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COPYRIGHT

2003

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PREPARED BY A UNITED STATES GOVERNMENT OFFICER OR EMPLOYEE AS
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FORM BY ANY MEANS, ELECTRONIC, MECHANICAL, PHOTOCOPYING,
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Aircraft Technical

Publishers

Customer Service

~u 101 South Hill Drive


Brisbane, CA 94005

6AM-5PM PST M-F

(800)227-4610

ATP Grid Index to Manufacturers Publications:

Learjet Corp.
20, 30 Series
Structural
Section
General

Repair Manual

TopiC
Information

Title Page

Safety Advisory
Manufacturers Introduction

Temporary

Revision No.

51-7

Source of Materials

Record of Revisions
Record of

Temporary

Revisions

Letter of transmittal
List of Effective

(Highlights of Changes)

Pages

Structures

51.00.00

Standard Practices

51.00.00

List of Effective

51.00.00

Structures

Pages

General

51.00.00

Aircraft Structural

51.00.00

Structural

51.00.00

Repairing

51.00.00

Loading
Secondary Structure
Primary
Aircraft Master Repair Index
Major Structural Member Locations (23/24 Series)
Major Structural Member Locations (25 Series)
Major Structural Member Locations (28/29 Series)
Major Structural Member Locations (31 Series)
Major Structural Member Locations (35/36 Series)
ID
Aicraft Measurement System
A/C Measurement System (23/24 Series)

51.00.00

51.00.00
51.00.00

51.00.00
51.00.00
51.00.00
51.00.00

51.00.01
51.00.01

06/11/2003

Description
Design Concept

Safe-Life Structure

Structure

Copyright

Aircraft Technical

GL

0020

R3)

Publishers

Page

1 of

Section

Topic

51.00.01

A/C Measurement System (25 Series)

51.00.01

A/C Measurement System (28/29 Series)

51.00.01

A/C Measurement System (31 Series)

51.00.01

A/C Measurement System (35/36 Series)

51.00.02

Restricted Ares

51.00.03

Access Doors

ID
ID

Panels

51.00.03

Access Doors

Panels (23 Series)

51.00.03

Access Doors

Panels (24/24A Series)

51.00.03

Access Doors

Panels (248 Series)

51.00.03

Access Doors

Panels (24D/E/F Series)

51.00.03

Access Doors

Panels (25/25A Series)

51.00.03

Access Doors

Panels (25/B/C/D/F Series)

51.00.03

Access Doors

Panels (28/29 Series)

51.00.03

Access Doors

Panels (31 Series)

51.00.03

Access Doors

Panels (35/36 Series)

51.10.00

Aerodynamic Smoothness
Investigation
Investigation
Materials Inspection
Airframe
Allowable Damage
Repair
Temporary Revision No. 51-1

51.30.00

Materials

51.10.00

51.10.00
51.10.00
51.10.00
51.10.00

51.30.00

Constuction Metals

51.30.00

Extrusion

51.30.01

Metal

51.30.01

Heat Treatment of Aluminum

51.30.02

Sealing Metals

51.30.03

Charts

51.30.04

Protective Treatment

51.40.00

Formed Sections
Protection

Parts-Repair

Structural

Tables

51.40.02

Rivets

51.40.03

Fastener Substitution

51.50.00
51.50.00
51.50.00
51.50.00
51.70,00
51.70.01

06/11/2003

ID

Fasteners

Threaded Fasteners

51.50.00

Alloys

Repair

Structural

51.40.01

51.40.04

Steel

Blind Fasteners

Countersinking
Structural
Repair
Support For Alignment
Symetry Inspection
Alignment
Surface Alignment Inspection
Elevation Inspection Procedures
Level
Support Equipment for Aircraft Repair
Repairs

ID

Aircraft Skin Dents

Copyright

Aircraft Technical
GL

0020

R3)

Publishers

Page

2 of

Secti on

Topic

Temporary Revision No. 51-2

51.70.01
51.70.02

Aircraft Skin

51.70.02

Temporary

Revision No.

51.70.03

Formed Section

51.70.04

Extruded Section

51.70.05

Fiberglass Structures

51.70.06

Corrosion

51.70.07

Honeycom Insert

51.70.08

Seat Rail

51-6

51.71.10

Repair Data
Wing-To-Fuselage Fittings
Flap Fittings
Spoiler Fittings
Aileron System
Tip Tank Fittings
Landing Gear Fittings
Engine Mount Fitting
Rudder Fittings
Horizontal Stabilizer Fittings
Elevator System

51.71.11

Keelbeam Assemblies

51.71.12

Mach Trim System

51.71.13

Control Column Assembly

51.71.14

51.71.18

Passenger/Crew Upper
Passenger/Crew Lower
Passenger/Crew Upper
Passenger/Crew Lower
Quadrant Assembly

51.71.19

MLG Power Brake Valve

51.71.20

Main Gear Door

51.71.21

Main Gear Shock Strut

51.71.22

Nose Gear Shock Strut

51.71.23

Main Gear Actuator

51.71.24

Main Door

51.71.25

Nose Gear Actuator

51.71.26

Nose Gear

51.71.27

Nose Gear Door Mechanism

51.71.28

Flap Peselect Assembly

51.71.00
51.71.01
51.71.02

51.71.03
51.71.04
51.71.05
51.71.06
51.71.07
51.71.08
51.71.09

51.71.15
51.71.16
51.71.17

Allowable Wear

Door

Door

Linkage

Uplatch

Uplatch

Mechanism

Uplatch

52.00.00

Doors

52.00.00

List of Effective Pages

06/11/2003

Door

Door

Copyright

Aircraft Technical Publishers


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0020

R3)

Page

3 of

Section

Topic

52.00.00

General

52.10.00

52.20.00

Passenger/Crew
ID
Passenger/Crew Upper Door (24 IN.)
ID
Passenger/Crew Upper Door (36 IN.)
Passenger/Crew Upper Door-Allowable Damage
ID
Passenger/Crew Lower Door (24 IN.)
ID
Passenger/Crew Lower Door (36 IN.)
Passenger/Crew Lower Door-Allowable Damage
Emergency Exit
Structural Identification-Damage and Repair

52.40.00

Service

52.10.00
52.10.00
52.10.00

52.10.10
52.10.10

52.10.10
52.20.00

52.40.00

Tailcone Access door

52.40.05

Nose

52.40.10

Oil

52.40.15

Oxygen Bottle Access Door

52.80.00

52.80.00
52.80.10
52.80.20
52.81.00

Compartment

Access Doors

Filter Access Door

Single-Point Pressure Refuel Door


Landing Gear
Main Landing Gear Doors
Main Landing Gear Inboard Door
Main Landing Gear Outboard Door
Nose Landing Gear Door

53.00.00

Fuselage

53.00.00

List of Effective

Pages

53.00.00

General

53.10.00

Nose

53.10.00

(23
Repair Index
(Late Model
Repair Index
Allowable Damage
Repair
Fuselage Assembly
Fuselage Assembly
Fuselage Frames
Fuselage Stringers

53.10.00
53.10.00
53.20.00
53.20.00
53.21.00
53.22.05

Assembly
Early Model
24

Windshield Structure

53.25.00

Fuselage Instrument Panel Support Structure


Fuselage circuit Breaker Panel Structure
Fuselage Skins

53.28.00
53.28.00
53.28.00
53.28.00

06/11/2003

Repair Index
Repair Index
Repair Index
Copyright

24 Series)

25/28/29/31/35/36)

53.24.00

53.26.00

Repair

Service Doors

52.40.01

52.40.20

Repair

(23/24 Series

(25/28/29 SRS.W/24IN.Psngr/Crw Door)


(25/28/29 SRS.W/36IN.Psngr/Crw Door)

Aircraft Technical
GL

0020

R3)

Publishers

Page

4 of

Section

Topic

53.28.00

Repair

53.28.00

Allowable Damage

53.28.00
53.29.00
53.30.00
53.30.00

Index

(31/35/36 Series)

Temporary Revision No. 53-1


Baggage Floor Structure
Fuselage Seat
Tailcone Assembly
Temporary Revision No. 53-4

53.31.00

Tailcone Bulkhead (Frame)

53.32.00

Tailcone

53.33.00

Tailcone Ventral Fin

53.33.00
53.33.00

Stringers
Stringer

Index

(35/36 Series)

Repair
Repair Index

(31 Series)

53.34.00

Tailcone Dorsal Assembly

53.35.00

Tailcone Skins

53.36.00

Delta Fins

53.36.00

53.40.05

Temporary Revision No. 53-2


Fuselage Fuel Cell
Fuselage Fuel Cell Structure

53.50.00

Keelbeam Assemblies

53.40.00

53.51.00

Forward Keelbeam

53.53.00

Underwing Keelbeam

53.55.00

Aft Keelbeam

54.00.00

Nacelles/Pylons

54.00.00

List of Effective Pages

54.00.00

General

54.10.00

Nacelles

54.10.10
54.20.00

Nacelle Firewall
Cowls

54.20.10

Upper Cowl

54.20.20

Lower Cowl

54.30.00
54.30.10

54.30.10
54.30.20
54.30.30

54.30.40
54.50.00
54.50.00

Engine Nacelle
Engine Inlet Assembly
Temporary Revision No. 54-1
Duct Assy, Fan and Inner Wall
Engine Nacelle Afterbody
Engine Exhaust Nozzle Assembly
Pylons
Structural Identification-Damage

55.00.00

Stabilizers

55.00.00

List of Effective Pages

06/11/2003

Copyright

Repair

Aircraft Technical Publishers


GL

0020

R3)

Page

5 of

Section

Topic

55.00.00

General

55.10.00

Horizontal Stabilizer

or

(23/24/25/28/29/31 Series)
(35/36 Series)

55.10.00

Repair Index
Repair Index

55.10.00

Allowable Damage and

55.10.00

Canard

Repair

Structural ID

55.20.00

Elevator

55.20.00
55.20.00

Repair
Repair

55.20.00

Allowable Damage

55.30.00

Vertical Stabilizer

Index

(23/24/25 Series)

Index

(28/29/31/35/36 Series)

Repair
Structural ID

55.30.00

Repair Index

(23/24/25 Series)

55.30.00

(28/29/31 Series)

55.30.00

Repair Index
Repair Index

55.30.00

Allowable Damages

55.35.00

55.35.00
55.35.00

55.35.00
55.40.00
55.40.00

Tip
Temporary Revision No. 55-2
Repair Index
Allowable Damage
Repair
Trim Tab

Rudder

Temporary Revision
Windows

56.00.00

List of Effective Pages

56.20.00
56.20.00

Windshield

Passenger Compartment
Cabine Window

56.20.00

56.20.00

Allowable Damage

Index

57.00.00

Wings

57.00.00

List of Effective Pages

57.00.00
57.10.00

57.11.00
57.11.10
57.11.20

06/11/2003

Early Mode: 24 Series)


25/28/29/31/35/36)
(Late Model 24
(23

Index

Repair
Repair

57.00.00

No. 55-1

Flight Compartment

56.20.00

57.00.00

(28/29/31 Series)

Rudder

56.00.00

56.10.00

Repair

Fin

55.40.00

56.10.00

(35/36 Series)

Repair

General

Temporary Revision
Temporary Revision

No. 57-1
No. 57-4

Center Wing

Wing

Structural ID

(23/34/35 Series)
(28/29/31 Series)

Repair Index
Repair Index

Copyright

Aircraft Technical
GL

0020

R3

Publishers

Page

6 of

Section

Topic

57.50.00

(35/36 Series)
Repair Index
Wing Tip
Winglet (Inner)
Winglet (Outer)
Tip Tank
Trailing Edge and Trailing Edge Devices
Structural Identification
Flap
(23
Early Model 24/25/35/36 Series)
Repair Index
28/29/31 Ser)
Repair Index (Late Mod 24/25/35/36 Ser
Allowable Damage
Repair

57.60.00

Aileron

57.11.30
57.30.00
57.30.10
57.30.20

57.31.00
57.50.00
57.50.00

57.50.00
57.50.00

57.60.00
57.60.00
57.60.00

57.60.00
57.60.00
57.60.00

57.60.10
57.60.10

57.60.10
57.60.10
57.60.20
57.60.20
57.60.20

57.60.20
57.60.20
57.70.00
57.70.00
57.70.00

Aileron

Repair
Repair
Repair
Repair

Structural

Identification

Index

(23 Series)

Index

(Early Model 24 Series)


(Early Model 25 Series)

Index
Index

Allowable Damage
Aileron Balance Tab

Repair Index
Repair Index
Allowable Damage
Aileron Trim Tab

(Late 24/25

All 28/29/31/35/36)

Repair
Structural

Identification

(23 Series)

(24/25/28/29/31/35/36

Series)

Repair
Structural

Identification

(23 Series)
Repair Index
(24/25/28/29/31/35/36 Series)
Repair Index
Allowable Damage
Repair
No. 57-3
Revision
Temporary
Spoilers
Repair Index
Allowable Damage
Repair

End of Index

06/11/2003

Copyright

Aircraft Technical Publishers


GL

0020

R3)

Page

7 of

NI FG

INTRO

~Learjet
Strwctwral

Repair Manual

Learj et
20/30

Series Aircraft

P.O. BOX 7707, MID-CONTINENT AIRPORT, WICHITA, KANSAS 67277-7707

May 15, 1992


SRM-4

Revised

Tuly 10,

1998 (Rev. No. 4)

STRUCTURAL REPAIR MANUAL


1.

Safety Advisory
WARNING:

BEFORE USING ANY OF THE MATERIALS CALLED OUT IN THIS PUBLICATION,


BE AWARE OF ALL HANDLING, STORAGE AND DISPOSAL PRECAUTIONS
RECOMMENDED BY THE MANUFACTURER OR SUPPLIER. FAILURE TO COMPLY WITH THE MANUFACTURERS OR SUPPLIERS RECOMMENDATIONS MAY

RESULT IN PERSONAL

INJURY

OR DISEASE.

This

publication describes physical and chemical processes which may require the use of chemicals, solvents, paints, and other commercially available materials. The user of this publication should obtain the
Material Safety Data Sheets (OSHA Form 20 or equivalent) from the manufacturers or suppliers of the
materials to be used. The user must become completely familiar with the manufacturer/supplier information and adhere to the

procedures, recommendations, warnings


handling, storage, and disposal of the materials.

and cautions set forth for the safe use,

Safety Advisory
Page 1
SRM~

Jan 15/93

RECORD OF REVISIONS

MFG REV
NO
4

DESCRIPTION

ISee Highlights

ISSUEDATE
7/10/98

ATPREVDAT

10/1/98

INSERTED BY
ATP/KS

jet
Record of Revisions

Record of
Revisions

Date of

Issue

Insertion

By

Date

Jan 15/93

05/19/931ATP/P

Jun 1/95

08/24/951ATP/JX

Jun 6/98

Jul 10/98

Record of

Date of

Insertion

Revisions

Issue

Date

By

07/23/98(ATP/ES

10/01/981ATP/KS

Record of Revisions
SRM-4

Page

Jul 10/98

RECORD OF TEMPORARY REVISIONS

ATP REV

INSERT

DATE

REV

REMOVE

ISSUE DATE

DATE

BY

REMOVED

INCOR

BY

TEMP
REV NO

DESCRIPTION

57-3

57-60-20:201

3/30/98

6/11/98

ATP/ES

53-1

53-36-00:102

7/1999

9116/99

ATPIVM

54-1

54-30-10:4

8/1 3/99

10/28/99

ATPIKS

57-4

57-00-00:205

8/31 /00

1 1 /9/00

ATPIM B

55-2

55-35-00:1

10/30/00

311 5101

ATP/IB

51-6

51-70-02:201

1/15/01

4/1 2/01

ATPIMG

53-1

53-28-00:101

6/1 5/01

8/1 6/01

ATP/MG

53-2

53-36-00:102

7/1/01

8/1 6/01

ATP/MG

53-4

53-30-00:201

1/18/02

4/25/02

ATP/MG

51-7

Manufactures Intro

4118/03

6/19/03

ATP/VDR

Page

8/16/01

TR

53-

ATP/MG

Learjet
Ledrjei(
Record of Temporary Revisions

Rev.
No.

51-1

Issue
Date

8/15/97

51-3

9/18/97

9/12/97

ATP/tIIB

ATP/XS

11

1(

Ir

2/13/98
11

5/14/98

/ES

53-1

7/01/99

9/16/99

/VM

54-1

08/13/99

10/28/99

ATP/KS

57-4

8/31/200

11/9/200

ATPI~B

03/14/01

ATP/IB

53-2

08/30/00
1/15/01

4/12/01

ATP/MC

6/15/01

8/16/01

ATPIMC~

7/1/01

II

,1

II

I~

Ir

1~

II

II

II

6/11/98

53-1

/,Me

7/23/98

/HP

3/30/98

51-6

6/6/98

1~

57-3

55-2

By

Insertion
Date

Issue
Date

~1

11/27/97

51-5

57-2

No.

11

51-4

55-1

Rev.

By

Date

11

51-2

57-1

Insertion

TR

53-

7/1/01

8/16/01

ATPI~"C-

Record of

Temporary Revisions
Page 1
Aug 13/99

SRM-J

Learjet
Record of

REV.

DATE

DATE

NO.

INSERTED

REMOVED

51-1

Aug 15/97

PAGE
NUMBER

REV.

DATE

NO.

INSERTED

Temporary Revisions

DATE
REMOVED

PAGE
NUMBER

51-10-00

Page 202
51-2

51-70-01

Aug 15/97

Page
51-3

51-4

51-5

Sep 12/97

Sep 12/97

Sep 12/97

201

Jun 6/98

51-71-10

Rev 3

Page 8

Jun 6/98

51-71-10

Rev 3

Page

Jun 6/98

51-71-10

Rev 3

Page

16

20

51
SILM--I

Record of

Temporary

Revisions

Page

jun 19/95

I)OM~ARDKR

BOMBARDIER
AEROSPACE
Learjet

Inc.

P.O. Box 7707

Wichita, KS 67277-7707 United States


Telephone 1(316) 946-2000
http://www.aerospace.bombardier.com

July 10,

1998

Holders of

TO:

Learjet 20/30

Revision No. 4, dated

SUBJECT:

Revision No. 4 consists of

Series Aircraft Structural

Repair Manual

July 10,.1998

total reissue of the List of Effective

Pages (LOEP)

for

chapter

51.

Revise the LOEP

After

by inserting revised

inserting this revision,

pages and

removing superseded

note necessary information

on

LOEP pages.

the "Record of Revisions" in

the front of the manual.


Direct any

questions concerning distribution (change in address, quantities, etc.)

Learjet Inc., P.O. Box 7707, Wichita, Kansas 67277-7707. Attn: Technical
Telephone (316) 946-2393. FAX (316) 946-2580.

Center (MS 71).

Jack Kramer

Manager,
Technical Publications

to

Data Control

BOMBARDIER

BOMBARDIER
AEROSPACE
Learjet

Inc.

P.O. Box 7707

Wichita, KS 67277-7707 United States

Telephone 1(3161 946-2000


htto.//www.aerosoace .bombardier. corn

Date:

June 19, 1998

To:

Holders of

Subject:

Correction to Record of

Description:

During development of

Learjet 20/30 Series Structural Repair

Temporary

Manual

(SRM4).

Revisions.

Revision 3 to the 20/30 Series Structural

Repair

Manual

dated June 6, 1998, incorporation of Temporary Revisions 51-1 and 51omitted, Please retain TR 51-1 and TR 51-2, both dated Aug 15/97, to

(SRM-4),
2 were

maintain the SRM-LF to the latest

Temporary
Note:

configuration.

Notate the TRs in the Record of

Revision.

Temporary

Revisions TR-51-3, TR 51-4 and TR-51-5

were

incorporated

in Revision 3.

Additional

copies

of TR 51-1 and TR 51-2

are

available

through Learjet Inc.,

P.O.

Box 7707, Wichita, Kansas 67277-7707, Technical Data Control Center (MS 71),
Telephone (316) 946-2393. FAX (316) 946-2580.
We at

Learjet apologize for any inconvenience.

LEARJET\NC.
Customer

Support

Learjet

STRUCTURAL REPAIR IIRANUAL


Chapter

Chapter
I

Section

Subject

Page

.TITLE

Date

Section

Subject

Page

Date

Jul 10/98

Squawk Sheet
Rec. of Revs.

Safety Advisory

Jul 10/98
Jan 15/93

Jul 10/98

May 15/92
May 15/92
May 15/92
May 15/92
May 15/92

*INTRODUCTIONList of Eff.

Pgs.

INTRODUCTION
Contents
INTRODUCTION

INTRODUCTION

INTRODUCTION

INTRODUCTION

Insert Latest Revised

Pages; Destroy Superseded or Deleted Pages.


Asterisk indicates pages revised, deleted, or added by current revision.
The portion of the text affected by the current revision is indicated by a vertical line in the outer

margin of the

page

INTRODUCTION
SRM-4

List of Effective

Pages
Pagel

Jul 10/98

Learjet

STRUCTURAL REPAIR MANUAL


Chapter
Section

Subject

Subject

INTRODUCTION

INTRODUCTION

Page

Scope

INTRODUCTION

Format

TNTRODUCTION

Repairs

INTRODUCTION

Part Numbers

Revisions

INTRODUCTION
INTRODUCTiON

Page Numbering System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INTRODUCTION

Source of Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INTRODUCTION

~TRODUCTION- Contents

SRM-II

Pagel
May 15/92

LEARJET 20/30 SERIES

STRUCTURAL REPAIR MANUAL

TEMPORARY REVISION NO. 51-7


MANUAL AFFECTED:

Learjet

20/30 Series Structural

adjacent

Insert

FILING INSTRUCTIONS:

to the

Repair

Manual

(SRM-4).

Introduction, page 1,dated May 15/92 and retain until fur-

ther notice.

REASON:

1.

Revise

2.

Add

INSIRUCTIONS:

1.
2.

paragraph A. under 1. SCOPE.


paragraph C. under 3. REPAIRS.

new

Update paragraph A. to read as follows:


new paragraph C. to read as follows:

Add

INTRODUCTION
1.

SCOPE
A.

repair manual is to acquaint maintenance personnel with the acceptable


repairs of the Learjet and to direct them in the proper procedures for maintaining the aircraft
in an airworthy condition. The ability of maintenance personnel is recognized, and procedures that are
considered common to all aircraft have been briefly referenced or omitted.

The function of this structural

structural

B.

(No changes)

2.

FORMAT(No changes)

3.

REPAIRS(Nochanges)
A.

(Nochanges)

B.

(Nochanges)

C.

provided in this Structural Repair Manual may be considered "data acceptable to the
administrator" per CFR 14, Part 43. Ultimately it is the responsibility of the person returning the
aircraft to service to determine the state of any repair made using this information with regard to the
requirement for FAA approval and obtain FAA approval if required. With this in mind, it is

The data

early contact be made with Learjet


may be provided in a timely manner.

recommended that

appropriate data

Field

Support Engineering

so

that the

provided by Field Support Engineering is based on information developed by the


cognizant engineer. Verbal information provided in person or by telephone is considered advisory and
does not carry any status relative to FAA approval. Written information provided by fax, memo, or email is used when required to address "Minor" repairs or deviations to published data. "Major" repairs
or alterations are addressed by released engineering drawings and are FAA approved when
accomplished by a DERs 8110-3 form.
All technical data

(Nochanges)

4.

PARTNUMBERS

5.

REVISIONS

6.

PAGE NUMBERING SYSTEM

(Nochanges)
(No changes)

TEMPORARY REVISION NO. 51-7

SRM-4

Page

1 of 1

Apr

18/03

Leariet i
Learjet

STRUCTURAL REPAIR MANUAL


INTRODUCTION
i.

SCOPE

A.

The function of this structural

repair manual is to acquaint maintenance personnel with the approved


repairs of the Leajet and to direct them in the proper procedures for maintaining the aircraft in an airworthy condition. The ability of maintenance personnel is recognized, and procedures
that are considered common to ail aircraft have been briefly referenced or omitted.
This manual is to be used in conjunction with the applicable maintenance manual.
structural

B.
2

FORMAT
A.

This manual has been


as a

3.

format to

prepared using the Air Transport Association (ATA) Specification Number


guide repair personnel in the inspection and repair of Learjets.

100

REPAIRS
A.

B.

Chapter 51 covers repairs that are common to more than one airframe structural section. These repairs are divided into "typical" and "special" classes. The typical repair section provides that data necessary for the repair person to develop his own repairs. The special repairs are located in their respective chapter and provide that data necessary to accomplish the repairs.
Repair coverage for Chapters 52 through 57 is found in the repair indexes for each chapter. These indexes consist of master repair indexes or component repair indexes as applicable. Repair indexes
give the Learjet drawing number, descriptive nomenclature, material data, and figure/reference number(s) for each item illustrated.

4.

PART NUMBERS

A.

This manual must not be used for

identifying spare parts by number. Consult the appropriate Leajet


for this information. Part numbers are used in this manual only as a means
of identification when the nomenclature alone is inadequate. The numbers are often incomplete.
Illustrated Parts

5.

Catalog

REVISIONS

A.

The "List of Effective

Pages" (LOEP)

with each

chapter

tool for maintaining the manual.


chapter is revised. When revision
pages are received, the list should be used as a cross reference for inserting the new/revised material
and deleting the obsolete material. This ensures that all obsolete material is destroyed and the manual is kept current. Revisions to text are indicated by change bars (vertical lines) in the outer margin of
the page adjacent to the revised material. Revisions to illustrations may be indicated by change bars
or pointing hands.
serves as a

The LOEP will be revised whenever the material in the affected

EFFECTIVITY:

ALL

NOTE: Please

see

the

TEMPORARY

SRM-4

REv,s,on,

that revises this page.

INTRODUCTION

Pagel
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
6.

PAGENUMBERING SYSTEM
A.

Page

numbers used in this manual consist of three element numbers

which the page number and date

B.

C.
D.

are

separated by dashes,

under

printed.

5lliPO1

Chapter/System

Section/Subsystem

Subject/Unit

(Structures General)

(Fasteners)

(Fastener Types)

chapter/system element number is followed by zeros in the section/subsystem and


subject/unit positions (51-00-00), the information is applicable to the entire system.
Whe~ver the sec~tion/subsystem element number is followed by zeros in the subject/unit position
(51-40-00), the information is applicable to the subsystems within the system.
The subject/unit element number is used to identify information applicable to units within. The subject/unit element number progresses from the number -01 in accordance with the number of subsysWhenever the

tem/units covered.
E.

system/subsystem/unit data is separated into specific types ofinformation.


bers are used to identify the type of information as follows:
All

Blocks of page

num-

Structural Identification
Ithrough 99
AllowableDamage
throughl99
201 through299 -Repairs

Pages
Pages
Pages

101

F.

Some units may not require all the information listed in these three blocks of
those blocks of numbers are omitted.

G.

The

numbers, in which

case

following is a breakdown of a typical page number:


Structures General

Fasteners

51~001

Second

Pageof Fastener
Type Structural

Page 2
May15/92

Fastener

Types

1
Date of Issue/Revision

Identification

H.

Illustrations
ure

use

the

same

figure number as the page block in which they appear. As an example, Figappearing in the structural identification section.

2, will be the second illustration

EFFECTIVITY:

ALL

INTRODUCTION

Page 2
SRM4

May 15/92

STRUCTURAL REPAIR MANUAL


7

SOURCE OFMATERIALS
A.

by federal
Figure 1.

Manufacturers shown
in numerical order in

VENDOR

CODE"

01022

vendor codes in tools and

I
MANUFACTURER

Phillips Screw

MANUFACTURER

B.F. Goodrich

92663

Co.

Akron, OH 44318
29666

Huck

6 Thomas

Gloucester, MA 01930

INine, CA 92714

Cherry/Textron Inc.

30655

Amerace

Corp.

2330 Vauxhall Road

Santa Ana, CA 92707

Union, NJ 07083

Dynatron/Bondo Corp.

Magnaflux Corp.

37676

7300 W. Lawrence Ave.

Chicago, IL

Martin-Senour Co., The

Corp.

ESNA Division

P.O. Box 2157

47695

60656-3811

Div. of Sherwin-WilIiams Co.

PPG Industries, Inc.


One Gateway Center

2500 S. Senour Ave.

Pittsburgh,

Chicago,IL

PA 15222

60608
60883

Ametek Inc.

Deutsch Fastener

Heat Transfer Division

Corp.
Imperial Highway
Los Angeles, CA 90045-3643
7001 W.

17431

Co.

One Kondelin Road

Atlanta, GA 30318

17419

Mfg.

Sub. of Federal-Mogul

2160 Hills Ave. N.W,

16772

500 S. Main

Div. of Rule Industries

Fasteners Products Division

16522

I VENDOR
I CODE*

25472

Newport Beach, CA

11815

Lok-Fast, Inc.
864 W. 16th St.

05755

equipments lists in the chapters are listed

2300 W. Marshall Drive

Grand Prairie, TX 75051

DeVilbiss Co.

P.O. Box 913

61102

Purer

Toledo, OH 43692

Corp.

Turco Products Division


P.O. Box 6200

Carson, CA 90749
24210

Leajet Inc.
P.O. Box 7707

71286

Rexnard Inc.

Specialty Fastener Div.

Wichita, KS 67277-7707

601 Rt. 46 West


Hasbrouck

Vendor code numbers

correspond

to those referenced in tools and

Heights, N~

equipment lists throughout

07604

the manual.

Source of Materials

Figure
EFFECTIVITY:

AU

(Sheet 1 of 2)

INTRODUCTION

Pa~e 3
May 15/92

Lear
~el

STRUCTURAL REPAIR MANUAL


VENDOR

CODE

73197

MAN~ACTURER

I VENDOR
I CODE

MANUFACTURER

Hi-Shear
2600

Corp.
Skypark Drive

Torrance, CA 90509
76689

Monogram Industries, Inc.


Sub. of Nortex Inc.
1299 Ocean Ave.
Santa Monica, CA 90401

82748

Ruger Equipment

Inc.

P.O. Box 724

Uhrichsville, OH 44683
83324

Rosan Inc.

2901 West Coast

Highway
Newport Beach, CA 92663
83574

Products Research and


Chemical

Corp.

5430 San Femando Road

Glendale, CA 91203
94961

Minnesota
3M Center

Mining Mfg.
Building

Co.

St. Paul, MN 55144


99384

M and T

Chemicals,

Inc.

Furane Products Division


5121 San Fernando Rd. W.
Los

Angeles, CA

Vendor code numbers

correspond

90039

to those

referenced in tools and

equipment lists throughout the manual.

Source of Materials

Figure
EFFECTIVITY:
SRM~

ALL

(Sheet 2 of 2)

INTRODUCTION

Page 4
May 15/92

CHAPTER

STANDARD
PRACTICESSTRUCTURES

Learjet I

STRUCTURAL REPAIR MANUAL


Chapter
Section

Subject

Subject
AIRCRAFT- STRUCTURAL IDENTIFICATION

Page

.................................................................51-00-00

Aircraft Structural

Description
Structural Design Concept
Repairing Safe-Life Structure
Structure Loading
Primary and Secondary Structure.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aircraft Master Repair Index
Major Structural Member Locations (Model 23/24 Series Aircraft)
Major Structural Member Locations (Model 25 Series Aircraft)
Major Structural Member Locations (Model 28/29 Series Aircraft)..........
Major Structural Member Locations (Model 31 Series Aircraft)
Major Structural Member Locations (Model 35/36 Series Aircraft)
Aircraft Measurement System Structural Identification
Aircraft Measurement System Description
Aircraft Measurement System (Model 23/24 Series Aircraft)
Aircraft Measurement System (Model 25 Series Aircraft).......
Aircraft Measurement System (Model 28/29 Series Aircraft).....
Aircraft Measurement System (Model 31 Series Aircraft)
Aircraft Measurement System (Model 35/36 Series Aircraft)

51-00-00

1
2

................................................................................................51-00-00

51-00-00

51-00-00

51-00-00

51-00-00

51-00-00

...........................51-00-00

51-00-00

10
12

...........................51-00-00

51-00-00

13

............................................51-00-01

51-00-01

51-00-01

51-00-01

15

....51-00-01

28

51-00-01

54

51-00-02

41

..............................51-00-01

Restricted Areas

Structural Identification

....................................................................51-00-02

Restricted Areas Description


Access Doors and Panels Structural Identification
Access Doors and Panels

Description

51-00-03
1

......................................................................51-00-03

(Model 23 Series Aircraft)....


Access Doors and Panels (Model 24/24A Series Aircraft)..........
Access Doors and Panels -(Model 24B Series Aircraft).....................................
Access Doors and Panels (Model 24DIEIF Series Aircraft)
Access Doors and Panels (Model 25/25A Series Aircraft)

51-00-03

51-00-03

51-00-03

Access Doors and Panels

51-00-03

12

51-00-03

15

Access Doors and Panels -(Model 25B1CIDIF Series Aircraft)

51-00-03

19

(Model 28/29 Series Aircraft)


Access Doors and Panels (Model 31 Series Aircraft)
Access Doors and Panels -(Model 35136 Series Aircraft)

51-00-03

24

51-00-03

29

51-00-03

34

Access Doors and Panels

INVESTIGATION AND AERODYNAMIC

SMOOTHNESS- STRUCTURAL IDENTIFICATION......................................................51-10-00

Investigation

51-10-00

Airframe and Materials Inspection


Airframe Inspection

51-10-00

1
1

....................................................................................................51-10-00

Overpressurization or Hard Landing Inspection


Overheat Inspection
Structural Joint Wear Inspection
Investigation and Aerodynamic Smoothness Allowable Damage
Damage Classifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Causes and Types of Damage.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Investigation and Aerodynamic Smoothness Repair. . . . . . . . . . . . . . . . . . . . . . . . . 51-10-00
Aerodynamic Smoothness

...................................................51-10-00

51-10-00

51-10-00

51-10-00
51-10-00

101

51-10-00

101

51-10-00

201

51-Contents

Page~
SRM-4

Jun 1/95

STRUCTURAL REPAIR MANUAL


Chapter
Section

Subject

Subject

MATERIALS- STRUCTURAL IDENTIFICATION

51-30-00
51-30-00

Construction Materials
Metal Parts

Repair and

51-30-01

Alloy
Alloys.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51-30-01
Repair

Sealing
Description
Tools and Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-30-02
Preparation of Faying Surfaces Prior to Sealing
Types and Classes Used for Sealing
Sealing Requirements
Sealing Application for Structural Repairs..........
Method of Application
Fillet Sealing
Injection Sealing.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Faying Surface Sealing.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Pack Sealing
Hole Sealing

51-30-02
51-30-02

.........51-30-02
51-30-02

51-30-02

51-30-02

51-30-02

51-30-02

12
12

51-30-02

Structural Identification

Specifications and Code Number..................................................................51-30-04


Vapor Degreasing.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solvent Cleaning.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abrasive Cleaning of Metals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Primer

51-30-04

51-30-04

51-30-04

51-30-04

51-30-04

11
12

Applying Epoxy
Applying Solid Dry Film Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-30-04
Applying Fuel Resistant and Corrosion Protection Finish....................................51-30-04
.............................................................................................51-30-04

Protection for Dissimilar Metal Contact...................................................................

