00.1
3. ENGINE JOB CARD INDEX------------------------------------------------------- 70.00.1
Revision 14 12-03-01 70.00-i

INTENTIONAL
BLANK
70.00-ii 12-03-01 Revision 14

70.00 INTRODUCTION
1. Purpose. The Recurring Non-Routine Job Card is provided to aid maintenance in performing
and recording frequently accomplished non-routine maintenance. It is intended to provide
the mechanic and inspector all the information required to perform a specific task (unless
otherwise noted) and a space for signatures of required accomplishment and inspection items
at specific steps within the process.
2. Use. Each task is assigned a Job Card Number which is displayed in the upper right corner.
To use a Non-Routine Job Card, photocopy the appropriate card as it appears in this section.
Fill in the information required in the un-shaded spaces on the top of each card. Shaded
areas require no entry. Each un-shaded area for both Mechanic and Inspector must be signed
to signify the completion of that step. Some cards may require only one signature while
others require multiple signatures. The inspector block must be signed by a person holding
RII authority for that ATA number and type aircraft. Forward the Job Card to Aircraft
Records after the card has been completed and reviewed by the station supervisor.
3. Engine Job Card Index.
NUMBER TITLE PURPOSE

Section 70.01 – Engine General
7001 Component Control - JT3D Removal To record engine component
inventory after engine removal.
7002 Component Control - JT3D Installation To record engine component
inventory after engine installation.
7003 Spare Engine ‘C’ Check - JT3D Accomplishes the intent of ‘C’
Check inspection items to the basic
engine while it is not installed on an
aircraft. Typically to return to
service an engine that was removed
from one aircraft and is intended for
reinstallation onto another.
7004 Component Control - CFM56 Removal To record engine component
inventory after engine removal.
7005 Component Control - CFM56 Installation To record engine component
inventory after engine installation.
7006 Spare Engine ‘C’ Check - CFM56 Accomplishes the intent of ‘C’
Check inspection items to the basic
engine while it is not installed on an
aircraft. Typically to return to
service an engine that was removed
from one aircraft and is intended for
reinstallation onto another.
Revision 10 08-01-00 70.00.1

70.00 ENGINE RECURRING NON ROUTINE JOB CARDS(cont’d)
Section 70.02 – Engine Removal & Installation

7101 Engine Removal JT3D-3B/-7 Self Explanatory
7102 Engine Installation JT3D-3B/-7 l Self Explanatory
7103 Engine Removal CFM56 l Self Explanatory
7104 Engine Installation CFM56 Self Explanatory
7105 CFM56-2 Max Power Assurance Run To document performance prior to
removing a serviceable engine. Max
Power Assurance limits are from the
CFM56-2 MM 71-00-00 Adjust/Test
01.
7106 Off-wing Engine T3/4 Disk Replacement – Self Explanatory
JT3D
Section 70.03 – Engine Inspection
7201 First Stage Nozzle Guide Vane Isotope Self Explanatory
Inspection
7202 Front Compressor Rear Hub Eddy Current Self Explanatory
Inspection
7203 Borescope Inspection Record CFM56-2 To document the Special, the
Scheduled and the Spare Engine ‘C’
Check Borescope Inspections.
7204 Borescope Inspection Record JT3D-3B/-7 To document all JT3D Borescope
Inspections.
Section 70.04 – Engine Fuel & Control
7301 Intermix of JT3D-3B & JT3D-7 Engines Engine rigging when engines are
intermixed.
Section 70.05 – Engine Controls
7601 “No Noise” Trim Mark Maintenance To provide reference points for
throttle alignment.
Section 70.06 – Engine Indicating
7701 EGT Indicator Range Marking Instructions Self Explanatory
70.00.2 05-11-07 Revision 28

JOB CARDS
70.01 – ENGINE GENERAL
TABLE OF CONTENTS
Job Card Page

7001 COMPONENT CONTROL – JT3D-3B / -7 REMOVAL ----------------------- 70.01.1
7002 COMPONENT CONTROL – JT3D-3B / -7 INSTALLATION ---------------- 70.01.3
7003 SPARE ENGINE “C” CHECK – JT3D-3B / -7 ---------------------------------- 70.01.5
7004 COMPONENT CONTROL – CFM56-2 REMOVAL --------------------------- 70.01.15
7005 COMPONENT CONTROL – CFM56-2 INSTALLATION -------------------- 70.01.19
7006 SPARE ENGINE “C” CHECK – CFM56-2--------------------------------------- 70.01.23
Revision 23 12-07-05 70.01-i

INTENTIONAL
BLANK
70.01-ii 12-07-05 Revision 23

CHAPTER – 70 – ENGINE JOB CARDS
7001
JOB TITLE
COMPONENT CONTROL - JT3D-3B / -7 REMOVAL
Job Card Reviewed By Date
Page 1 of 2
Mechanic Inspector
Engine Serial Number OFF: __________________ PCI D7203 or D7207
Removal Reason: ________________________________________________________
Engine TT: __________ Engine TC: __________ Engine TSLV: ________ Engine CSLV: ________
Instructions
This Job Card is to be completed by an inspector AFTER the engine change has taken place. This Component Control
Sheet will represent the status of the engine after necessary parts have been changed, and after the installed
replacement engine has passed a functional check. Identify unserviceable parts with N/S in the P/N column and
“Green-Tag” the unit on the engine.
Record the P/N & S/N of each component listed. The P/N must be completed only if it is different from the typical P/N
stated. The TSO column will be completed by the Aircraft Records Section. Use the following code for these
exceptions:
#1 - ITEM NOT INSTALLED #2 - P/N OR S/N, NOT LEGIBLE #3 - NO DATA/DATA PLATE
Fax the completed Job Card to the Engine Analyst. Send the original Job Card to the Aircraft Records Section along
with the engine change paperwork. The Engine Records Section will file the Job Card in the engine file.
Record the Following Information
Typical Part
Item Component PCI # Number Part Number Serial Number TSO
1 Fuel Pump 9477
2 Fuel Temp. Regulator UC529605-1
3 Boost Pump D7302A 64-1119-11
4 Fuel Control Unit D7305 711287-13
Record all Mod #’s: L#
5 P & D Valve 719499

6 Fuel / Oil Cooler 715447
7 AC Generator D2402 31229-000
8 CSD D2401 698870
9 CSD Cooler Jet Pump Valve 26230074
10 Exciter Box “A” (Bottom) D7401 42562
11 Exciter Box “B” (Top) D7401 42562
12 Oil Pump 422547
13 Hydraulic Pump D2902A PV3-160-4 /
371380
14 Pressure Regulating Valve 362160-4-1
th
15 16 Stage S / O Valve 2650169M2
th
16 9 Stage Check Valve 2985515-505
17 IGV Anti-Ice Valve (R) 431599
Revision 10 08-01-00 70.01.1

7001
JOB TITLE
COMPONENT CONTROL - JT3D-3B / -7 REMOVAL
Page 2 of 2
Mechanic Inspector
CONTINUED
Typical Part
18 IGV Anti-Ice Valve (L) 431599
19 Pressure Ratio Bleed Control D7501 563883

Valve
20 N1 Tach Generator D7704 A28071-11-302
22 Fuel Flow Transmitter D7303 8TJ85GAK2
23 Oil Quantity Transmitter B1239-3196
24 Oil Pressure Transmitter 41822044
25 Start Valve 397592-1
26 Starter D8001 383370-8-1
27 Inlet Anti-Ice Valve 431599
28 RH Fwd Mount Cone Bolt 96013-1
(BAC II Stage 3)
70.01.2 08-01-00 Revision 10

CHAPTER - 70 – ENGINE JOB CARDS
ATI-001
ATI RECURRING NON-ROUTINE
7002
JOB TITLE
COMPONENT CONTROL - JT3D-3B / -7 INSTALLATION
Page 1 of 2
Mechanic Inspector
Engine Serial Number ON: ___________________ PCI D7203 or D7207
Engine TT: __________ Engine TC: __________ Engine TSLV: ________ Engine CSLV: ________
Instructions
Sheet will represent the status of the engine after necessary parts have been changed, and after the installed engine has
passed a functional check.
Record the P/N & S/N of each component listed. The P/N must be completed only if it is different from the typical P/N
stated. The TSO column will be completed by the Aircraft Records Section.
Fax the completed Job Card to the Engine Analyst. Send the original Job Card to the Aircraft Records Section along
with the engine change paperwork. The Engine Records Section will file the Job Card in the engine file.
Typical Part Actual
1 Fuel Pump (High Pressure) 9477
2 Fuel Temp. Regulator UC529605-1
3 Boost Pump (Nash) D7302A 64-1119-11
4 Fuel Control Unit D7305 711287-13
Record all Model #’s: L#
5 P & D Valve 719499

6 Fuel / Oil Cooler 715447
7 AC Generator D2402 31229-000
8 CSD D2401 698870
9 CSD Cooler Jet Pump Valve 26230074
10 Exciter Box “A” (Bottom) D7401 42562
11 Exciter Box “B” (Top) D7401 42562
12 Oil Pump 422547
13 Hydraulic Pump D2902A PV3-160-4 /
371380
14 Pressure Regulating Valve 362160-4-1
th
15 16 Stage S / O Valve 2650169M2
th
16 9 Stage Check Valve 2985515-505
17 IGV Anti-Ice Valve (R) 431599
18 IGV Anti-Ice Valve (L) 431599
Revision 10 08-01-00 70.01.3

CHAPTER – 70 – ENGINE JOB CARDS
7002
JOB TITLE
COMPONENT CONTROL - JT3D-3B / -7 INSTALLATION
Page 2 of 2
Mechanic Inspector
CONTINUED
Typical Part
19 Pressure Ratio Bleed Control D7501 563883
Valve
22 Fuel Flow Transmitter D7303 8TJ85GAK2
23 Oil Quantity Transmitter B1239-3196
24 Oil Pressure Transmitter 41822044
25 Start Valve 397592-1
26 Starter D8001 383370-8-1
27 Inlet Anti-Ice Valve 431599
28 RH Fwd Mount Cone Bolt 96013-1
(BAC II Stage 3)
70.01.4 08-01-00 Revision 10

7003
JOB TITLE
SPARE ENGINE ‘C’ CHECK - JT3D-3B/-7
Page 1 of 10
Mechanic Inspector
JT3D-3B / JT3D-7 (Circle One) Serial Number:

Engine TSN: _________ Engine CSN: __________ Engine TSLV: ________ Engine CSLV: _________
General Information
This Job Card is in place to ensure engine inspection when an engine is removed
in a serviceable condition, intended for re-installation on another aircraft. It is
derived directly from the ‘C’ Check Job Card deck and can be referenced directly
to it to determine open items bridging between this document and Job Cards
already issued to the aircraft.
A. OIL FILTER SERVICE 43605
1. Remove main oil filter and disassemble. String discs and wafers on safety
wire and wash with solvent. Strain runoff through a paper disc filter and
check for contamination.
2. Remove the welded fitting from the oil filter cover. Using a new O-ring
(P/N M83248-1-905), install fitting into new filter assembly (P/N 581167).
Tighten and safety.
3. Install new filter into filter housing using new O-ring (P/N M83248-1-
237). Torque sleeve nuts to 25-30 in-lbs and safety (single wire safety is
okay).
4. Check nose bullet attach nut torque (100-140 in-lbs). Notify ATI QC Rep
if not able to reach proper torque. (N/A this step if N1 tach generator is
to be replaced or NGV Isotope Inspection is to be accomplished.)
B. CSD, GEARBOX OIL STRAINER AND STARTER SERVICING 43607
Note: Notify ATI QC Rep if any contamination is found during the
following steps.
1. Remove CSD reservoir drain plug and drain oil through filter paper and
check for contamination. Re-install plug using new O-ring (P/N M83248-
1-111). Then torque to 75-106 in-lbs and safety.
2. Remove magnetic chip detector and check for metal particles. Clean and
re-install plug using new O-ring (P/N MS29561-010). Then torque to 25-
35 in-lbs and safety.
3. Remove charge oil filter and check for contamination. Install serviceable
filter (P/N 7578137) using new O-rings (P/N M83248-1-128, M83248-1-
018, and M83248-1-014). Torque cap screws to 192-216 in-lbs.
4. Remove scavenge oil filter and check for contamination. Install
serviceable filter (P/N 7578137) using new O-rings (P/N M83248-1-133,
M83248-1-018, and M83248-1-014). Torque cap screws to 192-216 in-lbs.
Revision 11 11-01-00 70.01.5

7003
JOB TITLE
Page 2 of 10
Mechanic Inspector
5. Remove CSD output spline cavity fill / check valve and drain oil. Re-
install fill / check valve with new seal NAS1523C7E.
CAUTION: OUTPUT SPLINE CAVITY MUST BE SERVICED
SLOWLY. STOP SERVICING AS SOON AS OIL IS
VISIBLE IN SIGHT GAUGE. IT IS NOT NECESSARY TO
FILL THE SIGHT GAUGE. QUICK SERVICING OR
OVERFILLING CAN LIFT THE MAGNETIC OIL SEAL
OFF ITS SEAT RESULTING IN CSD REPLACEMENT.
6. Slowly service output spline cavity with 2380 oil until oil appears in upper
sight gauge on generator. Install cap on fill / check valve.
CAUTION: DO NOT OVERFILL CSD. OVERHEATING AND
SLUDGING CAUSED BY OVERFILLING CAN RESULT
IN DRIVE DAMAGE.
7. Slowly service CSD reservoir through pressure-fill connector with 2380
oil. Stop servicing when oil first appears in sight gauge. Allow 5 minutes
for oil level to stabilize. Continue to add oil until level stabilizes near
middle of green area on sight gauge.
(-62 or -63 only if nose cowl installed)
8. Check condition of CSD oil pressure switches and harness.
9. Remove gearbox oil strainer and drain oil through paper filter. Then check
strainer and paper for metal or contamination.
10. Clean strainer and re-install using new seal (P/N M83248-1-038), then
torque cap screws (2 each) to 50-60 in-lbs and safety.
11. Remove starter fill port and drain plugs. Drain oil into container.
12. Check magnetic drain plug for metal particles.
13. Clean drain plug and install new crush washer (P/N MS35769-6). Torque
drain plug to 50-70 in-lbs and safety.
14. Service starter with 2380 oil to bottom of fill port threads (approximately
12 fluid ounces).
15. Install new crush washer (P/N MS35769-8) on fill plug and install plug.
Torque plug to 70-90 in-lbs and safety.
70.01.6 11-01-00 Revision 11

7003
JOB TITLE
Page 3 of 10
Mechanic Inspector
C. JFC FUEL LINES CHECK AND FUEL TEMP REGULATOR FILTER CHECK 43608
1. Ensure JFC pressure, inlet, and bypass lines are free from damage caused
by chafing against engine case, clamp contact, scores, and scratches. JFC
line clamps, for security and proper position of the “figure of eight” type
arrangement, by attempting to move them with a rod by using hand press.
2. Open fuel temp regulator drain valve and drain fuel into 5 gallon can.
3. Remove marmon clamp on filter housing. Remove filter and check for
contamination.
4. Install new filter element (P/N 6667621) and cover using new O-ring (P/N
MS29513-153) and ensure drain valve is closed.
5. Install marmon clamp and torque nut to 55-75 in-lbs.
D. IGNITION SYSTEM SERVICE AND AURAL CHECK OF IGNITION OVERRIDE SYSTEM
43609
WARNING: HIGH VOLTAGE CAN BE FATAL.
1. Disconnect ignitor connector at exciter boxes and check for condition of
exciter boxes.
2. Disconnect connector at ignitor plugs and check condition of leads; then
remove ignitor plugs.
3. Apply anti-seize compound to threads then replace left and right ignitor
plugs P/N JB-3. Torque the plugs to 300-360 in-lbs. This must be done
with care to preclude the possibility of dislodging the #4 and / or #5
chambers, causing subsequent damage.
4. Reconnect ignitor leads.
5. Install connector at exciter boxes and safety.
WARNING: DO NOT PERFORM THIS CHECK IF THERE IS ANY
EVIDENCE OR SUSPICION OF FUEL IN THE
ENGINE. SERIOUS INJURY TO PERSONNEL AND
EQUIPMENT COULD RESULT. IGNITION
VOLTAGE CAN BE FATAL.
E. PRBC VALVE SERVICE 43610
1. Disconnect the PS4 line at the bleed valve screen fitting on the diffuser
case, and bleed valve close signal line at the bleed valve.
2. Visually check bleed valve & control actuator for condition & installation.
3. Install purging tool and fill trap end with Stoddard solvent.
Revision 11 11-01-00 70.01.7

7003
JOB TITLE
Page 4 of 10
Mechanic Inspector
4. Connect clean air supply (Min. 20 PSI - Max 100 PSI). Open and close
the valve on the tool to operate and purge bleed valve.
Note: Oscillation or “chugging” of bleed air is normal. Notify supervisor
if valve fails to operate properly.
5. Remove and replace bleed valve screen (P/N 260300) using a new gasket
(P/N 326241) safety housing.
6. Remove the purging tool. Connect signal line and PS4 lines; then safety.
a. Observe that bleed valve is open.
b. Disconnect the PS4 line at the bleed valve screen fitting on the
diffuser case fitting.
c. Disconnect the bleed valve close signal line at the bleed valve.
d. Connect the flex line of the purging tool to the close signal line port
on the bleed valve.
e. Connect the “trap” end of the tool to the PS4 line.
f. Fill “trap” with the required fluid until it overflows.
g. With the valve on the tool “OFF,” attach a regulated pressure
source of clean air or nitrogen to the air chuck on the tool. Have a
minimum of 20 PSI.
CAUTION: PRESSURE MUST NEVER EXCEED 100 PSI.
7. Open and close the valve on the tool to operate bleed valve; purge valve
thoroughly.
a. Opening the tool valve will close the bleed valve.
b. Closing the tool valve will open the bleed valve. CAUTION
c. The bleed valve control will chug, emit vapor, and the bleed valve
butterfly will be heard opening and closing.
(1) Some binding may be associated with the valve itself ( as
differentiated from the control position). In such cases
“assistance” by means of a rod inserted through the cover
screen mesh plus lubrication of the butterfly shaft is permissible
to get the action in step 7-c started. Use LPS-1 or equivalent.
(2) Chattering or oscillation of bleed valve while opening is normal
and to be expected.
(3) Bleed valve should close rapidly and with no hesitation or
oscillation.
d. Verify bleed valve operation is correct and satisfactory.
8. Remove the purging tool; connect and safety the signal and PS4 lines.
70.01.8 11-01-00 Revision 11

7003
JOB TITLE
Page 5 of 10
Mechanic Inspector
F. NOSE COWL, BI-DUCTS, TAILPIPE AND THRUST REVERSER ATTACHMENT
INSPECTION 43614
1. Inspect nose cowl, PT2 pressure probe for security of installation,
condition of interior and exterior skin, and structure visible through access
openings for cracks broken brackets, pneumatic duct damage. (If installed)
2. Inspect tail pipe and exhaust nozzle for general condition and security of
installation.
3. Inspect fan blades for dents, tears, abrasion, looseness, and security of
locks. Inspect inlet guide vanes for cracks and damage.
NOTE A: Unlimited number of blades are permitted to shift 0.030 inches.
NOTE B: Maximum number of 5 blades, of which 3 may be adjacent, are

permitted to shift up to 0.90 inches. Notify supervisor if
additional inspection is required.
4. Inspect entire engine and case sections for general condition and evidence
of any cracking or bulging. Inspect weld areas, which attach strut and
bosses, for evidence of cracking on fan and diffuser cases.
NOTE: If cracks are found, refer to Pratt and Whitney M/M Chapter 72.
Revision 11 11-01-00 70.01.9

7003
JOB TITLE
Page 6 of 10
Mechanic Inspector
5. Inspect all engine components for proper installation, condition, evidence
of fuel leakage, required and correct safeties.
Control and accessory brackets
Hydraulic Pump
Engine Driven Fuel Boost Pump (Nash)
Fuel / Oil Temperature Regulator
Fuel Control Unit
Fuel Flow Transmitter (-62 & -63 only)
Fuel Pressure Transmitter
CSD Oil Cooler and Thermostat (-62 & -63 if nose cowl installed)
Engine Oil Tank
Oil Quantity Transmitter
Generator
Fire Detection Elements
Bleed Air Heat Exchanger
Oil Pressure Transmitter
Oil Pressure Warning Switch
Starter and Shutoff Valve
Pneumatic Pressure Regulator
N2 Tach Generator
12th Stage Bleed Air Check Valve
16th Stage Shutoff Valve
Jet Pump Valve
Anti-Ice Air Regulators
Engine and Nose Cowl Anti-Ice Act. and Valve
Engine Mounts & Links
6. Inspect all tubes, ducts, lines, and wire bundles for chafing, dents, and
breakage.
70.01.10 11-01-00 Revision 11

7003
JOB TITLE
Page 7 of 10
Mechanic Inspector
G. MOUNT INSPECTION
1.
2.
3.
4.
5.
Revision 11 11-01-00 70.01.11

7003
JOB TITLE
Page 8 of 10
Mechanic Inspector
Figure 1
70.01.12 11-01-00 Revision 11

7003
JOB TITLE
Page 9 of 10
Mechanic Inspector
Figure 2
Revision 11 11-01-00 70.01.13

7003
JOB TITLE
Page 10 of 10
Mechanic Inspector
Figure 3
70.01.14 11-01-00 Revision 11

7004
JOB TITLE
COMPONENT CONTROL - CFM56-2 REMOVAL
Page 1 of 4
Mechanic Inspector
Engine Serial Number OFF: __________________ PCI D7256
Removal Reason: _______________________________________________________
Engine TSN: _________ Engine CSN: _________ Engine TSLV: ________ Engine CSLV: _________
Instructions
Sheet will represent the status of the engine after necessary parts have been changed, and after the installed
replacement engine has passed a functional check. Identify unserviceable parts with N/S in the P/N column and
“Green-Tag” the unit on the engine.
Record the P/N & S/N of each component listed. The P/N must be completed only if it is different from the typical
P/N stated. The TSO column will be completed by the Aircraft Records Section. Use the following code for these
exceptions:
#1 - ITEM NOT INSTALLED #2 - P/N OR S/N, NOT LEGIBLE #3 - NO DATA/DATA PLATE
Fax the completed Job Card to the Engine Analyst. Send the original Job Card to Aircraft Records Section along with
the engine change paperwork. The Engine Records Section will file the Job Card in the engine file.
Typical Part Actual
IIN Item Component PCI# Number Part Number Serial Number TSO
716 1 Generator D2402 31229-000
707 2 CSD D2401 698870
724 3 Boost Pump Adapter 0080-0015-1
704 4 Fuel Boost Pump (Nash) D7302 64-1119-4
706 5 Hydraulic Pump D2902 55097-01
717 6 Fuel Pressure 418-01034
Transmitter
710 7 Fuel Flow Transmitter D7303B S34T001-17
8TJ85GAK2
701 8 Starter D8001A 3505154-22
62X 9 TGB 305-100-1??-0
932 10 Main Engine Control D7304 8062-??? /
9275M73P??
8062-??? /
9278M73P??
8063-??? /
9278M47P??
933 11 Main Fuel Pump D7307 704300
301-776-106-0
935 12 Heat Exchanger 69-201-900-4
301-771-402-0
Revision 10 08-01-00 70.01.15

CHAPTER 71 - POWERPLANT
7004
JOB TITLE
Page 2 of 4
Typical Part Actual
IIN Item Component PCI# Number Part Number Serial TSO
Number
937 13 Fuel Servo Heater 45731-1231-2

301-772-901-0
934 14 Lube Unit 301-572-032-0
63X 15 AGB 302-100-???-0
702 16 Starter Valve 397892-1
911 17 Fan Speed Sensor 18E18-1
320-002-502-0
715 18 CSD Oil Cooler D2404 22E14-1
913 19 CIT Sensor 8901-180
9178M37P02
711 20 Hi Stage Bleed Regulator D3605 107464-3
940 21 TCC Valve 7061M31G0?
22 Hi Stage Solenoid Valve 320362-4-1
721 23 Hi Stage Bleed Valve 3214326-2
936 24 R/H VSV Actuator 1211175-7
9971M46P07
728 25 Forward Engine Mount D51B31100-3
D51B31100-1
720 26 Bleed Air Regulator Valve 3214324-2
727 27 Aft Engine Mount D51B31200-3
(Circle One) D51B31200-1
SR08720001-7001
SR08720001-7003
th
718 28 5 Stage Bld Check Valve 3202160-1
916 29 VBV Motor 396800
301-774-705-0
70.01.16 06-01-01 Revision 12


7004
JOB TITLE
Page 3 of 4
Typical Part Actual
IIN Item Component PCI# Number Part Number Serial TSO
Number
30 L/H VSV Actuator 1211175-7

9971M46P07
723 31 Anti-Ice Valve 979904-1
922 32 PMC 7076M20G0?
921 33 Upper Ignition Exciter D7401 83311-45570-1
10-631045-1
921 34 Lower Ignition Exciter D7401 1538M69P01
9238M66P07
9101M52P20
722 35 Oil Qty Transmitter 8TJ99GBN2
703 36 Oil Pressure Transmitter 418-07141

(PPB 71-00-01-1) 418-22044
714 37 Low Oil Pressure 12584
Warning Switch
713 38 Oil Differential Pressure 12583-1
Switch
914 39 T-12 Sensor 301-771-601-0
Revision 12 06-01-01 70.01.17


7004
JOB TITLE
Page 4 of 4
ENGINE SHIPPING / COMPONENT VERIFICATION
P/N AND S/N RECORDING IS NOT REQUIRED ENTER “X” in one block only
IIN Item Component Part Number Installed NOT Installed
96H 1 CSD QAD RING 693608
2 CONTROL ALTERNATOR (N2) 9974M82P02
712 3 OIL TEMPERATURE SENSOR 1122359
709 4 FUEL SHUT-OFF CABLE 7-43933-2
90N 5 MEC POWER CABLE 7-43804-2
731 6 EXHAUST NOZZLE DIFFUSER D51P41102-3
735 7 EXHAUST PLUG (1 pc. Modified) SR08780001-23
8 EGT JUMPER CABLE D51A56107-5
9 EGT L/H HARNESS
10 EGT R/H HARNESS
11 HOSE, FLEX (UPPER) W13-4-0140
12 HOSE, FLEX (LOWER) 92537
13 REG VALVE TUBE D51P58101-23
705 14 HYDRAULIC FILTER 3711826-5001
726 15 TRANSFORMER 5708065-503
16 FIRE LOOP, UPPER
17 FIRE LOOP, LOWER
18 NOSE COWL (Do not ship engine to
repair shop with Nose Cowl
installed.)
70.01.18 06-01-01 Revision 12

7005
JOB TITLE
COMPONENT CONTROL - CFM56-2 INSTALLATION
Page 1 of 3
Mechanic Inspector
Engine Serial Number ON: ___________________ PCI D7256
Engine TSN: _________ Engine CSN: _________ Engine TSLV: ________ Engine CSLV: _________
Instructions
Sheet will represent the status of the engine after necessary parts have been changed, and after the installed engine has
passed a functional check.
Record the P/N & S/N of each component listed. The P/N need be completed only if it is different from the typical
P/N stated. The TSO column will be completed by the Aircraft Records Section.
Fax the completed Job Card to the Engine Analyst. Send the original Job Card to Aircraft Records Section along with
the engine change paperwork. The Engine Records Section will file the Job Card in the engine file.
Typical Part
716 1 Generator D2402 31229-000
707 2 CSD D2401 698870
724 3 Boost Pump Adapter 0080-0015-1
704 4 Fuel Boost Pump (Nash) D7302 64-1119-4
706 5 Hydraulic Pump D2902D 55097-01
739 6 Fuel Filter Pressure 21SN04-384
Switch
717 7 Fuel Pressure 418-01034
Transmitter
710 8 Fuel Flow Transmitter D7303A S34T001-17
8TJ85GAK2
701 9 Starter D8001A 3505154-22
62X 10 TGB 305-100-1??-0
932 11 Main Engine Control D7304 8062-??? / WYG
9275M73P??
8062-??? /
9278M73P??
8063-??? /
9278M47P??
933 12 Main Fuel Pump D7307 704300-?
935 13 Heat Exchanger 69-201-900-4
301-771-402-0
Revision 12 06-01-01 70.01.19


7005
JOB TITLE
Page 2 of 3
Typical Part
937 14 Fuel Servo Heater 45731-1231-2
301-772-901-0
934 15 Lube Unit 301-572-032-0
63X 16 AGB 302-100-???-0
702 17 Starter Valve 397892-1
911 18 Fan Speed Sensor 18E18-1
320-002-502-0
715 19 CSD Oil Cooler D2404 22E14-1
913 20 CIT Sensor 8901-180
711 21 Hi Stage Bleed Regulator D3605 107464-3
940 22 TCC Valve 7061M31G0?
23 Hi Stage Solenoid Valve 320362-4-1
721 24 Hi Stage Bleed Valve D3605A 3214326-2
936 25 R/H VSV Actuator 1211175-7
728 26 Forward Engine Mount D51B31100-3
D51B31100-1
720 27 Bleed Air Regulator Valve D3605B 3214324-2
727 28 Aft Engine Mount D51B31200-3
D51B31200-1
SR08720001-7001
SR08720001-7003
th
718 29 5 Stage Bld Check Valve 3202160-1
916 30 VBV Motor 396800-?
936 31 L/H VSV Actuator 1211175-7
723 32 Anti-Ice Valve D3010 979904-1
922 33 PMC 7076M20G0?
921 34 Upper Ignition Exciter D7401 83311-45570-1
10-631045-1
921 35 Lower Ignition Exciter D7401 1538M69P01
9238M66P07
722 36 Oil Qty Transmitter 8TJ99GBN2
703 37 Oil Pressure Transmitter 418-07141
(PPB 71-00-01-1) 418-22044
70.01.20 06-01-01 Revision 12


7005
JOB TITLE
Page 3 of 3
Typical Part
714 38 Low Oil Pressure 12584
Warning Switch
713 39 Oil Differential Pressure 12583-1
Switch
914 40 T-12 Sensor 301-771-601-0
ENGINE SHIPPING / COMPONENT VERIFICATION

P/N AND S/N RECORDING IS NOT REQUIRED ENTER “X” in one block only
IIN Item Component Part Number Installed NOT Installed
96H 1 CSD QAD RING 693608
2 CONTROL ALTERNATOR (N2) 9974M82P02
712 3 OIL TEMPERATURE SENSOR 1122359
709 4 FUEL SHUT-OFF CABLE 7-43933-2
90N 5 MEC POWER CABLE 7-43804-2
731 6 EXHAUST NOZZLE DIFFUSER D51P41102-3
730 7 EXHAUST AFT PLUG D51P41101-53
729 8 EXHAUST FORWARD PLUG (2 pc.) D51P41101-51
735 9 EXHAUST PLUG (1 pc. Modified) SR08780001-23
10 EGT JUMPER CABLE D51A56107-5
11 EGT L/H HARNESS
12 EGT R/H HARNESS
13 HOSE, FLEX (UPPER) W13-4-0140
14 HOSE, FLEX (LOWER) 92537
15 REG VALVE TUBE D51P58101-23
705 16 HYDRAULIC FILTER 3711826-5001
726 17 TRANSFORMER 5708065-503
18 FIRE LOOP, UPPER
19 FIRE LOOP, LOWER
20 NOSE COWL
Revision 12 06-01-01 70.01.21

INTENTIONAL
BLANK
70.01.22 08-01-00 Revision 10

7006
JOB TITLE
SPARE ENGINE ‘C’ CHECK - CFM56-2
PAGE 1 OF 10
Mechanic Inspector
General Information
This Job Card is in place to ensure engine inspection when an engine is removed in a
serviceable condition, intended for re-installation on another aircraft. It is derived directly
from the ‘C’ Check Job Card deck and can be referenced directly to it to determine open
items bridging between this document and Job Cards already issued to the aircraft.
A. RECORD THE FOLLOWING INFORMATION:
1. Engine Serial Number: ____________________________
2. Removed from aircraft: N _______ Pos: ____ Or (Vendor & W/O): _______
3. TSN: CSN: TSLV: CSLV:
B. BORESCOPE INS-700S-7100
1. Perform Job Card 7203, CFM56-2 BORESCOPE INSPECTION
2. RECORD, first to determine serviceability of basic engine. PASS FAIL
C. AD COMPLIANCE
1. Inspect serviceable engine for the following: (Ref. GMM 6.106)
a. Serviceable vendor tag matches Engine S/N and maintenance release is signed.
b. Inspect engine for missing components, hardware, and clamps.
c. Inspect engine general condition for security, chafing and transport damage.
DOCUMENT DISCREPANCIES ON NON-ROUTINE FORM.
2. Ensure Airworthiness Directive Compliance:
a. AD 82-18-51
Record Starter P/N:_____________________
If Starter P/N: 3505154-18-1 is installed, replace starter with Starter
P/N: 3505154-19-1 series or subsequent approved starter.
b. AD 84-09-04
Locate Hydraulic Control Unit (HCU) on thrust reverser.
Record HCU P/N:____________________
If the HCU P/N C24466000 is installed, replace it with HCU P/N C24466000-2 or
or C24466001-2 or subsequent approved HCU’s. Route HCU P/N: C24466000
to Stores for modification in accordance with SB 78-057.
c. AD 84-26-03
Inspect engine for P/N 9984M90G20 fuel injectors. If these
injectors are installed they must be replaced. Contact Quality
Control if found installed. Are P/N 9984M90G20 injectors
installed? YES NO
d. AD 94-22-07 (supersedes 83-02-05)
Inspect Exhaust Plug Assy. For modifications with DACO SB 78-112 R2.
The assy. can be verified by having three access doors on the forward plug.
SB 78-112 is approved as an alternate means of compliance with AD 83-02-05.
Revision 36 04-06-11 70.01.23


7006
JOB TITLE
PAGE 2 OF 10
Mechanic Inspector
D. VISUAL CHECK OF ENGINE AND ACCESSORIES INS-7001-7102
1. As engine is being serviced, visually check engine and accessories for
condition: fluid leaks, lines, tubing, control cables, rods, and linkages.
a. Engine Inlet area e. Gearboxes and Accessories
b. Electrical (EGT and Fire Loops) f. Oil System
c. Mounts, Fwd & Aft g. Engine and Plumbing
d. Engine Controls h. Turbine area
E. ENGINE GENERAL INSPECTION INS-7001-7102
Perform a visual inspection of the engine, and accessories for condition,
security, and serviceability. Visually inspect the following:
1. Engine Inlet area: Spinner and T12 probe, Fan shroud module and blades,
acoustical panels (fwd, mid & aft), Fan Outlet Guide Vanes and Fan Frame
struts, and Fan inner flow path adapter shroud (stub barrel).
2. Electrical: Electrical harnesses and connectors, EGT (T49.5) probe
harnesses and connectors.
3. Forward and Aft Mount System: pylon bolts, fittings, links, uniball, shear
pin, and shoulder pins.
4. Engine Controls: Teleflex throttle, fuel shutoff, Variable Stator Vane and
Variable Bleed Valve feedback cables.
5. Oil System: Condition of plumbing, quantity and pressure transmitters,
pressure differential switch, temperature and bulb pressure warning switch,
tank and remote fill overflow ports, and fuel / oil heat exchanger. Lube
unit for discoloration.
6. Transfer and Accessory Gearbox: Gearbox mounted accessories including
Starter for discoloration, Starter shutoff valve, gearboxes, mounting
brackets, pins and bolts.
70.01.24 04-06-11 Revision 36

7006
JOB TITLE
JOB CARD REVIEWED BY DATE
PAGE 3 OF 10
Mechanic Inspector
7. Engine and Plumbing: All engine cases, frames and surfaces for cracks,
distortion, and discoloration. VSV hardware and mechanism, VBV gear
motor, doors and hardware, Turbine Clearance Control Valve, fuel lines,
hoses and tubes, ignition system, CSD Oil Cooler, hydraulic plumbing
(inboard engines), case drain and pressure check valves, engine air bleed
and cooling air tubes, Power Management Control.
8. Turbine area: Turbine Frame struts, 4th Stage LPT Blades, flame arrestor
screen (inside center vent tube), exhaust nozzle.
9. N1 Speed Sensor and Control Alternator (N2), for condition and security.
Also check associated wiring for chafing and security.
10. Visually inspect fuel pressure transmitter mounting bracket for cracks
around welds at engine mounting flanges. (See DACO SB 71-99 for
further information.)
F. ENGINE MOUNT INSPECTION INS-7001-7102
At each engine removal the mounts are to be inspected. The level of inspection is
determined by the Time Since Overhaul (TSO). If the TSO is below the
inspection threshold, the mounts will be visually inspected or, if above the
inspection threshold, the mounts will be overhaul inspected. These procedures
are in place to ensure mount inspection when an engine is removed in a
serviceable condition, intended for immediate re-installation.
1. If the engine is UNSERVICEABLE, the mounts are to be inspected by the
engine maintenance facility. Enter two discrepancies on the Non-Routine
form for the mount inspections and leave the corrective action open for the
engine maintenance facility.
N/A steps 2, 3, 4, 5 and 6 below.
2. Locate the S/N of the Aft Mount Assy. on the main fitting and contact
Engine Records Dept. to verify mount S/N times, cycles and TSO.
Aft Mount, Main Fitting P/N: ___________________ S/N: __________
TSN: ___________________
TSO: __________ CSN: _________ Visual Only Overhaul Required

Fwd Mount, Main Fitting P/N: ___________________ S/N: __________
NOTE: Any minor unserialized part replaced in the Aft Engine mount assembly
must be replaced by a new “zero-time” part.
Revision 36 04-06-11 70.01.25

7006
JOB TITLE
PAGE 4 OF 10
Mechanic Inspector
3. If mounts are below the inspection threshold and DO NOT require overhaul
inspection, with the mounts installed, visually inspect the Forward and Aft
assembly for the following:
a. Main Fittings and Links for gouges, nicks, scratches, sharp edges, and
other apparent damage.
b. Bearing assemblies for binding, end play, and excessive radial clearance.
c. Check threaded areas for evidence of wear, damage, stripping and cross-
threading.
d. Shoulder pins for wear.
Record Vendor Work Order: _____________________ as applicable.
Note defects found: _______________________________________________
_______________________________________________
4. Repairs must be made IAW the DC-8-70 Series Overhaul Manual (Fwd
Mount 71-20-3) (Aft Mount 71-20-4). Make entries for mount inspections
on Non-Routine form. N/A step 5 below, if the mounts were visually
inspected and returned to service.
5. If mounts are above the inspection threshold and DO require overhaul
inspection, overhaul inspect each assembly IAW the DC-8-70 Series
Overhaul Manual 71-20-3 & 4 and make entries for mount inspections on
Non-Routine form.
Record Vendor Work Order: _____________________

Note defects found: _______________________________________________
_______________________________________________
6. Create and attach to each mount assembly, an ATI Parts Control Tag (PCT)
with the vendor inspection certification papers. (Reference GMM Chapter
6)
G. VSV LINKAGE INSPECTION INS-7001-7103
1. Inspect bellcrank pins and bolts:
a. Inspect each of the 6 threaded pin locations (IGV and stages 1 and 2
on each side of the HPC) for proper assembly. At the associated
nuts, 2-bolt threads must protrude above the nut and the D-head of
the pin must be seated in the bellcrank.
b. Inspect stage 3 bellcrank attachment bolts for proper thread
protrusion through nuts.
2. Inspect all remaining VSV fasteners:
a. Inspect each of the 8 assembly mounting bolts (4 on each side of
the HPC) for security.
b. Inspect all VSV actuation assembly bolts not previously inspected
for proper thread protrusion through nuts.
70.01.26 04-06-11 Revision 36


7006
JOB TITLE
PAGE 5 OF 10
Mechanic Inspector
3. Inspect for any broken or bent lever arms or pins disengaged from
actuation rings.
H. PERFORM VISUAL CHECK/INSPECTION OF VBV SYSTEM
1. Perform a visual inspection of the engine VBV system per CFM MM-75-
31-00
I. PERFORM VISUAL CHECK/INSPECTION OF VSV SYSTEM
1. Perform a visual inspection of the engine VSV system per CFM MM 72-
32-00.
J. PERFORM VSV ACTUATOR RIG CHECK
1. Perform a VSV actuator rig check per CFM MM 75-32-00.
K. PERFORM VSV AND VBV FEEDBACK CABLE STATIC RIG CHECK
1. Perform VSV and VBV Feedback cable static rig checks per CFM MM
73-21-10.
L. PERFORM VSV FEEDBACK CABLE TRAVEL, PULL AND RESISTANCE CHECK
1. Perform VSV Feedback Cable Travel, Pull and Resistance Check per CFM
MM 75-32-20.
M. PERFORM VBV FEEDBACK CABLE TRAVEL, PULL AND RESISTANCE CHECK
1. Perform VBV Feedback Cable Travel, Pull and Resistance Check per
CFM 75-31-70.
N. CHECK MEC SPECIFIC GRAVITY
1. Check the Specific Gravity setting on the MEC per CFM MM 73-21-10.
O. PERFORM CIT SENSOR CHECK
1. Perform a CIT sensor check per CFM MM 73-21-20.
P. OIL SUPPLY AND SCAVENGE FILTERS SERVICE SVC-7001-2921
1. Remove, check and install oil supply filter.
WARNING: HOT OIL CAN CAUSE DEEP BURNS. AVOID
CONTACT WITH OIL SPLASHED WHEN REMOVING OR
INSTALLING THE FILTER.
NOTE: Consumable oil filter cartridge (P/N 301-535-734-0) is not to be
re-used.
Revision 36 04-06-11 70.01.27

7006
JOB TITLE
PAGE 6 OF 10
Mechanic Inspector
2. Remove, check and install oil scavenge filter.
a. Removal
(1) Place Container and filter paper with the capacity of one U.S.
gallon under filter to collect residual oil in filter.
(2) Remove plugs and allow oil to drain.
(3) Remove and discard O-ring located in plugs shoulder
(4) Remove locking collar.
(5) Insert screwdriver in cover lug holes and pull outward along
the axis of the filters. Remove cover and remove O-ring from
groove. Discard O-ring.
(6) Remove filter and collect filter deposits. If contaminated notify
ATI QC. Do not reuse contaminated or consumable cartridge
type filters.
b. Re-installation of reusable filter.
(1) Install new O-ring (P/N 649-393-119-0), lightly coated with
engine oil, into groove on upper part of filter.
engine oil, into groove on recessed part of cover.
(3) Check position of clogging indicator and, if necessary, reset as
follows:
(a) Remove splined bushing and transparent plug.
(b) Reset by pushing the end near the clogging indicator
with thumb.
(c) Lightly coat threads of splined bushing with engine oil.
Hand tighten splined bushing and transparent plug.
Safety wire splined bushing.
(4) Install filter (P/N 301-535-710-0, alternate P/N QA03522ISS6)
into housing.
CAUTION: ROTATING OF COVER MAY CAUSE DAMAGE TO
FILTER.
(5) Place cover in position and gently push into housing until it
contacts filter housing flange. Do not rotate cover.
(6) Coat inner edges of locking collars with Molykote G Rapid
spray.
(7) Install locking collar and torque bolt to 70-80 in-lbs.
engine oil, onto plug shoulder.
(9) Install plug, torque to 85-93 in-lbs and safetywire.
70.01.28 04-06-11 Revision 36


7006
JOB TITLE
SPARE ENGINE ‘C’ CHECK – CFM56-2
PAGE 7 OF 10
Mechanic Inspector
c. Installation of new main supply or scavenge consumable filter.
(1) Lightly coat 2 new O-rings (P/N 649-393-024-0) with engine
oil and install in grooves of mandrel.
(2) Install filter element (P/N 301-535-119-0 Alternate P/N
CH0451103432NOO) on mandrel, creating filter assembly.
(3) Lightly coat new O-ring (P/N 649-393-119-0) with engine oil
and install it at the top of filter assembly.
(4) Check clogging indicator and reset if necessary per Step b-3.
(5) Install new filter assembly in the recess in housing of lube unit.
(6) Install new O-ring (P/N 649-393-151-0) in groove of filter
cover, lightly coated with engine oil.
CAUTION: ROTATION OF FILTER COVER MAY CAUSE DAMAGE
TO FILTER ASSEMBLY.
(7) Install filter cover in housing of lube unit.
(8) Coat inner edges of coupling clamp with Molykote G Rapid
spray.
(9) Install coupling clamp and torque nut to 70-80 in-lbs.
CAUTION: FAILURE TO INSTALL O-RING SEALS CAN RESULT
IN EXCESSIVE OIL LOSS DURING ENGINE
OPERATION, WITH POSSIBILITY OF ENGINE
FAILURE.
engine oil, onto plug shoulder.
(11) Install plug and torque to 85-93 in-lbs, then safetywire.
Q. STARTER AND CSD SERVICE SVC-7001-7103
1. Starter drain and service (N/A AWC Starters)
a. Remove Starter fill port and drain port plugs. Drain oil into a
calibrated beaker. The minimum acceptable oil quantity is 300 cc.
If less oil is drained the Starter must be replaced. Notify
supervisor if discrepancy is noted.
b. Check magnetic drain plug for metal particles. Notify supervisor
if contaminated.
c. Clean drain plug and install new crush washer (P/N MS35769-6).
Torque drain plug to 50-70 in-lbs and safety.
d. Service Starter with Exxon/BP Turbo Oil (2380) to bottom of fill
port threads. (Use calibrated beaker to insure proper quantity in
Starter.)
e. Install new crush washer (P/N MS35769-8) on fill plug and
install plug. Torque plug to 70-90 in-lbs and safety.
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Mechanic Inspector
NOTE: Notify supervisor if any contamination is found during the
following.
2. Remove CSD reservoir drain plug and drain oil through filter paper.
Check paper for contamination. Re-install plug using new O-ring (P/N
M83248-1-111). Then torque to 25-35 in-lbs and safety.
3. Remove magnetic chip detector and check for metal particles. Clean and
re-install plug using new O-ring (P/N MS29561-010). Then torque to 25-
35 in-lbs and safety.
4. Check CSD filter differential pressure indicators for retracted position.
5. Remove charge oil filter and check for contamination. Install serviceable
filter (P/N 7578137) using new O-ring (P/N M83248-1-128, M83248-1-
018, and M83248-1-014). Torque cap screws to 192-216 in-lbs.
6. Remove scavenge oil filter and check for contamination. Install
serviceable filter (P/N 7578137) using new O-rings (P/N M83248-1-133,
M83248-1-018, and M83248-1-014). Torque filter housing to 192-216 in-
lbs and safety.
7. Remove CSD output spline cavity fill / check valve and drain oil. Re-
install fill check valve with new seal NAS1523C7E.
CAUTION: OUTPUT SPLINE CAVITY MUST BE SERVICED
SLOWLY. STOP SERVICING AS SOON AS OIL IS
VISIBLE IN SIGHT GAUGE. IT IS NOT NECESSARY TO
FILL THE SIGHT GAUGE. QUICK SERVICING OR
OVERFILLING CAN LIFT THE MAGNETIC OIL SEAL
OFF ITS SEAT RESULTING IN CSD REPLACEMENT
8. Slowly service output spline cavity with 2380 oil until oil appears in upper
sight gauge on Generator. Install cap on fill / check valve.
CAUTION: DO NOT OVERFILL CSD. OVERHEATING AND OIL
SLUDGING CAUSED BY OVERFILLING CAN RESULT
IN DRIVE DAMAGE.
9. Slowly service CSD reservoir through pressure-fill connector with 2380
oil. Stop servicing when oil first appears in sight gauge. Allow 5 minutes
for oil level to stabilize. Continue to add oil until oil level stabilizes near
upper limit of green area on sight gauge.
R. CHIP DETECTOR & OIL TANK SERVICE SVC-7001-7900
1. Remove engine oil system Magnetic Chip Detectors (4 each) and strainers.
Check for contamination and metal chips. Notify maintenance supervisor
of any abnormality. Replace O-ring on magnetic plug and re-install plug.
(O-ring P/N 649-393-027-0) -KIT- A.D. 89-23-06.
2. Check that the Fwd. Sump Chip Detector has no unacceptable metallic
debris. Acceptable Unacceptable
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3. Service engine oil tank to full mark on dipstick.
Enter quarts added ________________. (Exxon/BP 2380)
Check O-ring on cap and secure oil cap.
CAUTION: DO NOT OVERFILL. IF TANK IS OVERFILLED,
SCAVENGE PUMP MAY BUILD UP PRESSURE
SUFFICIENT TO RUPTURE TANK.
NOTE: Wait at least 5 minutes after engine shutdown before removing oil
tank cap, but if more than 2 hours have elapsed since engine shutdown,
engine must be motored for 30 seconds prior to servicing oil. (If oil
quantity checks full at tank and no work causing loss of oil has been
performed since shutdown, motoring is not required regardless of time
since shutdown.
S. CFM56 FAN BLADE DOVETAIL LUBE SVC-7001-7221

CAUTION: FAN BLADES SHOULD BE CAREFULLY MARKED
AND SEGREGATED TO INSURE RE-INSTALLATION IN
THE EXACT SAME LOCATION ON THE FAN DISK.
Reference CFM56 MM 72-21-00 and CESM 004
1. Remove spinner front cone. Ref. CFM56 MM 72-21-00.
2. Remove spinner rear cone. Ref. CFM56 MM 72-21-00.
3. Mark all 44 fan blades sequentially with position numbers and remove in
accordance with CFM56 MM 72-21-00.
4. Clean the fan blade dovetails, retainers, and the fan disk dovetail slots with
isopropyl alcohol. A soft bristle clean brush (i.e. toothbrush) may be used
to clean dirt buildup.
5. Inspect disk and fan dovetails for evidence of fretting, worn or missing
coatings, cracks, excessive wear or corrosion in accordance with CFM56
MM 72-21-00.
6. Apply Molykote G (CP2104) in the disk slots and on the blade dovetails
before re-installing blades. Lubricant should be applied liberally to all
dovetail and slot pressure faces. Brush application is preferred, but if
sprayed, a minimum of 4 to 6 passes are required to assure adequate
buildup. Allow to dry to opaque dull finish before re-assembling.
7. Re-install fan blades to exact location from which they were removed. Ref.
CFM56 MM 72-21-00.
8. Ensure all 44 blades, retainers and spacers are correctly installed. (RII
item)
9. Install Spinner Rear Cone.
10. Ensure bolts are torqued to 100-115 in-lbs. Check clearance between rear
cone aft edge and fan blades, Ref. CFM56 MM 72-21-00. (RII item)
11. Install Spinner Front Cone.
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12. Ensure spinner is properly installed and bolts are torqued to 100-115 in-
lbs. (RII item)
T. FUEL FILTER CARTRIDGE SERVICE SVC-7001-7311
1. Comply with ATI “C” Check Job Card SVC-7001-7311. Contact ATI
Q/C for a copy of the current card. Attach completed JC SVC-7001-7311
to this job card upon completion.
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JOB CARDS
70.02 – ENGINE REMOVAL & INSTALLATION
TABLE OF CONTENTS
Job Card Page

