HAWKER 800 STRUCTURAL REPAIR MANUAL

List of Effective Pages

CHAPTER 54 - NACELLES/PYLONS
CH-SE-SU PAGE DATE
54-LOEP 1 Aug.18
54-CONTENTS 1/2 Jun.13
54-00-01 201 thru 208 Sep.12
54-10-11 1 thru 23 Jun.16
101/102 Jun.16
201 thru 204 Apr.00
54-10-21 1 thru 38 Sep.14
101/102 Aug.18
201/202 Apr.00
54-10-31 1 thru 37 Jun.13
101/102 Aug.18
201/202 Jun.07
54-50-11 1 thru 16 Apr.00
101/102 Apr.00
201/202 Apr.00
54-50-21 1 thru 16 Jun.07
54-50-22 1 thru 14 Jun.13

Rev.45 Page 1
54-LOEP Aug.18
 HAWKER 800 STRUCTURAL REPAIR MANUAL

CHAPTER 54
NACELLES/PYLONS
11-Contents-HB0XXX

TABLE OF CONTENTS
00

Subject Ch-Se-Su Page

THRUST REVERSERS
STRUCTURE COMPLETE 54-00-01
Repair Schemes 201

NACELLES BEFORE MOD. 259283C

STRUCTURE COMPLETE 54-10-11
Identification 1
Allowable Damage 101
Repair Schemes 201

NACELLES AND THRUST REVERSER AFTER MOD. 259283C

STRUCTURE COMPLETE 54-10-21
Identification 1
Allowable Damage 101
Repair Schemes 201

NACELLES AND THRUST REVERSER AFTER MOD. 25G311E

STRUCTURE COMPLETE 54-10-31
Identification 1
Allowable Damage 101
Repair Schemes 201

PYLON BEFORE MOD. 259283C

STRUCTURE COMPLETE 54-50-11
Identification 1
Allowable Damage 101
Repair Schemes 201

Page 1
54-CONTENTS Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

Subject Ch-Se-Su Page

PYLON - THRUST REVERSER AFTER MOD. 259283C OR MOD. 25G311E
STRUCTURE COMPLETE 54-50-21
Identification 1
COMMON PYLON - THRUST REVERSER AFTER MOD. 25G389A
STRUCTURE COMPLETE 54-50-22
Identification 1

Page 2
Jun.13 54-CONTENTS
 HAWKER 800 STRUCTURAL REPAIR MANUAL

NACELLES - STRUCTURE COMPLETE

IDENTIFICATION

Contents Figure

Nacelles - Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Upper Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Forward Engine Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lower Door - Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear Engine Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

54-10-11
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HAWKER 800 STRUCTURAL REPAIR MANUAL

Nacelles - Location
Figure 1

54-10-11
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Jun.16
 HAWKER 800 STRUCTURAL REPAIR MANUAL

ITEM NOMENCLATURE REFERENCE

1 Rear Engine Cowl Fig.6
2 Lower Door - Cowl Fig.5
3 Intake Fig.2
4 Forward Engine Mounting Fig.4
5 Upper Panel Fig.3

ASSEMBLY DRAWING NO 25 8ES 201

Key to Figure 1

54-10-11
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 HAWKER 800 STRUCTURAL REPAIR MANUAL

FOR DETAIL A SEE SHEET 2

FOR SECTION B - B SEE SHEET 3

14
FOR DETAILS K, L AND P SEE SHEET 4

4
1
6
43

A 2

B
5

12 L
B

13
K
6

P
43 HA54E
11 10 9 8 7 029164AA.PDF

Intake
Figure 2 (Sheet 1 of 4)

54-10-11
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 HAWKER 800 STRUCTURAL REPAIR MANUAL

Q E 3

15
C
16 Q 16

G E
C 17

20 G

17

J J H H

18

18

20
16
D
F
19
3

16

16
FOR SECTIONS C - C, D - D, E - E, F - F,
G - G, H - H AND J - J SEE SHEET 3.
D FOR SECTION Q - Q SEE SHEET 4
F
DETAIL A R84007
HA00E998685AA

Intake
Figure 2 (Sheet 2 of 4)

54-10-11
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 HAWKER 800 STRUCTURAL REPAIR MANUAL

13 25 26 27 28 12 12
14

29
24
23

22 6 4 9 21 8

14

SECTION B-B 6

15
3
17
31

15 30
18 14
18
3 3
6 14

SECTION H-H 34

SECTION J-J SIMILAR SECTION C-C

SECTION D-D SIMILAR

6 6
15
15 3
35 32
6
33
18 15
3

14
SECTION F-F
14

SECTION G-G SECTION E-E R84010

HA00E998686AA

Intake
Figure 2 (Sheet 3 of 4)

54-10-11
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 HAWKER 800 STRUCTURAL REPAIR MANUAL

37 36

37
DETAIL K
R

N
N 5

DETAIL L RH ONLY
37

42 1
38
37

DETAIL N
DETAIL R
37
6 15 40 37
39

16
41

SECTION Q-Q DETAIL P R84013

HA00E998687AA

Intake
Figure 2 (Sheet 4 of 4)

54-10-11
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 HAWKER 800 STRUCTURAL REPAIR MANUAL

MATERIAL

ITEM DESCRIPTION SPECIFICATION THICKNESS REPAIR REFERENCE

OR
SECTION CODE in. mm

1 Angle GS180B9BR
2 Splice QQ-A-250/5 0.050 1.27
3 Frame MIL-S-6721 0.018 0.45 Renew
4 Stiffener QQ-A-250/5 0.040 1.00 Renew
5 Bracket QQ-A-250/5 0.050 1.27 Renew
6 Skin AMS4077 0.063 1.60
7 Splice QQ-A-250/5 0.063 1.60
8 Stiffener MIL-S-25043 0.025 0.64
9 Skin MIL-S-25043 0.020 0.50
10 Duct MIL-A-21180 Machined Renew
CL11
11 Doubler QQ-A-250/5 0.063 1.60 Renew
12 Manifold QQ-A-250/4 Machined
13 Nose Skin MIL-S-6721 0.063 1.60
14 Skin QQ-A-250/30 0.071 1.80
15 Cap QQ-A-200/3 - -
16 Doubler QQ-A-250/5 0.032 0.80
17 Splice QQ-A-250/5 0.040 1.00 Renew
18 Splice QQ-A-250/5 0.063 1.60 Renew
19 Doubler MIL-S-6721 0.032 0.80
20 Strap QQ-A-250/5 0.032 0.80
21 Bracket MIL-S-25043 0.032 0.80
22 Splice Strap QQ-A-250/5 0.040 1.00
23 Doubler MIL-S-6721 0.050 1.27 Renew
24 Clip MIL-S-25043 0.020 0.50 Renew
25 Bracket MIL-S-25043 0.018 0.45 Renew
26 Frame MIL-S-6721 0.018 0.45
27 Strap MIL-S-25043 0.020 0.50
28 Filler Strap MIL-S-6721 0.018 0.45 Renew
29 Splice Strap MIL-S-6721 0.040 1.00 Renew
30 Bracket QQ-A-250/5 0.032 0.80 Renew
31 Clip QQ-A-250/5 0.032 0.80 Renew

ASSEMBLY DRAWING NO. C46B11000

Key to Figure 2 (Sheet 1 of 2)

54-10-11
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 HAWKER 800 STRUCTURAL REPAIR MANUAL

MATERIAL

ITEM DESCRIPTION SPECIFICATION THICKNESS REPAIR REFERENCE

OR
SECTION CODE in. mm

32 Retainer QQ-A-250/5 0.063 1.60 Renew

33 Seal GT100A250 0.250 6.40 Renew
34 Filler QQ-A-250/5 0.063 1.60 Renew
35 Deflector QQ-A-250/5 0.050 1.27
36 Doubler QQ-A-250/5 0.050 1.27 Renew
37 Clip QQ-A-250/5 0.050 1.27 Renew
38 Clip QQ-A-250/5 0.080 2.00 Renew
39 Bracket QQ-A-250/11 0.050 1.27
40 Retainer MIL-S-6721 0.032 0.80 Renew
41 Seal Renew
42 Clip QQ-A-250/5 0.071 1.80 Renew
43 Sealant AMS 3276 or - - Renew
AMS 3277 Class
B 1/2
NOTE: Item 43, Adhesion promoter PR-148 is to be used with AMS 3276 Class B-1/2 sealants and
adhesion promoter PR-187 is to be used with AMS 3277 Class B-1/2 sealant. It is acceptable
not to apply sealant after the removal of existing sealant. Partial missing sealant around the
circumference is allowed.

ALLOWABLE DAMAGE PAGE 101

ASSEMBLY DRAWING NO. C46B11000

Key to Figure 2 (Sheet 2 of 2)

54-10-11
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Jun.16
 3

3 NSTA 218.63

DETAIL A
TYPICAL
18
8
9 17
19
16 3
NSTA 172.94 3
16 20
14 3
16
3
16
3 21
B
13 13
14 1
6
12
2
15

Upper Panel
11
15 3

Figure 3 (Sheet 1 of 2)
11
10
7
3

3 3
15
3
HAWKER 800 STRUCTURAL REPAIR MANUAL

7 3
11

3
4
5
4

A 5
4

R84016
3
4

HA00E998688AA
FOR DETAIL B SEE SHEET 2
5

Jun.16
Page 10
54-10-11
 HAWKER 800 STRUCTURAL REPAIR MANUAL

9 9 9 9

18

19

19

21

C C

17

23

0.063 0.020 0.063

( 1.60 ) ( 1.60 ) 23 DETAIL B 23 22
( 0.51 )

ALL DIMENSIONS ARE IN INCHES

( MILLIMETERS IN BRACKETS )
SECTION C-C R84019
HA00E998689AA

Upper Panel
Figure 3 (Sheet 2 of 2)

54-10-11
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 HAWKER 800 STRUCTURAL REPAIR MANUAL

MATERIAL

ITEM DESCRIPTION SPECIFICATION THICKNESS REPAIR REFERENCE

OR
SECTION CODE in. mm

1 Frame QQ-A-250/5 0.063 1.60 51-71-11

2 Guide Block AMS5343 Machined Renew
3 Stringer QQ-A-250/5 0.032 0.80 Renew
4 Angle QQ-A-20/4 0.032 0.80 Renew
5 Hinge MIL-A-21180/CL11 Machined Renew
6 Frame QQ-A-250/5 0.040 1.00 51-71-11
7 Frame QQ-A-250/5 0.032 0.80 51-71-11
8 Stiffener QQ-A-250/5 0.050 1.27 Renew
9 Doubler QQ-A-250/5 0.032 0.80 Renew
10 Clip QQ-A-250/5 0.040 1.00 Renew
11 Doubler MIL-S-25043 0.050 1.27 Renew
12 Bracket QQ-A-250/5 0.050 1.27 Renew
13 Gusset QQ-A-250/5 0.032 0.80 Renew
14 Bracket QQ-A-250/5 0.040 1.00 Renew
15 Guide MIL-S-5059 0.063 1.60 Renew
16 Gusset QQ-A-250/5 0.050 1.27 Renew
17 Doubler QQ-A-250/5 0.063 1.60 Renew
18 Skin AMS4077 Machined PB.201
19 Plate QQ-A-250/5 0.063 1.60 Renew
20 Deflector QQ-A-250/5 0.040 1.00 Renew
21 Inlet Scoop QQ-A-250/4 0.063 1.60 Renew
22 Shield MIL-S-6721 0.005 0.13 Renew
23 Plate QQ-A-250/5 0.040 1.00 Renew

ALLOWABLE DAMAGE PB.101

ASSEMBLY DRAWING NO. C46B1400

Key to Figure 3

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HAWKER 800 STRUCTURAL REPAIR MANUAL

THIS PAGE INTENTIONALLY LEFT BLANK

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HAWKER 800 STRUCTURAL REPAIR MANUAL

NSTA. 200

PYLON (REF.)