1
1

Finish

Chemical Film Treatment of Aluminum and Aluminum Alloys................


Applying Sanding Surfacer to Laminated Fiberglass Parts

201

51-30-04
51-30-04

General

12

51-30-03

51-30-03

Charts and Tables


Protective Treatment of Structural Materials

51-30-02

.................................................................................................................51-30-02

Sealing

.................................................................................................51-30-02

Charts and Tables

.....................................................51-30-02

Fastener

201
201

Heat Treatment of Steel

Structural

51-30-01

Protection

Heat Treatment of Aluminum

Metal

Page

13
14

51-30-04

16

51-40-00

FASTENERS- GENERAL.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-40-00

General
Threaded Fasteners

............................................................................................................51-40-01

Torquing Threaded Fasteners.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51-40-01


Installing Threaded Fasteners and Washers
Inspecting Threaded Fasteners..................................................................................
Using Torque Wrenches
Rivets and Blind Fasteners

51-40-01

51-40-01

51-40-01

................................................................................................51-40-02

51-40-02

Rivet Failures

51-40-02

Rivet

51-40-02

Description
Inspection

51-Contents

SRM-4

Page 2
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


Chapter
Section

Subject

Subject

Page

5140-03

Fastener Substi ution. ,. . . . . .

General

51-40-03

Countersinking

51-40-04
51-40-04

General
AIRCRAFI~ SUPPORT FOR ALIGNMENT AND REPAIR
STRUCTURAL IDENTIFICATION

Symmetry Inspectio,
Alignment
Surface Alignment Inspection
Level and Elevation Inspection Procedures.. . . . . . . . . . . . .. .51-50-00
Support Equipment for Aircraft Repair

51-50-00
51-50-00

and

1
1

1
2

....................51-50-00

3
30

..........................51-5MH)

5170-00

REPAIRS- GENERAL.. . . . . . . . . . . . .
General
Classification of Repairs

51-70-00

51-70-00

51-70-00

51-70-00

Typical Repair Procedure....................51-70-00


51-70-00
Structural Loading
51-70-00
and
Limitations
Inspections

Support of Structure During Repair


Checking Alignment

Materials and Proces es. . . . . . ~ 5170-0


Maintenance Practices. . . . . . 51-70-0O

Application of Loctite
Applying Loctie. . . . . . . - - 51~70-0O
Installing Oversized Fasteners
Installing Bushings in Oversized Holes
Application and Use of Structural Adhesive
Aircraft Skin Dents Typical Repair
Minor Dent Repair
Major Dent Repair
Application of Aerodynamic Fairing Compound
Aircraft Skin Typical Repairs. . . . . . . . . . 51-70-02
Skin Repairs. . . . . . .
Formed Section Typical Repairs..
Severed or Damaged Formed Section Repair
Extruded Section Typical Repairs......................
Extruded Section Repair
Fiberglass Structures

51-70-00

3
3
3

201
201
203

..........51~70-00

51-70-00

209
212

.......................51-70-00

51-70-01

51-70-01

201

51-70-01

201

51-70-01

202

51-70-02

201

51-70-03
51-7003

201

51-70-04
.......51-70-04

201

.........51-70-05

201

Approved Repairs
51-70-05
Dorsal Inlet Approved Repairs
51-70-06
Corrosion- Repair
51-70-06
Approved Repairs
.....51-70-07
Honeycomb Insert- Repair
...............................................51-70-07
Approved Repairs
..........,51-70-08
Seat Rail Repair.
Approved Repairs

201

Description
Radome

................-....-..-51-70-05

205
201

201
201

................51-70-08

51 -Contents

Page 3
SRM-4

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
Chapter
Section

Subject

Subject
ALLOWABLE WEAR AND REPAIR DATA

General

Page

51-71-00

GENERAL........

..............................................................................................................................51-71-00

Wing-to-Fuselage Fittings Allowable Wear and Repair Data.


Flap Fittings Allowable Wear and Repair Data
Spoiler Fittings Allowable Wear and Repair Data...............
Aileron System Allowable Wear and Repair Data...............
Tip Tank Fittings Allowable Wear and Repair Data............
Landing Gear Fittings Allowable Wear and Repair
Landing Gear Fittings Repair

Data

51-71-01

51-71-02

51-71-03

51-71-04

....51-71-05

51-71-06

51-71-06
201

General

51-71-06

Limitations and

51-71-06

201

Materials and Processes

51-71-06

201

Repair Frocedures......

51-71-06

202

51-71-06

202

Inspec~ions.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting Repair (PINs 2322146-1 thru -8,


2822159-21 b -22, and 540000V5-1 6 -2)..............................................

Forward Trunnion Mount

Allowable Wear and

Mount

Fittings
Engine
Engine Mount Fittings Repair
General

Repair

Data

....................~.............51-71-07

51-71-07

201

..................................................................................................................51-71-07

Limitations and

201

Inspections.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51-71-07
51-71-07

201

51-71-07
Repair Procedures
Forward Engine Mount (PINs 2651034-1 thru -3)
51-71-07
and Support Fitting (PINs 2612042-5 thru -14) Repair
51-71-08
Rudder Fittings Allowable Wear and Repair Data...............
51-71-09
Horizontal Stabilizer Fittings Allowable Wear and Repair Data
51-71-10
Elevator System Allowable Wear and Repair Data
51-71-11
Keelbeam Assemblies Allowable Wear and Repair Data
Mach Trim System Allowable Wear and Repair Data.........................................51-71-12
51-71-13
Control Column Assembly Allowable Wear and Repair Data
Passenger/Crew Upper Door Allowable Wear and Repair Data (36-Inch)..... 51-71-14
Passenger/Crew Lower Door Allowable Wear and Repair Data (36-Inch)..... 51-71-15
Passenger/Crew Upper Door Allowable Wear and Repair Data (24-Inch)..... 51-71-16
Passenger/Crew Lower Door Allowable Wear and Repair Data (2PInch)..... 51-71-17
51-71-18
Quadrant Assembly Allowable Wear and Repair Data
51-71-19
Allowable
Wear
and
Data...............
Valve
Brake
MLG Power
Repair
Linkage
51-71-20
Main Gear Door and Uplatch Allowable Wear and Repair Data
51-71-21
Main Gear Shock Strut Allowable Wear and Repair Data
51-71-22
Nose Gear Shock Strut Allowable Wear and Repair Data
51-71-23
Main Gear Actuator Allowable Wear and Repair Data
51-71-24
Main Door Uplatch Mechanism Allowable Wear and Repair Data
51-71-25
Nose Gear Actuator Allowable Wear and Repair Data.......................................
51-71-26
Nose Gear Uplatch- Allowable Wear and Repair Data
51-71-27
Nose Gear Door Mechanism Allowable Wear and Repair Data.................
51-71-28
Flap Preselect Assembly Allowable Wear and Repair Data

202

Materials and Processes

202
1
1
1
1
1

1
1
1

1
1

1
1
1
1
1
1
1
1
1
1
1

51-Contents

Page 4
SRM-4

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


Chapter

Chapter

Section

Section

Subject

Page

Date

51-TITLE
51-List of Eff.
51-List of Eff.

Pgs.
Pgs.
51-List of Eff. Pgs.
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51-00-01
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28

29

30

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Learjet

STRUCTURAL REPAIR MANUAL


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SRM-I

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STRUCTURAL REPAIR MANUAL


AIRCRAFT- STRUCTURAL IDENTIFICATION

1.

AIRCRAFTSTRUCTURAL DESCRIPTION

DRILLING, MODIFICATIONS, OR ANY TYPE OF WORK THAT CREATES A

WARNING:

BREAK 1N THE PRESSURE SECTION iS THE RESPONSIBILITY OF THE OWNER


OR FACILITY PERFORMING THE WORK. OBTAINING APPROVAL OF THE
WORK IS, THEREFORE, THEIR RESPONSIBILITY.

NOTE:

The

the

following structural data covers the basic non-modified aircraft. When applicable, refer to
appropriate kit drawing for additions, modifications and changes to the structural compo-

nents and assemblies.

A.

B.

C.

MajorStructural Groups
(1) The major structural groups
windows, and wings.

of the aircraft

are

the doors,

fuselage, naceiles/pylons, stabilizers,

Major Structural Members


(1) The major structural members of the aircraft are the forward and aft pressure bulkheads, floorboards, forward and ah engine beams, baggage compartment floor, under wing keelbeam, fuselage keelbeam, and the landing gear.
Type of Construction
(1) This is an all-metal aircraft with full cantilever wing and horizontal stabilizer. The fuselage is of
semimonocoque construction and supports an engine nacelle on each side in the area above and
ah of the wing.
(2) A two-piece passenger/crew door (upper and lower) is located on the fuselage left side. The
doors are hinged to the fuselage by piano-type hinges. The lower door incorporates the steps for
entering and exiting the aircraft. Additionally, there is an emergency exit, several service doors,
and the landing gear doors.
(3) The fuselage basic structure consists of a stressed skin structure with transverse frames and
longerons. The fuselage is comprised of four basic sections: the nose section, the pressurized section (cockpit and cabin), the fuel section, and the tailcone section.
(4) The pressurized section houses the crew, passenger, and baggage areas. Drilling, modifications,
or any type of work that creates a break in the pressure section is the responsibility of the owner
or facility performing the work. Obtaining approval of the work is, therefore, their responsibility.
(5) The principle structure of the engine nacelles consists of the nose section, upper and lower cowls
and the aft section. The complete nacelle assembly is cantilevered from the pylon by engine support fittings, and structural carry-through fittings that extend inboard from the nacelle, through
the pylon, and attach to the fuselage assembly.
(6) The horizontal stabilizer is a fully cantilevered one-piece construction consisting of a forward and
aft spar, transverse ribs, stringers, and skins.
(7) The vertical stabilizer is a fully cantilevered structure consisting of spars, transverse ribs, and
skins.

(8) The elevator and rudder consist of a forward spar and

EFFECTIVITY:

ALL

transverse ribs and skins.

51-00-00

Pagel
SRM-4

Jun 1/95

STRUCTURAL REPAIR MANUAL


(9) The

flight compartment

windows consist of the

pilots

and

copilots

windshield halves. On Model

23 Series Aircraft each windshield half is made up of separate, removable, inner and outer panes.
On Model 24/25/28/29 Series Aircvaft each windshield half is made up of three laminated layers of

acrylic plastic. Both outer layers are made of stretched acrylic and the middle layer is cast in place
acrylic. On Aircraft 31-001 thru 31-029. 35-001 thru 35-670 and 36-001 thru 36-063 eauitlt~ed with a
standard, non-heated windshield, the windshield is made up of three laminated layers of acrylic
plastic. Both outer layers are made of stretched acrylic and the middle layer is cast in place acrylic. On Aircraft 31-030 and Subseauenf, 35-671 and Subseauent, and 36-064 and Subseauent and prior air-

craft eauip~ed with

an

layers

of

layers.
er

Two

electricallu heated windshield, the windshield is made up of four laminated


polycarbonate are sandwiched between two outer layers of acrylic. A spac-

is bonded to the interior side of the windshield. The windshield has

and heat

The electric

element consists of

integral electric heater


layer gold laminated into the
yellow or gold color cast. The func-

thin

an

of

heating
gold layer, the windshield has a
tion of the heater is to provide windshield defogging. Terminal blocks are embedded in the windshield and provide the means for wiring the electric heater to the aircraft wiring. The windshield
is secured to the fuselage with screws and retainers.
(10) The cabin windows consist of two panes of stretched acrylic with dead air space between them.
The cabin windows are secured to the fuselage structure. The right rear window is removable
sensors.

windshield. Because of the

and

serves as

the emergency exit.

fully-cantilevered single-unit consisting of the leading edge, wing box section, ailewing
rons, flaps, spoilers, and tip tanks or winglets. The multicellular-type wing structure consists of
spars and ribs in each wing half. The upper and lower wing skins are taper-milled so the trailing
edge is thinner than the leading edge. Splice plates join the wing skin halves at the aircraft centerline. The winglets are built in two sections. The inboard section is conventional built-up construction and the outboard section is a bonded assembly consisting of aluminum skins and a fulldepth aluminum honeycomb core. The flaps, ailerons, and spoilers are constructed primarily of

(11) The

is

spars, transverse ribs, and skins.


2.

STRUCTURAL DESIGNCONCEPT
A.

Basic

Design Approach

(1) There

are

two basic

design approaches

integrity of an aircraft during


of
the Learjet incorporates both
design
concepts.
two basic approaches, definitions are presented in the

for

its service life: the "safe-life" and "fail-safe"

clarify the
following paragraphs.
Safe-Life Concept
concepts.

B.

To

differences in the

ensuring

the structural

The

as being capable of withstanding, without failure, the reduring the defined service life of the aircraft. Safemagnitudes
expected
peated
life is proved by either analysis or tests that include all scatter factors on material and load spectrums. Because of the proof of safe-life, alternate load paths are not necessarily deliberately pro-

(1) A safe-life aircraft

structure is defined

loads of variable

vided.
C.

Fail-Safe

Concept

(1) The concept of fail-safe design differs in that alternate load paths
methods for

EFFECTIVITY:

ALL

are

specifically provided

and

limiting crack propagation are employed.

51-00-00

Page 2
sRM-a

Tun 1/95

~j Leariet
STRUCTURAL REPAIR MANUAL
3.

REPAIRING SAFE -LIFE STRUCTURE


A.

Safe-LifeStructure

Repair

provide for alternate load paths or methods of limiting crack


propagation, it is mandatory that all damage to primary and secondary structure (other than allowable damage) be repaired upon discovery.
(2) Repairs in this manual are designed to restore the capability of the material in order to ensure the
safe-life characteristics of the structure. It is emphasized that other repairs, designed for a specific
"fix," must follow the same concept, i.e., that the ultimate allowable strength must be maintained,
to maintain structural integrity for the life of the aircraft.

(1) Since safe-life

4.

structure does not

STRUCTURE LOADING
A.

Structural

Loading

(1) Caps and flanges of spars, ribs, frames and beams are considered to be in tension or compression.
(2) Skin panels, together with spar, rib, frame and beam webs, are assumed to be in shear. Addition-

ally, skins may carry tension or compression loads. In the case of compression, loads are assumed
to be carried only by a small width of skin along the line of fasteners attaching skin to substructure.

(3) Stringers may be in tension or compression.


5.

PRIMARYAND SECONDARY STRUCTURE


A.

B.

Primary structure is considered to be that structure that is essential to continued safe flight and landing. Examples of this would be wing (spars, skins, ribs, fittings, etc.), fuselage, empennage, control
structure systems/support and mechanisms, engine mounts and pylon structure, landing gear and
actuator including attachment fittings, main cabin door and attachments, windshield, cabin windows,
escape hatch, and underwing keel beam.
Secondary structure is that not considered essential for continued safe flight and landing. Examples
of this would include fairings (wing-ta-body etc.), gear doors, nose access doors, dorsal fin, upper
tail fairing, parts of pylon fairvertical fin mailbox fairing, tailcone access door, horizontal-to-vertical
ing and nacelle covers.

EFFECTNTTY:

ALL

51-00-00

Page
SRM-4

lun 1/95

5PrF~

F=

Item

No.

Section Title

(n

Chapter

Doors

52

I~uselage
Nacelles/PyIons

53

3
4

Stabilizers

55

Windows

56

Wings

57

=D
C

0,

C)

54

~3

0
O

q~

I
rp,

^B

~X1
m
IC~

n~

b
~II

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OQOO
r

r"

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Z~h;
b

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I

,_____J

C)
~CI

h3~

o
hi

~JY
v=l

vl
NUI

Laarjet I
Learjet
STRUCTURAL REPAIR MANUAL

Forward Pressure Bulkhead


FS 60.04

Forward Edge of Door


FS 119.66

Aft

Edge of Door

FS 146.51 (24" Door)


FS 158.48 (36" Door)

Aft Pressure Bulkhead


F5272.44

Engine Beam
Floorboards
FS 90.74 to FS 196.65

WL 5.875 Constant

FS 51.89 (Extended)

FS 52.90 (Static)

FS 308.86

WL 42.83

FS 246.06 (Extended)
FS 246.85 (Static)

(TYPICAL)
14-6M: blOD)

EFFECTTVITY:

Major Structural Member Locations


Figure 2 (Sheet 1 of 2)
MODEL23/24 SERIESAIRCRA~T

51-00-00

Page 6
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

Baggage Compartment Floor


FS 196.65 to FS 272.44
WL 24.80

Aft Keel Beam

Keel Beam (Under Wing)


FS 196.65 to FS 271.39

FS 271.39 to FS 308.86

WL 0.00 at Forward End


WL 7.58 at Aft End

WL 10.31 at Aft End

WL 7.58 at Forward End

(TYPICAL)
14-214B (MOD)

EFFECTJVITY:

Major Structural Member Locations


Figure 2 (Sheet 2 of 2)
MODEL23/24 SERIESAIRCRAFT

51-00-00

Page 7
SRM-4

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

Forward Pressure Bulkhead


r

FS 174.01

Aft Pressure Bulkhead


FS381.79 (25C/25FAircraft)

Forward

Edge of Door

FS 233.69
Aft

Edge of Door

Aft Pressure Bulkhead


FS 421.41 (25/25A/25B/25D Aircraft)

FS 260.48 (24" Door)


FS 272.41 (36" Door)

ooo

ol

Floorboards
FS 184.78 to FS 346.63
WL 5.875 Constant

Engine Beam
FS 458.84
Nac Sta 52.35

FS 165.87 (Extended)
FS 166.87 (Static)
FS 167.13 (Deflated)

FS 396.03 (Extended)
FS 396.83 (Static)
FS 397.00 (with Nose Deflated)

(TYPICAL)
Repro

EFFECTIVITY:
SRM-4

Major Structural Member Locations


Figure 3 (Sheet 1 of 2)
MODEL 25 SERIES AIRCRAFT

51-00-00

Page 8
May15/92

Leariet

STRUCTURAL REPAIR MANUAL

Baggage Compartment
WL 24.80 Constant
FS 346.62 to FS 421.42
FS 346.62 to FS 381.79

Floor

(25/25A/25B/25D Aircraft)
(25C/25F Aircraft)

0000

it,

Aft Keel Beam


FS 421.42 to FS 458.84

Keel Beam (Under Wing)


FS 346.63 to FS 421.42

WL 7.58 at Forward End


WL 12.97 at Aft End

--J

WL 0.00 at Forward End


WL 758 at Aft End

(TYPICAL)
Repn,

EFFECTIVITY:
SRM4

Major Structural Member Locations


Figure 3 (Sheet 2 of 2)
MODEL 25 SERIESAIRCRAF~

51-00-00

Page 9
May 15/92

L9arjet I

STRUCTURAL REPAIR MANUAL

Forward

Edge of Door

FS 233.69
Aft

Edge of Door

FS 260.48 (24" Door)


FS 272.41 (36" Door)

Aft Pressure Bulkhead


FS 381.79 (29 Aircraft)

Forward Pressure Bulkhead


FS 174.01

Aft Pressure Bulkhead


FS 402.42 (28 Aircraft)

00001

Engine Beam
FS 458.84
Nac Sta 52.35

Floorboards

FS 184.78

to FS

346.63

WL 5.875 Constant

FS 165.87 (Extended)

FS 166.87 (Static)

Repro

EFFECTIVITY:
SRM-4

FS 396.03 (Extendcd)
FS 396.82 (Static)

Major Structural Member Locations


Figure 4 (Sheet 1 of 2)
MODEL 28/29 SERIESAIRCRAFI~

51-00-00

Page 10
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

Baggage Compartment

Floor
WL 24.80 Constant
FS 346.62 to FS 402.42 (28 Aircraft)
FS 346.62 to FS 381.79 (29 Aircraft)

0000

Keel Beam (Under Wing)


FS 346.63 to FS 421.42
WL 0.00 at Forward End

EFFECTIVITY:
SRMI

Aft Keel Beam


FS 421.42 to FS 458.84
WL 7.58 at Forward End
WL 12.97 at Aft End

WL 7.58 at Aft End

Repro

Major Structural Member Locations


Figure 4 (Sheet 2 of 2)
MODEL 28/29 SERIES AIRCRAFT

51-00-00

Page 11
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

Keel Beam (Under Wing)


FS 346.63 to FS 421.42
WL 0.00 at Forward End

Baggage Compartment Floor


WL 24.80

rAft Pressure Bulkhead

FS 346.62 to FS 421.42
FS 346.62 to FS 381.79

FS421.42

Forward Pressure Bulkhead


FS 160.77

0000

Aft

Engine Beam

WL 39.82 at Aircraft
473.00

SFenilretneC

Floorboards
FS 184.78 to 346.63
WL 5.87 Constant

I\

~Forward Engine
WL 40.00

at

Beam

Aircraft Centerline

FS 443.23
FS 152.62 (Extended)

Aft Keel Beam


FS 421.42 to FS 458.84
WL 7.58 at Forward End
WL 12.97 at Aft End

FS 153.63 (Static)
FS 153.88 (Deflated)

FS 396.03 (Extended)
FS 396.82 (Static)
FS 396.83 (Deflated)

Repro

EFFECTIVITY:
SRMI

Major Structural Member


Figure 5
MODEL31 SERIESAIRCRAFT

Locations

51-00-00

Page 12
May 15/92

Learjet

STRUCTURAL REPA\R NIANUAL

A~t Pressure Bulkhead


FS 381.79 (36/36A Aircraft)
Aft kessune Bulkhead
FS 421.41

(35/35A Aircraft)

Forward Pressure Bulkhead


FS 160.77

0000

Aft Engine Beam


FS 473.00

FloorboaTds
FS 184.78

to

FS 346.63

WL 5.875 Constant

FS 152.62 (Extended)

FS 153.63 (Static)
FS 153.88 (Deflated)

I~pro

EFFECTNITY:
SRM~

Fonuard Engine Beam


FS 443.23

FS 3%.03 (Extended)
FS 396.82 (Static)
FS 3%.83 (Deflated)

Major Structural Member Locations


Figure 6 (Sheet 1 of 2)
MODEL35/36SERIES ATR~RAFT

51-00-00

rage 13
May 15/92

Learjet
Leariet i
STRUCTURAL REPAIR MANUAL

Aft

Engine Beam

WL 39.82

Aircraft Centerline

Forward Engine Beam


Aircraft Centerline
WL 40.00

Baggage Compartment Floor


WL 24.80 Constant
FS 346.62 to FS 421.42 (35/35A Aircraft)
FS 346.62 to FS 381.79 (36/36A Aircraft)

0000

II-~- ~t--_

Aft Keel Beam


Keel Beam (Under

FS 346.63

to

Wing)

---r

FS 421.42

WL 0.00 at Forward End


WL 7.58 at Aft End

Repro

EFFECTn7ITY:
SRM-4

FS 421.42 to FS 458.84
WL 758 at Forward End
WL 12.97 at Aft End

Major Structural Member Locations


Figure 6 (Sheet 2 of 2)
MODEL 35/36SERIES AIRCRAFT

51-00-00

Page 14
May 15/92

~lit I

STRUCTURAL REPAIR MANUAL


AIRCRAFT MEASUREMENT SYSTEM

i.

STRUCTURAL IDENTIFICATION

AIRCRAFTMEASUREMENT SYSTEM DESCRIPTION


A.

This section

B.

presents

The dimensions of the aircraft and the


for reference

areas

of the control surfaces

are

carried to the nearest full inch.

not for

are
only
inspection purposes.
points along three axes and are measured in inches. These reference points provide a means of quickly identifying the location of a bulkhead, component, etc.
(I) Fuselage station (FS), water line (WL), and buttock line (BL) measurements used in this manual

These dimensions
C.

the aircraft dimensions, control surface areas, water lines, buttock lines, and sta-

designations.

tion

are

and

The aircraft is divided into reference

are

rounded to the nearest inch.


points may be converted to metric measurement (millimeters)

D.

All reference

E.

The

by multiplying

the refer-

point tin inches) by 25.4.


following terms are used for reference points.

ence

Fuselage

FS

ence

line

station is
on or near

Water line is

WL

vertical reference

the

nose

plane

measured

horizontally

from

vertical refer-

of the aircraft.

horizontal reference

plane measured vertically

from the horizontal reference

line of the aircraft.


vertical reference

plane measured horizontally

from the aircraft centerline.

BL

Buttock line is

WS

Right or left is added to indicate the direction from aircraft centerline (RBL
Wing station is a vertical reference plane measured horizontally from the

LBL).

wing

centerline

and

perpendicularly along wing datum.


Centerline is the center reference point of the aircraft or component.

CL

Reference

NACSTA

points that apply to

the

engine nacelle.

NAC WL
NAC BL
TIP TANK STA

Reference

points that apply to

Reference

points that apply to the winglet.

the

tip tank.

?T WL
TI BL

WINGLET STA
OML

Outside Mold Line is that line

IML

formed part.
Inside Mold Line is that line
formed

EFFECTIVITY:

ALL

corresponding
corresponding

to the outside contour of

to the inside contour of

fuselage

skin

or

fuselage

skin

or

part.

51-00-01

Pagel
SRM-4

Jun 1/95

Learjet I
STRUCTURAL REPAIR MANUAL

14 ft. 8 in.

12

1 fti3

in.

43 ft. 3 in.

34 ft. 1 in.

Repro

Aircraft Measurement

System

Dimensions

Figure 1(Sheet 1 of 13)


EFFECTIVITY:
SRM~

MODEL 23/24SERIESAIRCRAFT

51-00-01

Page 2
May 15/92

STRUCTURAL REPAIR NIANUAL


Subject

Dimensions

Aircraft

Span (overal ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Span (excluding tip tank fins)
Length (overall)
Height (overall)

35 ft. 7 in.
34 ft. 1 in.
43 ft. 3 in.
12 ft. 3 in.

Wing
Root Chord

fuselage centerline)

9 ft. 0 in.

Chord
WS 181)
Dihedral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 ft. 1 in.
2" 30

Sweepback (c/4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13"

Incidence

+lo

Aileron

Span (nominal)

4 ft. 8 in.

Root Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 ft. 5 in.

Tip Chord
Trim Tab Span (LH only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Balance Tab Span (RH
LH). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 ft. 1 in.
1 ft. 3 in.
1 ft. 9 in.

Flaps

Type
Span(nominal)

Single Slotted
9 ft. 2 in.

Root Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ft. 4 in.

Tip Chord

1 ft. 8 in.

Horizontal Stabilizer

Span

14 ft. 8 in.

Root Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 ft. 0 in.

Tip Chord
Sweepback (c/4 chord)

2 ft. 4 in.
25"

Dihedral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

O"

EIevators

Span (per side). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 ft. 4 in.

Root Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I ft. 4 in.

Tip Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 in.

Aircraft Measurement

Figure
EFFECTIVITY:

System

Dimensions

1 (Sheet 2 of 13)

MODEL 23/24 SERIESAIRCRAFT

51-00-01

Page
SRM-4

May 15/92

Leariet I
STRUCTURAL REPAIR MANUAL
Vertical Stabilizer
5 ft. 6 in.

Span

g ft 11 in.

Root Chord. . . . . . . . . . . . . . . .

Tip Chord
Sweepback

5 ft. 1 in.
35" 36

leading edge)

Fuselage
Fuselage Constant Section
Outside diameter

5 ft 3 in.

Inside diameter

4 ft. 9 in.

8 ft 8 in.

Length of passenger area......................................


Height (floor to ceilng). . . . . . . . . . . . . . . . . . . . . .- -

4 ft 4 in.

Miscellaneous Areas
231.90 ft.

Wing (WS 0.0 to WS ~81.10)


Aileron (per side, aft of hinge line)
Aileron Trim Tab (LH only)
Aileron Balance Tab (LH

5854 ft.
0.335 ft.
125 ft.

RH)

70 ft
540 ft.

Horizontal Stabilizer (total)

(excluding elevator)

1594 ft.

Vertical Stabilizer (total)

3748 it.

Vertical Stabilizer

3063 ft.

(excluding rudder)

Rudder

6.85 ft.

Rudder Trim Tab

069 ft.

Aircraft Measurement

Figure

SRM-4

38.06 ft.

...............................................i...................................................................

Elevator

EFFECTnTITY:

3685 ft.

Flaps (total)
Spoilers (total)
Stabilizer

System

Dimensions

1 (Sheet 3 of 13)

MODEL23/24 SERIESAIRCRAFT

51-00-01

Page 4
May 15/92

Leariet

S~RUCTURAL REPAIR MANUAL

25% Chord

Fuselage Vertical
Centerline

25% Chord

RBL

Buttock
Lines

Wing Stations

(BL 0.00)

cws o.oo,

LBL

Fuselage
Stations

(FS -13.976)

Waterlines
(WL 0.00)

BL 43.70

WL 42.83

Nacelle CL --/I

Fuselage Vertical
Centerline

Aircraft Measurement

Figure
EFFECTIVITY:
SRM-II

System

Reference roints

1 (Sheet 4 of 13)

MODEL23/24 SERTESAIRCRAFT

51-00-01

Page 5
May 15/92

Learjet
Learjet 1
STRU CTU RA L R EPAIR MAN UA L
I

sta. 474. 60

FS
;f(

fuselage skin.

~e

a39
Sce~

a46

Measured at OML of Bulkhead


Intersection with Bottom apt

,1\~C

ar

Inside Mold Line (IML)

ii

Outside Mold
Line (OML)

,n"Z~\

B
4

pan:,c~e

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Frame

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~S69

(TYPICAL)

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26

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,~650
4

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(TYPICAL)
(DOUBLE FRAME MEMBER
CROSS SECTION)

Icno

Aircraft Measurement

Figure
EFFECTIVITY:
SRM-P

MODEL 23/24 SERIES AIRCRAFT

System

Fuselage Stations

(Sheet 5 of 13)

51-00-01

Page 6
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

WL 52.08
Door

Passenger/Crew

Hinge CL

Fuselage Cross Section

WL 24.80

WL 5.87
WL 0.82

WL 0.00

14-1318

Aircraft Measurement

Figure
EFFECTTVITY:

System

Top of Baggage Floor

Top of Floorboard

Passenger/Crew Door Hinge CL


(Typical Frame 9 to Frame 15)

Fuselage Stations

1 (Sheet 6 of 13)

MODEL 23/24 SERTESAIRCRAFT

51-00-01

Page
SRM~

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
Stringere

Ui~

Stringer LO

Str1nger9

Stringer 11

Stringer 12
Stringer 13

Stringer 13
Stringer 14

Stringer 14
Stringer 15

Stringer 16
Stringer 17
Stringer 18
Stringer 19

0.0

Stringer 15
Stringer 16
Stringer 17
Stringer 18
Stringer 19

Stringer 21--~

Stringer 21

(FRAME 5 LOOKING AET)

B. L. 0. 00

xStringerl

Stringer 27
LStringer 3

~-Stringer 2

Stringer 4
Stringer 5
Stringer 6

O~- Stringerstringer 4
Stringer

6
Door

Window

Hinge

O~ening

t~-DOOr Opening
Stringer tl

Sl~lice

Stringer 12
Stringer 13

Stringer 14

\r(

SeatTrack

k\

/C Keel

Beam Web

Stringer 15

Stringer 16
Stringer 17
Stringer 18
Stringer

I-b

,Door Hinge

19

Stringer 21-~

--Stringer 21

(FRAME 11 LOOKING AFT)

Aircraft Measurement

Figure
EFFECTIVITY:

MODEL 23/24 SERIES AIRCRAF~

System

Fuselage Stations

(Sheet 7 of 13)

51-00-03

PageS
SRM~

May 15/92

~earjet

STRUCTURAL REPAIR MANUAL


B. L. D. 00

Stringer~

Stringer 2

Stringer 2

Stringer 3

Stringer 3
Stringer 4

Stringer 4
Stringer 5
Stringer 6

~o

Stringer
Stringer 6
Stringer

Y~-Door Hinge

Stringer 8

Stringer 9
Stringer 10

Stringer

11
Door Frame

Stringer 12
Stringer 13

Seat Track

Stringer 14

Stringer 15
Stringer 16
Keel Beam Web

Stringer
Door

Stringer 18
Stringer 19

Stringer

Stringer 21

IIinge

21

(FRAME 13 LOOKING AFT)


Stringer
Stringer 3
Stringer 4
Stringer 5Stringer 6 --~J_/
Stringer 7

j/

"7

rStringef~Stringer

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Stringer 4

Stringer.B

~Splice

Stringer 6
Stringer 7

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Stringer 8

Stringer 8

Stringer 9

Stringer 9

Stringer 10

Stringer 10
Support

Support

Stringer 11

Stringer 11

Stringer 12
Stringer 13
Longeron

\~n

(-r~c-Stringer
(FRAME 17 LOOKING AFT)

Aircraft Measurement

Figure

EFFECTIVITY:

Sti"per 12

B. L. 0.00

13

Longeron

System Fuselage Stations

1 (Sheet 8 of 13)

MODEL 23/24 SERIES AIRCRAFT

51-00-01

Page
SRM~

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
C~

P:

C:

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AILERON STRUCTURAL

WING STRUCTURAL

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i:

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I,

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FLAP STRUCTURAL
STATIONS

1
I

0~ 00

Aircraft Measurement

System Wing, Aileron and Flap Stations


Figure 1 (Sheet 9 of 13)

EFFECTIVITY:
SRM-b

MODEL 23/24 SERIES AIRCRAFT

51-00-01

Page 10
May 15/92

Leariet

STRUCTURAL REPAIR MANUAL


Tip Tank
Sta. 0. 00

,Tip Tank
15.70

Sta.

Tip Tank
Sta. 46.00

Tip Tank
Sta. 83.85

Tank

-Tip

98.86

Sta.

Tip Tank
Sta.

Tip

113.60

Tank

Sta. 149.94

Tip Tank
Sta.

160.42

Tip Tank
Sta.

113.30

TIP TANK STRUCT~RAL


STATIONS

Aircraft Measurement

Figure
EF~CTIVITY:

System

Tip

Tank Stations

(Sheet 10 of 13)

MODEL 23/24 SERIESAIRCRAFT

51-00-01

Page
SRM-4

11

May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

BL 0. 00
BL

9.512 1

BL 19. 40

BL 34. 80

HORIZONTAL
STABILIZER

BL 50. 20

STRUCTURAL
STATIONS

BL 65. 60
BL

.~r

81.00I,

BL 88. 20

BL 4. 50

BL 13. 24

BL

54

BL 23. 17

BL 33. 11
BL 44. 10
BL 56. 23

BL 86. 215

BL 67. 79
BL
79. 35

i Ji;

CI

ELEVATOR

STRUCTURAL
STATIONS

BL 1. 49

BL 81. 77

Aircraft Measurement

EFFECTIVITY:
SRM4

System Horizontal Stabilizer and Elevator Stations


Figure 1 (Sheet 11 of 13)

MODEL 23/24 SERIES AIRCRAFT

51-00-01

Page 12
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

BULLET
STRUCTURAL
STATIONS

STA
459. 350

STA

STA
423. 30

440.104

STA
423. 913

STA
500.023

RUDDER

STRUCTURAL

II)

VERTICAL STABILIZER
STRUCTURAL STATIONS

UcL

STATIONS

I----WL 100. 33
WL 96. 00

WL 95.