7101 ENGINE REMOVAL – JT3D-3B / -7 --------------------------------------------- 70.02.1
7102 ENGINE INSTALLATION – JT3D-3B / -7 -------------------------------------- 70.02.13
7103 ENGINE REMOVAL – CFM56-2 ------------------------------------------------- 70.02.27
7104 ENGINE INSTALLATION – CFM56-2 ------------------------------------------ 70.02.37
7105 MAX POWER ASSURANCE RUN – CFM56-2 -------------------------------- 70.02.51
7106 OFF WING ENGINE T3/T4 DISK REPLACEMENT – JT3D----------------- 70.02.53
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7101
JOB TITLE
ENGINE REMOVAL - JT3D-3B/-7
Page 1 of 11
Mechanic Inspector
1. Engine Serial Number OFF: ___________________
2. Removal Reason: __________________________________________________
General Information
This maintenance practice provides removal instructions for the engines. Instructions
provided are for the bootstrap method of engine removal using currently available
commercial equipment. If other equipment is used it may be necessary to modify specific
procedures. However, all caution and warning notes in these procedures should be
incorporated and strictly observed.
Engine inlet and exhaust covers should be installed prior to engine removal and
installation.
Sign off or stamp in the appropriate column as items are completed. The Inspector
column should only be completed by an ATI authorized RII Inspector.
Note: During the removal process, record hardware/component discrepancies/shortages
on Non-Routine form ATI-018.
Tools and Materials
Note: Equivalent substitutes may be used instead of the following listed items.
Name Part Number
Shipping/Transfer Stand EA6038
Engine Handling Sling C652-7762700HGH1
Engine Adapters EA6003
Engine Covers: Nose Cowl Inlet 5100212
Exhaust Nozzle 5100213 (use from replacement
engine)
Exterior Cover (use from replacement engine)
Torque Wrench Adapters: Front 4897253-2
Rear 4889553-1
Container—Approximately 5 Gallons
CAP Assembly AN929-8J
CAP Assembly AN929 6J
Warning Tag to inform personnel of danger.
References
Job Card 7001, Component Control (Removed Engine)
ATI DC-8 MM Chapter 29, Hydraulic Pump - Removal and Installation.
DACO DC-8 MM 78-30, Translating Ring - Removal and Installation.
Procedure
B. PREPARE AIRCRAFT:
1. Ensure aircraft is parked on a level area. If not on jacks, chock each main gear
securely.
2. Operate reverser translating ring aft with deflector doors faired (doors will remain
faired if pneumatic supply is zero). Place emergency bucket switch to “DUMP”
and tag with appropriate warning tag.
WARNING: MAKE CERTAIN ALL PERSONNEL AND EQUIPMENT ARE
CLEAR OF THRUST REVERSER BEFORE OPERATING
SYSTEM.
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3. Tag and close thrust reverser hydraulic system manual shutoff valve, located in left
main gear wheel well.
4. If inboard engine is being removed:
a. Relieve hydraulic system pressure by operating brakes.
b. Tag auxiliary hydraulic pump switches with appropriate warning tag.
c. Relieve hydraulic reservoir air pressure.
5. Tag and close fire shutoff valves by placing fire control handle, located in flight
compartment, in ‘FUEL AIR & HYD’ off position, tag with warning tag.
6. Tag throttle/thrust reverser lever and open the following circuit breakers.
NOTE: Numbering on circuit breaker panel denotes engine position. All are found on
the main panel.
Circuit Breaker Section
Auxiliary Hydraulic Pump Control (inboard engines only) Cabin bus 4
Static Ignition Inverter or Ignition Power Supply Control Battery bus
Static Ignition Inverter Control or Ignition Power Supply Control Battery bus
Engine Starters Battery bus
Engine Ignition AC bus 1, 2, 3, or 4
Generator Control Battery bus
Engine Anti-Ice DC bus 1 or 4
Pneumatic Crossfeed Valve DC bus 4
Jet Pump Valves DC bus 4
Engine Low Pressure Pneumatic Control DC bus 1 and 4
Takeoff Warning and Jet Pump Shutoff Arming DC bus 1
Engine Fuel Temperature DC bus 1
Standby Thrust Brake Hydraulic Pump Control AC bus 3
Thrust Brake Hydraulic Control Valve DC bus 4
Thrust Brake Hydraulic Control Relay DC bus 4
Generator Drive and Engine Oil Temperature DC bus 1 and 4
CSD Disconnect DC bus 1 and 4
Engine Oil Quantity DC bus 1 and 4
Engine Oil Pressure and Generator Drive Oil Warning Lights DC bus 1 and 4
Engine Hydraulic Pump Bypass (inboard engines only) DC bus 1
Engine Low Pressure Pneumatic Temperature Control AC bus 1, 2, 3, or 4
Engine Fire Detector AC bus 1, 2, 3, or 4
Engine Fuel Flow AC bus 1, 2, 3, or 4
CAUTION: MAIN LANDING GEAR WHEELS SHOULD BE CHOCKED BEFORE
REMOVING ENGINE.
C. OPEN ENGINE:
NOTE: Place removed parts on support stands or racks. Handle parts carefully to
prevent damage.
1. Remove nacelle doors.
a. Disconnect drain and compartment cooling air hoses from left aft door.
b. Remove forward and aft doors.
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2. Reverser translating ring lower track: (see Figure 2)
a. Remove reverser actuator rod end bolt and lower stop at forward link.
b. Remove the lower track from the engine and carefully slide it aft into the translating
ring as far as possible. Manually push translating ring against the aft stop.
3. Remove fan air ducts in accordance with ATI DC-8MM 71.03.
WARNING: BURBANK STAGE III HUSHKIT BI-DUCTS WEIGH
APPROXIMATELY 111 LBS.
4. Remove nose dome and extension in accordance with ATI DC-8MM 71.03.
5. Remove nose cowl in accordance with ATI DC-8MM 71.03.
6. Inspect nacelle doors, nose cowl, fan air ducts, and nose dome and extension for
damage. Repair as necessary.
D. DISCONNECT AT PYLON:
CAUTION: TO PREVENT DAMAGE TO FLUID LINES, PNEUMATIC DUCTS,
ELECTRICAL RECEPTACLES, AND TO PREVENT CONTAMINANTS
FROM ENTERING FUEL, OIL, HYDRAULIC, GENERATOR COOLING
INLET, AND PNEUMATIC SYSTEMS, MAKE CERTAIN ALL OPEN
LINES, DUCTS, AND RECEPTACLES ARE CAPPED.
1. Turn electrical power OFF.
2. Disconnect six electrical connectors at pylon (3 on right, 2 on left, and 1 aft of nose
cowl) (see Figure 3 view A, B, C)
3. Restore electrical power to aircraft as required.
4. Disconnect fuel lines and install protective covering.
5. Drain main fuel line by removeing plug from pipe at boost pump, left side of engine.
(Approximately 5-7 gallons.) (see Figure 3, view D)
6. Disconnect main fuel supply and fuel vent lines at pylon. (see Figure 4, view A-A)
7. Disconnect/remove hydraulic system units. (INBOARD ENGINES ONLY)
8. Disconnect hydraulic supply and return hoses at pylon. (see Figure 4, view A-A)
9. Remove supply, pressure, and return hoses necessary for replacement engine.
10. Remove hydraulic pump with filter assembly and install pad cover.
11. Cap openings and retain units for installation on replacement engine
¾ N/A this step if position is outboard.
½
CAUTION: MAKE CERTAIN SPILLED HYDRAULIC FLUID IS CLEANED UP
IMMEDIATELY TO PREVENT DAMAGE TO ACCESSORIES OR
ELECTRICAL WIRING
Disconnect pneumatic ducts and lines. (see Figures 4, 5, & 6)
12. Remove clamp and disconnect starter duct at pylon.
13. Remove clamp and disconnect nacelle bleed air duct at pylon.
14. Remove and disconnect engine fan cooling air duct at pylon.
15. Loosen B-nut and disconnect two pneumatic regulator sense lines at pylon, right side
above compressor case forward of engine mount.
16. Loosen B-nut and disconnect reverser interlock air hose at pylon. Disconnect strut
drain and EPR lines. (see Figure 4 view A-A, B, C, & Figure 5)
17. Disconnect two pylon drain lines, one from left side of disconnect box and one
from lower side of pylon.
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18. Disconnect two EPR transmitter lines at pylon.
CAUTION: TO PREVENT DAMAGE TO FLEXIBLE HOSES AND ENGINE,
HOSES MUST BE DISCONNECTED FROM PYLON INTERFACE
BEFORE LOWERING ENGINE.
E. DISCONNECT ENGINE CONTROLS:
DISCONNECT THE ENGINE FUEL SHUTOFF AND THROTTLE CONTROL RODS
AT PYLON CRANKS. (see Figure 6)
NOTE: Do not alter rod lengths.
F. INSTALL ENGINE HOIST EQUIPMENT: (Ref. DC-8 MM 71.03)
1. Check equipment for serviceable condition prior to use.
a. Hoist equipment.
b. Engine adapters.
2. Install engine adapters and sling.
a. Install right front adapter and spreader bars an assembly.
b. Install left front adapter using caution to prevent damage to oil tank sump
and/or lines.
c. Raise spreader bar and attach left front adapter to right front adapter and
spreader bar assembly.
NOTE: Be certain adapter-to-engine flange bolts are tight.
d. Install left and right rear adapters and spreader bar as an assembly.
e. Attach engine sling to adapters, being certain sling is attached to hoist at aft
shackle. Short cables attach to forward adapters. Long cables attach to aft
adapters.
G. REMOVE ENGINE FROM PYLON:
1. Loosen the Forward and Aft mount nuts to obtain 1/16 inch gap between engine
mounts and pylon.
2. Carefully operate manual hoists upward until hoists have assumed engine weight
without closing gap. This is confirmed when all bolts unscrew freely without an
increase in dimension of gap.
CAUTION: IT MAY BE NECESSARY TO USE SAND BAGS TO BALANCE THE
ENGINE IN THE SLINGS TO PREVENT DROPPING. APPROXIMATE
WEIGHT OF ENGINE, SLING AND ADAPTERS IS 7600 POUNDS.
NOTE: If a fork lift is used, bring it in at a 45º angle to the engine. Use side shift and
move lift for fore and aft movement.
3. Remove three mount nuts and lower engine to clear mount fittings. Move the
engine forward so exhaust cone will clear translating ring. Make certain electrical
connectors, fluid lines, and pneumatic ducting clear pylon mount support and
structure.
NOTE: When lowering engine, guide it carefully to clear pylon fittings. Also verify all
disconnects were made.
4. Operate manual hoists simultaneously and lower engine onto engine stand. Secure
engine to stand.
5. Operate manual hoists to relieve tension on load chains and disconnect hoisting
brackets from cradle.
6. Install Aft Mount shipping support to engine stand.
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Mechanic Inspector
7. Attach mount nuts to return with engine.
8. Install nose cowl inlet and exhaust nozzle covers.
H. CLEAN AND INSPECT PYLON AREA:
1. Thoroughly wash pylon structure exposed by removed engine.
NOTE: Ensure all lines and plugs have been properly capped off.
2. Inspect the following areas:
a. Inspect engine controls and cables, fairleads, pulleys and brackets in the pylon
area for security, condition and excessive wear.
b. Inspect pylon structure for condition.
c. Inspect the forward and aft pylon-to-engine attach fittings for cracks. Ensure
that shear pins are installed and secure.
d. Inspect electrical connectors, wires and fire warning system for security and
general condition.
e. Inspect fuel and hydraulic fire shutoff valves for evidence of leakage.
f. Inspect all firewall pneumatic hook-ups and hydraulic fittings for condition and
security.
3. Inspect pylon thrust links IAW Douglas Service Bulletin 54-92 as revised for
defects. Indicate below what part number links are installed. Pay particular
attention to the bottom flange of the link for chafe damage.
Unmodified P/N 5753005________ Modified P/N SR008540002________
A modified link may be identified by three HL426-6-5 Hi Locs being installed in
area A of Figure 1.
MODIFIED THRUST LINK

Figure 1
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Mechanic Inspector
I. COMPLETION:
1. Complete Component Control Job Card 7001 AFTER all parts needed for the
replacement engine have been removed.
2. If the engine was removed in a SERVICEABLE condition, N/A this step.
a. Attach completed “Green Tag” to engine.
b. Attach duplicate Non-Routines and Component Control Job Card 7001.
3. If the engine was removed in a UNSERVICEABLE condition, N/A this step.
a. Attach completed “Continued-Time” PCT to engine.
b. Attach duplicate of any Non-Routines generated against the engine.
c. Attach duplicate of Component Control Job Card 7001.
4. Prepare the removed engine for shipment.
a. Ensure all plugs, caps, blanking plates, and covers are installed on the engine.
b. Wrap the engine in plastic or install a full tarp on the engine.
c. Obtain the correct shipping information and complete a shipper and/or bill of
lading as directed by Maintenance Control/Planning.
Only Graphics Follow
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TRANSLATING RING LOWER TRACK

Figure 2
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Figure 3
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Mechanic Inspector
PYLON CONNECTIONS
Figure 4
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Mechanic Inspector
Figure 5
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Figure 6
Revision 23 12-07-05 70.02.11

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70.02.12 12-07-05 Revision 23

7102
JOB TITLE
ENGINE INSTALLATION - JT3D-3B/-7
Page 1 of 14
Mechanic Inspector
Engine Serial Number ON: __________________________
General Information
This maintenance practice provides installation instructions for the engines. Instructions
provided are for the bootstrap method of engine installation using currently available
commercial equipment. If other equipment is used, it may be necessary to modify specific
Engine inlet and exhaust covers must be installed prior to engine installation.
Sign-off or stamp in the appropriate column as items are completed. The Inspector
NOTE: During the engine installation process, record hardware/component
discrepancies/shortages on Non-Routine form ATI-018.
Tools and Materials
NOTE: Equivalent substitutes may be used instead of the following listed items.
Name Part Number Manufacturer
Engine Handling Sling C652-7762700HGH1
Engine Adapters, Set EA6003
Torque Wrench Adapters:
a. FRONT 4897253-2
b. REAR 4889553-1
Torque Wrench, 500 FT / LBS
Rig Pin, ¼ inch X 8 inch
MATERIALS:
Grease, MIL-L-25681
Oil, EXXON/BP 2380, 2 Cases
Nut, 2 ea. FN922-1414
Nut, 1 ea. FN922-1216
O-Ring, 1 ea. MS29512-4
Packing, 1 ea. 2033-226
Gask-O-Seal, 1 ea. 460-715-32
References
Job Card 7301, Intermix -3B & -7 Engines-Required
Job Card 7002, Component Control (Installed Engine)-Required
ATI DC-8 MM Chapter 71 for Hush Kit Procedures
ATI DC-8 MM Chapter 29 for Hydraulic Pump Removal and Installation
Procedure
B. ENGINE - RECEIVING INSPECTION:
a. Serviceable vendor tag matches Engine S/N and the maintenance release is
signed.
b. Inspect engine for missing components, hardware and clamps.
c. Inspect engine general condition for security, chafing, and transport damage.
d. DOCUMENT DISCREPANCIES ON NON-ROUTINE FORM (Form ATI-018).
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Mechanic Inspector
NOTE: Aircraft with BAC II, Stage 3 Hush Kits require a special Barry Controls P/N:
96013-1 right-hand, forward Cone Bolt. This bolt is serialized and life limited.
Ref. ATI DC8 MM Effectivity and 71.03.
2. Ensure Airworthiness Directive Compliance with AD 95-09-09.
Record Fwd, RH Cone Bolt P/N: ______________ and S/N: ___________
(4 digits)
If Cone Bolt BACII P/N DC-8-21005-7 is installed, replace it with Barry
Controls P/N 96013-1.
WARNING : IT IS NECESSARY TO REPLACE THE RIGHT FORWARD CONE
BOLT, DOUGLAS P/N 4775516-501 OR BAC II P/N DC-8-21005-7, WITH THE
HIGHER STRENGTH BARRY CONTROL P/N 96013-1, ON ALL BURBANK
STAGE 3 HUSHKIT AIRCRAFT.
Reference ATI DC-8 MM Chapter 71.
3. Locate Cone Bolt NDT tag in the vendor’s engine certification papers and ensure
S/N of bolt matches S/N on tag. S/N should be 4-digits.
4. MOUNTS CHECK RUNNING TORQUE NO LUBRICANT. Bolt & nut must
be
kept as a set once running torque checks have been made.
Running Torque Range
Nut or Bolt Size Minimum Maximum
1/2-inch 18 inch-lbs 150 inch-lbs
Minimum and Maximum Running Torque Range for Bolt and Self-locking Nut
Installation
5. COMPLETE ENGINE INVENTORY Job Card 7002.
C. PREPARE AIRCRAFT:
1. Ensure throttle/thrust reverser lever is tagged and circuit breakers are open and
tagged per Job Card 7101.
2. Ensure thrust reverser hydraulic system manual shutoff, normal and emergency stow
valves, located in the left main gear wheel well are closed and tagged.
3. Ensure following levers are in positions indicated.
a. THROTTLE............................................IDLE
b. THRUST REVERSER LEVER .............FORWARD THRUST
c. FUEL SHUTOFF LEVER......................FUEL OFF
CAUTION: MAIN LANDING GEAR WHEELS SHOULD BE CHOCKED BEFORE
INSTALLING ENGINE.
D. INSTALL ENGINE HOIST EQUIPMENT:
1. Install engine hoist per Job Card 7101.
2. Remove aft engine shipping support.
3. Position dolly or trailer with engine and cradle installed under pylon.
4. Install sling on engine.
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5. Carefully operate hoists to assume weight of engine, checking again for proper
rigging and cable chafing.
WARNING: ENSURE HOISTS ARE OPERATED TO KEEP ENGINE AT LEVEL
ATTITUDE. APPROXMATE WEIGHT OF ENGINE, SLING, AND
ADAPTERS IS 7600 POUNDS.
6. Operate hoists simultaneously and raise engine up to approximate position for
installation making certain electrical connectors, flexible lines, and piping are clear.
E. INSTALL ENGINE TO PYLON:
1. Lightly coat Forward and Aft mount bolt shanks and threads with oil (MIL-L-
25681).
2. Align engine mounts, raise engine and install washers and nuts.
3. Torque engine mount nuts:
a. Forward, right-hand (P/N 96013-1) ....400-420 foot/pounds.
b. Forward, left-hand ..............................325-375 foot/pounds.
c. Aft ....................................................225-275 foot/pounds.
4. Release weight of engine and remove lifting sling and adapters.
5. Install nose dome, nose dome extension, and nose cowl IAW DC-8 MM Chapter 71.
NOTE: Check firex discharge tube on right side of pylon, verify minimum 3/32 inch
clearance exists with engine bleed air duct in forward engine mount area. Check
firex discharge tube on left side of pylon forward of engine mount. Verify
minimum 3/32 inch clearance exists with engine anti-ice duct.
F. CONNECT AT PYLON:
1. Connect fuel and hydraulic lines. See Figure 1
a. Fuel supply line with new seal. Tighten flange mounting bolts.
b. Fuel vapor return line. Tighten B-nut.
c. Inboard engine only: IAW DC8 MM Chapter 29.
1. Hydraulic suction line.
2. Hydraulic pressure and case drain lines at check valve.
2. Connect the following pneumatic ducts and lines. See Figure 2
a. Starter duct. Tighten clamp.
b. Bleed air duct. Tighten clamp.
c. Engine fan cooling air duct. Tighten clamp.
d. Pneumatic regulator sense lines (2 ea.) Tighten B-nuts.
e. Reverser interlock air hose. Tighten B-nut.
3. Connect strut drain and EPR lines. See Figure 1
a. Connect and tighten strut drain lines (left and right side of pylon disconnect box)
b. Connect and tighten two EPR sense lines at pylon. (PT2 & PT7)
4. Connect electrical connectors. See Figure 2
a. Connect six electrical connectors (3 on right, 2 on left, and 1 aft of nose cowl).
Tighten and safety connectors.
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Mechanic Inspector
G. CONNECT ENGINE CONTROLS: See Figure 3
1. IN COCKPIT, gust lock OFF, fuel shutoff lever to FUEL ON, throttle Part Power
stop using fixture (65F1973) if fixture is not available, position throttle 3” (± 1/32”)
forward of idle position.
NOTE: Lever position must be measured on surface of control pedestal.
2. AT PYLON, insert ¼” rig pin through access door into power control drum. Rig pin
access door is located on right side of the pylon box forward of power lever and fuel
shutoff cranks. (SPRING-LOADED DOOR)
NOTE: This step verifies airframe rigging from the throttle lever to the main power
control drum in the pylon. Consult applicable maintenance manual if the rig pin
cannot be inserted.
3. AT THE FUEL CONTROL, rotate Part Power stop into the Part Power position.
Hold the control lever of the fuel control against the Part Power stop and adjust
the length of the UPPER THROTTLE PUSH ROD until the bolt can be inserted
through the throttle crank freely. Tighten nut and safety. Hold the fuel shutoff
lever of the fuel control against the FUEL ON stop. Adjust the fuel shutoff
UPPER CONTROL ROD until the bolt can be inserted freely through the fuel
shutoff crank. Finger tighten nut.
4. Remove rig pin and recheck rigging as follows:
a. Loosen throttle fixture.
b. Exercise throttle from idle to the Part Power position several times.
c. Exercise fuel shutoff lever from ON to OFF several times. Move lever to the
OFF position.
d. Move throttle to the Part Power position, allowing the throttle lever to relax
against the fuel control Part Power stop. Slide fixture back into position. The
stop index mark must line up with the index mark of the fixture bar ± 1/32”.
e. Remove fixture.
5. Stow fuel control Part Power stop. Do not safety at this time.
6. Check throttle system:
a. Exercise the throttle from idle to full power several times.
b. At the fuel control, ensure fuel control power lever contacts the full power stop.
c. In cockpit, check throttle lever ability to operate smoothly and unrestricted.
Throttle lever has ‘cushion’ at both extremes of travel.
d. Position throttle lever to idle.
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7. Check fuel shutoff system.
a. Exercise fuel shutoff lever several times.
b. Position fuel shutoff lever to ON.
c. Check fuel shutoff lever on fuel control contacts stop with ‘cushion’. If not,
remove bolt from fuel shutoff lever and LENGTHEN rod one complete turn.
Install bolt and tighten nut. Safety with cotter pin.
d. Position fuel shutoff lever to OFF.
8. Tighten jamb nuts on fuel shutoff and power lever control rods, then safety.
9. Check thrust reverser system.
a. Connect nose gear steering torque links or simulate compressed strut condition.
b. Ensure thrust reverser shutoff valve is CLOSED and NO hydraulic pressure to
the reverser system.
c. Exercise thrust reverser lever from REVERSE IDLE to FULL REVERSE
POWER. Operation smooth and unrestricted.
d. Install gust lock.
10. Check calibration of EGT system using Barfield EGT Test Box or Wheatstone
Bridge as follows:
a. Remove EGT indicator from engine instrument panel.
b. Remove one cable from EGT indicator and read system ohm value. Resistance
should be 22 ±0.05 ohms. If within limits, reinstall indicator. Refer to
applicable maintenance manual if reading is not within limits.
11. If required, install the following in accordance with ATI DC-8MM 71.03:
a. Fan Air Duct
b. Inlet
c. Bullet
12. Connect reverser translating ring.
a. Push reverser translation ring forward and connect upper cylinder rod end to
translating ring.
b. Tighten rod-end through-bolt to 600-800 inch/pounds.
c. Connect lower link at forward link and tighten retaining nut.
H. CHECK SYSTEMS:
NOTE: Set up ground communication between the cockpit and one person stationed at
the engine.
1. Check ignition system as follows:
a. Remove tags and reset circuit breakers for applicable engine to be tested.
CAUTION: ENSURE ALL OTHER PERSONNEL ARE CLEAR AND NO FIRE
HAZARDS EXIST.
b. Place ignitor selector to BOTH.
c. Place ignition override switch to OVERRIDE.
d. A cyclic ‘crack’ of both ignitor plugs should be clearly heard.
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2. Check fuel system as follows:
a. In cockpit, pull fire shutoff lever to ‘FUEL AIR & HYD’ to close shutoff valves
and turn Boost Pump switch ON. Check that no pressure is indicated on engine
fuel pressure gauge. If fuel pressure is indicated, recheck fire shutoff rigging.
b. Return fire shutoff lever to NORMAL to pressurize engine fuel system.
c. Check engine fuel lines, connections, and units for no leakage.
d. Turn Boost Pump switch OFF.
NOTE: Reset applicable circuit breakers as tests are being completed.
3. Check CSD shaft disconnect as follows:
a. Observe generator drive oil light illuminated.
b. Pull disconnect handle on bottom of CSD lightly until handle bottoms. Hold
handle lightly in this extended position.
c. Actuate and release flight compartment CSD disconnect switch.
d. CSD disconnect handle on bottom of CSD should pull in by spring action. Allow
handle to move in.
e. Pull CSD disconnect handle out until an audible ‘click’ is heard indicating the
disconnect is latched out.
NOTE: A reduction in pull force required on CSD disconnect handle is also evidence
that disconnect is latched out.
4. Perform fire warning test per JRH 2-2-1.
5. Check pneumatic system as follows:
a. Connect air supply to airplane and pressurize ducting on engine.
b. Check for any audible leaks in pylon and ducting on engine.
c. Test engine inlet and nose cowl anti-ice system for proper operation.
CAUTION: ENSURE REVERSER IS CLEAR OF PERSONNEL AND EQUIPMENT
AND THE REVERSER SHUTOFF VALVE IS CLOSED.
6. Thrust reverser check.
a. Ensure thrust reverser and main hydraulic systems are depressurized.
b. Remove thrust reverser lock.
c. Check controls:
1. Reverser lever corresponds with reverser.
2. Emergency dump switch is in NORMAL and guarded position.
d. Thrust reverser lever to forward thrust.
e. Slowly open reverser shutoff valve. After reverser movement stops, open valve
fully.
f. Thrust reverser lever to reverse idle.
g. Check thrust reverser indications.
1. Flashing during transition.
2. Steady light with translating ring full aft and buckets deployed.
h. Emergency dump switch to DUMP.
CAUTION: BUCKETS WILL SNAP TO STOWED POSITION WITH
APPROXIMATELY 1300 LBS. OF SPRING FORCE.
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i. Emergency dump switch to NORMAL.
j. Close thrust reverser shutoff valve.
k. Hydraulic pump OFF.
l. Depressurize pneumatic manifold.
m. Install thrust reverser lock.
I. SERVICE:
1. CSD (Exxon/BP 2380)
a. Slowly fill CSD until oil appears at bottom of oil level sight glass. STOP. Allow
three minutes for oil level to stabilize, continue to service slowly until oil
stabilizes near middle of green operating band.
CAUTION: DO NOT OVERFILL CSD AS OVERHEATING AND OIL SLUDGING
CAN OCCUR CAUSING DAMAGE TO THE CSD.
b. Fill CSD input spline cavity.
1. Remove input spline cavity oil stand-pipe plug.
2. Remove pressure-fill cap located aft right side of CSD transmission.
3. Service input spline cavity through pressure-fill port until oil flows out of the
stand-pipe.
NOTE: MAX fill pressure 40 PSI.
4. Replace as necessary, O-ring installed on stand-pipe plug. Install and safety.
5. Install pressure-fill port cap.
c. Fill CSD output spline cavity.
1. Remove pressure-fill cap located forward left side of CSD transmission.
2. Service output spline cavity until oil appears in upper sight glass.
NOTE: MAX fill pressure 27 PSI.
3. Remove pressure-fill hose and install pressure-fill cap.
CAUTION: THE OUTPUT SPLINE CAVITY MUST BE FILLED SLOWLY. STOP
SERVICING AS SOON AS OIL APPEARS IN THE SIGHT GLASS. IT
IS NOT NECESSARY TO COMPLETELY FILL THE SIGHT GLASS.
QUICK SERVICING OR OVERFILLING CAN LIFT THE MAGNETIC
SEAL OFF ITS SEAT CAUSING AN OIL LEAK AND SUBSEQUENT
CSD REPLACEMENT.
2. Service starter (Exxon/BP 2380). Remove starter oil fill plug, add oil until oil level
reaches the fill plug O-ring if necessary. Install plug and safety.
3. Service engine oil tank (Exxon/BP 2380). Service engine oil to FULL mark on
dipstick.
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4. Service main hydraulic reservoir (HYJET IV).
a. Service reservoir to FULL mark according to installed placard.
b. Service reservoir head pressure with dry nitrogen.
5. Lubricate thrust reverser.
a. Lube upper and lower tracks.
b. Lube stow latch mechanisms and actuator.
c. Lube gripper mechanism.
J. LEAK CHECK:
1. Wet-Motor engine per ERH 71.01. (Authorized personnel only)
2. Check CSD oil system per ERH 24.01.
3. Check for evidence of fuel, oil, and hydraulic leaks.
4. Check oil level.

a. Check oil tank level to bottom of filler neck opening. Add Exxon/BP 2380 as
required.
b. Ensure CSD oil level is in middle of green band. Add Exxon/BP 2380 as
required.
5. Oil quantity indicating system.
NOTE: Accomplish within 15 minutes after final oil tank level check.
a. Ensure cockpit indicator reads within ½ gallon of 5.2 gallons.
b. If adjustment is required, calibrate system.
6. Comply with ATI recurring non-routine job cards.
a. Install transition duct IAW DC8 MM Chapter 71.
b. Install constant section duct IAW DC8 MM Chapter 71.
c. Install right and left hand aft cowl doors and drain lines.
d. Install forward cowl doors. Position cowl doors open using hold-open rods.
NOTE: Ensure cowl pins are serviceable and installed pointing AFT.
WARNING: BURBANK STAGE 3 HUSH KIT BI-DUCTS WEIGH
7. Adjust reverser. REMOVE THRUST REVERSER LOCK PRIOR TO
OPERATING REVERSER.
a. Using manual shutoff valve in wheel well, slowly operate translating ring
forward and check clearance to aft engine cowl door. Adjust as required. Refer
to DC-8 M/M chapter 71.
b. Adjust lower track stop.
1. Loosen track stop. Operate translating ring to full aft position using full
hydraulic pressure.
2. Mark location of aft face of slide on bottom of lower track surface.
3. Using manual shutoff valve in wheel well, slowly move translating ring
forward approximately 6 inches.
4. Install and tighten stop with forward end ¼ inch forward of mark on track.
c. Check reverser operation. Leave reverser in stowed position after compliance.
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K. FINAL INSPECTION:
1. Inspection of engine installation:
a. Security of plumbing, conduits, hardware, and safeties.
b. Chaffing of plumbing, conduits, and moving parts.
2. Inspect pylon area:
a. Security of control rods, linkages, conduits, and hardware.
b. Chaffing of moving parts, cables, and conduits.
c. Check forward cowl door attach pins, pointing aft and lock balls visible.
3. Inspect thrust reverser:
a. Check thrust reverser and aft cowl fit.
b. Disturbed mechanisms for lubrication, installation, and missing safeties.
4. Remove tags from throttle/thrust reverser lever and close the following circuit
breakers:
Circuit Breaker Panel Section
Auxiliary Hydraulic Pump Control (Inboard Engines Only). Main Cabin Bus 4
Static Ignition Inverter or Ignition Power Supply. Main Battery Bus
Static Ignition Inverter Cntrl or Ignition Pwr Supply Cntrl Main Battery Bus
Engine Starters Main Battery Bus
Engine Ignition Main AC Bus 1, 2, 3, 4
Generator Control Main Battery Bus
Engine Anti-Ice Main DC Bus
Pneumatic Crossfeed Valve Main DC Bus 4
Jet Pump Valves & Oil Cooler Door Override Main DC Bus 4
Engine Low Pressure Pneumatic Control Main DC Bus 1 & 4
Takeoff Warning and Jet Pump Shutoff Warning Main DC Bus 1
Engine Fuel Temperature Main DC Bus 1
Engine Pressure Ratio Probe Heater Main DC Bus 1 & 4
Standby Thrust Brake Hydraulic Pump Main AC Bus 3
Thrust Brake Hydraulic Control Valve Main DC Bus 4
Thrust Brake Hydraulic Control Relay Main DC Bus 4
Generator Drive and Engine Control Main DC Bus 1 & 4
CSD Disconnect Main DC Bus 1 & 4
Engine Oil Quantity Main DC Bus 1 & 4
Engine Oil Pressure & Generator Drive Oil Warning Lights Main DC Bus 1 & 4
Engine Hydraulic Pump Bypass (Inboard Engines Only) Main DC Bus 1
Engine Low Pressure Pneumatic Temperature Control Main AC Bus 1, 2, 3, 4
Engine Oil Cooler Door Control Main AC Bus 1, 2, 3, 4
Engine Fire Detector Main AC Bus 1, 2, 3, 4
Engine Fuel Flow Main AC Bus 1, 2, 3, 4
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L. PERFORM ENGINE TEST RUN IAW JET RUN-UP HANDBOOK:
NOTE: Is this a -62 aircraft? Yes No
If YES, Job Card 7301 must be complied with. Attach Job Cards 7301 & 7701.
CAUTION: SET UP GROUND COMMUNICATION BETWEEN COCKPIT AND
GROUND MAN.
NOTE: It may be necessary to advance throttle to obtain idle RPM, as a safety precaution,
start an opposite wing engine to supply hydraulic and electrical power.
1. Allow engine to warm up for 5 minutes. During this time perform the following
checks.
a. ERH 36.01, Check pneumatic ducts and valves for proper operation and leaks.
b. ERH 29.01, Check hydraulic pump. (INBOARD ENGINES ONLY)
c. ERH 24.02, Check generator operation.
d. Check jet blowaway operation.
2. Engine trim:
a. Accelerate engine from idle to Part Power three times and return to idle.
NOTE: This will clear air and preserving oil from engine.
b. Adjust idle RPM per ERH 72.06.
c. Advance throttle to Part Power stop and adjust fuel control per ERH 72.05.
d. Record Fuel Control Trim Clicks, up or down:
1. _______________ 2. _______________ 3. ______________ 4. ______________

NOTE: -7 engines intermixed with -3B engines must be trimmed to -3B thrust (-62 only).
e. Recheck engine idle.
f. Stow and safety Part Power stop.
g. Close and secure forward engine cowls.
h. Obtain takeoff EPR per ERH 90.02:
1. Moderately advance throttle to obtain takeoff EPR. At takeoff EPR mark the
forward edge with a piece of masking tape. Return throttle to idle.
2. Rapidly advance throttle to the position obtained in step (1) and time
acceleration to takeoff power.
NOTE: Longer than 12 seconds is considered long.
i. Return throttle to idle and allow engine to cool for 3 minutes.
j. Shutdown engine per ERH 70.01.
3. Open engine cowls and inspect the following:
a. Part Power stop stowed and safetied.
b. No fluid leaks.
c. Engine installation complete.
4. Complete Component Control Job Card 7002.
5. Close and secure engine cowls.
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M. COMPLETION:
1. Enter in logbook compliance with this Job Card and any other Job Card issued since
determination of engine removal. Ensure that engine position and serial numbers
OFF & ON are recorded on the logsheet.
2. Request crew to perform “NO NOISE TRIM” procedure per ERH 72.02 on
outbound logsheet.
Figure 1
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Figure 2
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Figure 3
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NOTE: Whenever possible, the center line of the adapter should be used in one of two
positions within 10 degrees in relationship to the axis of the torque wrench.
1: One position is to have the adapter center line at right angles to the center line of the
torque wrench. In this position the indicator reading does not have to be calculated
and it may be read directly.
2: The other position is to have the center line of the adapter in line with the center line of
the torque wrench. In this case the indicator cannot be read directly unless a
corrected reading for that adapter is calculated in accordance with the correction
formula as follows:
a: Use the formula to determine the indication reading.
1: If the reading is to be INCH-POUNDS make all measurements in INCHES.
2: If reading is to be FOOT-POUNDS make all measurements in FEET.
Figure 3
Formula Application with Wrench and Adapter Center in Line
Formula: Dial Reading = (Required Torque) x L1

L1 + L2
Example 1 Example 2
Required Torque = 400 ft/lbs Required Torque = 225 ft/lbs
Wrench (L1) = 3 ft Wrench (L1) = 3 ft
Adapter (L2) = .33 ft Wrench (L2) = .33 ft
400 x 3 = 1200 = 225 x 3= 675 =
3 + .33 3.33 3 + .33 3.33
=360.36 ft/lbs =202.7 ft/lbs
360.36 x 12 = 4234.32 in/lbs 202.7 x 12 = 2432.43 in/lbs
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ENGINE REMOVAL - CFM56-2
Page 1 of 9
Mechanic Inspector
1. Engine Serial Number OFF: ________________________
2. Removal Reason: ___________________________________________________
General Information
This maintenance practice provides removal instructions for the engines. Instructions
provided are for the bootstrap method of engine removal using currently available
The fan cowl doors and fan reverser halves are opened and remain on the pylon during
engine removal and installation. The fan cowl doors and fan reverser halves are
supported in the open position by Ground Support Equipment (GSE) that is supported by
the pylon. Engine inlet and exhaust covers must be installed prior to engine removal.
column should only be completed by an authorized ATI RII Inspector.
NOTE: The engines can be changed with or without the nose cowl installed. If it is
desirable to remove nose cowl prior to engine removal, refer to DACO MM 71-10-1.
NOTE: During the removal process, record hardware/component discrepancies/shortages
on Non-Routine form ATI-018
NOTE: When removing a SERVICEABLE engine, a Power Assurance Run-Up must be
documented on ATI Job Card 7105.
Tools and Equipment
Adapter, torque, ¾ in. drive 4771880-1 DACO
Socket set, high torque double hex 3803981-1 DACO
Beam, aft hoist 5803518-1 DACO
Beam, forward hoist 5803517-1 DACO
Dispenser, cowl door actuator 55543 Malabar Aircraft Hydraulics
(two gallon unit MIL-L-23699B)
Fixture, fan reverser hold-open(2 ea.) 3803571-1 DACO
Hoist, manual ¾ ton (Tugit) (2 ea.) 234A Dresser Industries Inc.
Rig pin (¼ in. dia. X 2.4 in.) Manufacture locally
Rig pin “J” (¼ in. dia. X 3.28 in.) Manufacture locally
Torque wrench (0-300 ft./lb. range)
Trailer, CFM56 engine Commercially available
Fixture, forward engine mount 3803982-1 DACO
installation/transportation
Bracket, fan cowl door hold-open strut 3803987-1 DACO
Tags
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References
Job Card 7004, Component Control (Removed Engine)-Required
Job Card 7105, CFM56-2 Max Power Assurance Run Prior to Lease Return
DACO DC-8 Chapter 29
Procedure
B. PREPARE AIRCRAFT:
1. Tag throttle/thrust reverser lever and open the following circuit breakers.
NOTE: Numbering on circuit breaker panels denotes engine position.
Auxiliary Hydraulic Pump Control Cabin bus 4
Engine Starters Battery bus
Engine Ignition AC bus 1, 2, 3, or 4
Ignition P.S. Control (Engines 2 and 3) Battery bus
Ignition and Tach Power Supply (Engines 2 and 3) Battery bus
Generator Control Battery bus
Engine Anti-Ice DC bus 1 or 4
Pneumatic Crossfeed Valve DC bus 4
Engine Low Pressure Control DC bus 1 or 4
Takeoff Warning DC bus 1
Pneumatic High Stage Valve DC bus 4
Thrust Reverser Hydraulic Valve DC bus 4
Thrust Reverser Hydraulic Valve Control DC bus 4
Thrust Reverser Emergency Hydraulic Pressure DC bus 1
Thrust Reverser Hydraulic Low Pressure DC bus 1
Thrust Reverser Pressure and Unlock, Reverse Thrust. DC bus 1 or 4
Engine Fire Detector DC bus 1 or 4
Ground/Flight Idle DC bus 1 or 4
Generator Drive and Engine Oil Temp DC bus 1 or 4
CSD Disconnect DC bus 1 or 4
Engine Oil Quantity DC bus 1 or 4
Engine Oil Press and Generator Drive, Oil Warning Lights DC bus 1 or 4
Engine Hydraulic Pump Bypass (inboard engines only) DC bus 1
Engine Low Pressure Pneumatic Control DC bus 1 or 4
Engine Fire Detector AC bus 1, 2, 3, or 4
Engine Fuel Flow AC bus 1, 2, 3, or 4
Engine Tachometer N1 and N2 AC bus 1, 2, 3, or 4
Thrust Reverser Emergency Stow AC bus 3
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CAUTION: MAIN LANDING GEAR WHEELS SHOULD BE CHOCKED
BEFORE REMOVING ENGINE.
C. OPEN ENGINE:
1. Tag and close thrust reverser hydraulic system manual shutoff, normal and
emergency stow valves, located in left main gear wheel well.
2. Open left and right fan cowl doors and engage cowl door aft and forward struts.
NOTE: Aft strut should be attached to engine Fan Case first.
3. Extend fan cowl door struts to full length position.
4. Open left and right fan reverser halves to full open position.
5. Install thrust reverser hold-open fixtures between reverser halves and pylon, left
and right sides.
6. Check that quick-release pins are properly installed, connecting fixtures to reverser
halves and pylon.
7. Disconnect fan cowl door aft struts and retract to intermediate position and lock.
8. Attach fan cowl aft strut coupling ends to receiver fittings on reverser halves.
9. Disconnect fan cowl door forward struts and carefully lower doors down to rest on
reverser halves.
10. Stow forward struts on receiver fittings located on doors.
11. Disconnect thrust reverser opening cowl hydraulic actuator brackets from engine
and stow actuators on reverser halves.
12. Close VBV doors to prevent FOD as follows:
a. Remove the VBV access panel at the 2:30 O’clock position, aft looking fwd.
b. Insert wrench 856A2501 into the open socket used for the interconnecting flex
shaft.
NOTE: A ¼ inch drive may be used if wrench is unavailable.
c. Turn shaft. Approximately 18 revolutions are required for full system travel.
d. Listen for a ‘click’ as the system reaches full travel limit against the stop
mechanism within the hydraulic motor assembly.
e. Re-install VBV access panel.
f. Apply colored, self-adhesive tape to the VBV access panels (louvers) at all
positions.
CAUTION: VARIABLE BLEED VALVE (VBV) DOORS SHOULD BE PUMPED
CLOSED BEFORE PERFORMING MAINTENANCE IN ENGINE
FORWARD CORE COMPARTMENT TO PREVENT HARDWARE OR
DEBRIS FROM FALLING INTO ENGINE THROUGH VBV PORTS
CAUSING POSSIBLE FOREIGN OBJECT DAMAGE (FOD) TO
ENGINE.
D. DISCONNECT ENGINE CONTROLS:
1. Move throttle/thrust reverser lever to Part Power position 3-9/32 (± 0.030) inches
from forward idle position and clamp in place.
NOTE: Lever position must be measured on the surface of the control pedestal cover.
2. Ensure following levers are in positions indicated:
a. THRUST REVERSER LEVER.......................... FORWARD THRUST
b. FUEL SHUTOFF LEVER.................................. FUEL OFF
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3. Disconnect throttle and fuel shutoff push/pull control cables as follows:
a. Install rig pin in lower gearbox located at lower left side of engine.
b. Disconnect throttle push/pull control cable at quick disconnect fitting located
at upper left side of engine.
c. Disconnect fuel shutoff push/pull control cable at quick disconnect fitting
located at upper left side of engine.
d. Loose jam nuts on fuel shutoff push/pull control cable at upper support
bracket located at upper left side of engine. Move cable to clear bracket.
4. Remove bolt attaching thrust reverser interlock push/pull control cable to thrust
reverser interlock cam crank located at upper left side of engine.
5. Loosen jam nuts on thrust reverser interlock push/pull control cable at upper
support bracket located at upper left side of engine. Move cable to clear bracket.
E. DISCONNECT AT PYLON:
CAUTION: TO PREVENT DAMAGE TO FLUID LINES, PNEUMATIC DUCTS,
ELECTRICAL RECEPTACLES, AND TO PREVENT CONTAMINANTS
FROM ENTERING FUEL, OIL, HYDRAULIC, GENERATOR COOLING
INLET, AND PNEUMATIC SYSTEMS, MAKE CERTAIN ALL OPEN
LINES, DUCTS, AND RECEPTACLES ARE CAPPED.
1. Disconnect the following electrical connectors from pylon forward electrical
junction box located forward left side of pylon.
Connector Number Receptacle Number
P1-7000 P1-7003 R5-7000 R5-7003
P1-7001 P1-7004 R5-7001 R5-7004
P1-7002 R5-7002
2. Remove anti-ice duct clamp located on forward left side of engine at pylon
interface.
3. Disconnect the following electrical connectors from pylon aft electrical junction
box located aft left side of pylon.
P1-7006 R5-7006
P1-7007 R5-7007
4. Disconnect bleed duct support link located on aft left side of engine at pylon
interface. Secure link so it will not be damaged when engine is lowered.
5. Remove bleed duct clamp located on aft left side of engine at pylon interface.
6. Disconnect bleed duct support link located on aft right side of engine at pylon
interface. Secure link so it will not be damaged when engine is lowered.
7. Disconnect two ¼ inch flexible hoses located aft right side of engine at pylon
interface and aft junction box.
CAUTION: TO PREVENT DAMAGE TO FLEXIBLE HOSES AND ENGINE,
HOSES MUST BE DISCONNECTED FROM PYLON INTERFACE
BEFORE LOWERING ENGINE.
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8. Depressurize aircraft hydraulic system. (Ref. DC-8MM Chapter 29)
NOTE: Hydraulic pumps and hoses are installed on inboard engines only.
9. Close fire shutoff valves by placing fire control handle, located in flight
Compartment, in FUEL AIR & HYD “off” position.
10. Remove drain plug from Boost Pump fuel inlet line.
NOTE: Be prepared to catch fuel in a container with approximate capacity of 5 U.S. Gal.
11. Lightly coat new O-ring with Petrolatum VV P 236 and install on drain plug.
12. Install plug in Boost Pump fuel line. Safety plug with lock wire.
13. Disconnect the following hoses from fluid disconnect panel on forward right
sideof pylon:
a. Pylon drain 3/8 inch hose INBOARD ENGINES
b. Pylon drain ½ inch hose e. Hydraulic pressure hose
c. Fuel vapor return hose f. Hydraulic suction hose
d. Fuel supply hose g. Hydraulic case drain hose
CAUTION: MAKE CERTAIN SPILLED HYDRAULIC FLUID IS CLEANED UP
ELECTRICAL WIRING.
14. Remove starter duct clamp at Tee engine-to-pylon interface, located forward right
side of pylon.
15. Disconnect VSV/VBV, reset flexible line from thrust reverser, located forward
right side of pylon.
F. INSTALL ENGINE HOIST EQUIPMENT: (FIG 1 & 2)
1. Install forward hoist beam and cradle without left and right arms attached on pylon
engine forward mount thrust plate.
WARNING: SUPPORT BEAM AND CRADLE ADEQUATELY WHEN
ATTACHING TO THRUST PLATE. BEAM AND CRADLE WEIGH
APPROXIMATELY 28 POUNDS.
CAUTION: EXTREME CARE MUST BE EXERCISED WHEN PASSING
FORWARD HOIST BEAM AND CRADLE THROUGH
PYLON/ENGINE AREA TO PREVENT DAMAGE TO ELECTRICAL
CONNECTORS, WIRING, AND SURROUNDING COMPONENTS.
NOTE: Beam must rock freely in cradle.
2. Ensure quick-release pins are properly installed, connecting cradle to thrust plate.
3. Install forward hoist beam left and right arms with quick-release pins pointing
forward.
WARNING: SUPPORT ARMS ADEQUATELY WHEN ATTACHING TO BEAM.
EACH ARM WEIGHS APPROXIMATELY 41 LBS.
4. Check that quick-release pins are properly installed connecting arms to beam.
5. Install aft hoist beam on pylon fitting.
WARNING: SUPPORT BEAMS ADEQUATELY WHEN ATTACHING TO
PYLON FITTING. BEAM WEIGHS APPROXIMATELY 30 LBS.
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6. Ensure quick-release pin is properly installed connecting beam to pylon fitting.
7. Attach manual 3 ton hoists to each end of forward hoist beam arms.
8. Attach manual ¾ ton hoists to each end of aft hoist beam.
9. Position dolly or trailer, with engine cradle installed, under engine.
10. Operate manual hoists to extend load chains and attach load hooks to cradle
hoisting brackets.
11. Ensure manual hoists and beams are properly attached and quick-disconnect and
safety pins are properly installed.
12. Unlock engine cradle from dolly or trailer.
13. Carefully operate hoists to assume weight of engine cradle, checking again for
proper rigging and cable chafing.
14. Operate hoists simultaneously to raise engine cradle to engine, aligning forward
and aft cradle fittings with attach adapters and insert lockpins.
WARNING: MAKE CERTAIN ALL HOIST BEAMS AND MANUAL HOISTS
ARE SECURE BEFORE RAISING ENGINE CRADLE.
WARNING: MAKE CERTAIN MANUAL HOISTS ARE OPERATED TO KEEP
ENGINE CRADLE AT LEVEL ATTITUDE. CRADLE WEIGHS
15. Carefully operate hoists to remove all slack from load chains but do not preload
system.
G. REMOVE ENGINE FROM PYLON:
1. Loosen Forward and Aft mount bolts to obtain approximate 1/8 inch gap between
engine mounts and pylon support.
2. Carefully operate manual hoists upward until hoists have assumed engine weight
without closing gap. This is confirmed when all bolts unscrew freely without an
increase in dimension of gap.
3. Remove bolts from Forward and Aft engine mounts.
4. Carefully lower engine, making certain electrical connectors, fluid lines, and
pneumatic ducting clear pylon mount support and structure.
WARNING: ENSURE MANUAL HOISTS ARE OPERATED
SIMULTANEOUSLY DURING INITIAL LOWERING OF ENGINE.
EITHER LOWERING OR STOPPING OF SINGLE HOIST BEFORE
MOUNTS ARE WELL CLEAR OF PYLON STRUCTURE COULD
CAUSE PRYING LOADS AGAINST PYLON, CAUSING POSSIBLE
FAILURE OF HOISTING ELEMENTS WITH POSSIBLE INJURY
TO PERSONNEL.
WARNING: ENSURE HOISTS ARE OPERATED TO KEEP ENGINE AT LEVEL
ATTITUDE. ENGINE WEIGHS APPROXIMATELY 6046 LBS.
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5. Operate manual hoists simultaneously and lower engine onto dolly or trailer.
Secure engine to dolly or trailer.
6. Operate manual hoists to relieve tension on load chains and disconnect hoisting
brackets from cradle.
NOTE: Leave hoists attached to hoist beams to aid engine installation.
8. Roll dolly or trailer with engine and cradle clear of aircraft.
9. Check pylon firewall area for following:
a. Cracks, loose rivets, structural damage.
b. Condition and security of all electrical lines, ducts, fittings and electrical
connectors.
c. Electrical connectors for cleanliness.
d. Engine mount fittings and shear pins for condition and security.
H. COMPLETION:
1. Complete Component Control Job Card 7004 AFTER all parts needed for the
replacement engine have been removed.
2. If the engine was removed in an UNSERVICEABLE condition:
a. Attach completed “Green Tag” to engine.
b. Attach duplicate Non-Routines and Component Control Job Card 7004 to
engine.
If engine is removed SERVICEABLE, N/A this step.
3. If the engine was removed in a SERVICEABLE condition:
a. Attach completed “Continued-Time” PCT and MPA Run Job Card 7105 to
engine.
b. Attach duplicate of any Non-Routines generated against the engine.
c. Attach duplicate of Component Control Job Card 7004.
If engine is removed UNSERVICEABLE, N/A this step.
4. Prepare the removed engine for shipment.
a. Ensure all plugs caps, blanking plates, and covers are installed on the engine.
b. Wrap the engine in plastic or install a full tarp on the engine.
c. Obtain the correct shipping information and complete a shipper and/or bill of
lading as directed by Maintenance Control/Planning.
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FIGURE 1
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FIGURE 2
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ENGINE INSTALLATION - CFM56-2
Page 1 of 13
Mechanic Inspector
Engine Serial Number ON: ___________________

General Information
This maintenance practice provides installation instructions for the engines. Instructions
provided are for the bootstrap method of engine installation using currently available
The fan cowl doors and fan reverser halves are opened and remain on the pylon during
engine removal and installation. The fan cowl doors and fan reverser halves are
supported in the open position by Ground Support Equipment (GSE) that is supported by
the pylon. Engine inlet and exhaust covers must be installed prior to engine installation.
NOTE: The engine can be installed with or without the nose cowl installed. For nose
cowl installation, refer to DACO MM 71-10-1.
NOTE: During the engine installation process, record hardware/component
discrepancies/shortages on Non-Routine form ATI-018.
Tools and Materials
Adapter, torque, ¾ in. drive 4771880-1 DACO
Socket set, high torque double hex 3803981-1 DACO
Beam, aft hoist 5803518-1 DACO
Beam, forward hoist 5803517-1 DACO
Dispenser, cowl door actuator 55543 Malabar Aircraft Hydraulics
(two gallon unit MIL-L-23699B)
Fixture, fan reverser hold-open 3803571-1 DACO
(2 ea.)
Hoist, manual ¾ ton (Tugit) (2 ea.) 234A Dresser Industries Inc.
Rig pin (¼ in. dia. X 2.4 in.) Manufacture locally
Rig pin “J” (¼ in. dia. X 3.28 in.) Manufacture locally
Torque wrench(0-300 ft./lb. range)
Trailer, CFM56 engine Commercially available
Fixture, forward engine mount 3803982-1 DACO
installation/transportation
Bracket, fan cowl door hold-open 3803987-1 DACO
strut
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References
Job Card 7005, Component Control (Installed Engine)
Job Card 7105, Max Power Assurance Run-Up
DC-8 Engine Run Handbook (ERH)
Procedure
B. ENGINE - RECEIVING INSPECTION
a. Serviceable vendor tag matches Engine S/N and maintenance release is signed.
b. Inspect engine for missing components, hardware, and clamps.
c. Inspect engine general condition for security, chafing, and transport damage.
Document Discrepancies on Non-Routine Form, ATI 018.
d. If not installed, apply colored, self-adhesive tape to the VBV access panels
(louvers) at all positions.
2. Check Forward and Aft engine mount bolts and washers for plating wear, corrosion,
cracks, thread stripping, or cross threading. Bolts exhibiting wear through plating or
corrosion on shank, under bolt head, or threads must be replaced. Verify Aft Mount
S/N times, cycles, & TSO have been recorded on ATI Jobcard 7006.
3. Ensure Airworthiness Directive Compliance:
a. AD 82-18-51
Record Starter P/N: _____________________
If Starter P/N: 3505154-18-1 is installed, replace starter with Starter P/N:
3505154-19-1 series or subsequent approved Starter.
b. AD 84-09-04
Locate Hydraulic Control Unit (HCU) on thrust reverser.
Record HCU P/N: _____________________.
If the HCU P/N C24466000 is installed, replace it with HCU P/N C24466000-2
or C24466001-2 or subsequent approved HCU’s. Route HCU P/N: C24466000
to Stores for modification in accordance with SB 78-057.
c. AD 84-26-03
Inspect engine for P/N: 9984M90G20 fuel injectors. If these injectors are
installed they must be replaced. Contact Quality Control if found installed.
Are P/N 9984M90G20 injectors installed? Yes No
d. AD 94-22-07 (supersedes 83-02-05)
Inspect Exhaust Plug Assy. for modification with DACO SB 78-112 R2. The
assy. can be verified by having three access doors on the forward plug.
SB 78-112 is approved as an alternate means of compliance with AD 83-02-05.
e. Check running torque of mount bolts and nuts.
(1) Forward mount bolts and nut for 50 inch/pounds.
(2) Aft mount bolt and nut for 32 inch/pounds.
f. Complete Component Control Job Card 7005 (Installed Engine)
C. PREPARE AIRCRAFT:
1. Ensure throttle/thrust reverser lever is tagged and circuit breakers are open and
tagged per Job Card 7103.
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2. Ensure the thrust reverser hydraulic system manual shutoff, normal and emergency stow
valves, located in the left main gear wheel well, are closed and tagged.
3. Ensure following levers are in positions indicated:
a: THRUST REVERSER LEVER ........FORWARD THRUST
b: FUEL SHUTOFF LEVER ................FUEL OFF
4. Ensure throttle/thrust reverser lever is in Part Power position, 3-9/32 (±1/32) inches from
forward idle position and clamped in place.
D. INSTALL ENGINE HOIST EQUIPMENT:
1. Install engine hoist per Job Card 7103A.
2. Position dolly or trailer with engine and cradle installed under pylon.
3. Operate manual hoists to extend load chains and attach hoisting brackets to cradle.
4. Ensure manual hoists and hoist beams are properly attached and quick disconnect and
safety pins are properly installed. (Figure 1 and 2)
5. Unlock engine cradle from dolly or trailer.
6. Carefully operate hoists to assume weight of engine, checking again for proper rigging
and cable chafing.
7. Operate hoists simultaneously and raise engine up to approximate position for
installation.
CAUTION: WHEN RAISING ENGINE AND CRADLE FROM DOLLY OR TRAILER,
MAKE CERTAIN THAT ALL FOUR CORNERS OF THE CRADLE ARE
PICKED UP AT THE SAME TIME.
WARNING: MAKE CERTAIN HOISTS ARE OPERATED TO KEEP ENGINE AT
LEVEL ATTITUDE. ENGINE WEIGHS APPROXIMATELY 6046 LBS.
8. Clean engine mount interface surfaces and check that alignment shear-pins and engine
mount surfaces are free of lubricant.
9. Install washers under the heads of engine mount bolts.
NOTE: Countersunk side of washers must face bolt heads.
E. INSTALL ENGINE TO PYLON
1. Raise engine until Forward mount alignment pin and Aft mount alignment pins are
engaged and a gap of approximately 1/8 inch exists between engine mounts and pylon
mount supports.
CAUTION: USE HOIST WITH EXTREME CARE WHEN RAISING ENGINE TO FINAL
POSITION OR DAMAGE TO MOUNTS AND SUPPORTS COULD OCCUR.
NEVER OPERATE HOISTS TO COMPLETELY CLOSE THE GAP
BETWEEN ENGINE MOUNTS AND PYLON MOUNT SUPPORTS.
2. Install Forward and Aft mount bolts. Tighten bolts evenly on left and right sides of
engine until engine mounts are flush with pylon mount supports. Then release tension on
hoist units simultaneously.
CAUTION: TO PREVENT GALLING AND SCORING OF MOUNT BOLTS, DO NOT
ATTEMPT TO PULL ENGINE INTO PLACE WITH THE BOLTS UNTIL
FORWARD AND AFT ALIGNMENT PINS ARE ENGAGED AND A GAP
OF APPROXIMATELY 1/8” EXISTS BETWEEN ENGINE AND PYLON
MOUNT SUPPORT.
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3. Using a torque wrench adapter (4771879-1), torque Forward mount bolts 4200 to
4500 inch/pounds (350 to 375 foot/pounds) and safety. Read note prior to safety.
NOTE: Torque values are actual bolt values. See Figure 3 for torque value formula
when using torque adapter.
NOTE: Back off bolts approximately one-half turn and re-torque one bolt at a time.
4. Using torque wrench adapter (4771880-1), torque Aft mount bolts to 2400 to 2900
inch/pounds (200 to 241.7 foot/pounds) and install bolt retainers. The notes in step
3 above, apply to this as well.
F. REMOVE ENGINE HOIST EQUIPMENT:
1. Remove lock pins and disconnect fwd. and aft cradle fittings from attach adapters.
2. Operate manual hoists simultaneously and lower engine cradle on to dolly or trailer.
3. Secure cradle to dolly or trailer.
4. Operate manual hoists to relieve tension on load chains and disconnect cradle
hoisting brackets from cradle.
5. Remove forward and aft attach adapters from engine and install on engine cradle.
6. Roll dolly or trailer with engine clear of aircraft.
7. Remove engine hoist equipment as follows:
a. Remove manual hoists from forward and aft hoist beams.
b. Remove aft hoist beam from pylon fitting.
WARNING: SUPPORT BEAM ADEQUATELY WHEN REMOVING FROM