2
3

R84022
HA00E998102AA

Forward Engine Mounting

Figure 4

54-10-11
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 HAWKER 800 STRUCTURAL REPAIR MANUAL

MATERIAL

ITEM DESCRIPTION SPECIFICATION THICKNESS REPAIR REFERENCE

OR
SECTION CODE in. mm

1 Fitting GM3102 Machined Renew

2 Link GM3111 Machined Renew
3 Shim MIL-S-5059 - - Renew

ASSEMBLY DRAWING NO. C46B10010

Key to Figure 4

54-10-11
Page 15
Jun.16
 NSTA 218.63

6
4
24
26
6 1
24 2
28
NSTA 172.94 27
26

5
B 3
A 24
A
25 4
C 9
6
3
6
7
10
11
4 4
2 D 7
16
24 1 D 11
4 19
4

Lower Door - Cowl

Figure 5 (Sheet 1 of 2)
G
G F 3
23
F
E
6
22
HAWKER 800 STRUCTURAL REPAIR MANUAL

1
21 12
13
14 8
15
17
6
20
18

29
FOR DETAILS B, C AND E
SEE SHEET 2

R84025
SECTION A-A
FOR SECTIONS D-D, F-F AND G-G

HA00e998691AA
SEE SHEET 2 TYPICAL

Jun.16
Page 16
54-10-11
 HAWKER 800 STRUCTURAL REPAIR MANUAL

37 38 21 28 26 4 26

25
36 21

SECTION F-F 30

G-G SIMILAR
31
11

33

35
6

DETAIL B TYPICAL
34 4
3
28
11
33
DETAIL E 21

0.020 11 0.020
(0.51) (0.51)

21 24

32
21 0.063 4
(1.60) DETAIL C TYPICAL
ALL DIMENSIONS ARE IN INCHES
SECTION D-D (MILLIMETERS IN BRACKETS)
R84028
HA00E998692AA

Lower Door - Cowl

Figure 5 (Sheet 2 of 2)

54-10-11
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 HAWKER 800 STRUCTURAL REPAIR MANUAL

MATERIAL

ITEM DESCRIPTION SPECIFICATION THICKNESS REPAIR REFERENCE

OR
SECTION CODE in. mm

1 Tube QQ-A-200/3 - - Renew

2 Gusset QQ-A-250/5 0.032 0.80 Renew
3 Frame QQ-A-250/5 0.032 0.80 51-71-11
4 Stringer QQ-A-250/5 0.032 0.80 51-71-11
5 Hinge QQ-A-250/12 Machined Renew
6 Bracket QQ-A-250/5 0.040 1.00 Renew
7 Bracket QQ-A-250/5 0.050 1.27 Renew
8 Mast Nylafil G10/40 - - Renew
9 Hinge QQ-A-250/12 Machined Renew
10 Scupper Nylafil G10/40 - - Renew
11 Frame QQ-A-250/5 0.050 1.27 51-71-11
12 Duct MIL-T-8606 - - Renew
13 Ramp QQ-A-250/5 0.032 0.80 Renew
14 Retainer MIL-S-6721 0.028 0.70 Renew
15 Flange MIL-S-6721 0.035 0.89 Renew
16 Seal - - - Renew
17 Frame QQ-A-250/5 0.071 1.80 51-71-11
18 Support QQ-A-250/5 0.050 1.27 Renew
19 Hinge QQ-A-250/12 Machined Renew
20 Clip MIL-S-25043 0.063 1.60 Renew
21 Skin AMS4077 Machined PB.201
22 Louvre QQ-A-250/5 0.032 0.80 Renew
23 Frame QQ-A-250/5 0.063 1.60 51-71-11
24 Gusset QQ-A-250/5 0.050 1.27 Renew
25 Clip QQ-A-250/5 0.040 1.00 Renew
26 Doubler QQ-A-250/5 0.050 1.27 Renew
27 Doubler QQ-A-250/5 0.032 0.80 Renew
28 Fire Shield MIL-S-6721 0.005 0.13 Renew
29 Doubler QQ-A-200/3 - - Renew
30 Plate QQ-A-250/5 0.040 1.00 Renew
31 Guide MIL-S-5059 0.063 1.60 Renew
32 Angle QQ-A-250/4 0.032 0.80 Renew
33 Splice QQ-A-250/5 0.050 1.27 Renew
34 Fitting AMS5843 Machined Renew
35 Seal - - - Renew
36 Shim QQ-A-250/5 0.032 0.80 Renew
37 Hinge Half MIL-S-6721 0.032 0.80 Renew
38 Door MIL-S-6721 0.032 0.80 Renew
ALLOWABLE DAMAGE PB.101
ASSEMBLY DRAWING NO. C46B15000
Key to Figure 5

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THIS PAGE INTENTIONALLY LEFT BLANK

54-10-11
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HAWKER 800 STRUCTURAL REPAIR MANUAL

Rear Engine Cowl

Figure 6 (Sheet 1 of 2)

54-10-11
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HAWKER 800 STRUCTURAL REPAIR MANUAL

Rear Engine Cowl

Figure 6 (Sheet 2 of 2)

54-10-11
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 HAWKER 800 STRUCTURAL REPAIR MANUAL

MATERIAL

ITEM DESCRIPTION SPECIFICATION THICKNESS REPAIR REFERENCE

OR
SECTION CODE in. mm

1 Strap MIL-S-6721 0.032 0.80

2 Splice AMS5525 0.040 1.00
3 Skin QQ-A-250/5 0.040 1.00 51-71-12
4 Welded Skin QQ-A-250/5 0.032 0.80
5 Splice QQ-A_250/5 0.040 1.00
6 Duct MIL-S-6721 0.025 0.63 PB.201
7 Doubler QQ-A-250/5 0.032 0.80 Renew
8 Spacer MIL-S-6721 0.032 0.80 Renew
9 Clip QQ-A-250/5 0.032 0.80 Renew
10 Intercostal QQ-A-250/5 0.032 0.80 Renew
11 Plate QQ-A-250/11 0.032 0.80 Renew
12 Support MIL-S-25043 0.063 1.60 Renew
13 Cap GS183R3BR - -
Alternative
GS183B72BR - -
(2025-T8511)
14 Tube WW-T-700/4 - - Renew
.25000 x 0.35w
15 Spring QQ-A-250/13 0.020 0.40 Renew
16 Doubler QQ-A-250/5 0.032 0.80 Renew
17 Angle QQ-A-250/5 0.063 1.60 Renew
18 Skin QQ-A-250/30 Machined
19 Support GS180E50BE - -
Alternative
GS180E88BR - -
(2024-T8511)
20 Skin QQ-A-250/30 Machined
21 Flange MIL-S-6721 0.018 0.45 Renew
22 Fairing MIL-S-6721 0.018 0.45 Renew
23 Frame MIL-S-6721 0.018 0.45
24 Frame QQ-A-250/5 0.032 0.80 51-71-11
25 Support QQ-A-250/5 0.032 0.80
26 Flange QQ-S-763 Machined Renew
27 Frame MIL-S-6721 0.020 0.50 Renew

ASSEMBLY DRAWING NO. 25 8ES 203, C46B12000, C46B17011, C46B16000, C46B17080

Key to Figure 6 (Sheet 1 of 2)

54-10-11
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 HAWKER 800 STRUCTURAL REPAIR MANUAL

MATERIAL

ITEM DESCRIPTION SPECIFICATION THICKNESS REPAIR REFERENCE

OR
SECTION CODE in. mm

27A Reinforcing Rings 321 CRES 0.036 0.90

MIL-S-6721
29 Strap QQ-A-250/5 0.040 0.80 Renew
30 Support QQ-A-250/5 0.080 2.00 Renew
31 Bracket QQ-A-250/5 0.032 0.80 Renew
32 Gang Channel GN502BV08-12-13 - - Renew
33 Fairing QQ-A-250/5 0.032 0.80 Renew
34 Doubler QQ-A-250/5 0.125 3.17 Renew
35 Cover QQ-A-250/5 0.050 1.27 Renew
36 Cover AMS4077 Machined Renew
37 Shield See Note 0.090 2.29 Renew
38 Fitting AMS5732 Machined Renew
39 Stiffener MIL-S-6721 0.032 0.80 Renew
40 Fireproof Seal Fibreglass Silicone Renew
Rubber + Mesh
Wire
41 Doubler QQ-A-250/5 0.050 1.27 Renew
42 Door QQ-A-250/5 0.032 0.80 Renew

NOTE: Item 37, shield is made from Glasscloth No.106 as per MIL-C-9084. Impregnated with
silicone rubber ZZR7658 class 2, Grade 60

ALLOWABLE DAMAGE PB. 101

ASSEMBLY DRAWING NO. 25 8ES 203, C46B12000, C46B17011, C46B16000, C46B17080

Key to Figure 6 (Sheet 2 of 2)

54-10-11
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 HAWKER 800 STRUCTURAL REPAIR MANUAL

NACELLES/PYLONS
54-10-11

NACELLES
STRUCTURE COMPLETE
54-10-11

ALLOWABLE DAMAGE
100100

Contents Paragraph
Information 1
Damage 2

Page 101
54-10-11 Jun.16
 HAWKER 800 STRUCTURAL REPAIR MANUAL

1. INFORMATION
Except for the Forward Engine Mounting (Ref. 54-10-11, Figure 4), for which no general allowable damage
figures can be given, the relevant definitions in (Ref. 51-10-02) are applicable generally subject to the limits
and conditions specified below.

2. DAMAGE

A. Abrasions, Corrosion, scores and Scratches

For these forms of damage the blended-out depth allowable limit is one tenth of the material thickness.
Where frames, stiffeners and other annular, transverse or edge members are concerned, only damage
lengthwise in the member may be classified as allowable, otherwise (Ref. 51-10-02 para 2.A.) applies.

B. Dents in Skin Panels, Webs or Pressings

(1) Intake

Smooth dents in clear areas are generally allowable up to a maximum depth of 0.05 in. (1.27 mm),
otherwise (Ref. 51-10-02 para 2C) applies.
Where the dent is in the outer face of the Nose Skin (Item 13) it shall be allowable only when the
profile is restored as in (Ref. 51-72-00 para 4).
CAUTION: Restoration of profile by means of gap filler (Ref. 51-72-00 para 4.B.) must not be
applied to the frontal rounded surface of the nose skin or anywhere within this
including the whole interior of the duct skin (Item 14).

(2) Upper Panel (Ref. 54-10-11, Figure 3), Lower Door - Cowl (Ref. 54-10-11, Figure 5) and Rear
Engine Cowl (Ref. 54-10-11, Figure 6) smooth dents in clear areas are allowable up to a maximum
depth of 0.10 in. (2.54 mm), otherwise (Ref. 51-10-02 para 2.C.) applies.

C. Discoloration of Intake
If the intake lip is discolored, check for the following:-

(1) Make sure that there is no discoloration or blistering of the paint adjacent to the intake lip.

(2) There is no pitting of the intake lip material.

(3) The intake lip has not distorted.

If the intake lip is determined to be serviceable except for discoloration, the discoloration may be
reduced by polishing in accordance with AMM 125/H-20, 20-10-811, 201. The minimum thickness after
polishing to be 0.052 in. (1.32mm). Some discoloration is allowed.