WL 92. 83

WL 85.
r

WL 75.

-C-- WL 72. 56

WL 82. 70

f
f

WL 65.

i/

Aircraft Measurement

EFFECTIVITY:
SRM~

System
Figure

wt 61.96

Vertical Stabilizer and Rudder Stations


1 (Sheet 12 of 13)

MODEL23/24 SERIESAIRCRAI;T

51-00-01

Page 13
May 15/92

0~0\

8
in

NrY

~h
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STRUCTURAL REPAIR MANUAL

ii tt.

sin

12 it.
jia.

00(3

ft. 7

ia45

It.

It. 9 ia
35 it. 7 tn

Aircraft Measurement

System Dimensions
Figure 2 (Sheet 1 of 13)

EFFEC~IVITY:
SRM~L

MODEL25 SERTESAIRCRAFT

51-00-01

Page 15
May 15/92

Learjet
Learjetl
STRUCTURAL REPAIR MANUAL
Dimensions

Subject
Aircraft

Span (overal ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Span (excluding tip tank fins)
Length (overall)
Height (overall)

35 ft. 7 in.
34 ft. 1 in.
47 ft. 7 in.

12 ft. 3 in.

Wing
Root Chord

9 ft. 0 in.

(fuselage centerline)

5 ft. 1 in.

Chord (O WS 181)

2" 30

Dihedral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sweepback (c/4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13"

Incidence

1"

Aileron

Span (nominal)

4 ft. 8 in.

Root Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 ft. 5 in.

Tip

Chord

I ft. 1 in.

Span (LH only)


Balance Tab Span (RH
LH). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Trim Tab

1 ft. 3 in.
1 ft. 9 in.

Flaps
Type

Single Slotted

Span(nominal)

9 ft. 2 in.

Root Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ft. 4 in.

Tip

Chord

1 ft. 8 in.

Horizontal Stabilizer

Span

14 ft. 8 in.

Root Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 ft. O in.

Chord

Tip
Sweepback (c/4 chord)

2 ft. 4 in.
25"

Dihedral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

O"

Elevators

Span (per side). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 ft. 2 in.

Root Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 ft. 4 in.

Tip

Chord

7 in.

Aircraft Measurement

Figure
EFFECTIVITY:
SRM-4

MODEL 25 SERIES AIRCRAI~T

System

Dimensions

(Sheet 2 of 13)

51-00-01

Page 16
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


Vertical Stabilizer

Span

5 ft. 6 in.

Root Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 ft. 11 in.

Tip Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sweepback (c/4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 ft. 1 in.
35" 36

Fuselage
Fuselage Constant Section
Outside diameter

5 ft. 3 in.

Inside diameter

4 ft. 9 in.

Length of passenger area.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Height (floor to ceil ng). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 ft. 4 in.
4 ft. 4 in.

Miscellaneous Areas

Wing
Aileron

231.8 ft.

(per side)

5.854 ft.

Aileron Trim Tab (LH

only)

Aileron Balance Tab (LH

0.335 ft.

RH)

1.25 ft.

Flaps (total)
Spoilers (total)

36.85 ft.
7.0 ft.

Horizontal Stabilizer (total)

54.0 ft.

Stabilizer

40.4 ft.

(excluding elevator)

Elevator

13.6 ft.

Vertical Stabilizer (total)

38.35 ft.

Vertical Stabilizer

31.80 ft.

(excluding rudder)

Rudder

6.55 ft.

Rudder Trim Tab

0.69 ft.

Aircraft Measurement

Figur~!
EFFECTNITY:
SRM~

MODEL 25 SERIES AIRCRAFT

System

2
2
2
2
2
2
2
2
2
2
2

Dimensions

2 (Sheet 3 of 13)

51-00-01

Page 17
May 15/92

Leariet
STRUCTURAL REPAIR MANUAL

25% Chord

25% Chord

Fuselage Vertical
Centerline

RBL

Buttock

Lines

LBL

Wing Stations

(BL 0.00)

(WS 0.00)

Fuselage
Stations

(FS 100.00)

QOC1[3

Waterlines
(WL 0.00)

BL 43.70
WL 42.8

Nacelle CL

Fuselage Vertical
Centerline

Aircraft Measurement System

ReferencL Points

Figure 2 (Sheet 4 of 13)


EFFECTNITY:
sRM~

MODEL 25SERIESAIRCRAFT

51100-01

Page 18
May 15/92

Learjet I

STRUCTU RAL REPAIR MANUAL


J(

Measured at OML of Bulkhead


Intersection with Bottom ~of

fuselageskin,

99t~L*

Inside Mold Line (IML)

99:~;"\ eze\

1T

Outside Mold
Line (OML)

~pC

4L~

3b~

,1c:2;"*2\

c,m

Aircraft Skin (ReO

\F:FPb\

(TYPICAL)

(SINGLE FRAME MEMBER


CROSS SECTION)

\L~
n

8~

~c

4r9.

CII

SF"

\c
~*O

Frame

b.

9~C.SL
4~

BL

Assembly

~L

9\

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1841,\C"s\
E

9fr""

F~n\g

4L\

8p
~L

-;~;6,
C~gr

(TYPICAL)
(DOUBLE FRAME MEMBER
CROSS SECTION)

4*

16RB1

Aircraft Measurement

Figur~!
EFFECTIVITY:
SRM~

MODEL25 SERIESAIRCRAF~

System Fuselage Stations


(Sheet 5 of 13)

51MM1

Page 19
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

WL 52.08
Door

Passenger/Crew

Hinge CL

Fuselage Cross Section

WL 24.80

Top of Baggage Floor

WL 5.87 Top of Floorboard

WL 0.82
WL 0.00

14-131B

EFFECTIVITY:
SRM-4

Passenger/Crew Door Hinge CL


(Typical Frame 9 to Frame 15)

System Fuselage Stations


Figure 2 (Sheet 6 of 13)

Aircraft Measurement

MODEL 25 SERIES AIRCRAFT

51-00-01

Page 20
May 15/92

Learjet
Learjetl

STRUCTURAL REPAIR NIANUAL


Stringer

Dlj~

Stringer 10

Stringer

ool 10O

Stringer 10

Stringer
stringer

Il--/~tt"llolll

Stringer~2---,
Stringer

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1 I

II

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11

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ii

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I~-JI

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111

111"

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Stringer 13

13

111

11(
111

11

11

111

(11

11

IIW~----Stlinger

14

L5

Stringer 16
Stringer 17

Stringer 16
Stringer 17

Stringer 18
Stringer 19

0.0

Stringer 2r--c

Stringer r8
Stringer 19
~4
Stringer 21

(FRAME 5 LOOK1[NG AI;T)

B. L. 9.09
2

Stringer
Stringer 3
Stringer 4
Stringer 5

yStringer

/--Stringer

Stringer 3
Stringer 4
Stringer

Stringer
I)oor

Window Opening

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7y

~cDoor OyeninO

Stringer 11

Stringer

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12

Stringer 13
Stringer 14

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Keel Beam Web

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Stringer 16
Stringer 17
Stringer r8

IZb

Stringer

O
Deer

Hinge

19

Stringer 21--~

-Stringer

21

(FRAME 11Z~OOKING AFT)

System Fuselage Stations


Figure 2 (Sheet 7 of 13)

Aircraft Measurement

EFFECTIVITY:

MODEL25 SERIESAIRCRAFT

51-00-01

Page
SRM-4

21

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
B. L. 0.00

Stringer 2
Stringer

Stringerl
Stringer 3
Stringer4

Stringer 5
Stringer 6

Stringer
Stringer 6
Stringer

\C~z--Door

Hinge

Stringer 8

Stringer

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10

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11
Door Frame

Stringer 12
Stringer 13

Seat Track

Stringer 14
Stringer 15
Stringer 16
Keel Beam Web

iL1

Stringer

Door

Stringer 18
Stringer 19

Stringer

Stringer

21

IIinge

21

(FRAME 13 LOOKING AFT)


Stringer 2
Stringer 3
Stringer
Stringer 5
Stringer 6
Stringer 7

Stringer

"7

2
~--Strineer 3
4

Stringer.fi

j/ ~Splice

Stringer 6

/V

Splice

Stringer

Stringer 8

Stringer 9

Stringer 9

Stringer

1/

10

\\~Stringer
Support

Support

Stringer 11
Stringer 12

I \-B. L.

--/\\1~

Stringer 13

Longeron

MODEL 25SERIESAIRCRA~T

10

Stringer ii

I(,IlJ~-- Stringer

12

I-r~c--Stringer

13

(FRAME 17 LOOKING AFT)

Figure

SRM~

0.00

\iM

Aircraft Measurement

EFFECTIVITY:

Longeron

System Fuselage Stations

(Sheet 8 of 13)

51-00-01

Page 22
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
CT

P:

ro

AILERON STRUCTURAL

EC

E:E

C:

C~

d d d d d d
V1

II)

LO

V1

III

WING

STRUCTURAL

STATIONS

113

STATIONS

59. 46

~n

51.

181.10

i.

0
r

It
I

42. 66cFRI

\Z

34.

a.

t
1

157. 48

d
N

24.92~

5:nFr11i
t i

20. 96~

15.

ii

126. 1111

i !,i\\\\

117.10~e
ed

108.1

104.

125. 00

95.

86.

2.52

1\

77.

69.00
I:

60.05

i\

1;

\I

53. 04
k

51.1
o

42.
C

37.

31.
24.

85~\e

15. 87

FLAP STRUCTURAL

$Z

ii

0. 00

STATIONS

System Wing, Aileron and Flap Stations


figure 2 (Sheet 9 of 13)

Aircraft Measurement

EFFECTTVITY:

MODEL 25 SERIESAIRCRAFT

51-00-01

Page 23
S~M-4

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
Tip Tank
Sta. 0.00

,Tip Tank
Sta.

Tip

15.70

Tank

Sta. 46. 00

Tip Tank
Sta.

83.85

-Tip Tank
Sta.

98.86

Tip Tank
Sta.

113.60

Tip Tank
Sta.

149.94

Tip Tank
Sta.

160.42

Tip Tank
Sta.

1?3.30

TIP TANK STRUCTURAL

STATIONS

Aircraft Measurement

Figure
EFFECTIVITY:
SRM~

MODEL 25 SERIES AIRCRAFT

System Tip Tank Stations

2 (Sheet 10 of 13)

51-00-01

Page 24
May 15/92

Learjet
Leariet

STRUCTU RAL REPAIR MANUAL

BL 0. 00
BL

3.:2 1

BL 19. 40

B:L 34. 80

HORIZONTAL
STABILIZER

BL 50. 20

STRUCTURAL
STATIONS
BL 65. 60
BL 81. 00
BL 88. 20

,-"CJ

I~

-pd

---------I

kr

BL 4. 50

_~,

J,----~
BL 13. 24

BL

54

BL 23. 17

ELEVATOR
STRUCTURAL
BL 56. 23

BL 86. 215
BL

1~79.

35BL

67.

STATIONS

79Ji" i

BL 1. 49

BL 81. 77

Aircraft Measurement

EFFECTIVITY:
SRM~

System Horizontal Stabilizer and Elevator Stations


Figure 2 (Sheet 11 of 13)

MODEL 25SERIES AIRCRA~

51MM1

Page 25
May 15/92

Leariet

STROCTURAL REPAIR MANUAL

STA

STA

SI~A
644.89

STA

606.084

589.28

624.63

VERTICAL STABILIZER
STRUCTURAL STATIONS
ii

RUDDER

STRUCTURAL
STATIONS

I/

M
n

II
I

II

II

\NL 100. 33

//I

II

II

WL 95. 00

j/I~

I/

ii

II

II
I,

,I

I/
II

/I

I/
Ii

I,

WL 92. 83

lII

WL 85,

I,

I
I
I

lI

----WL 82. 70

g
d

,i
/I

WL 75. 00
I

I/

II

II

II

/I

N
I

WL 12. 58

II

/I
I,
I/

I/
/I

/I

/I

II

II

/I
I/

WL 65. 00--

/I

I//

81.98

Il

B
N
N

Aircraft Measurement

EFFECTIVITY:
SRM-4

System Vertical Stabilizer and Rudder Stations


Figure 2 (Sheet 22 of 13)

MODEL 25SERIESAIRCRAFT~

51-00-01

Page 2~
May 15/92

~hcJ

9~a\

8 gbv,
nc~

V,

kh

rd

r:

so

jk

NAC STA 86.25

NAC STA 85.29

10~---

NAC STX 80.44

Pe

Z"

~CO

Q)
L

Pc
LLI

Pe

61. 15 (RH OUTED)

(LH INBD)
NAC STA 62.30 (LH OUTED)

(RH INBD)

F. S. 458.83

c~C"
Pi

Q
pe

NAC STA 42.50

a~

Nne

ii

c>

28. L7

cn

~e
NAC STA 20.24

cn

d,

NAC STA 0.0

WEi

STRUCTURAL REPAIR MANUAL

14 ft. 8 in.

~n/7 /771

I I~ft.lin.

45 ft. O in.
47 ft. 7 in.

8 ft. 3 in.
43 ft. 8 in.

Aircraft Measurement

System Dimensions
Figure 3 (Sheet 1 of 13)

EFFECTIVITY:
SRM-4

MODEL 28/29 SERIES AIRCRAFT

51-00-01

Page 28
May 15/92

~Rariet

STRUCTURAL REPAIR MANUAL


Subject

Dimensions

Airoaft

Span (overal ). . ., . . . . . . . . . . . . . . . . . . . . . . . . ., . . . . . . . . . . . . . . . . . . . . .
Length (overall)
Height (overall)

43 ft. 8 in.
47 ft. 7 in.
12 it. 1 in.

Wing
Root Chord
Chord

(fuselage centerline)

9 fc~ 0 in.

WS 181)

5 ft~ 1 in.

20 30

Sweepback

13

Incidence

Aileron

Span (nominal)

4 ft. 8 in.

Root
Tip Chord

1 ft. 5 in.

Span (LH only)........................................


Balance Tab Span (RH

1 ft. 3 in.

1 ft 1 in.

Trim Tab

1 ft. g in.

Flaps

Type
Span(nominal)

Single Slotted
g ft~ 2 in,

Root

2 ft. 4 in.

Tip

I ft. 8 in.

Horizontal Stabilizer

Span

14 ft. g in.

Root

5 ft. O in.

Tip Chord
Sweepback (c/4 chord)

2 ft~ 4 in.

250
O

Elevators

Span (per

7 it. 2 in.

Root

1 ft. 4 in.

Tip

7 in.

Aircraft Measurement

System

Dimensions

Figure 3 (Sheet 2 of 13)


EFFECTIVITY:
SRM-L

MODEL28/29SERIES ATRCRAFT

51-00-01

Page 29
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
Vertical Stabilizer
5 ft. 6 in.

Span

8 ft. 11 in.

Root Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tip

5 ft. 1 in.

Chord

35" 36

Sweepback (c/4). . . . . . . . . . . . . . . . . . . .
Fuselage

Fuselage Constant Section


Outside diameter

5 ft. 3 in.

Inside diameter

4 ft. 9 in.
11 ft 4 in.

Length of passenger area


Height (floor to ceilng). . . . . . . . . . . . . . . . . .

4 ft 4 in.

Miscellaneous Areas
212.9 ft.

Wing
Aileron

5854 ft.

(per side)

Aileron Trim Tab (LH

2
0335 ft.

only)

Aileron Balance Tab (LH

1.25 ft.

RH)

3685 ft.

Flaps (total)
Spoilers ~total)

70 ft.

404 ft.

(excluding elevator)

2
136 ft.

Elevator

3835 ft.

Vertical Stabilizer (total)


Vertical Stabilizer

540 ft.

Horizontal Stabilizer (total)


Stabilizer

31.80 ft.

(excluding rudder)

Rudder

2
655 ft.

Rudder Trim Tab

069 ft.

Aircraft Measurement

Figure
EFFECTIVITY:
SRM-4

System

Dimensions

3 (Sheet 3 of 13)

MODEL28/29 SERIESAIRCRAFT

51-00-01

Page 30
May 15/92

STRUCTURAL REPAIR MANUAL

25% Chord

Fuselage Vertical

25% Chord

Centerline

RBL

Buttock
Lines

(BL 0.00)

LBL

Wing: Stations
(WS 0.00)

Fuselage
Stations

(FS 100.00)

00[30

Waterlines

(WL 0.00)

8~43.70--\

Nacelle CL

(I

Wt 42.83

cFuselage Vertical
Centerline

Aircraft Measurement

System Reference Points


Figure 3 (Sheet 4 of 13)

EFFECTNITY:

MODEL28/29 SERIESAIRCRAFT

51-00-01

Page 31
sRM-a

Jun 1/95

STRUCTURAL REPAIR MANUAL


Measured at OML of Bulkhead
Intersection with Bottom ~pf

fuselage skin.

r\*
959P.

pp

~L

Inside Mold Line (IML)

~c*e

3:&)e
\~""e

21

((o*C Zb\

Sd.
9P

Outside Mold
Line (OML)

Frame

I;

2\\

E~

~p ~2\ \c "O\

re

Aircraft Skin (ReO

(TYPICAL)
(SINC;LE FRAME MEMBER
CROSS SEcnoN)

~a

E;

s2 9~\3;\

.-2DE\10~

,413pb~
re

C:

~9

,e

9~
4~

ZJB

Frame

9QL*,.n*9
9b.",1~0
,c~\C

Assembly

P"

e
9"

AirQaft Skin (ReD

\1

eu

(TYPICAL)

~"".9\"
\cjP~

dp

(T)OUBLE FRAME MEMBER


CROSS SECTION)

90

14-77B1

Aircraft Measurement

Figure
EFFECTTVITY:
slM~

System Fuselage Stations

3 (Sheet 5 of 13)

MODEL 28/29SERIESAIRCRAFT

51MH)1

Page 32
May 15/92

Learjet
Ledljet

STRUCTURAL. REPAIR MANUAL

Passenger/Crew
Hinge CL

WL 52.08
Door

Fuselage Cross Section

WL 24.80

WL 5.87
WL 0.82

WL 0.00

14-1318

EFFECTIVITY:
SRM-4

Top of Baggage Floor

Top of Floorboard

Passenger/Crew Door Hinge CL


CTypical Frame 9 to Frame 15)

System Fuselage Stations


Figure 3 (Sheet 6 of 13)

Aircraft Measurem~,nt

MODEL 28/29 SERIES AIRCRAFT

51-00-01

Page 33
May 15/92

Learjet I
STRUCTURAL REPAIR MANUAL
Stringer 9

Stringer 9

oo110O O

Stringer 10

Stringer tO

Stringer
Stringer 11---/ ~OllulII

111

111

11

11

1111

111

111

Stringer 12
Stringer 13
Stringer 14
Stringer 15

11

111
Stringer 13

Stringer 16
Stringer 17 --~aK. I
Stringer 18

1 H 16

Stringer 19
Stringer 21~

Stringer 14
Stringer 15
Stringer 16
stringer 17
Stringer 18
Stringer 19

at H I I
0.0

Stringer 21

(FRAME 5 LOOKING AFT)

B.L. 0.007

Stringer
Stringer 3

~--Strinrrer I

27

~--Stringer

Stringer 4
Stringer5
Stringer

Stringer 3
Stringer 4
Stringer 5

~Stringer
Door

Window

Opening

11

Stringer

12

Opening

Splice

Stringer 13

Stringer

Hinge

~Y
~Door

Stringer

14

A--Seat

k\

Track

Keel Beam Web

Stringer 15
Stringer 16
Stringer 17
Stringer 18~

Stringer

!3nnY(

~lo
V

--I)OOr

Hinge

19

Stringer 21-

\--Stringer

21

(FRAME II LOOKING AFT)

Aircraft Measurement

Figure
EFFECTTVITY:
SRM4

System

Fuselage Stations

3 (Sheet 7 of 13)

MODEL 28/29SERIESAIRCRAFT

51-00-01

Page 34
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


B.L. 0.00

Stringer

Stringer 2
Stringer 3
stringer 4
Stringer 5
Stringer 6

Stringer 3
Stringer

4o

Stringer 5
Stringer 6
Stringer 7

\C~---Door

Hinge

Stringer 8

Stringer

Stringer 10

Stringer 11
Door Frame

Stringer 12

Stringer 13

Seat Track

Stringer 14

Stringer 15
Stringer I

r
Stringer 18
Stringer 19
Stringer

Keel Beam Web

1_1

Door

Stringer

21

Hinge

21

(FRAMIE 13 LOOKING AFT)


Stringer

Stringer 3

Stringef~cStringer 2
r

Stringer 4
Stringer 5
Stringer 6
Stringer 7

~Stringer.B

~Splicc

\1~

Stringer 8
Stringer 9

Stringer 9

Stringer 10

I
Support

Support

Stringer 11

~B.L.

Stringer 12
Stringer 13

Longeron

St ringer 6

Stringer 7

Splice

Stringer 8

StringerlO

Stringer 4

\itl

000

(FRAME 17 LOOKING AFT)


Aircraft Measurement

Stringer 11

Stringer 12
13

Longeron

System Fuselage Stations

3 (Sheet 8 of 13)

EFFECTNITY:
SRM-4

MODEL 28/29 SERIES AIRCRAF~

51-OM)1

Page 35
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


dLO$r
P:
WING STRUCTURAL

STATIONS

-W. S. 244. 102


W.S. 233.102

w. s.

213. 602

AILERON STRUCTURAL
STATIONS

59.46~
51.40

~51.10

-t7

W S

Isl 02

42. 66~

66---1 le ~--29. 35

34

24.92
20.98
15. 47

rW a

is.59

-W. S.

126. 17

125. 00

117.10

108.10

106.15

104

95.

-W. S. 92. 52

86.50

dj j

77.70
69.

60.05

51.10C

24.8542.

15cl

W.S. 53.04

00

37.85
31.35

15. 81e
Lj~L-L---U

W. S~ 0. 00

FLAP STRUCTURAL

STATIONS

System Wing, Aileron and Flap Stations


Figure 3 (Sheet 9 of 13)

Aircraft Measurement

EFFECTIVITY:
SRM-L

MODEL28/29 SERIESAIRCRAFT

51MHll
Page 36

May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

Winglet STA 44.87

Winglet
STA 44.87

Winglet S7;4

17.91

Winglet
STA 17.91

Wing
Reference
Plane

Winglet STA 0..00

Winglet STA 0

Winglet
Datum
Plane

(VIEW LOOKING AFII)

(LH SHC)WN, RH TYPICAL)

4~ss

Aircraft Measurement

System Winglet Stations


Figur~!3(SheetlOofl3)

EFFECTIVITT"Y:
SRM~

MODEL 28/29 SERIESAIRCRAFT

51-0001

Page 37
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

BL 0. 00
BL

9.:2 1

BL 19. 40

BL 34. 80

HORIZONTAL
STABILIZER

BL 50. 20

STRUCTURAL
STATIONS
BL 65. 60

b-I

BL 4. 50

BL 13. 24

BL

i?54

BL 23. 17

BL 44.

10BL

BL 56. 23

BL 86. 215

rilBLBL
79. 35

67. 79

33. 11

ELEVATOR
STRUCTURAL
STATIONS

BL 1. 49

BL 81. 77

Aircraft Measurement

EFFECTIVITY:
srun~

System Horizontal Stabilizer and Elevator Stations


Figure 3 (Sheet 11 of 13)

MODEL 28/29 SERIES AIRCRAFT

51-00-01

Page 38
May 15/92

Lear
Lealjet

STRUCTURAL REPAIR MANUAL

STA
589. 28

STA

STA

STA

606. 084

624. 63

64C 89

VERTICAL STABILIZER
STRUCTURAL STATIONS

RUDDER
STRUCTURAL

STATIONS

II

JI

81

II

I:

,WL 100. 33

II

1.1/

I
I

WL 95.
I

II

/II
I

I,

---WL 82. 70

I
I

WL 72. 56

II,

II

I,

/I

/I
II

/I

,I

/1

Ii
I

II

I/
I

WL 75. 00-

II

/I

--WL 92. 83

I/

/I

II
I

WL 65.

/I

I/

II

Ii

I/

WL 85.

,I
.I
I/

II

/I/

I/

I:

II
I

II

I/

I!
/I

I,

11
rI

II

I,

II

I,

WL 61. g6

I
n

II

Aircraft Measurement

EFFECTTVITY:
SRM-4

System Vertical Stabilizer and


Figure 3 (Sheet 12 of 13)

MODEL 28/29SERIESAIRCRAFT

Rudder Stations

51-00-0)

Page 39
May 15/92

~30

b~Q\

8 %b=;
56

s~

it"

I
NAC STA 86.25

NACSTA85.29

NAC STX 80.44

QI

I
Pe

~Q;
w

61. 15

(RH OUTED)
(LH INBD)

NAC STA 62. 30LH OUTED

F.S. 458.83

(RH IKBD)

,xp

Pe

Ir

NAC STA 42.50

rr

NAC STA 28. 17


1

Pe
)I
cn

NAC STA 0.0

C4

EZ

Learjet
Ledrjet
STRUCTURAL REPAIR MANUAL

14 ft. 8 in.

8 ft. 2 in.

12 ft. 3

00

C1

O O

20 ft. 2 in.
48 ft. 7

8 ft. 3 in.
43 ft. 8 in.

System Dimensions
Figure 4 (Sheet I of 13)

Aircraft Measurement

EFFECTIV~TY:
SRM~

MODEL31 SERTESAIRCRAFT

51-00-01

Page 41
May 15/92

Learjet i
STRUCTURAL REPAIR MANUAL
Subject

Dimensions

Aircraft

Span (overal ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Length (overall)..........
Height (overall)

43 ft. 8 in.

48 ft. 7 in.
12 ft. 3 in.

Wing
Root Chord

Chord

(fuselage centerline)

9 ft. 0 in.

WS 181.1)

5 ft. 1 in.
20 30

Sweepback (c/4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

Incidence

lo

Aileron

Span (nominal)

qft. gin.

Root Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 ft. 5 in.

Tip

Chord

1 ft. 1 in.

Trim Tab

Span (LH only)


Balance Tab Span (RH
LH). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 ft. 3 in.
1 ft. 9 in.

Flaps
Type
Span(nominal)

Single Slotted
9 ft. 2 in.

Root Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tip

2 ft. 4 in.

Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 ft. 8 in.

Horizontal Stabilizer

Span

14 ft. 8 in.

Root Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 ft. 0 in.

Chord

Tip
Sweepback (c/4 chord)

2 ft. 4 in.

250
O

Elevators

Span (per side). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 ft. 2 in.

Root Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 ft. 4 in.

Tip

Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 in.

Aircraft Measurement

Figure
EFFECTIVITY:
SRM-4

MODEL31 SERIESAIRCRAF~

System

Dimensions

(Sheet 2 of 13)

51-00-01

Page 42
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
Vertical Stabilizer
5 ft. 6 in.

Span

8 ft. 11 in.

Root Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 ft. 1 in.

Tip Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sweepback (c/4). . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35" 36

Fuselage
Fuselage Constant Section
Outside diameter

5 ft. 3 in.

inside diameter
Length of passenger area
Height (floor to ceil ng). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 ft. 9 in.
11 ft. 4 in.
4 ft. 4 in.

Miscellaneous Areas
2
264.5 ft.

Wing (excluding winglets)


Wing (total)
Aileron

(per

12.0 ft.

5.854 ft.

side)

Aileron Trim Tab (LH

0.335 ft.

only)

Aileron Balance Tab (LH

1.28 ft.

RH)

36.85 it.

Flaps (total)

7.0 it.

Spoilers (total)
Horizontal Stabilizer (total)

54.0 ft.

Stabilizer

40.4 ft.

(excluding

elevator)

13.6 ft.

Elevator

3835~t.

Vertical Stabilizer (total)


Vertical Stabilizer

31.80 ft.

(excluding rudder)

6.55 ft

Rudder

0.69 ft.

Rudder Trim Tab

26.34 ft.

Delta Fins (totai). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Aircraft Measurement

Figure

EFFECTIVITY:
SRM-4

MODEL31 SERIESAIRCRAFT

System

2
2
2

2
2
2

Dimensions

4 (Sheet 3 of 13)

51-00-01

Page 43
May 15/92

STRUCTURAL REPAIR MANUAL


25% Chord

25% Chord

Fuselage Vertical
Centerline

RBL

L LBL

Buttock
Lines

wi"s Stations

(BL 0.00)

1 I

cws o.oo,

Fuselage
Stations

(FS 8~.75)

00000

Waterlines

~WL 0.00)

BL 47.7

Wt, 48.75

Nacelle CL--I

FuselageVertical
Centerline

Aircraft Measurement

System I~eference Points


Figure 4 (Sheet 4 of 13)

EFFECTIVITY:
SRM-4

MODEL31 SERIESAIRCRAF~

51-00-01

Page 44
May 15/92

Learjet I
Leariet

STRUCTURAL REPAIR MANUAL


Measured at OML of Bulkhead
Intersection with Bottom Bpf

CX
,e~s
c

Q*

aS

8?

fuselage skin.

SF.

9"

[g
8b

Inside Mold Line (IML)

Outside Mold
Line (OML)

s7
Frame

0.

01;;8C

s"a"
9F~

$G

AlrrraftSkin(ReO

Co

(SINGLE FRAME MEMBER


CROSS SECTION)

51FJ4.*9\teF\ljE~gl

(TYPICAL)

~F"plD:

~P

7
sP

FrrameArrmmbly

9P\4bS~"
Aircraft Skin (ReD

5"I

s?4

9F

(TMJICAL)

(DOUBLE FRAME MEMBER


CROSS SECTION)

34-77B1

Aircraft Measurement

Figure
EFFECTIVITY:

SRM-4

MODEL31 SERIESAIRCRAFT

System

Fuselage Stations

(Sheet 5 of 13)

51-00-01

Page 45
Jun1/95

Learjet
STRUCTURAL REPAIR MANUAL

Passenger/Crew
Hinge CL

WL 5208
Door

Fuselage Cross Section

WL 24.80

Top of Baggage Floor

WL 5.87 Top of Floorboard

WL 0.82
WL 0.00

14-1318

Aircraft Measurement

Figure
EFFECTIVITY:
saM~

MODELS1 SERTESAIRCRAFT

Passenger/Crew Door Hinge CL


(Typicai Frame 9 to Frame 15)

System Fuselage Stations


(Sheet 6 of 13)

51-00-01

Page 46
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

Stringerg

Stringer9

oO

Stringer 10

o110

Stringer 10

Stringer ii

11~1

stringer 12
Stringer 13
Stringer 14
Stringer 15

111111

11

1~1 1

111

111

111,11" ft----Stringer

11

II1

IU

III I.lkL-----stringer

Stringer

12
13
14

Stringer 15
Stringer 16

Stringer 16
Stringer 17

Stringer 18

Stringer 17
Stringer 18
Stringer 19

000

Stringer 19
Stringer 21~

Stringer 21

(FRAME 5 LOOKING; AFT)

B.L. 0.007

~--Stringer 2
~SCringerJ

Stringer 21

Stringer3--\
,-~O
Stringer4
/T,/
Stringer 5
Stringer 6--~

Stringer 4
~Stringer 5
~Stringer 6

I
1

Door

Window

Hinge

Opening

~--Doar Opening
Stringer 11

Stringer

Splice

12

StringerlS
Stringer

14--/

\r(

~--Seat Track

k\

Keel Beam Web

Stringer 15
Stringer 16
stringer 17--~
Stringer
Stringer 19
Stringer 21

Qnr ~--t--710
i

---1

~Door Hinge

-Stringer

21

(FRAME 11 LOOKING AFT)

System Fuselage Stations


Figure 4 (Sheet 7 of 13)

Aircraft Measurement

EFFEC~VITY:
S~M4

MODEL31 SERIESAIRCRAFT

51-00-01

Fage47
May 15/92

Learjet

STRU%TURAL REPAIR MANUAL


B.L. 0.00

~Stringer

Stringer 3--~

Stringer
Stringer 6
Stringer

Stringer

Stringer 2

\o\ ~Stringer

7
Door

Hinge

Stringer 8

Stringer

Stringer 10

Stringer 11
Door Frame

Stringer 12
Stringer 13
Seat Track

Stringer 14
Stringer 15
Stringer 16

Stringer

Keel Beam Web

ii

Stringer 18
Stringer 19

Door

Stringer

Stringer

21

Hinge

21

(FRAME 13 LOOKING AFT)


Stringer 2 7
Stringer 3

yStringerj

Stringer 4
Stringer 5
Stringer 6
Stringer

Stringer

Stringer 2
r

Stringer.B
Stringer 6

Stringer 7

St~lice

Splice

Stringer 8

\~Stringer

Stringer 9
Stringer

Stringer

10~11
Support

11

Stringer ~2

Stringer 13
Longeron

0_00

System Fuselage
Figure 4 (Sheet 8 of 13)

SRM4

\\~Stringer

19

Stringer

ii

Stringer 12
13

Longeron

(FRAME 17 LOOKING AFT)

MODEL31 SERIESAIRCRAFT

Support

~L.

\iM

Aircraft Measurement

EFFECTIVITY:

Stringer 4

Stations

51-00-01

Page 48
May 15/92

Learjet
STRUCTU RAL REPAIR MANUAL
es~,

"4%%%%
I

AILERONSTRUCTURAL

%"41~1% 4

STA~IONS

WING STRUCTURAL

STATIONS

59.46
~W.S. 244.102
51.40 ----1---

51.10

34.6624.92

W.S. 233. 102

42.66

-----1 11--l

29.35

W.S. 213.602

20.98
15.47

9.59

------\~-w.s. 181.020

w.s.
179.11

W.S. 157.480

126.17
W.S.

117.10

137.61

108.10
104.20

106.15
W.S. 125.000

95.30
86.50
77.70

I-------Y

69.00

IZ\T

w.s. 92.520

60.05
51.10
4215
37.85
31.35

----1-------~

40.00
W.S. 53.040

24.85
15.87

I
FLAP STRUCTURAL

STATIONS

W.S. 0.000

System Wing, Aileron and Flap Stations


Figure 4 (Sheet 9 of 13)

Aircraft Measurement

EFFECTIVITY:
SRM-b

MODEL31 SERIESAIRCRAFT

51-00-01

Page 49
May 15/92

STRUCTURAL REPAIR MANUAL

Wingiet STA 44.87

Winglet
STA 44.87

Winglet STA 17.91

Winglet
SI~A 17.91

~--Winglet STA Oa0

Wing

Winglet

STA ~.00

Reference
Plane

Winglet
Datum
Plane

(VIEW LOOKING AFT)

(LH SHOWN, RH TYPICAL)

a-san

Aircraft Measurement

System Winglet Stations

Figure 4 (Sheet

EFFECT~VITY:
SRM~

MODEL31 SERIESAIRCRAF~

10 of 13)

51-00-01

Page 50
May 15/92

Leariet
STRUCTURAL REPAIR MANUAL

BL 0.00
BL 3.52
BL 19.40

BL 34.80

HORIZONTAL
STABILIZER
STRUCTURAL
STATIONS

BL 50.20

BL 65.60

BL 81.00

,"~P

BL 88.20

BL 4.50

BL 13.24

BL 2.54

BL 23. 17
BL 33. 11
BL 44.10

BL 56.23

BL 86.215

_i

BL 67.79

BL

sJ1 ~79.35

c,-

Ct

ELEVATOR

STRUCTURAL
STATIONS

BL 1.49

BL 81.77

Aircraft Measurement

EFFECTIVITY:
SRM~

System Horizontal Stabilizer and Elevator Stations


Figure 4 (Sheet 11 of 13)

MODEL31 SERIESAIRCRAFT

51-00-01

Page 51
May 15/92

Leartet

STRUCTURAL REPAIR MANUAL

STA.