PYLON FITTING. BEAM WEIGHS APPROXIMATELY 30 LBS.
c. Remove forward hoist beam left and right arms.
WARNING: SUPPORT ARMS ADEQUATELY WHEN REMOVING FROM
BEAM. EACH ARM WEIGHS APPROXIMATELY 41 LBS.
d. Remove forward hoist beam and cradle from pylon engine forward mount thrust
plate.
WARNING: SUPPORT BEAM AND CRADLE ADEQUATELY WHEN
REMOVING FROM THRUST PLATE. BEAM AND CRADLE
WEIGH APPROXIMATELY 28 LBS.
CAUTION: EXTREME CARE MUST BE EXERCISED WHEN PASSING
FORWARD HOIST BEAM AND CRADLE THROUGH
PYLON/ENGINE AREA TO PREVENT DAMAGE TO ELECTRICAL
CONNECTORS, WIRING, AND SURROUNDING COMPONENTS.
G. CONNECT AT PYLON:
1. Connect VBV Reset Signal Line from thrust reverser, located forward right side of
pylon.
Install starter duct clamp at tee engine-to-pylon interface forward of right side of
pylon. Torque clamp retaining nut to value indicated on clamp.
CAUTION: TO PREVENT PRELOADING OF STARTER DUCT AND PYLON
DUCT, MAKE CERTAIN THAT DUCTS ARE PROPERLY ALIGNED
BEFORE INSTALLING CLAMP.
2. Ensure hydraulic system is depressurized (Ref. DACO DC-8 MM Chapter 29).
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3. Ensure fire control handle located in flight compartment is in FUEL AIR & HYD
position.
4. Connect the following hoses to fluid disconnect panel on forward right side of
pylon:
a. Pylon drain 3/8 inch hose INBOARD ENGINES
b. Pylon drain 1/2 inch hose e. Hydraulic pressure hose
c. Fuel vapor return hose f. Hydraulic suction hose
d. Fuel supply hose g. Hydraulic case drain hose
NOTE: Hydraulic hoses are installed on inboard engines only.
CAUTION: MAKE SURE SPILLED HYDRAULIC FLUID IS CLEANED UP
ELECTRICAL WIRING.
5. Connect two ¼ inch flex hoses (bleed air sense) located aft right side of engine to
pylon interface at aft junction box.
6. Connect bleed duct support link located aft right side of engine to pylon interface
7. Install bleed duct clamp on bleed duct located on aft left side of engine to pylon
interface. Torque clamp retaining nut to value indicated on clamp.
8. Connect bleed duct support link located aft left side of engine to pylon interface.
9. Connect the following electrical connectors to receptacles on pylon aft electrical
junction box, aft left side of pylon.
P1-7006 R5-7006
P1-7007 R5-7007
10. Connect anti-ice duct clamp to anti-ice duct located on forward left side of engine to
pylon interface.
11. Connect the following electrical connectors to receptacles on pylon forward
electrical junction box, forward left side of pylon.
P1-7000 P1-7003 R5-7000 R5-7003
P1-7001 P1-7004 R5-7001 R5-7004
P1-7002 R5-7002
H. CONNECT ENGINE CONTROLS:
1. Connect reverser interlock push/pull cable as follows:
a. Connect the thrust reverser interlock push/pull control cable to thrust reverser
cam crank and install attaching hardware. Safety nut with cotter pin.
b. Install thrust reverser interlock push/pull control cable in the upper support
bracket and tighten jam nuts. Safety jam nuts with lock wire.
2. Connect throttle and fuel shutoff push/pull control cables as follows:
a. Connect lower throttle push/pull control cable to upper throttle push/pull control
cable at quick-disconnect fitting. Safety bolts with lock wire.
b. Connect lower fuel shutoff push/pull control cable to upper fuel shutoff push/pull
control cable at quick-disconnect fitting. Safety bolts with lock wire.
c. Install fuel shutoff push/pull control cable in upper support bracket and tighten
jam nuts. Safety jam nuts with lock wire.
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3. Adjust throttle and fuel shutoff push/pull control cables as follows:
a. Open access door 190A (Engines 1 & 4) or 290A (Engines 2 & 3) located on forward
upper outboard side of pylon (see DACO Chap. 6).
b. Check that throttle/thrust reverser lever is in part power position, 3-9/32 (± 1/32) inches
from forward idle position.
c. Move fuel shutoff lever to ON position.
d. Insert rig pin through fuel shutoff drum, power control drum, and support bracket.
e. Remove plug buttons from firewall and insert rig pins into upper gearbox and thrust
reverser balking lever. Retain plug buttons to aid installation.
f. Adjust micro-adjust on lower throttle gearbox until rig pin can be inserted into lower
throttle control gearbox and engine control lever. Safety micro-adjust with lock wire.
g. Check that fuel shutoff lever on MEC is positioned to full ON or open position and is
in contact with set screw stop.
h. If lever is not in contact with set screw stop, disconnect fuel shutoff push/pull control
cable from fuel shutoff lever and adjust rod end until bolt can be inserted freely
through bolt holes in lever and rod end.
i. Align fuel shutoff push/pull control cable rod end with fuel shutoff lever and install
bolt. Safety bolt with cotter pin.
j. Remove rig pins from upper gearbox and lower throttle control gearbox.
k. Remove rig pin from fuel shutoff drum, power control drum, and support bracket.
4. Check fuel shutoff system.
a. Exercise fuel shutoff lever several times.
b. Position fuel shutoff lever to ON.
c. Check fuel shutoff lever on MEC contacts stop.
NOTE: If the fuel shutoff lever fails the above test, see DACO MM 76-12-0.
5. Check throttle system:
a. Exercise throttle from idle to full power several times.
b. Check that the MEC power lever contacts forward stop when throttle is in full
forward thrust.
c. Check that the MEC power lever contacts the reverse stop when the lever is at full
reverse thrust position.
NOTE: If the MEC power lever fails to contact either stop, see DACO MM 76-11-0.
CAUTION: DO NOT ADJUST MEC POWER LEVER STOPS OR DAMAGE TO ENGINE
WILL RESULT.
6. Position fuel shutoff lever to OFF.
7. Move throttle/thrust reverser lever to forward idle position.
8. Install plug buttons in pylon firewall.
9. Close access door 190A (Engines 1 & 4) or 290A (Engines 2 & 3) located on forward
upper outboard side of pylon.
I. RESET SYSTEMS:
1. Open fire shutoff valves by placing fire control handle, located in flight compartment, in
NORMAL position.
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2. Connect thrust reverser opening cowl hydraulic actuator brackets to engine.
3. Raise fan cowl doors and connect forward struts to engine.
4. Disconnect fan cowl door aft strut coupling ends from receiver fittings on reverser
halves and connect to engine.
5. Remove thrust reverser hold open fixtures from left and right sides.
6. Close left and right fan reverser halves.
7. Remove tags from throttle/thrust reverser lever and close the following circuit breakers:
NOTE: Numbering on circuit breaker panels denotes engine position.
Auxiliary Hydraulic Pump Control (Inboard Engines Only) Cabin Bus 4
Engine Starters Battery Bus
Engine Ignition AC Bus 1, 2, 3, or 4
Ignition Power Supply Control (Engines 2 &3) Battery Bus
Ignition and Tach Power Supply (Engines 2 & 3) Battery Bus
Generator Control Battery Bus
Engine Anti-Ice DC Bus 1 or 4
Pneumatic Cross Feed Valve DC Bus 4
Engine Low Pressure Pneumatic Control DC Bus 1 or 4
Takeoff Warning DC Bus 1
Pneumatic High Stage Valve DC Bus 4
Thrust Reverser Hydraulic Valve Control DC Bus 4
Thrust Reverser Emergency Hydraulic Pressure DC Bus 1
Thrust Reverser Hydraulic Low Pressure DC Bus1
Thrust Reverser Pressure and Unlock Reverse Thrust DC Bus 1 or 4
Engine Fire Detector DC Bus 1 or 4
Ground/Flight Idle DC Bus 1 or 4
Generator Drive and Engine Oil Temperature DC Bus 1 or 4
CSD Disconnect DC Bus 1 or 4
Engine Oil Quantity DC Bus 1 or 4
Engine Oil Pressure and Generator Drive Oil Warning DC Bus 1 or 4
Engine Hydraulic Pump Bypass (Inboard Engines Only) DC Bus 1
Engine Low Pressure Pneumatic Control DC Bus 1 or 4
Engine Fire Detector AC Bus 1, 2, 3, or 4
Engine Fuel Flow AC Bus 1, 2, 3, or 4
Engine Tachometer N1 And N2 AC Bus 1, 2, 3, or 4
Thrust Reverser Emergency Stow AC Bus 3
8. Open thrust reverser hydraulic system manual shutoff normal and emergency stow
valves, located in left main gear well. Safety valves in open position with lock wire.
J. CHECK SYSTEMS:
1. Pressurize aircraft hydraulic system.
WARNING: ENSURE FLIGHT COMPARTMENT THRUST REVERSER LEVER
POSITION CORRESPONDS WITH THRUST REVERSER DOOR
POSITION AND THAT ALL PERSONNEL AND EQUIPMENT ARE
WELL CLEAR OF THRUST REVERSER BEFORE OPERATION.
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2. Energize aircraft electrical buses.
3. Check engine anti-ice valves and indicators as follows:
a. Place engine anti-ice switch in ON position.
b. Check that valves operate properly (light momentarily then off).
4. Check engine fuel system as follows:
a. Place Boost Pump switch in ON position.
b. Check that no fuel leakage exists at the fuel inlet supply line.
c. Place Boost Pump switch in OFF position.
5. Check CSD shaft disconnect as follows:
a. Pull disconnect handle on bottom of CSD lightly until handle bottoms. Hold
handle lightly in this extended position.
b. Actuate and release flight compartment CSD disconnect switch.
c. CSD disconnect handle on bottom of CSD should pull in by spring action. Allow
handle to move in.
d. Pull CSD disconnect handle out until audible ‘click’ is heard, indicating
disconnect is latched out.
NOTE: A reduction in pull force required on CSD disconnect handle is also evidence
that disconnect is latched out.
6. Check for pneumatic leaks utilizing ground pneumatic source as follows:
a. Check that air conditioning pack switches L/R PACK located on Flight
Engineer’s panel are in OFF position.
b. Connect ground pneumatic source to fuselage ground pneumatic connector.
c. Operate ground pneumatic source and check that ground source pneumatic
pressure regulator is set to provide pressure of 38 (±2) psig.
d. Check all pneumatic system mechanical joints, ducting, sense lines, and support
brackets for security, damage or deformation due to pressurization.
WARNING: PERSONNEL SHOULD EXERCISE CARE WHEN ENTERING
DUCTING AREA TO PREVENT INJURY.
e. Check for leaks by feel, sound, or application of soap solution around joints and
connections.
Note: If leaks are found, shut down pneumatic ground source and make repairs.
f. Operate ground pneumatic source and decrease pressure to zero.
7. Ensure following systems are serviced:
a. Engine oil system d. CSD
b. Fuel system e. Starter
c. Hydraulic system
8. Perform fire detector sensing element test.
K. LEAK CHECK:
NOTE: Remove self-adhesive tape from VBV access panels (louvers) at all positions.
1. Check that thrust reverser halves are closed and latched and transcowl is in stowed
and locked position.
NOTE: The fan cowl doors may be open for this procedure.
2. Check: THROTTLE LEVER.................... FORWARD IDLE
FUEL SHUTOFF LEVER .................... OFF DETENT
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3. Check that engine instrument circuit breakers are closed.
4. Pressurize aircraft pneumatic system with suitable air source for engine starting.
a. Check engine ducting for leakage.
b. Turn engine anti-ice ON and check for leakage. (Ref. ERH 36.02)
CAUTION: KEEP ENGINE ANTI-ICE SYSTEM ON FOR THE MINIMUM
AMOUNT OF TIME TO COMPLETE LEAK CHECK.
c. Turn engine anti-ice OFF.
NOTE: The wet motoring check is used for depreservation of the fuel system and for
fuel leak check.
5. Wet motor engine IAW ERH 71.01.
CAUTION: FUEL PUMP AND MAIN ENGINE CONTROL ARE FUEL
LUBRICATED. DO NOT MOTOR ENGINE UNLESS POSITIVE FUEL
INLET PRESSURE IS INDICATED.
6. If fuel flow and oil pressure are satisfactory, continue to wet motor engine for 30
seconds to purge fuel system.
7. During engine coast down, listen for unusual noise from rotating components.
Watch engine fan frame and turbine areas for unusual vibration.
NOTE: Normal rotational noise consists of clicking compressor and turbine blades, gear
noise, seal rubs, and starter ratcheting.
8. When engine has stopped, open fan cowl doors and thrust reverser halves and check
lube and fuel system lines, fittings, and accessories for leakage.
9. Check engine drain mast for signs of fuel leakage from fuel manifold shroud; last
hole aft in mast. No leakage is allowed.
10. Check oil level in oil tank and service if required.
11. Turn off tank fuel feed pump supplying engine just checked.
12. If applicable, wipe out any residual fuel at bottom of core exhaust nozzle.
13. Close and secure engine thrust reverser halves and cowling.
L. PERFORM ENGINE TEST RUN IAW ERH 70.01
1. From ERH 91.01 charts, determine 55% N1 target and N2, EGT, and Fuel Flow
limits.
2. Start engine IAW ERH 70.01.
3. Allow engine to warm up for five minutes. During this time conduct the following
tests:
a. ERH 36.02, check pneumatic valves for proper operation.
b. ERH 29.01, check hydraulic pump operation.
c. ERH 24.02, check generator operation.
4. Set bleeds to configuration of ERH 91.01.
5. Advance throttle to 55% N1 target and allow to stabilize for 2 minutes. Check that
N2, EGT, and Fuel Flow are within limits.
6. Perform PMC check IAW ERH 76.01.
7. Check Ground Idle and Flight Idle per ERH 91.01, adjust if necessary IAW ERH
91.01.
8. Shut down engine IAW ERH 70.01.
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M. SECURE ENGINE:
1. Open forward engine cowls and check for the following:
a. Oil leaks
b. Fuel leaks
c. Final inspection of safeties, hardware, wiring
d. Check drain mast for leakage
2. Complete Component Control Job Card 7005.
3. Close and secure engine cowls.
N. LOGBOOK COMPLETION:
1. Enter in logbook compliance with this Job Card and any other Job Card issued
since determination of engine removal. Ensure that engine position and serial
numbers OFF & ON are recorded on the logsheet.
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Figure 1
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Figure 2
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NOTE: Whenever possible, the center line of the adapter should be used in one of two
positions within 10 degrees in relationship to the axis of the torque wrench.
1: One position is to have the adapter center line at right angles to the center line of the
torque wrench. In this position the indicator reading does not have to be calculated
and it may be read directly.
2: The other position is to have the center line of the adapter in line with the center line of
the torque wrench. In this case the indicator cannot be read directly unless a
corrected reading for that adapter is calculated in accordance with the correction
formula as follows:
a: Use the formula to determine the indication reading.
1: If the reading is to be INCH-POUNDS make all measurements in INCHES.
2: If reading is to be FOOT-POUNDS make all measurements in FEET.
Figure 3
Formula Application with Wrench and Adapter Center in Line
Formula: Dial Reading = (Required Torque) x L1

L1 + L2
Example 1 Example 2
Required Torque = 5200 in/lbs Required Torque = 2700 in/lbs
Wrench (L1) = 37 inches Wrench (L1) = 37 inches
Adapter (L2) = 4 inches Wrench (L2) = 4 inches
5200 x 37 = 192400 = 2700 x 37 = 99900 =
37 + 4 41 37 + 4 41
=4692 in/lbs =2437 in/lbs
4692 = 391 ft/lbs 2437 = 203 ft/lbs

12 12
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ATI RECURRING NON ROUTINE ATI-001
7105
JOB TITLE
MAX POWER ASSURANCE RUN - CFM56-2
Page 1 of 1
Mechanic Inspector
Engine Serial Number:
Work Request Number initiating this action:
General Information
COMPLETION OF THIS JOB CARD IS REQUIRED PRIOR TO REMOVAL OF A
LEASE ENGINE.
Procedure
A. Prepare aircraft for engine run per company procedures.
B. Comply with Pre-start Checklist per ERH 70.01 and Review ERH 01.01.
C. Start Engines.
CAUTION: Max EGT during Start: 725°C
Max Fuel Flow during Start: 1100 PPH
Minimum Pneumatic Pressure During Start: 26 PSI
D. Ground Test Engines at Idle. If within limits, check mark the following lines.
Enter the actual reading if results are Out-of-Limits and initiate a Non-Routine.
EGT: 600°C Max _____________
N2 RPM: 59% (± 1% at 70°F) _____________
Fuel Flow: 600 - 1000 PPH _____________
Oil Pressure: 13 PSI Minimum _____________
Oil Temperature: 40 - 120°C _____________
Fuel Press: Boost OFF 8 - 28 PSI _____________
Fuel Press: Boost ON 26 - 38 PSI _____________
Perform Power Assurance Run Per CFM56-2 MM. Compare to CFM56-2 MM
71-00-00 Adjust/Test 01, not the JRH limits. Determine Target N1 (see Chart
pg. 529) and N2, EGT & FF limits (pg.530). Record OAT _______________
Target N2 Analog or Digital? FF
N1 Limit EGT Limit Limit
Record Actual Values for the same Parameters Below.
Analog or Digital
N1 N2 EGT FF
F. Perform PMC Drop Check Per ERH 76.01. N1 should decrease 0.5% to 5.5%
within 30 seconds. Note + or - N1 Change:
G. Upon engine removal, attach a PCT and a copy of this form to the engine.
H. Run Performed By: _____________________________Print Name
_____________________________Signature
_____________________________A&P
Revision 13 10-22-01 70.02.51

INTENTIONAL
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7106
JOB TITLE
Off-Wing Engine T3/4 Disk Replacement – JT3D
Page 1 of 14
Mechanic RII Insp.
I. Purpose: To replace disks which are becoming life cycle limited (LLP);
however, at the same time as a LLP disk is being replaced, the
opportunity will generally be taken to carry out a Hot Section Inspection
and, if required, parts replacement (already in the PWA Overhaul Manual
and DC8-60 Maintenance Manual). Since either the T3 or T4 disk may be
replaced, the disassembly and reassembly instructions should be
applied as necessary.
II. References:
• DACO DC8-60 Maintenance Manual
• PWA JT3D Overhaul Manual (OHM), 411568 (-3B) / 615105 (-7)
• PWA JT3D Maintenance Manual (MM), 411566 (-3B) / 615104 (-7)
• PWA JT3D OHM – Tierod Stretch Torque Values - Table 1
• Tooling List - Table 2
• PWA JT3D IPC/OHM, 72-00 (selected), 411570 (-3B) / 615111 (-7)
A. DISASSEMBLY PROCEDURE:
NOTE: The work stages below are to be carried out with the engine removed
from the Aircraft.
Record, Engine type JT3D -3B or -7 (circle one) S/N: _____________
1. Ensure the engine has been prepared for maintenance as required

(necessary tooling [alternate/equivalent ATI tooling may be used]).
2. Disassemble Thrust Reverser assembly (or tailpipe assembly) from engine,

if installed.
3. Disconnect the PT7 line.
4. Disconnect the #6 bearing oil pressure and scavenge lines.
5. Disconnect the EGT thermocouple harness from the Exhaust Case at the
fire seal (and brackets).
6. Support the engine at the turbine nozzle case assembly in a level horizontal
position.
7. Remove the engine rear mounting bolts, if necessary.
8. Remove the Exhaust Case assembly. Inspect for serviceability per MM 72-
00, page 664.
9. Remove the #6 bearing oil scavenge pump drive gear.

NOTE: Ensure seal assembly balance mark positions are noted during
turbine disassembly. This reference will be required during
reassembly. Ref. PWA OHM/Light OH, 72-54-0, p. 1303, para. (3).
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Off-wing Engine T3/4 Disk Replacement – JT3D
Page 2 of 14
Mechanic RII Insp.
10. Remove the #6 bearing inner race & roller assembly. Record Bearing P/N
and S/N below
P/N ______________________ S/N _____________
Inspect for serviceability per OHM, Inspection, 72-53-0, para. 1(1).
11. Remove #6 carbon seal and spacer assembly. Inspect for serviceability
per OHM, Inspection, 72-53-0, para. 1(1).
12. Remove the #4 ½ bearing (oil tube) rear seal’s sleeve. Inspect for
serviceability per OHM, Inspection, 72-53-0, para. 1(1).
13. Mark the tie-bolts position as they are removed. Loosen all the tie-rod nuts
and remove eight of the nuts. Leave two nuts lightly attached to ensure the
disk(s) do not fall accidentally.
14. Remove the turbine rear hub. Inspect for serviceability per OHM,
Inspection, 72-53-0, para. 1(1).
15. Remove the #4 ½ bearing oil tube (Bazooka). Inspect for serviceability per
OHM, Inspection, 72-53-0, para. 1(1).
16. Separate the T3 and T4 disks and remove the T4 disk. If re-installing the
T4 disk, inspect for serviceability per OHM, Inspection, 72-53-0, para. 1(1).
17. Measure NGV4 inner support to outer seal and record the dimension. M:
__________. See Figure 2.
18. Remove the 4th stage outer air seal. Inspect for serviceability per OHM,
Inspection, 72-53-0, para. 1(1).
19. Mark the position of the 4th stage NGV’s and remove them. Inspect for
serviceability per OHM, 72-53-0, para. 1(1).
20. Remove the 3rd stage outer spacer ring (3 segment). Inspect for
21. Remove the 4th stage NGV inner support. Inspect for serviceability per
OHM, 72-53-0, para. 1(1).
22. Remove the 4th stage inner air seal. Inspect for serviceability per OHM, 72-
53-0, para. 1(1).
23. Remove the 3rd stage disk and all of the tie-rods. If re-installing, inspect for
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Mechanic RII Insp.
NOTE: Record Disk P/N and S/N below for ON and OFF units. If job is single
disk replacement , unused blocks may be N/A, as required.
T3 DISK – P/N OFF _______ S/N OFF _____ P/N ON ________ S/N ON ______
T4 DISK – P/N OFF _______ S/N OFF _____ P/N ON ________ S/N ON ______
B. REASSEMBLY PROCEDURE:
1. Visually check the condition of the replacement disk/ blade assembly for
shipping damage or other defects. Check for serviceable tag.
2. Apply Fel-Pro C200 and install 2 of the tie-rods.
3. Check the positioning of the 3rd stage outer air seal and install the T3 disk
assembly over the 2 tie-rods and manually push the T3 disk into its
installed position.
4. Apply Fel-Pro C200 and install the other 8 tie-rods. Tighten them by hand
and then release ½-¾ turn back.
5. Install the 3rd/4th stage inner seal on the rear of the T3 disk (If applicable.
It may have been retained there during disassembly.)
6. Install the 4th stage NGV inner support, taking care to not damage the
knife edge seals of the inner seal.
7. Install the outer seal spacer (3 segments).
8. Install the 4th stage NGV’s back into their original positions.
9. Install the NGV4 inner support position check tooling in the inner support
and pull the vanes and support into position.
10. Install the 4th stage outer air seal and secure with four screws.
11. Measure from inner support to rear of outer air seal. Record: ______ and
then compare with disassembly dim. M: ______________ (+/- 0.100”).
12. Remove the NGV4 inner support position check tooling.
13. Install the T4 disk into its position.
14. Install three new Teflon seals and two new seal rings on the #4 ½ oil tube.
Install the oil tube into the turbine shaft; position the pin to locate into the
hub groove.
15. Install the rear hub on the T4 disk with the spring and washer. Align the
pin on the oil tube into the groove in the hub. Tighten nuts by hand with
tab locks (lubricate threads with Fel-Pro C200).
Revision 19 12-05-03 70.02.55


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Mechanic RII Insp.
16. Tighten nuts in pair 200-400-600-800 lbs/inch release and stretch to:
0.009”-0.010” – (short tie-rods); P/N 418915
0.016”-0.018” – (long tie-rods); P/N 492380.
NOTE: Refer to attached Table for procedure details/summary.
17. Lock the tie-rod nuts.
18. Clean and lube the Rear Sleeve unit as a preparatory step prior to
installation. Install the rear sleeve into the rear hub: align the bolt holes
and set height from rear of hub tabs to top of shoulder on sleeve to 0.270”
+/- 0.005”.
19. Heat the #6 bearing inner race in hot oil (80 deg. C) for 10 minutes.
20. Install the #6 carbon seal and spacer assembly. on the rear hub as
follows:
1) Front seal spacer plate, small O.D. to rear.
2) Carbon seal (Big Ring) grooves at rear.
3) Seal spacer plate, small O.D. to rear.
4) Sealing ring.
5) Spring washer.
6) Carbon seal, groove to rear.
7) Rear spacer, puller groove to rear.
Align the balance marks of the seal assembly. as per their disassembly
position.
21. Note the #6 bearing. Inner race S/N: _______. Install #6 bearing inner
race with puller groove to the rear.
22. Install #6 bearing oil pump drive gear on inner race and rear hub. Tighten
the six screws and torque.
NOTE: PINION P/N 302902 TORQUE LIMITS ARE 45-50 IN/LBS
PINION P/N 542016 or 762404 TORQUE LIMITS ARE 65-85 IN/LBS
23. Lock the bolts on the oil pump drive gear.
24. Apply Vaseline to the #6 bearing rollers to retain them in the “IN” position.
(BVP236 or equivalent).
25. Use the locating pin to position the exhaust case.
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Mechanic RII Insp.
26. Slowly and carefully move the exhaust case into position, taking care not
to damage the bearing or carbon seal assy.
27. Reassemble all brackets on the flange in reverse order; install the flange
nuts to a torque of a 110 lb/inch.
28. Install the rear engine mounting bolts, if removed; running torque of 30-
400 lbs/inch. NOT APPLICABLE, IF MOUNTS are not required.
29. Remove the engine support and ensure a level horizontal position is
maintained. Use a stand, as required.
30. Rotate the turbine by hand and check for free rotation.
31. Install Thrust Reverser assembly. (or tailpipe assembly. as applicable).
32. Reconnect all disassembled pipes and electrical connections in reverse

order to disassembly. Reconnect the EGT Thermocouple Harness to the
Exhaust Case at the Fire Seal. (brackets).
33. Carry out a final check of the reassembly.
34. Prepare Engine for Test Type III, per PWA Light Overhaul Manual and
notify the results to QC/Engineering.
35. Form 337 prepared by Engineering, including Test Cell results.

(Ref. _________________ company test cell report, title/no., date.)
Signature: ____________________________Date:_________________
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Mechanic RII Insp.
TURBINE NOZZLE CASE & COMPONENTS

Figure 1
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Mechanic RII Insp.
VIEW OF LPT SHOWING DIMENSION “M”

Figure 2
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Page 8 of 14
Mechanic RII Insp.
ILLUSTRATION OF REAR HUB ASSEMBLY

Figure 3
Ser. No. Operation Torque

1. Tighten nuts in pairs, in sequence. 150-250 lb. In.
2. Repeat 1. above to new torque. 350-450 lb. In.
3. Repeat 2. above to new torque. 550-650 lb in.
4. Repeat 3. above to new torque. 750-850 lb in.
5. Loosen 1 pair of nuts to zero (0) lb. in. Tighten to 40-50 lb. in. Install
gauge and tighten further to extend the tierod by:
a) 0.016-0.018 in. for (long) tierods PN 492380.
b) 0.009-0.010 in. for (short) tierods PN 418915.
6. Repeat this for each pair of nuts.
7. Recheck all tierods and adjust as necessary to ensure they all meet
the extension requirement.
8. Further tighten as required to lock the tablock.
Table 1 - Tierod Stretch Torques
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Mechanic RII Insp.
LPT ROTOR COMPONENTS

Figure 4
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Mechanic RII Insp.
LPT SHAFT & OIL TUBE

Figure 5
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Mechanic RII Insp.
LPT 2ND & 3RD STAGES

Figure 6
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Mechanic RII Insp.
LPT 3RD & 4TH STAGES

Figure 7
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Mechanic RII Insp.
REAR HUB & BUILD-UP OF NO. 6 BEARING CARBON SEAL

Figure 8
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Mechanic RII Insp.
TOOLING LIST
Item No. Tool No. Description
1 167-8542-00-00 Engine Rear Support Cradle
2 N/A Engine Support Jack or Stand
3 PWA8041 Puller - #6 Drive Gear
4 PWA6614 Puller - #6 Bearing
5 PWA16111 Puller – Turbine Rear Hub
6 PWA16036 Puller - #41/2 Bearing Heatshield
7 PWA6578 Puller – 3rd & 4th stage disks
8 PWA17830 4th stage NGVs Position Check Adaptor
9 PWA30084 3-Cable Sling
10 N/A Parallel Measuring Bar
11 PWA30188 Tierod Stretch Gauge
12 N/A Tierod Stretch Gauge adaptors (short or long)
13 PWA7172 #6 Inner Race Drift
NOTE: (1) Although PWA tools are listed for various tasks, these will only be used if necessary (e.g.
pullers).
(2) Alternative tooling may be used instead of the PWA tools were applicable.
Table 2
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JOB CARDS
70.03 – ENGINE INSPECTION
TABLE OF CONTENTS
Job Card Page

7201 FIRST STAGE NOZZLE GUIDE VANE ISOTOPE INSPECTION –
JT3D ------------------------------------------------------------------------------------ 70.03.1
7202 FRONT COMPRESSOR REAR HUB EDDY CURRENT INSPECTION –
JT3D ------------------------------------------------------------------------------------ 70.03.13
7203 BORESCOPE INSPECTION RECORD – CFM56-2---------------------------- 70.03.21
7204 BORESCOPE INSPECTION RECORD – JT3D-3B/-7 ------------------------- 70.03.29
Revision 28 05-11-07 70.03-i

INTENTIONAL
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70.03-ii 05-11-07 Revision 28

7201
JOB TITLE
FIRST STAGE NOZZLE GUIDE VANE ISOTOPE INSPECTION - JT3D
Page 1 of 11
Mechanic Inspector
RECORD ENGINE SERIAL NUMBER: _____________________here and on Pg. 6
Tools and Material
Name Quantity Part Number
Front Accessory Support Gasket 1 556312, 466113, or 745465
Spur Gear O-Ring 1 385983
Scavenge Tube O-Ring 2 MS83248-1-113
Scavenge Tube O-Ring 1 MS83248-1-111
Nose Dome O-Ring 2 MS9386-281
PT-2 O-Ring 2 S7E183-113
Tach Generator Gasket 1 MS9134-01
Jar of Petrolatum 1
0.020” & 0.032” Lock wire 1 roll ea.
Rivet Pin(for unmodified Spur 1 450116
Gear)
Locking Snap Ring Pliers for 1
Internal Snap Rings
PWA P/N 16050 or Equivalent 1
Puller (For the Spur Gear)
NOTE: If the front accessory drive spur gear is in an unmodified condition, it will be
necessary to obtain a PWA tool kit to remove and install the #1 bearing retaining nut
in order to access the shaft. See PWA JT3D MM Chap. 72-00 for tool kit inventory.
References
ATI DC-8 MM Chapter 71.03
DACO DC-8-60 MM Chapter 71-10-2
PWA JT3D MM Chapter 72-00
Procedure
CAUTION: ACCESS FOR REMOVAL AND INSTALLATION OF THE NOSE
DOME AND EXTENSION IS GAINED THROUGH THE NOSE COWL
INLET WITHOUT REMOVAL OF THE NOSE COWL.
ACCOUNT FOR ALL PARTS AND TOOLS TO PREVENT F.O.D.
A. REMOVE NOSE DOME (BULLET) AND EXTENSION
1. Remove the Nose Dome in accordance with Section 71.03 of the ATI DC-8 MM.
2. Remove the packing from the inlet compressor case. Inspect and replace as
necessary during assembly.
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Mechanic Inspector
B. REMOVE FRONT ACCESSORY SUPPORT
1. Disconnect N1 Tach Generator cannon plug. Stow connector to prevent damage.
2. If desired, remove the N1 Tach Generator from its mount pad on the front
accessory support. Removal facilitates gear engagement during re-assembly.
3. Remove bolts around circumference of the front accessory support. Pull support
forward and remove it from engine. For further information on dismantling, see
PWA JT3D MM, Chapter 72-00.
4. Remove the O-ring from groove in the front accessory support mating surface.
Prepare support for the installation of new O-ring during assembly.
C. ACCESSING THE SHAFT
NOTE: To gain access to the shaft, in order to introduce the isotope into the engine, it is
necessary to deal with the accessory drive spur gear, which is internally splined into
the front compressor shaft, thus blocking the shaft.
This gear may be in one of the following three configurations.
¾ Sign-off only the applicable configuration and N/A the remaining two. ½
Config. 1: Some engines have a large cap installed in the center of the spur gear.
Remove this cap to access the shaft. The part number of the cap is MS21914-
10FTL. (see Figure 1)
Config. 2: Some engines have their spur gear retained in the internal splines of the
compressor shaft by an internal snap-ring. In this case, the spur gear must come
out to access the shaft. To accomplish this, compress the internal snap-ring with a
pair of locking snap-ring pliers. Then using a PWA P/N 16050 or equivalent
puller, remove the spur gear from the compressor shaft. (see Figure 2)
Config. 3: A low number of engines do not have either of the above described
modifications. The spur gear is retained by the #1 bearing retaining nut. If the
engine is in this configuration, remove the spur gear in accordance with PWA
JT3D MM Chapter 72-00. The list of required tooling is contained in this manual
reference. (see Figure 3)
D. DEPLOY REVERSER, REMOVE AFT FIXED COWLING
1. Deploy the thrust reverser partially or fully, stowing the buckets to prevent
personal injury. Deactivate the reverser using the shutoff valve in the L/H wheel
well. Unsafety the valve and place in the OFF position. Tag both reverser lever
and shut off valve.
2. Remove the L/H and R/H aft fixed cowlings to provide access to the area of the
engine to which the film must be attached.
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Mechanic Inspector
E. RADIOGRAPHIC PROCEDURE
1. Ensure the aircraft is in a location which provides protection from radioactivity for (X-Ray
Agency NDT
the general public. Provide a portable warning barrier located far enough from the
Tech.
engine(s) being inspected to assure no exposure to passing personnel. Signatures).
2. Locally fabricate a tube to accept Iridium-192, type 100C source to fit through the
0.490 inch diameter hole in turbine shaft bearing oil pressure tube and heatshield
assembly (see Figure 4). Insert a cap in the inner end of the tube to provide a
locating stop for the source when it is in position. Mark the tube 107.125 inches
from the capped end for reference on the depth of insertion into the shaft. Locally
fabricate the tooling necessary to support the tube in position. THE PROPER
PERSPECTIVE MUST BE ACHIEVED IN ORDER TO RECEIVE AN
ACCURATE MEASURMENT OF NGV BOWING (see Figure 5).
NOTE: Equivalent type film may be used when exposures are adjusted to give the same
results as the procedure cited below.
3. Place the film on the engine.
a. Attach 0.010 inch thick lead screens to both the front and back of the film.
Place the film, Kodak type M, 7 x 17 inches, around the front of the turbine
nozzle case. Butt the film against the aft side of ‘K’ flange and attach to flange
by the hinge of the film holder. (see Figure 4)
b. Tape the film to the turbine nozzle case.
c. Number the films one through seven, clockwise, as viewed from the rear of the
engine, starting at the twelve o’clock position and placing numerals one inch
aft of the hinge of the film holder. Mark the engine serial number on the #1
film. (See diagram on Interpretation Form — Page 6.)
4. Preferred gamma-ray projector equipment is the Technical Operations Model 529
Gamma Ray Projector, with the Model 533 Shielded Container and flexible guide
tube. EQUIVALENT EQUIPMENT MAY BE USED.
5. Expose the film.
a. Crank the source tube into the core of the engine until the 107.125 inch mark
on the tube lines up with the front face of the compressor inlet cone support
assembly.
b. Using the projector equipment, crank the source out and expose the film for
875 curie/minutes. Bear in mind that if equivalent film and equipment are
being used, a different exposure time will probably be required.
6. Develop the film in accordance with the manufacturer’s recommendations.
Assure that proper exposure and coverage of the trailing edges if the nozzle guide
vanes and the leading edges of the T-1 blades are obtained. A ‘thin’ film with
clear detail is required to be read properly. (see Figure 5)
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Mechanic Inspector
F. INSTALL ACCESSORY DRIVE SPUR GEAR
1. For those engines with the cap mounted in the center of the spur gear, re-install the
cap on its fitting. Apply an approved anti-seize compound to the threads and
torque to 180 inch/pounds. Lock wire the cap.
2. For those engines whose spur gears are retained by an internal snap-ring, first
install a new O-ring on the spur gear. Lubricate the O-ring with petrolatum or
engine oil. Compress the snap-ring and lock into place with the snap-ring pliers.
Insert the spur gear into position in its internal splines and release the snap-ring,
confirming proper seating in its groove.
3. For those few engines which are unmodified, assemble the spur gear and the #1
bearing retaining nut in accordance with the PWA JT3D MM Chapter 72-00.
G. INSTALL FRONT ACCESSORY SUPPORT ASSEMBLY
1. Place a new seal, P/N 556312, in the groove on the rear face of the front accessory
support.
2. Replace seals as required on the front scavenge pump oil tube.
3. Align the pin in the front accessory support with the hole in the #1 bearing
support. Then bring the front accessory support into position making sure that the
scavenge pump and tachometer drive gears mesh properly with the main accessory
drive spur gear.
4. Secure the front accessory support to the bearing support with washers and bolts.
Tighten the bolts to 65-85 inch/pounds and safety.
5. If removed, reinstall the N1 Tach Generator using a new/serviceable gasket.
Connect and safety the Tach Generator electrical connector.
H. INSTALL AFT FIXED COWLINGS AND STOW THE REVERSER
1. Install the R/H and L/H aft fixed cowlings.
2. Re-activate the thrust reverser and stow it. Safety the thrust reverser shut-off
valve in the L/H wheel well in the open position.
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Mechanic Inspector
I. INSTALL NOSE DOME AND EXTENSION
1. Install the Nose Dome Extension.
a. Ensure the throttle and thrust reverser lever is tagged and the circuit breakers
are open in accordance with step #1 of this recurring non-routine.
b. Lightly lubricate the packing with petrolatum. Install the packing on the
engine compressor inlet case.
c. Position the nose dome extension over the packing and onto the engine attach
stud. Carefully align the PT2 extension tube and the PT2 fitting on the
engine.
d. Tighten the captive self-locking nuts on the aft end of the nose dome
extension to a torque of 100-140 inch/pounds. Check torque for BAC dome.
e. Tighten tube nut on the aft end of the PT2 tube extension to a torque of 100
inch/pounds and safety with 0.020” lock wire.
2. Install the Nose Dome in accordance with Section 71.03.
J. ENGINE RUN AND OPS CHECK
1. Ensure the entire engine has been secured and the engine inlet is free of foreign
objects.
2. Perform an engine run, checking the following items:
a. N1 Tach indication.
b. EPR indication.
c. After shut down, ensure that there is no oil leak on the front accessory support
split line, and no oil leaking out of the #1 bearing lab seal onto the C-1 Disk,
indicating an inoperative Front Scavenge Pump.
K. RADIOGRAPHIC INTERPRETATION (Form Follows)
1. X-ray Agency or other qualified company representative shall interpret the film (X-Ray Agency
NDT Tech.
and complete the following interpretation form to determine engine serviceability
Signature.)
before the aircraft is returned to service.
2. Use a 6” rule with graduations at least 1/32”. Refer to Figure 5 for reference
points. Measure the distance between the trailing edge of the Nozzle Guide Vane
and the leading edge of the Turbine Blade.
3. Categories correspond to clearance limits as described in the following table.
Determine the category of clearance for each NGV. The lowest category
clearance on a given film will determine the category of the film. The lowest
category clearance film will determine the category of the engine.
NOTE: A clearance of more than 21/32 inch as measured on the film is Category 5.
A Category 1A engine must be removed from service
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Mechanic Inspector
L. INTERPRETATION FORM
Category Inches Millimeters Disposition
3
1A Less than /16 Less than 5.0 Remove from service.
3
May remain in service but requires removal or re-
1B /16 to 1/4 5.0 to 6.5 inspection within 50 hours. If re-inspection shows no
progression, it may remain in service and additional 35
hours. Any progression requires immediate removal.
1 5
2 /4 to /16 6.5 to 8.0 Re-inspect prior to 275 hours.
5 7
3 /16 to /16 8.0 to 11.0 Re-inspect prior to 450 hours.
7
4 /16 to 21/32 11.0 to 16.5 Re-inspect prior to 1200 hours.
21
5 More than /32 More than 16.5 Re-inspect prior to 3000 hours.
ATI INSPECTOR, engine okay to continue in service? YES NO SIGNATURE:
Instructions: 1. Mark the position of the lowest category NGV for each film on the diagram provided. 2. List the
category of the worst NGV for each film in the column to the left. 3. Enter the category of the engine’s worst NGV in
the block at the center of the diagram. This category determines the category of the engine.
ENGINE SERIAL NUMBER:
______________________
Film Number
1. Category ______
2. Category ______
3. Category ______
4. Category ______
5. Category ______
6. Category ______
7. Category ______
NOTE: The film sequence is
clockwise as viewed from the
rear of the engine.
X-Ray Agency:
Completed by: (Tech) QC Review by: Date Reviewed:
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Mechanic Inspector
SPUR GEAR WITH CAP (Config. 1)

Figure 1
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Mechanic Inspector
SPUR GEAR MOFIFIED WITH SNAP-RING (Config. 2)

Figure 2
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Mechanic Inspector
UNMODIFIED SPUR GEAR (Config. 3)

Figure 3
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Mechanic Inspector
1. Capped Tube (Source Travels Inside)

2. 107.125 Inches
3. Kodak Type M Film (7 x 17 Inches), 7 Sheets
4. Iridium -192 Source
5. Cap (extend pointer 5 to end of capped tube)
6. 0.490 - 0.510 Inch Diameter Hole in Turbine Shaft Bearing Oil Pressure Tube and
Heatshield Assy.
7. Flexible Guide Tube
8. Shielded Container
9. Gamma Ray Projector
ISOTOPE INSPECTION OF STAGE 1 NGV’S

Figure 4
70.03.10 08-01-00 Revision 10

A/C NUMBER TAT TAC POS DATE DATE JOB CARD NUMBER
7201
JOB TITLE
Page 11 of 11
Mechanic Inspector
1. Trailing Edge Nozzle Guide Vane

2. Bowed Nozzle Guide Vane
3. Leading Edge Turbine Blade
REQUIRED PERSPECTIVE OF NGV RADIOGRAPH

Figure 5
Revision 10 08-01-00 70.03.11

INTENTIONAL
BLANK
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7202
JOB TITLE
FRONT COMPRESSOR REAR HUB EDDY CURRENT INSPECTION - JT3D
Page 1 of 7
Mechanic Inspector
Engine Serial Number: Work Request Number initiating this
action:
Tools and Materials
Part Name Quantity Part Number
Front Accessory Support Gasket 1 each 556312, 466113 or 745465
Spur Gear O-ring 1 each 385983
Scavenge Tube O-ring (ADC Hush Kit) 2 each MS83248-1-113
Scavenge Tube O-ring (ADC Hush Kit) 1 each MS83248-1-111
Nose Dome O-ring (ADC or QNC) 2 each MS9386-281
Nose Dome O-ring (QNC Hush Kit) 2 each 364525
PT-2 O-ring (ADC Hush Kit) 1 each S7E183-113
Tach Generator Gasket 1 each MS9134-01
Petrolatum 1 jar
0.020” & 0.032” Lock Wire 1 roll ea.
Rivet Pin (for unmodified Spur Gear) 1 each 450116
Locking Snap-Ring Pliers
PWA P/N 16050 Spur Gear Puller or Equivalent
Magnaflux ED 500 Series Eddy Current Tester or Equivalent
PWA 30518 FCR Hub Inspection Tool
NOTE: If the front accessory drive spur gear is in an unmodified condition, it will be
necessary to obtain a PWA tool kit to remove and install the #1 bearing retaining
nut in order to access the shaft. See PWA JT3D MM Chap. 72-00 for tool kit
inventory.
References
ATI DC-8 MM Chapter 71.03
DACO DC-8-60 MM Chapter 71-10-2
PWA JT3D MM Chapter 72-00
Procedure
CAUTION: ACCESS FOR REMOVAL AND INSTALLATION OF THE NOSE
DOME IS GAINED THROUGH THE NOSE COWL INLET WITHOUT
THE REMOVAL OF THE NOSE COWL.
ACCOUNT FOR ALL PARTS AND TOOLS TO PREVENT F.O.D.
A. REMOVE NOSE DOME (BULLET) AND EXTENSION
1. Remove Nose Dome in accordance with Section 71.03
a. Carefully pull Nose Dome Extension forward and off studs attaching it to
engine.
b. Remove the packing from the inlet compressor case. Inspect and replace as
necessary during assembly.
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Mechanic Inspector
B. REMOVE FRONT ACCESSORY SUPPORT
1. Disconnect N1 Tach Generator cannon plug. Stow connector to prevent damage.
2. If desired, remove N1 Tach Generator from its mount pad on the front accessory
support. Removal facilitates gear engagement during re-assembly.
3. Remove bolts around circumference of the front accessory support. Pull support
forward and remove it from engine. For further information on dismantling, see
PWA JT3D MM Chap. 72-00.
4. Remove O-ring from groove in front accessory support mating surface. Prepare
support for installation of new O-ring during assembly.
C. ACCESSING THE SHAFT
NOTE: In order to introduce the eddy current probe into the engine, it is necessary to
deal with the accessory drive spur gear which is internally splined into the front
compressor shaft thus blocking the shaft.
This gear may be in one of the following three configurations.
¾Sign-off the appropriate configuration and N/A the remaining two.½
Config. 1: Some engines have a large cap(P/N MS21914-10FTL) installed in the center
of the spur gear. Remove this cap to access the shaft. (see Figure 1)
Config. 2: Some engines have their spur gear retained in the internal splines of the
compressor shaft by an internal snap-ring. In this case, the spur gear must come
out to access the shaft. To accomplish this, compress the internal snap-ring with
a pair of locking snap-ring pliers. Then, using a PWA P/N 16050 or equivalent
puller, remove the spur gear from the compressor shaft. (see Figure 2)
Config. 3: A low number of engines do not have either of the above described
modifications. The spur gear is retained by the #1 bearing retaining nut. If the
engine is in this configuration, remove the spur gear in accordance with the PWA
JT3D MM Chap. 72-00. The list of required tooling is contained in this manual
reference. (see Fig. 3)
D. FCR HUB EDDY CURRENT INSPECTION (PWA JT3D MM CHAP. 72-00)
NOTE: For the inspection of the FCR HUB installed in the JT3D-3D/-7 use the
Magnaflux ED 500 Eddy Current Tester with the PWA 30518 inspection tool.
Equivalent equipment may be used. Remove tape from the end of the probe.
1. Equipment Set-Up Procedure for FCR Hub Inspection:
a. Set Frequency Control to ‘0,’ the highest frequency. Turn Sensitivity Control
to medium. Turn Balance Control as required to obtain on-scale readings.
b. Using a portable light, locate the lightening/counterweight hole (outer holes in
conical section) of hub which is located at or near bottom of hub.
CAUTION: EXERCISE EXTREME CAUTION TO AVOID DAMAGE TO
INSPECTION EQUIPMENT.
c. Insert inspection tool through bore of #1 hub and lightening/counterweight
hole.
d. Pull trigger on tool handle to release eddy current probe head enough to rest
probe head against conical section of rear side of hub. There should be no
pressure on trigger once probe head has been positioned against hub.
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JOB TITLE
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Mechanic Inspector
e. Cautiously extract tool toward front of engine until probe head has positioned
itself in hub flange-bell-radius which is inboard of #7 and #8 rotor spacer
flange ID.
f. While observing micro-ampere meter, rotate tool and scan radius in both
directions. Meter will indicate large deflections toward zero as probe passes
tierod holes. These deflections may be standardized to -100 units by careful
frequency selection.
g. Select proper frequency:
(1) Turn Liftoff Control to about 240 and repeat step f.
(2) Continue adjusting the Liftoff and Balance Controls until a point is
reached where tierod bolt proximity causes down-scale meter deflection
100 units. Tierod bolt effect should be no greater than 20 micro-ampere
deflection toward zero. Frequency Control should be in No. 2 or No. 3
position.
(3) Release forward pressure on tool and carefully push toward rear of engine
until probe head assumes a horizontal position, and extract from
lightening/counterweight hole.
(4) Extract tool from inside of engine through bore of #1 hub.
(5) Crack deflection definition of +150 units may be observed using a
simulated cracked test piece.
(6) The instrument is now ready for inspection of hub radius.
2. FCR Hub Inspection Procedure:
a. Repeat steps b. through e. in the Set-Up Procedure. Mark the first hole that is
being used for inspection with a magic marker to aid in determining starting
point of inspection.
b. Rotate probe slowly from one extreme to another and observe the meter for up-
scale deflection. Entire travel of probe head is approximately four inches.
Indication of a crack will be noted on the meter up-scale when 100 micro-
amperes or more are observed.
c. Repeat steps g. (4) and (5) of ‘Set Up Procedure.’
d. Continue to inspect the entire circumference of the hub flange-bell-radius
through the remaining five lightening/counterweight holes.
e. Crack indication (s) will require removal of engine from aircraft and
disassembly in order to confirm indication.
f.
SIGN IF...NO CRACK(S) SIGN IF... CRACK(S) INDICATED.
JOB CARD TERMINATED. ENGINE
WRITTEN UP FOR REMOVAL.
Record Engine Serial Number:
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Page 4 of 7
Mechanic Inspector
E. INSTALL ACCESSORY DRIVE SPUR GEAR
1. For those engines with the cap mounted in the center of the spur gear, re-install the
cap on its fitting. Apply an approved anti-seize compound to the threads and
torque to 180 inch/pounds. Safety the cap.
2. For those engines whose spur gears are retained by an internal snap-ring, first
install a new O-ring on the spur gear. Lubricate the O-ring with petrolatum or
engine oil. Compress the snap-ring and lock into place with the snap-ring pliers.
Insert the spur gear into position in its internal splines and release the snap-ring,
confirming proper seating in its groove.
3. For those few engines which are unmodified, assemble the spur gear and #1
bearing retaining nut in accordance with the PWA JT3D MM Chap. 72-00.
F. INSTALL FRONT ACCESSORY SUPPORT ASSEMBLY
1. Place a new seal, P/N 556312 in the groove on the rear face of the front accessory
support.
2. Replace seals as required on the front scavenge pump oil tube.
3. Align the pin in the front accessory support with the hole in the #1 bearing
support. Then bring the front accessory support into position, making sure that
the scavenge pump and tachometer drive gears mesh properly with the main
accessory drive spur gear.
4. Secure the front accessory support to the bearing support with washers and bolts.
Tighten the bolts to 65-85 inch/pounds and safety.
5. If removed, install the N1 Tach Generator using a new gasket. Connect and safety
the Tach Generator electrical connector.
G. INSTALL NOSE DOME AND EXTENSION
1. Install the Nose Dome Extension (if removed) in accordance with Section 71.03
2. Install the Nose Dome in accordance with Section 71.03.
H. ENGINE RUN AND OPS CHECK

1. Ensure the entire engine has been secured and the engine inlet is free of foreign
objects.
2. Perform an engine idle run. Check the following:
a. N1 Tach indication.
b. EPR indication.
c. After shut-down, ensure there is no oil leak on the front accessory support split
line, and no oil leaking out of the #1 bearing lab seal onto the C-1 Disk,
indicating an inoperative front scavenge pump.
(Only Graphics Follow)
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JOB TITLE
Page 5 of 7
Mechanic Inspector
SPUR GEAR WITH CAP (Config. 1)

Figure 1
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7202
JOB TITLE
Page 6 of 7
Mechanic Inspector
SPUR GEAR MODIFIED WITH SNAP-RING (Config. 2)

Figure 2
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7202
JOB TITLE
Page 7 of 7
Mechanic Inspector
UNMODIFIED SPUR GEAR (Config. 3)