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 HAWKER 800 STRUCTURAL REPAIR MANUAL

NACELLES & THRUST REVERSER - STRUCTURE COMPLETE

IDENTIFICATION

Contents Figure

Nacelles and Thrust Reverser - Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Upper Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Forward Engine Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lower Door Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Thrust Reverser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Thrust Reverser - Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Thrust Reverser - After Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

54-10-21
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HAWKER 800 STRUCTURAL REPAIR MANUAL

Nacelles and Thrust Reverser - Location

Figure 1

54-10-21
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Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

ITEM NOMENCLATURE REFERENCE

1 Thrust Reverser Fig.6

2 Belt Fig.7

3 After Body Fig.8

4 Lower Door - Cowl Fig.5

5 Intake Fig.2

6 Forward Engine Mounting Fig.4

7 Upper Panel Fig.3

ASSEMBLY DRAWING NO. 25 8ES201, 25 8ES333

Key to Figure 1

54-10-21
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Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

FOR DETAIL A SEE SHEET 2

FOR SECTION B - B SEE SHEET 3

14
FOR DETAILS K, L AND P SEE SHEET 4

4
1
6
43

A 2

B
5

12 L
B

13
K
6

P
R84004_1
43 11 10 9 8 7 HA54E998684AB

Intake
Figure 2 (Sheet 1 of 4)

54-10-21
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Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

Q E 3

15
C
16 Q 16

G E
C 17

20 G

17

J J H H

18

18

20
16
D
F
19
3

16

16
FOR SECTIONS C - C, D - D, E - E, F - F,
G - G, H - H AND J - J SEE SHEET 3.
D FOR SECTION Q - Q SEE SHEET 4
F
DETAIL A R84007
HA00E998685AA

Intake
Figure 2 (Sheet 2 of 4)

54-10-21
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Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

13 25 26 27 28 12 12
14

29
24
23

22 6 4 9 21 8

14

SECTION B-B 6

15
3
17
31

15 30
18 14
18
3 3
6 14

SECTION H-H 34

SECTION J-J SIMILAR SECTION C-C

SECTION D-D SIMILAR

6 6
15
15 3
35 32
6
33
18 15
3

14
SECTION F-F
14

SECTION G-G SECTION E-E R84010

HA00E998686AA

Intake
Figure 2 (Sheet 3 of 4)

54-10-21
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Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

37 36

37
DETAIL K
R

N
N 5

DETAIL L RH ONLY
37

42 1
38
37

DETAIL N
DETAIL R
37
6 15 40 37
39

16
41

SECTION Q-Q DETAIL P R84013

HA00E998687AA

Intake
Figure 2 (Sheet 4 of 4)

54-10-21
Page 7
Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

MATERIAL

ITEM DESCRIPTION SPECIFICATION THICKNESS REPAIR REFERENCE

OR
SECTION CODE in. mm

1 Angle GS180B9BR - -
2 Splice QQ-A-250/5 0.050 1.27 Renew
3 Frame MTI-S-6721 0.018 0.46
4 Stiffener QQ-A-250/5 0.040 1.00
5 Bracket QQ-A-250/5 0.050 1.27 Renew
6 Skin AMS4077 0.064 1.60
7 Splices QQ-A-250/5 0.064 1.60
8 Stiffener MIL-S-25043 0.025 0.64
9 Skin MIL-S-25043 0.020 0.50
10 Duct MIL-A-21180/CL11 Machined Renew
11 Doubler QQ-A-250/5 0.064 1.60 Renew
12 Manifold QQ-A-250/5 Machined
13 Nose Skin MIL-S-6721 0.064 1.60
14 Skin QQ-A-250/30 0.071 1.80
15 Cap QQ-A-200/3 - -
16 Doubler QQ-A-250/3 0.032 0.80
17 Splice QQ-A-250/5 0.040 1.00 Renew
18 Splice QQ-A-250/5 0.063 1.60 Renew
19 Doubler MIL-S-6721 0.032 0.80 Renew
20 Strap QQ-A-250/5 0.032 0.80 Renew
21 Bracket MIL-S-25043 0.032 0.80 Renew
22 Splice Strap QQ-A-250/5 0.040 1.00 Renew
23 Doubler MIL-S-6721 0.050 1.27 Renew
24 Clip MIL-S-25043 0.020 0.50 Renew
25 Bracket MIL-S-25043 0.018 0.46 Renew
26 Frame MIL-S-6721 0.018 0.46
27 Strap MIL-S-25043 0.020 0.50 Renew
28 Filler Strap MIL-S-6721 0.018 0.46 Renew
29 Splice Strap MIL-S-6721 0.040 1.00 Renew
30 Bracket QQ-A-250/5 0.032 0.80 Renew
31 Clip QQ-A-250/5 0.032 0.80 Renew
32 Retainer QQ-A-250/5 0.064 1.60 Renew

ASSEMBLY DRAWING NO C46B11000

Key to Figure 2 (Sheet 1 of 2)

54-10-21
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Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

MATERIAL

ITEM DESCRIPTION SPECIFICATION THICKNESS REPAIR REFERENCE

OR
SECTION CODE in. mm

33 Seal GT100A250 0.250 6.40 Renew

34 Filler QQ-A-250/5 0.064 1.60 Renew
35 Deflector QQ-A-250/5 0.050 1.27
36 Doubler QQ-A-250/5 0.050 1.27 Renew
37 Clip QQ-A-250/5 0.050 1.27 Renew
38 Clip QQ-A-250/5 0.080 2.00 Renew
39 Bracket QQ-A-250/11 0.050 1.27 Renew
40 Retainer MIL-S-6721 0.032 0.80 Renew
41 Seal - - Renew
42 Clip QQ-A-250/5 0.071 1.80 Renew
43 Sealant AMS 3276 or AMS - - Renew
3277 Class B 1/2

ALLOWABLE DAMAGE PB. 101

ASSEMBLY DRAWING NO C46B11000

Key to Figure 2 (Sheet 2 of 2)

54-10-21
Page 9
Sep.14
 3

3 NSTA 218.63

DETAIL A
TYPICAL
18
8
9 17
19
16 3
NSTA 172.94 3
16 20
14 3
16
3
16
3 21
B
13 13
14 1
6
12
2
15

Upper Panel
11
15 3

Figure 3 (Sheet 1 of 2)
11
10
7
3

3 3
15
3
HAWKER 800 STRUCTURAL REPAIR MANUAL

7 3
11

3
4
5
4

A 5
4

R84016
3
4

HA00E998688AA
FOR DETAIL B SEE SHEET 2
5

Sep.14
Page 10
54-10-21
 HAWKER 800 STRUCTURAL REPAIR MANUAL

9 9 9 9

18

19

19

21

C C

17

23

0.063 0.020 0.063

( 1.60 ) ( 1.60 ) 23 DETAIL B 23 22
( 0.51 )

ALL DIMENSIONS ARE IN INCHES

( MILLIMETERS IN BRACKETS )
SECTION C-C R84019
HA00E998689AA

Upper Panel
Figure 3 (Sheet 2 of 2)

54-10-21
Page 11
Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

MATERIAL

ITEM DESCRIPTION SPECIFICATION THICKNESS REPAIR REFERENCE

OR
SECTION CODE in. mm

1 Frame QQ-A-250/5 0.064 1.60 51-71-11

2 Guide Block AMS5343 Machined Renew
3 Stringer QQ-A-250/5 0.032 0.80 Renew
4 Angle QQ-A-250/4 0.032 0.80 Renew
5 Hinge MIL-A-21180/CL11 Machined Renew
6 Frame QQ-A-250/5 0.040 1.00 51-71-11
7 Frame QQ-A-250/5 0.032 0.80 51-71-11
8 Stiffener QQ-A-250/5 0.050 1.27 Renew
9 Doubler QQ-A-250/5 0.032 0.80 Renew
10 Clip QQ-A-250/5 0.040 1.00 Renew
11 Doubler MIL-S-25043 0.050 1.27 Renew
12 Bracket QQ-A-250/5 0.050 1.27 Renew
13 Gusset QQ-A-250/5 0.032 0.80 Renew
14 Bracket QQ-A-250/5 0.040 1.00 Renew
15 Guide MIL-S-5059 0.064 1.60 Renew
16 Gusset QQ-A-250/5 0.050 1.27 Renew
17 Doubler QQ-A-250/5 0.064 1.60 Renew
18 Skin AMS4077 Machined PB.201
19 Plate QQ-A-250/5 0.064 1.60 Renew
20 Deflector QQ-A-250/5 0.040 1.00 Renew
21 Inlet Scoop QQ-A-250/4 0.064 1.60 Renew
22 Shield MIL-S-6721 0.005 0.13 Renew
23 Plate QQ-A-250/5 0.040 1.00 Renew

ALLOWABLE DAMAGE PB. 101

ASSEMBLY DRAWING NO C46B14000

Key to Figure 3

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HAWKER 800 STRUCTURAL REPAIR MANUAL

THIS PAGE INTENTIONALLY LEFT BLANK

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Sep.14
HAWKER 800 STRUCTURAL REPAIR MANUAL

NSTA. 200

PYLON (REF.)

2
3

R84022
HA00E998102AA

Forward Engine Mounting

Figure 4

54-10-21
Page 14
Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

MATERIAL

ITEM DESCRIPTION SPECIFICATION THICKNESS REPAIR REFERENCE

OR
SECTION CODE in. mm
1 Fitting GM3102 Machined Renew
2 Link GM3111 Machined Renew
3 Shim MIL-S-5059 - - Renew

ASSEMBLY DRAWING NO C46B10010

Key to Figure 4

54-10-21
Page 15
Sep.14
 NSTA 218.63

6
4
24
26
6 1
24 2
28
NSTA 172.94 27
26

5
B 3
A 24
A
25 4
C 9
6
3
6
7
10
11
4 4
2 D 7
16
24 1 D 11
4 19
4

Lower Door - Cowl

Figure 5 (Sheet 1 of 2)
G
G F 3
23
F
E
6
22
HAWKER 800 STRUCTURAL REPAIR MANUAL

1
21 12
13
14 8
15
17
6
20
18

29
FOR DETAILS B, C AND E
SEE SHEET 2

R84025
SECTION A-A
FOR SECTIONS D-D, F-F AND G-G

HA00e998691AA
SEE SHEET 2 TYPICAL

Sep.14
Page 16
54-10-21
 HAWKER 800 STRUCTURAL REPAIR MANUAL

37 38 21 28 26 4 26

25
36 21

SECTION F-F 30

G-G SIMILAR
31
11

33

35
6

DETAIL B TYPICAL
34 4
3
28
11
33
DETAIL E 21

0.020 11 0.020
(0.51) (0.51)

21 24

32
21 0.063 4
(1.60) DETAIL C TYPICAL
ALL DIMENSIONS ARE IN INCHES
SECTION D-D (MILLIMETERS IN BRACKETS)
R84028
HA00E998692AA

Lower Door - Cowl

Figure 5 (Sheet 2 of 2)