STA.

589.28

606.084

STA.

STA.

624.63

644.89

VERTICAL STABILIZER
STRUCTURAL. STATIONS

I,
II

RUDDER
STRUCTURAL

STATIONS

/I/
II

/I

I/
,I

II

WL 100.33

I,/

WL 95.00

II

I/
I/

I/

Il

/I

I/
/I

I/

/i-------1-- WL 92.83

IT

/I
/I

I/

I,

WL 82.70

/I

II

WL 75.00
,I
I

II

I/
I

Aircraft Measurement

EFFECTIVZTY:
SRM-Q

,I

I/

II
I
II
I
III
I
I

I,

II
/I
g

System Vertical Stabilizer and


Figure 4 (Sheet 12 of 13)

MODEL31 SERIESAIRCRAFT

WL 72.56

/I

WL 65.00

II

I/
I

WL 85.00

r
I

II

WL 61.96

Rudder Stations

51-00-01

Page 52
May 15/92

Learie~]
STRUCTURAL REPAIR MANUAL

NAC BL
100.00
Nac Sta. 259,10

NAC WL
100.00

(ZSI SIDE LOOXING AFT)

1:

~88

P
r

o0~

h)
r
co

ES

e"

ulo

rrr

~3

S:

(LH SIDE LOOKING INBOARD)

14-1438-2

Aircraft ~easurement

Figure
EFFECTIVITY:
sRM-4

MODEL31 SERIESAIRCRAFT

System

Nacelle Stations

4 (Sheet 13 of 13)

51-00-01

Page 53
May 15/92

fear
~Learjet

STRUCTURAL REPAIR MANUAL

14 ft. 8 in.
8 ft. 2 in.

12 ft. 3 in.

R
F---

000

20 R. 2

C3

in.--------l
48 ft. 7 in.

8 ft. 3 in.

ft. 1 in.

39 ft. 6 in.

Aircraft Measurement

Figure
EFFECTIVITY:
sRM-4

System

Dimensions

5 (Sheet 1 of 13)

MODEL 35/36SERIESAIRCRAF~

51-00-01

Page 54
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


Dimensions

Subject
Airoraft

39 ft. 7 in.

Span (overal ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Span (excluding tip tank fins)
Length (overall)
Height (overall)

38 ft. 1 in.
48 ft. 7 in.
12 ft. 3 in.

Wing

(fuselage centerline)
Tip Chord (8 WS 229)

9 ft. 0 in.

Chord

5 ft. 1 in.

Root Chord

5 ft. 0 in.

WS 181)

Dihedral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sweepback (c/4)
Sweepback (c/4)

2" 30

panel (WS 0.0 to 181). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Outer panel (WS 181 to 229)
Inner

Incidence

130
20
1"

Aileron

Span (nominal)

4 ft. 9 in.

Root Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 ft. 5 in.

Tip Chord
Trim Tab Span (LH only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Balance Tab Span (RH
LH). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 ft. 1 in.
1 ft. 9 in.
1 ft. 9 in.

Flaps
Type

Single Slotted

Span(nominal)

9 ft. 2 in.

Root Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 ft. 4 in.

Tip Chord

1 ft. 8 in.

Horizontal Stabilizer

Span

14 ft. 8 in.

Root Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 ft. 0 in.

Tip Chord
Sweepback (c/4 chord)

2 ft. 4 in.
25"

Dihedral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

O"

Elevators

Span (per side). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 ft. 4 in.

Root Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 ft. 4 in.

Tip Chord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 in.

Aircraft Measurement

System Dimensions
Figure 5 (Sheet 2 of 13)

EFFECTIVITY:
SRM~

MODEL 35/36SERIESAIRCRAFT

51-00-01

Page 55
May 15/92

E~
STRUCTURAL REPAIR MANUAL
Vertical Stabilizer

Span

5 ft. 6 in.

Root Chord. . . . . . . . . . . . . . . . .~. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 ft. 11 in.

Tip Chord
Sweepback (c/4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuselage
Fuselage Constant

5 ft. 1 in.
35" 36

Section

Outside diameter

5 ft. 3 in.

Inside diameter

4 ft. 9 in.

Length of passenger area.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Height (floor to ceil ng). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 ft. 4 in.
4 ft. 4 in.

Miscellaneous Areas

Wing
panel (WS 0.0 to WS 181)
Outer panel (WS 181 to WS 229). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212.9 ft.

Total reference

253.3 ft.

Inner

Aileron

40.4 ft.

area

(per side)

5.854 ft.

Aileron Trim Tab (LH

only)

Aileron Balance Tab (LH

0.335 ft.

RH)

1.28 ft.

maps (total)
Spoilers (total)

36.85 ft.
7.0 ft.

Horizontal Stabilizer (total)

54.0 ft.

Stabilizer

40.4 ft.

(excluding elevator)

Elevator

14.13 ft.

Vertical Stabilizer (total)

38.35 ft.

Vertical Stabilizer

31.80 ft.

(excluding rudder)

Rudder

6.55 ft.

Rudder Trim Tab

0.69 ft.

Aircraft Measurement

Figure
EFFECTIVITY:
SRM~

System

2
2
2

2
2
2

2
2
2
2
2

2
2

Dimensions

5 (Sheet 3 of 13)

MODEL 35/36SERIES AIRCRAFT

51-00-01

Page 56
May 15/92

Leariet

STRUCTURAL REPAIR MANUAL

25% Chord
25% Chord

Fuselage Vertical

RBL

Centerline

Buttock
Lines

LBL

Wing Stations

(BL 0.00)

cwS 0.00)

Fuselage
Stations

(FS 87.00)

0000

Waterlines

(WL 0.00~
BL 48.0

WL 49.0

Nacelle CL

Fuselage Vertical
Centerline

Aircraft Measurement

System Reference Points


Figure 5 (Sheet 4 of 13)

EFFECTNITY:
SRM~

MODEL 35/36SERIES AIRCRAFI~

51M)-01

Page 57
May 15/92

STRUCTURAL REPAIR MANUAL


9(
14\

at OML of Bulkhead
Intersection with Bottom ~pf

Measured

fusehgeskin.

so"

~eZoo
Inside Mold Line (IML)

s~"51150

Outside Mold
Line (OML)

,i.",~cz
~EF.

4~

zer\
I I~Frame
O

9,-

fit:
52~.

,,c~,1\

E9

p nr

s
AirQaft Skin (ReD

(TYPICAL)

::1;J",

B9
55

(SINGLE FRAME MEMBER


CROSS SECTION)

9~F

ft:

9s~P\ce"~.
\FPs

CII

\C\

S~F

09

.L*3

O
4~F

4~P2S550\\\
\O~

S~PC.
P

9P9

,Ir

Frame

Assembly

,p:~""

G\

*F~

\te

Aircraft Skin (Rcf)


55

s~C

(TYPICAL)

s~"
51F

(DOUBLE FRAME MEMBER


CROSS SECTION)

14-77B1

Aircraft Measurement

Figure

EFFECTIVITY:
SRM~

System

Fuselage

Stations

5 (Sheet 5 of 13)

MODEL 35/36SERIESAIRCRAFT

51-00-01

Page 58
May 15/92

Learjet
~tl
STRUCTURAL REPAIR MANUAL

WL 52.08
Door

Passenger/Crew

Hinge CL

Fuselage Cross Section

WL 24.80

Top

of

Baggage Floor

WL 5.87 Top of Floorboard

WL 0.82
WL 0.00

14-1318

EFFECTIVITY:
SRM-4

Passenger/Crew Door Hinge CL


(Typical Frame 9 to Frame 15)

System Fuselage Stations


Figure 5 (Sheet 6 of 13)

Aircraft Measurement

MODEL35/36SERIES AIRCRAFT

51-OM)1

Page 59
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


Stringer 9
Stringer 10

r9

oO

.I lo

Stringer 10

11

Stringer 11--/ ~t Oljulll


Stringer 12
Stringer 13
Stringer 14

111

StringerlB---~iU

()1

111

1 I

11

11-11

111

111

11111""

Strineer 12

Stringer

13

14

111

Stringer 16
Stringer 17
Stringer 18

Stringer 19
Stringer 21-~

ii

II

I)(

II(

(jyf-------stringer

15

Stringer 16
Stringer 17
Stringer 18
Stringer 19

000

Stringer 21

(FRAME 5 LOOKING AFT)

B. L. 0.00

Stringer I

Stringer 2
nrineer 3~

Stringer
Stringer
Stringer 6

"ringedt~,,,

Stringer 5
6
Door

Hinge

Window Opening

~--Daar Opening
Stringer 11

Splice

Stringer 12
Stringer 13
Stringer 14

~--Seat

k\

Track
Keel Beam Web

Stringer 15

Stringer 16
Stringer 17
Stringer 18-~Stringer 19

~Door Hinge

-Stringer

Stringer 21

21

(FRAME 11 LOOKING AFT)

Aircraft Measurement

System Fuselage
Figure 5 (Sheet 7 of 13)

EFFECT7VITY:
SRM4

MODEL35/36SERIESAIRCRAF;.

Stations

51-00-01

Page 60
May 15/92

L~aljet
Learjet

STRUCTURAL REPAIR MANUAL


B. L. 0. 00

Stringer 2
~--Stringer 3
Stringer 4
Stringer 5

\o\ ~Stringer

StringerS
Stringer 3--~
Stringer 4
Stringer
Stringer 6--~
Stringer 7

Door

Hinge

Stringer 8

Stringer

Stringer 10

Stringer 11
Door Frame

Stringer 12
Stringer 13
Seat Track

Stringer 14

Stringer 15
Stringer 16

81155

Stringer 17
Stringer 18
Stringer 19
Stringer 21

Keel Beam Web


Door

Hinge

Stringer 21

(FRAME 13 LOOKING AFT)


Stringer
Stringer 3

"7

Stringer 2
ringer 3
Stringer 4
Stringer.S
Stringer 6

Stringer 4
Stringer 5
Stringer 6
Stringer 7
Stringer 8
Stringer 9

Stringer 10

Stringer

Stringer

Splice

Splice

Stringer 8

\~Stringer

Support

Support
Stringer 11

Stringer 12

I~ongeron

11

11

Stringer 13

Stringer 12

\M

13

(FRAME 17 LOOKING AFT)

Longeron

Aircraft Measurement

System Fuselage Stations


Figure 5 (Sheet 8 of 13)

EFFECTIVITY:
SI~M-4

MODEL 35/3CjSERIES AIRCRAFT

51-OM)1

Page 61
May 15/92

Learjet
f~

STRUCTURAL REPAIR MANUAL


g

sa a

ta

a a

WING STRUCTURAL

STATIONS
p

cn

h,r

-W.S. 205. 14

AILERON STRUCTURAL
STATIONS

I: j

t i 1
i

59.48c( L4~7
r

5~

i~

I-\W.S.

181.10

51.404~1

I
I

1\ih

42.66--

34.66-1 r

r1\

\1

W.S. 157.48

24.92
20.98
w

It
r

128.17-

E,

t t,

1-W.S.

125.00

117.10--

o
108.10
104.20
W.S. 92.52

95.30

86.50
77.70--

69.00

60.05
51.10

42.15

Oo

37.85

31.35
14.85

W.S. 53.04

-1~-

-1

15.87

f~

B i\J"I
ii

FLAP STRUCTURAL
STATIONS

Aircraft Measurement

System

Figure
EFFECTIVITY:
SRM4

Wing,

Aileron and

0.00

Flap Stations

5 (Sheet 9 of 13)

MODEL 35/36SERIES AIRCRAFT

51-00-01

Page 62

May15/92

Leariet
STRUCTURAL REPAIR MANUAL
Tip Tank
Sta. 0.00

,Tip Tank
Sin.

t5.70

Tip Tank
Sta. 46. 00

Tip Tank
Sta.

83.85

Tip Tank
Sta.

98.86

Tip Tank
Sta.

113.60

Tip Tank
Sta.

149.94

Tip Tank
Sta.

160.42

Tip Tank
SCa. 113.30

TIP TANK STRUCTURAL


STATIONS

Aircraft Measurement System Tip Tank Stations


Figure 5 (Sheet 10 of 13)

EFFEeTIVTTY:
SRM~L

MODEL 35/36SERIES AIRCRAFT

51-00-01

Page 63
May 15/92

Leariet

STRUCTURAL REPAIR MANUAL

BL 0. 00

BL 19. 40

BL 34. 80

HORIZONTAL
STABILIZER

BL 50. 20

STRUCTURAL
STATIONS
BL 65. 60
BL 8~.00
BL 88. 20

--9

88

I-

BL 4 50

BL

13:24

BL

54

BL, 23. 17

BL 44. l0
BL 86. 215
BL

35BL,

67.

-iJ97

i;

Ct

ELEVATOR
STRUCTURAL
STATIONS

BL L. 49

BL 81. 77

Aircraft Measurement

EFFECTIVITY:
SRM~

MODEL

System Horizontal Stabilizer and Elevator Stations


Figure 5 (Sheet 11 of 13)

35/36SERIESAIRCRA~T

51-00-01

Page 64
May 15/92

Learjet
Learjet
STRUCTURAL REPAIR MANUAL

STA

589.28

STA

STA

STA

606.084

624.63

644.89

VERTICAL STABILIZER
STRUCTURAL STATIONS
i

RUDDER

STRUCTURAL
STATIONS

I
I

II

II~

/L-~,

II

/I,

Il

Wt 92. 83

I,

WL 100. 33

II

WL 85.

I/
I

//I

WL 75. 00
I/

~WL 82. 70

I
II

i
I

(WL 72. 56

II

II
I

/I

WLgg.00

/I
I

Il
I

I
I

Aircraft Measurement

EFFE(-TIVITY:

czl

/I I
I

I/
I

.I

WL 61.96

I
Il

System Vertical Stabilizer and Rudder Stations


Figure 5 (Sheet 12 of 13)

MODEL 35/36SERIES AIRCRAFT

51-00-01

Fage
S(M-4

65

May 15/92

STRUCTURAL REPAIR MANUAL

NAC BL
100.00
Nac Sta. 259.10

NAC WL
100.00

oa

(LH SmB LDDKING ATT)

p
O

P,

Ny
O

00

Q)

00

DJ

o"

(LH SIDE LOOKING INBOARD)

14-1438-2

Aircraft Measurement

Figure
EFFECTIVITY:
SRM4

System

Nacelle Stations

5 (Sheet 13 of 13)

MODEL 35/36SERIES AIRCRAFT

51-00-01

Page 66
May 15/92

Learjet
~1
STRUCTURAL REPAIR MANUAL
RESTRICTED AREAS

STRUCTURAL IDENTIFICATION

RESTRICTED AREAS DESCRIPTION

i.

A.

See

Figure

1 for restricted

area

locations.

XQX

NO STEP AREAS

NO PUSH AREAS

HONEYCOMB::::::::::z:::::;:;:na:;x;:;:
(TYPICAL)
Restricted Area

Repro

Figure

EFFECTIVITY:

MODEL

Diagram

(Sheet 1 of 2)

23/24/25/35/36SERIES AIRCRAFT

51-00-02

Pagel
SRM~

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

Xi)X~

NO STEP AREAS
NO PUSH AREAS

E~

HONEYCOMB

(TYPICAL)
Repro

Restricted Area

Figure
EFFECTIVITY:
snM-4

Diagram

1 (Sheet 2 of 2)

MODEL28/29/31 SERIESAIRCRAFT

51-00-02

Page 2
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ACCESS DOORS AND PANELS

STRUCTURAL IDENTIFICATION

ACCESS DOORS AND PANELS DESCRIPTION

i.

A.

See

Figure

1 for

access

doors and

panels locations.
03

30

07
36

to

03

JO

"2f
318
II

CT)

9.

1.

FuelFiller

2.

FuelProbe

3.

TipTank Access
Directisyn

5.

Equipment, Oxygen and Air Bottles


Emergency Exit Window
Fuselage FuelTank Probe
WingTipFueland ElectricalConnections

7.
8.

o~

II

Vertical Stabilizer Attach Points and Controls

(LH Side Only)

4.
6.

11

FuxxValve

Electronic

10.

Nacelle Tailcone

11.

NacelleBottomSection

12.

Nacelle

13.
14.

NoseCap
NacelleTop Section
RudderHingeand RudderTabActuator

15.

StabilizerActuator

16.

TipTankFuelPump

(TYPICAL)
Access Doors and Panels

Figure
EFFECTIVITY:

MODEL23 SERIESAIRCRAFT

Fuselage, Empennage

Stabilizers

1 (Sheet 1 of 3)

51-00-03

rage
SRM-4

Mav 15/92

Leariet
STRUCTURAL REPAIR MANUAL

r3

o"O

Is

200

c>

o
o

og

BE

o
o

16

020
Z1

2\

29C1YV~19

27.

Rudder AttachPoints

27.

WingTankFuelPumps

18.

28.

19.

RudderHinge andBalanceWeights
Wing Fuel Tank ~ypical Both Wings)

29.

ElevatorControls (LHSideOnly)
Horizontal Stabilizer Attachment

20.

Aileron controls

30.

CabinDoor

21.

AileronActuatorand

31.

FuelVent Lines

22.

FuelVentLines

32.

FudShutoffValves

23.

WingFlapBellcrankand SpoilerActuator

33.

24.

Cablesand Pulleys
Batteries, Electrical

34.

PulleysandFuelLines
HydraulicLinesand WingFuelTanks

25.

frigeration and
26.

Fuel Lines and

Hinges

Components, Fuel Filters,


Hydraulic Components

Sump

Re-

Drains

35.
36.
37.

FuelLinesand Drain
Elevator Hinge
Pitch Axis Servo Access

(Optional)

(TYPICAL)

14-109C

Access Doors and Panels

Figure

EFFECTIVITY:

MODEL 23 SERIES AIRCRAFT

Fuselage, Empennage

Stabilizers

1 (Sheet 2 of 3)

51-00-03

Page
SRMI

May 15/92

Learjet
STRUCTU RAL REPAIR MANUAL

r!2

10

12

11

OI

It8

FLOORBC)ARDS AND INNER SKIN

O Q
1.

BrakeValveandRudder

2.

Control Cables,
Controls Sector

3.

Pulleys

PedalLinkage
Hydraulic Lines

(II)

and

7.

Hydraulic Lines -InnerSkin


BrakeSystem ShuttleValves
Control Cables, Pulleys and Roll Servo
Parking Brake Control Valve

8.

Cabin Air Distribution Ducts

9.

Hydraulic Lines
Control Cables, Pulleys and Aileron-Rudder Interconnect
Hydraulic Lines, Emergency Air Lines and Refrigerant Line
Control Cables, Pulleys and Anti-Collision Beacon
Fuselage Fuel Cell

4.
5.
6.

10.
11.

12.
13.

Inner Skin

(VIEW LOOKING FORWARD)


FRAME 24

(TYPICAL)

Access Doors and Panels

Figure

EFFECTIVITY:
SRM~

MODEL 23 SERIES AIRCRAFT

Floorboards

Fuel Cell Panel

(Sheet 3 of 3)

51-00-03

Page3
May 15/92

Learjet
~Fi

STRUCTURAL REPAIR MANUAL


d

os

0~

j~o

Uo$
100

whs
oo

st
(Zo

~IJ

1.

FuelFiller

10.

RearNacelle

2.

FuelProbe

11.

LowerNacelle

3.

TipTank Access

12.

4.

Directisyn

FluxValve

5.

Electronic

Equipment, Oxygen

and Air Bottles, and

Windshield De-Ice Tank


Exit Window

6.

Emergency

7.
8.

FuselageFuelTank Probe
WingTipFueland ElectricalConnections

9.

Vertical Stabilizer Attach Points and Controls (LH


Side

14.

NoseCap
UpperNacelle
RudderHingeand

15.

Stabi~izerActuatorLower

16.

TipTankFuel Pump

13.

Only)

Nacelle

RudderTab Actuator

Attach

17.

RudderAttach Points

18.
19.

RudderHingeand BalanceWeights
Wing Fuel Tank (Typical Both Wings)

20.

Aileron controls

(TYPICAL)

Access Doors and Panels

Fuselage, Empennage

Figure 2 (Sheet

EFFECTIVITY:
SRM~

MODEL 24/24A SERIES AIRCRAFT

1 of

Stabilizers

3)

51-00-03

Page4
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

E~B

o
o
Q

O
o

,1

Q
If

020

210
220

21

1157

29pYV_~29

21.

AileronActuatorand

32.

Fuel Shutoff Valves

22.

Fuel Vent Lines

33.

Fueland

23.

WingFlapBellcrankand SpoilerActuator
Fuselage Fuel Tank Probe (Lower Fitting)
Batteries, Electrical Components, Fuel Filters, Refrigeration and Hydraulic Components
Fuel Lines and Sump Drains
Wing Fuel Plumbing, Pumps and Hydraulic

34.

Hinges

35.

HydraulicLines
ElevatorHinge
Stabilizer ActuatorUpper

36.

Pitch Servo Cable Drum and

37.

WireBundleand Conduit

38.

Navl andNav2Antenna

39.

PitchServo

Lines

40.

Pitch Servo Cable Drum and

41.

RudderServo

29.

Elevator Controls (LH Side Only)


Horizontal Stabilizer Attachment

42.

Fuel/Defuel Adapter

30.

CabinDoor

43.

Precheck Panel

31.

FuelVent Lines

24.
25.
26.
27.
28.

Single

Attach

Pulleys (RH Only)

Pulleys (Optional)

Single Point (RH Only)


Point (RH Only)

(TWICAL)

Access Doors and Panels

Figure
EFFECTIVITY:
SRM-4

Fuselage, Empennage
2

Stabilizers

(Sheet 2 of 3)

MODEL 24/24ASERIES AIRCRAFT

51-00-03

Page 5
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

112,

ill

12

11

l1

0[
I

FLOORBOARDS AND INNER SKIN

D Aircraft 24-200 fhru 24-129

O O
T.

Brake Valve and Rudder Pedal

2.

Control

3.

Controls Sector

4.

Cables, Pulleys

and

Linkage

Hydraulic

Lines

7.

Hydraulic Lines-InncrSkin
Brake System Shuttle Valves
Control Cables, Pulleys and Roll Servo
Parking Brake Control Valve

8.

CabinAirDistribution Ducts-InnerSkin

9.

Hydraulic Lines

5.

6.

10.
11.

12.
13.

Control Cables, Pulleys and Aileron-Rudder Interconnect


Hydraulic Lines, Emergency Air Lines and D Refrigerant
Control Cables, Pulleys and Anti-Collision Beacon
Fuselage Fuel Cell

Line

(VIEW LOOKING FORWARD)


FRAME 24

(TYPICAL)
Access Doors and Panels

Floorboards

Figure 2 (Sheet 3
EFFECTIVITY:
SRM4

MODEL 24/24ASERIESA~RCRAFT

Fuel Cell Panel

of 3)

51-00-03

Page 6
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


2/1 b X~\\ \I

!l

Onb, r1\15
34

~7 o

Ji50

1.

Fuel Filler-Standard

14.

2.

FuelProbe

15.

3.

TipTank Access
Directisyn FluxValve
Wing Tip Fuel and Electrical Connections
Electronic Equipment, Oxygen and Air Bottles,

16.

4.
5.

6.

17.

Flap ActuatorAttachment
Wing map Sector, Spoiler Actuator
Fuel Vent Lines, Hydraulic Lines
Rudder and Elevator Cable Turnbuckles and Fuel
Drain Valve

and

18.
19.

Windshield De-Ice Tank

Hydraulic Lines
Fuel Crossflow Shutoff Valve,

Hydraulic Lines,

Pneumatic Lines, Jet Pump, Fuel Check Valve,


Wing Tank Drain Valve and os. Aircraft 24-190

11.

EmergencyExit Window
FuselageFuelTank Probe
Wing FuelTankCTypicalBoth Wings)
AileronTrim Tab Actuator (LH Only)
Aileron Controls, Autopilot Roll Follow-Up

12.

Fuel ProbeConnecto~

21.

FuelLines

13.

WingAccess

22.

Fuel Lines, Fuel Tank Drain Valve, Elevator, Aileron and Rudder Cables and Aileron Sector

7.
8.
9.
10.

and Subseauen_t. Defuel Valve


20.

Fuel

plumbing, Hydraulic Lines, Wing

Drain Valve and,

(LH

on

Tank

Aircraft 24-190 and Subse-

BL1-e~t/ Defuel Valve

Only)

(TWICAL)

Fuselage, Empennage
Figure 3 (Sheet 1 of 4)

Access Doors and Panels

EFFECTn7JTY:
SRM~

MODEL24B SERIESAIRCRAFT

Stabilizers

51-00-03

Page 7
May 15/92

Leariet
STRUCTURAL REPAIR MANUAL

18

000500
C

II

ooo,"

15

000

Detail A

T53
29,27

29

23.

Fuel and

Hydraulic Lines,

15

Aileron Cable Turnbuck-

40.
41.

les and Fuel Shutoff Valve

Stabilizer Actuator Lower Attachment


Stabilizer Actuator Upper Attachment and Eleva-

24.

Fuel

25.

Fuel DrainValve

42.

26.

FuselageFuelTankProbe (LowerFitting)

43.

27.

FuelVentLines, Elevatorand RudderCables

44.

Spring Upper Attachment


HingeandBellcrank
RudderHingeand Bellcrank
Pitch Servo Cable Pulley (RH Side)

28.

PylonAccess

45.

ElevatorControlsand IdlerArm

29.

Batteries, Electrical Components, Fuel Filters, Re-

46.

RudderHingeand

47.

PitchServo

30.

48.

YawServoand

31.

frigeration and Hydraulic Components


Horizontal StabilizerHinge Points
Elevator Hinge

49.

32.

CabinDoor

Rudder Bellcrank, Yaw Servo Sector, Bottom


Rudder Hinge Point, Servo Sector Cables and

33.
34.

NoseCap Air Intake


Upper Nacelle

35.

Bottom Nacelle

36.

RearNacelle

37.

Structural

38.

PitchServoElectrical

39.

Structural

Pump and

tor Down

Fuel Drain Valve

Elevatorinboard

RudderTabActuator

Follow-Up

Rudder Cables

Inspection

Plug

50.

RudderControl Cables

51.

Elevator Sector, Push-Pull Tubes, Autopilot Pitch


Follow-Up, Elevator and Rudder Control Cables

52.

Ram Air Fuel Vent Lines, Rudder and Elevator


Cables

Inspection
(TYPICAL)

Access Doors and Panels

Figure

EFFECTIVITY:
SRM-4

MODEL 24B SERIES AIRCRAFT

Fuselage, Empennage

Stabilizers

3 (Sheet 2 of 4)

51MM3

Page 8
May 15/92

Leariet

STRUCTURAL REPAIR MANUAL

II

T12

II

10

11

ii

FLOORROARDS AND INNER SKIN

2.

Linkage
Control Cables, Pulleys and Hydraulic Lines

3.

Elevatorand RudderSectors

1.

4.

(12)

Brake Valves and Rudder Pedal

O O

Hydraulic Lines, Distribution Ducts and Brake System Shuttle


Only)
Hydraulic Lines
Control Cables, Pulleys, Roll Servo and Warm Air Ducting
ParkingBrakeValvesand HydraulicLines
Control Cables, Pneumatic Lines, Hydraulic Lines, Aileron-

Valves (RH Side


5.
6.
7.
8.

Rudder Interconnect and Air Distribution Duct


9.
10.
11.
12.
13.

CabinAirDistribution Ducts
Control Cables, Pneumatic Lines, Hydraulic Lines and AntiCollision Beacon
Pneumatic Lines, Hydraulic Lines and Air Distribution Duct

(VIEW LOOKING FORWARD~

FuselageFuel Cell
FloatSwitchand FuselageVentLines

FRAME 24

IAirmaft 24-181 thrtr 24-209)

(TYPICAL)
Access Doors and Panels moorboards
Figure 3 (Sheet 3 of 4)

EFFECTIVITY:
sRM-4

MODEL24B SERIESAIRCRAFT

Fuel Cell Panel

51MH)3

Page 9
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

;I-~---F1
1

10

L\2

FLOORBOARDS AND INNER SKIN

1.

Brake Valves and I~uddcr Podal

2.

Control Cables,

3.

Elevatorand RudderSectors

4.
5.

Hydraulic Lines, Distribution


Valves (RH Side Only)
Hydraulic Lines

6.

Control Cables,

7.
8.

Pulleys

and

Linkage

c~

Hydraulic Lines
Ducts and Brake

System

O O

Shuttle

Pulleys, Roll Servo and Warm Air Ducting


ParkingBrakeValvesand HydraulicLines
Control Cables, Pneumatic Lines, Hydraulic Lines, AileronRudder Interconnect and Air Distribution Duct

9.
10.

CabinAirDistribution Ducts
Control

Cables, Pneumatic Lines, Hydraulic Lines and Anti-

Collision Beacon
12.

Pneumatic Lines, Hydraulic Lines and Air Distribution Duct


Fuselage Fuel Cell

13.

FloatSwitchand

11.

(VIEW LOOKING FORWARD)


FRAME 24

FuselageVentLines

(A ircraft 24-210 ann Subseauent)

(TYPICAL)
Access Doors and Panels

Floorboards

Figure 3 (Sheet 4
EFFECTIVITY:
SRM-4

MODEL 24B SERIES AIRCRAFT

Fuel Cell Panel

of 4)

51M)-03

Page 10
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
~I

~h

2\

L111

II

,I

,o

It

1.

FuelFiller

15.

2.

FuelProbe

16.

WingFlapSector, SpoilerActuator
FuelVentLines, HydraulicLines

3.

TipTank Access

17.

Rudder and Elevator Cable Tumbuckles and Fuel

18.

Hydraulic

19.

Fuel Crossflow Shutoff

4.
5.
6.

Drain Valve

muxValve

Directisyn
WingTip Fuel and Electrical Connections
Electronic Equipment, Oxygen and Air Bottles,

and

7.

Emergency Exit Window

8.

FuselageFuelTankProbe
Wing Fuel Tank (Typical Both Wings)

10.

Aileron Trim Tab Actuator

20.

(LH Only), Aileron

Aileron Controls,

Autopilot

Roll

Fuel

Plumbing, Hydraulic Lines, Wing

Follow-Up

21.

FuelLines

22.

Fuel Lines, Fuel Tank Drain Valve, Elevator, Aileron and Rudder Cables and Aileron Sector

(LH
23.

Only)

Fuel and

Hydraulic Lines,

12.

Fuel Probe Connector

buckles, Wing

13.

WingAccess
mapActuator

ShutoffValve

14.

Tank

Drain Valve and Defuel Valve

Hinge Bolt
11.

Valve, Hydraulic Lines,

Pneumatic Lines, Jet Pump, Fuel Check Valve,


Wing Tank Drain Valve and Defuel Valve

Windshield De-Ice Tank

9.

Lines

Aileron Cable Turn-

Fuel Pressure Switch and Fuel

Attachment

(TYPICAL)

Access Doors and Panels

Figure
EFFECTIVITY:

Fuselage, Empennage
4

(Sheet

MODEL 24D/E/FSERIES AIRCRAF~

1 of

Stabilizers

4)

51-00-03

Page
sahc4

11

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ss

000

0~----12

000,0-~
oOo

Detail A

14
ls
Is

29

15

\28

44.

Hingeand Bellcrank
RudderHinge andBalanceWeight
PitchDCTorquerCable Pulley(RHSide)

Aircraft)

45.

ElevatorControlsandIdler

27.

Elevatorand RudderCables

46.

28.

PylonAccess

47.

29.

Batteries, Electrical Components, Fuel Filters, Refrigeration and Hydraulic Components

Hinge and Rudder Tab Actuator


Pitch DC Torquer (RH Side,LH Side Optional)
YawDCTorquer andFollow-Up
Rudder Bellcrank, Yaw DC Torquer Sector, Bottom Rudder Hinge Point, DC Torquer Sector

Pump and

Fuel

25.

FuelDrainValve (24DIE~FAircraft)

26.

Fuel Tank Probe (Lower

Fuselage

42.

Fuel Drain Valve

24.

30.

HorizontalStabilizerHinge

31.

Elevator

32.
33.

CabinDoor
NoseCap AirIntake

43.

Fitting)

(24I~F

48
49.

Points

ElevatorInboard

Arm

Rudder

Cables and Rudder Cables

Hinge
50.

RudderControlCables

51.

Elevator Sector, Push-PullTubes, Autopilot Pitch


Follow-Up, Elevator and Rudder Control Cables

34.

Upper Nacelle

35.

Lower Nacelle

52.

Rudderand ElevatorCables

36.

RearNacelle

53.

Bleed Air Shutoff Valve

39.

Inspection
DCTorquer Electrical Plug
Structural Inspection

40.

StabilizerActuator Lower Attachment

41.

Stabilizer Actuator

37.

Structural

38.

Pitch

Down

Upper Attachment
Spring Upper Attachment

~ypical

LH

RH),

Air-

craft 24-350 and Subseauent

HingeBolt

54.

Aileron

55.

Aileron Drive Clevis

Bolt, Aileron Hinge bolt

and Elevator

(TYPICAZ.)
Access Doors and Panels

Figure
EFFECTTVITY:
SRM-4

Fuselage, Empennage
4

Stabilizers

(Sheet 2 of 4)

MODEL 24D/E/F SERIES AIRCRAFT

51-00-03

Page 12
MaY 15/92

Learjet
STRUCTURAL REPAIR MANUAL

ii

lo

ii

FLOORBQARDS AND INNER SKIN

2.

Linkage
Control Cables, Pulleys and Hydraulic Lines

3.

Elevatorand RudderSectors

4.

6.

Hydraulic Lines, Distribution Ducts and Brake System Shuttle


Valves (RH Side Only)
Hydraulic Lines
Control Cables, Pulleys, Roll DC Torquer and Air Distribution

7.

ParkingBrakeValvesand HydraulicLines

8.

Control Cables, Pneumatic Lines,


Rudder Interconnect

9.

Cabin Air Distribution Ducts

1.

5.

Brake Valves and Rudder Pedal

Duct

10.

Hydraulic

Control Cables, Pneumatic Lines,

Lines and Aileron-

Hydraulic

Lines and Anti-

Collision Beacon

Hydraulic Lines and Air Distribution Duct

II.

Pneumatic Lines,

12.

FuselageFuelCell (24DIFAircraft)
Float Switch and Fuselage Vent Lines

13.