Figure 3
Revision 10 08-01-00 70.03.19

INTENTIONAL
BLANK
70.03.20 08-01-00 Revision 10

7203
JOB TITLE
BORESCOPE INSPECTION RECORD - CFM56-2
J/C Reviewed By: Date:
Page 1 of 8
Mechanic Inspector
Engine Serial Number: Work Request Number or Log Page item
initiating this action:
General Information
Borescope inspection (BSI) of the engine is required for visual assessment as part of the
powerplant maintenance program described in the Powerplant Maintenance Program
Manual (PMPM). Routine inspections are at scheduled intervals; the Scheduled
Inspection and the ‘C’ Check Inspection. Other BSI checks, Special Inspections, will be
required resulting from engine problems, trend symptoms, or troubleshooting/fault
isolation. This Job Card shall be used for documenting the Special, the Scheduled
and the Spare Engine ‘C’ Check Borescope Inspections. In all cases, the Scheduled
Inspection should be accomplished.
Tools and Materials
Item Part Number
Borescope Kit MX-6213
Light Source MX-5507
Cowl Pump MX-7211
Graphite Grease MX-5177
O-Ring (2 ea.) J221P152 (ALT 649-393-152-0)
¾” Square Drive Adapter
2’ Breaker Bar
Safety Wire
CFM56-2C Maintenance Manual
Procedure
1. Types of Inspections:
A. The scope of Special Inspections is determined by the CFM56-2C MM.
B. The scope of the Scheduled Inspection is limited to the following:
Ο∗
HPT Blades and Shrouds and the LPT Stage 1 Blades.
C. The scope of the ‘C’ Check Inspection is limited to the following: HPC Rotor
Stages 1, 5, 8 and 9, Combustion Chamber (including Fuel Nozzles), HPT Nozzle,
∗
HPT Blades and Shrouds, and LPT Stage 1 Blades.
2. Accomplish each section completely according to type of inspection being performed.
Ο ∗
Type of inspection (circle one): SPECIAL SCHEDULED ‘C’ CHECK
3. If Special Inspection, what is the reason for inspection: _______________________
4. Check sections and circle stages to be inspected:
Fan & Booster
∗ ∗ ∗ ∗
Compressor Rotor, Stages 1 - 2 - 3 - 4 - 5 - 6 - 7 - 8 - 9
∗
Combustion Chamber
∗
HPT Nozzle
∗
HPT Rotor Ο
∗
LPT Rotor, Stages 1Ο - 2 - 3 - 4
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7203
JOB TITLE
J/C Reviewed By Date
Page 2 of 8
Mechanic Inspector
5. Documentation of Defects:
A record of the inspection will be maintained for each BSI conducted. Forms are
provided which include BSI record forms for each section of the engine. Provide
maps so that any damage can be recorded pictorially for description of damaged area
and understood by anyone at a remote location providing assistance. The propagation
of the damage can then be pictorially illustrated during subsequent inspections. The
inspection records and maps will remain with the engine records until the damaged
parts are repaired or replaced.
6. Mapping Defects:
Map over-serviceable defects on copies of diagrams from the CFM56-2C MM.
Record damage on maps at the inspection site. Do not rely on memory of the defect to
allow the mapping to be done in an office after the inspection.
7. Accurate description of defects are critical to the inspection process. Examples:
cracks or tears, nicks and scratches, dents, erosion, tip curl, pits, corrosion, distortion,
missing metal, dirt, discoloration, burns, blocked cooling air passages, buckling,
bowing, wear, leading edge, trailing edge, tip, platform. Use terms of CFM M/M.
8. All serviceability limits shall be those as stated in the CFM56-2C Maintenance
Manual. Questionable or over-serviceable defects may be extended only per 72-00-00
Limit Extensions. If Limit Extensions are used, a Carry-Over item would need to be
issued to permit operations to a station where repairs or an engine change could take
place. In certain cases it may be necessary to requeste a Customer Departure Record
from CFMI. If granted a CDR, reinspections are controlled by the Engine Records
Dept.
9. Record inspection on inspection record. Record quantity of Non-Serviceable blades in
“NS” block for each category. Do not record serviceable blade quantity, just a check
mark in either the Serviceable or No Defect block. (Only one of the three blocks in
each category should be marked.)
S=SERVICEABLE NS=NON-SERVICEABLE ND=NO DEFECT
10. If the Compressor or HPT Sections are to be inspected, have a Maintenance Technician
assist to accomplish the following:
Remove cover plate from core engine rotation pad located on left side (aft looking
forward) of the Transfer Gearbox (TGB), opposite starter. Remove and discard O-
ring. Install a ¾ in. square drive adapter with a 2 ft. long breaker bar into the drive
pad. Use a short extension to ensure clearance between breaker bar and TGB housing.
Rotate core rotor as required for borescope inspection, by turning the square drive
adapter counter-clockwise.
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7203
JOB TITLE
Page 3 of 8
Mechanic Inspector
11. Inspector: Inspect engine documenting defects using the Borescope Inspection Record
on pages 4 through 8 as required.
CAUTION: FAILURE TO INSTALL A NEW O-RING ON THE CORE ENGINE
ROTATION PAD COVER PLATE CAN RESULT IN LOSS OF OIL
DURING ENGINE OPERATION AND POSSIBLE ENGINE
FAILURE.
12. Remove the breaker bar from the TGB drive pad and install new O-rings on the drive
pad cover plate.
13. Lightly coat bolts with MIL-T-5544B grease. Install the cover plate on the TGB drive
pad and secure with 3 bolts and washers. Torque IAW the CFM56-2C MM.
NOTE: Borescope plugs and Ignitors should be lubricated with MIL-T-5544B grease
prior to installation. Ignitors should be started by hand for at least three turns
prior to torquing. Ignition leads should be carefully reinstalled to avoid twisting
and other damage.
14. Install and secure the borescope plug in the Booster section IAW 72-21-00 I/C.
15. Install and secure the borescope plugs in the Compressor section IAW 72-31-00 MP.
16. Secure the Combustion section IAW 72-42-00 MP, which includes the installation of
Fuel Nozzles and Ignitors.
17. Install and secure the borescope plugs in the HPT section IAW 72-52-00 MP.
WARNING: BORESCOPE PLUG S18 AT THE AFT SIDE OF THE HPT IS NOT
INTERCHANGEABLE WITH OTHER PLUGS. IT MUST BE
REINSTALLED IN ITS ORIGINAL LOCATION OR ENGINE
DAMAGE MAY RESULT.
18. Install and secure the LPT section IAW 72-54-00 I/C.
19. If Special or scheduled Inspection, enter compliance with this Job Card on Log Sheet
and any statement needed to extend an over-serviceable defect.
Carry Over # _______________________.
20. If Spare Engine ‘C’ Check, attach a copy of this Job Card to engine.
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JOB TITLE
Page 4 of 8
Mechanic Inspector
Inspection Detail for Fan & Booster Section 72-21-00 I/C
Special Inspections required in the Fan & Booster section are typically caused by Fan stall,
Foreign Object Damage (FOD) and suspect bird ingestion, and high Fan vibs.
BORESCOPE INSPECTION RECORD
ENGINE S/N: For Records Dept. Use Only
ENGINE TSN: ENGINE CSN:
FAN & BOOSTER SECTION
INSPECTION BY: ____________________________ TYPE OF INSPECTION: ____________________
INSPECTOR SIGNATURE: ___________________________ DATE: _____________________
FAN & BOOSTER ROTOR Remarks: A R
C E
NUMBER OF
TRAILING
Borescope
Insp Port
LEADING
C J
BLADES
E E
EDGE
EDGE
P C
L/E NICKS T/E NICKS TIP CURL/RUB BENT/DENTED T T
STAGE S NS ND S NS ND S NS ND S NS ND
1 1 44
2 83
S0 3 83
S0 4 83
Stage 2 is inspected through Booster inlet.
NOTES:
VIDEO? YES NO
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7203
JOB TITLE
Page 5 of 8
Mechanic Inspector
Inspection Detail for Compressor Section 72-31-00 MP
Special Inspections required in the Compressor section are typically caused by Core stall,
oil fumes detected in cabin air, Foreign Object Damage (FOD), and high Core vibs.
For Records Dept. Use Only
ENGINE S/N: ENGINE TSN: ENGINE CSN:
COMPRESSOR SECTION
HPC ROTOR Remarks: A R
C E
C J
TRAILING EDGE
LEADING EDGE
E E
Borescope
Insp Port
NUMBER OF
P C
BLADES
T T
L/E NICKS T/E NICKS TIP CURL/RUB BENT/DENTED
S1 1 38
S2 1 38
2 53
S3 2 53
3 60
S4 3 60
4 68
S5 4 68
5 75
S6 5 75
6 82
S7 6 82
7 82
S8 7 82
8 80
S9 8 80
9 76
NOTES:
VIDEO? YES NO
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JOB TITLE
Page 6 of 8
Mechanic Inspector
Inspection Detail for Combustion Section 72-42-00 MP
Special Inspections required in the Combustion section are typically caused by high
Exhaust Gas Temperature (EGT), overtemperature during takeoff or cruise and impact
damage observed on High Pressure Turbine (HPT) rotor blades.
For Records Dept. Use Only
ENGINE S/N: ENGINE TSN: ENGINE CSN:
COMBUSTOR SECTION
Combustor Remarks: A R
C E
Borescope
Insp Port
C J
COMBUSTON CHAMBER FUEL NOZZLES E E
P C
DISTORTION CRACKS CARBON Tip Pos to Swirler
T T
S NS ND S NS ND S NS ND S NS ND
S10 Igniter Plug
S11 Igniter Plug
S12
S13
S14
S15
When a fiberscope is used it is not necessary to remove all of the borescope plugs and spark igniters.
Description of Defects:
Inspection Detail for HPT Nozzle Section 72-51-00 MP

Special Inspections required in the HPT Nozzle are typically caused by over temperature operation, engine stall,
and Exhaust Gas Temperature (EGT) trend step increase.
HPT NOZZLE BURNS CRACKS CARBON MISSING METAL ACCEPT REJECT
S NS ND S NS ND S NS ND S NS ND
S10 Igniter
Plug
S11 Igniter
Plug
S12
S13
S14
S15
Description of Defects:
VIDEO? YES NO
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7203
JOB TITLE
Page 7 of 8
Mechanic Inspector
Inspection Detail for HPT Rotor Section 72-52-00 MP
Special Inspections required in the HPT section are typically caused by Core stall (N2),
overtemperature, metal in the tailpipe, N2 overspeed, core vibs, and hard landing. In all
cases, the general on-condition check should be accomplished.
HPT SECTION
HPT ROTOR Remarks: A R
C E
NUMBER OF
TRAILING
Borescope
Insp Port
LEADING
C J
BLADES
E E
EDGE
EDGE
P C
S10 1 72
S11
S17 1 72
S18
Two blades (90° apart) are notched to indicate the extent of blade tip rub.
Record number of tip notches remaining: Blade 1: _____________ Blade 19: _______________
NOTES:
Inspection Detail for HPT Shroud Section 72-53-00 MP

Engines that have experienced HPT Shroud Aft support failure exhibit unusual HPT Blade tip wear.
Engines that exhibit this wear to the bottom of the top trailing edge cooling slot are to be scheduled for removal.
(CESM-047)
Does this engine exhibit unusual wear characteristics? Yes____________ No_______________
NOTES:
VIDEO? YES NO
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JOB TITLE
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Mechanic Inspector
Inspection Detail for LPT Rotor Section 72-54-00 I/C
Special Inspections required in the LPT section are typically caused by overtemperature
(the LPT Stage 1 & 4 Blades must be inspected) and metal in the tailpipe (all LPT Stages
must be inspected).
LPT SECTION
LPT ROTOR Remarks: A R
C E
NUMBER OF
TRAILING
Borescope
Insp Port
LEADING
C J
BLADES
E E
EDGE
EDGE
P C
S17 1 174
S18
1 174
S20
2 162
2 162
S21
3 157
3 157
S22
4 160
Inspect the Stage 4 Blades for unlatching, shingling, and interlock wear in accordance with
72-54-00 I/C.
NOTES:
VIDEO? YES NO
21. For C-Check and Engine Acceptance Borescope: Record Borescope on DVD/CD and
send DVD/CD to Engine Analyst at LIT HQ.
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7204
JOB TITLE
BORESCOPE INSPECTION RECORD – JT3D-3B / -7
J/C Reviewed By: Date:
Page 1 of 16
Mechanic Inspector
Engine Serial Circle One: Work Request Number or Log Page item
Number: JT3D- 3B / 7 initiating this action:
General Information
Visual Inspections (VSI) and Borescope Inspection (BSI) of the engine is required for an
assessment of an engine’s serviceability, as part of the Company’s powerplant
maintenance program as described in the Powerplant Maintenance Program Manual
(PMPM). Scheduled / Routine BSI Inspections are not a requirement for JT3D engines.
Non-Routine BSI checks, or Special Inspections, will be required resulting from engine
problems, trend monitoring symptoms, or troubleshooting / fault isolation, Receiving
Inspections, and Lease Returns. Visual and BSI Inspections maybe performed either on-
wing or off-wing.
NOTE: This Job Card shall be used for documenting all JT3D Borescope Inspections.
Tools and Materials

Item Part Number Qty
Borescope Kit (6mm flexible w/min 2 meter length)
Borescope Kit (8mm flexible w/min 2 meter length)
Light Source (300 watt high intensity)
Starter Spline Quill Tool
NOTE Alternate procedures found in this Job Card

may allow for substitution of any BSI
equipment with suitable equivalent.
Tooling, as required, for performing maintenance tasks

may vary and is not listed herein. See applicable M/M.
References
Item Part Number
Pratt & Whitney, JT3D Maintenance Manual – Engine

Inspection / Check: 72-0.
Pratt & Whitney, Internal Engineering Notice – Engine

Borescope Inspection Procedures & Limits: IEN
99JC011
Company Powerplant Maintenance Program Manual
Company Engine Run Handbook
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7204
JOB TITLE
BORESCOPE INSPECTION RECORD - JT3D-3B / -7
Page 2 of 16
Mechanic Inspector
Procedure
1. Types of Inspections: (Inspector - sign or N/A applicable inspection type to be performed)
A. Special Borescope Inspection: The scope of Special Borescope Inspections may
vary, as required, to assess the serviceability of an engine:
1. Reason for Special Inspection: .
2. Using Inspection Matrix Below, Check Inspections to be Performed.
B. Receiving Borescope Inspection: The scope of the Receiving Borescope
Inspections, to assess the serviceability of an engine:
C. Overtemp Borescope Inspection: The scope of the Receiving Borescope
Inspections, to assess the serviceability of an engine:
D. Lease Borescope Inspection: The scope of the Lease Borescope Inspections, to
assess the serviceability of a leased engine:
RECEIVING
OVERTEMP
INSPECTION MATRIX
SPECIAL *
INSP TYPE
* SPECIAL
LEASE
INSPECTION
JOB CARD ONLY
PROCEDURE
INSPECTION DESCRIPTION REFERENCE INSPECTOR
X X X Fan Area: Fan Inlet & Exit Case VSI- 1
X X X Fan Area: Fan Inlet Guide & Case Vanes VSI- 2
X X X Fan Area: Fan Spacers VSI- 3
X X X C1 Blades VSI- 4
INSPECTION REQUIREMENTS
C2 Blades N/A
X X X 9th Stage LPC Blades, Low Pressure Compressor BSI- 1
X X X 10th Stage HPC Blades, High Pressure Compressor BSI- 2
X X X Combustion Chambers (Left Side # 8,7,6,5 from igniter access) BSI- 5
X X X Combustion Chambers (Right Side # 1,2,3,4 from igniter access) BSI- 5
X X X T1 HPT NGV, High Pressure Turbine Nozzle Guide Vanes BSI- 6
X X X T1 HPT Blades, High Pressure Turbine BSI- 7
T2 LPT Blades, Low Pressure Turbine N/A
T4 LPT NGV, Low Pressure Turbine Nozzle Guide Vanes N/A
X X X T4 LPT Blades, Low Pressure Turbine VSI-5
X X X Exhaust Area: Exit Case & EGT Probes VSI- 6
* SPECIAL INSPECTION: CHECK OR N/A AND SIGN FOR EACH SPECIAL INSPECTION TO BE PERFORMED
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Page 3 of 16
Mechanic Inspector
3. Inspection Procedures:
NOTE: Procedures and Equipment in this Job Card may be substituted with a
suitable equivalent, if available, as listed within Alternate Procedures,
the Pratt & Whitney Maintenance Manual, or other Approved
Documentation.
A. Preparation:
a. Allow proper cool down of engine, to prevent damage to Borescope
equipment.
b. Disconnect all ignition sources by pulling circuit breakers for affected engine
ignition (exciter boxes).
c. Tag all engine controls not to be operated for the engine Borescope inspection.
d. Remove engine cowlings, including all forward and aft long duct bifurcation
ducts per ATI DC-8 M/M 71.02.1.
e. Remove the #4 and #5 combustion chamber igniter plugs per DACO M/M
74-10-1 (If applicable)
f. Remove engine starter per DACO M/M 80-10-1.
g. Perform Freedom of Rotation Check, as follows:
i. Performing following freedom of rotation check reduces the possibility of
subsequent damage by foreign objects.
ii. Prior to engine inspection, high compressor must be rotated by turning
starter drive, using Starter Spline Quill Tool. The low compressor shall be
rotated manually by the first stage compressor blades.
iii. If there is any unusual resistance or unusual sound, an investigation must
be made to determine the cause.
CAUTION: ENGINE MUST BE TURNED IN THE NORMAL DIRECTION OF

ROTATION ONLY (COUNTERCLOCKWISE WHEN FACING THE INLET).
B. Visual Inspections: The Procedures for Visual Inspections, or VSI, may vary, as
required, to asses the serviceability of an engine. Inspections shall be performed in
accordance with P&W Maintenance Manual 72-00, Inspection and Check.
VSI- 1: Perform Visual Inspection of Inlet & Exit Case.
VSI- 2: Perform Visual Inspection of Fan Inlet Guide & Case Vanes.
VSI- 3: Perform Visual Inspection of Fan Spacers.
VSI- 4: Perform Visual Inspection of C1 Blades.
VSI- 5: Perform Visual Inspection of T4 LPT Blades, Low Pressure Turbine
VSI- 6: Perform Visual Inspection of Exhaust Area: Exit Case & EGT Probes
Revision 28 05-11-07 70.03.31

ATI-001
7204
JOB TITLE
Page 4 of 16
Mechanic Inspector
C. Borescope Inspections: The procedures of Borescope Inspections may vary, as
required, to assess the serviceability of an engine. Types and Requirements of
Inspections can be found in Section 1 of this job card.
NOTE: Perform Borescope inspection in an area with protection from the weather.
If Borescope inspection is done in wet conditions, use sufficient protection
to prevent damage to equipment and / or possible electrical shock hazard
to personnel.
Borescope Inspection Locations:
Figure 1.
70.03.32 05-11-07 Revision 28

ATI-001
7204
JOB TITLE
Page 5 of 16
Mechanic Inspector
BSI- 1: Perform Borescope Inspection of the 9th Stage LPC Blades, Low Pressure
Compressor
BLADE PERMITTED DAMAGE

AREA LIMITS (INCHES)
Tears & Nicks up to 3/16
A
Any Indentation
Sharp Indentations up to 5/16
Smooth Indentations up to 3/16
B
No Tears or Cracks
ANY DENT *
C
No Tears or Cracks
ANY DENT *
D ANY DENT *
E NO DAMAGE ALLOWED
* Dent must be smooth & rounded without
cracks, tears, or material removed
1. 3/16 2. 3/16 3. 3/32

Figure 2.
1. Connect 6mm flexible Borescope to light source.
2. Increase to maximum light output for the Borescope light source.
3. Insert the Borescope into the Ps3 boss port at the 12:00 position of the engine.
4. Move forward to view the 9th stage LPC compressor blades. Position the
Borescope tip to best view the entire blade. It is permissible to separately view
the root and the blade tip areas.
5. Inspect all blades by rotating the C1 fan.
6. Inspect using limits in the above figure. Document any defects using Inspection
Detail record, Section 3 of this Job Card.
7. If blade does not meet limits, the engine must be removed out of service for
repair.
Revision 28 05-11-07 70.03.33

ATI-001
7204
JOB TITLE
Page 6 of 16
Mechanic Inspector
BSI- 2: Perform Borescope Inspection of 10th Stage HPC Blades, High Pressure
Compressor.

A ANY DAMAGE

B
No Tears or Cracks
ANY DENT *
C
No Tears or Cracks
ANY DENT *
D ANY DENT *
E NO DAMAGE ALLOWED
1. 1/4 2. 1/2 3. 5/32

Figure 3.
3. Insert the Borescope into the Ps3 boss port at the 12:00 position of the engine.
4. Position the Borescope tip to inspect the 10th stage HPC compressor blades.
Position the Borescope tip to best view the entire blade. It is permissible to
separately view the root and the blade tip areas.
5. Inspect all blades by rotating N2 HPC compressor via the starter spline using
Starter Spline Quill Tool to ratchet at the N2 gearbox.
repair.
70.00.34 05-11-07 Revision 28

ATI-001
7204
JOB TITLE
Page 7 of 16
Mechanic Inspector
Perform Borescope Inspection of 12th Stage HPC Blades, High Pressure

Compressor.
BSI- 3:
Perform Borescope Inspection of 13th Stage HPC Blades, High Pressure
Compressor.

A
Any Indentation
B
No Tears or Cracks
ANY DENT *
C
No Tears or Cracks
ANY DENT *
D ANY DENT *
E NO DAMAGE ALLOWED
1. 7/32 2. 1/4 3. 1/8

Figure 4.
3. Insert the Borescope into the 12th stage bleed port take off (Interstage Bleed).
4. Position the Borescope tip to best view the entire blade. It is permissible to
repair.
Revision 28 05-11-07 70.03.35

ATI-001
7204
JOB TITLE
Page 8 of 16
Mechanic Inspector
BSI- 4: Perform Borescope Inspection of 16th Stage HPC Blades, High Pressure Compressor.

A
Any Indentation
B
No Tears or Cracks
ANY DENT *
C
No Tears or Cracks
ANY DENT *
D ANY DENT *
E NO DAMAGE ALLOWED
1. 3/16 2. 3/16 3. 3/32

Figure 5.
3. Position the Borescope forward into the diffuser case at the 16th stage HPC
compressor exit via the #4 or #5 igniter boss.
4. Position the Borescope tip to best view the entire blade. It is permissible to
repair.
70.03.36 05-11-07 Revision 28

ATI-001
7204
JOB TITLE
Page 9 of 16
Mechanic Inspector
BSI-5: COMBUSTION CHAMBER INSPECTION
Perform Borescope Inspection of Left & Right Side Combustion Chambers: Left via # 5
igniter, Chambers #8,7,6,5; Right via #4 igniter, Chambers #1,2,3,4:
STEP 1: Connect 8mm flexible Borescope to light source.
STEP 2: Increase to maximum light output for the Borescope light source.
STEP 3: Insert Borescope tip into the #4 or #5 combustion can by way of the
removed igniter plug hole.
STEP 4: Inspect each chamber by working the Borescope through the combustion
chamber cross over tubes, in accordance with Maintenance Manual Limits.
If found to exceed limits, engine must be removed from service. Document
any defects using Inspection Detail record, Section 3 of this Job Card.
Inspect: Liners #1 - #8 inner and front end, baffles, braces center tube and dilution
air holes for cracks, bulges, buckles, missing material and misalignment of
cross over tubes.
REFERENCE FIGURES 6. – 12. FOR COMBUSTION CHAMBER INSPECTION
ALTERNATE INSPECTION PROCEDURE
This Alternate Procedure is designed to allow for a LIMITED INSPECTION of the
combustion chambers. This procedure shall only be used when it is not practical to
perform inspection of ALL eight chambers.
The Inspector shall use his or her discretion for the use of this Alternate Procedure.
Perform LIMITED Borescope Inspection of Left & Right Side Combustion Chambers:
Left via # 5 igniter, Right via #4 igniter, CHECK ALL INSPECTED:
CHAMBER# 1 2 3 4 5 6 7 8 .
STEP 1: Connect 8mm flexible Borescope to light source.

STEP 2: Increase to maximum light output for the Borescope light source.
STEP 3: Insert Borescope tip into the #4 or #5 combustion can by way of the
removed igniter plug hole.
STEP 4: Inspect each chamber by working the Borescope through the combustion
chamber cross over tubes, in accordance with Maintenance Manual Limits.
If found to exceed limits, engine must be removed from service. Document
any defects using Inspection Detail record, Section 3 of this Job Card.
Inspect: Liners inner and front end, baffles, braces center tube and dilution air holes
for cracks, bulges, buckles, missing material and misalignment of cross
over tubes.
REFERENCE FIGURES 6. – 12. FOR COMBUSTION CHAMBER INSPECTION
Revision 28 05-11-07 70.03.37

ATI-001
7204
JOB TITLE
Page 10 of 16
Mechanic Inspector
COMBUSTION CHAMBER INSPECTION
Figure 6.
1. LOCATING LUG
2. COVER
3. BURNER PRESSURE TUBE
4. SWIRL CUP
4a. BAFFLE
5. OUTER BRACE
6. INNER BRACE
7. FORWARD END INNER LINER
8. INNER LINER SEGMENTS
9. AFT END INNER LINER
10. FORWARD OUTER LINER
11. OUTER LINER SEGMENTS
12. COMBUSTION AIR HOLES
13. COOLING AIR HOLES
70.03.38 05-11-07 Revision 28

ATI-001
7204
JOB TITLE
Page 11 of 16
Mechanic Inspector
Figure 7. Figure 8.
Revision 28 05-11-07 70.03.39

ATI-001
7204
JOB TITLE
Page 12 of 16
Mechanic Inspector
Figure 9. Figure 10. Figure 11. Figure 12.
70.03.40 05-11-07 Revision 28

ATI-001
7204
JOB TITLE
Page 13 of 16
Mechanic Inspector
BSI- 6: Perform Borescope Inspection of T1 HPT NGV Vanes, High Pressure Turbine Nozzle
Guide Vanes.

3. Insert Borescope tip into the #5 combustion can by way of the removed igniter
plug hole on either side of the engine.
4. Inspect by carefully moving the flex scope in and out, articulating the tip for the
best possible view of each T1 NGV from the concave to convex side top to
bottom and leading and trailing edges.
5. Inspect each vane from the exit of each combustion chamber, by working the
Borescope through the combustion chamber cross over tubes.
INSPECTION LIMITS: AFTER REPORTED OVERTEMP
i. Disruption in chromalized surface of the first stage vanes is not cause for
rejection.
ii. Whit material splatter which looks like solder splatter (which is bright,
thin, and random in shape and size), that is on the high pressure turbine
vanes and blades is magnesium zinconium oxide. Magnesium zinconium
oxide on these blades and vanes has no effect on the serviceability or the
performance of the item that is splattered, and is therefore acceptable.
iii. First stage turbine vanes exhibiting cracks in the trailing edge are
acceptable providing:
1. Cracks are not more than 0.4 inches in length
2. Cracks are separated by a minimum of 1.0 inches.
3. Cracks are not within 0.5 inches of the fillet area of OD and ID
buttresses.
a. Cracks exceeding 0.4 inch, but less than 0.5 inch may continue in
service for 200 hours.
b. Vanes having cracks >0.5 inch must be removed within 10 hours.
iv. Vanes having leading edge burn through must be removed within 10
hours.
v. Vane leading edge burning which is not open to the internal cavity is
permitted.
vi. Trailing edge burning exceeding 0.25 inch or any burning exposing the
internal cavity is cause for engine removal within 10 hours.
vii. Limits of abnormal vane bow will be determined by Isotope Inspection of
1st stage NGV’s and it’s associated Threshold Limits found within the
Company PMPM, Chapter 1. Excessive vane bow can cause blade
vibratory excitation and damage with possible failure. Indications of first
blade shroud wear or damage is cause for engine removal from service.
viii. Vane mismatch where the platforms are not aligned is permitted up to 0,1
inch. Vanes with mismatch >0.1 inch should be removed within 10 hours.
Revision 28 05-11-07 70.03.41

ATI-001
7204
JOB TITLE
Page 14 of 16
Mechanic Inspector
BSI- 7: Perform Borescope Inspection of T1 HPT, High Pressure Turbine Blades.
3. Insert Borescope tip into the #5 combustion can by way of the removed igniter
plug hole on either side of the engine.
4. Insert Borescope and carefully push it back through the NGV’s to view the 1st
stage turbine blades.
5. Locate best angle to view blade roots and lower half of blades on both convex and
concave sides of the blades.
7. Reposition the Borescope tip to view upper part of blade to the shroud and upper
seal.
INSPECTION LIMITS:
a. Inspect all (130) blades in accordance with P&W Maintenance Manual Limits
72-00 Inspection check pages 653 through 661. Document any defects using
Inspection Detail record, Section 3 of this Job Card.
b. AFTER REPORTED OVERTEMP-
i. First stage blades exhibiting cracks, distortion, or burning are cause for
immediate removal of engine from service.
ii. Blades with nicks and dents beyond 0.5 inch of the platform are
acceptable so long as the dents are limited to 0.015 inch and exhibits no
cracks or opposite side distortion where visible.
iii. Make inspection of the first stage blade shrouds. Any missing material in
the shroud notch area is cause for immediate removal from service. Any
shingling of the shrouds or excessive notch (hard face) wear is cause for
immediate removal.
9. If blades are found out of limits, the engine must be removed out of service for
repair.
70.03.42 05-11-07 Revision 28

7204
JOB TITLE
Page 15 of 16
D. INSPECTION FINDINGS:
Mechanic Inspector
Inspector: Detail inspection findings:
FAN INLET SECTION
COMPRESSOR SECTION
COMBUSTION SECTION
Revision 28 05-11-07 70.03.43

7204
JOB TITLE
Page 16 of 16
Mechanic Inspector
TURBINE SECTION
EXHAUST SECTION
E. Inspection Result:
a. Engine returned to service with no limitation (no required repetitive inspections).
b. Engine returned to service with the following limitation(s):
c. Engine found unserviceable (reason):
F. Return to Service: (As applicable)

a. Reconnect all ignition sources for affected engine ignition (exciter boxes).
b. Remove all tags on engine controls.
c. Reinstall engine cowlings, including all forward and aft long duct bifurcation
ducts per ATI DC-8 M/M 71.02.1.
d. Reinstall #4 & #5 combustion chamber igniter plugs per DACO M/M 74-10-1.
e. Reinstall engine starter per DACO M/M 80-10-1.
70.03.44 05-11-07 Revision 28

JOB CARDS
70.04 – ENGINE FUEL & CONTROL
TABLE OF CONTENTS
Job Card Page

7301 INTERMIX OF JT3D-3B & -7 ENGINES – DC-8-62 -------------------------- 70.04.1
Revision 14 12-03-01 70.04-i

INTENTIONAL
BLANK
70.04-ii 12-03-01 Revision 14

AIR TRANSPORT INTERNATIONAL, L.L.C.
7301
JOB TITLE
DC-8-62 INTERMIX OF JT3D -3B & -7 ENGINES
Page 1 of 1
Mechanic Inspector
General Information
JT3D-3B and JT3D-7 Engine Intermix:
ANY DC-8-62 AIRCRAFT WITH ONE TO THREE JT3D-7 ENGINES
INSTALLED MUST HAVE EACH -7 ENGINE DERATED TO JT3D-3B
THRUST.
Note: This Job Card accomplishes three things: 1) Placards
2) -3B Trim
3) EGT Ind. Range Marking
THE FOLLOWING CONDITIONS MUST BE MET FOR DERATED ENGINES.
Conditions:
1. Ensure the instruments for each -3B & -7 engine are identified with appropriate
placards manufactured locally. Even -62 aircraft with all -3B’s or all -7’s must be
placarded. The placards must be placed on the forward center instrument panel
below each row of engine instruments AND at the Flight Engineer’s station.
2. Ensure all EPR indicators are operative and equipped with a preset device.
3. Comply with Job Card 7701, -60 Series EGT Indicator Range Marking.
4. JT3D-7 Engines are to be trimmed according to JT3D-3B instructions. Comply with
Job Card 7102, Procedure L, steps 1 & 2.
NOTE: ALL ENGINES MUST BE OPERATED IN ACCORDANCE WITH
JT3D-3B GROUND AND FLIGHT OPERATING LIMITS.
Revision 10 08-01-00 70.04.1

AIR TRANSPORT INTERNATIONAL, L.L.C.
INTENTIONAL
BLANK
Revision 10 08-01-00 70.04.2

JOB CARDS
70.05 – ENGINE CONTROLS
TABLE OF CONTENTS
Job Card Page

7601 “NO NOISE” TRIM MARK MAINTENANCE – DC-8-60 SERIES --------- 70.05.1
Revision 14 12-03-01 70.05-i

INTENTIONAL
BLANK
70.05-ii 12-03-01 Revision 14

ATI-001
7601
JOB TITLE
“NO NOISE” TRIM MARK MAINTENANCE - DC-8-60 Series
Page 1 of 1
Mechanic Inspector
General Information
This procedure describes the initial throttle pedestal marks. It will also prescribe the
procedure for maintaining these marks. This procedure coincides with DC-8 Engine Run
Handbook 72.02. These marks are installed to provide a reference point at which the
flight crew members can position each throttle and record values when throttle alignment
is unsatisfactory. This will provide maintenance with the necessary information to trim
the engine and achieve satisfactory alignment.
Sign-off in the appropriate boxes as items are completed or N/A as procedures dictate.
Procedure
NOTE: If the original paint stripe has not been completely obliterated, N/A steps 1
through 6, as they may not be necessary.
1. Install Part Power stops on engine fuel control for all engines OR skip to step 4 for
Alternate Method.
2. Push throttle handles forward to contact the Part Power stop and hold in position.
3. Scribe a line across the three metal strips between throttle handles to line up with aft
edges of the throttle levers. N/A step 4.
4. Alternate method: Measure control pedestal arc from the idle position forward,
= 3” ± 1/32”
a. Scribe a line across the three metal strips between throttle handles.
b. N/A steps 1, 2, 3 above and step 5.
5. Move the throttles out of the way; stow and safety the Part Power stops on the
engines.
6. Scribe a second line parallel to the first line exactly ½” aft.
7. Using masking tape to protect surrounding area, mask off the pedestal.
Leave area between the scribe marks open (or existing mark if it is satisfactory).
8. Clean area that is not taped to provide paint adhesion.
9. Paint (WHITE) the area not taped.
10. Remove the tape from the area and clean any residue.
11. Return aircraft to normal.
Revision 13 10-22-01 70.05.1

INTENTIONAL
BLANK
70.05.2 08-01-00 Revision 10

JOB CARDS
70.06 – ENGINE INDICATING
TABLE OF CONTENTS
Job Card Page

7701 EGT INDICATOR RANGE MARKING – DC-8-60 SERIES------------------ 70.06.1
Revision 14 12-03-01 70.06-i

INTENTIONAL
BLANK
70.06-ii 12-03-01 Revision 14

ATI-001
7701
JOB TITLE
EGT INDICATOR RANGE MARKING - DC-8-60 Series
Page 1 of 1
Mechanic Inspector
General Information
The Exhaust Gas Temperature (EGT) indicators are located on the forward center
instrument panel in the flight compartment. Removal and installation procedures for all
four EGT indicators are identical.
Procedure
1. Remove Indicator:
a. Loosen the indicator mounting clamp screw.
b. Carefully pull indicator clear of panel.
c. Disconnect electrical connector and tag.
d. Disconnect thermocouple leads and tag.
CAUTION: TO PREVENT POSSIBLE DAMAGE DURING HANDLING, INSTALL
SHUNT BAR BETWEEN THE INDICATOR THERMOCOUPLE
TERMINALS.
2. Install Range Markings using RED tape or paint, 1/8” wide at the EGT indicator
mark indicated below. Apply mark to glass face of indicator.
Sign-off only ONE of a, b, or c below.
a. –3B install red line at 555° C
b. –7 install red line at 575° C
c. if –3B & -7 intermix install red line at 555° C on ALL indicators
3. Install WHITE glass slippage mark from glass to indicator case.
4. Record EGT Indicator Serial Number: ______________________
5. Install Indicator:
a. Remove shunt between indicator thermocouple terminals.
b. Connect thermocouple leads and remove tags.
c. Connect electrical connector and remove tag.
d. Carefully insert indicator into panel.
e. Tighten indicator mounting clamp screw.
6. Perform engine ground run functional check per DC-8 ERH (idle only).
Revision 27 03-05-07 70.06.1

INTENTIONAL
BLANK
70.06.2 03-05-07 Revision 27

TABLE OF CONTENTS
Page
71.01 DC-8-60 SERIES ENGINE HUSH KIT DESCRIPTION &
IDENTIFICATION---------------------------------------------------------------- 71.01.1
71.02 DC-8-60 HUSH KIT COMPONENT REMOVAL AND
INSTALLATION (S.T.C.’s SA4892NM & SA5455NM)-------------------- 71.02.1
71.03 DC-8-60 HUSH KIT ILLUSTRATED PARTS CATALOG
(S.T.C.’s SA4892NM & SA5455NM) ------------------------------------------ 71.03.1
71.04 STRUCTURAL REPAIR MANUAL FOR BAC II STAGE III HUSH
KITS (S.T.C. SA4892NM) ------------------------------------------------------- 71.04.1
71.05 STRUCTURAL REPAIR MANUAL FOR BAC II ADC UPGRADE
HUSH KIT (S.T.C. SA5455NM) ------------------------------------------------ 71.05.1
71.06 DC-8 SEVENTY SERIES – NACELLE INLET COWL--------------------- 71.06.1
Revision 14 12-03-01 71-i

INTENTIONAL
BLANK
71-ii 12-03-01 Revision 14

POWERPLANT
71.01 – DC-8-60 SERIES ENGINE HUSH KIT DESCRIPTION &
IDENTIFICATION
TABLE OF CONTENTS
Paragraph Page
1. GENERAL----------------------------------------------------------------------------- 71.01.1
2. EFFECTIVITY------------------------------------------------------------------------ 71.01.1
3. STRUCTURAL REPAIR DAMAGE LIMITS AND REPAIR CRITERIA
REFERENCES ------------------------------------------------------------------------ 71.01.1
TABLES
71.01-1 STRUCTURAL REPAIR MANUAL REFERENCE MATRIX---------------- 71.01.2
Revision 14 12-03-01 71.01-i

INTENTIONAL
BLANK
71.01-ii 12-03-01 Revision 14

CHAPTER 71 - POWER PLANT
71.01 DC-8-60 SERIES ENGINE HUSH KIT DESCRIPTION & IDENTIFICATION
1. General
a. The DC-8 series aircraft have been modified to comply with FAR 36 Stage III noise
abatement requirements by two Supplemental Type Certificates (S.T.C.). Refer to the
Effectivity List in the Introduction Section for applicability of hush kit installation.
The following text describes the two types of hush kits used for these S.T.C.'s.
b. The DC-8-62 and DC-8-63 aircraft engines have been modified by the Burbank
Aeronautical Corporation(BAC) with the following S.T.C.’s:
(1) The BAC II Stage III Hush Kit, S.T.C. SA4892NM, kit uses acoustic materials to
reduce the noise level of engine intake air and fan-bypass exhaust air. It contains a
modified engine nose cowl, a modified engine center body (bullet), with a modified
PT2 tube, two modified fan air bypass bifurcated ducts, and two modified fan-air
bypass aft section ducts.
(2) The BAC II ADC Upgrade, S.T.C. SA5455NM (previously modified in accordance
with Aeronautical Development Corp[ADC] S.T.C. SA2494NM), kit contains an
extended nose cowl, an extended nose dome and PT2 tube, and acoustically treated
hinged constant section and forward transition ducts. This hush kit is easily
identified by the extended nose cowl. It shares some common components with
S.T.C. SA4892NM (described below), however, no intermix of non-acoustically
treated nacelle inlet, nose domes, and fan ducts is permitted.
2. Unless otherwise described, the component removal and installation procedures detailed in
Section 71.02 and parts catalogs detailed in Section 71.03 are applicable to both the BAC II
ADC Upgrade and the BAC II Stage III Hush Kit. Where maintenance procedures are
similar in the two S.T.C.’s, the most restrictive (conservative) have been retained for use on
Company aircraft. Where maintenance procedures are significantly different in the two
S.T.C.’s, both procedures are outlined in Section 71.02 for the respective S.T.C.
3. Structural Repair Damage Limits and Repair Criteria References
a. Table 71.01-1 lists the correct Structural Repair Section for each hush kit component.
Each hush kit has a maintenance manual section for the affected areas for which the
S.T.C. was reworked from the original production parts. A Part Number listed below the
S.T.C. indicates that the affected part is subject to the limits specified in the applicable
Structural Repair Section of this manual.
Revision 10 08-01-00 71.01.1

CHAPTER 71 - POWER PLANT
71.01 DC-8-60 SERIES ENGINE HUSH KIT DESCRIPTION & IDENTIFICATION
(cont’d)
b. Structural Repair Sections contained in this Chapter:
(1) BAC II, Stage III S.T.C. SA4892NM is Section 71.04
(2) ADC Upgrade S.T.C. SA5455NM is Section 71.05
SECTION 71.04 SECTION 71.05

COMPONENT BAC II Stage III ADC Upgrade
STC SA4892NM STC SA5455NM
Nose Cowl DC8-22000-XXX 236-0045-XXX

Nose Dome DC8-28000-X DC8-38000-X
(2)
Nose Dome Extension (1) N/A 236-0002-509
PT2 Tube Extension N/A 236-0010-501
Bifurcated Duct DC8-24000-301
DC8-24000-303 (2)
Constant Section Duct (USE DACO SRM) 236-0005-507
Forward Transition Duct (USE DACO SRM) 236-0006-509
Aft Transition Duct DC8-27000-47 (2)
Notes:
(1) As installed by ATI E.O. 71-DC8-1029
(2) Use Section 71.04, Structural Repair Manual for BAC II Stage III. Section 71.05, Structural
Repair Manual for ADC Upgrade does not contain repair procedures for these components.
STRUCTURAL REPAIR MANUAL REFERENCE MATRIX

Table 71.01-1
71.01.2 08-01-00 Revision 10

71.02 – DC-8-60 HUSH KIT COMPONENT REMOVAL AND

INSTALLATION (S.T.C.’s SA4892NM & SA5455NM)
TABLE OF CONTENTS
Paragraph Page
1. NOSE COWL REMOVAL AND INSTALLATION ---------------------------- 71.02.1
2. INLET CENTER BODY (BULLET) REMOVAL AND INSTALLATION - 71.02.11
3. ENGINE MOUNT STEP BOLT REPLACEMENT ----------------------------- 71.02.15
4. HEAT EXCHANGER BRACKET REPLACEMENT (S.T.C. SA4892NM)- 71.02.19
5. BIFUCATED DUCTS REMOVAL AND INSTALLATION (S.T.C.
SA4892NM) --------------------------------------------------------------------------- 71.02.22
6. HINGED CONSTANT SECTION FAN DUCTS REMOVAL AND
INSTALLATION --------------------------------------------------------------------- 71.02.26
7. TRANSITION SECTION DUCT REMOVAL AND INSTALLATION ----- 71.02.30
FIGURES
71.02-1 NOSE COWL INSTALLATION --------------------------------------------------- 71.02.5

71.02-2 NOSE COWL SLING INSTALLATION ----------------------------------------- 71.02.7
71.02-3 ANTI-ICE DUCT INSTALLATION ---------------------------------------------- 71.02.8
71.02-4 CSD OIL COOLER ATTACH POINT -------------------------------------------- 71.02.9
71.02-5 NOSE COWL STUD PATTERN--------------------------------------------------- 71.02.10
71.02-6 INLET CENTER BODY (BULLET) INSTALLATION ------------------------ 71.02.13
71.02-7 ENGINE MOUNTS ------------------------------------------------------------------ 71.02.17
71.02-8 FORWARD ENGINE MOUNTS SHOWING STEP BOLTS ------------------ 71.02.18
71.02-9 HEAT EXCHANGER BRACKET INSTALLATION -------------------------- 71.02.20
71.02-10 HEAT EXCHANGER FUEL LINE ROUTING---------------------------------- 71.02.21
Revision 14 12-03-01 71.02-i

FIGURES (cont’d)
71.02-11 HINGED CONSTANT SECTION DUCT INSTALLATION ------------------ 71.02.28

71.02-12 FORWARD BIFURCATED DUCT INSTALLATION ------------------------- 71.02.29
71.02-13 TRANSITION & AFT SECTION DUCT REMOVAL/INSTALLATION --- 71.02.33
71.02-14 TRANSITION DUCT BRACKETS------------------------------------------------ 71.02.34
71.02-ii 12-03-01 Revision 14

71.02 DC-8-60 HUSH KIT COMPONENT REMOVAL AND INSTALLATION
(S.T.C’s. SA4892NM & SA5455NM)
1. Nose Cowl Removal and Installation (Either S.T.C.)

a. Access for removal and installation of nose cowl is gained by opening of forward cowl
doors.
b. Tools and Equipment Required
Item Name Number Manufacturer Use

Modify per Nose cowl
A Sling Figure 71.02-2 removal/installation
B Torque 100-140 in-lb

Wrench
c. Remove nose cowl. (See Figure 71.02-1)

(1) Tag throttle/thrust reverser lever and open circuit breakers in accordance with
procedures in the Douglas Aircraft DC-8 Sixty Series Maintenance Manual,
Chapter 71.
(2) Open left and right cowl doors in accordance with procedures in the Douglas
Aircraft DC-8 Sixty Series Maintenance Manual, Chapter 71.
(3) Disconnect anti-icing duct from upper right side of aft bulkhead on nose cowl.
(4) Disconnect vortex spoiler coupling from lower right side of aft bulkhead on nose
cowl.
(5) Remove screws, washers, and seal attaching CSD oil cooler duct on lower right side
of aft bulkhead on nose cowl to CSD duct flange.
(6) Remove clamps attaching oil tank scupper drain line to bottom of aft bulkhead on
nose cowl.
(7) Disconnect interphone plug and wire harness on left side of aft bulkhead of nose
cowl.
(8) Remove hoist point filler plugs from four hoist point locations on nose cowl.
(9) Install four sling pads to hoist points.
WARNING: NOSE COWL WEIGHS APPROXIMATELY 240 LBS, USE
SLING AND HOIST FOR REMOVAL TO AVOID INJURY
TO PERSONNEL OR DAMAGE TO NOSE COWL.
Revision 10 08-01-00 71.02.1

(S.T.C’s. SA4892NM & SA5455NM) (cont’d)
(10) Position RSE1077 sling or modified existing sling adapter (P/N 5771659) (See
Figure 71.02-2) on four sling pads and adjust sling to remove slack for equal load
distribution.
(11) Remove nuts and washers attaching nose cowl to engine flange studs, starting at the
top and proceeding down each side, to the bottom.
(12) Support nose cowl weight with hoisting sling and tip aft side of nose cowl down
slightly so electrical junction box vent clears pylon junction box.
CAUTION: ENSURE NOSE COWL IS CLEAR BEFORE LOWERING TO
PREVENT DAMAGE TO NOSE COWL OR BULLET.
(13) Pull nose cowl straight forward to disengage from engine flange studs and to clear
bullet.
(14) Remove nose cowl and place on a suitable protective pad.
(15) Remove sling and four sling pads from hoist points.
(16) Install hoist point filler plugs.
d. Install nose cowl. (See Figure 71.02-1)
(1) Ensure throttle/thrust reverser lever is tagged and circuit breakers are open in
accordance with procedures in the Douglas Aircraft DC-8 Sixty Series Maintenance
Manual, Chapter 71.
(2) If CSD duct flange on engine has been previously modified in accordance with
Figure 71.02.4, proceed to step (3). If flange has not been modified, perform the
following steps.
(a) Remove rivets attaching nutplates on upper area of engine CSD duct flange.
(Fig. 71.02-4).
(b) Trim upper edge of flange using a template fabricated in accordance with the
dimensions in Figure 71.02-4.
(c) Locate nutplates on upper area of flange and install with rivets.
71.02.2 08-01-00 Revision 10

(3) Verify that seals are installed on anti-ice duct using the following procedures.
(a) Remove bolts and washers attaching anti-ice duct to aft bulkhead of nose cowl.
(b) Slide anti-ice duct aft through opening in aft bulkhead. Verify seals ( 2 seal
rings and 1 back up ring) are installed on forward end of anti-ice duct. (Fig.
71.02-4)
(c) Slide anti-ice duct forward through opening in aft bulkhead and engage in anti-
ice center duct. Install using bolts and washers.
(4) If needed, modify CSD oil cooler shroud flange to clear modified inlet panels per
Figure 71.02-4
(5) Verify the correct installation of nose cowl mounting studs (P/N 4766158-1) per
BAC II drawing DC8-21001 (Figure 71.02-5). If needed, install additional nose
cowl mounting studs to match pattern specified.
(6) Remove hoist point filler plugs from four hoist point locations on nose cowl.
(7) Install four sling pads to hoist points.

(8) Position RSE1077 sling or modified existing sling adapter(P/N 5771659) (See
Figure 71.02-2) on four sling pads and adjust sling to remove slack for equal load
distribution.
CAUTION: ENSURE NOSE COWL CLEARS NOSE DOME DURING
INSTALLATION TO PREVENT DAMAGE TO NOSE COWL
OR BULLET.
(9) Position nose cowl for installation and carefully move aft, making certain to clear
bullet and electrical junction box, to engage engine flange studs.
(10) Align electrical junction box inlet on pylon with junction box vent on nose cowl.
Revision 10 08-01-00 71.02.3

(11) Install nuts and washers attaching nose cowl to engine flange studs at engine
bracket locations. (See Figure 71.02-5) If there is obvious wear on the Mounting
ring at the attachment holes use AN122583 washers in place of the AN960C516L
washers. AN122583 washers may be relieved to clear radius of angle (DC8-22000-
53, mounting ring) if required.
(12) Tighten nuts to a torque of 100-140 lb-in. in an alternating sequence.
(13) Remove four sling pads and sling from nose cowl.
(14) Install hoist point filler plugs.
(15) Connect interphone plug and wire harness to receptacles on aft bulkhead on nose
cowl.
(16) Install clamps attaching oil tank scupper drain line to bottom of aft bulkhead on
nose cowl.
(17) Install screws, washers, and seal attaching CSD oil cooler duct on lower right side
of aft bulkhead on nose cowl to CSD engine duct flange.
(18) Attach vortex spoiler duct to lower right side of aft bulkhead on nose cowl using
coupling.
(19) Attach anti-icing duct to upper right side of aft bulkhead on nose cowl.
(20) Remove tag from throttle/thrust reverser lever and close circuit breakers in
Manual, Chapter 71.
(21) Close cowl doors in accordance with procedures in the Douglas Aircraft DC-8
Sixty Series Maintenance Manual, Chapter 71.
71.02.4 08-01-00 Revision 10

NOSE COWL INSTALLATION

Figure 71.02-1(1 of 2)
Revision 10 08-01-00 71.02.5


Figure 71.02-1(2 of 2)
71.02.6 08-01-00 Revision 10

NOSE COWL SLING INSTALLATION

Figure 71.02-2
Revision 10 08-01-00 71.02.7

ANTI-ICE DUCT INSTALLATION

Figure 71.02-3
71.02.8 08-01-00 Revision 10

CSD OIL COOLER ATTACH POINT

Figure 71.02-4
Revision 10 08-01-00 71.02.9

NOSE COWL STUD PATTERN

Figure 71.02-5
71.02.10 08-01-00 Revision 10

2. Inlet Center Body (Bullet) Removal and Installation (Either S.T.C. except as noted)
a. Access for removal and installation of bullet is gained through nose cowl inlet without
removal of nose cowl.
b. Tools and Equipment Required. Equivalent substitutes may be used instead of the
following listed items.
A Petrolatum VV-P-236 Lubricate

O-rings
B Wire MS20995C20 Commercially Lockwire Pt2
Available Tube nut
C TORQUE 100-140 in-lb
WRENCH Bullet Installation
c. Remove Inlet Bullet. (See Figure 71.02-6)

Chapter 71.
(2) Loosen captive self-locking nuts attaching bullet to mounting flange (or nose dome
to nose dome extension).
(3) Carefully pull bullet forward to disengage from Pt2 probe and remove.
(4) Place bullet on protective pad to prevent damage.
(5) Remove packing from forward ring of nose dome extension and packings from Pt2
probe. Inspect and replace packings if necessary. (Figure 71.02-6)
d. Remove nose dome extension(if equipped). (Figure 71.02-6 (2 of 2)
(1) Remove lockwire from aft nut on PT2 tube extension and loosen until free from
engine fitting.
(2) Remove sleeve nuts, washer assemblies, and washers from engine attach studs.
(3) Carefully pull nose dome extension forward and remove from engine attach studs.
Revision 10 08-01-00 71.02.11

(4) Remove washers, washer assemblies, and sleeves from engine attach studs.
(5) Place nose dome extension on protective pat to prevent damage to PT2 probe.
(6) Remove packing from engine compressor inlet case. Inspect and replace packing if
necessary.
e. Install nose dome extension(if equipped).
accordance with procedures in the DACO Sixty Series Maintenance manual,
Chapter 71.
(2) Loosen nuts to allow movement of PT2 tube extension and Pt2 probe within clamp.
(3) Position nose dome on forward end of nose dome extension and tighten captive nuts
in nose dome finger tight only.
(4) Push PT2 probe extension through loosened clamp to place PT2 probe into PT2
receptacle in nose dome.
(5) Torque nuts to 20-25 in-lb.
(6) Lubricate packing lightly with petrolatum(VV-P-236) and install on engine
compressor inlet cast.
f. Install Inlet Bullet. (See Figure 71.02-6)
(1) Make certain throttle/thrust reverser lever is tagged and circuit breakers are open in
Manual, Chapter 71.
(2) Inspect O-ring packing. Replace if necessary. Lightly lubricate packings. Install
packings on Pt2 probe and install packing on engine compressor case.
(3) Position bullet, carefully align Pt2 probe fittings and install bullet.
(4) Tighten captive self-locking nuts to a torque of 100-140 lb-in.
(5) Check gap between Inlet Bullet base and Compressor case. For BAC II Bullet
Only (P/N DC8-28000-1 and DC8-38000-1) the allowable gap is Min. 0.020 to
Max. 0.104 inch. (Reference BAC II Dwg DC8-31300)
Manual, Chapter 71.
71.02.12 08-01-00 Revision 10

INLET CENTER BODY (BULLET) INSTALLATION

Figure 71.02-6 (1 OF 2)
Revision 10 08-01-00 71.02.13

INLET CENTER BODY (BULLET & EXTENSION) INSTALLATION

Figure 71.02-6 (2 OF 2)
71.02.14 08-01-00 Revision 10

3. Engine Mount Step Bolt Replacement (Either S.T.C.)
a. Mounts - Description and Operation. A three point mounting system, consisting of two
forward mounts and an aft mount, connects the engine to the pylon (see Figure 71.02-7).
All three mounts compensate for engine case expansion and contraction. Side loads are
normally transmitted to the pylon by the left forward mount and the aft mount. Thrust
loads are normally transmitted to the pylon by the right forward mount. All three mounts
transmit vertical loads to the pylon.
b. Forward Mounts
(1) The left mount consists of two A-shaped links, a brace and a step bolt. These parts
are attached to the left forward side of the engine, between the integral forward
mount ring flanges, and to the pylon forward mount. When the power plant is
installed, the left mount step bolt is installed in the pylon forward mount and
secured with a slef locking nut.
(2) The right mount consists of two A-shaped links, a brace and a step bolt. These
parts are attached to the right forward side of the engine, between the integral
forward mount ring flanges and to the pylon forward mount. When the power plant
is installed, the right mount step bolt is installed in the pylon forward mount and
secured with a self-locking nut.
c. Aft Mounts. The aft mount consists of two arms, a step bolt and a flange support. These
parts are attached to the engine between the integral aft mount ring flanges and to the
pylon aft mount link. When the power plant is installed the step bolt in the aft mount is
installed in the pylon aft mount link and secured with a self-locking nut.
d. Step Bolt Replacement. (Figure 71.02-8)
(1) It is only necessary to replace the right forward mount step bolt, Douglas P/N
4775516-501, using the higher strength Berry Controls P/N 96013-1, engine mount
bolt.
(2) This engine mount bolt may be replaced with the engine on the aircraft. The engine
must be adequately supported before removal of the mount to prevent injury to
personnel, damage to the engines, or overload damage to the other mounts.
(a) Remove bolt P/N 4775516-501 per Douglas DC-8 Maintenance Manual,
Chapter 71-20-1, Page 204, Section 8 Para. A(2).
Revision 10 08-01-00 71.02.15

(b) Install bolt P/N 96013-1 per Douglas DC-8 Maintenance Manual, Chapter 71-
20-1, Page 204 Section 3 Para. B (2).
(c) Inspection/Check per Douglas DC-8 Maintenance Manual, Chapter 71-20-1,

Page 205, Section 4.
71.02.16 08-01-00 Revision 10

ENGINE MOUNTS
Figure 71.02-7
Revision 10 08-01-00 71.02.17

FORWARD ENGINE MOUNTS SHOWING STEP BOLTS

Figure 71.02-8
71.02.18 08-01-00 Revision 10

4. Heat Exchanger Bracket Replacement.(S.T.C. SA4892NM) (Figure 71.02-9)
a. General. On some DC-8-62/63 aircraft nacelle configurations, the fuel/oil heat

exchanger assembly interferes with the increased wall thickness of the bifurcated duct.
b. Replacement of Mounting Brackets. The replacement of the forward heat exchanger

bracket with BAC II P/N DC8-21005-3 is required to maintain clearance between the
Heat Exchanger and the BAC II modified bifurcated duct. The replacement of the aft
heat exchanger bracket with BAC II P/N DC8-21005-5 is optional if the existing original
part provides clearance.
3. Reroute Fuel Lines. If additional clearance is required to clear fuel lines, reroute lines as
shown in Figure 71.02-10.
4. Torque. Torque all bolts per Douglas DC-8 Maintenance Manual.
Revision 10 08-01-00 71.02.19

HEAT EXCHANGER BRACKET INSTALLATION -- LEFT SIDE

FLANGES F THROUGH H
Figure 71.02-9
71.02.20 08-01-00 Revision 10

HEAT EXCHANGER FUEL LINE ROUTING

Figure 71.02-10
Revision 10 08-01-00 71.02.21

5. Bifurcated Ducts Removal and Installation.(S.T.C. SA4892NM)
a. Access for removal and installation of bifurcated section ducts is gained by opening
forward cowl doors and removing the hinged constant section duct.
b. Removal / Installation Bifurcated Ducts
(1) Hinged Constant Section Ducts Removal. (See Figure 71.02-11)
(a) Tag throttle/thrust reverser lever and open circuit breakers in accordance with
procedures in the Douglas aircraft DC-8 Sixty Series Maintenance Manual,
Chapter 71.
(b) Open forward cowl doors in accordance with procedures in the Douglas Aircraft
DC-8 Sixty Series Maintenance Manual, Chapter 71.
(c) Remove bolts attaching upper and lower ends of both channels.
(d) Remove bolt attaching lanyard to fitting on bottom of hinged constant section
duct.
(e) Support hinged constant section duct and remove pins at top of both channels.
(f) Carefully remove hinged constant section duct and place on suitable protective
padding.
(g) Remove channels from hinged constant section duct.
(2) Forward Bifurcated Ducts Removal:
(a) Remove bolt and spacer attaching nose cowl ice protection duct to support
bracket (right side only).
(b) Remove nose cowl ice protection duct from nose cowl anti-icing air shutoff
valve and heat exchanger tee duct on pylon (right side only) (see Chapter 75).
(c) Mark location of nose cowl ice protection duct support bracket, located on
forward bifurcated duct front flange above horizontal centerline (right side
only).
(d) Remove bolts attaching support bracket to duct front flange and remove bracket.
71.02.22 08-01-00 Revision 10

(e) Remove bolts attaching two brackets supporting fire sensing element to bottom
aft end of forward bifurcated duct (right side only).
(f) Disconnect electrical connector (If installed) from engine compartment cooling
shutoff valve, located on bottom inboard side of forward bifurcated duct
manifold (left side only).
(g) Remove clamp connecting Y duct to forward bifurcated duct manifold port at
top of duct manifold.
(h) Remove clamps from forward section of generator cooling duct located at
bottom centerline of engine.
(i) Move generator cooling duct forward to provide access to area where forward
bifurcated ducts join.
(j) Mark location of engine ground handling bracket.
(k) Remove bolts attaching spacer and bracket to forward bifurcated duct front
flange; remove spacer and bracket.
(l) Remove bolts attaching forward bifurcated duct to engine flange. Leave several
bolts spaced around flange for support.
(m) Support duct and remove remaining bolts.