54-10-21
Page 17
Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

MATERIAL

ITEM DESCRIPTION SPECIFICATION THICKNESS REPAIR REFERENCE

OR
SECTION CODE in. mm
1 Tube QQ-A-200/3 - - Renew
2 Gusset QQ-A-250/3 0.032 0.80 Renew
3 Frame QQ-A-250/5 0.032 0.80 51-71-11
4 Stringer QQ-A-250/5 0.032 0.80 51-71-11
5 Hinge QQ-A-250/12 Machined Renew
6 Bracket QQ-A-250/5 0.040 1.00 Renew
7 Bracket QQ-A-250/5 0.050 1.27 Renew
8 Mast Nylafil G10/40 - - Renew
9 Hinge QQ-A-250/12 Machined Renew
10 Scupper Nylafil G10/40 - - Renew
11 Frame QQ-A-250/5 0.050 1.27 51-71-11
12 Duct MIL-T-8606 Renew
13 Ramp QQ-A-250/5 0.032 0.80 Renew
14 Retainer MIL-S-6721 0.028 0.70 Renew
15 Flange MIL-S-6721 0.035 0.89 Renew
16 Seal - - Renew
17 Frame QQ-A-250/5 0.071 1.80 51-71-11
18 Support QQ-A-250/5 0.050 1.27 Renew
19 Hinge QQ-A-250/12 Machined Renew
20 Clip MIL-S-25043 0.064 1.60 Renew
21 Skin AMS4077 Machined PB.201
22 Louvre QQ-A-250/5 0.032 0.80 Renew
23 Frame QQ-A-250/5 0.064 1.60 51-71-11
24 Gusset QQ-A-250/5 0.050 1.27 Renew
25 Clip QQ-A-250/5 0.040 1.00 Renew
26 Doubler QQ-A-250/5 0.050 1.27 Renew
27 Doubler QQ-A-250/5 0.032 0.80 Renew
28 Fire Shield MIL-S-6721 0.005 0.13 Renew
29 Doubler QQ-A-200/3 - - Renew
30 Plate QQ-A-250/5 0.040 1.00 Renew
31 Guide MIL-S-5059 0.064 1.60 Renew
32 Angle QQ-A-250/4 0.032 0.80 Renew
33 Splice QQ-A-250/5 0.050 0.13 Renew
34 Fitting AMS5843 Machined Renew
35 Seal - - Renew
36 Shim QQ-A-250/5 0.032 0.80 Renew
37 Hinge Half MIL-S-6721 0.032 0.80 Renew
38 Door MIL-S-6721 0.032 0.80 Renew
ALLOWABLE DAMAGE PB.101
ASSEMBLY DRAWING NO C46B15000
Key to Figure 5

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HAWKER 800 STRUCTURAL REPAIR MANUAL

THIS PAGE INTENTIONALLY LEFT BLANK

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Sep.14
HAWKER 800 STRUCTURAL REPAIR MANUAL

Thrust Reverser
Figure 6 (Sheet 1 of 8)

54-10-21
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Sep.14
HAWKER 800 STRUCTURAL REPAIR MANUAL

Thrust Reverser
Figure 6 (Sheet 2 of 8)

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Sep.14
HAWKER 800 STRUCTURAL REPAIR MANUAL

Thrust Reverser
Figure 6 (Sheet 3 of 8)

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Sep.14
HAWKER 800 STRUCTURAL REPAIR MANUAL

Thrust Reverser
Figure 6 (Sheet 4 of 8)

54-10-21
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Sep.14
HAWKER 800 STRUCTURAL REPAIR MANUAL

Thrust Reverser
Figure 6 (Sheet 5 of 8)

54-10-21
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Sep.14
HAWKER 800 STRUCTURAL REPAIR MANUAL

Thrust Reverser
Figure 6 (Sheet 6 of 8)

54-10-21
Page 25
Sep.14
HAWKER 800 STRUCTURAL REPAIR MANUAL

Thrust Reverser
Figure 6 (Sheet 7 of 8)

54-10-21
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Sep.14
HAWKER 800 STRUCTURAL REPAIR MANUAL

Thrust Reverser
Figure 6 (Sheet 8 of 8)

54-10-21
Page 27
Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

MATERIAL

ITEM DESCRIPTION SPECIFICATION THICKNESS REPAIR REFERENCE

OR
SECTION CODE in. mm

1 Stop 2024-T3 QQ-A-250/5 Machined

2 Door Assembly See Note - -
3 Activator Fairing 6061-0 QQ-A-250/11 0.050 1.27
4 Fairing 2024-0 QQ-A-250/5 0.032 0.80
5 Deflector 2024-T42
QQ-A-250/5 0.048 1.20
6 Bracket 6061-0 QQ-A-250/11 0.064 1.60
7 Doubler 6061-0 QQ-A-250/11 0.040 1.00
8 Seal MF 846 - - Renew
9 Retainer 2024-T3QQ-A-250/5 0.050 1.27
10 Fan Duct - Half 2024-0 QQ-A-250/5 0.080 2.00
11 Retainer (5 Lams 0.01 in) Kevlar 0.050 1.27
12 Fan Duct Doubler 2024-0 QQ-A-250/5 0.080 2.00
13 Hinge Fitting 2024-T351
(Eff 54-001 to 54-140) QQ-A-225/6 Machined
(Eff 54-141 & subs) 2219-T852
AMS4144 Forging
14 Shim 2024-0 QQ-A-250/5 Machined
15 Cover Strip 2024-0 QQ-A-250/5 0.080 2.00
16 Angle Fitting 2024-0 QQ-A-250/5 0.032 0.80
17 Stiffener 2024-0 QQ-A-250/5 0.032 0.80
18 Flange 2024-0 QQ-A-250/5 0.125 3.18
19 Angle Fitting Doubler 2024-0 QQ-A-250/5 0.050 1.27
20 Angle Fitting 2024-0 QQ-A-250/15 0.050 1.27
21 Doubler 4130 ANNEALED 0.090 2.29
22 Splice 2024-0 QQ-A-250/5 0.032 0.80
23 Hook 321-SS MIL-S-5059 Welded Assy
24 Pick Up Angle 2024-0 A-250/5 0.050 1.27
25 Splice 2024-T3 QQ-A-250/5 0.032 0.80
26 Rib 2024-0 QQ-A-250/5 0.050 1.27
27 Rib 2024-0 QQ-A-250/5 0.063 1.60
28 Doubler 2024-0 QQ-A-250/5 0.063 1.60
29 Strap 2024-T QQ-A-250/5 0.090 2.29

ASSEMBLY DRAWING NO 25 8ES 333

Key to Figure 6 (Sheet 1 of 2)

54-10-21
Page 28
Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

MATERIAL

ITEM DESCRIPTION SPECIFICATION THICKNESS REPAIR REFERENCE

OR
SECTION CODE in. mm

30 Rear Fitting A357-T61 Casting

MIL-A-21/80
31 Hinge Fitting 17-4PH AMS5355C Casting

32 Shutter 2024-T3 QQ-A-250/5 0.078 1.98

33 Angle 2024-T42 0.055 1.40
34 Front Fitting A357-T61
MIL-A-21180 Casting
35 Doubler 2024-T42 0.055 1.40
36 Angle 2024-0 QQ-A-250/5 0.080 2.00
37 Spar 2024-0 QQ-A-250/5 0.050 1.27
38 Hat Section 2024-T42 0.048 1.20
39 Door Skin Panel 2024-0 QQ-A-250/5 0.080 2.00
40 Doubler 2024-0 QQ-A-250/5 0.050 1.27
41 Serrated Plate 321-SS Machined
42 Staple 17-4PH
AMS5355C Casting
43 Angle Fitting A-S7G06T6 Casting
44 Latch Box Assembly Dee Howard - -
45 Striker Plate 321-SS MIL-S-6721 0.032 0.80
46 Latch Box Cover Dee Howard - -

NOTE: Item 2 - Door Assembly consists of Items 1,5,13,24,37,38,39,40,41,42 & 43

ALLOWABLE DAMAGE PB. 101

ASSEMBLY DRAWING NO 25 8ES 333

Key to Figure 6 (Sheet 2 of 2)

54-10-21
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Sep.14
HAWKER 800 STRUCTURAL REPAIR MANUAL

Thrust Reverser - Belt

Figure 7

54-10-21
Page 30
Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

MATERIAL

ITEM DESCRIPTION SPECIFICATION THICKNESS REPAIR REFERENCE

OR
SECTION CODE in. mm

1 Belt Skin 2024-0 QQ-A-250/5 0.032 0.80

2 Channel 2024-T3 QQ-A-250/5 0.040 1.00
3 Doubler 2024-T3 QQ-A-250/5 0.040 1.00
4 Grommet MS21266-IT - - Renew
5 Clip Dee Howard
6 Latch Assembly Dee Howard
7 Shim Dee Howard
8 Plate Dee Howard
9 Tongue Dee Howard
10 Angle Dee Howard
11 ‘U’ Bolt Dee Howard

ALLOWABLE DAMAGE PB. 101

ASSEMBLY DRAWING NO 25 8ES 333

Key to Figure 7

54-10-21
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Sep.14
HAWKER 800 STRUCTURAL REPAIR MANUAL

Thrust Reverser - After Body

Figure 8 (Sheet 1 of 5)

54-10-21
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Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

NOZZEL
ENGINE

(REF.)

16
24

24
D
34
DETAIL
37

33

25

A
DETAIL
26
31

(REF)
CLIP
40

39

38

32

27
31

30

28
29
TYPICAL
35

36
24

B
D

DETAIL
33
C DETAIL

16
34

R84061
HA00E998707AA

Thrust Reverser - After Body

Figure 8 (Sheet 2 of 5)

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HAWKER 800 STRUCTURAL REPAIR MANUAL

Thrust Reverser - After Body

Figure 8 (Sheet 3 of 5)

54-10-21
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Sep.14
HAWKER 800 STRUCTURAL REPAIR MANUAL

Thrust Reverser - After Body

Figure 8 (Sheet 4 of 5)

54-10-21
Page 35
Sep.14
HAWKER 800 STRUCTURAL REPAIR MANUAL

Thrust Reverser - After Body

Figure 8 (Sheet 5 of 5)

54-10-21
Page 36
Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

MATERIAL

ITEM DESCRIPTION SPECIFICATION THICKNESS REPAIR REFERENCE

OR
SECTION CODE in. mm

1 Frame - Upper and Lower 2024-0 ALC AL 0.032 0.80

QQ-A-250/5
2 Hook SH-321-SS 0.080 2.00
3 Aft Flange DS-112-4 - -
4 Strap 2024-0 QQ-A-250/5 0.040 1.00
5 Splice Clip 2024-0 QQ-A-250/5 0.032 0.80
6 Outer Skin - Top and Lower 2024-0 QQ-A-250/5 0.032 0.80
7 Outer Fan Duct - Top and 2024-0 QQ-A-250/5 0.032 0.80
Lower
8 Plate 2024-0 QQ-A-250/5 0.062 1.60
9 Tube 5052-0 WW-T-700/4 - - Renew
10 Doubler 2024-T3 QQ-A-250/5 0.032 0.80
11 Seal QQ-S-776 0.064 1.60 Renew
12 Angle 2024-0 QQ-A-250/5 0.032 0.80
13 Strap 2024-T3 QQ-A-250/5 0.032 0.80
14 Doubler 2024 QQ-A-250/5 0.040 1.00
15 Door - Outer Skin 2024-0 QQ-A-250/5 0.032 0.80
16 Doubler 6061-0 QQ-A-250/11 0.040 1.00
17 Outer Fan Duct Door 6061-0 QQ-A-250/11 0.040 1.00
18 Forward Flange DS-112-3 - -
19 Frame - Upper and Lower 321-N-SS MIL-S-6721 0.032 0.80
20 Clip 6061-T6 QQ-A-250/11 0.032 0.80
21 Channel 2024-0 QQ-A-250/5 0.032 0.80
22 Door - Outer Skin 2024-0-T3 QQ-A-250/5 0.032 0.80
23 Grommet MS21 266-IT - - Renew
24 Inner Fan Duct - Top and
Lower 6061-0 QQ-A-250/11 0.040 1.00
25 Inner Fan Duct Door 6061-0 QQ-A-250/11 0.040 1.00
26 Shim 6061-T6 QQ-A-250/11 0.040 1.00 Renew
27 Pad 321-SS MIL-S-5059 0.050 1.27 Renew
28 Inner Fan Duct - Forward 6061-0 QQ-A-250/11 0.040 1.00
29 Bubble 6061-0 QQ-A-250/11 0.040 1.00