(VIEW LOOKING FORWARD)


FRAME 24

~24D/F Aircraft)

with 2Clnch Door)

(Aircraft

(TYPICAL)
Access Doors and Panels

Figure

EFFECTIVITY:
SRM~

moorboards

Fuel Cell Panel

(Sheet 3 of 4)

MODEL 24D/E/FSERIES AIRCRAFT

51-00-03

Page 13
May 15/92

Learjet
~i
STRUCTURAL REPAIR MANUAL
s

112~5

10

11

(Aircraft 24-230 thru 241253)

I
r

24-243 and Subseauent)

(VIEW LOOKING FORWARD)


FRAME 24

(Airmaft 24-243 and Subseauent)


FLOORBOARDS AND INNER SKIN

PedalLinkage

i.

BrakeValvesandRudder

2.

Control

3.

Elevatorand RudderSectors

4.

Hydraulic Lines, Distribution Ducts and Brake System Shuttle

Valves (RH Side

Cables, Pneumatic Lines, Hydraulic Lines

8.

Control

9.

and Aileron-Rudder Interconnect


Cabin Air Distribution Ducts

Cables, Pulleys and Hydraulic Lines


10.

Control Cables, Pneumatic Lines,

Hydraulic

Lines

and Anti-Collision Beacon

Only)
11.

5.

Hydraulic Lines

6.

Control Cables, Pulleys, Roll DC


Distribution Duct

7.

ParkingBrakeValvesand HydraulicLines

Torquer

Pneumatic

Lines, Hydraulic Lines and Air Distribu-

tion Duct

and Air
12.

FuselageFuelCell

13.

Float Switch and

Fuselage

Vent Lines (24D/F Air-

(Aircraft eauiaaed with 36-Xlzch Door)


(TYPICAL)
Access Doors and Panels

Figure
EFFECTIVITY:
SRM~

Floorboards

Fuel Cell Panel

(Sheet 4 of 4)

MODEL 24D/E/F SERIES AIRCRAFT

51-00-03

Page 14
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


2

obo

0-9

21

Jl
IZ

--5

43

16

11

10 11

;?6
o~-FCSt
37

000

52

33

34

53

39

35

55

51

i.

Fuel Filler-Standard

15.

2.

FuelProbe

16.

Flap ActuatorAttachment
Wing map Sector, Spoiler Actuator

3.

TipTank Access
Directisyn FluxValve
FuelDumpValve

17.

FuelVent Lines

4.

5.
6.
7.

WingTipFueland ElectricalConnections
Electronic Equipment, Air Bottle, Alcohol
Tank and,

on

Aircrafe 25-003

25-024,

Anti-ice

Rudder and

19.

Sump Drain Valve


HydraulicLines

20.

Fuel Crossflow Shutoff

11.

EmergencyExit Window
Fuselage Fuel Tank Probe
Wing Fuel Tank ~ypical Both Wings)
AileronTrimTab Actuator (LHOnly)

12.

Aileron Controls and

8.
10.

Autopilot
13.
14.

Roll

on

Cable Turnbuckles and

Valve, Hydraulic Lines,


Lines, Jet Pump, Fuel Check Valve
and on.Aircraft 25-030 and 5ubseauent, Fuel
Pneumatic

Oxygen

Bottle
9.

Elevator

18.

Drain Valve
21.

Fuel

Plumbing, Hydraulic

Lines and,

on

Aircraft

25-030 and Subseauent. Fuel Drain Valve


22.

Fuel Lines, Sump Drain, Elevator, Aileron and


Rudder Cables and Aileron Sector

23.

FuelLines

Aircraft 25-025 and Subse-

Follow-Up (LH Only)

24.

FuelProbeConnector

Fuel and

Hydraulic Lines,

Aileron Cable Turn-

buckles and Fuel Shutoff Valve

WingAccess
(TYPICAL)

Access Doors and Panels

Rgure
EFFECTIVITY:
SRM~

Fuselage, Empennage

Stabilizers

5 (Sheet 1 of 4)

MODEL 25/25ASERIES AIRCRAFT

51-00-03

Page 15
May 15/92

Leariet
STRUCTURAL REPAIR NIANUAL
I
25
22
19

---I

21

aoo

Detail A

0 0 0

/29,28

tol

A
oo

ElectricalPlug

25.

Fuel

43,

PitchServo

26.

Fuel DrainValve

44.

Stabilizer ActuatorLower Attachment

27.

FuselageFuelTank Probe (LowerFitting)

45.

Stabilizer Actuator

28.

Fuel Vent Lines

29.

PylonAccess

30.

Batteries, Electrical Components, Fuel Filters, Re-

Pump and Fuel Drain Valve

48.
49.

ElevatorControlsand IdlerArm

50.

PitchServo

51.

52.

RudderHingeand RudderTabActuator
PrimaryYawServoand Follow-Up

53.

Rudder Bellcrank,

46.

and

47.

Down

32.

frigeration Equipment, Hydraulic Components


Secondary Yaw Servo
Horizontal Stabilizer Hinge Points
Elevator Hinge

33.

Cabin Door

34.

Fuel/Defuel Adapter (Single Point) RH Only

35.

Precheck Panel

36.
37.

NoseCap AirIntake
Upper Nacelle

54.

RudderControl Cables

38.

Bottom Nacelle

55.

Elevator

39.

RearNacelle
Oxygen Bottle ~Aircraft25-025 andSuhseauent)

56.

31.

40.
41.

Structural

42.

Structural

(Single Point)

RH

and Eleva-

Upper Attachment
Spring Upper Attachment
ElevatorInboard Hingeand Bellcrank
RudderHingeand BalanceWeight
Pitch Servo Cable Pulley (RH Side)

tor

Primary Yaw Servo Sector,


Hinge Point, Servo Sector Cables,
Rudder Cables and Secondary Follow-Up

Bottom Rudder

Only

Sector, Push-Pull Tubes, Autopilot Pitch

Follow-Up,

Elevator and Rudder Cables

Ram Air Fuel Vent Lines, Rudder and Elevator

Cables

Inspection
Inspection
(TYPICAL)

Access Doors and Panels

Figure

EFFECTIVITY:
SRM~

Fuselage, Empennage

Stabilizers

5 (Sheet 2 of 4)

MODEL 25/25ASERIES AIRCRAFT

51-00-03

Page 16
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

to

T!Z

~1

10

ii

12

II

tt

11

10

10

FLOORBOARDS AND INNER SKIN

(1J)
2.

3.

Control Sector

4.

8.

Hydraulic Lines
Brake System Shuttle Valves and Hydraulic L.incs
Control Cables, Pulleys and Roll Servo
ParkingBrakeValvesand HydraulicLines
Control Cables, Pulleys and Aileron-Rudder Interconnect

9.

WireBundle Conduit

5.

6.

7.

10.

CabinAirDistribution Ducts

11.

Hydraulic Lines, Emergency Air Lines


Control Cables, Pulleys and Anti-Collision Beacon
Fuselage Fuel Cell

12.

13.

~Tj)

Brake Valves and Rudder Pedal

Linkage
Control Cables, Pulleys and Hydraulic Lines

1.

00
(VIEW LOOKING FORWARD~
FRAME 25

(Aivcraft 25-00~fhru 25-039 and 25-041 thru 25-045)

(TYPICAL)
Access Doors and Panels

Floorboards

Frgure 5 (Sheet 3
EFFECTIVITY:

MODEL 25/25ASERIES AIRCRAFT

Fuel Cell Panel

of 4)

51~X203

Page
SRM-4

17

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

9\\

II

lgl

LlZ-F

it

19

r~

Ill

(1

11

FLOORBOARDS AND INNER SKIN

O
2.
3.

Control Sector

4.

8.

Hydraulic Lines
Brake System Shuttle Valves and Hydraulic Lines
Control Cables, Pulleys and Roll Servo
Parking Brake Valves and Hydraulic Lines
Control Cables, Pulleys and Aileron-Rudder Interconnect

9.

CabinAirDistribution Ducts

5.
6.
7.

10.
11.

12.

(lr)

BrakeValvesand Rudder

PedalLinkage
Control Cables, Pulleys and Hydraulic Lines

1.

Hydraulic Lines, Emergency Air Lines


Control Cables, Pulleys and Anti-Collision
FuselageFuel Cell

00

Deacon

(VIEW LOOKING FORWARD)


FRAME 25

(Airmaft 25-040 and 25-046 and Subseauent)

(TYPICAL)

Access Doors and Panels Floorboards


Figure 5 (Sheet 4 of 4)

EFFECTIVITY:
SRM~

MODEL 25/25ASERIES AIRCRAFT

Fuel Cell Panel

51-00-03

Page 18
May 15/92

Learjet
Lear]et

STRUCTURAL REPAIR MANUAL


13
11

14
I

ct

15
16

~---17

18

~15

11

Detail A

A
O

~3

io
9

1.

Electronic

Air Bottle,

Equipment,

Oxygen

Bottle

12.

Rudder and Elevator Cable Turnbuckles and

Sump

Drain Valve

and Anti-Ice Tank

3.

(Optional)
FuselageFuelTank Probe
PylonAccess

4.

Fuel VentValves

5.

Batteries, Electrical Components, Fuel Filters, Re-

14.

Fuel Lines and

frigeration Equipment, Hydraulic Components


and Secondary Yaw Servo
Fuselage Fuel Tank Probe (Lower Fitting)
Rudder Bellcrank, Primary Yaw Servo Sector,
Rudder Bottom Hinge Point, Servo Sector C:ables,
Rudder Cables and Secondary Yaw Follow-Up

15.

Fuel and

17.

Pump and Fuel Drain Valve


Fuel Lines, Fuel Tank Drain Valve, Elevator, Aileron
and Rudder Cables, and Aileron Sector

8.

Rudder Control Cables

18.

Fuel Drain Valves

9.

Elevator Sector, Push-Pull Tubes, Autopilot Pitch


Follow-Up, Elevator and Rudder Control Cables

19.

2.

6.
7.

13.

Fuel Crossnow Shutoff Valve, Hydraulic Lines, PneuLines, Jet Pump, Fuel Check Valve and Fuel

matic

Drain Valve

10.

Rudderand ElevatorCables

11.

Hydraulic Lines

Wing

on

25 C/F Aircraft. Transfer Valve

Hydraulic Lines,

Aileron Cable Turnbuckles,

Fuel Pressure Switch and

on

25 B/D Aircraft.

Fuel Shutoff Valve


16.

Fuel

Fuel

Plumbing, Hydraulic Lines, Wing

Tank Drain

Valve and Defuel Valve

(TYPICAL)

Fuselage
Figure 6 (Sheet 1 of 5)

Access Doors and Panels

EFFECTIVITY:
SRM-4

MODEL

25B/C/D/FSERIES AIRCRAFT

Empennage

51-00-03

Page 19
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

000

~BB

60

,00

O O

80

0"

5.

TipTankAttach Fittings
Wing Tip Fuel Electrical Connections
Wing FuelTank
Fuel VentPlumbing
AileronControlsand Follow-Ups

6.

Fuel ProbeConnector

7.

WingAccess
map ActuatorAttachment
FlapSectorand SpoilerActuator

1.

2.
3.
4.

8.

9.

10.

Fuel Vent Lines

11.

Main GearAftTrunnion Pin

12.

Sparlt7
Spar#5

13.

C11
413

I
12

oO

(TYPICAL)
Access Doors and Panels

Wing
Figure 6 (Sheet 2 of 5)

EFFECTIVITY:
SRM~

MODEL 25B/C/D/FSERIES AIRCRAFT

51MM3

Page 20
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

D
11

(Optional)

1.

Oxygen Cylinder

2.

Rudder Trim Tab Motor and Center

3.
4.

Access

Hinge
RudderDalanceWeight Access
PrimaryYawServoand CapstanAccess

Access

Ei.

ElevatorServo Access

6.

Vertical Stabilizer Rib

7.

Elevator Down

8.

Lower Horizontal Stabilizer Actuator Attach Point Access


Upper Horizontal Stabilizer Actuator Attach Point Access

9.

Inspection Access
Spring and Servo Cable Turnbuckle

17.

Upper Rudder Attach Point Access


Leading Edge Hot Air Tube Access
Horizontal Stabilizer Hinge Pin Access
Pitch Capstan Pulley and Cable Access
Pitch CapstanAccess
Vertical Stabilizer Rib Inspection Access

18.

AccessCover

19.

Stinger
Oxygen Regulator Access (Optional)

10.
11.

12.

13.

14.

15.
16.

20.

(TYPICAL)

MIA-1

EFFECIIVITY:
sRM4

Access Doors and Panels Stabilizers


Figure 6 (Sheet 3 of 5)

MODEL 25B/C/D/FSERIES AIRCRAFT

51MM3

Page 21
May 15/92

Learjet
~i
STRUCTURAL REPAIR MANUAL

9\\9

u_!

r]

11

Il

10

10

11

FLOORBOARDS AND INNER SKIN

00

1.

BrakeValveand Rudder

2.

Control Cables,

3.

Controls Sector

4.

8.

HydraulicLinesand AirDucts
Brake System Shuttle Valves and Hydraulic Lines
Control Cables, Pulleys and Roll Servo
ParkingBrakeValvesand Hydraulic Lines
Control Cables, Pulleys and Aileron-Rudder Interconnect

9.

CabinAirDistribution Ducts

5.
6.
7.

10.
11.
12.

Pulleys

PedalLinkage
Hydraulic Lines

and

(VIEW LOOKING FORWARD)

Emergency Air Lines


Control Cables, Pulleys and Anti-Collision Beacon
FuselageFuel Cell
Hydraulic

Lines and

FRAME 25

(Aircvaff eauitttled with 24-~nch Door)

(TWICAL)

Access Doors and Panels

moorboards

Figure 6 (Sheet 4
EFFECTIVITY:
SRM-4

MODEL 25B/C/D/FSERIES AIRCRAFT

Fuel Cell Panel

of 5)

51-00-03

Page 22
May 15/92

Learjet
Leariet j

STRUCTURAL REPAIR MANUAL


9

11

11

10

10

(Aiwsft 25-061 thru 25-074)

o
11

00

33

11244
04

($Aircraft 25-105 and Subseauen))

(VIEW LOOKING FORWARD)


FRAME 24

(Airmaft 25-075 and Subseauent)


PLOORBOARDS AND INNER SKIN

BrakeValveandRudder

2.

Control Cables,

3.

ControlSector

4.

Hydraulic LinesandAirDucts
Brake System Shuttle Valves and

5.
6.
7.

8.

PedalLinkage
Pulleys and Hydraulic Lines

1.

Control Cables,

Pulleys

and Aileron-Rudder Inter-

connect

9.
10.
11.

Hydraulic Lines
RollServo
ControlCables,Pulleysand
Parking Brake Valves and Hydraulic Lines

12.

CabinAirDistribution Ducts

HydraulicLinesand EmergencyAirLines
Control Cables, Pulleys and Anti-Collision Beacon
FuselageFuelCell

(Aiucraft eauirmed with 3ti-lnch Door)

(TYPICAL)
Access Doors and Panels

Figure
EFlFECTIVITY:
SRM~

MODEL

Floorboards

Fuel Cell Panel

6 (Sheet 5 of 5)

25B/C/D/FSERIES AIRCRAFf

51-00-03

Page 23
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
13
14

11

lu

15

/-3

16

12---1

F--17
18

11---/

g~cL4

~Y

~---15

\CLg

Detail A

/--20

0000
ro

18
9

i.

Electronic

Equipment,

Air

12.

Bottle, Oxygen Bottle

2.

(Optional)
Fuselage FuelTank Probe

3.

PylonAccess

4.

Fuel VentValves

5.

Batteries, Electrical

Rudder and Elevator Cable Turnbuckles and

Sump

Drain Valve

and Anti-Ice Tank


13.

Fuel Crossflow Shutoff Valve, Hydraulic Lines, Pneumatic Lines, Jet Pump, Fuel Check Valve and Fuel

Drain Valve

Model 29 Aircraft, Transfer Valve

Components,
frigeration Equipment, Hydraulic Components
and Secondary Yaw Servo
Fuselage Fuel Tank Probe (Lower Fitting)
Rudder Bellcrank, Primary Yaw Servo Sector,
Rudder Bottom Hinge Point, Servo Sector Cables,
Rudder Cables and Secondary Yaw Follow-Up

14.

Fuel Lines and

15.

Fuel and

17.

Fuel Pump and Fuel Drain Valve


Fuel Lines, Fuel Tank Drain Valve, Elevator, Aileron
and Rudder Cables, and Aileron Sector

8.

Rudder Control Cables

18.

Fuel

9.

Elevator Sector, Push-Pull Tubes, Autopilot Pitch


Follow-Up, Elevator and Rudder Control Cables

19.

Fuel

10.

Rudder and Elevator Cables

20.

11.

Hydraulic Lines

6.
7.

Fuel Filters, Re-

Wing

on

Hydraulic Lines, Aileron Cable TurnbucWes,

Fuel Pressure Switch and

on

Model 28 Aircraft.

Fuel Shutoff Valve


16.

Pump and Fuel Drain Valve


Plumbing, Hydraulic Lines, Wing

Tank Drain

Valve and Defuel Valve

Fuselage FuclTankFiller

(TYPICAL)
Access Doors and Panels

Fislre
EFFECTIVITY:
SRM~

MODEL28/29SERIES AIRCRAFT

Fuselage

Empennage

(Sheet 1 of 5)

51-00-03

Page 24
May 15/92

STRUCTURAL REPAIR MANUAL

O
O
O
1.

FluxValve Installation

2.

Electrical Connections

3.

Wing FuelTank
Plumbing

4.

FuelVent

5.

AileronControlsand

6.

Fuel Probe Connector

7.

WingAccess

8.

map

9.

FlapSectorand SpoilerActuator

10.

Follow-Ups

ActuatorAttachment

\O

FuelVentLines

11.

Main Gear AftTrunnionPin

12.

Spar#7
SparfS

13.

1,

Tn,

I\ \o\O

(TYPICAL)
Access Doors and Panels

Figure 7 (Sheet 2
EFFECTIVITY:
Sf~M-4

MODEL 28/29 SERIES AIRCRAFT

Wing

of 5)

51~X)a3

Page 25
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

Vs
15)/ U3

to
Il

1)

(3

BottleAccess

(Optional)

1.

Oxygen

2.

Rudder Trim Tab Motor and Center

3.
4.

Hinge
Weight Access
PrimaryYawServoand CapstanAccess

Access

Rudder Balance

5.

ElevatorServo Access

6.

Vertical Stabilizer Rib

7.

Elevator

8.

Lower Horizontal Stabilizer Actuator Attach Point Access

9.

Upper Horizontal Stabilizer Actuator Attach Point


UpperRudder AttachPointAccess
Leading Edge Hot Air Tube Access
Horizontal Stabilizer Hinge Pin Access
Pitch Capstan Pulley and Cable Access
PitchCapstan Access
Vertical Stabilizer Rib Inspection Access

10.
II.

12.

13.

14.

15.
16.
17.

Inspection Access
DownSpringand ServoCableTurnbuckle

18.

AcccssCover

19.

Stinger
OxygcnRegulator Access(Optional)

20.

Access

(TYPICA~)
Access Doors and Panels

Figure
EFFECTIVITY:
sRM-4

MODEL 28/29SERIESAIRCRAFT

Stabilizers

(Sheet 3 of 5)

51-00-03

Page 26
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

u_ 1

I.

sn

lI

11

11

10

10

11

FLOORBQARDS AND INNER SKIN

BrakeValveandRudder
Control Cables,
ControlSedor

3.
4.

5.
6.
7.

8.
9.

00

PedalLinkage
Pulleys and Hydraulic Lines

1.

2.

HydraulicLinesand AirDucts
Brake System Shuttle Valve and Hydraulic Lines
RollServo
ControlCable,Pulleysand
HydraulicLines
ParkingBrakeValvesand
Control Cables, Pulleys and Aileron-Rudder interconnect
Cabin Air Distribution Ducts

10.

Hydraulic Lines, Emergency Air Lines

11.

Control Cables, Pulleys and Anti-Collision Beacon


Fuselage Fuel Cell

12.

(VIEW LOOKING FORWARD)


FRAME 25

with 24-Inch Door)

(Aircraft

(TYPICAL)
531A-1

EFFECTIVITY:
SRM-4

Access Doors and Panels Floorboards


Figure 7 (Sheet 4 of 5)

MODEL 28/29SERIES AIRCRAFT

Fuel Cell Panel

51MN)3

Page 27
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

11

7
s

s
4

tt

tt

to

to

FLOORBOARDS AND INNER SKIN

1.

2.

Control Sector

4.

8.

HydraulicLinesand AirDucts
Brake System Shuttle Valve and Hydraulic Lines
Control Cable, Pulleys and Roll Servo
Parking Brake Valves and Hydraulic Lines
Control Cables, Pulleys and Aileron-Rudder Interconned

9.

CabinAirDistribution Ducts

5.
6.

7.

10.

Hydraulic Lines, Emergency Air Lines

11.

Control Cables, Pulleys and Anti-Collision Beacon


FuselageFuel Cell

12.

00

BrakeValve andRudder PedalLinkage


Control Cables, Pulleys and Hydraulic Lines

3.

(VIEW LOOKING FORWARD)


FRAME 25

(Aircraft eauitmed with 36-Inch Doov)

(TYPICAL)
Access Doors and Panels

moorboards

Figure 7 (Sheet 5
EFFECTIVITY:
SRM-4

MODEL 28/29SERIES AIRCRAF~

Fuel Cell Panel

of 5)

51-00-03

Page 28
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

(r5

3~

j.

~8

~--10

~13

L 9--1

0-7

10

L8
11

12

00000

14

1.
2.
3.
4.
5.

Oxygen Bottle (Optional), Avionics and Radio


Equipment, Air Bottle and Alcohol Anti-Ice Tank
Fuselage FuelTank Probe
Hydraulic Lines and Electric Scavenge Pumps
Rudder and Elevator Cable Turnbuckles, Sump

Fuel Drain Valve

12.

Fuselage Fuel Tank Probe (Lower Fitting)

13.

FuelVent Lines

14.

Batteries, Electrical Components, Fuel Ellters, ReMg-

Equipment, Hydraulic Components, Engine


Extinguishers and Throttle Cables

eration

Fuel Crossflow Shutoff

Rre

Fuel

6.

FuelPumpand

11.

Drain Valve and Throttle Cables

Valve, Hydraulic Lines,


Pneumatic Lines, Jet Pump, Fuel Check Valve,
and Fuel Drain Valve

15.
16.

Standby
Pump
Plumbing, Hydraulic Lines, Wing Tank
Drain, Drain Valve, Standby Fuel Pump and De-

17.

fuel Valve

18.

Fuel LinesandTransferValve

8.

Fuel and

Hydraulic

Rudderand ElevatorCables
Elevator Sector, Push-Pull Tubes, Elevator and Rudder Control Cables

Fuel

7.

FuelDrainValve

10.

RudderControl Cables

Lines and Aileron Turnbuck-

Primary Yaw Servo Sector, Bottom


Hinge Point, Servo sector Cables and Rudder

Rudder Bellcrank,
Rudder
cables

les
9.

Fuel Lines, Fuel tank Drain Valve, Elevator, Aileron and Rudder Cables, aileron Sector and throttle Cables

(TYPICAL)
14-90(3-4

14-909-6

EFFECTMTY:
SRM~

Access Doors and Panels

Fuselage
Figure 8 (Sheet 1 of 5)

MODEL31 SERIESAIRCRAFT

Empennage

51-00-03

Page 29
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

2.

FluxValve Installation
Electrical Connections

3.

Wing

Fuel Tank

4.

Fuel Vent

5.

AileronControlsand

6.

Fuel ProbeConnector

7.

WingAccess
Flap ActuatorAttachment
FlapSectorand SpoilerActuator

1.

8.

9.

1QI

Plumbing
Follow-Ups

10.

FuelVent Lines

11.

Main Gear AftTrunnionPin

12.

Spar#7

rM,

13

(TYPICAL)
Access Doors and Panels Wing
Figure 8 (Sheet 2 of 5)

EFFErrNITY:
SRM-4

MODEL31 SERIESAIRCRAFT

51-00-03

Page 30
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

15)/ ~3

i3

10
I

1.

Oxygen BottleAccess (Optional)

2.

Rudder Trim Tab Motor and Center

3.

RudderBalanceWeight

Hinge

Access

Access
Access

4.

Primary Yaw Servo and Capstan

5.

Elevator Servo Access

6.

Vertical StabilizerRib

7.

ElevatorDown

8.

Lower Horizontal Stabilizer Actuator Attach Point Access

9.

17.

Upper Horizontal Stabilizer Actuator Attach


UpperRudder AttachPointAccess
Leading Edge Hot Air Tube Access
Horizontal Stabilizer Hinge Pin Access
Pitch Capstan Pulley and Cable Access
PitchCapstan Access
Vertical Stabilizer Rib Inspection Access

18.

AccessCover

19.

Stinger
Oxygen Regulator Access (Optional)

10.
11.

12.

13.

14.
15.
16.

20.

Inspection Access
Springand ServoCableTurnbuckle
Point Access

(TYPICAL)
Access Doors and Panels

Figure 8 (Sheet 3

EFFECTIVITY:
sRM-4

MODELS1 SERIESAIRCRAFT

Stabilizers
of 5)

51-00-03

Page 31
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

9
4

--r---

255

3&
1

11

8
5

~12

10

FLOORBOARDS AND INNER SKIN

Q
1.

Brake Valve and Rudder Pedal

2.

Control

3.

Control Sector

4.

Aux

5.

Brake

Linkage

Cables, Pulleys and Hydraulic Lines and Rudder

00

Boost Force Sensors

6.
7.
8.

Defog Control Box, Hydraulic Lines and Air Ducts


System Shuttle Valves and Hydraulic Lines
Control Cables, Pulleys and Roll Servo (31-002 thru 32-034)
ParkingBrakeValvesand HydraulicLines
Control Cables and Pulleys

10.

CabinAirDistribution Ducts
Aural Warning Conrol Unit,

11.

gency Air Lines


Control Cables, Pulleys and Anti-Collision Beacon

12.

Squat

9.

Switch

Relay

Hydraulic

Lines and Emer-

Panel and Rudder Boost Control Box

(VIEW LOOKING FORWARD)


FRAME 25

(31-002 thru 31-034)


13.

FuselageFuel

Cell

(Aircraft eaui~aed with 24-Inch Door)

(TYPICAL)
5J1A-1

Access Doors and Panels

Figure
EFFECTIVITY:
sRM-4

MODEL31 SERIESAIRCRAFT

Floorboards

Fuel ~ell Panel

8 (Sheet 4 of 5)

51-00-03

Page 32
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

ta

2
O

12

11

3~

8
5

10

FLOORBOARDS AND INNER SKIN

O
1.

BrakeValveand

2.

Control

RudderPedalLinkage

Cables, Pulleys and Hydraulic Lines and Rudder

00

Boost Force Sensors


3.

ControlSector

4.

8.

Defog Control Box, Hydraulic Lines and Air Ducts


System Shuttle Valves and Hydraulic Lines
Control Cables, Pulleys and Roll Servo (32-002 tht7e 31-03~t)
ParkingBrakeValvesand Hydraulic Lines
ControlCables and Pulleys

9.

Cabin AirDistribution Ducts

5.
6.

7.

10.

Aux

Brake

Aural

Warning

Conrol

Unit, Hydraulic Lines

and Emer-

gency Air Lines


11.
12.

Control

Squat

Cables, Pulleys and Anti-Collision Beacon

Switch

Relay

Panel and Rudder Boost Control Box

(VIEW LOOKING FORWARD)


FRAME 25

(31-002 thru 31-034)


13.

FuselageFuel Cell

(Aircuaft eauil7tled with 36-Inch Door)

(TYPICAL)
Access Doors and Panels

Figure

EFEECTIVITY:
sRM-C

MODEL31 SERIESAIRCRAF~

Floorboards

Fuel Cell Panel

8 (Sheet 5 of 5)

51M)-03

Page 33
May 15/92

Leariet
STRUCTURAL REPAIR MANUAL

3-~/r5

----1

r7

L-8 )-10 r13

r 9~1

\L6

~1

~----14

L,7 ~R

~2

0000

14

1.

2.

3.
4.

5.

Equipment, Air Bottle, Oxygen


(Optional) and Anti-Ice Tank
FuselageFuelTank Probe
Hydraulic Lines
Electronic

Bottle

Fuel Lines, Fuel Tank Drain Valve, Elevator, Aileron


and Rudder Cables, Aileron Sector, Throttle Cables,

9.

10.

equipped) Drag Chute Cable


FuelPumpand FuelDrainValve

Rudder and Elevator Cable Turnbuckles, Sump


DrainValve, Throttle Cables, and (if so equipped)

11.

FuelDrainValve

12.

Fuselage Fuel Tank Probe (Lower Fitting)

Drag Chute Cable

13.

FuelVent Lines

Fuel Crossflow Shutoff Valve, Hydraulic Lines,


Pneumatic Lines, Jet Pump, Fuel Check Valve,

14.

Batteries, Electrical Components, Fuel Filters, Refrig-

and (if

7.

Fire

Plumbing, Hydraulic Lines, Wing Tank


Drain, Drain Valve and Defuel Valve

15.

Cables

Model 36 Aircraft. Transfer

16.

Fuel

Fuel Lines and

on

Rudder and Elevator Cables


Elevator Sector, Push-Pull Tubes, Elevator, and Rudder Control Cables

Valve
8.

Equipment, Hydraulic Components, Engine


Extinguishers, Secondary Yaw Servo and Throttle

eration

and Fuel Drain Valve


6.

so

Fuel Pressure Switch, Fuel and Hydraulic


Lines, Aileron Cable Turnbucklcs, and on Modl?l

Wing

17.

RudderControlCables

18.

Rudder Bellcrank, Primary Yaw Servo Sector, Bottom


Rudder Hinge Point, Servo Sector Cables and Rudder

35 Aircraft. Fuel Transfer Valve

Cables

(Aircraft 35-002 thru 35-646. nnd 36-002 thru 36-058)


(TYPICAL)

14-I09C

Access Doors and Panels

Fuselage

Figure 9 (Sheet

EFFECTnlTITY:
SRM~

MODEL 35/36SERTES AIRCRAFT

Empennage

1 of 6)

51-00-03

Page 34
May 15/92

Learjet
~Learjet

STRUCTU RAL REPAIR MANUAL

--~/r5 r7

s-~

~-8

15~r16

~17

a-l~

15"-16

L17

3--~\L6 L7

~18

0000

14

Air Bottle,

1.

Electronic

2.

(Optional) and Anti-Ice Tank


FuselageFuelTank Probe
Hydraulic Lines

3.
4.

5.

Equipment,

Oxygen

nettle

9.

10.

7.

Fuel Lines, Fuel Tank Drain Valve, Elevator, Aileron


and Rudder Cables, Aileron Sector, Throttle Cables,
and (if so equipped) Drag Chute Cable
FuelPumpandFuelDrain Valve

11.

Drag Chute Cable

13.

FuelDrainValve
Fuselage Fuel Tank Probe (Lower
FuelVent Lines

Fuel Crossflow Shutoff Valve, Hydraulic Lines,


Pneumatic Lines, Jet Pump, Fuel Check Valve,

14.

Batteries, Electrical Components, Fuel Filters, Rcfrig-

12.

15.

Monel 36 Aircraft. Transfer

16.

on

Equipment, Hydraulic Components, Engine


Extinguishers, Secondary Yaw Servo and Throttle

Cables

Plumbing, Hydraulic Lines, Wing Tank


Drain, Drain Valve and Defuel Valve
Fuel

Fuel Lines and

Fitting)

eration
Fire

Rudderand ElevatorCables
Elevator Sector, Push-Pull

Tubes, Elevator, and Rud-

der Control Cables

Valve
8.

17

Rudder and Elevator Cable Turnbuckles, Sump


DrainValve, Throttle Cables, and (if so equipped)

and Fuel Drain Valve


6.

15-iL16

Fuel Pressure Switch, Fuel and Hydraulic


Lines, Aileron Cable Turnbuckles, and on 1Monrl
35 Aircraft. Fuel Transfer Valve

Wing

17.
18.

RudderControl Cables

Primary Yaw Servo Sector, Bottom


Hinge Point, Servo Sector Cables and Rudder

Rudder Bellcrank,
Rudder
Cables

(Aircraft 35-647 anbSubseauenf, nzzn 36-059 Rnn Subseauazt)

(TYPICAL)
14-109C-1

EFFECT~VITY:

Fuselage
Figure 9 (Sheet 2 of 6)

Access Doors and Panels

MODEL 35/36SERIESAIRCRAFT

Empennage

51-00-03

Page 35
SRM-4

May 15/92

Learjet

STRUCTLIRAL REPAIR MANUAL

01 00
000

8
FORWARD

OBB

O
60

,~B

B B

80

5.

TipTankAttach Fittings
Wing Tip Fuel Electrical Connections
Wing FuelTank
Fuel Vent Plumbing
Aileron Controls and Follow-Ups

6.

Fuel Probe Connector

7.

WingAccess

1.

2.
3.
4.

:11

~w
I

ActuatorAttachment

8.

Flap

9.

mapSectorand SpoilerActuator

10.

Fuel Vent Lines

11.

Main GearAftTrunnionPin

12.

Spar#7
Spar#5

13.

0"

12

oO
(TYPICAL)

Access Doors and Panels

Figure 9 (Sheet 3
EFFECT~VITY:
SRM~

MODEL 35/36 SERIES AIRCRAFT

Wing

of 6)

51-00-03

Page 36
May 15/92

Learjet
Learjet

STRUCTURAL REPAIR MANUAL

i4~
15)/ U3

0,
Il

1)\

~3

1.

13.

Hinge Access

Rudder Trim Tab Motor and Center

3.
4.

RudderBalanccWeight Access
PrimaryYawScrvoand Capstan

5.

ElevatorServo Access

6.

Vertical Stabilizer Rib

7.

Elevator Down

8.

Lower Horizontal Stabilizer Actuator Attach Point Access

9.

17.

Upper Horizontal Stabilizer Actuator Attach Point


Upper Rudder Attach Point Access
Leading Edge Hot Air Tube Access
Horizontal Stabilizer Hinge Pin Access
Pitch Capstan Pulley and Cable Access
PitchCapstan Access
Vertical Stabilizer Rib Inspection Access

18.

AccessCover

19.

Stinger
Oxygen Regulator

10.
11.

OxygenBottleAccess (Optional)

2.

12.
14.
15.

16.

20.

Access

Inspection Access
Spring and Servo Cable Turnbuckle

Access

Access

(Optional)

(TYPICAL)

5-31A-1

Access Doors and Panels

Figure

EFFECTIVITY:
sRM-4

Stabilizers

9 (Sheet 4 of 6)

MODEL 35/36SERIES AIRCRAFT

51M203

Page 37
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

04
1

345
1

15

12

13

14

11

6
5

10

04

FLOORBOARDS AND INNER SKIN

c;a,
i.

2.

BrakeValveand Rudder PedalLinkage


Control Cables, Pulleys and Hydraulic Lines

3.

Control Sector

4.

HydraulicLinesand

5.

8.

Hydraulic Lines
Pulleys and Roll Servo
ParkingBrakeValvesand HydraulicLines
Control Cables, Pulleys and Aileron Rudder Interconnect

9.