CAUTION: MOVE DUCT STRAIGHT AWAY FROM THE ENGINE,

HOLDING DUCT PARALLEL TO ENGINE UNTIL INNER
FLANGE IS CLEARED OR DAMAGE TO DUCT MAY
RESULT.
(n) Carefully remove duct section and place on suitable protective padding.
Note: If difficulty is experienced in separating the forward bi-ducts at forward
top and bottom areas where duct sections are joined and sealed, use a shot
bag large enough in areas to prevent damage to honeycomb structure and
tap duct section loose.
Revision 10 08-01-00 71.02.23

Note: It is unnecessary to perform steps (o) and (p) if duct section was removed
to gain access to engine for maintenance and new duct is not being
installed.
(o) Remove clamp and engine compartment cooling shutoff valve from lower
inboard side of forward bifurcated duct manifold (left side only).
(p) Remove clamp and plug from lower inboard side of forward bifurcated duct
manifold (right side only).
(3) Bi-Duct Installation. (Figure 71.02-12)
(a) Check that bi-duct is serviceable, free of dirt, and not damaged.
(b) Check seals at aft end of duct for damage. If damaged, replace with new seal.
(c) Seal upper and lower faying surfaces of bifurcated duct sections as follows:
1) Clean faying surface of both ducts with solvent and allow to dry.
2) Apply a thin coat of primer to both surfaces and allow to dry for a
minimum of 30 minutes before applying sealant. (Red high temperature
RTV silicon rubber. Minimum rating of 500 degrees F. continuous and
600 degree F. intermittent.)
3) Apply five coats of release agent to smooth fitting on each duct allowing
thirty seconds drying time between each coat. This is the bottom fitting on
the left hand duct and the top fitting on the right hand duct.
4) Apply a layer of sealant to the grooved fitting on each duct. This is the top
fitting on the left hand duct and the bottom fitting on the right hand duct.
5) Avoid touching surface coated with release agent during installation.
6) Install ducts with a minimum of relative motion between ducts until final
tightening.
7) Allow sealant to dry and trim off excessive sealant.
(d) Install plug and clamp on bottom of forward bifurcated duct manifold (right side
only).
71.02.24 08-01-00 Revision 10

(e) If installation is required, install engine compartment cooling shutoff valve on

bottom of forward bifurcated duct manifold (left side only).
(f) Install duct section on engine flange and install several bolts spaced around
flange for support.
WARNING: BIFURCATED DUCT WEIGHS APPROXIMATELY 111

LBS. USE SUFFICIENT PERSONNEL TO SUPPORT DUCT
SECTION WHEN INSTALLING DUCT TO PREVENT
INJURY OR DAMAGE.
(g) Install engine ground handling bracket, spacer and bolts on duct section front
flange, at position marked during removal.
Note: Spacer is installed on aft of engine ground handling bracket.
(h) Install nose cowl ice protection duct support bracket on duct section front
flange, at position marked during removal (right side only).
(i) Install remaining bolts in duct section front flange.
(j) Align generator cooling duct at bottom centerline of engine and install clamp.
(k) Connect “Y” duct to forward bifurcated duct manifold at top of duct manifold
and install clamp.
(l) Connect Electrical connector to engine compartment cooling shutoff valve.

Safety connector with lockwire (left side only).
(m) Align duct section bracket mounting holes with fire sensing element bracket
mounting holes and install bolts (right side only).
(n) Install nose cowl ice protection duct to nose cowl anti-icing air shutoff valve
and heat exchanger tee duct on pylon (right side only).
(o) Install spacer and bolt attaching nose cowl ice protection duct to support bracket
(right side only).
(p) Install hinged constant section duct if combined transition section and aft
section duct are in place.
Revision 10 08-01-00 71.02.25

6. Hinged Constant Section Fan Ducts Removal and Installation (Either S.T.C.)
a. Remove constant section fan ducts. (Figure 71.02-11)
DACO DC-8 Sixty Series Maintenance Manual, Chapter 71.
(2) Open forward cowl doors in accordance with DACO DC-8 Sixty Series
Maintenance Manual, Chapter 71.
(3) Remove bolts attaching upper and lower ends of both channels.
(4) Remove bolt attaching lanyard to fitting on bottom of hinged constant section fan
duct.
(5) Support hinged constant section fan duct and remove pins at the top of both
channels.
(6) Carefully remove constant section fan duct and place on suitable protective
padding.
(7)) Remove channels from constant section fan duct.
b. Install Hinged Constant Section Duct. (Figure 71.02-11)
Manual, Chapter 71.
(2) Check that hinged constant section duct is serviceable, free of dirt, and not
damaged.
(3) Check seals at forward and aft end of hinged constant section duct for damage. If
damaged, replace with new seals.
(4) Install channels on hinged constant section duct.
(5) Install hinged constant section duct on engine and install pins as top of both
channels.
71.02.26 08-01-00 Revision 10

(6) Install bolts attaching upper and lower ends of both channels.
(7) Install bolt attaching lanyard to fitting on bottom of hinged constant section duct.
(8) Close forward cowl doors in accordance with procedures in the Douglas DC-8 Sixty
Series Maintenance Manual, Chapter 71.
Manual, Chapter 71.
Revision 10 08-01-00 71.02.27

INSTALLATION OF HINGED CONSTANT SECTION DUCT

Figure 71.02-11
71.02.28 08-01-00 Revision 10

INSTALLATION OF FORWARD BIFURCATED DUCT

Figure 71.02-12
Revision 10 08-01-00 71.02.29

7. Transition Section Duct Removal and Installation.(Either S.T.C.)
a. Access for removal and installation of transition section duct is gained by removal of
forward cowl doors, aft cowl doors, and hinged constant section duct. See Paragraph 6
preceeding.
b. The thrust reverser translating ring must be in aft position with deflector doors faired.
WARNING: INADVERTANT OPERATION OF THRUST REVERSERS

COULD CAUSE SERIOUS INJURY TO PERSONNEL
WORKING IN THE ENGINE AREA.
c. Tools and Equipment Required
A Stop safety thrust 3889701 Douglas Aircraft Used to lock thrust

reverser translating Company Inc. reverser translating ring
ring in fully deployed
position.
B Methyl Ethyl Ketone Commercially To clean surfaces before

Available applying primer.
C Sealant, silicone General Electric To seal forward

rubber-based Co. bifurcated ducts and
transition section duct to
aft duct.
D Primer, silicone Dow Corning Used to prime metal

silastic, RTV-1200 Corp. surfaces before applying
sealant.
E Lubricating oil MIL-L- Commercially To lubricate aft duct

molybdenum 25681 Available attach bolts.
disulfide, silicone
base, high
temperature
71.02.30 08-01-00 Revision 10

d. Removal Transition Section Duct(See Figures 71.02-13 and -14)
(1) Open forward and remove aft cowl doors in accordance with procedures in the
Douglas Aircraft DC-8 Sixty Series Maintenance Manual, Chapter 71.
(2) Position translating ring in aft position with deflector doors faired.
WARNING: MAKE CERTAIN THAT ALL PERSONNEL AND

EQUIPMENT ARE CLEAR OF THRUST REVERSERS
BEFORE OPERATION OF SYSTEM.
NOTE: When operating thrust reversers without hydraulic pressure, deflector

doors will not rotate to deployed position when translating ring moves aft.
(3) Close thrust reverser hydraulic system manual shutoff valve in accordance with
Chapter 78.
(4) Install safety stops in translating ring upper outer tracks in accordance with
Chapter 78.
WARNING: ENSURE SAFETY STOPS ARE INSTALLED WITH WIDE

DOUBLE PRONGED ENDS FACING TOWARD
TRANSLATING RING FORWARD SLIDERS.
Chapter 71.
(6) Make certain that thrust reverser standby hydraulic pump switch is off.
(7) Remove hinged constant section duct in accordance with procedures in Chapter 78-
10-0.
CAUTION: THE COMBINED TRANSITION AND AFT SECTION DUCTS

WEIGH APPROXIMATELY 270 LBS. USE SUFFICIENT
PERSONNEL TO SUPPORT DUCTS WHEN REMOVING OR
INSTALLING TO PREVENT INJURY TO PERSONNEL OR
DAMAGE TO DUCTS OR ENGINE.
Revision 10 08-01-00 71.02.31

NOTE: The transition section duct and aft duct are bolted together and should be
removed and installed on engine as a complete unit. The duct sections can
be separated by removing connecting bolts.
(8) Remove clamp and disconnect hose attaching shroud cooling line to top of
transition section duct (left side only).
(9) Remove nuts and remove straps connecting aft duct to exhaust nozzle duct.
(10) Remove lower bolts connecting aft duct to exhaust nozzle.
(11) Remove upper bolts connecting aft duct to exhaust nozzle.
(12) Remove bolts connecting lower rod and center rod to engine brackets. Tape rods to
duct.
(13) Support combined duct sections and remove bolt connecting upper rod to engine
bracket.
(14) Carefully remove combined duct sections and place on suitable protective padding.
(15) Item deleted

(16) Remove fitting and packing from top of left transition section duct or plug and
packing from bottom of right duct. Retain for use on installation of duct. Inspect
packing and replace if necessary.
(17) Remove bolts and remove support rods from inboard side of transition section duct.
(18) Remove bolts attaching transition section duct to aft duct and separate duct
sections.
71.02.32 08-01-00 Revision 10

TRANSITION & AFT SECTION DUCTS REMOVAL/INSTALLATION

Figure 71.02-13
Revision 10 08-01-00 71.02.33

TRANSITION DUCT BRACKETS

Figure 71.02-14
71.02.34 08-01-00 Revision 10

e. Install transition section duct. (Figure 71.02-13 and -14)
(1) Make certain throttle/thrust reverser lever in tagged and circuit breakers are open in
Manual, Chapter 71.
NOTE: The transition section duct and aft duct are bolted together and should be
removed and installed on engine as a complete unit.
(2) Check that transition section duct and aft duct are serviceable, free of dirt, and not
damaged.
(3) Check seal at forward end of transition section duct. If damaged, replace with new
seal.
WARNING: METHYL ETHYL KETONE IS HIGHLY FLAMMABLE,
AVOID SOURCES OF IGNITION. VAPOR IS IRRITATING
TO EYES, NOSE AND THROAT. USE ONLY IN AREAS WITH
ADEQUATE VENTILATION, AVOID PROLONGED
BREATHING OF VAPOR AND PROLONGED OR REPEATED
CONTACT WITH SKIN. PROTECTIVE GLOVES SHOULD
BE WORN DURING USE. SOLVENT MAY CAUSE
DERMATITIS BY REMOVING OILS FROM THE SKIN.
(4) Scrape off sealant and primer from mating surfaces of duct sections.
(5) Wipe surfaces with a clean cloth or swab dampened in methyl ethyl ketone (MEK).
Wipe areas dry before solution evaporates.
(6) Apply primer (RTV-1200 or equivalent) to both mating surfaces of duct sections
with a brush.
(7) Allow primer to dry for a minimum of 30 minutes.
(8) Apply Hi-temp. (500 F continuous, 600 F intermittent) Red RTV sealant(or
equivalent) to one duct section mating surface.
(9) Join duct sections and install bolts.
NOTE: Direction of bolt head is optional.
(10) Install rods and spacers to brackets on inboard side of transition section duct. Tape
rods to duct surface.
Revision 10 08-01-00 71.02.35

(11) Using new packing install fitting in top of left transition section duct and plug in
bottom of right duct.
(12) Install upper and lower corner seal assemblies and on forward end of transition
section duct and install attaching hardware.
(a) Adjust upper and lower corner seal assemblies on forward end of transition
section duct to maintain 1/4-inch gap between fireseal and inner surface of
brackets. Tighten attaching hardware.
(b) Scrape off sealant and primer from joint where bracket joins duct section.
(c) Wipe area with a clean cloth or swab dampened in MEK. Wipe area dry before
solution evaporates.
(d) Apply primer (RTV-1200 or equivalent) to joint with a brush.
(e) Allow primer to dry for a minimum of 30 minutes.
(f) Apply sealant to joint.
CAUTION: THE COMBINED TRANSITION AND AFT SECTION DUCTS

WEIGHT APPROXIMATELY 270 LBS. USE SUFFICIENT
PERSONNEL TO SUPPORT DUCTS WHEN REMOVING OR
INSTALLING TO PREVENT INJURY TO PERSONNEL OR
DAMAGE TO DUCTS OR ENGINE.
(13) Install combined duct sections on engine, align upper rod end with engine flange
bracket and install bolt.
(14) Apply coating of oil (MIL-L-25681) on bolt threads and install bolts connecting
upper end of aft duct to exhaust nozzle.
(15) Align center and lower rods with engine flange brackets and install bolts.
(16) Apply coating of oil (MIL-L-25681) on bolt threads and install bolts connecting
lower end of aft duct to exhaust nozzle.
(17) Adjust rods to maintain 1/4 inch gap between fireseal and inner surface of transition
section duct. Tighten rod nuts to a torque of 160 to 180 lb-in.
71.02.36 08-01-00 Revision 10

(18) Tighten upper and lower bolts connecting aft duct to exhaust nozzle.
NOTE: Allowable splitter mismatch between the aft fan duct and the exhaust
nozzle is an average of 1/8 inch or less. This figure is obtained by adding
together the mismatch of each nozzle splitter with the corresponding
splitter on the aft fan duct and dividing by eight (the number of splitters).
The maximum mismatch of an individual splitter is 1/4 inch and may not
occur on more than two splitters in any one nozzle. Normal splitter
mismatch is 1/16 inch. The aft fan duct does not have a center line
splitter, therefore, the exhaust nozzle center line splitter is not considered.
Misalignment of splitters at duct separation forward of the aft fan duct is
not considered critical.
(19) Install seals and straps connecting aft duct to exhaust nozzle and install nuts.
Tighten to running torque of nut plus 40 to 45 lb-in. maximum.
(20) Install shroud cooling line hose to fitting at top transition section duct and install
clamp (left side only).
(21) Install hinged constant section duct in accordance with procedures in Section 6
preceeding (See Figure 71.02-14).
(22) Close forward and install aft cowl doors in accordance with procedures in the
Douglas Aircraft DC-8 Sixty Series Maintenance Manual, Chapter 71.
(23) Make certain that throttle/thrust reverser lever is in reverse thrust detent position.
(24) Remove safety stops from translating ring upper outer tracks in accordance with
Chapter 78.
(25) Open thrust reverser hydraulic system manual shutoff valve in accordance with
Chapter 78.
Manual, Chapter 71.
(27) Perform thrust reverser translating ring operation test in accordance with
Chapter 78.
Revision 10 08-01-00 71.02.37

(28) If not previously installed, install nose cowl door pans in accordance with BAC II
drawing DC8-23000 and check for clearance between door and door hold-open
bracket on bifurcated ducts.
CAUTION: CHECK TO VERIFY THERE IS NO INTERFERENCE BETWEEN

COWL DOORS AND ENGINE WIRE HARNESS PRIOR TO
CLOSING OF FORWARD AND AFT COWL DOORS.
71.02.38 08-01-00 Revision 10

71.03 – DC-8-60 HUSH KIT ILLUSTRATED PARTS CATALOG

(S.T.C.’s SA4892NM & SA5455NM)
TABLE OF CONTENTS
Paragraph Page
1. ILLUSTRATED PARTS CATALOG --------------------------------------------- 71.03.1
FIGURES
71.03-1 NOSE COWL ASSEMBLY (FULL KIT) ----------------------------------------- 71.03.1

71.03-2 FLAP MARKINGS INSTALLATION -------------------------------------------- 71.03.3
71.03-3 NOSE COWL & CSD COOLER INSTALLATION----------------------------- 71.03.5
71.03-4 NOSE COWL ASSEMBLY--------------------------------------------------------- 71.03.7
71.03-5 INLET PANEL ASSEMBLY ------------------------------------------------------- 71.03.28
71.03-6 BULLET ASSEMBLY--------------------------------------------------------------- 71.03.29
71.03-7 ADC UPGRADE TWO PIECE NOSE DOME & NOSE DOME
EXTENSION -------------------------------------------------------------------------- 71.03.41
71.03-8 BRACKET-HEAT EXCHANGER------------------------------------------------- 71.03.43
71.03-9 BIDUCT ASSEMBLY --------------------------------------------------------------- 71.03.45
71.03-10 BIDUCT ASSEMBLY - SPLITTER INSTALLATION ------------------------ 71.03.51
71.03-11 CONSTANT SECTION & TRANSITION DUCT ASSEMBLIES ------------ 71.03.57
71.03-12 AFT DUST ASSEMBLY ------------------------------------------------------------ 71.03.60
71.03-13 AFT DUCT ASSEMBLY - SPLITTER PANEL INSTALLATION----------- 71.03.64
Revision 14 12-03-01 71.03-i

INTENTIONAL
BLANK
71.03-ii 12-03-01 Revision 14

(S.T.C.’s SA4892NM AND SA5455NM)
1. Illustrated Parts Catalog. This section is applicable to the following:
a. BAC II Full Kit S.T.C. SA4892NM [Usage Code “A”], and
b. BAC II ADC Upgrade Retro Fit S.T.C. SA5455NM [Usage Code “B”].
NOSE COWL ASSEMBLY (FULL KIT)

Figure 71.03-1 (1 of 2)
Revision 10 08-01-00 71.03.1

(S.T.C.’s SA4892NM AND SA5455NM) (cont’d)
ITEM PART NUMBER 1 2 3 4 5 6 7 NOMENCLATURE USAGE QTY

1 DC8-22000-201 NOSE COWL ASSY. A 4
236-0045-505 NOSE COWL ASSY. B
2 DC8-28000-1 BULLET ASSY. FULL KIT A 4
DC8-38000-1 BULLET ASSY. RETROFIT B
3 N/A
4 DC8-24000-301 DUCT ASSY. - BIFURCATED A&B 8
-303
5 5757511-XXX CONSTANT SECTION A 8
236-0005-XXX CONSTANT SECTION B 8
6 5757513-XXX FWD TRANSITION DUCT A 8
236-0006-XXX FWD TRANSITION DUCT B 8
7 DC8-27000-47 AFT SECTION DUCT A&B 8
8 DC8-21007-1 MARKINGS INSTL. FLAP POSITION A&B 1
9 DC8-21005-1 BRACKET - HEAT EXCHANGER A&B 2
USAGE CODES
BAC FULL KIT STC SA4892NM A
ADC RETROFIT STC SA5455NM B
NOSE COWL ASSEMBLY (FULL KIT)

Figure 71.03-1 (2 of 2)
71.03.2 08-01-00 Revision 10

FLAP MARKINGS INSTALLATION

Figure 71.03-2 (1 of 2)
Revision 10 08-01-00 71.03.3

ITEM PART NUMBER 1 2 3 4 5 6 7 NOMENCLATURE QTY

1 DC8-21007-1 MARKINGS, INSTALLATION 1
2 DC8-21007-3 • • FLAP QUADRANT MARKINGS 1
3 DC8-21007-5 • • INDICATOR MARKINGS FLAP 1

POSITION
4 DC8-21007-7 • • WARNING PLACARD 2
5 DC8-21007-9 • • WARNING DECAL. 1
6 DC8-21007-11 • • SOFTGUARD 1
7 AN526-832R5 • • SCREW 2
8 MS35333-155 • • WASHER 2
FLAP MARKINGS INSTALLATION

Figure 71.03-2 (2 of 2)
71.03.4 08-01-00 Revision 10


Figure 71.03-3 (1 of 3)
CSD COOLER INSTALLATION

Figure 71.03-3 (2 of 3)
Revision 10 08-01-00 71.03.5

ITEM PART NUMBER 1 2 3 4 5 6 7 NOMENCLATURE QTY

1 NOSE COWL ASSY. INSTL. 1
2 DAC0-4766158-1 • STUD 9
3 H2O-5 • NUT 9
4 AN960C516L • WASHER 9
5 DC8-21004-1 • • CSD COOLER INSTL. 1
6 DACO-3754203-1 • • SEAL 1
7 AN960-10L • • WASHER AR
8 NAS1096-3-9 • • BOLT AR

Figure 71.03-3 (3 of 3)
71.03.6 08-01-00 Revision 10

NOSE COWL ASSEMBLY

Figure 71.03-4 (1 of 21)
Revision 10 08-01-00 71.03.7

NOSE COWL ASSEMBLY

Figure 71.03-4a (2 of 21)
71.03.8 08-01-00 Revision 10

NOSE COWL ASSEMBLY

Figure 71.03-4b (3 of 21)
Revision 10 08-01-00 71.03.9

NOSE COWL ASSEMBLY

Figure 71.03-4c (4 of 21)
71.03.10 08-01-00 Revision 10

NOSE COWL ASSEMBLY

Figure 71.03-4d (5 of 21)
Revision 10 08-01-00 71.03.11

NOSE COWL ASSEMBLY

Figure 71.03-4e (6 of 21)
71.03.12 08-01-00 Revision 10

NOSE COWL ASSEMBLY

Figure 71.03-4f (7 of 21)
Revision 10 08-01-00 71.03.13

NOSE COWL ASSEMBLY

Figure 71.03-4g (8 of 21)
71.03.14 08-01-00 Revision 10

NOSE COWL ASSEMBLY

Figure 71.03-4h (9 of 21)
Revision 10 08-01-00 71.03.15

NOSE COWL ASSEMBLY

Figure 71.03-4j (10 of 21)
71.03.16 08-01-00 Revision 10

FIG. ITEM PART NUMBER 1 2 3 4 5 6 7 NOMENCLATURE USAGE QTY

4 1 DC8-22000-201 • NOSE COWL ASSY. A 1
236-0045-501 B
• • • DC8-21006-1 ID PLATE 1
• • • • MS20470AD3 RIVET AR
4b 2 DC8-22200-1 • • • PANEL ASSY. 1
4g 3 DC8-22000-49 • • SUPPORT ANGLE 4
• • • CR3213-4 RIVET, BLIND AR
4g 4 DC8-22000-51 • • SUPPORT ANGLE 1
4a 5 DC8-22000-59 • • DOUBLER 2
• • • MS20426AD5 RIVET AR
4a 6 DC8-22000-67 • • SPLICE 1
4a 7 DC8-22000-69 • • SPLICE 1
4a 8 DC8-22000-203 • • SKIN 1
4b 9 DC8-22000-205 • • SKIN 1
• • • NAS517-2 SCREW AR
4a 10 DC8-22000-207 • • SKIN 1
4b 11 DC8-22000-209 • • SKIN 1
4a 12 DC8-22000-213 • • CHANNEL 1
• • • AN960-8 WASHER AR
• • • NAS679-08 NUT AR
USAGE CODES
BAC FULL KIT STC SA4892NM A
NOSE COWL ASSEMBLY
Figure 71.03-4 (11 of 21)
Revision 10 08-01-00 71.03.17


4a 13 DC8-22000-214 • • CHANNEL 1
• • • NAS697-08 NUTPLATE AR
• • • NAS679-08 NUT AR
4a 14 DC8-22000-215 • • CHANNEL 1
• • • NAS679-08 NUT AR
4b 15 DC8-22000-217 • • CHANNEL 1
• • • NAS697-08 NUTPLATE AR
• • • NAS679-08 NUT AR
4b 16 DC8-22000-219 • • • INTERCOSTAL 1
• • • • CR3213-5 RIVET, BLIND AR
4a 17 DC8-22000-220 • • • INTERCOSTAL OPP. 1
4a 18 DC8-22000-221 • • • INTERCOSTAL LWR. 1
NOSE COWL ASSEMBLY

Figure 71.03-4 (12 of 21)
71.03.18 08-01-00 Revision 10


4b 19 DC8-22000-223 • • • INTERCOSTAL LWR 1
4b 20 DC8-22000-225 • • • ANGLE UPPER AFT 1
• • • DC8-22000-239 SHIM 1
4a 21 DC8-22000-226 • • • ANGLE OPP. 1
• • • DC8-22000-241 SHIM 1
4a 22 DC8-22000-227 • • • ANGLE LWR. AFT 1
• • • DC8-22000-239 SHIM 1
4b 23 DC8-22000-228 • • ANGLE OPP. 1
• • • DCI-22000-241 SHIM 1
4b 24 DC8-220000-229 • • • ANGLE UPR. FWD. 1
• • • DC8-22000-243 SHIM 1
4a 25 DC8-22000-230 • • • ANGLE OPP. 1
• • • DC8-22000-243 SHIM 1
NOSE COWL ASSEMBLY

Figure 71.03-4 (13 of 21)
Revision 10 08-01-00 71.03.19

FIG. ITEM PART NUMBER 1 2 3 4 6 7 NOMENCLATURE USAGE QTY

4a 26 DC8-22000-231 • • • ANGLE LWR. FWD. 1
• • • DC8-22000-243 SHIM 2
4c 32 DC8-22000-253 • • • ANGLE 1
• • • MS20426AD5 RIVET, AR
FLUSH
4c 33 DC8-22000-255 • • PLATE 1
4b 34 DC8-22000-257 • • • SCOOP ASSY. 1
4c 35 DC8-22000-263 • • • DOUBLER 1
• • • • NAS1097-5 RIVET, AR
FLUSH
4c 36 DC8-22000-265 • • • CLIP 2
• • • • MS20470AD5 RIVET, AR
FLUSH
4c 37 DC8-22000-267 • • • ANGLE 1
4c 38 DC8-22000-269 • • • ANGLE 1
• • • •MS20426AD4 RIVET, AR
FLUSH
4c 39 DC8-22000-273 • • • ANGLE 1
• • • • NAS1097-5 RIVET, AR
FLUSH
4c 40 DC8-22000-275 • • • ANGLE 1
• • • • NAS1097-5 RIVET, AR
FLUSH
4c 41 DC8-22000-277 • • • GUSSET 1
• • • • MS20426AD5 RIVET, AR
FLUSH
NOSE COWL ASSEMBLY

Figure 71.03-4 (14 of 21)
71.03.20 08-01-00 Revision 10


4c 42 DC8-22000-278 • • • GUSSET OPP. 1
• • • • MS20426AD5 RIVET, AR
FLUSH
4c 43 DC8-22000-279 • • • GUSSET 1
• • • • MS20426AD5 RIVET, AR
FLUSH
4c 44 DC8-22000-280 • • • GUSSET OPP. 1
• • • • MS20426AD5 RIVET, AR
FLUSH
4b 45 DC8-22000-281 • • • ANGLE 1
4a 46 DC8-22000-283 • • • FRAME. 3
4a 47 DC8-22000-285 • • • SPLICE 3
• • • • NAS623-3 SCREW AR
• • • • AN960-10 WASHER AR
• • • • MS21042-3 NUT AR
4c 48 DC8-22000-233 • • • ANGLE 1
• • • • NAS1097-5 RIVET, AR
FLUSH
4c 49 DC8-22000-291 • • • ANGLE 1
• • • • NAS1097-5 RIVET, AR
FLUSH
4c 50 DC8-22000-293 • • • DOUBLER 1
• • • • CR3522-3 RIVET AR
NOSE COWL ASSEMBLY

Figure 71.03-4 (15 of 21)
Revision 10 08-01-00 71.03.21


4c 51 DC8-22000-215 • • • ANGLE ASSY. 1
• • • • NAS698A-08 NUTPLATE AR
• • • • • MS20426AD3 RIVET, AR
FLUSH
4c 52 DC8-22000-299 • • • DOUBLER 1
• • • • NAS623-2-1 SCREW AR
• • • • AN960-8 WASHER AR
• • • • MS21042-08 NUT AR
• • • • AN960-416 WASHER AR
• • • • MS21042-4 NUT AR
4h 53 DC8-22000-301 • • CLIP 3
• • • NAS1068A08 NUTPLATE AR
4e 54 DC8-22000-303 • • CLIP 2
4b 55 DC8-22004-1 • • SPLICE 2
4b 56 DC8-22400-1 • VORTEX INSTL. 1
• • • MS27039C1-09 BOLT 4
• • • AN960C10L WASHER 5
4e 57 DC8-22400-3 • • TUBE ASSY. 1
• • • NAS594-12 COUPLING 1
• • • NAS595-12E RING 1
• • • NAS596-12 NUT 1
NOSE COWL ASSEMBLY

Figure 71.03-4 (16 of 21)
71.03.22 08-01-00 Revision 10


4e 58 DC8-22400-5 • • TUBE EXTENSION 1
4e 59 DACO 5753944-1 • • VORTEX INSTL. 1
4e 64 AN742H12 • • CLAMP 1
• • • NAS1103-2 BOLT 1
• • • MS21042-3 NUT 1
• • • AN960C10L WASHER AR
4e 65 DC8-22002-1 • • CLIP 1
4f 69 DC8-22500-1 • ANTI-ICING DUCT ISTL. 1
• • • MS27039C1-09 BOLT 6
• • • AN960C10L WASHER 6
4f 76 YR-364 • • METALIZED GLASS CLOTH AR
4f 77 DC8-22500-10 • • SAFETY WIRE AR
4b 78 DC8-22208-5 • • DEFLECTOR 2
4a 79 DC8-22005-5 • • DOUBLER 1
4a 80 DC8-22005-3 • • DOUBLER 2
4a 81 DC8-22005-6 • • DOUBLER 1
4a 82 DC8-22207-13 • • • DOUBLER ASSY. 2
4h 89 DACO
P/N 3754290-1 • INTERPHONE JACK INSTL. 1
NOSE COWL ASSEMBLY

Figure 71.03-4 (17 of 21)
Revision 10 08-01-00 71.03.23


4g 90 DACO
P/N 9753938-47 • • CLIP 2
• • • NAS623-2-1 SCREW AR
• • • MS21042-08 NUT AR
4d 91 DC8-22603-1 • • RING SEGMENT 2
• • • DC8-22603-3 SPLICE 2
• • • • CR3213-5 RIVET AR
4g 93 DC8-22602-1 • • • TEE RING SEGMENT 2
• • • DC8-22602-3 SPLICE 4
ANGLE
• • • • CR3213-5 RIVET AR
4g 96 DC8-22603-1 • • • RING SEGMENT 2
• • • DC8-22603-3 SPLICE 2
• • • DC8-22603-5 SPLICE 2
• • • • CR3523-5 RIVET AR
4h 100 DACO • • VENT ASSY. 1
P/N 3758691-1
4h 101 DC8-22000-47 • • DOUBLER 1
• • • CR3523-5 RIVET AR
4a 102 DC8-22000-251 • • • BLKHD. ASSY. 1
4d 103 DC8-22101-7 • • • WEB LWR. 1
• • • • CR3523-5 RIVET BLIND AR
• • • • MS21060-3 NUTPLATE AR
NOSE COWL ASSEMBLY

Figure 71.03-4 (18 of 21)
71.03.24 08-01-00 Revision 10


4d 104 DC8-22101-5 • • • WEB UPR. 1
• • • • MS21060-3 NUTPLATE AR
4c 105 DC8-22302-37 • • • • ANGLE ASSY. 1
• • • • • MS20426AD3 RIVET, AR
FLUSH
4c 106 DC8-22302-41 • • • ANGLE ASSY. 1
• • • • • MS20426AD3 RIVET, AR
FLUSH
4c 107 DC8-22302-45 • • • ANGLE ASSY. 1
• • • • • MS20426AD3 RIVET, AR
FLUSH
4c 108 DC8-223-2-46 • • • ANGLE ASSY. OPP. 1
• • • • • MS20426AD3 RIVET, AR
FLUSH
4c 109 DC8-22302-7 • • • • DOUBLER ASSY. 1
• • • • • CR3522-5 RIVET AR
4c 110 DC8-22302-0 • • • SHIM 1
NOSE COWL ASSEMBLY

Figure 71.03-4 (19 of 21)
Revision 10 08-01-00 71.03.25


4c 111 DC8-22000-317 • • • ANGLE ASSY. 1
• • • • • MS20463AD3 RIVET, AR
FLUSH
4c 114 DC8-223-2-29 • • • ANGLE 1
• • • • • MS20426AD3 RIVET, AR
FLUSH
4c 115 DC8-22302-31 • • • ANGLE 1
• • • • • MS20426AD3 RIVET, AR
FLUSH
4d 116 DC8-22103-5 • • • ACCESS COVER 2
• • • • MS27039C1-06 SCREW AR
• • • • AN960C10 WASHER AR
4d 117 DC8-22103-13 • • • DOUBLER 1
• • • • CR3523-5 RIVET AR
4d 118 DC8-22103-15 • • • SPLICE 2
4d 119 DC8-22103-17 • • • PLATE 1
• • • • MS21060-3 NUTPLATE 6
• • • • • MS20426AD3 RIVET AR
4d 120 DC8-22103-19 • • • ACCESS COVER 2
• • • • MS27039C1-06 SCREW AR
NOSE COWL ASSEMBLY

Figure 71.03-4 (20 of 21)
71.03.26 08-01-00 Revision 10


4d 121 DC8-22103-21 • • • ACCESS COVER 2
• • • • MS27039C1-06 SCREW AR
4d 122 DC8-22103-23 • • • ACCESS COVER 1
• • • • MS27039C1-06 SCREW AR
4d 123 DC8-22100-3 • • RUB STRIP AR
• • • 201-120911-00-0101 AR
PLASTIC RIVET
4d 125 DACO • • • CAP 1
P/N 9751873-3
4d 125 DACO
P/N 9751871-5 • • • CAP 1
4d 126 DACO
P/N 9751871-25 • • • SPLICE 1
4d 127 DACO
P/N 9751871-51 • • • SPLICE 1
4c 128 DC8-22301-25 • • • BOX EXTENSION ASSY. 1
4b 155 DC8-22000-305 • • BOT. SCOOP 1
• • • NAS1097-5 RIVET, FLUSH AR
4j 156 DC8-2220-3-1 • • PAN 1
NOSE COWL ASSEMBLY

Figure 71.03-4 (21 of 21)
Revision 27 03-05-07 71.03.27

S.T.C.’s SA4892NM & SA5455NM (cont’d)

5 1 DC8-22200-1 • INLET PANEL ASSEMBLY 1
5 2 DC8-22200-117 • • SHIM. 1
5 3 DC8-22203-1 • • PAN-CSD COOLER 1
INLET PANEL ASSEMBLY

Figure 71.03-5
71.03.28 08-01-00 Revision 10

BULLET ASSEMBLY
Figure 71.03-6 (1 of 12)
Revision 10 08-01-00 71.03.29

BULLET ASSEMBLY
Figure 71.03-6a (2 of 12)
71.03.30 08-01-00 Revision 10

BULLET ASSEMBLY
Figure 71.03-6b (3 of 12)
Revision 10 08-01-00 71.03.31

BULLET ASSEMBLY
Figure 71.03-6c (4 of 12)
71.03.32 08-01-00 Revision 10

BULLET ASSEMBLY
Figure 71.03-6d (5 of 12)
Revision 10 08-01-00 71.03.33

BULLET ASSEMBLY
Figure 71.03-6e (6 of 12)
71.03.34 08-01-00 Revision 10

BULLET ASSEMBLY
Figure 71.03-6f (7 of 12)
Revision 10 08-01-00 71.03.35

BULLET ASSEMBLY
Figure 71.03-6g (8 of 12)
71.03.36 08-01-00 Revision 10

BULLET ASSEMBLY
Figure 71.03-6h (9 of 12)
Revision 10 08-01-00 71.03.37

BULLET ASSEMBLY
Figure 71.03-6j (10 of 12)
71.03.38 08-01-00 Revision 10


6 1 DC8-28000-1 • BULLET ASSEMBLY A 1
6 1 DC8-38000-1 • BULLET ASSEMBLY. B 1
6 2 DC8-28000-25 • • NOSE DOME ASSY. - INNER 1
6 3 DACO
P/N 5890308-3 • • NOSE DOME ASSY.-OUTER 1
6 4 DC8-28000-25 • • BULLET BONDED ASSY. 1
6f 5 DC8-28002-1 • • MOUNTING RING 1
620 6 DC8-28003-1 • • STIFFENER A 5
6d 7 DC8-28004-1 • • DOUBLER 5
6f 8 DC8-28005-1 • RETAINER CLIP-ATTACH NUT 5
6d 9 DC8-28007-1 • BLOCKING CLIP 4
6 10 DC8-28100-1 • • PT2 PROBE ASSY. A 1
6d 11 DC8-28006-1 • • BRACKET - SUPPORT, PT2 1
PROBE
6j 12 DC8-28006-3 • • CLIP - PT2 PROBE TUBE 1
SUPPORT
6a 13 DC8-28100-7 • • PLENUM CHAMBER 1
6d 14 DC8-28100-5 • • COUPLING, SLEEVE AND 1
FLANGE ASSY.
6j 15 DC8-28100-3 • • TUBE, PT2 PROBE - AFT 1
6a 16 DC8-28100-9 • • TUBE, PT2 PROBE -FWD 1
6f 17 MS20470AD5 • • RIVET AR
6j 18 AN742-5 • • CLAMP 1
6f 19 MS20426AD5 • • RIVET, 100 DEGREES CSK. AR
6b 20 MS20426AD4 • • RIVET, 100 DEGREES CSK AR
BULLET ASSEMBLY
Figure 71.03-6 (11 of 12)
Revision 10 08-01-00 71.03.39


6f 21 CR3213-5 • • BLIND RIVET - AR
CHERRYMAX
6f 22 CR3213-4 • • BLIND RIVET - CHERRY AR
MAX
6j 23 NAS679-C3 • • NUT 3
6j 24 AN3C5A • • BOLT 2
6j 25 AN960C10 • • WASHER 7
6j 26 NAS1103-2W • • BOLT 5
6d 27 DC8-21006-3 • • IDENTIFICATION PLATE 1
6f 28 MS102531A • • NUT 5
6h 29 HL2377-5-8 • • HI LOK ASSY. 1
6c 30 DACO-7660001-3 • • GROMMET OR 17130 1
SEALANT
6e 31 MS9386-281 • • O--RING 1
6 32 DC8-38003-1 • • STIFFENER B 5
6 33 DC8-38100-1 • • PT2 PROBE ASSY. B 1
USAGE CODE BAC FULL KIT STC SA4892NM A

BULLET ASSEMBLY
Figure 71.03-6 (12 of 12)
71.03.40 08-01-00 Revision 10

ADC UPGRADE TWO PIECE NOSE DOME & NOSE DOME EXTENSION
FIGURE 71.03-7 (1 OF 2)
(Note: Two piece Nose Dome & Nose Dome extension may be installed in accordance with
ATI EO 71-DC8-1029)
Revision 10 08-01-00 71.03.41


7 60 236-0010-501 • • PT2 TUBE EXTENSION 1
7 65 236-002-509 • • NOSE DOME EXTENSION 1
ATTACHING PARTS
7 70 236-0125-501 • • SLEEVE NUT 5
7 75 236-0126-501 • • SLEEVE 5
7 80 AN960XC716LL • • WASHER 10
7 85 236-0055-5 • • WASHER ASSY 20
7 90 236-0002-13 • • CLIP 1
ATTACHING PARTS
7 95 MS21043-3 • • NUT 1
7 100 AN960-10L • • WASHER 2
7 105 NAS6203-3 • • BOLT 1
ATTACHING PARTS
7 115 MS21043-3 • • NUT 1
7 120 AN960-10L • • WASHER 2
7 125 NAS6203-4 • • BOLT 1
7 140 420184 •PACKING 2

7 150 5890308-501 •NOSE DOME 1
7 155 S7E183-113 •PACKING 2
7 160 4754145-1 •PROBE 1
ADC UPGRADE TWO PIECE NOSE DOME & NOSE DOME EXTENSION
FIGURE 71.03-7 (2 OF 2)
71.03.42 08-01-00 Revision 10

(S.T.C.’s SA4892NM & SA5455NM) (cont’d)
BRACKET-HEAT EXCHANGER
Figure 71.03-8 (1 of 2)
Revision 10 08-01-00 71.03.43

FIG. ITEM PART NUMBER 1 2 3 4 5 6 7 NOMENCLATURE USAGE QT

Y
8 1 DC8-21005-1 • BRACKET-HEAT EXCHANGER 1
INST..
8 2 DC8-21005-3 • • BRACKET 1
8 3 DC8-21005-5 • • BRACKET 1
8 4 DC8-21005-7 • • CONE BOLT 1
BRACKET-HEAT EXCHANGER
Figure 71.03-8 (2 of 2)
71.03.44 08-01-00 Revision 10

BIDUCT ASSEMBLY
Figure 71.03-9a (1 of 6)
Revision 10 08-01-00 71.03.45

BIDUCT ASSEMBLY
Figure 71.03-9b (2 of 6)
71.03.46 08-01-00 Revision 10

BIDUCT ASSEMBLY
Figure 71.03-9c (3 of 6)
Revision 10 08-01-00 71.03.47

BIDUCT ASSEMBLY
Figure 71.03-9d (4 of 6)
71.03.48 08-01-00 Revision 10


9 1 DC8-24000-301 • DUCT ASSEMBLY L.H. 1
9c 2 DC8-24000-303 • DUCT ASSY R. H. 1
9 3 DACO
P/N 52602658- • • BRACKET 1
204
9c 4 DACO
P/N 575509-235 • • BRACKET 1
9 5 DC8-24003-1 • • TAPERED WASHER AR
9 7 DC8-24100-1 • • SPLITTER INSTL. 1
9a 8 DC8-21006-5 • • IDENTIFICATION PLATE 1
9a 9 DC8-24000-305 • • VENT COVER 2
9c 10 DC8-24000-307 • • PAN 1
9 11 NAS517-2-3 • • SCREW AR
9 12 AN960416L • • WASHER AR
9 13 NAS603-18 • • SCREW AR
9 14 MS21042-3 • • NUT AR
9c 15 NAS603-13 • • SCREW AR
9 16 61689 • • WASHER AR
9a 17 CR3213-4 • • CHERRY RIVET AR
9c 18 AN960-PD10 • • WASHER AR
9 19 CR3523-4 • • RIVET AR
9a 20 NAS679A08 • • NUT AR
9a 21 NAS623-2-6 • • SCREW AR
9a 22 CCR2755-3-2 • • RIVET AR
BIDUCT ASSEMBLY
Figure 71.03-9 (5 of 6)
Revision 10 08-01-00 71.03.49


9a 23 B23848 • • WASHER AR
9c 24 NAS517-2-4 • • SCREW AR
9c 25 TYE 1005-08- • • NUT AR
250
9c 26 A3135-017-24A • • WASHER AR
9c 27 27SS32 • • BLIND RIVET AR
9 28 SL5-08-30-S • • INSERT SHUR-LOK AR
BIDUCT ASSEMBLY
Figure 71.03-9 (6 of 6)
71.03.50 08-01-00 Revision 10

BIDUCT ASSEMBLY - SPLITTER INSTALLATION

Figure 71.03-10 (1 of 6)
Revision 10 08-01-00 71.03.51


Figure 71.03-10a (2 of 6)
71.03.52 08-01-00 Revision 10


Figure 71.03-10b (3 of 6)
Revision 10 08-01-00 71.03.53


Figure 71.03-10c (4 of 6)
71.03.54 08-01-00 Revision 10


Figure 71.03-10d (5 of 6)
Revision 10 08-01-00 71.03.55


10 1 DC8-24100-1 • SPLITTER PANEL INSTL. 1
10a 2 DC8-24100-3 • • PANEL ASSY. 1
10a 3 DC8-24100-4 • • PANEL ASSY. OPP. 1
10a 4 DC8-24100-5 • • PANEL ASSY. 1
10a 6 DC8-24100-7 • • PANEL ASSY. 1
10a 8 DC8-24100-9 • • PANEL ASSY. 1
10a 10 DC8-24100-11 • • PANEL ASSY. 1
10a 12 DC8-24100-27 • • LEADING EDGE 1
10a 13 DC8-24100-29 • • LEADING EDGE 2
10b 14 DC8-24100-33 • • SHIM 5
10b 15 DC8-24100-35 • • SHIM 5
10c 16 MS20470A4 • • RIVET AR
100b 17 NAS517-2-5 • • SCREW AR
10c 18 AN960-C4 • • WASHER AR
10b 19 A8-106 • • RIVNUT AR
10c 20 92352A 140 • • RIVET AR
10b 21 MS20426B4 • • RIVET CSK AR

Figure 71.03-10 (6 of 6)
71.03.56 08-01-00 Revision 10

CONSTANT SECTION & TRANSITION DUCT ASSEMBLIES

Figure 71.03-11 (1 of 3)
Revision 10 08-01-00 71.03.57


Figure 71.03-11 (2 of 3)
71.03.58 08-01-00 Revision 10


11 10 5757511-XXX • CONSTANT SECTION DUCT A 2
ASSY
11 20 3758145-501 • • SEAL A 2
11 10 236-0005-507 • CONSTANT SECTION DUCT B 2

ASSY
11 20 236-0005-77 • • SEAL (make from S700S0746 X B 2
110.0 inchs)
11 30 5757513-501 • TRANSITION DUCT ASSY A 2

11 40 3758145-1 • • SEAL A 1
11 50 3751496-501 • • BRACKET ASSY, LOWER A 2
SEAL
11 60 3751497-501 • • BRACKET ASSY, UPPER A 2
SEAL
11 30 236-0006-509 • TRANSITION DUCT ASSY B 2

11 40 236-0006-159 • • SEAL (make from S700S0746 X B 1
110.0 inches)
11 50 236-0043-501 • • CORNER SEAL ASSY, B 2
LOWER
11 60 236-0043-503 • • CORNER SEAL ASSY, UPPER B 2
USAGE CODES BAC FULL KIT STC SA4892NM A


Figure 71.03-11 (3 of 3)
Revision 10 08-01-00 71.03.59

DUCT ASSEMBLY AFT SECTION

Figure 71.03-12 (1 of 4)
71.03.60 08-01-00 Revision 10

AFT DUCT ASSEMBLY

Figure 71.03-12a (2 of 4)
Revision 10 08-01-00 71.03.61

AFT DUCT ASSEMBLY

Figure 71.03-12b (3 of 4)
71.03.62 08-01-00 Revision 10


12 1 DC8-27000-47 • DUCT ASSY. AFT SECTION 1
12b 2 DC8-24003-1 • • TAPERED WASHER AR
12 4 DC8-21006-11 • • IDENTIFICATION PLATE 1
12 5 DC8-27100-1 • • SPLITTER PANEL INSTL. 1
12a 6 DC8-27000-49 • • STRAP 1
12a 7 DC8-27000-51 • • STRAP 2
12a 8 DC8-27000-53 • • STRAP 1
12a 9 DC8-27000-55 • • STRAP 1
12a 10 DC8-27000-57 • • STRAP 1
12a 11 98848A011118-8 • • S.S. THREADED ROD 3
12a 12 AN960 CO8L • • WASHER AR
12a 13 NAS517-2-4 • • SCREW AR
12a 14 SL5-08-31-S • • NUT AR
12a 15 AN960-416L • • WASHER AR
12 16 C43213-4-2 • • CHERRY RIVET AR
12b 17 MS20615-4M • • MONEL RIVET AR
12 18 59FH-1032 • • NUT SHELF LOCKING AR
12a 19 AN96010L • • WASHER AR
12 20 NAS679A3 • • NUT AR
12a 21 NAS517-2 • • SCREW AR
12a 22 NAS679A08 • • NUT AR
12b 23 61689 • • WASHER AR
12 24 DC8-27000-45 • • PLATE 3
AFT DUCT ASSEMBLY

Figure 71.03-12 (4 of 4)
Revision 10 08-01-00 71.03.63

AFT DUCT ASSEMBLY SPLITTER INSTALLATION

Figure 71.03-13 (1 of 6)
71.03.64 08-01-00 Revision 10

AFT DUCT ASSEMBLY - SPLITTER INSTALLATION

Figure 71.03-13a (2 of 6)
Revision 10 08-01-00 71.03.65


Figure 71.03-13b (3 of 6)
71.03.66 08-01-00 Revision 10


Figure 71.03-13c (4 of 6)
Revision 10 08-01-00 71.03.67


Figure 71.03-13d (5 of 6)
71.03.68 08-01-00 Revision 10


13 1 DC8-2700-1 • SPLITTER PANEL INSTL. 1
13a 2 DC8-27100-3 • • PANEL ASSY. 1
13a 4 DC8-27100-5 • • PANEL ASSY. 1
13a 6 DC8-27100-7 • • PANEL ASSY 1
13a 8 DC8-27100-9 • • PANEL ASSY. 1
13a 10 DC8-27100-23 • • LEADING EDGE 4
13a 11 DC8-27100-25 • • LEADING EDGE 4
13b 12 DC8-27100-27 • • SHIM 16
13d 13 MS20470AD4 • • RIVET AR
13b 14 NAS517-2-5 • • SCREW AR
13d 15 AN960-C4 • • WASHER AR
13b 16 A8 106 • • RIVNUT AR
13b 17 MS20426AD3 • • RIVET AR
13c 18 92352 A 140 • • RIVET AR

Figure 71.03-13 (6 of 6)
Revision 10 08-01-00 71.03.69

INTENTIONAL
BLANK
71.03.70 08-01-00 Revision 10

71.04 – STRUCTURAL REPAIR MANUAL FOR BAC II STAGE III HUSH

KITS (S.T.C. SA4892NM)
TABLE OF CONTENTS
Paragraph Page
1. INTRODUCTION -------------------------------------------------------------------- 71.04.1
2. GENERAL REPAIR PRACTICES------------------------------------------------- 71.04.1
3. WELDED REPAIRS ----------------------------------------------------------------- 71.04.2
4. FASTENER SUBSTITUTION ----------------------------------------------------- 71.04.4
5. BONDED ACOUSTIC PANEL REPAIR ----------------------------------------- 71.04.4
6. CORROSION CONTROL----------------------------------------------------------- 71.04.28
7. NOSE COWL REPAIRS ------------------------------------------------------------ 71.04.31
8. FAN EXHAUST DUCT REPAIRS ------------------------------------------------ 71.04.53
FIGURES
71.04-1 PANEL REPAIR PREPARATION ------------------------------------------------ 71.04.8

71.04-2 PANEL DELAMINATION REPAIR (A) ----------------------------------------- 71.04.11
71.04-3 PANEL DELAMINATION REPAIR (B) ----------------------------------------- 71.04.12
71.04-4 ACOUSTIC PANEL NICK & SMALL HOLE REPAIR ----------------------- 71.04.14
71.04-5 ACOUSTIC PANEL DENT REPAIR WITHOUT SKIN PENETRATION -- 71.04.15
71.04-6 PARTIAL PENETRATION, IMPACT DAMAGE ------------------------------ 71.04.18
71.04-7 PANEL PARTIAL PENETRATION REPAIR (A) ------------------------------ 71.04.19
71.04-8 PANEL PARTIAL PENETRATION REPAIR (B) ------------------------------ 71.04.20
71.04-9 PANEL PARTIAL PENETRATION REPAIR (C) ------------------------------ 71.04.21
71.04-10 ACOUSTIC PANEL COMPLETE PENETRATION REPAIR (A) ----------- 71.04.25
71.04-11 ACOUSTIC PANEL COMPLETE PENETRATION REPAIR (B)------------ 71.04.26
71.04-12 REPAIR PLUG - COMPLETE PENETRATION REPAIR--------------------- 71.04.27
Revision 14 12-03-01 71.04-i

FIGURES(cont’d)
71.04-13 AFT DUCT FITTING REPLACEMENT ----------------------------------------- 71.04.37

71.04-14 SKIN DEBOND REPAIR (A) ------------------------------------------------------ 71.04.41
71.04-15 MATERIAL REFERENCE - NOSE COWL BARREL PANELS ------------- 71.04.43
71.04-16 MATERIAL REFERENCE - BULLET ASSEMBLY --------------------------- 71.04.47
71.04-17 BIFURCATED DUCT TYPICAL LAY-UP -------------------------------------- 71.04.55
71.04-18 AFT SECTION DUCT INBOARD WALL --------------------------------------- 71.04.56
71.04-19 AFT SECTION DUCT INBOARD WALL REPAIR(A)------------------------ 71.04.56
71.04-20 AFT SECTION DUCT INBOARD WALL REPAIR (B) ----------------------- 71.04.57
71.04-21 PERFORATED SKIN PATCH PLACEMENT----------------------------------- 71.04.58
71.04-22 AFT DUCT OUTER WALL REPAIR --------------------------------------------- 71.04.59
71.04-23 AFT SECTION DUCT INBOARD WALL --------------------------------------- 71.04.60
71.04-24 ACOUSTIC PANEL NICK AND SMALL HOLE REPAIR ------------------- 71.04.62
71.04-25 ACOUSTIC PANEL DENT REPAIR WITHOUT SKIN PENETRATION -- 71.04.63
71.04-26 PERFORATED SKIN REPAIR ---------------------------------------------------- 71.04.65
71.04-27 PERFORATED SKIN --------------------------------------------------------------- 71.04.66
71.04-28 SPLITTER PANEL SPLICE -------------------------------------------------------- 71.04.68
71.04-29 SPLITTER PANEL REPAIR ------------------------------------------------------- 71.04.70
71.04-30 MATERIAL REFERENCE BIFURCATED FAN EXHAUST DUCT -------- 71.04.72
71.04-31 MATERIAL REFERENCE ALL FAN EXHAUST DUCTS SPLITTER
ATTENUATION PANELS---------------------------------------------------------- 71.04.77
71.04-ii 12-03-01 Revision 14

71.04 STRUCTURAL REPAIR MANUAL FOR BAC II STAGE III HUSH KITS
(S.T.C. SA4892NM)
1. Introduction
a. General. This section provides information for the structural repair of DC-8-62/63 parts
and assemblies as modified for the BAC II Stage III Hush Kits. Those parts and
assemblies are identified in Table 71.01-1, STRUCTURAL REPAIR MANUAL
REFERENCE MATRIX. For repairs to items of other manufacturers, refer to the
appropriate manufacturers structural repair manual or other sections of this manual.
b. Parts Beyond Economical Repair. In the event that a part sustains damage beyond
reasonable repair, a replacement part should be obtained from the appropriate vendor and
installed per the applicable installation instructions in Section 71.02.
c. Scope. The repairs described in this manual do not exclude repairs described in other
approved sources of repair information.
2. General Repair Practices
a. General Requirements. The following requirements are necessary to accomplish the

repairs contained in this chapter and are in addition to the specific repair requirements
listed with the individual repairs.
(1) The recommended edge distance for all attachments in the repair areas is two
diameters plus one-sixteenth inch, unless otherwise noted. The minimum edge
distance is two diameters.
(2) All repair materials must be of the same material and heat-treat condition as the part
being repaired, unless otherwise noted. If substitution of materials is required, this
must be accomplished according to the materials substitution chart, Douglas DC-8
Structural Repair Manual, Chapter 51, Structures -- General.
CAUTION: DO NOT SUBSTITUTE CLAD MATERIAL FOR BARE IN
AREAS OF BONDED STRUCTURE.
(3) If forming operations require repair material to be in the soft (-0) condition, the part
must be heat-treated to the appropriate ‘T’ condition after forming.
(4) All metal repair parts must be cleaned and corrosion protected in accordance with
Paragraph 12 below, unless otherwise noted in the individual repair.
(5) All repair parts must be free from cracks, burrs, dings, and sharp edges. This
requirement applies also to the parts being repaired.
Revision 10 08-01-00 71.04.1

(S.T.C. SA4892NM) (cont’d)
(6) All attachment holes must be prepared in accordance with General Repair
Procedures and Processes, Douglas DC-8 Structural Repair Manual, Chapter 51,
General Structures.
(7) The minimum attachment spacing in repair areas is four diameters, unless otherwise
noted.
(8) Stop drilling of cracks should be accomplished by drilling #30 (or larger per
Douglas DC-8 Structural Repair Manual) holes except as noted. All stop drill holes
must be de-burred and polished.
b. Riveted Skin Patches and Doublers. The requirements for the installation of skin patches
and doublers are as follows.
(1) Form the doubler to the contour of the part to be repaired.
(2) Install the doubler with a minimum of two diameters edge distance for all
attachments.
(3) For rivet diameter not to exceed 5/32, space rivets 3/4 to 1 inch and surround the
affected cutouts with two rows of attachments, unless otherwise noted in the
individual repair.
(4) Pick up existing attachments wherever possible.
(5) Chamfer all external patches to a 45-degree angle and round all corners for
aerodynamic cleanness and clearance of the adjoining structures.
(6) Use the same gage and type of material (or one gage heavier) for repairs, unless
otherwise specified.
(7) When existing fasteners are oversized, use the next size larger fastener. For
fastener substitution refer to Paragraph 10 below.
3. Welded Repairs
a. Weldability Of Material
(1) The suitability of materials for welded repairs not specifically identified in this
manual may be determined by referring to MIL-HDBK-5 or other acceptable
sources of information.
71.04.2 08-01-00 Revision 10

(2) On the BAC II nose cowl assembly, welded repairs are limited to the nose ring on
the outboard side and to the narrow inner skin panels forward of the acoustic
attenuation panels on the inner surfaces.
CAUTION: THE HEAT OF WELDING MAY DAMAGE THE BONDS IN

BONDED ASSEMBLIES. NEVER PERFORM WELDED
REPAIRS ON BONDED ASSEMBLIES. EXERCISE
EXTREME CAUTION WHEN WELDING IN THE VICINITY
OF ANY BONDED ASSEMBLIES.
b. Preparation Of Material. In weld repairs applied to older parts, care must be taken in
preparing materials to be welded to avoid weakening the weld by inclusion of
contaminants.
(1) Parts and repair materials should be formed and fitted to allow for expansion and
distortion of the material during welding.
(2) Parts to be welded must be clean and free of any contaminants which might
adversely affect the quality of the weld. Remove any anodize, alodine or other
conversion coating material in the immediate area of the weld.
(3) If parts show evidence of corrosion, they should be cleaned using mechanical
means (bead blast, scraper, etc.) Total removal of material must not exceed 10% of
the original thickness of the base material without specific engineering approval.
Follow by treatment with a good metal brightener and conversion coating.
(4) Exercise care to remove all sealants, paints or other coatings from the area to be
welded and the area wiped with a good degreasing solvent.
c. All welds to be done by approved methods and to be free of cracks and visible inclusions.
Revision 10 08-01-00 71.04.3

4. Fastener Substitution. Except as listed herein fasteners may be substituted per the
information provided in the Douglas DC-8 Structural Repair Manual.
a. RIVETS. For Applications requiring the replacement of solid rivets by blind fasteners,
the following substitutions are acceptable.
Solid SUBSTITUTE RIVETS FOR SHEET THICKNESS IN INCHES

Rivet .025 .032 .040 .050 .063 .071
AD4 CR3243-5 CR3213-4 CR3213-4
AD5 ------------- CR3243-6 CR3243-5 CR3213-5
AD6 ------------- ------------- ------------- CR3243-6
AD4 ------------- CR3242-5 CR3242-4 CR3212-4
AD5 ------------- ------------ CR3242-6 CR3242-5
AD6 ------------- ------------ ------------ ------------ CR3242-6
If hole size is not within the limits shown below, an oversize or next size larger
CherryMax fastener must be used.
C/MAX DIAMETER NOMINAL OVERSIZE

(CR3212/CR3213) (CR3242/CR3243)
-4 0.129 to 0.132 0.143 to 0.146
-5 0.160 to 0.164 0.176 to 0.180
-6 0.192 to 0.196 0.205 to 0.209
5. Bonded Acoustic Panel Repair.
a. All repairs will be accomplished using Dexter Hysol EA934NA Epoxy Adhesive. All
parts should be cleaned in accordance with Paragraph c.(1) below prior to bonding.
71.04.4 08-01-00 Revision 10

b. Tools And Materials Required. Following is the list of basic equipment which should be
on hand for most damage repairs.
DESCRIPTION MATERIAL SOURCE

Epoxy Adhesive High EA934MA ( A & B ) Dextor Hysol
Temp. Aerospace Adhesive
Products
Pittsburgh, CA
94565-0031
Fastener, (temporary) Cleco Commercially available
Conversion Coating Alodine 1200 Parker + Amchem
32100 Stephenson
Highway
Madison Heights, MI
48071
Heat Blanket (or Heat 0 to 250 deg. F Atacks Products
lamp) 1120 SW 16th St.
Renton, WA 98055
c. Preparation For Bonding Of Aluminum Surfaces.