ASSEMBLY DRAWING NO. 25 8ES 333

Key to Figure 8 (Sheet 1 of 2)

54-10-21
Page 37
Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

MATERIAL

ITEM DESCRIPTION SPECIFICATION THICKNESS REPAIR REFERENCE

OR
SECTION CODE in. mm

30 Doubler 6061-T6 QQ-A-250/11 0.040 1.00

31 Fairing 321-SS MIL-S-6721 0.036 0.90

32 Channel 321-SS MIL-S-6721 0.036 0.90
33 Flange 321-SS MIL-S-6721 0.036 0.90
34 Angle 6061-0 QQ-A-250/11 0.032 0.80
35 Bracket 6061-0 QQ-A-250/11 0.032 0.80
36 Pad KUNGERIT 1000 0.100 2.54 Renew
37 Coupling GRUMMAN - -
38 Ring MIL-S-6721 Machined
39 Exhaust Stub MIL-S-6721 0.032 0.80
40 Strap MIL-S-6721 0.025 0.64
41 Shim 2024-T3 QQ-A-250/5 0.025 0.64 Renew
42 Hat Channel 2024-T3 QQ-A-250/5 0.064 1.60
43 Doubler 2024-T3 QQ-A-250/5 0.040 1.00
44 Shim 2024-T3 QQ-A-250/5 0.064 1.60 Renew
45 Doubler 321-N-SS MIL-S-6721 0.032 0.80
46 Fairing 6061-0 QQ-A-250/11 0.032 0.80
47 Outer Fan Duct Door 2024-0 QQ-A-250/5 0.032 0.80
48 Doubler 6061-0 QQ-A-250/11 0.032 0.80
49 Bonding Strap GRUMMAN - -
50 Close Out Angle 6061-0 QQ-A-250/11 0.032 0.80
51 Plate 304 QQ-S-762 0.020 0.50
52 Plate 304 QQ-S-763 0.020 0.50
53 Seal DEE HOWARD - - Renew
54 Bracket 6061-0 QQ-A-250/11 0.032 0.80
55 Splice 6061-0 QQ-A-250/11 0.032 0.80

ALLOWABLE DAMAGE PB. 101

ASSEMBLY DRAWING NO. 25 8ES 333

Key to Figure 8 (Sheet 2 of 2)

54-10-21
Page 38
Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

NACELLES/PYLONS
54-10-21

NACELLES AND THRUST REVERSER

STRUCTURE COMPLETE
54-10-21

ALLOWABLE DAMAGE
100100

Contents Page
General 102

Page 101
54-10-21 Aug.18
 HAWKER 800 STRUCTURAL REPAIR MANUAL

1. GENERAL
The relevant definitions in 51-10-02 are applicable to Figure 1 items 4, 5 and 7 generally subject to the limits
and conditions specified below.

A. Abrasions, Corrosion, Scores and Scratches

(1) For these forms of damage the blended-out depth allowable limit is one tenth of the material
thickness.

(2) Where frames, stiffeners and other annular, transverse or edge members are concerned only
damage lengthwise in the member may be classified as allowable, otherwise 51-10-02 paragraph
2.A applies.

B. Dents in Skin Panels, Webs or Pressings

(1) Intake (Figure 2)

(a) Smooth dents in clear areas are generally allowable up to a maximum depth of 0.05 in. (1.27
mm), otherwise 51-10-02 paragraph 2.C applies.

(b) Where the dent is in the outer face of the Nose skin (Item 13), it shall be allowable only when
the profile is restored as in 51-72-00 paragraph 3.

CAUTION: Restoration of profile by means of gap filler (Ref. 51-72-00 paragraph 3B) must
not be applied to the frontal rounded surface of the Nose skin or anywhere within
this including the whole interior of the duct skin (Ref. 54-10-31, Figure 2,
Item 14).

(2) Upper panel (54-10-31, Figure 3), Lower Door Cowl (Ref. 54-10-31, Figure 5) and Rear Engine
Cowl (Ref. 54-10-31, Figure 6) smooth dents in clear areas are allowable up to a maximum depth
of 0.10 in. (2.54 mm), otherwise 51-10-02 paragraph 2.C applies.

C. Discoloration of Intake
If the intake lip is discolored, check for the following:-

(1) Make sure that there is no discoloration or blistering of the paint adjacent to the intake lip.

(2) There is no pitting of the intake lip material.

(3) The intake lip has not distorted.

If the intake lip is determined to be serviceable except for discoloration, the discoloration may be
reduced by polishing in accordance with AMM 125/H-20, 20-10-811, 201. The minimum thickness after
polishing to be 0.052 in. (1.32mm). Some discoloration is allowed.

Page 102
Aug.18 54-10-21
 HAWKER 800 STRUCTURAL REPAIR MANUAL

NACELLES/PYLONS
NACELLES AND THRUST REVERSER AFTER MOD. 25G311E
54-10-31

STRUCTURE COMPLETE
IDENTIFICATION
00

Contents Figure
Nacelles with Thrust Reverser - Location 1
Intake 2
Upper Panel 3
Forward Engine Mount 4
Lower Door - Cowl 5
Thrust Reverser 6
Thrust Reverser - Belt 7
Thrust Reverser - After Body 8

Page 1
54-10-31 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

5 6 7 1

2
3
4

VIEW A
(LH SHOWN, RH OPPOSITE)

HA54E
058222AA.AI

Figure 1
Nacelles with Thrust Reverser - Location

Page 2
Jun.13 54-10-31
 HAWKER 800 STRUCTURAL REPAIR MANUAL

Table 1
Key to Figure 1
Item Description Reference
1 Thrust Reverser Fig. 6
2 Belt Fig. 7
3 Afterbody Fig. 8
4 Lower Door - Cowl Fig. 5
5 Intake Fig. 2
6 Forward Engine Mount Fig. 4
7 Upper Panel Fig. 3

Page 3
54-10-31 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

13 1

32

13
29

32

12
4
HA54E
058223AB.AI

Figure 2 (Sheet 1 of 3)
Intake

Page 4
Jun.13 54-10-31
 HAWKER 800 STRUCTURAL REPAIR MANUAL

31

10 7

6
16

14

17

19
18

20

5
11
15
21

9 8

HA54E
058224AA.AI

Figure 2 (Sheet 2 of 3)
Intake

Page 5
54-10-31 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

23
23 25
22

24

26

27

28
DETAIL A HA54E
058225AA.AI

Figure 2 (Sheet 3 of 3)
Intake

Page 6
Jun.13 54-10-31
 HAWKER 800 STRUCTURAL REPAIR MANUAL

Table 2
Key to Figure 2 (Sheet 1), Figure 2 (Sheet 2) and Figure 2 (Sheet 3)
Material
Item Description Specification Thickness Repair
or Reference
Section Code in. cm
1 Attach Flange AMS4311 Machined
2 Doubler AMS-QQ-A-250/11 0.040 0.102 Renew
2A* Doubler AMS4900 0.040 0.102 Renew
3 Bulkhead AMS5599 0.020 0.051
4 Outer Skin AMS-QQ-A-250/5 0.040 0.102
5 Doubler AMS-QQ-A-250/5 0.040 0.102
6 ZEE AMS-QQ-A-250/11 0.040 0.102
6A* ZEE AMS4900 0.040 0.102
7 Shroud Skin AMS5510 0.020 0.051
7A* Shroud Skin AMS4901 0.020 0.051
8 Duct AMS4217 Casting Renew
9 Doubler AMS-QQ-A-250/11 0.071 0.180 Renew
10 Stand-offs AMS-QQ-A-200/3 Machined
10A* Stand-offs AMS5639 Machined
11 Stand-offs AMS5510 Machined
11A* Stand-offs AMS5639 Machined
12 Lipskin AMS5510 0.063 0.160
13 Inner Barrel Skin AMS-QQ-A-250/11 0.071 0.180
14 TEE AMS-QQ-A-200/3 Machined
15 Doubler AMS5599 0.063 0.160 Renew
16 Doubler AMS5599 0.032 0.081 Renew
17 Doubler AMS5599 0.032 0.081 Renew
18 Clamp - - Renew
19 Bracket AMS5599 0.032 0.081 Renew
20 Bulkhead AMS5599 0.032 0.081
21 Doubler AMS5599 0.032 0.081 Renew
22 Sleeve AMS5596 Machined
23 Ring AMS5537 0.056 0.142

Page 7
54-10-31 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

Table 2
Key to Figure 2 (Sheet 1), Figure 2 (Sheet 2) and Figure 2 (Sheet 3)
Material
Item Description Specification Thickness Repair
or Reference
Section Code in. cm
24 Bracket AMS5510 0.063 0.160 Renew
25 Bracket AMS5510 0.063 0.160 Renew
26 Bracket AMS5510 0.063 0.160 Renew
27 Bracket AMS5510 0.040 0.102 Renew
28 Bracket AMS5510 0.040 0.102 Renew
29 Rub Strip PCS5900 0.070 0.178 Renew
30 Not Used
31 Tube Assembly AMS5510/AMS5570/AMS5645 Variable
32 Sealant AMS 3276 CLASS B 1/2 - - Renew

NOTE: Items denoted * are applicable to SB 71-4080 and HA0203 and after.
NOTE: Allowable damage refer to 54-10-31, page 101.
NOTE: Assembly drawings 716RA0001-3, 716RA0001-4 and MK716RA0001-5.

Page 8
Jun.13 54-10-31
 HAWKER 800 STRUCTURAL REPAIR MANUAL

11

12 10
15
16
17

10

12

4
B
A 2
1 4

C
HA54E
058118AA.AI

Figure 3 (Sheet 1 of 3)
Upper Panel

Page 9
54-10-31 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

14
13

DETAIL B 5
TYPICAL 4 PLACES
2

18

9 7
(3 PLACES) (3 PLACES)

8
(3 PLACES)
DETAIL A HA54E
058119AA.AI

Figure 3 (Sheet 2 of 3)
Upper Panel

Page 10
Jun.13 54-10-31
 HAWKER 800 STRUCTURAL REPAIR MANUAL

1
4

10

19

19

3
(3 PLACES)

1
19

19 DETAIL C
HA54E
058226AA.AI

Figure 3 (Sheet 3 of 3)
Upper Panel

Page 11
54-10-31 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

Table 3
Key to Figure 3 (Sheet 1), Figure 3 (Sheet 2) and Figure 3 (Sheet 3)
Material
Item Description Specification Thickness Repair
or Reference
Section Code in. cm
1 ZEE Frame AMS-QQ-A-250/5 0.040 0.102 Renew
2 Longeron Pan AMS-QQ-A-250/11 0.032 0.081 Renew
3 Hinge AMS4050 Machined Renew
4 Hat Frame AMS-QQ-A-250/5 0.032 0.081 Renew
5 Angle Stiffener AMS-QQ-A-250/5 0.032 0.081 Renew
6 Longeron ZEE AMS-QQ-A-250/5 0.032 0.081 Renew
7 Doubler AMS5510 0.050 0.127 Renew
8 Latch Bracket AMS4050 Machined
9 Latch 711RA0123-2 - 0.000 Renew
10 Doubler AMS-QQ-A-250/5 0.040 0.102 Renew
11 Skin AMS-QQ-A-250/5 0.040 0.102 Renew
12 Shear Latch 711RA0125-1 - 0.000 Renew
13 Sleeve Bolt 711RA0131-1 - 0.000 Renew
14 Retainer Washer 711RA0159-1 - 0.000 Renew
15 Vent Intake AMS-QQ-A-250/5 0.032 0.081 Renew
16 Vent Deflector AMS-QQ-A-250/5 0.032 0.081 Renew
17 Angle Support AMS-QQ-A-250/5 0.032 0.081 Renew
18 Shield AMS5510 0.005 0.013 Renew
19 Filler AMS-QQ-A-250/5 0.040 0.102 Renew

NOTE: Allowable damage refer to 54-10-31, page 101.