CabinAirDistribution Ducts

6.
7.

Brake

System

Control Cables,

10.

HydraulicLinesand EmergencyAirLines

11.

Control Cables, Pulleys and Anti-Collision Beacon


AuralWarningControl Unit
MachTrim Computer
Spoiler Computer
Squat Switch Relay Panel
FuselageFuel Cell

12.
13.

14.
15.
16.

00

AirDuds

Shuttle Valves and

(VIEW LOOKING FORWARD)


FRAME 25

(Aircraft eauit~ed with 24-Inch Door)

(TYPICAL)
Access Doors and Panels

Figure 9 (Sheet 5
EFFECTIVITY:
SRM~

MODEL35/36SE~IES AIRCRAFT

Fuselage

of 6)

51~X)-03

Page 38
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

9
O

sp
1

4
7

15

12

13

14

11

rD

04
9

FLOORBOARDS AND INNER SKIN

1.

BrakeValveandRudderPedallinkagc
Control Cables,
ControlSedor

4.

8.

HydraulicLinesand AirDucts
Brake System Shuttle Valves and Hydraulic Lines
Control Cables, Pulleys and Roll Servo
ParkingBrakeValvesand HydraulicLines
Control Cables, Pulleys and Aileron Rudder interconnect

9.

Cabin AirDistribution Ducts

5.
6.
7.

10.

Hydraulic

11.

Control

12.
13.
14.
15.

16.

Pulleys

Lines and

and

Hydraulic Lines

2.
3.

00

EmergencyAir Lines

Cables, Pulleys and Anti-Collision Deacon

WarningControlUnit
Computer
Spoiler Computer
Aural

MachTrim

Squat Switch Relay Panel


FuselageFuel Cell

(VIEW LOOKING FORWARD)


FRAME 25

(Aircraff eauiatled with 36-Inch Door)


(TWICAL)

Fuselage
Figure 9 (Sheet 6 of 6)

Access Doors and Panels

EFFECTNITY:
SRM-4

MODEL 35/36SERIESAIRCRAFT

51-00-03

Page 39
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
INVESTIGATION AND AERODMAMJC SMOOTHNESS

1.

STRUCTURAL IDENTIFICATION

INVESTIGATION
A.

to resist variable forces imposed upon it in operation.


the
The structure must distribute these forces to
principal structural strength members of the wing
and fuselage. When a member has been damaged, a complete and thorough inspection must be
made. This inspection should include the damaged structural member and the adjacent or attaching

The

primary

structure of

an

aircraft is

designed

possible that the damaging force might have been transmitted over the surrounding
structure, causing secondary damage ir~ areas other than the primary damage area. Should the
secondary damage not be discovered, forces distributed through the structure during normal aircraft
operations may cause this structure to fail. Careful investigation must be made of all structure across
which the forces must travel, and parts must be checked for possible misalignmcnt. Additionally, the
use of X-ray and Eddy current inspections will further support the search for secondary damage. (Refer to the appropriate Leajet Non-Destructive Inspection [NDI] Manual.)
members. It is

2.

AIRFRAMEAND MATERIALS INSPECTION


A.

AirframeInspection
(1) Preliminary External Inspection
A

great deal may be learned about the

condition of the internal structure of

an

aircraft

by

a care

wings, stabilizers, and fuselage. Some indications might be


buckle patterns on surface skin of stabilizers and along the sides, top, and bottom of fuselage.
Loose, tipped, or sheared fasteners, and joggles or bulges in the skin at structural joints or where
ful examination of the skin

heavy fittings

are

on

the

thorough inspection of the underneath structure


parts for tears, cracks, buckles, and misthese parts is reason for a close inspection of the stntc-

attached, indicate that

and other nonstructural

should be made.

Inspect fairings

alignment. Any
tures they cover.

unusual appearance of

Check also the fit of doors, covers, panels, etc. Anything unusual about their fit or alignment may
indicate a warped or sprung structure, and is cause for inspection of that structure.
When

possible,

actuate control

surfaces, flaps, spoilers,

etc.

Observe these units

closely through-

They should operate freely and without binding or chafing. Check the units in
closed positions for proper alignment with adjacent members.

out their travel.

the

zero or

(2) Detailed Visual Inspection

Carefully inspect

all

areas

adjacent

to the obvious

damage. Inspect forgings

and other machined

often be done

by observhaving
the
rivet
at
bolt
or
a
or
heads,
edge of
by slight space
edges, by tipped
ing
paint
for
bolts
examine
from
and
bolts
When
two
a
surfaces.
remove
suspected fitting
possible,
faying
evidence of shearing or bending. Check bolt holes for elongation.
parts

for cracks and for evidence of their

the

been moved. This

can

around the

warpage and jogglcs. Check for sheared, loose, or


members is also important. Using a straightedge,
frame
webs and bulkheads. Any deviation should be
webs,
spar

Inspect supporting structures for buckling


tipped fasteners. Alignment with adjacent
check known flat

areas

such

as

thoroughly investigated.

EFFECTIVITY:
SRM-4

ALL

51-10-00

rage 1
May 15/92

Leariet
STRUCTURAL REPAIR MANUAL
damage is suspected, a close examination is justified for
joined or where heavy weights are supported. The princimajor components
their
with
of
this
areas
nature,
supporting structures, are as follows:
pal
(a) Wing-to-fuselage attachments

When
all

03)
(c)
(d)
(e)
(f)

aircraft has been

an

areas

damaged,

where

or

are

Vertical stabilizer attachments


Rudder

hinge
Landing gear trunnions and actuator attach points
Pylon and nacelle attachments
Engine mounts

inspection throughout disassembly and repair of aircraft. During this time, indications
unsuspected damage are often revealed. When new parts being installed do not fit properly,
find out why. It may be because of damage that has been overlooked.
Overpressurization or Hard Landing Inspections
When an aircraft has been subjected to overloads from overpressurization or hard landing, a careful
inspection of the structure should be made to determine whether damage was sustained. Inspection
of the structure should be concentrated on finding fractures, or partial fractures (appearing as cracks),
sheared or partially sheared fasteners, cracked or broken lugs (or other fittings), cracked or broken
spars, longerons, etc.
(1) Hard or Overweight Landings
After every hard or overweight landing, inspect the following components and areas:
(a) Wing lower skin in landing gear rib area for skin buckles, fastener failures, security of landing gear rib and trunnion fittings.
(b) Wing-to-body fittings and supporting structure for security, fastener condition, and permaContinue
of

B.

nent

deformation.

(c) Trailing

edge region

of

wing

for local deformation

affecting

normal usage of

flaps

and aile-

rons.

(d)

Tip tank-to-wing
tener

attachment and

wing

extension attachment at WS 181 rib for

tion. It is not necessary to


evident.

remove access

security,

fas-

failures and/or permanent deformastraps unless excessive fastener load or working is

condition, and evidence of excessive load such

as

(e) Keel beam and attachments for security, fastener condition, permanent deformation and
(f)

torque of primary tension joint bolts.


landing gear assemblies, and

Nose and main

damage

or

deformation. Actuator attach

nose

points

and

and main gear actuator assemblies for


support structure for security, fastener

condition and permanent deformation.

(g) Engine mount castings, for permanent deformation or cracks and support structure,
ing pylon beams and beam-to-fuselage fittings, for security and fastener condition.

includ-

(2) Severe Turbulence and/or Maneuvers


After

and

flight involving

severe

turbulence and/or maneuvers,

inspect

the

following components

areas:

(a) Wing-to-body fittings and supporting

structure for

security,

fastener condition, and perma-

nent deformation.

Cb)

Trailing edge region

of

wing

for local deformations

affecting

normal usage of

flap

and aile-

ron.

EFFECTIVITY:
SRM-4

ALL

51-10-00

Page 2
May 15/92

Learjet
STRUCTU RAL REPAIR MANUAL
(c) Tip tank-to-wing attachment for security, fastener condition and permanent deformation.
(d) Keel beam and attachments for security, fastener condition permanent deformation, and

torque of primary

tension

joint bolts.

(e) Canted bulkheads and lower fin spar attachments in aft tailcone. Check for fastener security,

permanent deformation of bulkheads and spar assemblies.


(f) Horizontal stabilizer hinge fittings, actuator and fittings, and stabilizer center section structure for security, permanent deformation, skin buckles, or other evidence of overload.
stabilizer for permanent deformation, skin buckles, and security at primary attachVertical
(g)
ments.
mount castings for permanent deformation or cracks and support structure, including
pylon beams and beam-to-fuselage fittings, for security and fastener condition.
OverheatInspections
Three methods are used in checking airplane structures after overheating: visual inspection for
buckles, canning, and primer discoloration; hardness testing of questionable parts with a portable
or a stationary hardness tester; and tension-testing of specimens taken from areas of doubtful val-

(h) Engine

C.

ues.

(1) Buckles, Canning and Primer Discoloration Visual Inspection

inspection of an airplane, the search for buckles or canning is primarily conpossibly weakened condition of primary internal structures. This is especialwhen
the overheating has been in the wing area. It is possible that an area unafimportant
ly
fected by the fire directly may have been bent enough to receive a permanent set.
In the visual

cerned with the

Large (or thick)

aluminum parts, such

and extruded

Similar

as

forgings,

are

not as

quickly

affected

components. However, when heat has been great enough

thinner and smaller

parts, all heavy fittings

parts from unaffected

areas

in the

area

by

heat

to

injure

as are

sheet

should be removed and hardness-tested.

may be used for

comparison.

It is often necessary to remove sample disks from sheet-metal parts, except wing skins, in order to test them on a bench-type hardness tester. Disks for this purpose should be removed

with

one-inch hole

saw.

If the

parts are

to be retained in use, make

repairs as directed

in the

applicable chapter of this manual.


Access hole

also

covers

in the overheated

area are

provide an easily replaceable part

samples
testing.

excellent

for destructive

for hardness

sampling. They

When tension bars from sheet-metal parts are taken for laboratory testing, the blanks removed should measure 1 x 7 inches. However, pieces measuring 1 x 5 inches are acceptable.

They should be cut

with the

long edges in line

with the

grain whenever possible.

samples are sent to a laboratory for analysis, information as to the type and
duration of the overheating should be included. Also, the part number, whether metal or alloy, grain direction, etc., should be included wherever determinable.
When

EFFECTIVITY:

ALL

parts

or

51-10-00

rage 3
SRM-4

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
Determining the extent of overheat damage by primer comparison can be a good indication
when used carefully. A clean sample of the primer known to be unaffected by heat is compared with primer in the heated area. The sample should be from the same general area of
the structure in question. The suspected area must be free of dirt, oil, and smoke.
exposed to about 3000F of heat for a few minutes, it darkens. Temperatures that discolprimers will change the physical properties of 2024-T4 and 7075-T6 alloys. The 7000 Series
alloys that are already in the T6, or artificially aged, condition are softened and weakened.
The 2024-T4 is artificially aged and hardened, until the temperature reaches 500"F; then, with

When
or

increased heat, this metal also softens and weakens. When the temperature of 2024-T4 is
raised to 3000F to 5000F for a short period under uncontrolled conditions, as is the case in an
aircraft fire, the inherent corrosion-resisting properties are seriously affected.
Both 2024-T4 and 7000 Series
be

subjected

er

is evident.

to

more

alloys (T6 condition) that are of questionable value and should


testing when the slightest discoloration of the prim-

accurate methods of

(2) Hardness-Testing and Tension-Testing


Reliable limits of correlation between hardness tests and tensile tests have been established

alloys. Materials
reading may be considered acceptable:

for the 7000 Series aluminum


"B" scale

that meet the

following

minimum Rockwell

Rg 88 (min)

(a) 7075-T6

replaced, or specimens should be rereadings and sent to a laboratory for ten-

Material that falls below the minimum should be


moved from the

areas

with the lowest Rockwell

sion tests.

readings are not accurate indications of heat damage on 2024-T4 because of


quick heating to 3000F may not raise the hardness number above
normal but will affect the corrosion resistance. Therefore, if primer discoloration indicates that heat has affected the material, the material should be replaced or a specimen
tests.
should be removed and sent to a laboratory for tension and corrosion-susceptibility
Hardness test

the corrosion factor. A

undergone slight meoverheating, every effort should be made to protect the metal.
Painted areas should be stripped, treated with phosphoric cleaner, chemical-film-treated,
and repainted. Surfaces not normally painted should be treated with phosphoric cleaner.
Structural Joint Wear Inspection
Wear allowances and repair data for fittings, forgings, and structural joints are shown in 51-71-00.
If

decision is made to retain in

chanical

D.

EFFECTNITY:
sRM-a

ALL

change

use a

section of 2024-T4 that has

due to

51-10-00

Page 4
May 15/92

Leariet
~Learieti
STRUCTURAL REPAIR MANUAL

LOADS

/--TRANSITION POINT
LOAD PATTERNS
HARD TWO-WHEEL

(MAINGEAR)LANDING
Resultant Inertia Load-

ing

Distribution

Loads
these
the

are

the

loading
local

(weight),

on

~21

-~Initial Loads

LOADS

Airframe.

of

product

intensities and

distributed

BUCKLES

mass

combined with the

Lbl4P

initial external loads.

BUCKLE PATTERNS

HARD TWO-WHEEL

(MAIN GEAR) LANDING


NOTES:
Buckle

patterns shown

in the dia-

grams indicate the directions of


the buckles that would tend to
form in the skin

as a

loads

in

wheel

imposed
landing.

result of the

hard

two-

B~1

Location of transition of buckle di-

loading transition
point may be in a difpoint.
ferent location for each landing,
depending on gross weight, CG
location, sinking speed, angle
rection matches

This

BUCKLES

from horizontal, etc.

Buckles shown

are

for

fuselage

only.
(TYPICAL)
Load and Buckle Patterns
Figure 1 (Sheet 1 of 3)

EFFECTIVITY:

ALL

51-10-00

Page
SRM~

May15/92

Learjet
~arjet

STRUCTURAL REPAIR MANUAL


LOADS

BUCKLES

/zi~b

oooo~ll

HARD

10000

THREE-WHEEL LANDING

LOADS

BUCKLES

TRANSITION POINT

OD00

HARD NOSE WHEEL LANDING

---)Initial Loads
----tResultant Inertia Load-

ing

Distribution

Loads

are

loading

the

on

Airframe.

product of

these

intensities and the lo-

cal distributed

(weight),

mass

combined with the initial

ex-

LOADS

ternal loads.

TRANSITION POINT

NOTES:

Buckle patterns shown in the diagrams indicate the directions of


the buckles that would tend to
form in the skin

as a

result of the

imposed in the landing


figuration shown.
loads

con-

Location of transition of buckle direction matches

loading

transition

may be in a different location for each landing,


depending on gross weight, CG

point.

This

point

location, sinking speed,


from horizontal, etc.
Buckles shown

are

for

angle

fuselage

SUDDEN STOP

only.

LEFT WHEEL

(RightWheelOpposite)
(TYPICAL)
Load and Buckle Patterns

Figure
EFFECTIVITY:
SRM4

ALL

(Sheet

2 of 3)

51-10-00

Page 6
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
~Initial Loads

~Resultant Inertia LoadDistribution

ing

Loads

are

loading

the

Airframe.

on

product of

these

intensities and the lo-

cal distributed

mass

(weight),

combined with the initial

ex-

ternal loads.

TRANSITION POINT

SUDDEN STOP

RIGHT WING

(Left Wing Opposite)

NOTES:

SIDE TOW TOWARD READER

Buckle

SIDE DRT~T TOWARD READER

patterns shown

in the dia-

grams indicate the directions of


the buckles that would tend to

YAW (TAIL AWAY FROM READER)

form in the skin

loads
tions

imposed
given.

Buckles

shown,

may be of either type


or a

combination of both.

Buckles shown

COMPRESSION
BUCKLES- ONE

as a result of the
under the condi-

are

for

fuselage

only.

SIDE ONLY
SIDE TOW TOWARD READER
YAW (TAIL AWAY EROM READER)

SIDE DRIFT LANDING


AND SIDE TOW

DIAGONAL SMEAR BUCKLES ON BOTH SIDES


BUT OFPOSITE IN DIRECTION

(TYPICAL)

Load and Buckle Patterns

Figure 1 (Sheet 3
EFFECTIVITY:
SRM-b

ALL

of 3)

51-10-00

Page 7
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
INVESTIGATION AND AERODYNAMIC SMOOTHNESS
1.

DAMAGE CLASSIFICATIONS

A.

damage is damage that can be permitted to be "as is", or may be corrected by a simple procedure, without restricting flight. In most cases, a corrective action must be taken to keep the damage
from spreading. Frequent inspection of areas with allowable damage is necessary to ensure the damage does not spread. Limitations regarding the extent of allowable damage vary in different locations
throughout the airplane. These limitations are shown on the illustrations of allowable damage for the
Allowable

various
B.

C.
D.

2.

ALLOWABLE DAMAGE

components.

flight damage is damage that can be left "as is" or requires only minor repairs to allow the
aircraft to be flown to a repair facility,
Repairable damage is damage that may be repaired so as to make the strength of the repaired structure equal to, or greater than, that required to maintain the structural capability of the airplane.
Damage requiring replacement of parts including any damaged component that must be replaced
when the location or the extent of damage makes it impractical to repair. When a damaged component or part is replaced, care should be taken to avoid damage to adjacent or attaching structure.
One-time

CAUSESANDTWES OFDAMAGE
which may occur to an aircraft. However, for purposes of
or impact, stress, fatigue, corrosion, erosion and overheat.
description, some of the causes are
minor damage, such as a small hole or dent, to extensive
from
varies
A. Collision or impact damage

There

are

many

causes

and

degrees of damage
collision

B.

C.

D.

damage, such as torn, crushed, or burned skin and structural members, and misalignment of the airplane. Damage such as this can occur at any point on the airplane.
Stress damage generally consists of loosened, sheared, or popped fasteners, wrinkled skin or webs,
and cracked or deformed structural members. Damage such as this is caused by abnormal stresses
imposed upon the members.
Fatigue damage generally consists of small cracks that are caused by vibration, "oil cans," and variable loads imposed on skin, fittings, and load-bearing members where fittings are attached. Damage
of this type occurs more frequently as the operation time of the aircraft accumulates.
Corrosion damage may be defined as the gradual chemical or electromcchanical attack on a metal by
atmosphere, moisture and other agents. The types of corrosive attack most commonly encountered
are ordinary corrosion, resulting in a uniform deterioration or pitting attack on the surface; intergranular corrosion, resulting in a grain boundary attack; and stress corrosion and galvanic corrosion, resulting in the deterioration of the more active of two dissimilar metals in contact. Corrosion products
from the deterioration of the

instance, magnesium
and

more

active metal will sometimes corrode the other dissimilar metal (for

and aluminum).

fire-extinguishing agents

Corrosion caused

by foreign

Monobromotrifl u orometha ne, which i s used i n the

NOTE:

materials such

as

battery

acid

may be encountered under certain conditions.

portable

an d

engin e

fire

ex

tinguishers,

is non-corrosive.

(1) Ordinary corrosion may be recognized by


aluminum and

duIling or pitting of the surface, accompanied by


by a reddish rust coating on steel. Corrosion cannot
a

powdery deposits
always be detected by a visual examination alone,
where the paint falls off under pressure.
white

EFFECTIVJTY:
SRM-4

ALL

on

but may sometimes be discovered under

paint

51-10-00

Page 101
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
(2)

the grain boundaries of the material resulting


potential between the grain boundary material
(or center of the grains). This corrosion cannot be readily recognized during a sur-

Intergranular corrosion
from

is corrosion

occurring along

difference in corrosion (or electrochemical)

and the matrix

face examination until actual failure of the material. This failure then shows up much

as a

crack

might appear.
(3) Stress corrosion occurs

as a

result of the

susceptibility of materials

to

intergranular corrosion com-

bined with presence of internally or extcnlally applied stresses such as residual stresses developed from quenching, welding, severe forming, or externally applied severe stress.
occurs in the presence of moisture when two different metals are in actual
contact, an electric current flows from one metal to the other, resulting in corrosive attack on one
of the materials. This is similar to the action that takes place within a common storage battery. In
galvanic corrosion, the more active of the two dissimilar metals serves as the anode, the moisture

(4) Galvanic corrosion

becomes the

electrolyte,

and the less active metal acts

as

the cathode. The

more

active of the two

metals suffers the corrosive attack.

(5) Corrosive Effects of Dry Chemical Powder (Sodium Bicarbonate). Dry chemical powder is

a speWhen sodium bicarbonate is heated, it decomposes


and releases carbon dioxide gas and water vapor. The decomposed product is sodium carbonate
(soda ash). In the dry state, sodium bicarbonate is harmless and sodium carbonate is relatively

cially prepared grade of sodium bicarbonate.

so.

In the wet state tin solution with

craft metals, and sodium carbonate is


als.

water), sodium bicarbonate is mildly corrosive

extremely

(6) Corrosive Effects of Mechanical Foam.


harmless

vegetable compound.

The

The

only

caustic and will

rapidly attack

agent combined with

water to

to most air-

most aircraft met-

produce

foam is

corrosive action of this combination is that caused

by

the water used.

(CF? Br), and Carbon Dioxide. These fireextinguishing agents evaporate rapidly and are relativePy harmless. No cleanup is required following use of these agents.
Erosion damage is usually encountered on reinforced glass-fabric component such as antennas, radomes and wing tips. While this material is resistant to rain, weather, and aging, it may be eroded by
hail, sharp objects, flying stones, or sharp blows.
Overheat damage is most likely to occur in the engine nacelle structure and skins. Overheat damage
may be detected by skin and web buckles, canning and primer discoloration.
(7) Corrosive E ffects of Monobromo trifluorometha ne

E.

F.

EFFECTIVITY:
SRM4

ALL

51-10-00

Page 102
May 15/92

Learjet
11Rrpl
STRUCTURAL REPAIR MANUAL
INVESTIGATION AND AERODYNAMIC SMOOTHNESS
1.

REPAIR

AERODYNAMIC SMOOTHNESS
Modern aircraft

specifications require that the aircraft exterior surfaces be of extremely smooth construcdesign performance. The structural repair person must keep this in mind when making reor
pairs changes. Figure 201 shows the areas that are most critical aerodynamically; however, smoothness
of the entire aircraft surface area is a critical requirement from the performance standpoint. The seriousness of this condition is proportional to the airflow disturbance created. (Refer to 51-40-04 for classification of zone and fastener smoothness requirements.)
tion to obtain

The

prime considerations of aerodynamic smoothness are.parasite drag (drag caused by skin friction and
nonlifting surfaces of an aircraft) and the aerodynamic load distribution on the surface. Any repair or
change that increases parasite drag will reduce the top speed of the aircraft. Also, range will be reduced,
since more power, and thus more fuel, is required to maintain cruising speed.

Any change that disturbs the smooth flow of air over a critical surface will change the load
face, as well as increase the drag.

Any change in the airflow around

on

that

sur-

the control surfaces is critical, since the control effectiveness may be af-

fected.

problem that may arise is buffeting. Buffeting can be caused by airflow separation around an
abrupt change, such as a nonflush patch, in the mold line.
Another

Temporary (Nonflush) repairs are permitted in some areas designated "critical". (See Figure 201.)
porary repairs must be replaced by permanent repairs at the earliest possible time.

Tem-

Paste-type fillers, that cure to a hard-rubber-like consistency, are used to fill skin and door gaps, to blend
overlapping surfaces, and in other similar conditions to achieve a satisfactory degree of aerodynamic
smoothness. (Refer to 51-70-01.)

EFFECTIVITY:

SRM-4

ALL

51-10-00

Page 201
Jun1/95

Leariet
Cearjei
TEMPORARY REVISION NO. 51-1
MANUAL AFFECTED:

Leajet 20/30 Series Structural Repair Manual (SRM-4).

FILING INSTRUCTIONS:

Insert

adjacent

to

51-10-00, page 202, dated

May 15/92,

and retain until fur-

ther notice.

REASON:

To

INSTRUCTIONS:

clarify and
Revise

define

Aerodynamically Critical Areas.

Figure 201, Sheets

TEMPORARY REVISION NO. 51-1

2,

as

shown

on

enclosed pages.

51-10-00

Page
SRM-~

1 of 3

Aug 25/97

Learjet

STRUCTURAL REPAIR MANUAL


CRITICAL AREAS

Horizontal Stabilizer
Lower Surfaces)

Temporary (nonRush) repairs are not


pennitted in these areas.

mmmnm

(Upper and

Flight characteristics could be affected by


temporary (nonflush) repairs in these areas.
If temporary repairs are made, a review by
Leajet Customer Service Engineering is
mandatory and a Right test maybe required.

Elevator

LeadingEdge

FonvardoiCutout

nidettinrepaiIsare
nep
these

areas.

Fuselage skin

Vertical Stabilizer
areas

adjacent to pyion,
pyIon,

and lower surfaces of


a;ld inboard half of nacelle.
upper

Engine Inlets

Rudder Leading Edge


Skin and 6-Inches
Forward of Cutout

Wing Surfaces, Ailerons and

Flap-Leading Edge Skin

n0
\I

Wing Leading Edge

Aileron Leading Edge and Upper


Main Box Skins forward of AiTeron

Static Port

(If Installed)

Model 23/24/25/35/36 Series Aircraft

(TYPICAL)
clloc-2

TEMPORARY REVISION NO. 51-1

SRM-I

Aerodynamically Critical Areas


Figure 201 (Sheet 1 of 2)
51-10-00

Page 2 of 3
Aug 15/97

Learjet

STRUCTURAL REPAIR MANUAL


CRITICAL AREAS

Temporary (nonflush) repairs


permitted in these areas.

mmmmn

are not

Flight characteristics could be affected by


temporary (nonnush) repairs in these areas.
If temporary repairs are made, a review by
Leajet Customer Service Engineering is
mandatory and a flight test may be required.
Temporary (nonflush) repairs are permitted
in these

areas.

Elevator Leading Edge


Skin and
Forward of Cutout

Horizontal Stabilizer
(Upper and Lower Surfaces

Vertical Stabilizer

Winnlet

(Bot~ Surfaces)

Fuselage skin

areas

adjacent

to

pylon,

surfaces of pylon,
a~d inboard half of nacelle.
upper and lower

Engine Inlets

Delta Fins

(BothSuriace5)

Rudder Leading Edge


Skin and ~-lnches
Forward of Cutout

Wing Surfaces, Ailerons and

Flapteading Edge Skin

o"
O

Wing Leading Edge


Aileron Leading Edge
and Upper Main BoSi Skins
Fonvaia of Aileron.

Static Port

(If Installed)

Model 28/29/31 Series Aircraft

(TYPICAL)

Aerodvnamically Critical Areas


Figure 201 (Sheet 2 of 2)
TEMPORARY REVISION NO. 51-1

51-10-00

Page 3 of 3
SRM~

Aug 15/97

Learjet

STRUCTURAL REPAIR MANUAL


NOTE: Please
CRITICAL AREAS

see

the

TEMPORARY
REVISION
revises this page.

Temporary (nonflush) repairs are not


permitted in these areas.
Elevators (Upper and
Lowa SurfaQs)

Flight characteristics could be affected by


temporary (nonflush) repairs in these areas.
If temporary repairs are made, a review by
Leaiet Field Service Engineering is required
and a flight test must be performed.

Temporary (nonflush) repairs are permitted


in these

areas.

Horizontal Stabilizer
(Upper and Lower Surfaces)
Vertical Stabilizer

adjacent to pyion,
lower surfaces of pylon, and

Fuselage skin
upper and

areas

inboard half of nacelle.

Rudder (Both Surfaces)

Ailerons (Upper and


Lower Surfaces)

Flaps (Upper

and

Lower Surfaces)

Nacelle Inlet

OV~

Wing Leading Edge

SpoilcrP(UppcrSurfarr)

Static Port

(RH Side

Only)
(TYPICAL)

6110GZ

EFEECT~IVITY:
SRM-(

Wings (Upper

and

Lower Surfaces)

Aerodynamically Critical Areas


Figure 201 (Sheet 1 of 2)
MODEL 23/24/25/35/36 SERIES AIRCRAFT

Q
51-10-00

Page 202
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
CRITICAL AREAS

Temporary (nonflush) repairs are not


permitted in these areas.

Flight characteristics could be affected by


temporary (nonflush) repairs in these areas.
If temporary repairs are made, a review by
Learjet Field Service Engineering is required
and a flight test must be performed.

Elevators

(Upper and

Lower Surfaces)

Temporary (nonflush) repairs are permitted


in these

areas.

Fuselage skin areas adjacent to pylon,


upper and lower surfaces of pylon, and

Horizontal Stabilizer

inboard half of nacelle.

(Upper and Lower Surfaces)

BiiQ-~
ii,

i:iii-ii:~

Vertical Stabilizer
Biia~isiiiiisii_i,:

Rudder

I
Ailerons

(Both Surfaces)

(Upper and

Delta Fins

Lower Surfaces)

(Both Surfaces)

Flaps (Upper and

Nacelle Inlet

Lower Surfaces)

Static Port

(RH Side

Only)

C)

~Spoilers (Upper Surface)

Wing Leading Edge

Wings (Upper and--

Winglet

Lower Surfaces)

(Both Surfaces)

(TYPICAL)

Aerodynamically Critical Areas


Figure 201 (Sheet 2 of 2)
EFFECTIVITY:
SRM-4

MODEL28/29/31 SERIESAIRCRAFT

hL

NOTE: Please

see

fhe

TEMPORARY
REV/SION
that revises this page.

51-10-00

Page 203
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


MATERIALS- STRUCTURAL IDENTIFICATION
CONSTRUCTION MATERIALS

i.

A.

repair of this aircraft may be listed in the following


alloys, steels, extrusions, and formed sections), transparent plastic, and

Most of the materials used in the construction and

categories:

metals (aluminum

fasteners.
As a general-purpose material, 2024 aluminum alloy is used: where greater compressive strength is required, 2014-T6 aluminum alloy is used. 2014-T6 is used for die forgings.
6061 alloy is used in areas where welding is required.
(2) Steel -The principal steel alloy used in this aircraft is 4130 low-alloy steel.
(3) Plastic Transparent plastics used in this aircraft for cabin windows is MIL-P-25690 stretched
acrylic.
(4) Fasteners The majority of the structure of this aircraft is assembled with conventional fixed and
removable fasteners, such as standard aluminum alloy and steel rivets (driven and blind), screws,
bolts, nuts, and quick-attach fasteners. For additional information concerning fasteners, refer to

(1) Aluminum

51-40-00.
B.

The

following

materials

to the referenced

ALL

were

used in the construction of the

Learjet. Repair

materials must conform

specifications, as applicable

51-30-00

Page
SRM-4

May 15/92

Learjet:

STRUCTURAL REPAIR MANUAL


SPECIFICATION

MATERIAL

REMARKS

ALUMINUM BARS AND SHAPES

or

2014-T6511

aluminum

alloy shape

2024-0

2024-T351

2014-0

or

aluminum

Fed.

Spec QQ-A-200/2

Fed.

Spec QQa-225/6

alloy. Use 2024-0 only


forming is too severe for 2024-T351. Heat-treat all
2024-0 parts to 2024-T42 condition after forming.
Rolled bar. General purpose
if

alloy shape

Do not weld.
2024-0

or

aluminum

Fed.

2024-T3511

alloy bar

or

Spec QQ-A-200/3

shape

Use 2024-0

if

forming

Extruded bar

or

is too

for 2024-T3511. Heat-treat all 2024-0

severe

shape.

to 2024-T42 condition after

parts

only

forming. Do

not

weld.
6061-0

or

6061-T6

T6511 aluminum

Fed.

or

Spec QQ-A-225/3

alloy bar
ALUMINUM CASTINGS

356-T6 aluminum
sand

Fed.

alloy

Spec QQ-A601

High-strength

structural

casting alloy. Heat-

treatable and weldable.

casting

ALUMINUM FORGINGS
201 4-T6 and 7175-r/36

Fed.

Spec QQa-367

High-strength

heat-treated. Not weldable.

ALUMINUM SHEET AND PLATE


2024-0

or

Fed.

2024-T3

bare aluminum

alloy

Spec QQd-250/4

Gages

from 0.010 to 0.250. Use 2024-0 when part

cannot be made from 2024-T3. Heat-treat all

sheet

2024-0

parts

to 2024-T42 condition after

forming.

Not weldable.
Fed.

2024-0, 2024-T351
bare aluminum

Spec QQ-A-250/4

Plate thicknesses from 0.250 to 3.000. Use 2024-0


when

alloy plate

parts

cannot be formed from 2024-T351.

Heat-treat all 2024-0


after
Fed.

2024-0 and 2024-T3

clad aluminum

alloy sheet

Spec QQ-A-250/5

forming.

parts

to 2024-T42 condition

Not weldable.

0.010 to 0.250. Use 2024-0 only when


part cannot be made from 2024-T3. Heat-treat all
2024-0 parts to 2024-T42 condition after forming.
May be spot- or seam-welded but not fusion-

Gages from

welded.

Construction Metals
Table 1 (Sheet 1 of 3)

EFFECTIVITY:

ALL

51-30-00

Page 2
SRM-4

Tun 1/95

STRUCTURAL REPAIR MANUAL


REMARKS

SPECIFICATION

MATERIAL

ALUMINUM SHEET AND PLATE


6061-0, 6061-T4 and

Fed.

Spec OQ-A-250/11

6061-T6 aluminum alloy


sheet

or

Sheet gages from 0.010 to 0.250. Plate thicknesses


from 0.250 to 3.000. Not to be used where other

alloys

plate

are

suitable. Use 6061-0 only if part cannot

be made from 6061-T4. Use 6061-T4

only

if part

cannot be made from 6061-T6. Heat-treat 6061-0

and 6061-T4 to T6 condition when required. May be


spot- or seam-welded in the treated condition, and
fusion-welded if resultant annealed condition in
area

of weld is

acceptable.

STEEL BARS
4130 condition D,
condition F

Spec MIL-S-6758

4340 steel bar

Spec MIL-S-5000

condition D

Low-alloy steel. Condition D (normalized) may


copper-brazed or fusion-wekled, but not spotor seam-welded. May be heat-treated.

be

Low-allow steel. May be fusion-wekfed, but not


or seam-welded. May be heat treated.

spot-

STEEL SHEETS AND PLATES


301 CRES sheet and

Spec MIL-S-5059

Sheet gages from 0.012 to 0.250. Plate thicknesses


from 0.250 to 2.000. Unstabilized. Maximum
service temperature is 7000F. Annea)ed material is
nonmagnetic. May be spot- or seam-welded but not
brazed or fusion-welded.

Spec MIL-S-6721

Sheet gages from 0.012 to 0.250. Plate thicknesses


from 0.150 to 1.000. Use Specification MIL-S-5059

plate, annealed and


1/2 hard

321 heat-resistant and

CRES sheet and

plate

if possible. Forms easily, annealed and


non-magnetic. Not to be heat-treated. Can be spotor seam-welded, fusion-welded, or silver-brazed.
4130 steel sheet and

plate, condition

or

Spec MIL-S-18729

Sheet gages from 0.020 to 0.250. Plate thicknesses


from 0.250 to 1.000 low-alloy steel. May be

copper-brazed
seam-welded.

or

fusion-welded, but

May

not

spot-

or

be heat-treated.