(1) Cleaning.
(a) All damaged areas must be reworked and the repair parts fitted, drilled,
deburred and break sharp edges before cleaning can be accomplished. (No
deburring is required on honeycomb or other core materials.)
(b) Remove any paint, lacquer, or primer to approximately 3 inches beyond the
faying surface of the bond area with paint stripper.
(c) Treat the finished part with an approved aluminum metal brightener rinse and
dry, then apply Alodine 1200 and again rinse and dry.
(d) Just prior to bonding, wipe the metal faying surface area with a small clean
cotton cloth dampened with Methyl Ethyl Keytone (MEK), followed by wiping
dry with a clean cotton cloth.
Revision 10 08-01-00 71.04.5

(e) Prepared aluminum honeycomb or Flexcore repair plugs should be cleaned just
prior to final installation. Dip the plug into a bath of MEK and shake off excess
fluid. Allow to air dry for a minimum of 15 minutes. Visually inspect cells for
trapped fluid droplets. If present, blow dry with clean, low pressure, air.
(2) Handling. All materials that are clean and ready for bonding should be handled
with clean white cotton gloves that are free from any oils, waxes, or silicones. Any
source of compressed air must be clean and free of entrapped oil.
(3) Mixing Of Adhesives. The EA934NA epoxy adhesive system is a material used as
a bonding agent to bond Acoustic panel repairs. This system is a two-part adhesive
which must be mixed just prior to use. Part A is a gray thrixptropic paste, and part
B is an amber liquid amine curing agent. Only the quantity that may be
conveniently used during the useful life of the adhesive should be mixed. Combine
by weight 100 parts of part A with 33 parts of part B, and mix thoroughly. THIS
IS IMPORTANT! No thinners should be used. Temperature prior to and during
mixing is not critical but should be close to 77 deg. F. A useful working potlife for
the material is 40 minutes at 77 degrees F for a one pound mixture.
WARNING: EPOXY RESINS CONTAINED IN THIS ADHESIVE MAY CAUSE SKIN

SENSITIVITY OR OTHER ALLERGIC REACTIONS. AVOID
CONTACT WITH SKIN AND EYES. AVOID BREATHING FUMES. IF
CONTACT IS MADE WASH THE AREA THOROUGHLY WITH SOAP
AND WATER.
(a) Mix thoroughly in a clean metal or plastic container.
(b) If not to be used immediately, cover container to prevent contamination of

mixture. Store in a cool dry place until used.
(c) If adhesive is to be used immediately, it can be mixed on a clean, flat non-

porous surface.
d. Preparation Of Panel For Repair.
(1) Stabilizing Areas To Be Cut (See Figure 71.04-1)
(a) Certain materials used in the BAC II modified fan exhaust ducts may require
stabilization before cutting operations can be performed. These materials are
found on the surfaces of the splitter attenuation panels in the Fan Exhaust ducts
(Chapter 78) A masking technique is used to accomplish this.
71.04.6 08-01-00 Revision 10

(b) Mask area on the face of the attenuation material to provide a 0.37 inch
stabilized area, using a 0.5 inch teflon tape.
(c) Place a nonporous parting film over the stabilized area and tape in place.
(d) Cure at room temperature for 24 hours or to accelerate the cure, place a heat
blanket over the parting film and cure at 180 deg. F to 200 deg. F for 30
minutes.
(e) Remove heat blanket and parting film.
(2) Cutting And Preparation Of Panel For Repair.
(a) After stabilizing the area to be cut, use the center of the stabilized area a guide
to cut out the repair area. Make sure all cutting tools used in this operation are
sharp and in good condition. Dull cutting tools can cause severe damage and
present a safety hazard to the worker. Best results will be obtained using a high
speed (18,000 to 23,000 rpm) router or cutting motor. A straight flute right
hand cut router bit provides superior cutting action and edge finish. Care must
be taken to provide a medium feed with the material feeding into the cutting
edge of the router bit. Feeding the material away from the cutting edge does not
allow adequate control of the tool and should be avoided.
(b) Using hole saw or router, cut through the aluminum core material. When
cutting out damage always cut to the smallest diameter possible to remove all
damage. Exercise caution to avoid damage to the next layer of skin.
Honeycomb or Flexcore and any adhesive should be cleaned away completely
from the back skin.
(c) If the Attenuation panel face sheet is perforated aluminum or stainless steel
sheet, bevel the edge of the perforated face sheet to 45 degrees. Use 320-400
grit abrasive paper aluminum oxide only, to produce a smooth surface finish.
Revision 10 08-01-00 71.04.7

PANEL REPAIR PREPARATION

Figure 71.04-1
71.04.8 08-01-00 Revision 10

e. Repair Types And Procedures
(1) Face Skin Delamination Repairs (Figure 71.04-1)
(a) Use tap test method and determine area of delamination.
(b) Using a #40 drill, make a series of (0.097 to 0.102 inch to a maximum of .130)
holes on each side of the delaminated area. One side will serve as injection
holes and the other will serve as vent holes. (This is not usually necessary in
perforated panels).
(c) Clean area to be cold bonded using a clean cloth with MEK or Acetone. Wipe
area dry with a clean dry cloth before solvent evaporates.
(d) Mix required amount of Epoxy adhesive and place adhesive in an injection
syringe.
(e) Inject adhesive into injection holes until delaminated area is completely filled
and adhesive flows out of the vent holes opposite.
(2) Delamination or Disbond at Panel Edges. (Figure 71.04-3)
(a) Inspect visually to determine extent of disbond.
(b) If necessary, remove any fasteners from area of disbond. If fastener holes are
not present, drill a series of #40 (0.097 to 0.102 inch) holes, at 0.50 inch to 0.75
inch on centers, along the edge of the disbond away from the edge of the panel.
(If the gap between the layers or sheets of material is large enough the injection
holes are not necessary.)
(c) Carefully open the delaminated skins without tearing or otherwise damaging the
skins. Carefully clean away as much of the remaining adhesive as possible.
Clean the inside and outside of the area using a clean cloth with a solvent such
as MEK or Acetone. Wipe the surface with a clean dry cloth before the
adhesive evaporates and blow dry the area between the skins with clean, dry,
low pressure air.
(d) Inject adhesive into the delaminated area until it is full and excess adhesive
flows out at the edge.
Revision 10 08-01-00 71.04.9

(e) Clean up excess adhesive and place a nonporous parting film over the repair
area. Apply pressure by mechanical means to maintain contact between face
skin and core throughout the cure cycle. For cure at 77 degrees F leave clamps
in place for 8 hours, after 24 hours 75% of strength is obtained. Full strength is
not reached for 5 to 7 days.
(f) To accelerate cure, apply heat by means of a heat blanket at a temperature of

200 degrees F for 1 hour to obtain a full cure. If a heat lamp is used, the surface
temperature must be monitored to prevent excessive temperatures. A
thermocouple or other temperature control must be used to prevent overheating
the resin.
(g) Remove clamping and parting film, clean up any excess adhesive using 240 to
320 grit aluminum oxide abrasive cloth.
71.04.10 08-01-00 Revision 10

PANEL DELAMINATION REPAIR

Figure 71.04-2
Revision 10 08-01-00 71.04.11

PANEL DELAMINATION REPAIR

Figure 71.04-3
71.04.12 08-01-00 Revision 10

(3) Acoustic Panel Dent with Nick or Gouge, to a Maximum of 1.00 Inch Diameter
(Per Figure 71.04-4 & -30)
(a) Drill or cut out damage using smallest diameter and depth possible to remove
all damage.
(b) Clean area with a clean cloth with MEK or Acetone. Wipe the surface using a
clean dry cloth before the solvent dries.
(c) Mask repair area (if necessary to stabilize surface) using teflon tape.
(d) Mix required amount of adhesive in accordance with instructions. (See

Paragraph 11. (c) (3) above.
(e) Fill repair cutout with adhesive using a spatula or flexible putty knife.
(f) Place nonporous parting film over repair area and tape in place.
(g) Allow to cure at room temperature (77 degrees F) for 8 hours, or apply a heat
blanket over the parting film and cure at 200 degrees F for 1 hour.
(h) Remove heat blanket and parting film. Sand to a feather edge using 240-320
grit aluminum oxide abrasive paper as needed to produce a smooth surface.
Revision 10 08-01-00 71.04.13

ACOUSTIC PANEL NICK AND SMALL HOLE REPAIR

Figure 71.04-4
71.04.14 08-01-00 Revision 10

ACOUSTIC PANEL DENT REPAIR WITHOUT SKIN PENETRATION

Figure 71.04-5
Revision 10 08-01-00 71.04.15

(4) Repair to Attenuation Panel, Partial Penetration
(a) Stabilize face skin if required
(b) Cut out damage to smallest diameter possible to remove all damage per
Paragraph 11. (d) (2) above. Damaged core should be removed to the next layer
of skin without damage to the skin.
(c) Make a core repair plug from the appropriate Honeycomb or flexcore material.
Machine core plug to a net height and diameter to match cutout diameter and
depth.
(d) Cut Attenuation (perforated) skin repair patch and doubler per Figures 71.04-7
thru 71.04-9.
(e) Place core repair plug and skin repair patch(es) into position in the damage
cutout. If applicable, perforations in the skin repair patch should be aligned
with the perforations in the original skin as closely as possible. (Figure 71.04-
8)
(f) With repair parts in position, drill fastener holes as required for installation of
repair.
(g) Remove repair parts and clean all drilling debris from repair cutout. Clean
repair area and parts with a clean cloth moistened with Methyl Ethyl Ketone
(MEK). Wipe all surfaces dry with a clean cloth before solvent evaporates.
Make certain all solvent is removed from the open core cells.
WARNING: METHYL ETHYL KETONE (MEK) IS HIGHLY
FLAMMABLE. USE ONLY IN A WELL VENTILATED
AREA. AVOID BREATHING FUMES.
(h) Mix the required amount of adhesive in accordance with Paragraph 11. (c) (3)
above.
(i) Apply a coat of EA934NA Epoxy Adhesive on both sides of skin doubler and
on faying surface of skin repair patch.
(j) Apply adhesive to core by placing adhesive on a clean flat surface. Then place
the core on the adhesive coated surface and work slightly to assure a good
coating of adhesive on the wall edges of the core.
(k) Thoroughly coat the inner diameter of the cutout and the outer diameter of the
core repair plug with adhesive.
71.04.16 08-01-00 Revision 10

(l) Install inner skin doublers and core plug into cutout and add adhesive around
the diameter of the repair plug to ensure all cut core cells are completely full of
adhesive.
(m) If skin patch is acoustic material with a sintered coating apply directly to the
repair area. If the skin patch is perforated sheet with open holes, apply a very
thin coat of adhesive to the surface adjacent to the core material before placing
patch in position.
(n) Clean away excess adhesive. Place a nonporous parting film over the repair
area and tape it in place. Apply pressure with Teflon tape or by mechanical
means to maintain contact between face skin and core until the adhesive has
cured.
(o) Allow to cure for 8 hours at 77 degrees F or 1 hour at 200 degrees F before
removing clamping pressure. Cure for 24 hours to obtain 75% of full strength
and 5 to 7 days to achieve full strength at 77 degrees F or full strength may be
obtained after 1 hour at 200 degrees F.
(p) When the adhesive has set, clean up the repair and drill a pattern of fastener
holes completely through the panel at approximately .75 inches on center with
an edge distance of 0.31 min. using a # 21 drill. Deburr the holes at both sides
of the panel and countersink the hole on the perforated side of the panel.
(q) Clean area of holes thoroughly using a rag dampened with MEK and fill the
holes with EA934NA epoxy adhesive.
(r) While the adhesive is still wet, Install NAS517-2 flush head screw with an
AN960-08 washer and with an MS21042-8 nut or an SL5-08-31-S Shur-lok nut
as specified in a particular repair. Tighten fasteners snug taking care not to
crush the panel. See Figure 71.04-9 for typical fastener installation.
(s) While still wet clean away any excess adhesive from fasteners leaving a small
witness fillet to ensure sealing of the fastener.
Revision 10 08-01-00 71.04.17

PARTIAL PENETRATION, IMPACT DAMAGE

Figure 71.04-6
71.04.18 08-01-00 Revision 10

PANEL PARTIAL PENETRATION REPAIR

Figure 71.04-7
Revision 10 08-01-00 71.04.19


Figure 71.04-8
71.04.20 08-01-00 Revision 10


Figure 71.04-9
Revision 10 08-01-00 71.04.21

(5) Complete Panel Penetration. (Figures 71.04-10 thru 71.04-12) If damage occurs
that results in a complete penetration of an attenuation panel, each event must be
evaluated by BAC II (or other qualified) engineering as to the feasibility of repair.
If damage falls within the limits shown, repair using the following method:
(a) If required, stabilize repair area following the instructions in Paragraph 11. (d)
(1) above.
(b) Using a hole saw of the smallest diameter necessary to remove all of the
damage through the panel.
(c) To prepare the panel for the repair plug using one of the following methods (see
Figure 71.04-10.) Use extreme caution to avoid damage to the back skin.
1) Using a piloted hole saw 1.5 inches larger in diameter than the damage
cutout, remove skin and core as shown in Figures 71.04-10 & 71.04-11.
Fabricate a wood plug that will fit tightly in the hole (use a piloted hole
cutter that will give a pilot hole in the exact center of the plug.) Add tape
if needed to prevent the plug from turning in the hole.
2) Fabricate a wooden plug as in paragraph 1) above and using a router set up
as in Figure 71.04-10, cut a hole through the face skin and core .75 inch
larger radius than the damage removal hole and to the required depth. DO
NOT DAMAGE THE BACK SKIN
(d) Using a grinder disc, as in Figure 71.04-11, remove core and adhesive adhering
to the inner face of the back skin.
(e) Fabricate a doubler using the same material and thickness as the back skin to fit
into the cutout as shown in Figure 71.04-11 and form to match contour of back
skin.
(f) Make a core repair plug using material of the same type and thickness as the
original as shown in Figure 71.04-11. Machine the aluminum core material to a
net height and diameter to match the cutout diameter and the depth to the
Doubler face.
(g) Cut a skin repair patch that will overlap the perforated skin by .75 inch all
around.
71.04.22 08-01-00 Revision 10

(h) Place core repair plug and skin repair patch(es) into position in the damage
cutout. If applicable, perforations in the skin repair patch should be aligned
with the perforations in the original skin as closely as possible.
(i) With repair parts in position, drill fastener holes per Figure 71.04-12 for
installation of repair.
(j) Remove repair parts and clean all drilling debris from repair cutout. Clean
repair area and parts with a clean cloth moistened with Methyl Ethyl Ketone
(MEK). Wipe all surfaces dry with a clean cloth before solvent evaporates.
Make certain all solvent is removed from the open core cells.
WARNING: METHYL ETHYL KETONE (MEK) IS HIGHLY
FLAMMABLE. USE ONLY IN A WELL VENTILATED
AREA. AVOID BREATHING FUMES.
(k) Mix the required amount of adhesive in accordance with Paragraph 11 (c) (3)
above.
(l) Apply a coat of EA934NA Epoxy Adhesive on both sides of skin doubler and
on faying surface of skin repair patch.
(m) Apply adhesive to core by placing adhesive on a clean flat surface. Then place
the core on the adhesive coated surface and work slightly to assure a good
coating of adhesive on the wall edges of the core.
(n) Thoroughly coat the inner diameter of the cutout and the outer diameter of the
core repair plug with adhesive.
(o) Install inner skin doublers and core plug into cutout and add adhesive around
the diameter of the repair plug to ensure all cut core cells are completely full of
adhesive.
(p) If skin patch is acoustic material with a sintered felt metal coating apply
adhesive directly to the repair area. If the skin patch is perforated sheet with
open holes, apply a very thin coat of adhesive to the surface adjacent to the core
material before placing patch in position.
(q) Clean away excess adhesive. Place a nonporous parting film over the repair
area and tape it in place. Apply pressure with Teflon tape or by mechanical
means to maintain contact between face skin and core until the adhesive has
cured.
Revision 10 08-01-00 71.04.23

(r) Allow to cure for 8 hours at 77 degrees F or 1 hour at 200 degrees F before
removing clamping pressure. Cure for 24 hours to obtain 75% of full strength
and 5 to 7 days to achieve full strength at 77 degrees F or full strength may be
obtained after 1 hour at 200 degrees F.
(s) When the adhesive has set, clean up the repair and drill a pattern of fastener
holes completely through the panel at approximately .75 inches on center with
an edge distance of 0.31 min. using a #21 drill. Deburr the holes at both sides
of the panel and countersink the hole on the perforated side of the panel.
(t) Clean area of holes thoroughly using a rag dampened with MEK and fill the
holes with EA934NA epoxy adhesive.
(u) While the adhesive is still wet, Install NAS517-2 flush head screw with an
AN960-08 washer and with an MS21042-8 nut or an SL5-08-31-S Shur-lok nut
as specified in a particular repair. Tighten fasteners snug taking care not to
crush the panel. See Figure 71.04-11 for typical fastener installation.
(v) While still wet, clean away any excess adhesive from fasteners leaving a small
witness fillet to ensure sealing of the fastener.
71.04.24 08-01-00 Revision 10

ACOUSTIC PANEL COMPLETE PENETRATION REPAIR

Figure 71.04-10
Revision 10 08-01-00 71.04.25


Figure 71.04-11
71.04.26 08-01-00 Revision 10

REPAIR PLUG -- COMPLETE PENETRATION REPAIR

Figure 71.04-12
Revision 10 08-01-00 71.04.27

6. Corrosion Control. The following general Corrosion Control information is provided. For
additional information refer to Chapter 51 of the Douglas DC-8 Structural Repair
Manual or AC 43.13-1B.
a. Corrosion Removal. When corrosion is detected, remove it as quickly as possible and

protect the surface from further corrosion. In those cases where the corrosion has
progressed extensively, the strength of the part may be in jeopardy and the part may need
to be replaced.
(1) For steel parts, except for highly stressed steel or stainless steel surfaces, the use of
abrasive papers, buffers, and wire brushing, and steel wool are acceptable cleanup
procedures. However, it should be recognized that it is practically impossible to
remove all corrosion products from the bottom of small pits and crevices. As a
result, a part once rusty usually corrodes again, more easily than it did the first time.
Removing corrosion products from highly stressed steel parts requires careful
handling.
(2) For aluminum parts, treatment includes the mechanical removal of as much of the
corrosion products as practical, the inhibition of residual material by chemical
means, followed by the restoration of permanent surface coatings. Do not use steel
wool, emery cloth, steel (except Stainless Steel) wire brushes, or severely abrasive
materials because particles of the steel wool or emery cloth will become embedded
in the soft material and cause corrosion. Hand polishing corroded areas with
household abrasives or with metal polish available under specification MIL-P-6888
is acceptable for use on clad aluminum but must not be used on anodized aluminum
since it is severe enough to actually remove the protective anodized film. If the
surface is particularly difficult to clean, type II material under specification MIL-C-
5410 mixed 50-50 percent with solvent or mineral spirits may be used. Treat any
superficial corrosion with a 10 percent solution of sodium dichromate to which one
percent of chromium trioxide has been added or with material available under
specification MIL-C-5541. Allow these solutions to remain on the corroded area
for 5 to 20 minutes and then wipe the surface dry. A more severe cleaning
procedure consists of using a 10 percent solution of chromic acid to which has been
added approximately 20 drops of battery electrolyte per gallon. Thorough brushing
with a stiff fiber brush should loosen or remove most existing corrosion and assure
complete penetration of the inhibitor into crevices and pits. Allow the chromic acid
to remain in place for at least 5 minutes, then remove the excess by flushing with
water or wiping with a wet cloth. Apply a protective coating the same day that the
corrosion treatment is accomplished.
71.04.28 08-01-00 Revision 10

(3) When an anodized surfaced coating is damaged, it can only be partially restored by
chemical surface treatment. Therefore, exercise care in any cleaning process to
avoid unnecessary breaking of the protective film, particularly at the edges of the
aluminum sheet. Chromic acid and other inhibitive treatments tend to restore the
oxide film.
(4) More severe cleaning is necessary with intergranular corrosion (attack along grain
boundaries). The mechanical removal of all corrosion products and visible
delaminated metal layers must be accomplished in order to determine the extent of
the destruction and to evaluate the remaining structural strength of the component.
Inspection with a 5 to 10 power magnifying glass or the use of dye penetrant will
assist in determining if all unsound metal and corrosion products have been
removed. Grinding to blend or fair out the edges of damaged areas can best be
accomplished by using aluminum oxide-impregnated rubber based wheels.
Chemically inhibit the exposed surfaces and restore chemical surface films or paint
in the same manner as for other aluminum surfaces.
Revision 10 08-01-00 71.04.29

INTENTIONAL
BLANK
71.04.30 08-01-00 Revision 10

7. Nose Cowl Repairs. This section describes repairs to DC-8-62/63 Nose Cowl Assemblies
modified by Burbank Aeronautical Corp. II to P/N DC8-22000-1, and Inlet Center Bodies
(Bullets) P/N DC8-28000-1 and DC8-38000-1. This section includes repairs to associated
parts of the anti-icing system which are located in the nose cowl assembly. Repairs to parts
or components not modified by B. A. C. II will conform to the requirements and repair
instructions of the original manufacturer.
a. Classification of Damage
(1) Allowable Damage. Allowable damage data defines when a damaged part or
component may be returned to service without immediate repair. Damage
permitted will have no significant effect on strength of the structure, which will
remain capable of fulfilling its design function. The types of allowable damage
permitted along with a brief descriptions for procedures to prevent damage
propagation or improve aerodynamic smoothness of a damaged part are given
below.
(2) Damage Limits. All allowable damage is either "unlimited usage" or "time limited".
(a) Unlimited usage is defined as negligible damage. it does not affect the
structural integrity or functional capability of the part or component and
requires no repair over the design life of the aircraft.
(b) Time limited damage is minor damage not affecting the structural integrity of
the part in normal service, but could reduce the design life of the part. Time
limited damage must be permanently repaired no later than the next
maintenance “C” check (or equivalent major inspection period). The location
and size of the damage is to be noted and checked at each periodic inspection
until permanent repairs are accomplished. If damage has grown beyond "time
limited" damage limits, repairs must be accomplished immediately.
(3) Damage Types
(a) Abrasion: Damage which results in a cross-sectional area loss due to scuffing,
chafing, scraping or other erosion of surface material. An abrasion is usually
rough and irregular.
(b) Gouge: Damage of any size which results in a change in cross-sectional area
caused by contact with an object which produces a continuous groove in the
material resulting from removal of base material. Gouges may frequently be
associated with dents.
Revision 10 08-01-00 71.04.31

(c) Nick: A small gouge with sharp edges. A series of nicks in a line should be
considered a gouge.
(d) Scratch: A line of damage to the base material which results in cross-sectional
change caused by displacement of material by contact with a sharp object.
(e) Dent: An area depressed with respect to its normal contour. No change in
cross-sectional area unless the dent is associated with other types of damage.
(f) Crack: A partial fracture or complete break in the base material which produces
a discontinuity in cross-sectional area. It usually appears as an irregular line on
the surface of the material.
(g) Puncture hole: A complete penetration of the material cause by impact with a
sharp object.
(h) Void delamination: A separation of the face sheet from its associated core or
faying surface at the bond line. Usually caused by the failure or lack of
adhesive bond. Frequently found in association with other damage defined
above.
Note: These damages apply only to the parent material and do not include
damage to surface finishes such as paint or other nonstructural covering.
(4) Material Types
(a) The basic materials used in the construction of the BAC II nose cowl are 2024-
T3/-T42 aluminum and 300 series corrosion resistant steels.
(b) The sheet metal parts of the leading edge and anti-icing system of the nose cowl
are original DC-8 parts and unless otherwise noted may be repaired by the
methods and techniques specified in the Douglas DC-8 Structural Repair
Manual or by standard methods as explained in this manual.
(c) Since the design requirements for sheetmetal structure and bonded panels differ,
the allowable damage limits are given separately. Unless described in this
manual, all sheetmetal repairs will be accomplished in accordance with the
Douglas DC-8 Structural Repair Manual.
71.04.32 08-01-00 Revision 10

DAMAGE LIMITS, SHEETMETAL STRUCTURE
TYPES OF LIMITS NOTES

DAMAGE
Nicks, Gouges & Maximum 10% of basic material thickness. O.K. for flight.
Scratches Unlimited usage.
Greater than 10% to a maximum of 25% of Blend and polish.
material thickness. Length not to exceed 12 in. Time limited.
Greater than 25% of material thickness. Repair before next
flight
Cracks - in a A crack extending between two adjacent O.K. for flight.
stiffener. In joint of fasteners and terminating at the fastener holes, Unlimited usage.
ten or more not within 6.0 inches of stiffener termination
fasteners points, and not more than one such crack in
any group of ten fasteners.
A crack extending between two adjacent Stop drill before next
fasteners and extending beyond one fastener. flight. Time limited.
A crack extending between three adjacent Time limited.
fasteners and terminating at the fastener holes.
Cracks - in skins Terminating at a fastener hole. Not more than Unlimited usage.
from edge of skin. one such crack in any group of ten fasteners.
Between two fasteners not more than 0.50 inch Stop drill before
in length. flight. Unlimited
Usage.
Not more than 1.0 inch. Stop drill before
flight. Time limited.
More than 1.0 inch but not more than 2.0 inch. Stop drill before
flight. Repair at next
periodic inspection.
Revision 10 08-01-00 71.04.33

DAMAGE LIMITS, SHEET METAL STRUCTURE(cont’d)

DAMAGE
Cracks - skins on In perforated skins not to exceed 1.0 inch. Stop drill before next
face of panel. Maximum of two cracks in one part with a flight. Permanent
minimum distance between cracks of 15.0 repair at next
inches. scheduled
maintenance.
In solid skins, cracks not exceeding 1.0 inch. Stop drill before next
Minimum distance between cracks, 10.0 flight. Time Limited.
inches.
Length greater than 1.0 but less than 2.0 Stop drill before next
inches. flight. Repair at next
Scheduled
maintenance.
Cracks - stiffeners Length 1.0" Maximum located lengthwise Stop drill before next
along bend. Min. 5.0 inches distance from end flight. Time Limited.
of stiffener.
From edge of stiffener. Maximum length less Stop drill or remove
than 25% of flange width. crack and blend and
polish before next
flight.
Holes/Punctures NOT PERMITTED! ! Repair before next
flight.
Dents - panels Maximum dimension 5.0 inches. Depth must O.K. for flight.
not be more than 10% of longest dimension to
a max. of .25 inch. Minimum distance from
edge of panel is 20 X sheet thickness.
Minimum distance, edge to edge, between
dents is 2 X longest dim. Of the largest dent.
71.04.34 08-01-00 Revision 10

DAMAGE LIMITS, BONDED STRUCTURE, UNLIMITED USAGE

Note: No cracks or other ruptures are permitted on the bonded aluminum panel areas of
the nose cowl inner barrel. Negligible damage is listed below.

DAMAGE
Nicks - Aluminum Maximum length, 0.75 inch and Maximum O.K. for flight if
depth 0.010 inch. Minimum 1.5 inch distance within limits.
from reinforced area or edge of honeycomb.
Minimum distance between nicks 12.0 inches.
Scratches - Maximum length 1.50 inch and maximum O.K. for flight if
Aluminum depth 0.005 inch. Minimum 1.50 inch distance within limits.
Minimum distance between scratches 12.0“
Revision 10 08-01-00 71.04.35

DAMAGE LIMITS, BONDED STRUCTURE, TIME LIMITED

DAMAGE
Dent - Aluminum Maximum diameter 2.0 inch and 0.13 inch Inspection required
Large depth. Minimum 1.0 inch distance from at next periodic
reinforced area or edge of honeycomb. inspection interval.
Minimum distance. Minimum distance edge to
edge between dents, 15.0 inches.
Small Maximum diameter .38 to a depth of 0.032.
Minimum distance between dents, 3.0 inch
Gouge - Aluminum Maximum 1.50 inch long by 0.10 inch wide by Inspection required
0.010 deep. Minimum 3.0 inch distance from at next periodic
reinforced area or edge of honeycomb. inspection interval.
Minimum distance between gouges 15.0
inches.
Void/delamination Maximum 15% of area for any one linear inch Inspection required
Aluminum faying in non-riveted joint. at next periodic
surface inspection interval.
Void/delamination Maximum dimension 1.50 inch. Minimum 2.0 Inspection required,
face sheet to core. inch distance from reinforced area or edge of next periodic
honeycomb. Minimum distance between inspection interval.
voids/delaminations, 4 X Maximum dimension
of void. Void must not be opposite void on
opposite face. Number of voids not to exceed
two per square foot.
71.04.36 08-01-00 Revision 10

(2) Anti-Ice Aft Duct Aft Fitting Replacement. When worn, the fitting at the forward
end of the Anti-Ice Aft Duct may be replaced by riveting in place BAC II P/N DC8-
950246. This part should be a light interference fit and riveted in place using 14
MS20615-3M3 rivets equally spaced around the circumference.
AFT DUCT FITTING REPLACEMENT

Figure 71.04-13
Revision 10 08-01-00 71.04.37

(3) Bonded Acoustic Panel Repair. All repairs will be accomplished using Dexter
Hysol EA934NA Epoxy Adhesive. All parts should be cleaned in accordance with
paragraph 3 of this section prior to bonding.
(a) Tools and Materials Required. The following table lists the basic equipment
which should be on hand for most damage repairs:
DESCRIPTION MATERIAL SOURCE

Epoxy Adhesive High Temp. EA934Na (A & B) Dextor Hysol Aerospace
Adhesive Products
Pittsburgh, CA 94565-0031
Fastener, temporary Cleco Commercially available
Conversion Coating Alodine 1200 Parker + Amchem; Henkel
Corp.
32100 Stephenson Highway
Madison Heights, MI 48071
Heat Blanket (or Heat lamp) 0 to 250 deg. F Atacks Products
1120 SW 16th St.
Renton, WA 98055
(b) Preparation for Bonding of Aluminum Surfaces
1) Cleaning
a) All damaged areas must be reworked and the repair parts fitted, drilled,
deburred and break sharp edges before cleaning can be accomplished.
(No deburring is required on honeycomb or other core materials.)
b) Remove any paint, lacquer, or primer to approximately 3 inches

beyond the faying surface of the bond area with paint stripper.
c) Treat the finished part with an approved aluminum metal brightener

rinse and dry, then apply Alodine 1200 and again rinse and dry.
71.04.38 08-01-00 Revision 10

d) Just prior to bonding, wipe the metal faying surface area with a small
clean cotton cloth dampened with Methyl Ethyl Keytone (MEK),
followed by wiping dry with a clean cotton cloth.
e) Prepared aluminum honeycomb or Flexcore repair plugs should be

cleaned just prior to final installation. Dip the plug into a bath of MEK
and shake off excess fluid. Visually inspect cells for trapped fluid
droplets. If present, blow dry with clean low pressure air. Allow to air
dry for a minimum of 15 minutes.
2) Handling. All materials that are clean and ready for bonding should be
handled with clean white cotton gloves that are free from any oils, waxes,
or silicones. Any source of compressed air must be clean and free of
entrapped oil.
3) Mixing of Adhesives. The EA934NA epoxy adhesive system is a material

used as a bonding agent to bond Acoustic panel repairs. This system is a
two-part adhesive which must be mixed just prior to use. Part A is a gray
thixotropic paste, and part B is an amber liquid amine curing agent. Only
the quantity that may be conveniently used during the useful life of the
adhesive should be mixed. Combine by weight 100 parts of part A with 33
parts of part B, and mix thoroughly. THIS IS IMPORTANT ! No
thinners should be used. Temperature prior to and during mixing is not
critical but should be close to 77 degrees Fahrenheit. A useful working
potlife for the material is 40 minutes at 77 degrees Fahrenheit for a one
pound mixture is normal.
WARNING: EPOXY RESINS CONTAINED IN THIS ADHESIVE MAY

CAUSE SKIN SENSITIVITY OR OTHER ALLERGIC
REACTIONS. AVOID CONTACT WITH SKIN AND EYES.
AVOID BREATHING FUMES. IF CONTACT IS MADE,
EASH THE AREA THOROUGHLY WITH SOAP AND
WATER.
a) Mix thoroughly in a clean metal or plastic container.
b) If not to be used immediately, cover container to prevent

contamination of mixture. Store in a cool dry place until used.
Revision 10 08-01-00 71.04.39

c) If adhesive is to used immediately, it can be mixed on a clean, flat non-

porous surface.
(c) Cutting and Preparation of Panel for Repair
1) Stabilizing Areas to be Cut (See Figure 71.04-26)
a) Certain material used in the BAC II splitter attenuation panels requires

stabilization before cutting operations can be performed. These
materials are found on the surfaces of the splitter attenuation panels in
the Fan Exhaust ducts. A masking technique is used to accomplish this.
b) Mask areas on the face of the attenuation material to provide a 0.375

inch stabilized area, using a 0.5 inch teflon tape.
c) Place a nonporous parting film over the stabilized area and tape in
place.
d) Cure at room temperature for 24 hours or to accelerate the cure, place a

heat blanket over the parting film and cure at 180 deg. F to 200 deg. F
for 30 minutes.
e) Remove heat blanket and parting film.
2) Cutting and Preparing Damage
a) After stabilizing the area to be cut, use the center of the stabilized area
a guide to cut out the repair area. Make sure all cutting tools used in
this operation are sharp and in good condition. Dull cutting tools can
cause severe damage and present a safety hazard to the worker. Best
results will be obtained using a high speed (18,000 to 23,000 rpm)
router or cutting motor. A straight flute right hand cut router bit
provides superior cutting action and edge finish. Care must be taken to
provide a medium feed with the material feeding into the cutting edge
of the router bit. Feeding the material away from the cutting edge does
not allow adequate control of the tool and should be avoided.
b) Using hole saw or router, cut through the aluminum core material.
Exercise caution to avoid damage to the next layer of skin. Honeycomb
or Flexcore and any adhesive should be cleaned away completely from
the back skin.
71.04.40 08-01-00 Revision 10

c) If the Attenuation panel face sheet is perforated aluminum or stainless

steel sheet, bevel the edge of the perforated face sheet to 45 degrees.
Use 320-400 grit abrasive paper, aluminum oxide only, to produce a
smooth surface finish.
d. Nose Cowl Bullet Repairs. Repairs to bonded body assembly are generally limited to the
replacement of parts or the addition of fasteners.
(1) Outer Skin Seam Debond (Figure 71.04-14). Inject EA934NA into disbonded
seam through the perforation holes until the epoxy adhesive extrudes from the
seam. Install HI-LOK fasteners (HL70-5) as shown in Figure 71.04-14.
SKIN DEBOND REPAIR

Figure 71.04-14 (1 of 2)
Revision 10 08-01-00 71.04.41

SKIN DEBOND REPAIR

Figure 71.04-14 (2 0f 2)
71.04.42 08-01-00 Revision 10

e. Nose Cowl Material Reference
NOSE COWL BARREL PANELS

Figure 71.04-15 (1 of 4)
Revision 10 08-01-00 71.04.43


Figure 71.04-15 (2 0f 4)
71.04.44 08-01-00 Revision 10


Figure 71.04-15 (3 of 4)
Revision 10 08-01-00 71.04.45

Nose Cowl Barrel Panel Material Reference Table
ITEM DESCRIPTION GAGE MATERIAL

1 Inner Skin .020 BRUNSMET FM 820
2 Center Skin Aft .020
3 Center Skin Fwd .025 2024-0 AL SHEET (QQ-A-250/4)
4 Close-out Zees .032
5 Outer Skin .020 321 CRES ANNEALED (QQ-S-
766)
6 Pan-Csd Cooler
7 Pan-Vent Assy. .032
8 Aft Skin .025 301 CRES 1/2 HARD (QQ-S-766)
9 Splice Strap .071 2024-T3 CLAD (QQ-A-250/5)
10 Strap .032 2024-T3 AL SHT (QQ-A-250/4)
11 Doubleflex Core .25 CR III 5052-F25-.007 HEXCEL
CORP.
12 Doubleflex Core .35
13 Drain Tube .375 O.D.X .035 W T304 CRES
TUBE

Figure 71.04-15 (4 of 4)
71.04.46 08-01-00 Revision 10

f. Bullet Materials Reference
BULLET ASSEMBLY
Figure 71.04-16 (1 of 6)
Revision 10 08-01-00 71.04.47

BULLET ASSEMBLY
Figure 71.04-16 (2 of 6)
71.04.48 08-01-00 Revision 10

BULLET ASSEMBLY
Figure 71.04-16 (3 of 6)
Revision 10 08-01-00 71.04.49

BULLET ASSEMBLY
Figure 71.04-16 (4 of 6)
71.04.50 08-01-00 Revision 10

BULLET ASSEMBLY
Figure 71.04-16 (5 of 6)
Revision 10 08-01-00 71.04.51

BULLET ASSEMBLY MATERIAL REFERENCE LISTS

1 OUTER SKIN .040
2 PAN-AFT CLOSEOUT
3 INNER SKIN .032 6061-T6 AL SHT (QQ-A-250/11)
4 SKIN SPLICE
5 MOUNTING RING 2.00 2024-T351 AL PLATE
6 DOUBLER .050 2024-T3 AL SHT (QQ-A-250/4)
7 SUPPORT CLIP .063
8 STIFFENER .040 2024-T42 AL SHT (QQ-A-250/5)
9 SUPPPORT BRACKET .063
10 DOUBLEFLEX CORE .14 CR III 5052/F25-.0025
11 DOUBLEFLEX CORE .20
12 DOUBLEFLEX CORE .35
13 CENTER SKIN .0015 1145-0 ALUMINUM FOIL
BULLET ASSEMBLY
Figure 71.04-16 (6 of 6)
71.04.52 08-01-00 Revision 10

8. Fan Exhaust Duct Repairs. This section describes repairs to DC-8-62/63 Bifurcated Ducts
and the Aft Transition Ducts as modified by BAC II for use with the BAC II, Stage III Hush
Kit. Those parts and assemblies are identified in Table 71.01-1, STRUCTURAL REPAIR
MANUAL REFERENCE MATRIX. The Constant Section and Forward Transition Ducts
remain unmodified in this configuration. For repairs to Douglas or ADC Upgrade(STC
SA5455NM) Constant Section or Transition Ducts, refer to the DACO Structural Repair
Manual or other sections of this manual. Allowable bonded repairs to fan exhaust ducts must
be accomplished by a qualified bonding facility in accordance with the material
manufacturers procedures and specifications.
a. Classification of Damage
(1) Allowable Damage and Damage Limits. Allowable damage data defines when a
damaged part or component may be returned to service without immediate repair.
Damage permitted will have no significant effect on strength of the structure, which
will remain capable of fulfilling its design function. The types of allowable damage
permitted along with brief descriptions for procedures to prevent damage
propagation or improve aerodynamic smoothness of a damaged part are given
below:
(2) Damage Limits. All allowable damage is either "unlimited usage" or "time
limited". Unlimited usage is defined as negligible damage. It does not affect the
structural integrity or functional capability of the part or component and requires no
repair over the design life of the aircraft. Time limited damage is minor damage not
affecting the structural integrity of the part in normal service, but could reduce the
design life of the part. Time limited damage must be permanently repaired no later
than the next maintenance "C" check (or equivalent major inspection period). The
location and size of the damage is to be noted and checked at each periodic
inspection until permanent repairs are accomplished. If damage has grown beyond
time limit damage, repairs must be accomplished immediately.
(3) Damage Types
(a) Abrasion: Damage which results in a cross sectional area loss due to scuffing,
chafing, scraping or other erosion of surface material. An abrasion is usually
rough and irregular.
(b) Gouge: Damage of any size which results in a change in cross sectional area
caused be contact with an object which produces a continuous groove in the
material resulting from removal of base material.
Revision 10 08-01-00 71.04.53

(c) Nick: A small gouge with sharp edges. A series of nicks in a line should be
considered a gouge.
(d) Scratch: A line of damage to the base material which results in cross sectional
change caused be displacement of material contact with a sharp object.
(e) Dent: An area depressed with respect to its normal contour. No change in cross
sectional area unless dent is associated with other types of damage.
(f) Crack: A partial fracture or complete break in the base material which produces
a discontinuity in cross sectional area. It usually appears as an irregular line on
the surface of the material.
(g) Puncture (Hole): A complete penetration of the material caused by impact with
a sharp object.
(h) Void / Delamination: A separation of the dace sheet from its associated ore or
faying surface at the bond line. Usually caused by the failure or lack of
adhesive bond. Frequently found in association with other damage as defined
above.
Note These damages apply only to the parent material and do not include damage to
surface finishes such as paint or other nonstructural covering.
(4) Material Types
(a) The construction of the BAC II Fan Exhaust ducts is a composite of original
bonded aluminum structure with added areas of composite materials to form the
new pressure shell in the attenuation areas. These areas of attenuation are made
up of large cell aluminum core material with layers of "E" glass and aluminum
foil composing the pressure shell.
(b) The outer heat or fire barrier may be one of several basic configurations. The
first configuration (see Figure 71.04-17) includes the following parts;
Bifurcated Ducts (Bi-ducts) DC8-22000-1 and -2 and Aft Section duct 27000-1.
The heat barrier construction on these parts consists of layers of a white silicone
ablative material with a stainless steel foil covering. Damage to the bifurcated
ducts in this series that penetrates or results in loss of the ablative/insulating
covering is not repairable due to silicone contamination of the pressure vessel
skins and should be returned to the manufacturer for repairs.
(c) Aft section ducts in the DC8-27000-1 configuration may be repaired as follows.
In areas not covered by the stainless steel foil retainer, seal the edges of any torn
ablative area using DEVCON Silite high temperature silicone sealant or
equivalent (500 degree F continuous, 600 degree F intermittent.)
71.04.54 08-01-00 Revision 10

BIFURCATED DUCT TYPICAL LAY-UP

FOR DC8-22000-1 AND -2
Figure 71.04-17
(d) Configuration two includes Bi-ducts DC8-22000-201 and -203 and Aft Section
duct DC8-27000-25. The construction of these parts includes layers of rigid
syntactic foam core covered by a shell of graphite and ceramic fabrics (Figure
71.04-18) A variation on the aft section ducts is DC8-27000-41 which has an
aluminum skin mechanically fastened to the existing inner inboard skin and
standard sheet metal repairs may be made on this configuration.
(e) Repairs to the composite inner wall of the aft section -25 duct may be made by
removing damaged material and replacing it with the appropriate materials as
shown in figure 3.
(f) Repairs to the outer wall of the DC8-27000-25/-41/-47 aft section ducts should
be made using the techniques and procedures outlined in previously in Section
71.04 using the materials specified for the appropriate duct section as follows
(Figures 71.04-21 & -22) These figures show a repair for a full penetration of
the panel. If there is no full penetration of the panel then only those layers
damaged must be repaired.
Revision 10 08-01-00 71.04.55

AFT SECTION DUCT DC8-27000-25 INBOARD WALL

Figure 71.04-18
AFT SECTION DUCT DC8-27000-25/-47 INBOARD WALL REPAIR

Figure 71.04-19 (1 of 2)
71.04.56 08-01-00 Revision 10

DC8-27000-25/-47 INBOARD WALL REPAIR(cont’d)

Figure 71.04-19 (2 of 2)
AFT SECTION DUCT DC8-27000-25/-47 INBOARD WALL REPAIR

Figure 71.04-20
Revision 10 08-01-00 71.04.57

SEE FIGURE 71.04-35 FOR INITIAL CUTOUT OF DAMAGED MATERIAL.
PERFORATED SKIN PATCH PLACEMENT

Figure 71.04-21
71.04.58 08-01-00 Revision 10

AFT DUCT OUTER WALL REPAIR

Figure 71.04-22
Revision 10 08-01-00 71.04.59

(g) Additional Bifurcated Duct Configuration. One other configuration includes

Bi-ducts DC8-22000-301 and -303. The fire barrier on these Bi-ducts consists
of a layer of ceramic felt with a covering of aluminum foil, glass and ceramic
fabrics bonded into a solid shell. Damage to composite inner shell of this
configuration is not normally repairable in the field. Refer to
manufacturer for disposition.
(h) Additional Aft Section Duct Configuration. Another Aft Section duct
configuration DC8-27000-47 is similar to the -25 but the inner wall consists of a
layer of ceramic paper with the BMI syncore. For repairs to this aft section
inboard wall use the method described in Figures 71.04-19 & -20 but
substituting material shown in Figure 71.04-23 below.
AFT SECTION DUCT DC8-27000-47 INBOARD WALL

Figure 71.04-23
71.04.60 08-01-00 Revision 10

b. Sheet Metal Repairs
(1) Repairs to Perforated Skins. Dent with nick or gouge or small hole not exceeding
1.00 inch diameter. (See Figures 71.04-24 and 71.04-25)
(a) Drill or cut out damage using smallest diameter and depth possible to remove
all damage.
(b) Clean area with a clean cloth with MEK or Acetone. Wipe the surface using a
clean dry cloth before the solvent dries.
(c) Mask repair area (if needed, stabilize the surface following instructions in
Section 71.04, Paragraph 7.C.(3)(c) 1).
(d) Mix required amount of adhesive in accordance with instructions in Section

71.04, Paragraph 7.c.(3)(b) 3).
(e) Fill repair cutout with adhesive using a spatula or flexible putty knife.
(f) Place nonporous parting film over repair and tape in place.
(g) Allow to cure at room temperature (77 degrees F) for 8 hours or apply a heat
blanket over the parting film and cure at 200 degrees F for 1 hour.
(h) When cured, sand to a feather edge using 240-320 grit aluminum oxide abrasive
paper as needed to produce a smooth surface.
Revision 10 08-01-00 71.04.61

ACOUSTIC PANEL NICK AND SMALL HOLE REPAIR

Figure 71.04-24
71.04.62 08-01-00 Revision 10

ACOUSTIC PANEL DENT REPAIR WITHOUT SKIN PENETRATION

Figure 71.04-25
Revision 10 08-01-00 71.04.63

(2) Cracks And Damage. Dent with nick or gouge or small hole not exceeding 0.25
inch to 3 inch in diameter (Figures 71.04-26 and 71.04-27)
(a) Stop drill all cracks using a # 30 drill.
(b) Clean damaged area using a clean cloth moistened with Methyl Ethyl Ketone
(MEK.) Wipe surface dry before solvent evaporates.
(c) Fabricate doubler per Figures 71.04-26 & -27.
(d) Mix required amounts of adhesive in accordance with instructions in section

71.04, Paragraph 7.c.(3)(b) 3).
(e) If skin is not delaminated, fill crack and pot holes full using EA934NA epoxy
adhesive.
(f) If skin is delaminated, inject adhesive between skins until adhesive escapes
through the holes in the perforated surface.
(g) Install doubler wet using adhesive and fasten using specified fasteners.
(h) The maximum total area of perforated skin covered by repairs in any one
bifurcated duct is not to exceed 75 square inches or in any one aft section duct
is not to exceed 36 square inches. (4% of attenuation area)
71.04.64 08-01-00 Revision 10

PERFORATED SKIN REPAIR

Figure 71.04-26
Revision 10 08-01-00 71.04.65

See Figure 71.04-26 for additional details.
PERFORATED SKIN
Figure 71.04-27
71.04.66 08-01-00 Revision 10

(3) Splitter Attenuation Panel Repair (Figures 71.04-28 and 71.04-29).
(1) If damage is 6.00 inches or less in the airflow direction or 3.00 inches or less
from the edge of the panel, repair as described below or if materials are not
available repair per Figure 71.04-29. Pick up existing fasteners locations where
possible and incorporate them into the repair. All doublers and fasteners to be
bonded in place using EA934NA epoxy adhesive or equivalent.
(2) If damage extends beyond the limits described above, repair as in Figure 71.04-
28, by splicing new material into the Attenuation panel.
(3) Remove damaged material from panel, leaving a slightly rolled edge on existing
material as shown in Figure 71.04-28, Detail A (3/16 to 5/16 inch). This will
lock the special attenuation material edge into the repair.
(4) Cut out a section large enough to extend 1.0 inch beyond the damage. (see
Figure 71.04-28 for layout of repair.) Attenuation materials may vary in type
from unit to unit. These attenuation panel variations may be used
interchangeably for purposes of repair.
(5) If attenuation panel material is used for repairs as above, seal around all edges
of repair using PRO SEAL 890 or PR1422 fuel tank sealant.
(6) After installation of the repair is complete and all adhesives are cured, restore
fillet along the edges of the repaired splitter using the same types of tank
sealants as used in step 5 above.
Revision 10 08-01-00 71.04.67

SPLITTER PANEL SPLICE

Figure 71.04-28 (1 of 2)
71.04.68 08-01-00 Revision 10

SPLITTER PANEL SPLICE

Figure 71.04-28 (2 of 2)
Revision 10 08-01-00 71.04.69

SPLITTER PANEL REPAIR

Figure 71.04-29 (1 of 2)
71.04.70 08-01-00 Revision 10

SPLITTER PANEL REPAIR

Figure 71.04-29 (2 of 2)
Revision 10 08-01-00 71.04.71

c. Bifurcated Fan Exhaust Duct Material Reference
BIFURCATED FAN EXHAUST DUCT

Figure 71.04-30 (1 of 5)
71.04.72 08-01-00 Revision 10


Figure 71.04-30 (2 of 5)
Revision 10 08-01-00 71.04.73


Figure 71.04-30 (3 of 5)
71.04.74 08-01-00 Revision 10


Figure 71.04-30 (4 of 5)
Revision 10 08-01-00 71.04.75

BIFURCATED FAN EXHAUST DUCT MATERIAL LIST

1 DOUBLEFLEX CORE .70 GRILL 5052/F25-0047
2 .50
3 .37
4 SPACER .310 PHEMOLIC MIL-P-15605
5 .510
6 REPLACEMENT .063 2024-T3 ALCLAD
SPLITTER
7 EPOXY PREPREG .010 L 552/701 (JD LINCOLN)
8 CERAMIC FELT .125 COTRONICS 372 0
9 NEXTEL FABRIC 290 XC566-38
10 "E" GLASS FABRIC 702861 7520
11 EXISTING PARTS REFER TO DOUGLAS
DC-8 STRUCTURAL
REPAIR MANUAL

Figure 71.04-30 (5 of 5)
71.04.76 08-01-00 Revision 10

d. All Fan Exhaust Ducts Splitter Attenuation Panels
ALL FAN EXHAUST DUCTS SPLITTER ATTENUATION PANELS