NOTE: Assembly drawings 716RA0001-3, 716RA0001-4 and MK716RA0001-5.

Page 12
Jun.13 54-10-31
 HAWKER 800 STRUCTURAL REPAIR MANUAL

STN 200

A
PYLON (REF)

2
3

A
DETAIL
FORWARD ENGINE
HA54E
MOUNTING 058229AA.AI

Figure 4
Forward Engine Mount

Page 13
54-10-31 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

Table 4
Key to Figure 4
Material
Item Description Specification Thickness Repair
or Reference
Section Code in. cm
1 Yoke AMS4928 Machined Renew
2 Link AMS4928 Machined Renew
3 Shim AMS5517 - - Renew
Option: AMS5518

NOTE: Assembly drawings 716RA0001-3, 716RA0001-4 and MK716RA0001-5.

Page 14
Jun.13 54-10-31
 HAWKER 800 STRUCTURAL REPAIR MANUAL

11

10
11
4
16 3 5

11 22
2

5
6
6
4

23

22

3
A B 12
1
23

19
C
24

BRACKET

6 (REF)

3 (REF)

19 (REF)

DETAIL B
HA54E
058230AA.AI

Figure 5 (Sheet 1 of 2)
Lower Door - Cowl

Page 15
54-10-31 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

7
(3 PLACES)

9 8
(3 PLACES)

17

18

DETAIL C 9

20
21

14

14 14
13

13

13

15

14

15
DETAIL A 14 14 HA54E
058231AA.AI

Figure 5 (Sheet 2 of 2)
Lower Door - Cowl

Page 16
Jun.13 54-10-31
 HAWKER 800 STRUCTURAL REPAIR MANUAL

NOTE: For the Inspection/Rework of the right fan cowl door aft rod bracket refer to Service Bulletin 71-4014

Table 5
Key to Figure 5 (Sheet 1) and Figure 5 (Sheet 2)
Material
Item Description Specification Thickness Repair
or Reference
Section Code in. cm
1 Hold Open Rod AMS4082 - - Renew
2 Hold Open Rod AMS6360 - LH / - - Renew
AMS4082 - RH
3 ZEE Frame AMS-QQ-A-250/5 0.040 0.102 Renew
4 Longeron Pan AMS-QQ-A-250/11 0.032 0.081 Renew
5 Hinge AMS4050 Machined Renew
6 Hat Frame AMS-QQ-A-250/5 0.032 0.081 Renew
7 Latch Bracket AMS4050 Machined Renew
8 Latch 711RA0123-2 - - Renew
9 Doubler AMS5510 0.050 0.127 Renew
10 Longeron ZEE AMS-QQ-A-250/5 0.032 0.081 Renew
11 Angle Stiffener AMS-QQ-A-250/5 0.032 0.081 Renew
12 Drain Mast AMS4217 Casting Renew
13 Seal Fabric Reinforced Silicon Variable Renew
14 Tie Doubler AMS-QQ-A-250/11 0.032 0.081 Renew
15 Gen Exhaust AMS5510 0.040 0.102 Renew
16 Shield AMS5510 0.005 0.013 Renew
17 Drain Scupper AMS-QQ-A-250/4 0.032 0.081 Renew
18 AC Gen Deflector AMS-QQ-A-250/5 0.032 0.081 Renew
19 Vent Exhaust AMS-QQ-A-250/11 0.032 0.081 Renew
20 Oil Door AMS5510 Machined Renew
21 Oil Door Hinge AMS5510 Machined Renew
22 Hold Open Rod Bracket AMS5510 0.050 0.127 Renew
23 Hold Open Rod Hinge AMS5510 0.032 0.081 Renew
24 Skin AMS-QQ-A-250/5 0.064 0.163 Renew

NOTE: Allowable damage refer to 54-10-31, page 101.

NOTE: Assembly drawings 716RA0001-3, 716RA0001-4 and MK716RA0001-5.

Page 17
54-10-31 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

N 1

3
Y

A 2

C 1
P

U
7 3 6 6
4
5

7
DETAIL A HA54E
058248AA.AI

Figure 6 (Sheet 1 of 8)
Thrust Reverser

Page 18
Jun.13 54-10-31
 HAWKER 800 STRUCTURAL REPAIR MANUAL

11 8

23 17 16 10 9
10
F 15
SECTION B-B TYPICAL
B B
12
18
8
8
19
20
22 11

D D 13

E E 14

21 11
20
19
8
8
18
12

J 15

17 16 10
DETAIL C
24 25 20
24

22
17
19
18 16
21

SECTION D-D
SECTION E-E SIMILAR
HA54E
10 058249AA.AI

Figure 6 (Sheet 2 of 8)
Thrust Reverser

Page 19
54-10-31 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

16 15 10

18 H
17
27
G

23
26

26

20
G

4 28 26 29 4
DETAIL F 10

17

18
28 2 16

10 20 26 15 10 27

SECTION H-H

10 20 26 15 26 27 10

SECTION G-G HA54E

058250AA.AI

Figure 6 (Sheet 3 of 8)
Thrust Reverser

Page 20
Jun.13 54-10-31
 HAWKER 800 STRUCTURAL REPAIR MANUAL

16 15 10

18 L
17
20
K

26

27
28

20
K

L
20 10 15 10 20 DETAIL J 10

18

17

10 20 15 20 10
ROTATED TO TRUE VIEW

4 26 28 29 27 4

SECTION L-L
ROTATED TO TRUE VIEW

16 26 28 27 2

SECTION K-K HA54E

058251AA.AI

Figure 6 (Sheet 4 of 8)
Thrust Reverser

Page 21
54-10-31 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

34 17 35
4

18

28
30
16

33
31
15 10

31
32
R

DETAIL N
36 36

32

DETAIL R
DETAIL S SIMILAR

32

31 15 10

33

18 16
30
28
17

34

4
35 DETAIL P HA54E
058252AA.AI

Figure 6 (Sheet 5 of 8)
Thrust Reverser

Page 22
Jun.13 54-10-31
 HAWKER 800 STRUCTURAL REPAIR MANUAL

13
1

V
38

W
24
5

DETAIL U SIMILAR
T
37
2

DETAIL
39

X
38

HA54E
058253AA.AI

Figure 6 (Sheet 6 of 8)
Thrust Reverser

Page 23
54-10-31 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

13
39
1

W-W
SECTION
13
37
24
38

V-V

38
SECTION

37
5

39

X-XSECTION
1

41

40
43

42

38
13

HA54E
058254AA.AI

Figure 6 (Sheet 7 of 8)
Thrust Reverser

Page 24
Jun.13 54-10-31
 HAWKER 800 STRUCTURAL REPAIR MANUAL

45 44

ACTUATOR ASSEMBLY
(REF)
46

45

DETAIL Y

HA54E
058255AA.AI

Figure 6 (Sheet 8 of 8)
Thrust Reverser

Page 25
54-10-31 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

Table 6
Key to Figure 6 (Sheet 1), Figure 6 (Sheet 2), Figure 6 (Sheet 3), Figure 6 (Sheet 4), Figure 6 (Sheet 5),
Figure 6 (Sheet 6), Figure 6 (Sheet 7) and Figure 6 (Sheet 8)
Material
Item Description Specification Thickness Repair
or Reference
Section Code in. cm
1 Stop 2024-T3 QQ-A-250/5 Machined
2 Door Assembly See Note - -
3 Activator Fairing 6061-0 QQ-A-250/11 0.050 0.127
4 Fairing 2024-0 QQ-A-250/5 0.032 0.081
5 Deflector 2024-T42
QQ-A-250/5 0.048 0.122
6 Bracket 6061-0 QQ-A-250/11 0.064 0.163
7 Doubler 6061-0 QQ-A-250/11 0.040 0.102
8 Seal MF 846 - - Renew
9 Retainer 2024-T3 QQ-A-250/5 0.050 0.127
10 Fan Duct - Half 2024-0 QQ-A-250/5 0.080 0.203
11 Retainer Kevlar 0.050 0.127
(5 Kans 0.010 in)
12 Fan Duct Doubler 2024-0 QQ-A-250/5 0.080 0.203
13 Hinge Fitting 2024-T351
(Eff 54-001 to 54-140) QQ-A225/6 Machined
(Eff 54-141 & subs) 2219-T852
AMS4144 Forging
14 Shim 2024-0 QQ-A-250/5 Machined
15 Cover Strip 2024-0 QQ-A-250/5 0.080 0.203
16 Angle Fitting 2024-0 QQ-A-250/5 0.032 0.081
17 Stiffener 2024-0 QQ-A-250/5 0.032 0.081
18 Flange 2024-0 QQ-A-250/5 0.125 0.318
19 Angle Fitting Doubler 2024-0 QQ-A-250/5 0.050 0.127
20 Angle Fitting 2024-0 QQ-A-250/5 0.050 0.127
21 Doubler 4130 ANNEALED 0.090 0.229
22 Splice 2024-0 QQ-A-250/5 0.032 0.081
23 Hook 321-SS MIL-S-5059 Welded Assembly

Page 26
Jun.13 54-10-31
 HAWKER 800 STRUCTURAL REPAIR MANUAL

Table 6
Key to Figure 6 (Sheet 1), Figure 6 (Sheet 2), Figure 6 (Sheet 3), Figure 6 (Sheet 4), Figure 6 (Sheet 5),
Figure 6 (Sheet 6), Figure 6 (Sheet 7) and Figure 6 (Sheet 8)
Material
Item Description Specification Thickness Repair
or Reference
Section Code in. cm
24 Pick Up Angle 2024-0 A-250/5 0.050 0.127
25 Splice 2024-T3 QQ-A-250/5 0.032 0.081
26 Rib 2024-0 QQ-A-250/5 0.050 0.127
27 Rib 2024-0 QQ-A-250/5 0.063 0.160
28 Doubler 2024-0 QQ-A-250/5 0.063 0.160
29 Strap 2024-T QQ-A-250/5 0.090 0.229
30 Rear Fitting A357-T61 Casting
MIL-A-21180
31 Hinge Fitting 17-4PH AMS5355C Casting
32 Shutter 2024-T3 QQ-A-250/5 0.078 0.198
33 Angle 2024-T42 0.055 0.140
34 Front Fitting A357-T61
MIL-A-21180 Casting
35 Doubler 2024-T42 0.055 0.140
36 Angle 2024-0 QQ-A-250/5 0.080 0.203
37 Spar 2024-0 QQ-A-250/5 0.050 0.127
38 Hat Section 2024-T42 0.048 0.122
39 Door Skin Panel 2024-0 QQ-A-250/5 0.080 0.203
40 Doubler 2024-0 QQ-A-250/5 0.050 0.127
41 Serrated Plate 321-SS Machined
42 Staple 17-4PH AMS5355C Casting
43 Angle Fitting A-S7G06T6 Casting
44 Latch Box Assembly NORDAM - -
45 Striker Plate 321-SS MIL-S-6721 0.032 0.081
46 Latch Box Cover NORDAM - -

NOTE: Item 2, Door Assembly consist of Items 1, 5, 13, 24, 37, 38, 39, 40, 40, 41, 42 and 43.
NOTE: Allowable damage refer to 54-10-31, page 101.
NOTE: Assembly drawings 716RA0001-3, 716RA0001-4 and MK716RA0001-5.