Construction Metals
Table 1 (Sheet 2 o~ 3)

EFFECTNITY:

ALL

1
51-30-00

Fage 3
SRM~

lun 1/95

~Leariefl
STRUCTURAL REPAIR MANUAL
MATERIAL

REMARKS

SPECIFICATION
STEEL TUBING

Spec MIL-T-6736

4130 steel tube

BRONZE BAR AND CASTINGS


Aluminum-bronze bar

Used in the manufacture of

AMS4640

bushings and bearings.

STEEL CASTINGS
17-4 PH and 15-5 PH

AMS5355 and AMSS357

Used in forward and aft

engine mounts, and in

spoiler actuator fittings.

Construction Metals
Table I (Sheet 3 of 3)

EFFECTIVITY:

ALL

51-30-00

Page 4
SRM-4

Jun1/95

E~t
STRUCTURAL REPAIR MANUAL
0312

0~030
01)60

0~062

Ok~L_r
1.000

0~062

--I

Material:

High Tear Silicone Rubber Dow Coming Silastic 55U Silicone Rubber

Durometer:

Shore A 40 to 50

Tolerances:

1116

~0.015)

5/16 (f0.015)

(I~t0.030)

1.0

Grey

Color:

EXTRUDED SEAL S-306

(MOLDED)

5 Points Centered
0.030 high at 45" angle
0~275 R

0.125

t,0.OSO (f0.030) Constant

0.170 to 0170

0.125R

0.187
00628

(Typical)

0.750

0.120

0.030

Tear Silicons Rubber Dow

Material:

High

Durometer:

Installation:

Shore A 50 (~5)
No. 21 Hole Recommended

Color:

Grey

1500 Between Pull Thrus

Coming Silastic 55U Silicone Rubber

CABIN DOOR SEAL S-308

(MOLDED)

Extrusions and Formed Sections

Figure 1(Sheet 1)
EFFECTIVITY:

ALL

51-30-00

Page 5
SRM-4

Jun 1/95

Learjet
~Learjet(
STRUCTURAL REPAIR MANUAL
0.062

CTypical)

0.062R

0375

0.06

~-0.046
0.171

Extrusion Die No.:

Material:

High Tear Silicone Rubber Dow Coming Silastic


Synthetic Rubber

Specification:

Mll-S-6855, Class

Durometer:

Shore A 60

Color:

White

55U Silicone Rubber

EXTRUDED RUBBER CHANNEL S-325

(MOLDED)

0500

Coming

Silastic 55U Silicone Rubber

Material:

Dow

Durometer:

Shore A 50

Dimensions:

(In Inches~ Tolerances 0.500 (M.030), 0.062 (M.015)


Grey

Color:

(~t5)

EXTRUDED SEAL S-341

(MOLDED)

Extrusions and Formed Sections

Figure
EFFECTIVITY:

ALL

(Sheet 2)

51-30-00

Page6
sRM-a

Jun 1/95

Leariet

STRUCTURAL REPAIR MANUAL

0.190 (+o.olo/-o.ooo)

0.250 (+0.000/-0.010)

Extrusion Die No.:

N/A

Material:

Nylon

6/6 DuPont Zytel 42

Specification:
Durometer:
Color:

Translucent

EXTRUDED TUBE S-355

Extrusions and Formed Sections

Figure
EFFECTIVITY:

ALL

(Sheet 3)

51-30-00

Page 7
sRM-4

Jun 1/95

Learjet
STRUCTURAL REPAIR MANUAL
0.016
-0.008

0.984

0.079

t
0.984

0.079

Extrusion Die No.:

Alcoa 152232

Material:

2024-T4

Specification:

QQ-A-267

or

0.008
-0.004

r
0.016
0.008

0.098R ~0.024

0.008-0.004I-t:

2024-T3511

QQ-A-200/3

or

ANGLE S-502

.059 +0.008

900fl"

-0.004

0.709

f36~J

0.079R f 0.016

0.551f0.012

0.059+0.008
-0.004

Extrusion Die No.:

Alcoa 151922

Material:

2024-T4

SpeclficaUon:

QQ-A-267

or

2024-T3511

or

QQ-A-200/3

ANGLE S-512

Extrusions and Formed Sections

Figure
EFFECTIVITY:

ALL

1 (Sheet 4)

51-30-00

Page 8
SRM-4

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL

870

0.079

0.787 +0.016

1I

+0.008-0.004

0098R f 0.024

-0.008

0.787 +0.016

I_

~i

Alcoa 152022
2024-T4 or 2024-T3511

Specification:

QQ-A-267

or

1).079 +0.008
-0.004

-0.008

Eltruslon Die No.:


Material:

\I

QQ-A-200/3

ANGLE S-515

Extrusions and Formed Sections

Figure
EFFECTNITY:

ALL

(Sheet 5)

51-30-00

Page 5!
SRM-4

Jun 1/95

Learjet
~Learjetl
STRUCTURAL REPAIR MANUAL
1.260

,-r

+0.016~
-0.008

0.157 +0.012
-0.008

1.260 +0.016
0.098R f 0.024

-0.008

85"10"f10
0.157

+0.012,I
-0.008

Extrusion Die No.:


Material:

Alcoa 152072; Pimalco 11225


2024-T6 or 2024-T6511

Specification:

QQ-A-261

or

QQ-A-200/2

ANGLE 5-516

61860

0.157 +0.012

-0.008

f 10

0.098R f 0.024

1.260 +0.016

1.260

+0.016-0.008

0.157

Extrusion Die No.:

Alcoa 152082

Material:

2024-T4

Specification:

QQ-A-267

or

+0.012-0.008

2024-T3511

or

QQ-A-200/3

ANGLE S517

Extrusions and Formed Sections

Figure
EFFECTIVITY:

ALL

1 (Sheet 6)

51-30-00

Page
SRM-4

10

Jun 1/95

Leariet I

STRUCTURAL REPAIR MANUAL

85" 40 f 1"
0.118 +0.008
-0.004

T
0.098R f 0.024

0.984 +0.016
-0.008

0.984 +0.01

:t---if0.118

-0.008

Extrusron Die No.:


Material:

2024-T4

Specification:

QQ-A-267

+0.008

-0.004

Alcoa 152102
or

2024-T3511
or

QQ-A-200/3

ANGLE S-519

Extrusions and Formed Sections

Figure
EFFECTTVITY:

ALL

1 (Sheet 7)

51-30-00

Page
SRM-4

11

Jun1/95

Learjet

STRUCTURAL REPAIR MANUAL


0.098 +0.008
-0.004
1.575 +0.016

-0.008

-~I

0.098R f 0.024
1.575 +0.016
-0.008
90"f 1"

Extrusion Die No.:

Alcoa 152192

Material:

2024-T4

Specification:

QQ-A-267

or

2024-T351 1

or

QQ-A-200/3

ANGLE S520

-It-

0.050

0.050R

0.075R

0.563

0.075R

J
0.750

0.050

Extrusion Die No.:

AND 10135-0601

Material:

2024-T4

Specification:

QQ-A-267

or

2024-T3511

or

QQ-A-200/3

EXTRUDED ANGLE 5-522

Extrusions and Formed Sections

Figure
EFFECTIVITY:

ALL

1 (Sheet 8)

51-30-00

Page
SRM~

12

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


0.118

+0.00S-0.004

850 Lt 10

1.574 +0.024

0.098R f 0.024

-0.012

0.787

0.118 +0.008
-0.004
-0.012

Alooa 152142; Pimalco 11230


or 2024-T3511

Extrusion Die No.:


Material:

2024-T4

Specification:

QQ-A-267

or

QQ-A-200/3

TEE S-524

1.574 +0.024

(e

0.118 +0.008
-0.004

-0.012

0.787

0.098R f 0.024
1.574 +0.024

-0.012

880 30 f 10

-1

-/lt
Extrusion Die No.:
Material:

Alcoa 152132

Specification:

QQ-A-261

2024-T6

or

0.118

+0.008-0.004

2024-T6511

or

QQ-A-200/2

TEE S525

Extrusions and Formed Sections

Figure

EFFECTIVITY:

ALL

1 (Sheet 9)

51-30-00

Page
SRM-4

13

Jun 1/95

Learjet
~Learjet

STRUCTURAL REPAIR MAN1JAL

I0.118

+0.008
-0.004

870 30 fl

1.574 +0.024

0.098R f 0.024

-0.012

ij/ f

0.118 +0.008
-0.004

0.787

-0.012

Extrusion Die No.:

Material:

Alcoa 152162; Pimalco 11229


2024-T4 or 2024-T3511

Specification:

QQ-A-267

or

QQ-A-200/3
TEE S-526

0.118 +0.008

-1.197 +0.024

-0.004

-0.012

-t
1.574
0.098R f:0.024

+0. 240.78
-0.012

860 10 f 10

0.118

Material:

Alcoa 152152; Pimalco 10966


2014-T6 or 2014-T6511

Specification:

QQ-A-261

Extrusion Die No.:

or

+0.008-0.004

QQ-A-200/2

TEE 5527

Extrusions and Formed Sections

Figure 1(Sheet 10)


EFFECTIVITY:

ALL

51-30-00

Page
sRM-a

14

Tun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


0.016
-0.012

2284
1.142~0.008
0.157 f 0.008

+0047

0.197R
1574

;I

0.118

0.008
-0.004

0.059f0.008

-0.000

+0.024
-0.012

900 40 f 10

ExtNsion Die No.:


Material:

Alcoa 152212

Specification:

QQ-A-261

2014-T6

or

,I

0.008
-0.004

0.118

11

2014-T6511

or

QQ-A-200/2

TEE S-534

91"f 1"

-0.004

t
1.574 +0.024

0.047

0.197;R

-0.000

lil

-0.012

0.059f0.00s

0.157 f 0.008
1.142 f 0.008

0.118 +0.008
-0.004

2.284 +0.016

-0.012

Extrusion Die No.:

Alcoa 152222

Material:

2014-T4

Specification:

QQ-A-267

or

2014-T3511
or

QQ-A-200/3

TEE S-535

Extrusions and Formed Sections

Figure 1(Sheet 11)

EFFECTIVITY:

ALL

51-30-00

Page
SRM-4

15

Jun 1/95

Learjet
~Learjetl

STRUCTURAL REPAIR MANUAL


1.969

0.512

0.177
0.394

0.098

i
0.980

jl

0.098R

0.039R

0.063R

0.689

C0.079
Extrusion Die No.:

Alcoa 165812

Material:

2024-74

Specification:

QQ-A-267

or

2024-73511

or

QQ-A-200/3

SEAT RAIL S-537

0.625

0.093R

_yaoa~rrwi
1.000

Extrusion Die No.:

Pioneer Aluminum Co. PA5580

Material:

2024-74

Specification:

QQd-267

or

17

2024-73511

or

QQ-A-20013

EXTRUDED ANGLE S-545

Extrusions and Formed Sections

]l;igure 1(Sheet 12)


EFFECTIVITY:

ALL

51-30-00

Page
SRM-I

16

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL

-II-

0.079

-r n
0.787

0.008-0.004

0.098B~0.024

0.016-0.008 IIJ

1~-----1 i

0.787

0.079

0.008
-0.004

0.0163-0.008

Extrusion Die No.:


Material:

Alcoa 151982
2024-T4 or 2024-T3511

Specifrcation:

QQ-A-267

or

QQ-A-200/3

ANGLE S-548

Extrusions and Formed Sections

Figure 1(Sheet 13)


EFFECTNITY:

SRM-4

ALL

51-30-00

Page 17
Jun1/95

Learjet
~Learjetl
STRUCTURAL REPAIR MANUAL
0.062R

(Typical 2 Places)

r:

0.094

1.312
0.1259

I
0.875

Extrusion Die No.:

I-

.i

0.0169

(Typical 3 Places)

Pioneer Aluminum, Inc. PA4126


or 2024-T3511

Material:

2024-T4

Speclfrcation:

QQ-A-267

or

QQ-A-200/3

EXTRUDED ANGLE S-549

,lyo.oss

1970

01163R C~ypical)

7
0.690

-I I-~

Extrusion Die No.:

Pimalco 20168, Alcoa 265045, or


Pioneer Aluminum, Inc. PA19680

Material:

2024-T4

SpecificaUon:

QQ-A-267

or

2024-T351

or

QQ-A-200/3

EXTRUDED TEE S-551

Extrusions and Formed Sections

Figure 1(Sheet 14)

EFFECTIVITY:

ALL

51-30-00

Page
SRM-4

18

Tun 1/95

Learjet

STRUCTURAL REPAIR I\RANUAL


Radii Not Noted

0.016

are

0.020R

0.050R

f~JO.:25

~t

fe

0.060 f 0.010
1.150

0.350
l.ooo-

-I

1
2.500

-1

TT_0.241(Check
0.040

3.000R

Dim)

0.012

-0.000

Extrusion Die No.:

Texas Aluminum Co. T-8319, Alcoa 68115, Pimalco 20169,


PA31694

Alaterial:

2024-T4

Speoifioetion:

QQ-A-267

or

or

Pioneer Aluminum Inc.

2024-T3511

or

QQ-A-200/3

DOOR STRUCTURAL CARRY THRU

(MALE) EXTRUDED S-552

Extrusions and Formed Sections

Figure 1(Sheet 15)


EFFECTIVITY:

ALL

51-30-00

Page
sRM-a

19

Jun 1/95

~Learjetl
STRUCTURAL REPAIR ~AANUAL
4L

I /r O.OM)R

0.130R

(TypicalBplaces)

0.075R

0.3130R

0.665

~Y_U/

-I~-

0.080

(-f
0.950

_j-0.060

0.350

0.200

1.000i

0. 050

1.570

Material:

Texas Aluminum Co. T-8320


Alcoa 68671, or Pioneer Aluminum Inc. PA31960
2024-T4 or 2024-T3511

Specification:

QQ-A-267

Extrusion Die No.:

or

0.016
-0.000

QQ-A-200/3

EXTRUDED DOOR STRUCTURAIL OARRTTHRU 5-553

CTypical)

01150

-~11

r
_L
0.750

0.010R

CTypical 3 Places)

)1

0.075R
0.075R

I- -I-l
0.750

Extrusion Die No.:

Pioneer Aluminum, Inc. PA5324, Alcoa 33372


or 2024-T3511

Material:

2024-T4

Specification:

QQ-A-267

or

QQ-A-200/3

EXTRUDED BULB AN(;LE S-554

Extrusions and Formed Sections

Figure

EFFECTIVITY:

ALL

1 (Sheet 16)

51-30-00

Page 20
SRM-4

Jun 1/95

~it

STRUCTURAL REPAIR MANUAL

r
0.120R

l.qW~-- 1.WOi

1.WO

0.850

(Typical)

i.

j-Extrusion Die No.:

0.080

(Typical)

0.050

(Typical)

3.000

Pimalco 11246, Texas Aluminum Co. T-8321


or 2024-T3511

Material:

2024-T4

Specification:

QQ-A-267

or

QQ-A-200/3

EXTENDED WEB CHANNEL S555

2.9501

i
0.080

II

II

0.120(Typical)

1.950

Extrusion Die No.:

Alcoa 315942

~Haterlal:

2024-0

Specification:

QQ-A-267

or

or

Pioneer Aluminum, Inc. PA20333

QQ-A-20013

EXTENDED WEB CHANNEL S-556

Extrusions and Formed Sections

Figure 1(Sheet 17)


EFFECT~VITY:

ALL

51-30-001

Page 21
SRM-4

Jun

1/95(

Learjet

STRUCTURAL REPAIR EAANUAL

Sharp Edges_

0.125

Rounded U.olO- Inch

T
I

0.875

0.125

~e
Extrusion Die No.:
Material:

AND 10133-0703

Specification:

QQ-A-267

2024-T4

or

0875

CTypical)

-~T

2024-T3511
or

QQ-A-200/3

EXTRUDED ANGLE S557

0.0478

0.750

111

LI0.094R

~0.125R

0.094

CTypical)

-t

1500

Extrusion Die No.:


Material:

AND 10136-1402; Pimalco 10180


2024-T4 or 2024-T3511

Specification:

QQ-A-267

or

QQ-A-200/3

EXTRUDED TEE S-558

Extrusions and Formed Sections

E;igure 1(Sheet 18)

EFFECTIVITY:

ALL

51-30-00

Page 22
SRM-4

inn 1/95

Learjet
Leariet i

STRUCTURAL REPAIR MANUAL

0.1Z0R
0.620
0.12R

I- 0.620Ij
Tool No.:

Roll

Material:

0.032 2024-T4 Clad

Specification:

QQ-A-362

Tolerance 0.00

0.030

Inch)

Forming Corp. RFCd00-1

ROLLED J-SECTION S-559

(Typical All Comers)


920 8

1 I

j1.250

~0.156R

i i

0.156(Typical)

1.500

Extrusion Die No.:


Nlaterial:

2024-T4

Pioneer Aluminum Inc. PA 1373

Specification:

QQ-A-267

or

2024-T3511

or

QQ-A-200/3

EXTRUDED ANGLE S-565

Extrusions and Formed Sections

Figure 1(Sheet 19)


EFFECTTVITY:

ALL

51-30-001

Page 23
SRM-1

Jun 1/95)

Learjet
STRUCTURAL REPAIR MANUAL

0.118R

0.118

-((C

0.118

0.010 Inch Radius

on

all

Outside Comers

30.71R

Extrusion Die No.:

Pima\co 11227, Alcoa 153332

Texas Aluminum Co. 19471

Material:

2024-T4

Specification:

QQ-A-267

2024-T3511

or

or

QQ-A-200/3

EXTRUDED TEE S-566

0.094R

CTypical)

SharpEdRes

RoundedD.010

0.875

0.0948

LI

f0.094R (Typical)
0.875

Extrusion Die No.:

AND 10133-0702

Material:

2024-T4

Specification:

QQ-A-267

or

Inch

--1

2024-T3511

or

QQ-A-20013

EXTRUDED ANGLE S-568

Extrusions and Formed Sections

Figure

EFFECTIVITY:

ALL

(Sheet 20)

51-30-00

Page 24
SRM-I

Jun 1/95

Leariet

STRUCTURAL REPAIR MANUAL


2598

0.016
-0.008

0.138

f~

3
1.181

0.016
-0.008

0.098R f 0.024

900

-/C

10

0.980

0.010 On all outside

Extrusion Die No.:


Material:

Specification:

corners

Alcoa 152202

2024-74 or 2024-73511
QQ-A-267 or QQ-A-200/3

EXTRUDED TEE S-569

0.063

C~ypical)

0.750

0.0949

IExtrusion Die No.:

AND10133-0601

Material:

2024-74

Specification:

QQ-A-267

or

0.750

0.063(7ypirJI)

II~f

2024-73511

or

QQ-A-20013

EXTRUDED TEE 5-571

Extrusions and Formed Sections

Figure 1 (Sheet 21)


EFFECTIVITY:

ALL

51-30-001

Page 25
SRM-4

Jun 1/95(

Learjet
STRUCTURAL REPAIR MANUAL
0.072

900 f 10

1.000

ya

1.080

Extrusion Die No.:

Pioneer Aluminum Inc. PA 1036

Material:

2024-T4

Specification:

QQ-A-267

or

i~
It

0.0308

0.125

2024-T3511

or

QQ-A-200/3

EXTRUDED ANGLE S575

0.125R

(Typical 2 Places)

Sharp Edges
Rounded 0.031

1.250

0.1878

0.250

(Typical)

j
Extrusion Die No.:

Pioneer Aluminum, Inc. PA4210, Pimalco 10967


or 2024-T3511

Material:

2024-T4

Specification:

QQ-A-267

or

QQ-A-200/3

EXTRUDED ANGLE S-578

Extrusions and Formed Sections

Figure
EFFECTIVITY:

ALL

(Sheet 22)

51-30-00

Page 26
SRM-4

Jun 1/95

~9 Learjet
STRUCTURAL REPAIR MANUAL
0.0168
0.875

0.047R

f_

I
Extrusion Die No.:

Pioneer Aluminum Co. PA5578

I~aterial:

2024-T4

Specification:

QQ-A-267

or

1.000

OS9ilCrypicnD

--I

2024-T351 1

or

QQ-A-20013

EXTRUDED ANGLE S580

896f1O

t-

Break sharp
at

comers

0.016R

1.200

0.1208

0.250

1.650

Extrusion Die No.:

Texas Aluminum Co. T-8557, Alcoa 345282,


Pimalco 10967, or Pioneer Aluminum Inc. PA 31516

Material:

2014-T6

Specification:

QQ-A-261

or

2014-T651

or

QQ-A-200/2

EXTRUDED ANGLE S-588

Extrusions and Formed Sections

Figure
EFFECTIVITY:

ALL

(Sheet 23)

51-30-001

Page27
SRM-4

Jun

1/95(

Learjet
STRUCTURAL REPAIR MANUAL
Break

Sharp Comers

at 0.016R

860 30 f 1"

jl

0.090

1.100

0.120R

1_
0.170

1.600

Extrusion Die No.:

Texas Aluminum Co. T-8558, Pimalco 11206,


Pioneer Aluminum Inc. PA19925

Material:

2014-T6

Specification:

QQ-A-261

or

or

2014-T6511

or

QQ-A-200/2

EXTRUDED ANGLE S589

Ic

84" 45 f10

t
1.070

0.120R

1.600

Extrusion Die No.:

Texas Aluminum Co. T-8559, Alcoa 223495,


Pimalco 20196, or Pioneer Aluminum Inc. PA19926

Material:

2014-T6

SpecTfication:

QQ-A-261

or

~I

0.140

2014-T651 1

or

QQ-A-200/3

EXTRUDED ANGLE S-590

Extrusions and Formed Sections

Figure

EFFECTIVITY:

ALL

(Sheet 24)

51-30-00

Page 28
SRM-I

Jun 1/95

Learjet I

STRUCTURAL REPAIR MANUAL


0.125

CIjpical)
BI~eak sharp
0.010R

corners

at

1.000

0.156R

0.125R

_E

I
2000

Extrusion Die No.:


Material:

AND10134-2001
2014-T6 or 2014-T6511

Specification:

QQ-A-261

or

QQ-A-200/2

EXTRUDED ANGLE S591

II""

TI

0.120R

1.700

at

-I i-

Comers

0.156

Extrusion Die No.:

Pioneer Aluminum Inc. PA11250

Meterlal:

2024-T4

Specification:

QQ-A-267

or

0.030RBreak Sharp

2024-T3511

or

QQ-A-200/3

EXTRUDED TEE S-592

Extrusions and Formed Sections

Figure

EFFECTIVITY:

SRM-4

ALL

(Sheet 25)

51-30-00)
Page 29
Jun 1/951

Learjet
STRUCTURAL REPAIR MANUAL

1.600

-I

.060R

0.060

(Typical)

1.150
Break

at

-II-

sharp corners

O.030R

0.102

Aluminum, inc. PA~544

Extrusion Die No.:

Pioneer

Material:

2024-T3511

Alternate Material 2014-T6511

Specification:

QQ-A-267

Alternate Material

Spec. QQ-A-261

EXTRUDED TEE S596

zooo

0.094

T
0.0949

CTypical)

1.000
94 20

Break sharp
0.0169

corners

at

-I lcOD94

Material:

Pioneer Aluminum, Inc. PA10728


7075-T651

Specification:

QQ-A-277

Extrusion Die No.:

EXTRUDED TEE S-597

Extrusions and Formed Sections

Figure
EFFECTIVITY:

ALL

(Sheet 26)

51-30-00

Page 30
SRM-I

Tun 1/95

Learjet I

STRUCTURAL REPAIR MANUAL


1.7so

0.090

-f
0.125R

CTypical)

1.000

9306

0.045R

0.090--(IZ
Extrusion Die No.:

Pioneer Aluminum, Inc. PA10642

Material:

7075-T651

Specification:

QQ-A-277

or

or

CTypical 2 Places)

7075-T6511

QQ-A-200/11

EXTRUDED TEE S-598

10 30 fl"

2.600

0.010R

0.;98_L

1.340

Break

Sharp Corners

at 0.016R

0.100

Extrusion Die No.:

Martin Marietta 50810, Pimalco 20202,


or Pioneer Aluminum Inc. PA20088

Material:

2024-T3511

Specification:

QQ-A-267

or

Harvey Aluminum

50810

QQ-A-200/3
EXTRUDED TEE S599

Extrusions and Formed Sections

Figure

EFFECTIVITY:

ALL

(Sheet 27)

51-30-001

Page 31
SRM-4

Jun 1/95(

Learjet

STRUCTURAL REPAIR MANUAL


0.350
30 fl"

2600

0.010R

7
1.390

Break

Sharp Corners

at 0.016R

--IC~.loo
Extrusion Die No.:

Martin Marietta 50812, Harvey Aluminum 50812 Pimalco 20203,


Pioneer Aluminum Inc. PA19837

or

Material:

2024-T3511

Specification:

.QQ-A-267

or

QQ-A-200/3

EXTRUDED ANGLE S-600

Break

Sharp Corners

at 0.016R

jl

83" 30

0.940

0.080R

C 0.940(Typical)
Extrusion Die No.:

Pioneer Aluminum, Inc. PA 1523


or 7075-T6511

Material:

7075-T651

Specification:

QQ-A-277

or

QQ-A-200/11

EXTRUDED ANGLE S603

Extrusions and Formed Sections

Figure

EFFECTIVITY:

ALL

(Sheet 28)

51-30-00

Page 32
SRM-I

Jun 1/95

Learjet I
LearJet

STRUCTURAL REPAIR MANUAL


3.130

------I

0~250

0.1876

Brea~ sharp corners


at0.031R

4.130

IC
Extrusion Die No.:
Material:

Specification:

0lm

Pioneer Aluminum, Inc. PA6745; Pimalco 10836


or 2024-T3511
QQ-A-267 or QQ-A-200/3
2024-T4

EXTRUDED TEE S-604

Sharp edRes
roun;ded D.OIOR
0.0636

1.000
0.1256
0.063

(Typical)

I---Extrusion Die No.:

AND10134-1204

Material:

2024-T4

Specification:

QQ-A-267

or

-----I

2024-T3511

EXTRUDED ANGLE S-606

Extrusions and Formed Sections

Figure
EFFECTIVITY:

ALL

(Sheet 29)

n-~o-oo

Page33
SRM4

Jun 1/95 1

Learjet
~LearjetJ

STRUCTURAL REPAIR MANUAL

r
1.000
0.156R

BIO~LIC.mBJ

~_

Extrusion Die No.:

AND10134-1403

Material:

2024-74

Specification:

QQ-A-267

or

17

2024-73511

EXTRUDED ANGLE S-607

I.oOo

I I

0.56R

0.125

(Typical)

t-Extrusion Die No.:

AND10134-1601

Material:

2024-74

Specification:

QQ-A-267

or

2024-T3511

EXTRUDED ANGLE S608

Extrusions and Formed Sections

Figure
EFFECTIVITY:

ALL

(Sheet 30)

51-30-00

Page 34
SRM-4

lun 1/95

Learjet I

STRUCTURAL REPAIR ~ANUAL


0.090R

0.125Ji

Extrusion Die No.:

0.600

Pioneer Aluminum, Inc. PA 17956


or 2024-T351 1

Material:

2024-T4

Specification:

QQ-A-267

EXTRUDED BAR 5610

00946

1.250

0.188R

0.125

-f(Typical)
2500

Extrusion Die No.:

Pioneer Aluminum, Inc. PA 4430

Material:

2024-T3511

Specification:

QQ-A-267

EXTRUDED ANGLE S-612

Extrusions and Formed Sections

Figure 1 (Sheet 31)

EFFECTIVITY:

ALL

51-30-00

Page 35
sRM-4

Jun 1/95

Leariet

STRUCTURAL REPAIR MANUAL

0.160

f jL
1.576

1.200 f 0.010

1.200 f 0.010

0.120R

r.

0.600R
0.125R

0.500 +0.010 J

0500

0.009

-0.030

~c- 1.500

IC----- 2.oso---~l
Extrusion Die No.:

Alcoa 182732

Material:

2014-T60r-T6511

Specification:

QQ-A-261

EXTRUDED S-613

M0D1FIED OHANNEL

-1,1.

o~w,

0.188R

Tli,I I

II~-

oaso~z

2750

Extrusion Die No.:

Pioneer Aluminum Inc. PA 1310

Material:

2024-T3511

Specification:

QQ-A-267

fl""
I

EXTRUDED ANGLE S-614

Extrusions and Formed Sections

Figure
EFFECTIVITY:

ALL

(Sheet 32)

51-30-00

Page 36
SRM-4

Jun 1/95

~Learjet
STRUCTURAL REPAIR MANUAL
0.020R

0.043

1.000

0.040

0.580
0.062R

"12~1

_I
0.016R

Extrusion Die No.:

Martin Marietta 51199,


Inc. PA20085

Material:

6061-T6

Specification:

QQ-A-270

or

Han/ey Aluminum 51188, Pimalco 20213,

or

Pioneer Aluminum

6061-T6511
or

QQ-A-200/8

EXTRUDED TEE S-621

Extrusions and Formed Sections

Figure
EFFECTTVITY:

ALL

(Sheet 33)

51-30-00

Page 37
SRM-4

~un 2/95

Learjet
STRUCTURAL REPAIR MANUAL
Sharp Corners

0.118

Rounded 0.016

rn
i)

1.181

~0.190R

Extrusion Die No.:

Pimalco 10970, Alcoa 303322,

Material:

2024-T3511

Specification:

QQ-A-267

or

or

Pioneer Aluminum Inc. PA19343

QQ-A-200/3

EXTRUDED ANGLE S622

Sharp Comers
Rounded 0.016

1.20 0.190Rti~0.150

r/1~7
1.181

1~

~U

~n lann

950 45 f 10

0.118

Extrusion Die No.:

Pimalco 10969

Material:

2014-T6511

Specification:

QQ-A-261

EXTRUDED ANGLE S623

Extrusions and Formed Sections

Figure

EFFECTIVITY:

ALL

(Sheet 34)

51-30-00

Page 38
SRM-I

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL

ir
0.060R
0.500

_
Extrusion Die No.:

AND101350401

Material:

2024-T3511

Specification:

QQ-A-267

EXTRUDED BULB ANGLE S626

QS401C~k

0.OSO

TB R
II

3MxI

II

liUli,

0.125R

(Typical)

I-

Extrusion Die No.:

Pioneer Aluminum, Inc. PA 11808

Material:

2024-73511

Specification:

QQ-A-267

0,120

EXTENDED WEB CHANNEL S627

Extrusions and Formed Sections

Figure

EFFECTIVITY:

ALL

1 (Sheet 35)

51-30-001

Page 39
SRM-4

Jun 1/95(

~Learjetl
STRUCTURAL REPAIR MANUAL

~i=ri0.1M)

Break sharp

comers

at 0.016R

1.500

0.050

0.060R

(Typical 3 Places)

I-----lsso
Extrusion Die No.:

Reynolds

Material:

2014-T6511

Specification:

QQ-A-261

-t

0.050

Metal Co. 02946, Pimalco 20217,


or

or

Alcoa 157005

QQ-A-200/2

EXTRUDED FLANGED TEE 5-630

Sharp edRes
rouniiedCJ.010R

~--o-I
(Typical 2 Places)

0.063

0.875

-cl
1(

0.063
0.125R

(Typical 2 Places)
0.063 C~ypical)

I- -I
0.750

Extrusion Die No.:

AND10138-0704; Pimalco 50169

Material:

2024-T3511

Specification:

QQ-A-267

EXTRUDED ZEE S633

Extrusions and Formed Sections

Figure 1 (Sheet 36)

EFFECTIVITY:

ALL

51-30-00

Page 40
SRM-4

Tun 1/95

Leariet
~Learjetl

STRUCTURAL REPAIR MANUAL


Isoo

Sharp comers

roun~ded 0.016R

O~OR

0.094R
1.400

j
-)IExtrusion Die No.:

Pioneer Aluminum Inc. PA 6910

Material:

7075T6511

Specificatior:

QQ-A-277

0225

EXTRUDED TEE S-634

0.031R

r_

r,.,,

~040

17

Extrusion Die No.:

Pioneer Aluminum, Inc. PA 2822

Material:

2024-T3511

Specification:

QQ-A-267

or

QQ-A-200/3

EXTRUDED BAR S-636

Extrusions and Formed Sections

Figure

EFFECTIVITY:

ALL

(Sheet 37)

51-30-00(
Page 41

SRM-4

Jun 1/951

STRUCTURAL REPAIR MANUAL

Tn
0.750

II

I_0.125R
1.500

Material:

Pioneer Aluminum, inc. PA5595


2024-T3511

Specification:

QQ-A-267

Extrusion Die No.:

0.062

---I7-

EXTRUDED ANGLE S-637

0375

5" 30

(ReD
0.062R

so 30 (Ren

(mM)

t-

0.032R

0.010R

-----t0.136

(Maximum)

Extrusion Die No.:

Material:

AZ61 F-F

Specification:

QQ-M-31

EXTRUDED BAR S-639

Extrusions and Formed Sections

Figure

EFFECTIVITY:

ALL

1 (Sheet 38)

51-30-00

Page 42
SRM-I

Tun 1/95

Leariet

STRUCTURAL REPAIR MANUAL


0.460
0.140
0.020

0.042

CTypical)

CTypical)

f
0.080

0.680
0~034

CTypical)

Full
R

18.006
0.040

4.750

Extrusion Die No.:

Alcoa 263215, Pimalco 20223,

Material:

2024-T3511
QQ-A-267 or QQ-A-20013

Specification:

or

Pioneer Aluminum Inc. PA20602

EXTRUDED BAR S-841

0.120

i
0.080

1.970

0.090R

(Typical)

0.120

(Typical)

Extrusion Die No.:


Material:

Alcoa 181235, Pimalco 20224,

Specification:

QQ-A-261

or

Pioneer Aluminum Inc. PA20959

2014-T6511
or

QQ-A-20012

EXTRUDED I-BEAM S-642

Extrusions and Formed Sections

Figure
EFFECTIVITY:

ALL

(Sheet 39)

51-30-001

Page43
SRM-4

Jun

1/95(

~LBarjetJ
STRUCTURAL REPAIR MANUAL

0.031R

0.625

0.062R

Extrusion Die No.:

Pioneer Aluminum, Inc. PA 4030

Material:

2024-T3511

Specification:

QQ-A-267

0.062

EXTRUDED ANGLE S-644

0.062R

0.062

(Typical)

0.750

0.125R

(Typical 2

Places)

0.812

Extrusion Die No.:

Pioneer Aluminum Inc. PA 7539

Material:

2024-T4

Specification:

QQ-A-267

or

2024-T3511

EXTRUDED CHANNEL S-646

Extrusions and Formed Sections

Figure 1 (Sheet 40)

EFFECTIVITY:

ALL

51-30-00

Page 44
SRM-4

lun 1/95

E~ Learjet
STRUCTURAL REPAIR MANUAL
0~500

~I

0.130R

(ReD

(SUM)
0~280

1
0.010R

(Maximum)