Figure 71.04-31 (1 of 5)
Revision 10 08-01-00 71.04.77

ALL FAN EXHAUST DUCTS SPLITTER ATTENUATOR PANELS

Figure 71.04-31 (2 of 5)
71.04.78 08-01-00 Revision 10


Figure 71.04-31 (3 of 5)
Revision 10 08-01-00 71.04.79


Figure 71.04-31 (4 of 5)
71.04.80 08-01-00 Revision 10

SPLITTER ATTENUATION PANELS MATERIAL LIST

1 ACOUSTIC SKIN FM 832 BRUNSMET
ALTERNATE ACOUSTIC POROPLATE P/N
1739453-23 FACET CORP.
2 DOUBLEFLEX CORE .30 CR III 5052/F25-0047
3 ALUMINUM FOIL .0015 AL 1145-0
4 LEADING EDGE 6063-T4 AL EXTRUSION (QQ-
A-200/9)
5 SHIM .160 2024-53 AL BAR
6 SEALANT PRO-SEAL 890 B-2
ALTERNATE PR1422

Figure 71.04-31 (5 of 5)
Revision 10 08-01-00 71.04.81

INTENTIONAL
BLANK
71.04.82 08-01-00 Revision 10

71.05 – STRUCTURAL REPAIR MANUAL FOR BAC II ADC UPGRADE

HUSH KITS
TABLE OF CONTENTS
Paragraph Page
1. INTRODUCTION -------------------------------------------------------------------- 71.05.1
2. STRUCTURE IDENTIFICATION------------------------------------------------- 71.05.1
3. ALLOWABLE DAMAGE ---------------------------------------------------------- 71.05.44
4. REPAIRS ------------------------------------------------------------------------------ 71.05.50
5. REPAIR NO. 1 – WOVEN WIRE TEAR, RIP, AND SCRATCH REPAIR - 71.05.57
6. REPAIR NO. 2 – ACOUSTIC PANEL NICK, GOUGE, AND SMALL
HOLE REPAIR ----------------------------------------------------------------------- 71.05.60
7. REPAIR NO. 3 – ACOUSTIC PANEL CRACK REPAIR --------------------- 71.05.64
8. REPAIR NO. 4 – ACOUSTIC PANEL PARTIAL PENETRATION
REPAIR -------------------------------------------------------------------------------- 71.05.68
9. REPAIR NO. 5 – ACOUSTIC PANEL DELAMINATION REPAIR--------- 71.05.73
10. REPAIR NO. 6 – ACOUSTIC PANEL COMPLETE PENETRATION
REPAIR -------------------------------------------------------------------------------- 71.05.76
11. REPAIR NO. 7 – FIRE PROTECTION AND THERMAL COATING
REPAIR -------------------------------------------------------------------------------- 71.05.83
12. REPAIR NO. 8 – LARGE AREA DYNAROHR WOVEN WIRE
REPLACEMENT --------------------------------------------------------------------- 71.05.98
FIGURES
71.05-1 INLET COWL OUTER BARREL ASSEMBLY--------------------------------- 71.05.2

71.05-2 FORWARD BULKHEAD----------------------------------------------------------- 71.05.11
71.05-3 ANTI-ICING DUCT THERMAL BLANKET------------------------------------ 71.05.14
71.05-4 ANTI-ICING DUCT ----------------------------------------------------------------- 71.05.15
71.05-5 VORTEX SPOILER ASSEMBLY ------------------------------------------------- 71.05.16
Revision 14 12-03-01 71.05-i

FIGURES(cont’d)
71.05-6 VENT ASSEMBLY ------------------------------------------------------------------ 71.05.18

71.05-7 AFT BULKHEAD -------------------------------------------------------------------- 71.05.19
71.05-8 INLET COWL INNER BARREL -------------------------------------------------- 71.05.24
71.05-9 NOSE DOME EXTENSION ASSEMBLY --------------------------------------- 71.05.29
71.05-10 PT2 TUBE EXTENSION ASSEMBLY-------------------------------------------- 71.05.32
71.05-11 CONSTANT SECTION FAN AIR DUCT ASSEMBLY ----------------------- 71.05.33

71.05-12 TRANSITION FAN AIR DUCT ASSEMBLY----------------------------------- 71.05.36
71.05-13 MAKING REPAIR PLUG FROM REPAIR PANEL---------------------------- 71.05.54
71.05-14 WOVEN WIRE TEAR, TIP, AND SCRATCH REPAIR ----------------------- 71.05.58
71.05-15 ACOUSTIC PANEL NICK, GOUGE, AND SMALL HOLE REPAIR------- 71.05.61
71.05-16 ACOUSTIC PANEL CRACK REPAIR ------------------------------------------- 71.05.65
71.05-17 ACOUSTIC PANEL PARTIAL PENETRATION REPAIR-------------------- 71.05.69
71.05-18 ACOUSTIC PANEL DELAMINATION REPAIR ------------------------------ 71.05.74
71.05-19 ACOUSTIC PANEL COMPLETE PENETRATION REPAIR ---------------- 71.05.77
71.05-20 PROTECTIVE COATING APPLICATION -------------------------------------- 71.05.88
71.05-21 ABLATIVE INSULATION --------------------------------------------------------- 71.05.90
71.05-22 WOVEN WIRE REPLACEMENT ------------------------------------------------- 71.05.99
71.05-ii 12-03-01 Revision 14

71.05 STRUCTURAL REPAIR MANUAL FOR BAC II ADC UPGRADE HUSH KITS
(S.T.C. SA5455NM)
1. Introduction
a. Purpose. This section provides information for the structural repair of DC-8-62/63 parts
and assemblies as modified for the BAC II ADC Upgrade Hush Kit. Those parts and
assemblies are identified in Table 71.01-1, STRUCTURAL REPAIR MANUAL
REFERENCE MATRIX. For repairs to items of other manufacturers, refer to the
appropriate manufacturers structural repair manual or other sections of this manual.
b. Use the procedures in this section for the repair of engines modified by ADC upgrade
S.T.C. SA5455NM. These engines are identified in the “effectivity” section in the
introduction to this manual.
c. Organization and Use. The section is divided into three parts. The first, Structure
Identification, contains an identification of the materials used in the structure of the new
or modified parts. The second part, Allowable Damage, gives the allowable damage that
may be sustained by the kit parts. The third part, Repairs, contains typical composite
structure repairs for damage that may occur to the DynaRohr kit parts, as well as repairs
to the fire protection coatings on the fan air constant section and transition section ducts.
The information covers only kit components. Refer to the McDonnell Douglas Structural
Repair Manual, Chapter 71-2-0, for the repair of all other components of the engine
nacelle.
2. Structure Identification
a. General. Structure identification is by an illustrated listing of items in the structure of the

various components of the kit. The section is divided into five parts to identify the items
in the inlet cowl, nose dome extension, PT2 probe extension, constant section fan air
duct, and transition fan air duct. The structure items, and the materials from which they
are made are listed in tables for each major component, beginning with Table 71.05-1.
The locations of typical parts made from particular materials are shown for each major
component in illustrations, beginning with Figure 71.05.1. This facilitates identification
of a damaged part and the material of manufacture to aid in:
(1) the selection of a suitable repair from those given in this manual;
(2) the design of a repair where a suitable scheme is not shown;
NOTE: Any repair scheme not shown in this manual will require FAA approval.
(3) making a new part for urgent replacement;
(4) determining those parts which an operator should not attempt to fabricate.
Revision 10 08-01-00 71.05.1

b. Inlet Cowl Structure Identification
INLET COWL OUTER BARREL ASSEMBLY

Figure 71.05-1 (1 of 9)
71.05.2 08-01-00 Revision 10


Figure 71.05.1 (2 of 9)
Revision 10 08-01-00 71.05.3


Figure 71.05.1 (3 of 9)
71.05.4 08-01-00 Revision 10


Figure 71.05.1 (4 of 9)
Revision 10 08-01-00 71.05.5


Figure 71.05.1 (5 of 9)
71.05.6 08-01-00 Revision 10


Figure 71.05.1 (6 of 9)
Revision 10 08-01-00 71.05.7

GAGE
ITEM DESCRIPTION (INCH) MATERIAL
1 Inlet Cowl Assembly
2 LH Outer Barrel Skin 0.050 2024-T3 Clad Aluminum Sheet,
QQ-A-250/5
3 Frame 0.063 2024-T3 Clad Aluminum Sheet,
QQ-A-250/5
Heat Treat T-62
4 Lip Assembly
QQ-A-250/5
Heat Treat T-62
6 Splice 0.063 2024-T3 Clad Aluminum Sheet,
QQ-A-250/5
7 Hoist Point Plug 0.2500 Dia. Cres Self-Locking Set Screw
8 Forward Bulkhead See Figure 2 for Details
9 RH Outer Barrel Skin 0.050 2024-T3 Clad Aluminum Sheet,
QQ-A-250/5
10 Scoop Assembly
11 Thermal Blanket See Figure 3 for Details.
12 RH Lower Inner Barrel Bonded
Panel Assembly
13 Vortex Spoiler Assembly
14 Inner Barrel 0.050 2024-T3 Clad Aluminum Sheet,
Inner Splice QQ-A-250/5
15 Lower Panel Assembly
16 Inlet Cowl Aft Attach Ring 1.00 15-5 PH Cres Bar, AMS5659,
1.0 X 2.0 X 166.0, Heat Treat
H925
17 Anti-Icing 0.035 C.P. Titanium Tube AMS4900,
Duct Assembly Wall 2.25 Inch Diameter X 0.035
Wall
Outer Splice QQ-A-250/5
19 Splice Blanket See Figure 3 for Details
20 Aft Bulkhead See Figure 7 for Details
21 LH Lower Inner Barrel Bond
Panel Assembly
Inner Splice QQ-A-250/5
23 Vent, Weld Assembly See Figure 6 for Details
24 Splice Blanket Heat Protection Blanket, 581ºF
Continuous
25 Frame 0.063 2024-0 Clad Aluminum Sheet,
QQ-A-250/5, Heat Treat T62

Figure 71.05-1 (7 of 9)
71.05.8 08-01-00 Revision 10

GAGE
QQ-A-250/5, Heat Treat T62.
31 Outer Barrel Splice 0.063 2024-T3 Clad Aluminum Sheet,
QQ-A-250/5
33 Scoop Weld Assembly 0.050 6061-0 Bare Aluminum Sheet,
QQ-A-327, Heat Treat to T42
Before Welding, Age Welded
Assembly to 6061-T62
34 Angle 0.040 6061-0 Bare Aluminum Sheet,
QQ-A-250/11, Heat Treat to
T42 Before Welding
T42 Before Welding
QQ-A-250/5
T42 Before Welding
38 Angle Make From Douglas Aircraft
Company Part 5753935, Heat
Treat T42 Before Welding
39 Angle 0.040 2024-T3 Clad Aluminum Sheet,
QQ-A-250/5
QQ-A-250/5
QQ-A-250/5
QQ-A-250/5
43 Duct Half 0.050 6061-0 Bare Aluminum Sheet,
QQ-A-327, Heat Treat to T42
Before Welding, Age Welded
Assembly to 6061-T62
44 Stiffener 0.050 2024-0 Clad Aluminum Sheet,

Figure 71.05-1 (8 of 9)
Revision 10 08-01-00 71.05.9

GAGE
45 Skin 0.050 2024-0 Clad Aluminum Sheet,
46 Knob 1.00 302 Cres Bar, QQ-S-763
Dia.
47 Vent 0.050 2024-0 Clad Aluminum Sheet,
48 Plate 0.063 2024-T3 Clad Aluminum Sheet,
QQ-A-250/5
49 Doubler 0.063 2024-0 Clad Aluminum Sheet,
50 Doubler 0.050 2024-T3 Clad Aluminum Sheet,
QQ-A-250/5
51 Access Door 0.071 X 2024-T42 Clad Aluminum
5X8 Sheet, QQ-A-250/5
52 Radius Filler 0.100 X 2024-T3 Clad Aluminum Sheet,
1X8 QQ-A-250/5
53 Door Land 0.063 X 2024-T42 Clad Aluminum
6 X 11 Sheet, QQ-A-250/5

Figure 71.05-1 (9 of 9)
71.05.10 08-01-00 Revision 10

FORWARD BULKHEAD
Figure 71.05-2 (1 of 3)
Revision 10 08-01-00 71.05.11

FORWARD BULKHEAD
Figure 71.05-2 (2 of 3)
71.05.12 08-01-00 Revision 10

GAGE
1 Forward Bulkhead Assembly
QQ-A-250/5
3 Splice Angle 0.063 2024-0 Clad Aluminum Sheet,
4 Web, RH 0.125 2024-T3 Bare Aluminum Plate,
QQ-A-250/4, Chem-Milled and
Primed
5 Attach Angle Inner Barrel, Upper 0.063 2024-0 Clad Aluminum Sheet,
6 Attach Angle Outer Barrel Upper 0.063 2024-0 Clad Aluminum Sheet,
RH QQ-A-250/5, Heat Treat T62
9 Attach Angle Scoop Assembly 0.063 2024-0 Clad Aluminum Sheet,
10 Attach Angle Inner Barrel, Lower 0.063 2024-0 Clad Aluminum Sheet,
11 Attach Angle Outer Barrel, Lower 0.063 2024-0 Clad Aluminum Sheet,
RH QQ-A-250/5, Heat Treat T62
QQ-A-250/5
14 Attach Angle, Outer Barrel LH 0.063 2024-0 Clad Aluminum Sheet,
15 Web, LH 0.125 2024-T3 Bare Aluminum Plate,
QQ-A-250/4, Chem Milled and
Primed
16 Heatshield 0.010 321 Cres Sheet, MIL-S-6721,
Comp T1 Annealed
FORWARD BULKHEAD
Figure 71.05-2 (3 of 3)
Revision 10 08-01-00 71.05.13

GAGE
1 Forward Blanket Heat Protection Blanket, 581ºF
Continuous
2 Blind Rivet 5/32 Monel
Dia.
3 Aft Blanket Heat Protection Blanket, 581ºF
Continuous
4 Splice Blanket Heat Protection Blanket, 581ºF
Continuous
ANTI-ICING DUCT THERMAL BLANKET
Figure 71.05-3
71.05.14 08-01-00 Revision 10

GAGE
ITEM DESCRIPTION INCH MATERIAL
1 Anti-Icing Duct Assembly CP Titanium, AMS4900, Welded
Assembly
2 Duct Section Forward Section of Douglas Anti-
Icing Duct
3 Duct Section 2.25 CP Titanium, AMS4900, 0.035-
Dia. Inch Wall
4 Duct Section Aft Section of Douglas Anti-Icing
Duct
ANTI-ICING DUCT
Figure 71.05-4
Revision 10 08-01-00 71.05.15

VORTEX SPOILER ASSEMBLY

Figure 71.05-5 (1 of 2)
71.05.16 08-01-00 Revision 10

GAGE
1 Vortex Spoiler Assembly
2 Tube 0.75 321 Cres Tube, MIL-T-8808,
O.D. 0.028-Inch Wall
3 Flange 17-4 Cres Investment Casting,
AMS5342
4 Plate 0.063 2024-T3 Bare Aluminum Plate,
QQ-A-250/5
5 Clamp
6 Bracket Assembly 0.063 2024-0 Clad Aluminum Sheet,
QQ-A-250/5
7 Nutplate
8 Support Assembly 0.040 2024-T3 Clad Aluminum Sheet,
9 Coupling
10 Liner
VORTEX SPOILER ASSEMBLY

Figure 71.05-5 (2 of 2)
Revision 10 08-01-00 71.05.17

GAGE
1 Vent Weld Assembly
2 Seal Carrier 0.032 321 Cres Sheet, MIL-S-6721, Comp
TI, Annealed
3 Duct Half 0.032 321 Cres Sheet, MIL-S-6721, Comp
TI, Annealed
4 Base 0.032 321 Cres Sheet, MIL-S-6721, Comp
TI, Annealed
5 Duct Half 0.032 321 Cres Sheet, MIL-S-6721, Comp
TI, Annealed
6 Seal
VENT ASSEMBLY
Figure 71.05-6
71.05.18 08-01-00 Revision 10

AFT BULKHEAD
Figure 71.05-7 (1 of 5)
Revision 10 08-01-00 71.05.19

AFT BULKHEAD
Figure 71.05-7 (2 of 5)
71.05.20 08-01-00 Revision 10

AFT BULKHEAD
Figure 71.05-7 (3 of 5)
Revision 10 08-01-00 71.05.21

AFT BULKHEAD
Figure 71.05-7 (4 of 5)
71.05.22 08-01-00 Revision 10

GAGE
1 Aft Bulkhead Assembly
2 Web, Upper 0.050 CP Titanium Sheet, AMS4901
3 Nutplate
4 Cover 0.040 CP Titanium Sheet, AMS4901
QQ-A-250/5 Heat Treat T62
6 Splice Angle 0.050 CP Titanium Sheet, AMS4901
7 Cap, RH 0.063 2024-0 Clad Aluminum Sheet,
11 Nutplate
12 Splice Angle 0.050 CP Titanium Sheet, AMS4901
13 Splice 0.050 CP Titanium Sheet, AMS4901
14 Rubstrip, Upper 0.060 Nylatron GS Strip
16 Rubstrip, Lower 0.060 Nylatron GS Strip
17 Clip 0.063 2024-T3 Clad Aluminum
Sheet, QQ-A-250/5
18 Doubler 0.050 CP Titanium Sheet, AMS4901
20 Web, Lower 0.050 CP Titanium Sheet, AMS4901
Sheet, QQ-A-250/5
QQ-A-250/5,
Heat Treat T62
26 Cap, LH 0.063 2024-%3 Clad Aluminum
Sheet, QQ-A-250/5,
Heat Treat T62
27 Sleeve
28 Expander
QQ-A-250/5,Heat Treat T62
30 Filler 0.063 2024-T3 Clad Aluminum
Sheet, QQ-A-250/5
Sheet, QQ-A-250/5
AFT BULKHEAD
Figure 71.05-7 (5 of 5)
Revision 10 08-01-00 71.05.23

INLET COWL INNER BARREL

Figure 71.05-8 (1 of 5)
71.05.24 08-01-00 Revision 10


Figure 71.05-8 (2 of 5)
Revision 10 08-01-00 71.05.25


Figure 71.05-8 (3 of 5)
71.05.26 08-01-00 Revision 10


Figure 71.05-8 (4 of 5)
Revision 10 08-01-00 71.05.27

GAGE
1 Inlet Cowl Inner Barrel Assembly
2 Upper Bonded Panel Assembly
3 Inner Barrel Outer Splice 0.040 X 2024-T3 Clad Aluminum Sheet, QQ
2 X 34 A-250/1
4 Lower R/H Bonded Panel Assembly
5 Tee 50-in. 2024-0 Aluminum Alloy Extrusion,
QQ-A-200/3 Heat Treat to T62
6 Inlet Cowl Aft Attach Ring 1.00 X 15-5 PH CRES Bar AMS5659, Heat
2.00 X Treat to H925
166.0
7 Inner Barrel Inner Splice 0.050 X 2024-T3 Clad Aluminum Sheet, QQ
2 X 34 A-250/5
8 Lower L/H Bonded Panel Assembly
9 Inner Barrel Inner Splice 0.050 X 2024-T3 Clad Aluminum Sheet, QQ
2 X 36 A-250/5
2 X 34 A-250/5
13 Inner Barrel Inner Splice 0.050 X 2024-T3 Clad Aluminum sheet, QQ-
2 X 36 A-250/5
2 X 32 A-250/5

Figure 71.05-8 (5 of 5)
71.05.28 08-01-00 Revision 10

c. Nose Dome Extension Structure Identification
NOSE DOME EXTENSION ASSEMBLY

Figure 71.05-9 (1 of 3)
Revision 10 08-01-00 71.05.29


Figure 71.05-9 (2 of 3)
71.05.30 08-01-00 Revision 10

GAGE
Nose Dome Extension Assembly
1 Forward ring 7075-T351 Aluminum Bar AMS4311,
Heat Treat T62
2 Bonded Panel Assembly
3 Clip 0.032 2024-T3 Clad Aluminum Sheet, QQ-
A-250/5
4 Retainer 0.032 2024-T3 Clad Aluminum Sheet, QQ-
A-250/5
5 Aft Ring 7075-T351 Aluminum Bar AMS4311,
Heat Treat T62
6 Outer Splice 0.050 2024-T3 Clad Aluminum Sheet, QQ-
A-250/5
7 Inner Splice 0.040 2024-T3 Clad Aluminum Sheet, QQ-
A-250/5
8 Stud 1.00 X 2.0 15-5PH Steel Bar, AMS8659
9 Spacer 0.250 X 2024T3 Clad Aluminum Sheet, QQ-
1X2 A-250/5
10 Clip 0.063 X Cres 321, AMS5510
0.75 X
3.0
11 Clip 0.063 X Cres 321, AMS5510
0.75 X
2.5
12 Fitting 1X2X3 Cres Bar, 15-5PH,
AMS5659, Condition A
13 Fitting 1 X 2 X 3 2024-T351 Aluminum Bar,
QQ-A-225/6
14 Spacer 0.040 X 1 2024-T3 Clad Aluminum Sheet, QQ-
X1 A-250/5
15 Shim 0.125 X 2 X 10 MIL-S-22499 Aluminum Alloy

Figure 71.05-9 (3 of 3)
Revision 10 08-01-00 71.05.31

d. PT2 Tube Extension Structure Identification
GAGE
1 PT2 Tube Extension Assembly
2 Union
3 Nut
4 Sleeve
5 Tube 0.25 OD X CRES 321 Tube,
0.020 Composition 321, Type 2
X 11
6 Clamp
PT2 TUBE EXTENSION ASSEMBLY

Figure 71.05-10
71.05.32 08-01-00 Revision 10

e. Constant Section Fan Air Duct Structure Identification
CONSTANT SECTION FAN AIR DUCT ASSEMBLY

Figure 71.05-11 (1 of 4)
Revision 10 08-01-00 71.05.33


Figure 71.05-11 (2 of 4)

Figure 71.05-11 (3 of 4)
71.05.34 08-01-00 Revision 10

GAGE
1 Splice 0.032 2024-T3 Bare Aluminum Sheet,
QQ-A-250/4 Temper T3
2 Fireshield 0.005 CRES 321 Sheet,
MIL-S-6721
3 Lanyard Fitting 2024-T351 Aluminum Bar,
QQ-A-225/6
4 Lanyard Fitting 2024-T351 Aluminum Bar,
QQ-A-225/6
5 Fireshield 0.005 CRES 321 Sheet,
MIL-S-6721
6 Inboard Seal Retainer 2024-0 Aluminum Alloy Extrusion,
QQ-A-200/3Heat Treat T62
7 Outboard Seal Retainer 2024-0 Aluminum Alloy Extrusion,
8 Seal 56-in. Make from S700S0746
9 Retainer 0.62 CRES 302 Bar,
Dia. QQ-S-763
10 Bumper Teflon, Silicone Rubber
11 Lanyard Fitting 2024-T351 Aluminum Bar, QQ-A-
225/6
12 Lanyard Fitting 2024-T351 Aluminum Bar, QQ-A-
225/6
13 Outboard Bonded Panel Assembly
14 Splice 0.032 X 2024-T3 Bare Aluminum Sheet,
3 X 25 QQ-A-250/4 Temper T3
15 Splitter Assembly
16 Retainer 0.62 CRES 302 Bar,
Dia. QQ-S-763
17 Inboard Bonded
Panel Assembly
18 Outboard Seal Retainer 2024-0 Aluminum Alloy Extrusion,
19 Inboard Seal Retainer 2024-0 Aluminum Alloy Extrusion,
QQ-A-200/3
Heat Treat T62
20 Splice 0.032 2024-0 Bare Aluminum Sheet,
QQ-A-250/4
Temper 0
21 Closure 0.032 2024-0 Bare Aluminum Sheet,
QQ-A-250/4
Temper 0
22 Seal 56-in. Make from S700S0746
23 Ablative Coating

Figure 71.05-11 (4 of 4)
Revision 10 08-01-00 71.05.35

f. Transition Fan Air Duct Structure Identification
TRANSITION FAN AIR DUCT ASSEMBLY

Figure 71.05-12 (1 of 8)
71.05.36 08-01-00 Revision 10


Figure 71.05-12 (2 of 8)
Revision 10 08-01-00 71.05.37


Figure 71.05-12 (3 of 8)
71.05.38 08-01-00 Revision 10


Figure 71.05-12 (4 of 8)
Revision 10 08-01-00 71.05.39


Figure 71.05-12 (5 of 8)
71.05.40 08-01-00 Revision 10


Figure 71.05-12 (6 of 8)
Revision 10 08-01-00 71.05.41

GAGE
1 Forward Channel Assembly 0.063 2024-T3 Clad Aluminum Sheet,
QQ-A-250/5
2 Corner Seal 0.025 CRES 321 Sheet,
MIL-S-6721,Composition
T1 Annealed
3 Splice Strap 0.050 2024-0 Clad Aluminum Sheet,
QQ-A-250/5
Heat Treat T62
4 Rubstrip 0.012 CRES 321 Sheet,
MIL-S-6721,Composition
T1 Annealed
5 Fitting CRES Steel Investment Casting,
17-4PH, AMS5432
6 Boss Assembly
7 Splice Plate 0.050 2024-T3 Clad Aluminum Sheet,
QQ-A-250/5
8 Angle 2219-0 Aluminum Alloy
Extrusion, ASTM-B-221-64,
Temp-0, Heat Treat T62
QQ-A-250/5
Extrusion, ASTM-B-221-64, Heat
Treat T62
Treat T62
12 Inboard Bonded
Panel Assembly
QQ-A-250/5
QQ-A-250/5
15 Fireshield 0.005 X CRES Sheet, Type 321
15 X 63 MIL-S-6721, Comp
T1 Annealed
16 Outboard Bonded
Panel Assembly
QQ-A-250/5,
Heat Treat T62
18 Fitting 22024-0 Aluminum Alloy
Extrusion, QQ-A-200/3

Figure 71.05-12 (7 of 8)
71.05.42 08-01-00 Revision 10

GAGE
19 Fireshield 0.005 X CRES Sheet, Type 321
15 X 63 MIL-S-6721, Comp
T1 Annealed
20 Corner Seal CRES 321 Sheet, MIL-S-6721,
Composition T1 Annealed
21 Bumper Teflon-Silicone Rubber
22 Fitting 2X3X3 CRES Bar, 15-5PH, AMS5659
Heat Treat T62
24 Seal 2219-0 Aluminum Alloy
Treat T62
25 Retainer 0.025 CRES 321 Sheet, MIL-S-6721,
Composition T1 Annealed
QQ-A-250/5
29 Splitter Assembly
QQ-A-250/5
Treat T62
Heat Treat T62
QQ-A-250/5,Heat Treat T62
34 Ablative Coating
35 Retainer 0.375 X 1.0 CRES Bar, Type 302, QQ-S-763
36 Insert
37 Thermal Blanket

Figure 71.05-12 (8 of 8)
Revision 10 08-01-00 71.05.43

3. Allowable Damage
a. General. This section provides information containing allowable damage limits for both
sheet metal structure and bonded panel structure components of the BAC II ADC
Upgrade Hush Kit. Any damage found to exceed the allowable damage limits of this
section must be repaired in accordance with the Repair Section of this structural repair
manual.
b. Organization and Use. The information in this section is presented in five parts. Sub-
paragraph ‘c’ covers general information concerning allowable damage definitions,
structure material, and damage types. Subparagraph ‘d’ covers allowable sheet metal
structure damage limits classified as “Unlimited Usage”. Subparagraph ‘e’ covers sheet
metal allowable damage classified as “Time Limited”. Subparagraph ‘f’ covers bonded
panel structure allowable damage classified as “Unlimited Usage”. Subparagraph ‘g’
covers bonded panel structure allowable damage classified as “Time Limited”.
c. Allowable Damage Definitions.
(1) General – Allowable damage data is intended to permit an operator to determine

whether a damaged nacelle component may be returned to service without repair.
Damage permitted by these data will have no significant effect on strength or
fatigue life of the structure, which will remain capable of fulfilling its design
function. The types of allowable damage permitted are defined and brief
descriptions are given of cleanup procedures required to prevent damage
propagation or improve aerodynamic smoothness of a damaged part.
(2) Material Types – The basic material used in the construction of the quiet nacelle
components is aluminum. It comprises the sheet metal construction of the inlet
cowl outer barrel and the bonded panel construction of the inlet cowl inner barrel,
nose dome extension, constant section fan duct, and transition fan duct. Since the
structural design requirements for sheet metal and bonded panel components differ,
the allowable damage data for each is given separately.
(3) Damage – All damage limits assume that exposed edges do not protrude from the
skin contour. Any such damage should be reworked to remove or feather
protrusions. Holes and cracks in pressure boundaries must be sealed with
aerodynamic tape. Allowable damage is classified as either unlimited usage or time
limited. Damage classified as unlimited usage is defined as minor damage not
affecting the structural integrity of functional capability of the component and
requiring no repairs over the aircraft design life. Time limited damage is defined as
minor damage not affecting the structural integrity of the component in normal
71.05.44 08-01-00 Revision 10

operation, but could reduce the design life of the component. Therefore, damage
must be permanently repaired no later than the next maintenance “C” check. The
location and size of the damage is to be noted and checked at each subsequent “A”
check to ensure that the damage has not grown beyond the time limited damage
allowances.
(4) Damage Types – The types of allowable damage permitted on nacelle components
are defined below. They apply only to the parent material and do not include
damage to surface finishes such as paint.
TYPE DEFINITION
Abrasion An abrasion is a damage area which results in a cross-sectional area change
due to scuffing, rubbing, scraping or other surface erosion. An abrasion is
usually rough and irregular.
Gouge A gouge is a damage area of any size which results in a cross-sectional
change. It is usually caused by contact with a relatively sharp object which
produces a continuous sharp or smooth channel-like groove in the material.
Nick A nick is a local gouge with sharp edges. Consider a series of nicks in a
line pattern to be a gouge.
Scratch A scratch is a line of damage in the material which results in a cross-
sectional area change. It is usually caused by contact with a very sharp
object.
Crack A crack is a partial fracture or complete break in the material and produces
a most significant cross-sectional area change. In appearance, it is usually
an irregular line.
Dent A dent is a damage area which is depressed with respect to its normal
contour. There is no cross-sectional area change in the material and
boundary areas are smooth. Its form is generally the result of contact with
a smoothly contoured object.
Hole A hole is a complete penetration of the material.
Void/ A void or delamination is the separation of the face sheet from its
Delamination honeycomb core or a faying surface.
Rip/Tear A rip or tear in woven wire is a sharp, continuous separation of the wire
fibers.
Revision 10 08-01-00 71.05.45

d. Sheet Metal Structure Allowable Damage Limits – UNLIMITED USAGE
Damage Type Limitations Disposition

Nicks- panels and Maximum 25% of basic material thickness. Ok for flight if
stiffener Maximum width 0.10 inch (2.54 mm). If greater within limits.
than 25%, regard as a crack.
Gouges/Scratches- Maximum 10.0 inches (254 mm) long in any OK for flight if
panels direction. Maximum depth of gouge 0.010-inch. within limits.
Maximum depth of scratch 0.005-inch. Minimum
distance between gouges/scratches 10.0 inches
(254 mm).
Cracks- Termination between two adjacent fasteners in a Must be stop
fasteners joint of ten or more fasteners and not within 5.0 drilled before next
inches (127 mm) of stiffener termination points. flight.
Minimum distance between cracks 10.0 inches
(254mm)
Holes Any complete penetration not permitted. Repair holes in fire
barrier before next
flight. Seal all
other holes with
aerodynamic tape
before next flight.
Dents- Maximum dimension 5.0 inches (127 mm). OK for flight if
panels Dimension-to-Depth ratio must be greater than within limits.
10.0. Minimum distance from edge of panel is
20x sheet thickness. Minimum distance between
dents 10.0 inches (254 mm).
71.05.46 08-01-00 Revision 10

e. Sheet Metal Structure Allowable Damage Limits – TIME LIMITED.

Cracks- Minimum distance between cracks 10.0 inches Stop drill before next
Panels (254 mm). flight.
Length less than 1.0 inch (25.4mm). Monitor for growth at

“A” checks until
repaired.
Length greater than 1.0 inch (25.4 mm) but less Permanently repair at
than 3.0 inches (76.2 mm). next “A” check.
Cracks- Crack termination between three adjacent Stop drill before next
involving fasteners in a joint of ten or more fasteners. flight.
fasteners Minimum distance between cracks 10.0 inches
(254 mm).
Cracks- Length less than 1.0 inch (25.4 mm) in bend Stop drill before next
Stiffeners area. Minimum 5.0 inches (127 mm) distance flight.
from stiffener termination point.
Length less than 25% of flange width. Stop drill before next
Minimum distance 5.0 inches (127 mm) from flight.
stiffener termination point.
Holes Maximum diameter 1.0 inch (25.4 mm) within Repair holes in fire
panels 20x sheet thickness from reinforcement. 3.0 barrier before next flight.
inches (76.2 mm) maximum diameter in all Seal all other holes with
other areas. Minimum distance between holes aerodynamic tape before
10.0 inches (254 mm). next flight.
Revision 10 08-01-00 71.05.47

f. Bonded Panel Structure Allowable Damage Limits – UNLIMITED USAGE
NOTE: Bonded aluminum panel areas include the following: Inlet cowl inner barrel, nose
dome extension, constant section fan duct, and transition fan duct.
NOTE: No cracks or other ruptures are permitted.

Nicks- Maximum length 0.75 inch (19.05 mm) and OK for flight if within
aluminum maximum depth 0.010 inch (0.254 mm). limits.
Minimum 1.5 inch (3.81 mm) distance from
reinforced area or edge of honeycomb. Minimum
distance between nicks 2.0 inches (50.8 mm).
Scratches- Maximum length 1.50 inch (3.81 mm) and OK for flight if within
aluminum maximum depth 0.005 inch (0.127 mm). limits.
reinforced area or edge of honeycomb. Minimum
distance between scratches 2.0 inches (50.8 mm).
71.05.48 08-01-00 Revision 10

g. Bonded Panel Structure Allowable Damage Limits – TIME LIMITED

NOTE: Aluminum bonded areas include the following: Nose dome extension, inlet cowl
inner barrel, constant section fan duct, and transition fan duct.
NOTE: No cracks or other ruptures are permitted.

Nicks- Maximum 0.75 inch (19.05 mm) length by 0.10 inch Permanently repair
ablative coating (0.254 mm) width by 0.050 inch (1.27 mm) depth. at next “A” check
insulation Minimum distance between nicks 10.0 inches
(254 mm).
Dent- Maximum diameter 2.0 inches (50.8 mm) and 0.12 Inspection required
aluminum inch (3.04 mm) depth. Minimum radius 0.25 inches at “A” check.
(6.35 mm). Minimum 1.0 inch (25.4 mm) distance
Minimum distances between dents 3.0 inches
(76.2 mm).
Gouge- Maximum 1.50 inch (3.81 mm) long by 0.10 inch Inspection required
aluminum (2.54 mm) wide by 0.010 inch (0.254 mm) deep. at “A” check.
Minimum radius 0.05 inch (1.27 mm). Minimum 3.0
inches (76.2 mm) distance from reinforced area or
edge of honeycomb. Minimum distance between
gouges 3.0 inches (76.2 mm).
Void/ Maximum 15% of area for any one linear inch (25.4 Inspection required
Delamination- mm) in non-riveted joint. Minimum 0.12 inch (3.04 at “C” check
aluminum mm) sound joint between edges. Maximum 25%
faying surface area within two adjacent rivets in riveted joint.
reinforced area or edge of honeycomb. Must not
extend from one edge to the opposite edge.
Void/ Maximum dimension 1.50 inches (3.81 mm). Inspection required
Delamination- Minimum 2.0 inches (50.8 mm) distance from at “A” check.
face sheet to reinforced area or edge of honeycomb. Minimum
core distance between voids/delaminations 4x maximum
dimension of void. Void must not be opposite void
on opposite face. Number of voids not to exceed two
per square foot.
Rips/Tears- Maximum of 0.25 inch length. Minimum 3.0 inches Monitor for growth
between defects at “A” checks until
permanently
repaired.
From 0.25 inch to 2.0 inches Permanently repair
at next “A” check.
Revision 10 08-01-00 71.05.49

4. Repairs
a. General
(1) This section covers repairs to the BAC II ADC Upgrade components only. Repairs
to components other than the kit components should be accomplished in accordance
with the applicable repair manuals.
(2) Sheet Metal Structure Repairs. Refer to McDonnell-Douglas DC-8 Structural

Repair Manual, Chapter 71-2-0, for BAC II ADC Upgrade sheet metal repairs.
b. DynaRohr Acoustic Panel Repairs
(1) Repair Limits – Acoustic
(a) Repairs to DynaRohr acoustic bonded panels affect the ability of the panels to
reduce noise. A change of 0.1 EPNdB or more is significant. A loss in
acoustic area cannot result in noise level increases greater than 0.1 EPNdB.
(b) The BAC II ADC Upgrade acoustic area is divided into two categories. They
are the Inlet area, consisting of the inlet cowl and nose dome extension, and
the Fan Duct area, consisting of the constant section and transition section fan
ducts.
(c) The maximum allowable area losses for the BAC II ADC Upgrade due to
either repairs which diminish the acoustic area or to missing woven wire are as
follows:
Inlet Total Acoustic Area 4520 in2

Maximum Allowable Area Loss 100 in 2
Fan Duct Total Acoustic Area 15430in2
Maximum Allowable Area Loss 200in2
(d) If the amount of missing woven wire exceeds the limits noted in paragraph
4.b.(1)(c) contact Rohr Industries, Inc. Warranty Administration, for
replacement of woven wire per Rohr specification 128d111.
71.05.50 08-01-00 Revision 10

(2) Repair Limits – Structural
(a) Structural Repairs to DynaRohr acoustic bonded panels are designed to return
the panels to their original strengths. However, limits exist regarding the
maximum repair size and the minimum distance between repairs. The repair
limits for the repairs covered in this section are as follows:.
MINIMUM DISTANCE
REPAIR MAXIMUM SIZE BETWEEN REPAIRS
Woven Wire Tear, Rip and Scratch Unlimited (See Unlimited (See Acoustic
Repair Acoustic Limits in Limits in Paragraph
Paragraph 2.A.(3)) 2.A.(3))
Acoustic Panel Nick, Gouge and Small 1.50 in. 3.0 in.
Hole Repair
Acoustic Panel Crack Repair 5.0 in. length 10.0 in.
Acoustic Panel Partial Penetration 5.0 in. Dia. 10.0 in.
Repair
Acoustic Panel Delamination Repair 5.0 in. Dia. 10.0 in.
Acoustic Panel Complete Penetration 5.0 in Dia. 10.0 in.
Repair
(3) Mixing of Adhesives
WARNING: EPOXY RESINS ARE CLASSIFIED AS A HAZARDOUS MATERIAL

WHICH MAY CAUSE INJURY OR ILLNESS IF NOT PROPERLY USED.
THIS PRODUCT SHOULD BE USED ONLY IN ACCORDANCE WITH
THE MANUFACTURER’S SPECIFIC SAFETY AND HEALTH
RECOMMENDATIONS. PRIOR TO USE OF THIS PRODUCT,
CAREFULLY READ THE APPLICABLE “MATERIAL SAFETY DATA
SHEET” AND FOLLOW ALL LISTED SAFETY AND HEALTH
PRECAUTIONS.
(a) The EA9390 parts A and B adhesive system is an epoxy material used as a
bonding agent for the DynaRohr acoustic panel repairs. It is a two-part
adhesive which must be mixed just prior to use. Only the quantities that may
conveniently be used during the useful life (prior to gel) of the adhesive
should be mixed. A useful life of 120 minutes for a one pound mixture is
normal, but the useful life is extended for smaller quantities and shortened for
larger ones.
Revision 10 08-01-00 71.05.51

WARNING: EA9390 ADHESIVE, PARTS A AND B, IS CLASSIFIED AS A

HAZARDOUS MATERIAL WHICH MAY CAUSE INJURY OR ILLNESS
IF NOT PROPERLY USED. THIS PRODUCT SHOULD BE USED ONLY
IN ACCORDANCE WITH THE MANUFACTURER’S SPECIFIC SAFETY
AND HEALTH RECOMMENDATIONS. PRIOR TO USE OF THIS
PRODUCT CAREFULLY READ THE APPLICABLE “MATERIAL
SAFETY DATA SHEET” AND FOLLOW ALL LISTED SAFETY AND
HEALTH PRECAUTIONS.
1) Mix thoroughly in a metal or plastic container 100-parts-by weight (pbw)

of EA9390 part A with 56 pbw of EA9390 part B. Use a spatula.
2) Cover container to prevent contamination of mixture and store in a cool

place until used.
NOTE: Useful life for a one pound mixture is approximately 120 minutes. Exposure to heat
greatly accelerates both adhesive gel time and cure time.
(b) The EA934NA parts A and B adhesive system is an epoxy material used as a
liquid shim, potting compound, and as a bonding agent for the DynaRohr
acoustic panel repairs. It is a two-part adhesive which must be mixed just
prior to use. Only the quantities that may conveniently be used during the
useful life (prior to gel) of the adhesive should be mixed. A useful life of 35-
40 minutes for a four ounce mixture is normal, but the useful life is extended
for smaller quantities and shortened for larger ones.
WARNING: EA934NA ADHESIVE, PARTS A AND B, IS CLASSIFIED AS A

HEALTH PRECAUTIONS.
1) Mix thoroughly in a metal or plastic container 100-parts-by-weight (pbw)

of EA934NA part A with 33 pbw of EA934NA part B. Use a spatula.

place until used.
Note: Useful life for a four ounce mixture is approximately 35-40 minutes. Exposure to heat
71.05.52 08-01-00 Revision 10

(c) The EA956 parts A and B adhesive system is an epoxy material

used as a liquid shim, potting compound, and as a bonding agent
for the DynaRohr acoustic panel repairs. It is a two-part adhesive
which must be mixed just prior to use. Only the quantities that
may conveniently be used during the useful life (prior to gel) of the
adhesive should be mixed. A useful life of 30 minutes for a one
pound mixture is normal, but the useful life is extended for smaller
quantities and shortened for larger ones.

HEALTH PRECAUTIONS.
1) Mix thoroughly in a metal or plastic container 100-parts-by-weight (pbw)

of EA956 part A with 58 pbw of EA956 part B. Use a spatula.

place until used.
Note: Useful life for a one pound mixture is approximately 30 minutes. Exposure to heat
(4) Cutting a Repair Plug from a Repair Panel. (See Figure 71.05-13.)
(a) Stabilizing Woven Wire on Face Skin: Prior to the cutting operation, EA956,
Part A and Part B, adhesive must be applied to the woven wire at the cutting
locations. The application of adhesive is required to assure total encapsulation
of the wire strands and to provide adequate backup for the cutting operation.
To provide good penetration a 0.005 to 0.010-inch surface coat is required.
Allow 10 to 15 minutes before removal of any excess coating from the wire
surface. The best application and removal results can be achieved using a
rubber applicator with a 30 degree chamfered edge.
1) Mask cutting areas on the wire mesh face skin to provide a 0.375-inch
stabilized area, using 0.5-inch Teflon tape.
Revision 10 08-01-00 71.05.53

MAKING REPAIR PLUG FROM REPAIR PANEL

Figure 71.05-13
71.05.54 08-01-00 Revision 10


PRODUCT, CAREFULLY READ THE “MATERIAL SAFETY DATA
PRECAUTIONS.
2) Mix EA956 parts A and B in accordance with instructions in paragraph

4.b.
3) Apply adhesive to masked area using a rubber applicator with a 30 degree

chamfered edge. (Remove excess adhesive after 10 to 15 minutes.)
4) Place nonporous parting film over stabilized area and tape in place.
5) Place a heat blanket over parting film and cure at 180ºF to 200ºF for 30
minutes or 24 hours at room temperature.
6) Remove heat blanket, parting film, and mask tape.
(b) Cutting, Routing or Drilling Woven Wire and Perforated Face Skins: After
stabilizing areas to be cut, the repair plug can be cut using center of stabilized
areas as a guide. Sharpness of cutting edge is the first requirement of the
cutting operation. When sharp cutting edges are maintained on high speed
cutting disc, routers, and drills, acceptable results are achieved. When the
proper cutting edge is lost, fraying and unraveling of the woven wire is
experienced. The best cutting or routing results are achieved using a 18,000 to
23,000 RPM motor. A straight flute right hand cut router bit provides superior
cutting action and edge finish. Care must be taken to provide a medium feed
with material feeding into the cutting edge of the router bit. Feeding the
material away from cutting edge or climb cutting should be avoided.
1) Cut through woven wire and perforated face skin using a 18,000 to
23,000 RPM motor and router bit or cutting disc. Center of stabilized
area may be used as a guide.
2) Use proper size hole saw and cut through aluminum honeycomb core.
3) Chamfer edge of woven wire and perforated face sheet to 45 degrees.

Use 320-400 grit abrasive paper to produce a smooth surface finish.
Apply Alodine 1200 to chamfered surface.
Revision 10 08-01-00 71.05.55

(c) Cutting and Shaping of Aluminum Honeycomb Core: Cutting aluminum

honeycomb core to the proper depth can best be achieved using a band saw
capable of a speed range of 2,500 to 4,500 feet per minute. A blade with 4 to
7 teeth per inch will provide a smooth cut with no cell tearing. Cutting the
core at speeds less than 2,500 feet per minute will cause cell walls to tear and
deform. The core can be shaped to contour and cut to net diameter fit using a
18,000 to 23,000 RPM motor and standard cutting and sanding discs.
1) Cut core to net depth using a band saw turning at 2,500 to 4,500 feet per
minute, with a saw blade having 4 to 7 teeth per inch.
2) Cut core to net diameter and contour using a 18,00 to 23,000 RPM motor
and standard cutting and sanding discs.
c. Fire Protection and Thermal Coating Repairs
(1) General: The fan by-pass air ducts are exposed to high temperatures from the
compressor section and turbine section of the Pratt & Whitney JT3D engine.
Special thermal materials are used to coat the surfaces of the acoustic bonded panels
of the fan-bypass exhaust air constant section ducts and transition ducts.
Instructions are provided in this section for the repair of damaged coatings and
application of coatings to new or repair parts. (See Repair No. 7.)
71.05.56 08-01-00 Revision 10

(S.T.C. SA5455NM)
REPAIR NO. 1
WOVEN WIRE TEAR, RIP, AND SCRATCH REPAIR

1. Woven Wire Tear, Rip, and Scratch Repair (See Figure 71.05-14.)
NOTE: For large areas of missing woven wire, refer to Paragraph 4.b.(1)(d).
CAUTION: USE EXTREME CARE TO ENSURE ALL LOOSE WIRE PARTICLES ARE
CLEANED AWAY. THE STAINLESS STEEL WIRE HAS A STRONG
ELECTROLYTIC REACTION WHEN IN CONTACT WITH ALUMINUM
ALLOYS, CAUSING GALVANIC CORROSION TO OCCUR.
A. Stabilize the woven wire on face skin in accordance with instructions in Repair General,
Paragraph 4.b.(4).
B. Use cuticle scissors, X-Acto knife or equivalent to remove all loose woven wire. Do not
cut the perforated skin that is under the woven wire.
WARNING: METHYL ETHYL KETONE (MEK) IS CLASSIFIED AS A HAZARDOUS
MATERIAL WHICH MAY CAUSE INJURY OR ILLNESS IF NOT
PROPERLY USED. THIS PRODUCT SHOULD BE USED ONLY I
ACCORDANCE WITH THE MANUFACTURER’S SPECIFIC SAFETY
PRODUCT, CAREFULLY READ THE APPLICABLE “MATERIAL
HEALTH PRECAUTIONS.
C. Clean repair area with a clean cloth moistened with methyl ethyl ketone. Wipe surface
dry with a clean cloth before solvent evaporates.
D. Mask repair area with teflon tape.
HEALTH PRECAUTIONS.
E. Mix the EA9390 adhesive in accordance with instructions in Paragraph 4.b.(3).
Revision 10 08-01-00 71.05.57

WOVEN WIRE TEAR, TIP, AND SCRATCH REPAIR

Figure 71.05-14 (1 of 2)
71.05.58 08-01-00 Revision 10

F. Use a spatula to fill an area with EA9390 adhesive.
G. Cure the adhesive at 190ºF-210ºF (87ºC-98ºC) for 220 minutes.
H. Use the 150-320 grit abrasive paper to make the adhesive level with the surrounding
surface.
I. Remove sanding dust from the repair surface with a clean cloth moistened with methyl
ethyl ketone. Wipe surface dry with a clean cloth before solvent evaporates.
NOMENCLATURE DESCRIPTION MANUFACTURER

ABRASIVE SYSTEM, EA9390 DEXTER HYSOL AEROSPACE, INC.
EPOXY BASE CATALYST Part A THE DEXTER CORPORATION
Part Bb 2850 WILLOW PASS ROAD
P.O. BOX 312
PITTSBURGH, PA 94565-3237
PAPER, ABRASIVE 150-320 GRIT COMMERCIALLY AVAILABLE
SILICON CARBIDE
SOLVENT METHYL ETHYL COMMERCIALLY AVAILABLE
KETONE
SPATULA METAL OR PLASTIC COMMERCIALLY AVAILABLE
TAPE, TEFLON 2-INCH WIDE COMMERCIALLY AVAILABLE
WOVEN WIRE TEAR, TIP, AND SCRATCH REPAIR

Repair Materials and Equipment
Figure 71.05-14 (2 of 2)
Revision 10 08-01-00 71.05.59

REPAIR NO. 2
ACOUSTIC PANEL NICK, GOUGE, AND SMALL HOLE (1.00-INCH OR LESS)

REPAIR
1. Acoustic Panel Nick, Gouge and Small Hole (1.00-Inch or Less) Repair (See Figure 71.05-
15.)
A. Stabilize woven wire on face skin in accordance with instructions in Paragraph 4.b.(4).
B. Drill or cut out damage using smallest diameter and depth possible to remove all damage.
C. Cut woven wire back from edge of cutout 0.125-inch using cuticle scissors, X-Acto knife
or equivalent.

PROPERLY USED. THIS PRODUCT SHOULD BE USED ONLY IN
PRODUCT, CAREFULLY READ APPLICABLE “MATERIAL SAFETY
DATA SHEET” AND FOLLOW ALL LISTED SAFETY AND HEALTH
PRECAUTIONS.
D. Clean repair area with a clean cloth moistened with methyl ethyl ketone. Wipe surface
dry with a clean cloth before solvent evaporates.
E. Mask repair area with teflon tape.
71.05.60 08-01-00 Revision 10

ACOUSTIC PANEL NICK, GOUGE, AND SMALL HOLE REPAIR

Figure 71.05-15 (1 of 2)
Revision 10 08-01-00 71.05.61


PRECAUTIONS.
F. Mix the EA9390 adhesive in accordance with instructions in Paragraph 4.b.(3). Add 5-
percent-by-weight of micro balloons and mix thoroughly to a paste consistency.
G. Fill repair cutout with adhesive/micro balloon mixture using a spatula.
H. Place nonporous parting film over repair area and tape in place.
I. Place a heat blanket over the parting film and cure at 190ºF to 210ºF for 220 minutes.
J. Remove heat blanket, parting film, and mask tape. Sand to a feather-edge using 150-320
grit abrasive paper as required to produce a smooth service.

PRECAUTIONS.
K. Remove sanding dust from surface using a clean cloth moistened with methyl ethyl
ketone. Wipe surface dry with a clean cloth before solvent evaporates.
71.05.62 08-01-00 Revision 10


EPOXY BASE PART A THE DEXTER CORPORATION
CATALYST PART B 2850 WILLOW PASS ROAD
P.O. BOX 312
PITTSBURG, CA 94565-3237
BLANKET, HEAT 0ºF-250ºF, ATACS PRODUCTS, INC.
102/IN.2 1120 S.W. 16TH STREET
RENTON, WA 98055
FILM, PARTING NONPOROUS COMMERCIALLY AVAILABLE
MICRO BALLOONS PHENOLIC, UNION CARBIDE CORP.
5 – 135 MICRON CHEMICALS AND PLASTICS DIV.
BOUND BROOK PLANT
RIVER ROAD
P.O. BOX 181
BOUND BROOK, NJ 08805
SILICON CARBIDE
KETONE
ACOUSTIC PANEL NICK, GOUGE, AND SMALL HOLE REPAIR

Figure 71.05-15 (2 of 2)
Revision 10 08-01-00 71.05.63

REPAIR NO. 3
ACOUSTIC PANEL CRACK REPAIR
1. Acoustic Panel Crack Repair (See Figure 71.05-16.)
A. Make a doubler from sheet stock of same material and gage as original skin (except use
non-perforated). Use full radius and chamfer doubler edge at 45 degrees all around.
Apply Alodine 1200 to chamfered surface.
B. Stabilize woven wire on face skin in accordance with instructions in Paragraph 4.b.(4).
Using cuticle scissors, X-Acto knife or equivalent, cut and remove woven wire 0.125-
inch larger all around than doubler.
C. Use size No. 30 drill and drill a 0.1285-inch diameter stop hole at each end of crack.
Remove all drilling debris.
D. Use size No. 16 drill and drill 0.177-inch diameter rivet holes in doubler at 0.75-inch
pitch and 0.31-inch edge margin. Temporarily attach doubler with Cleco fasteners or
equivalent.
E. Remove doubler and burr rivet holes. Remove all drilling debris.

PRECAUTIONS.
F. Clean repair area and doubler with a clean cloth moistened with methyl ethyl ketone.
Wipe surface dry with a clean cloth before solvent evaporates.
71.05.64 08-01-00 Revision 10


Figure 71.05-16 (1 of 2)
Revision 10 08-01-00 71.05.65


PRECAUTIONS.
G. Mix the EA9390 adhesive in accordance with instructions in Paragraph 4.b.(3).
H. Use a stiff bristle brush and coat the repair area and doubler back face with adhesive.
I. Align rivet holes and place doubler over repair area. Attach doubler using CR3253-5-2
rivets. Wet install rivets with adhesive.
J. Place nonporous parting film over repair area and tape in place.
K. Place a heat blanket over parting film and cure at 190ºF to 210ºF for 220 minutes.
L. Remove heat blanket and parting film. Sand to a feather-edge using 150-320 grit
abrasive paper as required to produce a smooth surface between doubler and original face
skin.

PRECAUTIONS.
M. Remove sanding dust from surface using a clean cloth moistened with methyl ethyl
71.05.66 08-01-00 Revision 10


ADHESIVE SYSTEM, EA 9390 DEXTER HYSOL AEROSPACE, INC.
EPOXY BASE PART A THE DEXTER CORPORATION
CATALYST PART B 2850 WILLOW PASS ROAD
P.O. BOX 312
ALUMINUM SHEET 2024-T3, 0.032-IN. COMMERCIALLY AVAILABLE
THICK
BLANKET, HEAT 0ºF-250ºF, 10W/IN.2 ATACS PRODUCTS
1120 S.W. 16TH STREET
RENTON, WA 98055
FILM, PARTING NONPOROUS COMMERCIALLY AVAILABLE
MICRO BALLOONS PHENOLIC, UNION CARBIDE CORP.
5-135 MICRON CHEMICALS AND PLASTICS DIV.
BOUND BROOK PLANT
RIVER ROAD
P.O. BOX 181
RIVETS CR3253-5-2 CHERRY/TEXTRON INC.
CHERRY COMMERCIAL FASTENERS
PRODUCTS
DIVISION OF TEXTRON, INC.
1223 E. WARNER STREET
P.O. BOX 2157
SANTA ANA, CA 92707
SILICON CARBIDE
KETONE

Figure 71.05-16 (2 of 2)
Revision 10 08-01-00 71.05.67

REPAIR NO. 4
ACOUSTIC PANEL PARTIAL PENETRATION REPAIR
1. Acoustic Panel Partial Penetration Repair (See Figure 71.05-17.)
B. Use a hole saw to cut out damage. Cut damage to smallest diameter and depth possible to
remove all damage.
C. Use cuticle scissors, X-Acto knife or equivalent and cut woven wire 0,875-inch from
edge of cutout. This will provide 0.125-inch larger area than diameter of repair plug.
D. Make a repair plug from repair panel section in accordance with instructions in,
Paragraph 4.b.(4). Machine aluminum honeycomb core to a net height and diameter to
match cutout diameter and depth. Cut repair plug woven wire and perforated face skin to
overlap the original perforated face skin by 0.75-inch and chamfer edge to 45 degrees all
around. Apply Alodine 1200 to chamfered surface.
E. Place repair plug into cutout and align perforations in the original face skin to
perforations in repair plug face skin. Use size No. 16 drill and drill 0.177-inch rivet holes
using 0.75-inch pitch and 0.31-inch edge margin. Temporarily attach repair plug with
Clecos or equivalent.
F. Remove repair plug and burr rivet holes. Remove all drilling debris from repair area and
repair plug.
71.05.68 08-01-00 Revision 10


Figure 71.05-17 (1 of 2)
Revision 10 08-01-00 71.05.69


PRECAUTIONS.
G. Clean repair area and repair plug with a clean cloth moistened with methyl ethyl ketone.
Wipe surface dry with a clean cloth before solvent evaporates.