Page 27
54-10-31 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

4
2
3

1
1

STN 237.36
VIEW LOOKING OUTBOARD
A
VIEW LOOKING INBOARD

6 5
TYPICAL
7 7
8 8

11

10

DETAIL B
1 1

SECTION A-A HA54E

058256AA.AI

Figure 7
Thrust Reverser - Belt

Page 28
Jun.13 54-10-31
 HAWKER 800 STRUCTURAL REPAIR MANUAL

Table 7
Key to Figure 7
Material
Item Description Specification Thickness Repair
or Reference
Section Code in. cm
1 Belt Skin 2024-0 QQ-A-250/5 0.032 0.081
2 Channel 2024-T3 QQ-A-250/5 0.040 0.102
3 Doubler 2024-T3 QQ-A-250/5 0.040 0.102
4 Grommet MS21266-IT - - Renew
5 Clip NORDAM
6 Latch Assembly NORDAM
7 Shim NORDAM
8 Plate NORDAM
9 Tongue NORDAM
10 Angle NORDAM
11 ‘U’ Bolt NORDAM

NOTE: Allowable damage refer to 54-10-31, page 101.

NOTE: Assembly drawings 716RA0001-3, 716RA0001-4 and MK716RA0001-5.

Page 29
54-10-31 Jun.13
 Jun.13
Page 30
STN 240.0 STN 226.6 STN 216.75 5 19 7 1 6 1 2

3 3

18 18

54-10-31
21

12
12 4
4 4
22
23
TYP
20
22
12

21

Figure 8 (Sheet 1 of 5)
21

Thrust Reverser - Afterbody

17

16
HAWKER 800 STRUCTURAL REPAIR MANUAL

B A
5
15
E
14 14
13
12 12 11 10 9 8 7 6 1 15

HA54E
VIEW LOOKING OUTBOARD VIEW LOOKING INBOARD

058257AA.AI
 HAWKER 800 STRUCTURAL REPAIR MANUAL

NOZZLE
ENGINE

16
(REF)

24

24
D
34
DETAIL
37

33

25

A
DETAIL
26
31

(REF)
CLIP
40

39

38

32

27
31

30

29

28
TYPICAL
35

36
D
24

B
L

DETAIL
33
C DETAIL

16
34

HA54E
C

058258AA.AI

Figure 8 (Sheet 2 of 5)
Thrust Reverser - Afterbody

Page 31
54-10-31 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

42 19
43

43 FITTED ON 7
RH NACELLE FITTED ON 41
42 ONLY LH NACELLE
ONLY 42

19
RH G
LH K
H RH
13 44
J LH

SECTION F-F
42 42
FITTED ON FITTED ON
RH NACELLE
ONLY
F LH NACELLE
ONLY

19

F
DETAIL E
LOOKING AFT

RH IS THE SAME UNLESS INDICATED HA54E

058259AA.AI

Figure 8 (Sheet 3 of 5)
Thrust Reverser - Afterbody

Page 32
Jun.13 54-10-31
 HAWKER 800 STRUCTURAL REPAIR MANUAL

6
19
13 44 13

44 41
44
7 19
45 45

42 7
6 6
13
19

44
19

7
13
7
6

DETAILK
LH NACELLE

7 7
6 19
7
13

19 19

44
6 7

6 19
13 45
45
13

44 44

13 44 6

DETAILJ DETAILH DETAILG

LH NACELLE RH NACELLE RH NACELLE HA54E
058260AA.AI

Figure 8 (Sheet 4 of 5)
Thrust Reverser - Afterbody

Page 33
54-10-31 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

21
6
7

12 48

22 34 24
47
46

49
N 16

ENGINE MOUNT
(REF)

48
N
34
22
12 7

6
21
SECTION L-L 21

54
47

48

46

55

7
46

54

1 53 52 51 21 50
ENGINE MOUNT
(REF)
SECTION N-N HA54E
058261AA.AI

Figure 8 (Sheet 5 of 5)
Thrust Reverser - Afterbody

Page 34
Jun.13 54-10-31
 HAWKER 800 STRUCTURAL REPAIR MANUAL

Table 8
Key to Figure 8 (Sheet 1), Figure 8 (Sheet 2), Figure 8 (Sheet 3), Figure 8 (Sheet 4) and Figure 8 (Sheet 5)
Material
Item Description Specification Thickness Repair
or Reference
Section Code in. cm
1 Frame - Upper and 2024-0 ALXC AL 0.032 0.081
Lower QQ-A-250/5
2 Hook SH-321-SS 0.080 0.203
3 Aft Flange DS-112-4 - -
4 Strap 2024-0 QQ-A-250/5 0.040 0.102
5 Splice Clip 2024-0 QQ-A-250/5 0.032 0.081
6 Outer Skin - Top and 2024-0 QQ-A-250/5 0.032 0.081
Lower
7 Outer Fan Duct - Top 2024-0 QQ-A-250/5 0.032 0.081
and Lower
8 Plate 2024-0 QQ-A-250/5 0.062 0.157
9 Tube 5052-0 WW-T-700/4 - - Renew
10 Doubler 2024-T3 QQ-A-250/5 0.032 0.081
11 Seal QQ-S-776 0.064 0.163 Renew
12 Angle 2024-0 QQ-A-250/5 0.032 0.081
13 Strap 2024-T3 QQ-A-250/5 0.032 0.081
14 Doubler 2024 QQ-A-250/5 0.040 0.102
15 Door - Outer Skin 2024-0 QQ-A-250/5 0.032 0.081
16 Doubler 6061-0 QQ-A-250/11 0.040 0.102
17 Outer Fan Duct Door 6061-0 QQ-A-250/11 0.040 0.102
18 Forward Flange DS-112-3 - -
19 Frame - Upper and 321-N-SS MIL-S-6721 0.032 0.081
Lower
20 Clip 6061-T6 QQ-A-250/11 0.032 0.081
21 Channel 2024-0 QQ-A-250/5 0.032 0.081
22 Door - Outer Skin 2024-T3 QQ-A-250/5 0.032 0.081
23 Grommet MS21 266-IT - - Renew
24 Inner Fan Duct - Top 6061-0 QQ-A-250/11 0.040 0.102
and Lower
25 Inner Fan Duct Door 6061-0 QQ-A-250/11 0.040 0.102

Page 35
54-10-31 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

Table 8
Key to Figure 8 (Sheet 1), Figure 8 (Sheet 2), Figure 8 (Sheet 3), Figure 8 (Sheet 4) and Figure 8 (Sheet 5)
Material
Item Description Specification Thickness Repair
or Reference
Section Code in. cm
26 Shim 6061-T6 QQ-A-250/11 0.050 0.100 Renew
27 Pad 321-SS MIL-S-5059 0.040 0.102 Renew
28 Inner Fan Duct - 6061-0 QQ-A-250/11 0.040 0.102
Forward
29 Bubble 6061-0 QQ-A-250/11 0.040 0.102
30 Doubler 6061-T6 QQ-A-250/11 0.040 0.102
31 Fairing 321-SS MIL-S-6721 0.036 0.091
32 Channel 321-SS MIL-S-6721 0.036 0.091
33 Flange 321-SS MIL-S-6721 0.036 0.091
34 Angle 6061-0 QQ-A-250/11 0.032 0.081
35 Bracket 6061-0 QQ-A-250/11 0.032 0.081
36 Pad KUNGERIT 1000 0.100 0.254 Renew
37 Coupling GRUMMAN - -
38 Ring MIL-S-6721 Machined
39 Exhaust Stub MIL-S-6721 0.032 0.081
40 Strap MIL-S-6721 0.025 0.064
41 Shim 2024-T3 QQ-A-205/5 0.025 0.064 Renew
42 Hat Channel 2024-T3 QQ-A-205/5 0.064 0.163
43 Doubler 2024-T3 QQ-A-205/5 0.040 0.102
44 Shim 2024-T3 QQ-A-205/5 0.064 0.163 Renew
45 Doubler 321-N-SS MIL-S-6721 0.032 0.081
46 Fairing 6061-0 QQ-A-250/11 0.032 0.081
47 Outer Fan Duct Door 2024-0 QQ-A-205/5 0.032 0.081
48 Doubler 6061-0 QQ-A-250/11 0.032 0.081
49 Bonding Strap GRUMMAN - -
50 Close Out Angle 6061-0 QQ-A-250/11 0.032 0.081
51 Plate 304 QQ-S-762 0.020 0.051
52 Plate 304 QQ-S-763 0.020 0.051
53 Seal NORDAM - - Renew

Page 36
Jun.13 54-10-31
 HAWKER 800 STRUCTURAL REPAIR MANUAL

Table 8
Key to Figure 8 (Sheet 1), Figure 8 (Sheet 2), Figure 8 (Sheet 3), Figure 8 (Sheet 4) and Figure 8 (Sheet 5)
Material
Item Description Specification Thickness Repair
or Reference
Section Code in. cm
54 Bracket 6061-0 QQ-A-250/11 0.032 0.081
55 Splice 6061-0 QQ-A-250/11 0.032 0.081

NOTE: Allowable damage refer to 54-10-31, page 101.

NOTE: Assembly drawings 716RA0001-3, 716RA0001-4 and MK716RA0001-5.

Page 37
54-10-31 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

NACELLES/PYLONS
54-10-31

NACELLES AND THRUST REVERSER AFTER MOD. 25G311A

STRUCTURE COMPLETE
54-10-31

ALLOWABLE DAMAGE
100100

Contents Page
Information 102

Page 101
54-10-31 Aug.18
 HAWKER 800 STRUCTURAL REPAIR MANUAL

1. INFORMATION
Except for the Forward Engine Mounting (Ref. 54-10-31, Figure 4) for which no general allowable damage
figures can be given, the relevant definitions in 51-10-02 are applicable generally subject to the limits and
conditions specified below.

A. Abrasions, Corrosion, Scores and Scratches

(1) For these forms of damage the blended-out depth allowable limit is one tenth of the material
thickness.

(2) Where frames, stiffeners and other annular, transverse or edge members are concerned only
damage lengthwise in the member may be classified as allowable, otherwise 51-10-02 paragraph
2.A applies.

B. Dents in Skin Panels, Webs or Pressings

(1) Intake

(a) Smooth dents in clear areas are generally allowable up to a maximum depth of 0.05 in.
(0.13 cm), otherwise 51-10-02 paragraph 2.C applies.

(b) Where the dent is in the outer face of the Nose skin (Ref. 54-10-31, Figure 2, Item 12), it shall
be allowable only when the profile is restored as in 51-72-00 paragraph 3.

CAUTION: Restoration of profile by means of gap filler (Ref. 51-72-00 paragraph 3B) must
not be applied to the frontal rounded surface of the Nose skin or anywhere within
this including the whole interior of the duct skin (Ref. 54-10-31, Figure 2,
Item 14).

(2) Upper panel (Ref. 54-10-31, Figure 3 (Sheet 1)), Lower Door Cowl (Ref. 54-10-31, Figure 5) and
Rear Engine Cowl (Ref. 54-10-31, Figure 6) smooth dents in clear areas are allowable up to a
maximum depth of 0.10 in. (0.25 cm), otherwise 51-10-02 paragraph 2.C applies.

C. Discoloration of Intake
If the intake lip is discolored, check for the following:-

(1) Make sure that there is no discoloration or blistering of the paint adjacent to the intake lip.

(2) There is no pitting of the intake lip material.

(3) The intake lip has not distorted.

If the intake lip is determined to be serviceable except for discoloration, the discoloration may be
reduced by polishing in accordance with AMM 125/H-20, 20-10-811, 201. The minimum thickness after
polishing to be 0.052 in. (1.32mm). Some discoloration is allowed.

Page 102
Aug.18 54-10-31
 HAWKER 800 STRUCTURAL REPAIR MANUAL

NACELLES/PYLONS
COMMON PYLON - THRUST REVERSER AFTER MOD.25G389A
54-50-22

STRUCTURE COMPLETE
IDENTIFICATION
00

Contents Figure
Fixed Cowl 1
Pylon Structure 2
Pylon Skins 3
Pylon Closing Panels 4

Page 1
54-50-22 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

Figure 1
Fixed Cowl

Page 2
Jun.13 54-50-22
 HAWKER 800 STRUCTURAL REPAIR MANUAL

Table 1
Key to Figure 1
Material
Item Description Specification Repair Reference
or Thickness
Section Code in. mm.
1 Frame TA2 0.036 0.90
2 Cleat TA2 0.028 0.70 Renew
3 Gusset TA2 0.028 0.70 Renew
4 Fork End HC106 Machined Renew
5 Bracket S154 Machined Renew
6 Landing TA2 0.036 0.90 Renew
7 Packing TA2 0.036 0.90 Renew
8 Frame TA2 0.028 0.70 Renew
9 Bracket TA2 0.028 0.70 Renew
10 Packing TA2 0.028 0.70 Renew
11 Bracket S154 Machined Renew
12 Skin TA2 0.022 0.55
13 Angle TA2 0.028 0.70
14 Edge Member TA2 0.028 0.70
15 Plate TA2 0.028 0.70 Renew
16 Diaphragm TA2 0.036 0.90 Renew
17 Diaphragm TA2 0.028 0.70 Renew
18 Joint Strap TA2 0.036 0.90 Renew
19 Bracket TA2 0.036 0.90 Renew
20 Bracket TA2 0.048 1.20 Renew
21 Shear Pin S154 Machined Renew
22 Reinforcing Plate TA10 0.080 2.00 Renew
NOTE
1. For Allowable Damage (Ref. 54-50-11, 101).
2. For cleat locations not referenced on figure 1, refer to item 2 for material specification and
thickness.
ASSEMBLY DRAWING NO: 900-449022

Page 3
54-50-22 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

28 1
1
2

7
FR22 14 L
K
H J
FR21 11
16 M
27
3
1
26 4
FORWARD
14 3
5
25 N
SKIN
16 6
8 (REF)
7 19 26 20 29 1
E 9
FR20A G 10
52

C F
1
B 20
FR19 A D
12 18
24 SKIN
13
(REF)
14
C 16
15
1 30 31 26
20

19 21 SKIN 1
23 22 21 20 19 18 17
(REF)

FIXED COWL
DETAIL A
25 VIEW LOOKING FORWARD
STRUCTURE (REF)
26
33
25

1 FIXED COWL
15 STRUCTURE (REF)
17
34

32

33
21

FIXED COWL 21
1 SKIN 30
STRUCTURE (REF)
(REF)
SECTION C-C DETAIL B HA54E
VIEW LOOKING AFT 028982AA.AI

Figure 2 (Sheet 1 of 4)
Pylon Structure

Page 4
Jun.13 54-50-22
 HAWKER 800 STRUCTURAL REPAIR MANUAL

ALL POCKET THICKNESSES ARE

18 26 52 0.180 in. (4.57 MM)
37 42
41
1 FIXED COWL
STRUCTURE SKIN 16
(REF) 26 (REF)
10

51

DETAIL G
VIEW LOOKING AFT

FIXED COWL
21 SKIN 35 16
STRUCTURE
FIXED COWL (REF)
(REF)
STRUCTURE
(REF) SKIN
(REF) 16
DETAIL D
26 VIEW LOOKING FORWARD

39 36
41
1
27

17
40 36
18

18 37
39
42
37

38 43

16
1
DETAIL E
38 VIEW LOOKING INBOARD

FIXED COWL
STRUCTURE SKIN
(REF)
DETAIL F (REF)

VIEW LOOKING FORWARD HA54E

028984AA.AI

Figure 2 (Sheet 2 of 4)
Pylon Structure

Page 5
54-50-22 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

1 16 29 1 3

20

1 44 L.H. ONLY 1 3

DETAIL H
1 46 45 1 3

20

1
DETAIL J 46 1 3

DETAIL K SIMILAR

1 50 2 49

DETAIL M
1 48 47 1 3 20

1 16 DETAIL L 1
HA54E
028983AA.AI

Figure 2 (Sheet 3 of 4)
Pylon Structure

Page 6
Jun.13 54-50-22
 HAWKER 800 STRUCTURAL REPAIR MANUAL

14 7 SKIN (REF) 3 5 4

P P

FR. 22
7 8 6 SKIN (REF) 3 20

DETAIL N
0.077in. (1.95mm.)
0.064in. (1.6mm.) FR. 22

4
5

SECTION P-P
HA54E
028985AA.AI

Figure 2 (Sheet 4 of 4)
Pylon Structure

Page 7
54-50-22 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

Table 2
Key to Figure 2 Sheet 1, Figure 2 Sheet 2, Figure 2 Sheet 3, Figure 2 Sheet 4
Material
Item Description Specification Repair Reference
or Thickness
Section Code in. mm.
1 Angle L167 0.048 1.20 (Ref. 51-71-11)
2 Rib L166 0.028 0.70 Renew
3 Landing L166 0.036 0.90
4 Web TA10 0.039 1.00 Renew
5 Web TA10 Machined Renew
6 Rear Engine Bracket S98 Machined Renew
7 Landing TA2 0.036 0.90
8 Landing S524 0.048 1.20 Renew
9 Web TA10 0.064 1.60 Renew
10 Bracket TA2 0.048 1.20 Renew
11 Cleat TA2 0.036 0.90 Renew
12 Reinforcing Plate TA10 0.080 2.00 Renew
13 Bracket TA2 0.036 0.90 Renew
14 Angle S524 0.048 1.20 (Ref. 51-71-11)
15 Access Panel TA2 0.036 0.90 Renew
16 Angle L97 Machined
17 Reinforcing Plate TA2 0.036 0.90 Renew
18 Firewall TA2 0.036 0.90
19 Seal PSS1007 - - Renew
20 Angle L166 0.036 0.90 Renew
21 Lower Angle S515 0.064 1.60
22 Nose Piece L166 0.028 0.70 Renew
23 Angle See Note Below - - Renew
24 Strip See Note Below - - Renew
25 Web TA2 0.036 0.90
26 Upper Angle S515 0.064 1.60
27 Angle TA2 0.064 1.60 Renew
28 Packing Wedge L168 Machined Renew

Page 8
Jun.13 54-50-22
 HAWKER 800 STRUCTURAL REPAIR MANUAL

Table 2
Key to Figure 2 Sheet 1, Figure 2 Sheet 2, Figure 2 Sheet 3, Figure 2 Sheet 4 (Continued)
Material
Item Description Specification Repair Reference
or Thickness
Section Code in. mm.
29 Rib L97 Machined Renew
30 Flange S154 Machined Renew
31 Web L167 0.048 1.20 Renew
32 Packing L166 0.064 1.60 Renew
33 Angle L166 0.028 0.70 Renew
34 Stiffener L166 0.028 0.70 Renew
35 Main Engine Bracket S98 Machined
36 Door TA2 0.028 0.70 Renew
37 Angle TA2 0.036 0.90 Renew
38 Angle TA2 0.028 0.70 Renew
39 Landing TA2 0.028 0.70 Renew
40 Plate TA2 0.056 1.40 Renew
41 Angle S535 0.064 1.60 Renew
42 Web S535 0.064 1.60 Renew
43 Pressing TA2 0.028 0.70 Renew
44 Bracket L166 0.036 0.90 Renew
45 Bracket L166 0.028 0.70 Renew
46 Channel L166 0.028 0.70 Renew
47 Angle L167 0.036 0.90 Renew
48 Rib L167 0.036 0.90 Renew
49 Packing Wedge L168 Machined Renew
50 Landing L166 0.048 1.20 Renew
51 Angle TA6 0.071 1.80 Renew
52 Firewall TA2 0.028 0.70 Renew
NOTE
1. Item 23 Angle and 24 Strip form a welded assembly and are made from L59, 0.064 in. (1.6 mm)
thick.
2. Item 17 Reinforcing Plate is spot welded to Item 18 Firewall to form an assembly.
ASSEMBLY DRAWING NO: 25-8ES297

Page 9
54-50-22 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

1
1 B

D
D

FOR CLOSING PANELS

SEE FIGURE 4
C
2

3
6
4

A E
4

A
E 5

6 7

10

9 8

SECTION A-A
HA54E
028986AA.AI

Figure 3 (Sheet 1 of 2)
Pylon Skins

Page 10
Jun.13 54-50-22
HAWKER 800 STRUCTURAL REPAIR MANUAL

Figure 3 (Sheet 2 of 2)
Pylon Skins

Page 11
54-50-22 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

Table 3
Key to Figure 3 Sheet 1, Figure 3 Sheet 2
Material
Item Description Specification Repair Reference
or Thickness
Section Code in. mm.
1 Panel L167 Machined (Ref. 54-50-11, 201)
2 Access Panel TA2 Machined
3 Landing TA2 0.036 0.90
4 Door Skin See Note Below - -
5 Skin Panel TA10 Machined
6 Nose Skin L166 0.036 0.90
7 Packing L166 0.064 1.60 Renew
8 Angle L166 0.028 0.70
9 Plug - Neoprene 53/soft 0.500 12.70 Renew
10 Seal X73 - - Renew
11 Doubler L167 0.048 1.20
12 Plate L167 0.040 1.00
NOTE
1. For Allowable Damage (Ref. 54-50-11, 101).
2. Item 4 Door Skins (x2) form a welded door assembly and are made from TA2, 0.028 in. (0.7 mm)
thick.
ASSEMBLY DRAWING NO: 25-8ES297

Page 12
Jun.13 54-50-22
 HAWKER 800 STRUCTURAL REPAIR MANUAL

FR. 22 FUSELAGE
FR. 21

A
1 D B 1 PYLON
TRAILING
EDGE

C C

C
1
C THRUST
REVERSER
D VIEW LOOKING DOWN ON TOP
B CLOSING PANELS. BOTTOM 1

4 1 7
CLOSING PANELS SIMILAR E
A
PYLON
STRUCTURE
(REF)
5
3 10 1
8
3

8 DETAIL E 1

7
5
2
SECTION A-A 1
PYLON
4 STRUCTURE
(REF)

4
1 SECTION D-D
6
1
5
4

SECTION C-C
BOTTOM PANELS SIMILAR
2 SECTION B-B
HA54E
028988AA.AI

Figure 4
Pylon Closing Panels

Page 13
54-50-22 Jun.13
 HAWKER 800 STRUCTURAL REPAIR MANUAL

Table 4
Key to Figure 4
Material
Item Description Specification Repair Reference
or Thickness
Section Code in. mm.
1 Skin Panel 2024-T3 QQ-A-250/5 0.080 2.00
2 Packing L166 0.064 1.60 Renew
3 Rib 2024-T3 QQ-A-250/5 0.032 0.80 Renew
4 Seal - Rubber 50744 SF14-1252 - - Renew
5 Retainer Strap 2024-T3 QQ-A-250/5 0.032 0.80
6 Bracket 2024-0 QQ-A-250/5 0.032 0.80
7 Shim 2024-T3 QQ-A-250/5 0.063 1.60
8 Angle 2024-T3 QQ-A-250/5 0.032 0.80
9 Bracket 2024-T3 QQ-A-250/5 0.032 0.80
10 Shim 2024-T4 QQ-A-200/3 Machined Renew
NOTE
For Allowable Damage (Ref. 54-50-11, 101).
ASSEMBLY DRAWING NO: 25-8ES335 (750 and 850XP), 25-8ES443 (900XP)

Page 14
Jun.13 54-50-22