PRECAUTIONS.
H. Mix the EA9390 adhesive in accordance with instructions in Paragraph 4.b.(3).
I. Use a stiff bristle brush and thoroughly coat repair area and repair plug with adhesive.
NOTE: Use enough adhesive on the outer diameter of repair plug and inner diameter of repair
cutout to ensure all cut core cells are completely full of adhesive.
J. Insert repair plug into repair cutout. Rotate repair plug 360 degrees to ensure a good
adhesive bond between repair plug and repair cutout. Align rivet holes and attach repair
plug using CR3253-5-2 rivets. Wet install rivets with adhesive.
K. Place nonporous parting film over repair area and tape in place.
L. Place a heat blanket over parting film and cure at 190ºF to 220ºF for 220 minutes.
M. Remove heat blanket and parting film. Sand to a feather-edge using 150-320 grit
abrasive paper as required to produce a smooth surface between repair plug and original
face skin.
71.05.70 08-01-00 Revision 10


PRECAUTIONS.
N. Remove sanding dust from surface using a clean cloth moistened with methyl ethyl
Revision 10 08-01-00 71.05.71

REPAIR KIT, INLET COWL 236K9001-1 ROHR INDUSTRIES, INC.
INNER BARREL CONSISTS CHULA VISTA, CA 92012
OF : REPAIR PANEL AND
ITEMS MARKED WITH 236-0080 ROHR INDUSTRIES, INC.
ASTERISK
REPAIR KIT, FAN DUCT, 236K9001-5 ROHR INDUSTRIES, INC.
INNER WALL CONSISTS OF:
REPAIR PANEL AND ITEMS
MARKED WITH ASTERISK 236-0082-1 ROHR INDUSTRIES, INC.
OUTER WALL, CONSISTS
OF: REPAIR PANEL AND
ITEMS MARKED WITH 236-0082-2 ROHR INDUSTRIES, INC.
ASTERISK
ADHESIVE SYSTEM, EPOXY EA9390 DEXTER HYSOL AEROSPACE, INC.
BASE CATALYST PART A THE DEXTER CORPORATION
PART B 2850 WILLOW PASS ROAD
P.O. BOX 312, PITTSBURG, CA 94565-3237
*ALUMINUM SHEET 2024-T3, 0.032-IN. COMMERCIALLY AVAILABLE
THICK
BLANKET, HEAT 0ºF-250ºF, ATACS PRODUCTS, INC.
10W/IN.2 1120 S.W. 16TH STREET
RENTON, WA 98055
CONVERSION COATING ALODINE 1200 PARKER + AMCHEM
32100 STEPHENSON HIGHWAY
MADISON HEIGHTS, MI 48071
*FILM, PARTING NONPOROUS COMMERCIALLY AVAILABLE
*MICRO BALLOONS PHENOLIC, 5 – UNION CARBIDE CORP., CHEMICALS AND
135 MICRON PLASTICS DIV., BOUND BROOK PLANT
RIVER ROAD, P.O. BOX 181
*RIVETS CR3253-5-2 CHERRY/TEXTRON INC.
PRODUCTS DIVISION OF TEXTRON, INC.
1224 E. WARNER STREET
P.O. BOX 2157
SANTA ANA, CA 92707
SILICON CARBIDE
KETONE
SPATULA METAL OR COMMERCIALLY AVAILABLE
PLASTIC
SYRINGE, INJECTION PLASTIC NOZZLE COMMERCIALLY AVAILABLE
*TAPE, TEFLON 2-INCH WIDE COMMERCIALLY AVAILABLE

Figure 71.05-17 (2 of 2)
71.05.72 08-01-00 Revision 10

REPAIR NO. 5
ACOUSTIC PANEL DELAMINATION REPAIR
1. Acoustic Panel Delamination Repair (See Figure 17.05-18)
A. Use tap test method and determine area of delamination.
B. Use a size No. 30 drill and drill a series of 0.1285-inch injection holes on one side of the
delaminated area and a series of vent holes on the opposite side. Vacuum any drilling
debris.

PRECAUTIONS.
C. Clean delaminated area using a clean cloth moistened with methyl ethyl ketone. Wipe
surface dry with a clean cloth before solvent evaporates.

PRECAUTIONS.
D. Mix the EA9390 adhesive in accordance with instructions in Paragraph 4.b.(3).
E. Pour adhesive into an injecting syringe. Inject adhesive into injection holes until
delaminated area is completely filled and adhesive exits through vent holes.
Revision 10 08-01-00 71.05.73


Figure 71.05-18 (1 of 2)
71.05.74 08-01-00 Revision 10

F. Clean up excess adhesive. Place nonporous parting film over repair area and tape in
place. Apply pressure with Teflon tape or by mechanical means to maintain contact
between face skin and core throughout the cure cycle.
G. Place a heat blanket over repair area and cure at 190ºF to 210ºF for 220 minutes.
H. Remove heat blanket and parting film. Sand any excess adhesive to a feather-edge using
150-320 grit abrasive paper as required to produce a smooth surface.

PRECAUTIONS.
I. Remove sanding dust from surface with a clean cloth moistened with methyl ethyl

EPOXY BASE CATALYST PART A THE DEXTER CORPORATION
PART B 2850 WILLOW PASS ROAD
P.O. BOX 312
BLANKET, HEAT 0ºF-250ºF, 10W/IN.2 ATACS PRODUCTS, INC.
RENTON, WA 98055
SILICON CARBIDE
SOLVENT METHYL ETHYL KETONE COMMERCIALLY AVAILABLE
SYRINGE, INJECTION PLASTIC NOZZLE COMMERCIALLY AVAILABLE

Figure 71.05-18 (2 of 2)
Revision 10 08-01-00 71.05.75

REPAIR NO. 6
1. Acoustic Panel Complete Penetration Repair (See Figure 17.05-19.)
B. Use a hole saw and cut through panel. Use the smallest diameter possible to remove all
damage.
C. Use cuticle scissors, X-Acto knife or equivalent and cut woven wire 0.875-inch back
from edge of cutout all around. This will provide 0.125-inch clearance from edge of
repair plug face skin.
D. Use hole saw or router jig to concentrically enlarge size of hole through perforated face
skin 0.75-inch all around.
(1) Use piloted hole saw 1.5-inch larger diameter than hole saw used to cut through
panel. Fabricate wood plug which will fit snug in panel and has a pilot hole in its
center to accept hole saw pilot. Insert plug in hole sawn through panel. Add tape to
plug periphery if required to prevent turning during use. Use hole saw and cut
through perforated face skin. Peel skin ring from core and remove plug.
(2) Use router jig and router bit to cut hole through perforated face skin 0.75-inch larger
than hole sawn through panel. Fabricate wood plug which will fit snug in panel and
has a hole for a bolt in its center around which router arm can rotate. Assemble
router arm (set to proper length), wood plug, and bolt. Insert wood plug in hole
sawn through panel. Add tape around plug periphery if required to prevent plug
movement during routing operation. Use router jig and router bit to cut through
perforated face skin. Remove router jig and plug from panel. Peel skin ring from
core.
71.05.76 08-01-00 Revision 10


Figure 71.05-19 (1 of 4)
Revision 10 08-01-00 71.05.77


Figure 71.05-19 (2 of 4)
71.05.78 08-01-00 Revision 10


Figure 71.05-19 (3 of 4)
Revision 10 08-01-00 71.05.79

E. Use a grinding disc and remove core to inner face of back skin.
F. Make a doubler using same material as back skin, one gage thicker. Cut doubler to fit
into cutout and form to mate with inner surface of back skin.
G. Make a repair plug from repair panel section in accordance with instructions in Repair
General, Paragraph 4.b.(4). Machine aluminum honeycomb core to a net height and
diameter to match cutout diameter and depth to doubler face. Cut repair plug woven wire
and perforated face skin to overlap the original perforated skin by 0.75-inch and chamfer
edge to 45 degrees all around. Apply Alodine 1200 to chamfered surface.
H. Place repair plug into cutout. Align the perforations in the repair plug face skin to the
perforations in the original face skin. Use a size No. 16 drill and drill 0.177-inch rivet
holes at 0.75-inch pitch and 0,31-inch edge margin. Temporarily attach plug with Cleco
fasteners or equivalent.
I. Remove repair plug and burr rivet holes. Clean up all drilling debris from repair area and
repair plug.
PRECAUTIONS.
J. Clean repair area, repair plug, and doubler with a clean cloth moistened with methyl ethyl
ketone. Wipe surfaces dry with a clean cloth before solvent evaporates.
PRECAUTIONS.
K. Mix the EA9390 adhesive in accordance with instructions in Repair General, Paragraph
4.b.(3).
71.05.80 08-01-00 Revision 10

L. Use a stiff bristle brush to apply a coat of adhesive to the doubler back face 0.75-inch all
around. Apply a coat of adhesive to inner surface of back skin. Insert doubler through
cutout and mate to back skin inner face.
M. Apply a coat of adhesive to doubler inner face. Thoroughly coat the outer diameter of
repair plug and inner diameter of cutout with adhesive.
NOTE: Use enough adhesive on outer diameter of repair plug and inner diameter of repair
cutout to ensure all cut core cells are completely full of adhesive.
N. Insert repair plug into repair cutout. Rotate repair plug 360 degrees to ensure a good
adhesive bond between repair plug and repair cutout. Align rivet holes and attach repair
plug using CR3253-5-2 rivets. Wet-install rivets with adhesive.
O. Place nonporous parting film over repair area and tape in place.
P. Place a heat blanket over parting film and cure at 190ºF-210ºF for 220 minutes.
Q. Remove heat blanket and parting film. Sand to a feather-edge using 150-320 grit
abrasive paper as required to produce a smooth surface between repair plug and original
face skin.

PRECAUTIONS.
R. Remove sanding dust from surface using a clan cloth moistened with solvent. Wipe
surface dry with a clean cloth before solvent evaporates.
Revision 10 08-01-00 71.05.81

REPAIR KIT, INLET COWL 236K9001-1 ROHR INDUSTRIES, INC.
INNER BARREL CONSIST CHULA VISTA, CA 92012
ITEMS MARKED WITH 236-0080 ROHR INDUSTRIES, INC.
ASTERISK.
INNER WALL CONSISTS
ASTERISK
OUTER WALL CONSISTS
ASTERISK
ADHESIVE SYSTEM, EA9390 DEXTER HYSOL AEROSPACE, INC.
EPOXY BASE CATALYST PART A THE DEXTER CORPORATION
PART B 2850 WILLOW PASS ROAD, P.O. BOX 312
*ALUMINUM SHEET 2024-T3, 0.032-IN. COMMERCIALLY AVAILABLE
THICK
BLANKET, HEAT 0ºF-250ºF, 10W/IN.2 ATACS PRODUCTS, INC.
RENTON, WA 98055
CONVERSION COATING ALODINE 1200 PARKER + AMCHEM
32100 STEPHENSON HIGHWAY
MADISON HEIGHTS, MI 48071
*FILM, PARTING NONPOROUS COMMERCIALLY AVAILABLE
*MICRO BALLOONS PHENOLIC, 5-135 UNION CARBIDE CORP.
MICRON CHEMICALS AND PLASTICS DIV.
BOUND BROOK PLANT
RIVER ROAD, P.O. BOX 312
*RIVETS CR3253-5-2 CHERRY/TEXTRON INC.
PRODUCTS DIVISION OF TEXTRON, INC.
1224 E. WARNER STREET, P.O. BOX 2157
SANTA ANA, CA 92707
PAPER, ABRASIVE 150-320 GRIT SILICON COMMERCIALLY AVAILABLE
CARBIDE
KETONE
*TAPE, TEFLON 2-INCH WIDE COMMERCIALLY AVAILABLE
Figure 71.05-19 (4 of 4)
71.05.82 08-01-00 Revision 10

REPAIR NO. 7
FIRE PROTECTION AND THERMAL COATING REPAIR
1. Fire Protection and Thermal Coating Repair.

A. The following procedures cover the materials and processes used in the application and
repair of fire and thermal protection coatings to new or damaged parts.
B. General Requirements
(1) Ablative insulation and thermal control coating are used in a dual coat application
on new or repair parts. Firewall sealant is used for edge and fillet sealing and to
repair damaged ablative insulation/thermal control coatings. Fire and thermal
protection coating materials are listed in Figure 71.05-21.
(2) Coatings used are silicone-base materials which have a high contamination
potential. Therefore, great care must be exercised to prevent contamination spread
to adjacent materials and areas. Silicone materials used are adversely affected by
butyl and chlorinated rubbers, or materials containing amines, sulfur or tin
compounds.
(3) Equipment used to mix and apply the coatings should not be used for other
materials.
(4) Materials which require the addition of a catalyst prior to application should be
mixed in quantities needed for immediate application and used within their pot life
period.
(5) Materials are normally applied by spray coating but may be brushed on or applied
with a spatula if necessary. Coatings are usually cured at room temperature.
Increased temperatures may be used to reduce cure time but must be closely
controlled.
C. Mixing Ablative Insulation Coating Materials
CAUTION: DO NOT MIX SILICONE MATERIALS, ABLATIVE INSULATION,
FIREWALL SEALANT, AND THERMAL CONTROL COATINGS WHERE
CONTAMINATION OF OTHER ASSEMBLIES OR FACILITIES CAN OCCUR.
TO PREVENT CONTAMINATION, ISOLATE MIXING EQUIPMENT FROM
CONVENTIONAL PAINTS OR SEALANTS.
Revision 10 08-01-00 71.05.83

NOTE: Containers for weighing and mixing catalyst and thinner shall be constructed of an inert
material such as polyethylene or polyethylene coated paper cups. Do not use uncoated
paper cups.
(1) Premix equal parts by weight (pbw) of MA-25S catalyst and MA-25S thinner to
make a mixed catalyst material.
(2) Measure accurately 16.67 parts by weight (pbw) of MA-25S ablative insulation
(base material) to one pbw of mixed catalyst.
(3) Slowly add the premixed catalyst to the base material while stirring by hand.
Continue stirring for at least 5 minutes.
NOTE: Do not add catalyst and thinner separately to the base material as local over-catalyzed
lumpy material will result.
(4) Use mixed coating material within two hours or store in sealed phenolic lined metal
cans. Stored material is usable until viscosity increases so as to make spraying
impossible (approximately six hours at standard shop temperatures of 70ºF – 90ºF).
D. Mixing Firewall Sealant Coating Materials
(1) Mix 100 pbw of Dapco 18-4 sealant with 7.0 pbw of Dapco 18-4 catalyst. (See
Figure 71.05-21.)
(2) Stir thoroughly for at least 3 minutes with a clean wood or metal spatula.
(3) Catalyzed material will remain usable for approximately four hours at normal shop
temperatures. Dispose of all unused catalyzed material after that time.
E. Mixing of Thermal Control Coating Materials
(1) The DC-92-007 thermal control coating may be thinned to a sprayable consistency
with DC-92-007 thinner. This material does not require addition of a catalyst. (See
Figure 71.05-21.)
F. Spray Equipment
CAUTION: SPRAY EQUIPMENT USING DC-1200 PRIMER, ABLATIVE INSULATION

OR THERMAL COATING MUST BE PERMANENTLY MARKED AND
ISOLATED TO PREVENT THEIR USE WITH OTHER MATERIALS.
71.05.84 08-01-00 Revision 10

(1) Spray equipment capable of depositing a nominal coating thickness of 10 to 15 mils

must be used for application of ablative insulation material. Pot and atomization
pressures should be set to deposit a coating of 10 to 15 mils thickness.
(2) DC-1200 and DC-92-007 can be sprayed with conventional equipment.
(3) Spray equipment for DC-1200, MA-25S and DC-92-007 must not contain hoses or
seals of vinyl, n-Buna, or neoprene rubbers.
CAUTION: DO NOT PERMIT VINYL, N-BUNA, OR NEOPRENE RUBBERS TO COME

INTO CONTACT WITH UNCURED SILICONE MATERIALS AT ANY TIME.
(4) Clean mixing and spraying equipment with methyl ethyl ketone, acetone, or
naphtha. (See Figure 17.05-21.)
NOTE: Do not use chlorinated solvents such as trichloroethane or trichlorethylene.
G. Surface Preparation
(1) Clean metal or painted surfaces to obtain a water-break-free condition.
(2) Aluminum-clad
(a) Wipe surface with clean cheesecloth moistened with methyl ethyl ketone
(MEK) to remove oil, grease, fingerprints, lettering, etc.
(b) Swab surface with Scotch Brite A for one to three minutes at room
temperature and GMC 528B (or equivalent) which has been diluted to 25
percent by volume with water.
(c) Thoroughly spray-rinse with cold demineralized (DM) water (90ºF maximum)
for a minimum of three minutes.
(d) Check surface for water-break-free condition. Repeat steps (2) (b) and (2)
(c), if necessary.
(3) Aluminum-bare
(a) Contact Materials and Process Engineer for specific procedures for surface
preparation of bare aluminum alloy.
Revision 10 08-01-00 71.05.85

(4) Aluminum-primed
(a) Wipe surface with clean cheesecloth moistened with MEK to remove oil,
grease, fingerprints, lettering, etc.
(b) Abrade lightly with 240 grit aluminum oxide paper.
(c) Wipe abraded surface with clean cheesecloth saturated with DM water until all
loose soil (abrasive) is removed. Wipe dry with clean cheesecloth.
(d) Check surface for water-break-free condition with DM water. Repeat steps (4)
(b) and (4) (c), if necessary.
NOTE: Removal of primer shall not be cause for rejection of surface condition.
(5) Corrosion-resistant steel and titanium
(a) Wipe surface with clean cheesecloth moistened with MEK to remove oil,
grease, fingerprints, lettering, etc.
(b) Abrade with 180 grit aluminum oxide paper until surface oxides have been
removed.
(c) Hand wipe abraded areas with clean cheesecloth saturated with MEK solvent.
Wipe dry with clean cheesecloth before solvent evaporates.
(d) Check surface for water-break-free condition with DM water. Repeat steps (5)
(a), (5) (b) and (5) (c), if necessary.
(6) Mask adjacent areas of the assembly to prevent oversprayed material from
contaminating other areas of the assembly.
NOTE: Use only mylar or polyethylene type masking tapes within one inch of the final sprayed
surface. Neutral kraft paper and paper-type masking tapes may be used to prevent
oversprayed material from contaminating other areas of the assembly or handling
fixture.
(7) Apply a coat of DC-1200 primer on all surfaces except silicone or surfaces coated
with silicone coatings such as ablative insulation, firewall sealant, and thermal
control coating.
71.05.86 08-01-00 Revision 10

H. Coating Application and Cure
WARNING: SPRAY OPERATORS REQUIRE COMPLETE PROTECTIVE

CLOTHING (HEAT TO FOOT) AND SHOULD WEAR A RESPIRATOR
TO PREVENT INHALATION OF TOXIC FUMES.
CAUTION: VISITORS TO THE SPRAY AREA SHOULD WEAR DISPOSABLE SHOE

COVERS TO PRECLUDE TRACKING OF SILICONE MATERIALS INTO
OTHER SHOP AREAS.
CAUTION: HANDLE CLEANED, PRIMED, AND SPRAYED SURFACES ONLY WITH

CLEAN, WHITE COTTON GLOVES UNTIL FINAL CURE OF THE
OVERCOAT MATERIAL.
(1) DC-1200 Primer (See Figure 71.05-20.)
(a) Apply a coat of DC-1200 primer by spraying surfaces (except silicone) to

which MA-25S ablative insulation is to be applied. Best adhesion is obtained
with a very thin film of DC-1200. Allow primer to dry 30 to 90 minutes at
shop temperature at a relative humidity of 50 percent or 120 minutes at a
relative humidity below 50 percent. Protect if necessary to prevent
contamination with atmospheric dusts. (See Figure 71.05-20.)
Revision 10 08-01-00 71.05.87

Protective Coating Application

Figure 71.05-20
71.05.88 08-01-00 Revision 10

NOTE: Do not allow primer to puddle on horizontal surfaces or in confined areas. Excessive
primer application is evident if the coating blushes to a “milky” appearance within five
minutes after application. Wipe with a clean, dry cloth to remove “milky” appearance.
Application of additional primer is not required.
(2) Dapcoat 1-100 Primer. (See Figure 71.05-20.)
(a) Apply a coat of Dapcoat 1-100 primer 0.5 mil to 2 mils thick, by brush or with
cheesecloth, on all surfaces to which firewall sealant is to be applied. Allow
primer to cure for a minimum of 60 minutes, but not to exceed 24 hours. A
pink hue indicates primer is curing.
(3) Ablative Insulation. (See Figures 71.05-20 and 71.05-21.)
(a) Apply a coat of DC-1200 primer.
(b) Spray apply the mixed MA-25S coating to a nominal application thickness of
10 to 15 mils per coat. Allow a minimum of three minutes flash time between
coat applications. Film thickness can be measured wet as no appreciable
shrinkage occurs.
CAUTION: THIS MATERIAL WILL NOT CURE FELLOW 74ºF OR 150ºF.
(c) Cure for a minimum of 24 hours at 74ºF-90ºF or for a minimum of 12 hours at

90ºF-150ºF.
(d) Check hardness of coating. The coating shall be considered cured when it has
reached a Shore A Durometer hardness of 40 points or more and the odor of
solvent is minimal.
NOTE: See ASTM D2240, Indentation Hardness of Rubber and Plastics by use of
a Durometer.
(e) Perform adhesion test on test panel that has been processed and coated in
conjunction with the surface receiving the fire protection coating. The
minimum test value shall be 35 psi. (See Figure 71.05-21)
Revision 10 08-01-00 71.05.89

Ablative Insulation (Constant Section Fan Air Duct)

Figure 71.05-21 (1 of 5)
71.05.90 08-01-00 Revision 10

Ablative Insulation (Transition Fan Air Ducts 1 of 3)

Figure 71.05-21 (2 of 5)
Revision 10 08-01-00 71.05.91


Figure 71.05-21 (3 of 5)
71.05.92 08-01-00 Revision 10


Figure 71.05-21 (4 of 5)
Revision 10 08-01-00 71.05.93

(f) Cool assembly to room temperature and apply a top coat of Thermal Control
Coating (DC-92-007).
(4) Firewall Sealant. (See Figure 71.05-20.) Dapcoat 18-4 firewall sealant may be
applied to faying surfaces of hardware during installation, after hardware
installation to seal between existing fireshield material and the installed hardware,
and as a repair material when the fire protection coatings have been damaged.
(a) During Hardware Installation

1) Apply Dapcoat 1-100 primer to the faying surfaces of the assembly and
the hardware. Overlap the primer by approximately ¼ inch around the
area to be sealed. Allow primer to dry for 30 minutes.
2) Apply a coat of Dapcoat 18-4 firewall sealant which has been mixed in
accordance with preceding instructions. Coat should be sufficient to
cause a generous squeeze-out during assembly. Coating may be applied
by brush or spatula.
3) Wet install fasteners which pass through a bonded panel with Dapcoat 18-
4 sealant and complete the assembly procedure.
4) Touch up sealant squeeze-out as necessary to ensure continuity of the
fireshield across the face of the bonded panel. Use a 50 percent solution
of isopropyl alcohol in water to smooth the sealant where it is accessible.
5) Cure sealant for 48 hours at room temperature. It becomes a rubbery
solid. Accelerate cure at temperatures up to 250ºF.
(b) After Hardware Installation. (See Figure 71.05-20.)
1) Apply Dapcoat 1-100 primer locally to the area between existing
fireshield material and the installed hardware. Overlap the primer by
approximately ¼ inch at both sides of the area to be sealed.
2) Apply Dapcoat 18-4 firewall sealant which has been mixed with catalyst
in accordance with preceding instructions. Coating may be applied by
brush or spatula.
3) Touch up sealant as necessary to ensure continuity of the fireshield across

the face of the bonded panel. Use a 50 percent solution of isopropyl
alcohol in water to smooth the sealant.
71.05.94 08-01-00 Revision 10

4) Cure sealant for 48 hours at room temperature. It becomes a rubbery

solid. Accelerate cure at temperatures up to 250ºF.
(5) Repair Damaged Fire Protection Coatings. (See Figure 71.05-20.)
(a) Locally remove all loose pieces of existing fire protection material. Leave
edges square and not faired.
(b) Remove loose particles with a soft bristle brush, or a low pressure blast of
clean air.
CAUTION: DO NOT USE A SOLVENT
(c) Clean the affected area with clean wipers.
(d) Apply Dapcoat 18-4 firewall sealant to damaged area using a spatula or knife
blade. Apply to a thickness to match adjacent area and fair into surrounding
area.
(e) Cure at room temperature for 48 hours. Cure can be accelerated at

temperatures up to 250ºF. Material cures to a rubbery solid. It is touch dry in
12 hours.
(6) Thermal Control Coating.
NOTE: Dow Corning, DC-92-007, thermal control coating is used as a topcoating for ablative
insulation (MA-25S).
(a) Check surface of MA-25S ablative insulation to determine that it is clean and
undamaged.
NOTE: Do not use solvent cleaners on ablative insulation prior to application of thermal control
coating.
NOTE: DC-1200 primer is not required on ablative insulation prior to application of thermal
control coating.
(b) Spray apply a smooth coat of DC-92-007 thermal control coating directly on
top of the ablative insulation coating. Apply to a nominal dry film thickness
of 4.5 to 6 mils. Use a test panel as a control panel. (See Figure 71.05-21.)
Revision 10 08-01-00 71.05.95

NOTE: DC-92-007 does not require addition of a catalyst. Thin to sprayable consistency with
naphtha.
(c) Cure for 24 hours at room temperature. Assemblies may be handled as soon
as the coating is tack-free (2-4 hours).
(d) Repair cuts or tears in thermal control coating with firewall sealant which has
been properly mixed with catalyst. See preceding instructions for mixing and
repair application.
NOTE: DC-92-007 thermal coating cures upon exposure to moisture. Keep containers closed
when not in use.
71.05.96 08-01-00 Revision 10


Alcohol Isopropyl Commercially Available
Brush 1.0-In. Soft Bristle Commercially Available
Brush 2.0-In. Stiff Bristle Commercially Available
Cleaner GMC528B Greater Mountain Chem. Co.
Div. of Thatcher Chem. Co.
1900 Fortune Rd., Salt Lake City, UT 84104
Coating, Thermal DC-92-007 Dow Corning
Control 3901 S. Saginaw Rd.
Midland, MI 48640
Cup Polyethylene Commercially Available
Gloves Cotton, White Commercially Available
Insulation, Ablative MA-25S Martin Marietta Manned Space Systems
13800 Old Gentilly Road
New Orleans, LA 70129
Pad, Abrasive Scotchbrite A Minnesota Mining & Mfg. Co.
Pint Trades Div., 3M Center
St. Paul, MN 55101
Panel, Test 2024-T3 Alum. Alloy Commercially Available
0.040 X 1 x 6-In.
Paper Kraft, Neutral Commercially Available
Paper, Abrasive Aluminum Oxide Commercially Available
180, 240-grit
Primer, Sealant Dapcoat 1-100 D Aircraft Products Co.
1191 Hawk Circle
Anaheim, CA 92708
Primer, Silicone DC-1200 Dow Corning
3901 S. Saginaw Rd.
Midland, MI 48640
Sealant, Firewall Dapcoat 18-4 D Aircraft Products Co.
1191 Hawk Circle
Anaheim, CA 92708
Spatula Wood or Metal Commercially Available
Solvent Methyl Ethyl Ketone Commercially Available
Solvent Naphtha Commercially Available
Tape, Masking Mylar or Polyethylene Commercially Available
Water Demineralized Commercially Available
Wiper, Cloth Cheesecloth Commercially Available
ABLATIVE INSULATION
Figure 71.05-21 (5 of 5)
Revision 10 08-01-00 71.05.97

REPAIR NO. 8
LARGE AREA DYNAROHRTM WOVEN WIRE REPLACEMENT
1. General
A. This repair may be done to the nose cowl, nose dome extension, constant fan duct
assembly, and the transition fan duct assembly.
B. This repair must be done by persons who have been trained to do repairs of this type.
C. Many of the materials used in this repair are proprietary and must be purchased in repair
kits from Rohr Industries, Inc.
D. Refer to Figure 71.05-22 and to the list of Repair Materials and Equipment to determine
which repair kit to use for each repair.
2. Prepare the Damaged Area for Repair (See Figure 71.05-22)
A. Make a mark on the woven wire around the edge of the damaged area.
B. Stabilize the woven wire in accordance with instructions in Repair General, Paragraph
4.b.(4).
C. Cut the woven wire along the mark with a razor knife. Do not cut the perforated skin that
is under the woven wire.
D. Remove the woven wire from the perforated skin in 1.0-2.0 in. (25.4-50.8 mm) wide
strips. Remove all loose woven wire particles.
71.05.98 08-01-00 Revision 10

WOVEN WIRE REPLACEMENT

Figure 71.05-22 (1 of 9)
Revision 10 08-01-00 71.05.99


Figure 71.05-22 (2 of 9)
71.05.100 08-01-00 Revision 10


Figure 71.05-22 (3 of 9)
Revision 10 08-01-00 71.05.101

HEALTH PRECAUTIONS.
CAUTION: REMOVE ALL OIL, WATER, AND DIRT FROM THE REPAIR AREA. IF YOU
DO NOT DO THIS, THE REPLACEMENT WOVEN WIRE WILL NOT BOND
TO THE PERFORATED SKIN.
E. Clean the repair area of the assembly with Methyl Ethyl Ketone (MEK). Flush the area
with MEK until all oil, water, and dirt is removed. Force air dry the assembly for 30
minutes at 150ºF-170ºF (65ºC-76ºC).
F. Vacuum bag the assembly. (See Figure 71.05-22.)
(1) Put a minimum of four thermocouples around the edge of the repair area. Hold
them in position with teflon tape.
(2) Put one layer of 181 fiberglass cloth over the repair area, one layer of RC3000
breather cloth over the fiberglass cloth, and one layer of nonporous parting film over
the breather cloth. Hold them in position with teflon tape.
(3) Put a heat blanket over the nonporous parting film. The heat blanket must be 1.3
times larger than the repair area. Hold it in position with teflon tape.
NOTE: It may be necessary to use additional heat sources to make sure of proper temperatures
in areas where the metal structure absorbs more heat.
(4) Put a strip of masking tape on the woven wire around the edge of the heat blanket.
Put the masking tape a minimum of 6 in. (152.4 mm) from the heat blanket. Put
tacky tape on the masking tape. The tacky tape will be used to seal the edges of the
vacuum bag in step (10).
(5) Put one layer of nonporous parting film over the heat blanket. Hold it in position
with teflon tape.
(6) Put one thermocouple on top of the nonporous parting film at the center of the heat
blanket. Hold it in position with teflon tape.
71.05.102 08-01-00 Revision 10


VACUUM BAG FOR REPAIR AREA OIL CONTAMINATION INSPECTION
Figure 71.05-22 (4 of 9)
Revision 10 08-01-00 71.05.103

(7) Put five layers of fiberglass cloth over the nonporous parting film and one layer of
RC3000 breather cloth over the fiberglass cloth. Hold them in position with teflon
tape.
(8) Put a vacuum bag over the RC3000 breather cloth.
(9) Attach two vacuum connectors to the vacuum bag.
(10) Seal the edges of the vacuum bag to the masking tape with tacky tape.
(11) Do a leak test of the vacuum bag.
(a) Create a vacuum of 25in. Hg in the vacuum bag.
(b) Check the leak rate of the vacuum bag. The maximum allowable leak rate is
5in. Hg in 5 minutes.
(12) Connect the thermocouple on top of the heat blanket to the temperature controller.
Connect the remaining thermocouples to the temperature recorder.
G. Examine the assembly for oil contamination.
(1) Position the assembly so that any oil in the repair area will flow to the fiberglass
cloth that is nearest to the perforated skin.
CAUTION: INCREASE THE TEMPERATURE OF THE HEAT BLANKET AT A

MAXIMUM RATE OF 10ºF (5.6ºC) PER MINUTE. IF YOU DO NOT DO THIS
THE WOVEN WIRE CAN DELAMINATE FROM THE PERFORATED SKIN.
(2) Increase the temperature of the heat blanket to 230ºF-270ºF (110ºC-132ºC) at a rate
of 10ºF (5.6ºC) per minute under 25in. Hg minimum vacuum. Keep the heat
blanket at this temperature for 120 minutes. Then increase the temperature to
340ºF-360ºF (171.4ºC-182.6ºC) at a rate of 10ºF (5.6ºC) per minute under 25in. Hg
minimum vacuum. Keep the heat blanket at this temperature for 120 minutes.
CAUTION: DECREASE THE TEMPERATURE OF THE HEAT BLANKET AT A

(3) Decrease the temperature of the heat blanket to 150ºF (66ºC) or less at a rate of 10ºF
(5.6ºC) per minute under 25in. Hg minimum vacuum.
(4) Remove the vacuum bag materials from the repair area.
71.05.104 08-01-00 Revision 10

CAUTION: YOU MUST MAKE SURE THAT ALL OIL HAS BEEN REMOVED FROM
THE REPAIR AREA. THE REPLACEMENT WOVEN WIRE WILL NOT
BOND TO THE PERFORATED SKIN IF ANY OIL REMAINS IN THE REPAIR
AREA.
(5) Examine the fiberglass cloth that was nearest to the perforated skin for oil. If you
find oil on the fiberglass cloth, do steps E., F., and G. again.
H. Protect the area around the repair area with 2-inch wide masking tape and barrier paper.
WARNING: SANDING OF ADHESIVES AND STAINLESS STEEL PRODUCES DUST
AND FLYING PARTICLES WHICH ARE POTENTIAL HEALTH
HAZARDS. WEAR PROTECTIVE CLOTHING, GLOVES, DUST
MASKS, AND SAFETY GLASSES. AVOID BREATHING OF DUST OR
PROLONGED CONTACT OF DUST ON THE SKIN.
I. Remove adhesive, interply, and small areas of corrosion from the perforated skin with
320-400 grit aluminum oxide abrasive paper. Use a wire brush to remove interply and
adhesive from the holes in the perforated skin. Do not remove the primer from the
perforated skin unless necessary. Use a vacuum to remove loose particles from the
assembly.
HEALTH PRECAUTIONS.
J. Clean the repair area surface with MEK. Let the surface air dry for 30 minutes minimum.
K. Apply RMS058, Type 5 primer to areas of bare metal on the perforated skin.
(1) For small areas of bare metal, apply the primer with a brush then let the primer air
dry for 30 minutes.
(2) For large areas of bare metal, apply the primer to a thickness of 0.0005-0.0009 in.
(0.013-0.023 mm) with a spray gun. Cure the primer for 60 minutes minimum at
340ºF-360ºF (171ºC-182ºC) with an explosion proof heat lamp.
Revision 10 08-01-00 71.05.105

3. Repair Instructions
NOTE: Do the repair procedure to a test panel and the assembly at the same time with the same
adhesives, materials and processes. A destructive test of the test panel will make sure
the assembly repair is correct.
WARNING: RMS070 ADHESIVE IS CLASSIFIED AS A HAZARDOUS MATERIAL

WHICH MAY CAUSE INJURY OR ILLNESS IF NOT PROPERLY USED.
THIS PRODUCT SHOULD BE USED ONLY IN ACCORDANCE WITH
THE MANUFACTURER’S SPECIFIC SAFETY AND HEALTH
RECOMMENDATIONS. PRIOR TO USE OF THIS PRODUCT,
CAREFULLY READ THE “MATERIAL SAFETY AND DATA SHEET”
AND FOLLOW ALL LISTED SAFETY AND HEALTH PRECAUTIONS.

HEALTH PRECAUTIONS.
CAUTION: YOU MUST WEAR CLEAN COTTON GLOVES WHEN YOU TOUCH THE
TEST PANEL, REPAIR AREA, OR REPAIR MATERIALS. IF YOU DO NOT
DO THIS YOU WILL CONTAMINATE THE MATERIALS AND THE
REPLACEMENT WOVEN WIRE WILL NOT BOND TO THE PERFORATED
SKIN.
A. Dilute the RMS070 adhesive 100 percent by volume with MEK and mix for 5 minutes.
B. Apply the adhesive to the test panel and the repair area.
(1) Weigh the test panel and write a record of the weight.
(2) Apply one layer of adhesive to the test panel and the repair area with a spray gun.
Apply the adhesive in vertical and horizontal directions to make sure there is full
and equal coverage.
NOTE: You can put the test panel on the assembly adjacent to the repair area to make sure the
adhesive is applied equally to the test panel and the repair area.
71.05.106 08-01-00 Revision 10

(3) Let the adhesive air dry for 5 minutes at room temperature.
(4) Weigh the test panel. Subtract the weight written in step (1) from the weight
measured in this step to determine the wet adhesive weight of the test panel. If the
test panel wet adhesive weight is 4.8-5.1 grams/ft2, go to step 5. If the wet adhesive
weight is less than 4.8 grams/ft2, do steps (2), (3), and (4) again until the wet
adhesive weight is 4.8-5.1 grams/ft2.
(5) Dry the test panel for 15 minutes at 140ºF (60ºC).
(6) Weigh the test panel. Subtract the weight written in step (1) from the weight
measured in this step to determine the dry adhesive weight of the test panel. If the
test panel dry adhesive weight is 4.2-4.5 grams/ft2, go to step C. If the dry adhesive
weight is less than 4.2 grams/ft2, do steps (2), (3), (4), (5), and (6) again until the dry
adhesive weight is 4.2-4.5 grams/ft2.
CAUTION: DO NOT LET THE BARRIER PAPER TOUCH THE ADHESIVE ON THE
REPAIR SURFACE OR THE TEST PANEL. IT WILL BOND TO THE
ADHESIVE. USE THE BARRIER PAPER AS A TENT TO PROTECT THE
ADHESIVE FROM DUST OR OTHER CONTAMINATION.
C. Cover the test panel and the repair area of the assembly with barrier paper and let the
adhesive air dry for 2 hours minimum at room temperature.
D. Remove the barrier paper and masking tape.
E. Apply RMS042 Type 2, Grade B adhesive film to the perforated skin around the edge of
the repair area.
(1) Make the perforated skin moist with MEK around the edge of the repair area.
(2) Apply one strip of 0.25 in. (6.4mm) wide RMS042 Type 2, Grade B adhesive film
to the MEK-moistened perforated skin around the edge of the repair area.
CAUTION: DO NOT WRINKLE THE REPLACEMENT WOVEN WIRE. IF YOU

WRINKLE THE REPLACEMENT WOVEN WIRE, IT WILL NOT BOND
CORRECTLY TO THE PERFORATED SKIN.
F. Cut the replacement woven wire so that it overlaps the edge of the repair area 0.75 in.
(19.0 mm) on all sides.
Revision 10 08-01-00 71.05.107


HEALTH PRECAUTIONS.
G. Flush the woven wire with MEK. Let the woven wire air dry for 30 minutes. Then dry
the woven wire for 30 minutes minimum at 160ºF (71ºC).
H. Use a heat gun to apply the woven wire to the test panel and to the assembly. The woven
wire may be cut and spliced to meet contour or size restrictions and to reduce wrinkles.
Small wrinkles are permitted if there are no voids or delaminations between the woven
wire and the perforated skin. The total area of the splices must not exceed 2 percent of
the net acoustic area of the assembly.
I. Make a mark on the replacement woven wire around the edge of the repair area where the
replacement woven wire meets the existing woven wire.
J. Cut the replacement woven wire along the mark with a razor knife. Do not cut the
perforated skin under the woven wire. Remove the loose wire particles.
4. Cure the Repair and Test Panel
NOTE: You can put the test panel on the assembly adjacent to the repair area and vacuum bag it
with the repair area. Or you can vacuum bag the test panel separately on a metal sheet.
A. Vacuum bag the assembly and the test panel (See Figure 71.05-22)
71.05.108 08-01-00 Revision 10


VACUUM BAG FOR CURE OF THE REPAIR AND TEST PANEL
Figure 71.05-22 (5 of 9)
Revision 10 08-01-00 71.05.109

(1) Put a minimum of four thermocouples around the edge of the repair area. Hold
them in position with teflon tape.
(2) Put a layer of porous parting film over the repair area. Hold it in position with
teflon tape.
(3) Put a heat blanket over the porous parting film. The heat blanket must be 1.3 times
larger than the repair area. Hold it in position with teflon tape.
NOTE: It may be necessary to use additional heat sources to make sure of proper cure
temperatures in areas where the metal structure absorbs more heat.
(4) Put a strip of masking tape on the woven wire around the edge of the heat blanket.
Put the masking tape a minimum of 6 in. (152.4 mm) from the heat blanket. Put
tacky tape on the masking tape. The tacky tape will be used to seal the edges of the
vacuum bag in step (10).
(5) Put a layer of nonporous parting film over the heat blanket. Hold it in position with
teflon tape.
(6) Put one thermocouple on top of the nonporous parting film at the center of the heat
blanket. Hold it in position with teflon tape.
(7) Put five layers of fiberglass cloth over the nonporous parting film and one layer of
RC3000 breather cloth over the fiberglass cloth. Hold them in position with teflon
tape.
(8) Put a vacuum bag over the RC3000 breather cloth.
(9) Attach two vacuum connectors to the vacuum bag.
(10) Seal the edges of the vacuum bag to the masking tape with tacky tape.
(11) Do a leak test of the vacuum bag.
(a) Create a vacuum of 25in. Hg in the vacuum bag.
(b) Check the leak rate of the vacuum bag. The maximum allowable leak rate is
5in. Hg in 5 minutes.
(12) Connect the thermocouple on top of the heat blanket to the temperature controller.
Connect the remaining thermocouples to the temperature recorder.
71.05.110 08-01-00 Revision 10

B. Cure the repair test panel.
CAUTION: INCREASE THE TEMPERATURE OF THE HEAT BLANKET AT A

(1) Increase the temperature of the heat blanket to 340ºF-360ºF (171ºC-

182ºC) at a rate of 10ºF (5.6ºC) per minute under 25in. Hg minimum vacuum. Keep
the heat blanket at this temperature for a minimum of 120 minutes.
CAUTION: DECREASE THE TEMPERATURE OF THE HEAT BLANKET AT A

(2) Decrease the temperature of the heat blanket to 150ºF (66ºC) or less at a rate of 10ºF
(5.6ºC) per minute under 25in. Hg minimum vacuum.
CAUTION: REMOVE THE VACUUM BAG MATERIALS WITH CARE. IF YOU DO NOT
DO THIS, YOU MAY CAUSE THE REPLACEMENT WOVEN WIRE TO
DELAMINATE FROM THE PERFORATED SKIN.
(3) Remove the vacuum bag materials from the test panel and the assembly with care.
5. Examine the Test Panel
A. Peel the woven wire from the test panel. Use a Floating roller Test Arrangement in
accordance with ASTM D 3167-76 (Reapproved 1986). Test speed must be 3in./min.
(76mm/min.). The minimum acceptable peel strength is 6 lbs/in. width. A minimum of
three samples is required.
6. Finalize the Repair
A. Apply the RMS078 liquid stabilizer to the woven wire splice joints.
(1) Put masking tape on the woven wire 0.25 in. (6.35 mm) from each side of the
woven wire splice joints.
(2) Apply the RMS078 liquid stabilizer to a thickness of 0.005-0.010 in. (0.13-0.25
mm) in the 0.50 in. (12.7mm) wide area between the pieces of masking tape.
Revision 10 08-01-00 71.05.111

(3) Let the RMS078 liquid stabilizer air dry for 30 minutes.
(4) Remove the masking tape.
B. Cure the RMS078 adhesive for 60 minutes at 190ºF-210ºF (87ºC-98ºC) with an explosion
proof heat lamp.
C. Apply the Proseal 899B-2 aerodynamic sealant to the woven wire splice joints.
(1) Put masking tape on the woven wire and the liquid stabilizer 0.050 in. (1.30 mm)
from each side of the woven wire splice joints.
(2) Apply the Proseal 899B-2 aerodynamic sealant to the 0.10 in. (2.54 mm) wide area
between the pieces of masking tape.
(3) Let the aerodynamic sealant air dry for 120 minutes.
(4) Remove the masking tape.
D. Cure the Proseal 899B-2 aerodynamic sealant for 8 hours at 140ºF (60ºC) with an
explosion proof heat lamp.
71.05.112 08-01-00 Revision 10

DESCRIPTION DESIGNATION MANUFACTURER

Balance, Analytical Commercially Available
Barrier Paper Kraft Paper Commercially Available
Blanket, Heat 0ºF-360ºF Atacs Products, Inc., 1120 Southwest 16th Street
Renton, WA 98055
Brush, Wire Commercially Available
Cloth, Breather RC3000-10 Richmond Technology, Inc.
Colton & Opal Street, P.O. Box 1129
Redlands, CA 92373
Clothing, Protective Commercially Available
Connector, Vacuum Atacs Products, Inc.
Container Metal or Plastic Commercially Available
Container, Cover Metal or Plastic Commercially Available
Controller, Temperature Commercially Available
Fabric, Fiberglass Style 181 Commercially Available
Film, Nylon Bag 400ºF, 2 mil Commercially Available
Film, Parting Nonporous Richmond Technology, Inc.
Porous
Gauge, Vacuum 0-30 In.-of-Mercury Commercially Available
Glasses, Safety Commercially Available
Gloves Cotton, white and Commercially Available
Neoprene or Polyvinyl
Chloride
Gun, Heat Explosion Proof Atacs Products, Inc.
0-170ºF
Gun, Spray Paint Commercially Available
Hose, Vacuum Commercially Available

REPAIR MATERIALS AND EQUIPMENT
Figure 71.05-22 (6 of 9)
Revision 10 08-01-00 71.05.113


TM
Kit, DynaRohr 236K9001-11 Rohr Industries, Inc
Repair Bulk Material P.O. Box 878
Shelf Life Chula Vista, CA 92012-0878
(To be used with the
following DynaRohrTM Repair
Kit) consisting of:
*Adhesive, Temperature
Curing Nitrile/Phenolic RMS042, Type 2
Structural Grade B
4 Square Ft 6 Months Shelf Life at
(0.3716 Square Meters) 40ºF (4.4ºC)
*Adhesive, Structural, 350ºF
Service Temperature, RMS058, Type 5
Environmentally Resistant 2 6 Months Shelf Life at
Gallons (7.57 Liters) 0ºF (-17.8ºC)
*Adhesive, DynaRohrTM
Liquid
2 Gallons
(7.57 Liters) RMS070
6 Months Shelf Life at
40ºF (4.4ºC)
*Stabilizer, Liquid RMS078
1 Quart 6 Months Shelf Life at
(0.946 Liter) 40º F (4.4ºC)

Figure 71.05-22 (7 of 9)
71.05.114 08-01-00 Revision 10


TM
Kit, DynaRohr Repair (To 236K9001-9 Rohr Industries, Inc
be used with Nose Cowl, P.O. Box 878
Nose Dome Extension, Chula Vista, CA 92012-0878
Transition Fan Duct
assembly, and Constant Fan
Duct Assembly) consisting
of:
*Test Panel, Perforated 12 X
12 in. TP140
(304.8 X 304.8 mm)
*Test Panel, Woven Wire 12
X 12 in. RMS059, Class 5
(304.8 X 304.8 mm)
(304.8 X 304.8 mm)
(304.8 X 304.8 mm)
*Woven Wire
48 in. X 8 Ft. RMS059, Class 10
(1219.2 X 2438.4 mm)
*Woven Wire
(1219.2 X 2438.4 mm)
*Woven Wire
(1219.2 X 2438.4 mm)
*Woven Wire
(1219.2 X 2438.4 mm)
*Woven Wire
(1219.2 X 2438.4 mm)

Figure 71.05-22 (8 of 9)
Revision 10 08-01-00 71.05.115


Knife, Razor Commercially Available
Lamp, Heat Commercially Available
Mask, Dust Regulatory Agency Commercially Available
Approved
Paper, Abrasive 320-, 400-Grit Commercially Available
Aluminum Oxide
Paper, Kraft Commercially Available
Pump, Vacuum 0-30 In.-of-Mercury Commercially Available
Recorder, Temperature Commercially Available
Respirator Regulatory Agency Commercially Available
Approved
Sealant, Aerodynamic Proseal 899B-2 Products Research and Chemical Corp.
5430 San Fernando Road
Glendale, CA 91203
Sealant, Bag Tacky Tape Schnee-Morehead Chemicals, Inc.
111 North Nursery Road
P.O. Box 1305
Irving, TX 75060
Solvent Methyl Ethyl Ketone Commercially Available
(MEK)
Spatula Metal or Plastic Commercially Available
Tape, Masking 2-Inch Wide Commercially Available
Tape, Teflon 2-Inch Wide Commercially Available
Thermocouples Atacs Products, Inc.
*Materials are proprietary and are not to be substituted.

Figure 71.05-22 (9 of 9)
71.05.116 08-01-00 Revision 10

71.06 – DC-8 SEVENTY SERIES – NACELLE INLET COWL

TABLE OF CONTENTS
Paragraph Page
1. NACELLE INLET COWL LIP DENT DAMAGE LIMITS-------------------- 71.06.01
2. REPAIR INFORMATION ---------------------------------------------------------- 71.06.01
FIGURES
71.06-1 DC-8-70 NACELLE INLET COWL LIP DENT LIMITS ---------------------- 71.06.02
Revision 14 12-03-01 71.06-i

INTENTIONAL
BLANK
71.06-ii 12-03-01 Revision 14

71.06 DC-8 SEVENTY SERIES - NACELLE INLET COWL
1. Nacelle Inlet Cowl Lip Dent Damage Limits – Dent limits for the inlet cowl lip are contained
in Figure 71.06-1.
a. The limits shown in Figure 71.06-1 result in negligible effects on essential aerodynamic
characteristics. Damage exceeding these limits cannot be generalized since any effect on
essential inlet characteristics is dependent upon the nature and extent of the damage.
Any denting in excess of that shown must be evaluated and evaluated on an individual
basis as to the adverse effects on inlet aerodynamic characteristics.
b. Evaluation of damage exceeding the limits in Figure 71.06-1 concerning adverse affects
to the inlet cowl lip should include the following considerations:
(1) All damage will be shallow, smooth, free from cracks or abrasions, and without
adjacent sheared rivets or elongated holes.
(2) Nose cowl anti-ice system will be taken into consideration to prevent hot spot areas
and metal fatigue caused by this condition.
(3) Comply with "Yellow Dot Damage" procedure of the General Maintenance
Manual.
2. Repair Information. Inlet cowl repairs and related data are contained in DACO Seventy
Series Structure Repair Manual Microfilm Supplement 71-5-2 and it's temporary revisions.
Revision 10 08-01-00 71.06.01

71.06 DC-8 SEVENTY SERIES - NACELLE INLET COWL (cont”d)
REGION “A” is defined as the area inside the leading edge from the beginning of the perforated
skin and a portion of the outside area up to .44 inch from the leading edge (anti-ice area).
REGION “B” is all other skin surfaces outside Region “A”.
NACELLE INLET COWL LIP DENT LIMITS

Figure 71.06-1
71.06.02 06-01-01 Revision 12

Complete DC-8 MM R36 Vol 3

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AIR TRANSPORT INTERNATIONAL

DC-8 MAINTENANCE MANUAL

36.01 – PNEUMATIC SYSTEM DECAY CHECK

RECURRING NON-ROUTINE JOB CARDS

Job Card Page

Revision 34 04-28-10 36.01-i

36.01-ii 04-28-10 Revision 34

a. Non-routine Job Card DC8-36.01-1 “DC-8 Pneumatic System Decay Check” is

d. Accomplish Non-routine Job Card DC8-36.01-1 every 200 days.

Revision 34 04-28-10 36.01.1

ATI RECURRING NON-ROUTINE ATI-001

2. All operable low-pressure pneumatic shutoff switches “LOW

3. Pneumatic crossfeed switch “PNEU X-FEED”............ CLOSE

4. All cabin compressor switches “CABIN COMPRESSORS” (on

5. Freon compressor switch “FREON COMPRESSORS” (on side

6. AC pack off switches “L PACK” and “R PACK” [Applicable to

7. Rain removal lever “RAIN REMOVAL”(on side being

8. All engine anti-icing switches “ENGINES 1 2 3 4 ANTI-

9. Scoops anti-icing switch “SCOOPS ANTI-ICE”.............. OFF

10. Airfoil de-icing switch “AIRFOIL DE-ICE” .................... OFF

36.01.2 04-06-11 Revision 36

ATI RECURRING NON-ROUTINE ATI-001

13. All operable low-pressure pneumatic shutoff switches “LOW

16. Momentarily crack the RAIN REMOVAL lever on the side

Revision 36 04-06-11 36.01.3

ATI RECURRING NON-ROUTINE ATI-001

19. Circuit Breaker “ANIMAL COMPT HEAT SHUTOFF

36.01.4 04-06-11 Revision 36

DC-8-61, -71, -63, & -73 SERIES DECAY GRAPH

Revision 36 04-06-11 36.01.5

DC-8-30, -40, -50, -62, & -72 SERIES DECAY GRAPH

36.01.6 04-06-11 Revision 36

Revision 23 12-07-05 52-i

52-ii 12-07-05 Revision 23

52.01 – LEFT HAND FORWARD ENTRY DOOR HINGE COVERS

52.01-1 LH FWD ENTRY DOOR JAMB HINGE COVERS ---------------------------- 52.01.2

Revision 14 12-03-01 52.01-i

52.01-ii 12-03-01 Revision 14

a. Remove any remaining portions of hinge cover.

Revision 6 07-01-98 52.01.1

LH FWD. ENTRY DOOR JAMB HINGE COVERS

52.01.2 07-01-98 Revision 6

LH FWD. ENTRY DOOR HINGE COVERS

Revision 6 07-01-98 52.01.3

52.01.4 07-01-98 Revision 6

1. This section is reserved for future use.

Revision 23 12-07-05 52.02.1

52.02.2 12-07-05 Revision 23

52.03 – LOWER CARGO COMPARTMENT DOORS DEACTIVATION

52.03-1 DEACTIVATION STRAP ---------------------------------------------------------- 52.03.2

Revision 14 12-03-01 52.03-i

52.03-ii 12-03-01 Revision 14

a. If it is determined a lower cargo door should be deactivated, a logbook discrepancy

Revision 6 07-01-98 52.03.1

52.03.2 07-01-98 Revision 6

1. This section is reserved for future use.

Revision 23 12-07-05 52.04.1

52.04.2 12-07-05 Revision 23

52.05 – NATIONAL AIRCRAFT SERVICE VENT DOOR (STC SA1614GL)

52.05-1 “HOOK” STYLE DOOR TENSION ADJUSTMENT ------------------------ 52.05.5

Revision 14 12-03-01 52.05-i

52.05-ii 12-03-01 Revision 14

(1) “Hook” Style Door – 41CX, 799AL