CTypical)
Extrusion Die No.:
Material:

AZG1A-F

Specification:

QQ-M61
EXTRUDED BAR S-649

0.063R

0.500
0.063R

CExtrusion Die No.:

0.750

Material:

AND10134-0601
2024-T4 or 2024-T3511

Specification:

QQ-A-267

or

0.063

QQ-A-200/3

EXTRUDED ANGLE S854

Extrusions and Formed Sections

Figure

EFFECTIVITY:

ALL

(Sheet 41)

51-30-001

Page 45
SRM-4

Jun

1/95(

Learjet
STRUCTURAL REPAIR MANUAL
OJ00

0.105R

60 (ReD

-T0310

_I

0.145R

O.O1OR(Ma~imum)

CTypicai)
Extrusion Die No.:

Material:

AZG1A-F

Specification:

QQ-M-31

EXTRUDED BAR S-657

0.031R

on

All Outside Comers

2.600

0.025 f 0.005

~L

0.100R

(Typical)

30.008

Extrusion Die No.:

0.800

-c( C1- 0.100

Material:

Alcoa 217342-A, Pimalco 20235,


2024-T4 or 2024-T3511

Specification:

QQ-A-267

or

0100

or

Pioneer Aluminum Inc. PA24766

QQ-A-200/3

EXTRUDED TEE S-681

Extrusions and Formed Sections

Figure

EFFECTIVITY:

ALL

1 (Sheet 42)

51-30-00

Page 46
SRM-4

Jun 1/95

Learpt
I~il
STRUCTURAL REPAIR MANUAL
Sharp ednes

rrr\r-

rouniied b.OlOR

oSwl I

L Ilc~ei0.063R0.063R

(Typical)

f
0~500

Extrusion Die No.:


Material:

AND10133-0401

Specification:

QQ-A-267

2024-74

or

2024-T3511

or

QQ-A-200/3

EXTRUDED ANGLE S-699

.m~

0.750

I:

0.062R

CTypical)

Extrusion Die No.:


Material:

2024-T3511

Pioneer Aluminum Inc. PA5540

Specification:

QQ-A-267

or

QQ-A-200/3

EXTRUDED ANGLE S-705

Extrusions and Formed Sections

Fi~ure
EFFECT~VITY:

ALL

(Sheet 43)

51-30-001

Page47
SRM-4

Jun 1/95

Learjet
STRUCTURAL REPAIR MANUAL

0.750R

0.15~3

Ef Co-o-IT

Extrusion Die No.:


Material:

2024-T4

Pimalco 20240

Specification:

QQ-A-267

or

or

Pioneer Aluminum Inc. PA31794

2024-73511

or

QQ-A-200/3
EXTRUDED BAR S-706

Extrusions and Formed Sections

Figure

EFFECTNITY:

ALL

(Sheet 44)

51-30-00

Page 48
SRM-4

Jun 1/95

Learjet i
STRUCTURAL REPAIR MANUAL
0.025R

0.050

1.500
0.060R

(Typical 2 Places)
0.050R

1_

(Typical 2 Places)

tC--Extrusion Die No.:

---tl

Iooo

Material:

Pimalco 20241, Alcoa 236012


2014-76511

Specltication:

QQ-A-200/2

or

0.050

Pioneer Aluminum Inc. PA29028

EXTRUDED TEE S-707


1.073

0.512

0.098R

0.177

I
0.394

0.098ypical)
0.063R~

~--0.063R

_r

0.098

7
0.689

Extrusion Die No.:


Material:

2024-73511

Speciilcation:

QQ-A-200/3

Reynolds

54260

~JC0.079

EXTRUDED SEAT RAIL S-713

Extrusions and Formed Sections

Figure 1(Sheel 45)


EFFECTNITY:

ALL

51-30-00

Page 49
SRM-4

Jun 1/95

Learjet

STRUCTURAL REPAIR MAMUAL

z.wo

0.185

1~
Extrusion Die No.:
Material:

Alcoa 250372
6061-0

Specification:

QQ-A-20018

0.093

EXTRUDED BAR S-715

Extrusions and Formed Sections

Figure 1 (Sheet 46)


EFFECTIVITY:

ALL

51-30-00

Page 50
SRM-I

Jun 1/95

Learjet
Learjet

STRUCTURAL REPAIR MANUAL


60(ReD

i,0.6450.500

60(Ref)1
_

0.310

0.470
0.200

0.490

96" (Ref)

---;--$-fi

0.010R (Max)

(Typical)

90"(Ren

i-

0.125

Extrusion Die No.:

Standard

Material:

AZG1A-F

Specification:

QQ-M-31

Magnesium

288

EXTRUDED BAR S-717

Sharpedges~

mun;ded 0.010R

-~1 I r-

1.000

0.094

0.125R
0.09411

(Typical)

1-

2000T,0.094

1.000

Extrusion Die No.:


Material:

AND10136-2002

Specification:

QQ-A-200/3

(Typical)

2024-T3511

EXTRUDED TEE S-727

Extrusions and Formed Sections

Figure

EFFECTIVITY:

sRM-4

ALL

(Sheei 47)

51-30-00

Page 51 1
Jun 1/95)

Learjet

STRUCTURAL REPAIR MANUAL


-I~- CTypical)

0.082 f 0.004

0.016R

on

all

outsidecomers

f
1~320 ~0.012

CTypical)
0.120R

(Typical)

I------ -~11-----(
Extrusion Die Na.:

Material:

Pioneer Aluminum PA 27155


2014-76511

Specification:

QQ-A-200/2

EXTRUDED CHANNEL S-728

Break

sharp comers 0.016R

100 f 0.010

0.080

0.030R

CTypical)
0.030R

CTypical 2 Places)

0375

CTypical)

1.188 f 0.010

0.188R

(Typical

(Typicai 2 Places)

1.135

1.135

0.125R

CTypical 4 Places)

3 Places)

1,90" (Typical)

0.080

0010
-0.005
C

f 0.010
r--- 3.766
(At base only)

Extrusion Die No.:

Pimalco 11245, Texas Aluminum

Material:

2024-73511

Specification:

QQ-A-200/3

Company

T-17884

EXTRUDED CHANNEL S-729

Extrusions and Formed Sections

Figure

EFFECTIVITY:

ALL

(Sheet 48)

51-30-00

Page 52
SRM-4

Jun 1/95

Leariet
~Learjet

STRUCTURAL REPAIR MANUAL

1.6u,

Bruak

0.010

LI

-(MD5

sharp comers 0.016R

rOMO

900
0.800

0.010
-0.005

1.060 f 0.010

~le

0~070

Extrusion Die No.:

Alcoa 276155, Pimalco 20259, Texas Aluminum Co. T-17885,


or Pioneer Aluminum Inc. PA29135

Material:

2024-73511

Specification:

QeA-200/3

EXTRUDED TEE S-731

1.500

0.010
-0.005

90"

II

Illr0.060
71

~0.120R

0.940 f 0.010

0.720

i_l

0.010-0.005

I_

Extrusion Die No.:

Texas Aluminum Co. T-17886

Material:

2024-73511

Specification:

QQ-A-200/3

or

Pimalco 11406

EXTRUDED TEE S732

Extrusions and Formed Sections

Figure

EFFECTNITY:

SRM-4

ALL

(Sheet 49)

51-30-00(
Page 53
Jun 1/951

Learjet
~Learjetl

STRUCTURAL REPAIR MANUAL


Odl~R

(Typical

Places)

0.031R(Typical

Places)

1.000

11

0.094R

(Typical 2 Places)

-~1 ~e 0.062

Extrusion Die No.:

PA 6104 Pioneer Aluminum, Inc.

Material:

2024-73511

Specification:

QQ-A-200/3

EXTRUDED TEE S-733

0.016R on all
outside corners

Fa080

in t
0.156R

I I

1.000

I~alu

Extrusion Die No.:

Pimalco 11228

Material:

2014-T6511

Specification:

QQ-A-200/2

or

Texas Aluminum Co. T-18430

EXTRUDED TEE S-734

Extrusions and Formed Sections

Figure

EFFECTIVITY:

ALL

(Sheet 50)

51-30-00

Page
SRM-4

54

Jun 1/95

Learjet I

STRUCTURAL REPAIR MANUAL

-rl ~-0a94cT,icas

0.094R

~I

(TYPical)

1.000

0.125R

CT

1.

2.000

Extrusion Die No.:

AND10137-2004

Material:

2024-T3511

Specification:

QQ-A-200/3

tl:

0.010R

(Typical)

EXTRUDED CHANNEL S1735

0.225R

(Typical)

1~

0.125R
1.000

(Typical)

0.010R

(Typical)
-I

Extrusion Die No.:

AND10137-1113

Meteriei:

2024-73511

Specitrcation:

QQ-A-200/3

EXTRUDED CHANNEL S-736

Extrusions and Formed Sections

Figure 1 (Sheet 51)


EFFECTIVITY:

ALL

51-30-001

Page 55
SRM-4

Jun

1/951

Learjet

STRUCTURAL REPAIR MANUAL

i" Y
1.493

ri

0.125R

0.130

0.0318 (5 Places)

j
79"

(Typical)
Extrusion Die No.:

Aicoa 71223

Material:

2024-T351 1

Specification:

QQ-A-200/3

EXTRUDED ANGLE S-738

r1.200

Break sharp comers


at 0.016R

I
0.3a3

0.740

0.023 (Ref)

I-

0.1208

CTypical)

0.180

86" 30 fl

Extrusion Die No.:


Material:

Aicoa 349252, Pimaloo 20265,


2024-T4 or 2024-T3511

Specification:

QQ-A-200/3

or

Pioneer Aluminum Inc. PA31720

EXTRUDED TEE S-739

Extrusions and Formed Sections

Figure
EFFECTIVITY:

ALL

(Sheet 52)

51-30-00

Page 56
SRM-4

Jun 1/95

Learjet
STRUCTURAL REPAIR MANUAL

r
cj~
27oo1.050

0.740

j-

Break s~arp

corners

at OD16R

~1

0.1U0R

(Typical)

0.280

940+1

Extrusion Die No.:


Material:

Alcoa 349242, Pimalco 20266,


2024-74 or 2024-73511

Speoitioation:

QQ-A-200/3

or

Pioneer Aluminum Inc. PA31721

EXTRUDED TEE S-740

830

0.750

0.125R

t 0.062 CTypical)
Extrusion Die No.:

Pioneer

Material:

2024-73511

Specifioatron:

QQ-A-200/3

Aluminum, Inc. PA1509

EXTRUDED ANGLE S-744

Extrusions and Formed Sections

Figure 1 (Sheet 53)


EFFECTIVITY:

ALL

51-30-001

Page 57
SRM-4

Jun

1/95(

Learjet
~arjet

STRUCTURAL REPAIR MANUAL


0.016R On

lametxElA

Corners
83"

r
0.620

0.090R

0.062

ic~-Extrusion Die No.:

Alcoa 377162

Material:

2024-T3511

Specification:

QQ-A-200/3

or

0.6U)

(Typical)

0.062 X 450 Chamfer

Pioneer Aluminum Inc. PA31251

EXTRUDED ANGLE S745


0~016R

on

all oubide comers

0.025450
0.0908

0.090R

0.625

0.0168

0.070

0.025R

0.0908

Extrusion Die No.:

C~---- 0.700

---I

0.063

Alcoa 353302

Material:

2024-T3511

Specification:

QeA-200/3

EXTRUDED STRINGER SPLICE S-748

Extrusions and Formed Sections

Figure

EFFECTIVITY:

ALL

(Sheet 54)

51-30-00

Page 58
SRM-4

Tun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


2aoa

:I

0.350

840 50 f 10

Extrusion Die No.:

Pioneer Aluminum Inc. PA32173

Material:

2024-T3511

Specitlcation:

QQ-A-200/3

0.125R

(Typical)
1.700

0.188~1

EXTRUDED TEE S-759


0.016R On All Outside Corners

0.188

890 25 f 10

1.900
0.125R

(Typical)

0.200

1476~1
Extrusion Die No.:

Pioneer Aluminum Inc. PA32176

Material:

7075-73511

Specification:

QQ-A-200/11

Z.98

.I

EXTRUDED TEE S762

Extrusions and Formed Sections

Figure

EFFECTIVITY:

ALL

1 (Sheet 55)

51-30-00

Page 59
SRM-4

Jun 1/95

Learjet
~Learjetl

STRUCTURAL REPAIR MANUAL


4.500
3.000

---cl

0.310f 0.012

--L~I t

0.125R

1.550

(Typical)

_L
0.188

850 45 f 10

-cl

Extrusion Die No.:

Pioneer Aluminum Inc. PA32177

Material:

7075-T3511

Specification:

QQ-A-200/11

EXTRUDED TEE 5765

jt

2.360

0.340

0.190R

(Typical)

i2.0 0

93" 30

1"

-tl

Extrusion Die No.:

Pioneer Aluminum Inc. PA32180

Material:

7075-T3511

Specification:

QQ-A-200111

EXTRUDED TEE ST15

Extrusions and Formed Sections

Figure

EFFECTNITY:

ALL

(Sheet 56)

51-30-00

Page 60
SRM-4

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL

0.190R

(Typical);r
2.200

940 15 f 10

~e
Extrusion Die No.:

Pioneer Aluminum Inc. PA32181

Material:

7075-T3511

Specification:

QQ-A-200/11

0.080

EXTRUDED TEE S-n6

0.190R(Typical)

1 I

1.600

900 40 f 1"

o.loo

Extrusion Die No.:

Alcoa 32182

Material:

7075-T3511

Specification:

QQ-A-200/11

EXTRUDED TEE S-777

Extrusions and Formed Sections

Figure
EFFECTIVITY:

ALL

1 (Sheet 57)

51-30-00

Page 61
SRM-4

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


o.oso

1
1.600

_I

JahORiiypii~U

00~

2.700

Extrusion Die No.:

Pioneer Aluminum Inc. PA32183

Material:

7075-T3511

Specification:

QQ-A-200/11

EXTRUDED TEE s-ns

i---I

f
0.900

(Typical)

0.120R

0.170

(Typical)

0.180(Typical)

tl

Extrusion Die No.:

N/A

Material:

7075-T3511

Specification:

QQ-A-200/11
EXTRUDED HAT SECTION S-783

Extrusions and Formed Sections

Figure

EFFECTIVITY:

ALL

1 (Sheet 58)

51-30-00

Page 62
SRM-4

Tun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


0.031R

SYM

r
0.750

0.125R

900f 10

I:0.062

0.062R

J
1.500

Extrusion Die No.:


Material:

AND10136-1401

Specification:

QQ-A-267

Sharp Comer

2024-T3511

EXTRUDED TEE S-787

Extrusions and Formed Sections

Figure
EFFECTIVITY:

ALL

(Sheet 59)

51-30-00

Page 63
sRM-a

Jun 1/95

STRUCTURAL REPAIR MANUAL

r
0.750

I
1~0.75o--tl
Extrusion Die No.:

Pioneer Aluminum Inc. PA4026

Material:

2024-T3511

Specification:

QQ-A-200/3

or

Pimalco 50087

or

Tiernay 60-3754

EXTRUDED ANGLE S-5001

rn
II
0.125R

1- 1.450-I
Extrusion Die No.:

Martin Marietta 69359

Material:

2024-13511

Specification:

QQ-A-267

or

0.157

(Typical)

QQ-A-200/3

EXTRUDED ANGLE S-5017

Extrusions and Formed Sections

Figure 1 (Sheet 60)

EFFECTIVITY:

ALL

51-30-00

Page
SRM-4

64

Jun 3/95

Learjet

STRUCTURAL REPAIR MANUAL


0.340

2.360

0.190R

(Typical)

2.000

920 30 It 30

0.125-~
Extrusion Die No.:

N/A

Material:

7075T73511

Specification:

QQ-A-200111

EXTRUDED TEE S-5022

0.030R

Breaksharpedp"
(Typical)

0.112

\i

I- -0.1660332
Extrusion Die No.:

Pioneer Aluminum Inc. PA33576

Material:

6061-T6511

Specitication:

QQ-A-200/8 (for 6061)

or

6063-T6
or

QQ-A-200/9 (for 6063)

EXTRUDED SHAPE S-5075

Extrusions and Formed Sections

Figure
EFFECTIVITY:

ALL

(Sheet 61)

51-30-00

Page 65
SRM-4

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL

0.160
3.160

Full R

0.190R

(Typical)

1500

Extrusion Die No.:

Pioneer Aluminum Inc. PA33573, Alcoa 373892

Material:

6061-T6511

Specification:

QQ-A-200/8

0.100

EXTRUDED TEE S5078

1
2.000

0.125R
0.125R

ii
t,,,.125

Extrusion Die No.:

AND10136-2407

Material:

2024-T3511

Specification:

QQ-A-200/3

EXTRUDED TEE 8-5088

Extrusions and Formed Sections

Figure 1 (Sheet 62)

EFFECTNITY:

ALL

51-30-00

Page 66
SRM-4

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL

1 I-0.238

Break all

ednes

sharp

comers

Om6R

r1.190

0.098R

0318

85" 20

Extrusion Die No.:

Alcoa 389282

Material:

7050-T3511

Specification:

AMS 4341

1.120

-I

EXTRUDED ANGLE S-5091

0.004

Break all sharp edges


0.031R maximum

0.005
-0~000
1300

1.000

0.500

t -71+
0.028_

0.017

+0.008
0.000

0.1000.012
0.000

0.100R

0.800f0.007

30.000R(ReO

~11-o.1mtaM6
SYM
Extrusion Die No.:
Material:

Alcoa 390672

Specification:

QQ-A-267

2024-T3511
or

QQ-A-200/3

EXTRUDED TEE S-5093

Extrusions and Formed Sections

Figure 1 (Sheet 63)

EFFECTIVITY:

ALL

51-30-00

Page 67
SRM-4

Jun 1/95

Leariet
Learjet

STRUCTURAL REPAIR MANUAL


METAL PARTS

i.

REPAIR AND PROTECTION

HEATTREATMENT OFALUMINUMALLOY
A.

is required for the fabrication of some aluminum parts used on the Leajet. These prorequired to give the parts the physical characteristics they need for the situations to which
they are applied. These characteristics include, but are not limited to, strength and malleability.
Heat treating processes include annealing, solution heat treating, and aging.
Aluminum alloy parts shall be heat treated per AMS2770.
Heat

treating

cesses are

B.

C.
2.

HEATTREATMENTOF STEELALLOYS
A.

Steel

alloys shall be heat treated per MIL-H-6875.

EFFECTIVITY:
srzM-4

ALL

51-30-01

Page 201
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


SEALING METAL
1.

STRUCTURAL REPAIR

DESCRIPTION
A.

Sealing

of the aircraft is

required

to eliminate

leakage

of air pressure,

liquids, dust,

and heat

through

the airframe structure.


B.

This section
on

2.

and the

provides sealing procedures

equipment

necessary for

performing

maintenance

the aircraft.

TOOLSAND

EQUIPMENT

following materials have been found


interchanged.

A.

The

B.

Sealant

to be the most efficient in their

PART NUMBER

NAME

applications and must not be

MANUFACTURER

USE

SEALANTS
Class A

Sealant

Products Research
Chemical

Corp.

Pay and hole


sealing

5430 San Fernando Rd


P.O. Box 1800

Glendale, CA 91209
Sealant

Sealant

Pro-Seal 890

Products Research

(MIL-S-8802)
Class B-1/2

Chemical

Corp.

Fillet, injection,
fay, and hole
sealing within

Class B-2

1/2-, 2-,

Class B-4

hour work life

or

4-

Pro-Seal 890

Products Research

Pay sealing

(MIL-S8802)

Chemical

Class C-24

within 24-, 48-,


or 80-hour

Class C-48

squeeze-out life

Corp.

Class C-80

Sealant

Pro-Seal 890

Products Research

(MIL-S8802)

Chemical

Corp.

Sealing in wet
fuel areas only

SOLVENTS

Methyl Ethyl Ketone (MEK)

1T-M-261

Commercially available

Toluene, Type Ii

TT-N-95

Commercially available

Aliphatic Naptha, Type II

TT-N-95

Commercially available

EFFECTIVITY:

ALL

51-30-02

Page
SRM-4

Jun 1/95

Learjet
STRUCTURAL REPAIR MANUAL
NAME

PART NUMBER

MANUFACTURER

USE

TOOLS

Sealant Removal and

(See Figure 1.)

Fabricated

locally

(See Figure 1.)

Fabricated

locally

Stiff Bristle Brushes

(Not nylon)

Commercially available

Solvent

(Polyethylene
squirt bottle)

Commercially available

Cutting Tools
Sealant

Fairing Tools

Dispensers

Sealant Gun

Semco No. 250

Polyethylene Nozzles

(For Sealant Gun)

Polyethylene Cartridges

(For Sealant Gun)


MATERIALS

Lint-Free Clean

White Cotton Cloth

Vinyl Plastic Tape

CT-93 (0.010"

1")

:Borden Chemical

Company

Lint-Free White

Cotton Gloves

Commercially available

Masking Tape

Commercially available
Rezolin 8300

Parting Agent

or

832A

Rezolin,
Hexcel

Clean Gauze

Division of

Corp.

Commercially available

Lubricant

Shell L-73101
Mobil

3.

or

Commerically available

Jet 35

PREPARATION OF FAYING SURFACES PRIOR TO SEALING


A.

Cleaning
(1) Clean existing aluminum alloy parts and repair parts in accordance with 51-30-04.
(2) Immediately prior to applying sealant clean metal surfaces with 1,1,1, trichloroethane (MIL-T81533) or methyl ethyl ketone (MEK). Apply solvent with a damp cloth and wipe dry with a lintfree, clean, white, cotton cloth.

EFFECTIVITY:
SRM-4

ALL

51-30-02

Page 2
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

glnches

Approx.

(LARGESEALANT

BeveledSharp

CUTI1NG TOOLS)

Edge
bInches

Approx.

Surface

1_\

6-Indhes

Sharp Edge
(SEALANT FAIRING TOOL)

Approx.

6-Inches
Beveled

(LARGE SEALANT
CUTIING TOOLS)

Approx.

Surface

(SMALL SEALANT

Sharp Edge

FAIRING TOOL WITH


SPOON TYPE HEAD)
O.OlO-Inch

Approx.

6-Inches

Approx.

bInches

Approx.
0.050-Inch

Approx.
(LARGE SEALANT

IZ

(SEALANT REMOVAL TOOL)

FAIRING TOOLS)

eInches

Approx.
NOTE:

Beveled
Surface

(SMALL SEALANT
CUT~ING TOOL)

NOTE:

These tools may be made of l/~-lnch diameter bronze or s~teel welding rod and mav be
plated to improve smoothness.

Sharpe
Edge

These tools should be made of hardwood to


reduce the possibilih of shuctural damage.

Repro

EFFECTIVITY:

Sealant

ALL

Cutting and Fairing Tools


Figure 1
51-30-02

Page 3
sRM-a

Jun 1/95

STRUCTURAL REPAIR MANUAL


WARNING:

SPECIAL PRECAUTIONS SHOULD BE OBSERVED DURING CLEANING.


SOLVENTS ARE TOXIC AND FLAMMABLE. FRESH AIR
MASKS AND/OR ADEQUATE VENTILATION SHOULD BE AVAILABLE
IN ALL CLOSED AREAS.
CLEANING

NOTE:

Never pour

or spray cleaning solvent on aircraft structure. If this is done, the solmay run back between structure layers, then after cleaning is completed, solvent may creep back out and contaminate previously cleaned surface.

vent

Use

lint-free, clean, white,

cotton cloth to

ensure

that

no

dye residue is left on treat-

ed surfaces.

(3) Thoroughly scrub the

area

to be sealed. Extreme care shall be exercised to clean inaccessible

cor-

ners, gaps, etc. A small

paint brush or pipe cleaners may be used for these areas. Always clean an
area larger than that required for the sealant.
(4) Before solvent has evaporated, wipe area dry with a lint-free, clean, white, cotton cloth.
(5) Repeat steps (3) and (4) until no discoloration is evident on the drying cloth.
If

NOTE:

primer is removed during cleaning, the exposed metal surface need not be furprovided the cleaning is accomplished per steps (3), (4), and (5). However,
if primer is completely removed, reprime surface after completion of all sealing.
some

ther treated

(6) After surfaces

gloves
4.

The

(1)
(2)
(3)
(4)

6.

are

thoroughly cleaned, personnel should wear lint-free, clean, white,


applying sealant.

cotton

prevent surface contamination while

TYPES AND CLASSES USED FOR SEALING


A.

5.

to

following is a list of metal bonding uses, and required


Fay seal with Class A, Class 8, or Class C sealant.

sealants.

Fillet seal with Class B sealant.

Injection seal

with Class B sealant.

Hole fill with Class A

SEALING

or

machine-mixed Class B sealant.

REQUIREMENTS

A.

Metals finished with epoxy


tion.

B.

C.

Fay sealed joints must be closed and securely fastened before work life expiration.
Threaded fasteners which have been shank or underhead sealed shall not be retorqued
tion of application time.

D.

~oints shall

primers

shall have

aged

minimum of 48 hours

prior

to sealant

applica-

after

expira-

not be flexed until sealant is tack-free.

SEALING APPLICATIONFOR STRUCTURALREPAIRS


A.

Mix sealant in accordance with the manufacturers instructions, or refer to


Learjet Maintenance Manual for mixing, handling, and application.

Chapter 20

in the

applica-

ble

B.

Apply sealant to cleanedareas.

C.

Install all fasteners within work life of the sealant.

D.

Allow sealant to

E.

cure. Cure times may be accelerated by heat application.


Fillet seals may be applied to all edges of repaired and original parts. Fair-in sealant with
tool so a continuous smooth fillet is formed.

EFFECTIVITY:

ALL

fairing

51-30-02

Page 4
SRM4

Jun1/95

Learjet

STRUCTURAL REPAIR MANUAL


7.

METHOD OFAPPLICATION
A.

Sealant material may be applied with a brush, an extrusion gun, or a spatula. Each method works
best in a particular situation. The following paragraphs describe these methods and the situations in
which

(1)

they are used.

A stiff-bristled brush (not

nylon)

is used to

apply

the precoat of Class A sealant. Sealant shall be

onto the surface and into the joint which is to be sealed.

brushed

thoroughly
faying surface, and pre-pack seals may be applied with an extrusion gun. Injection seals
must be applied with an extrusion gun. The extrusion gun uses air pressure to force the sealant
material through a nozzle onto the surface or into the cavity to be sealed. Nozzles are available in
different sized beads of extruded sealant. The nozzle tips may be shaped locally to produce a
bead of sealant with the shape and dimensions to fit a specific job. Pre-pack seals are used to fill
voids in structure which cannot be reached by the injection method. These voids are packed with
sealant before they are closed by the assembly of the structure.
(3) A spatula is used to spread sealant material for faying surface and pre-pack seals. Small repair fiE
let seals may be applied with a spatula if an extrusion gun is not available.

(2) Fillet,

8.

FILLET SEALING
A.

Repair Fillet Seal (See Figure 2.)


(1) Use sealant cutting tools similar to those shown in Figure 1.
(2) Cut faulty section from fillet. Slope cuts at ends of section so new sealant
tions of old fillet in these areas. Avoid abrupt changes in cross section.
NOTE:

Remove

rial is

enough sealant on both sides

of defective

area

to be

will

sure

lap remaining

that

por-

remaining mate-

satisfactory.

cut surfaces. Remove loose cuts or flaps. Make sure that no faulty sealant remains. If
fillet adhesion is good, it is not necessary to cut sealant down to bare metal.
(4) Refinish damaged surface if necessary.
(5) Clean surface to be sealed.

(3) Examine all

NOTE:

If epoxy finish is removed in the fuel area during cleaning operation, it is permissible
directly over the bare metal. Touch up exposed areas after the sealant has been

to seal

applied.
(6)
B.

Apply new fillet seal.

Repairing FilletSealed Fasteners


(1) Leaking fastener fillet seals are repaired by replacing the faulty sealant. Proceed as follows:
(a) Using a sealant cutting tool; cut around seal at base of fastener to separate sealant from structure.

(b) Grasp seal with pliers, and pull up and away from fastener end. Most of seal should be

by this process.
(c) Cut away remaining sealant with cutting tool. Small
ly to fastener need not be removed.

re-

moved

NOTE:

quantities

of sealant which adhere firm-

Tightening fasteners during or after sealing destroys sealant effectiveness.

(d) Clean fastener and surrounding area with cleaning solvent.


(e) Using an extrusion gun or spatula, apply a coat of Class B sealant around and over fastener.
(f) Work sealant with fairing tool until fillet seal dimensions given in Figure 2 are obtained.

(g)
EFFECTIVITY:

Use extreme

ALL

care

to eliminate any visible voids

or

bubble

areas

around the fastener base.

51-30-02

Page 5
sRM-a

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


Force Sealant
ahead of gun

Cut

Away

Fillet
Bead

~s
C

C
O
C

Outlirr

C
i~

(FILLET SEAL REMOVAL)

(APPLICATION OF FIRST FILLET)

Remove trapped air


from fairedfillet

Cut nozzle material


to fit size of fillet

by brushing.
Press fillet
into seam

o
\t,
a

firmly

FairingTool -~C7

(APPLICATION OF FINAL SEALANT)

(PRESSINC FIRST FILLET INTO SEAM)

Repro

EFFECTIVITY:

Fillet

Sealing
Figure 2 (Sheet 1 of 2)
ALL

51-30-02

Page 6
SRM-4

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL

Fillet
Reentrant

R~entrant

Edge

Edge

Fillet

(RE-ENTRANT FILLET)

b r 0.125Inch
Maximum

0.126 to 0.349-Inch

0.350" Minimun

rl

\-r

-II

[L~lil

0.150-Inch
~d
Minimun

d 0.150-Inch
Minimun

d 0.150-Inch
Minimun

(VIEW A)

(VIEW C)

(VIEW B)

(FILLET DIMENSIONS)

For View A
0.250" to 0.500"
w

For View B and C


0.350" to 0.500"

0.150-inch minimum,
0 when b
and c 0.350" or more.

except a

w,

0.35

except a

0 when

or more

-I~ t

~t

t
Gap must be filled, not bridged

-L1C 14-

(BUTT JOINT FILLER DIMENSIONS)

Sealing
Figure 2 (Sheet 2 of 2)
Fillet

Repro

EFFECTIVITY:

ALL

51-30-02

Page 7
sRM-a

Jun 1/95

Learjet I

STRUCTURAL REPAIR MANUAL


C.

ApplyNewFilletSeal (SeeFigure2.)
(1) Prior to fillet sealing, all fasteners in the area to be sealed must be installed. All bolts must be torqued to their respective values as retorquing is not permitted after sealing. The proper nozzle for
the sealing gun must also be used. If a small fillet is to be applied, use a small nozzle; a large fillet
requires a large nozzle.
(2) With extrusion gun, apply a small fillet of Class B sealant as shown in Figure 2.
(3) When a nozzle tip is used, point it into the seam and maintain nearly perpendicular to the line of
travel.
SEALANT MUST BE APPLIED CAREFULLY TO AVOID TRAPPING AIR IN

CAUTION:

FILLET. OPERATE GUN SO THAT A BEAD OF SEALANT IS CONTINUALLY

FORCED AHEAD OF NOZZLE TIP, IN THE DIRECTION OF NOZZLE TRAVEL.

(4) Using

fillet

fairing tool,

press the first fillet

firmly into position as

shown. Work the entire bead-

ed section.
CAUTION:

CHECK THAT THE FAIRING TOOL IS ABSOLUTELY CLEAN. DO NOT USE


SOLUTION OR LUBRICANT TO MAKE TOOL SLIDE SMOOTHLY OVER
THE SEALANT. WIPE THE TOOL WITH CLEAN GAUZE

FREQUENTLY TO

AID IN THE FAIRING OPERATION.

(5) If the first fillet has cured but is

not

clean, then it

must be cleaned before the

application

of the

shown. A

larger

second fillet.

(6) Apply the second application of Class

B sealant to

produce

full-bodied fillet

as

extruded nozzle head is used, make


cuts in nozzle to fit fillet and make it conform to the dimensions given in Figure 2. If extruded
nozzle will be

required

than

head nozzle is not used,


fillet dimensions.

was

use a

used for the first fillet. If

fairing

tool

as

required

an

to make sealant conform to the full-bodied

Keep the sealing gun nozzle in direct contact with the work to prevent inclusion of air
bubbles between fillets. Do not hurry. Good sealant application requires patience as

NOTE:

as proper technique. If a fillet extrusion


firmly against the part in such a position that
be directly over the edge.

well

head is used, the head shall be pressed


the maximum thickness of the fillet will

(7) Work out any evident air bubbles.


(8) Fillet re-entrant edges are not acceptable.
(9) A typical finished fillet seal with dimensions is shown in Figure 2.
9.

INJECTION
A.

SEALING

Repair Injection Seal


(1) Remove sealant from short injection channels with

hooked wire and small

require disassembly of structure.


injection
(2) Clean injection channel all the way through, since trapped

cutting tools. Longer

channels

air will

prevent complete filling

of the

channel with sealant.

(3) Exercise care so that structure is not damaged during the removal process.
(4) Clean channel with cleaning solvent and pipe cleaners.

EFFECTIVITY:

ALL

51-30-02

Page8
SRM-C

Jun 1/95

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


(5) Apply solvent with saturated pipe cleaner
until

drying

at least

(6) Clean channel

brush.

Wipe

surface

dry

with

pipe

cleaner.

Repeat

once more

after visible evidence of

impurities

has been removed and the

to be clean.

thought
injection seal.
Apply New Injection Seal (See Figure 3.)
(1) To apply a new injection seal; a fairing tool, pipe cleaners, and an extrusion gun with an injection
nozzle attachedare required.
(2) Ensure that channel is thoroughly cleaned.
(3) Inject channel full, from one end only, with Class B sealant until sealant emerges from all other
openings. Completely fill joggles and channels that require continuity of seal, or block off seal.
surfaces

(7) Apply

B.

or

cleaner remains clean.

are

new

ENSURE GUN HAS ENOUGH SEALANT TO MAKE COMPLETE SEAL AT


STOPPING AND STARTING
ONE INJECTION WITHOUT ANY BREAK.

CAUTION:

WILL CAUSE AIR BUBBLES IN SEAL AND IS CAUSE FOR

REJECTION

OF

JOB.
(4) Remove excess sealant with fairing tool and smooth out ends of seal.
(5) Inspect finished job, checking for poor adhesion and air bubbles. Any air bubble is

jecting

seal. Rework

(6) Check that the

area

only

area

cause

for

re-

that has bubbles.

protrudes, into the fillet seal area, has no abrupt changes in


gradually into the area that is to be fillet sealed.

where the sealant

section. Sealant must be faired out


10. FAYING SURFACE SEALING

A.

Repair Faying Surface Seal (See Figure 4.)


(1) Disassemble structure surrounding seal.
(2) Remove all sealant from faying surfaces with sealant cutting tools and suitable plastic scrapers.
(3) Refinish damaged surface.
(4) Clean faying surfaces with cleaning solvent.
(5) Apply a coat of Class B sealant to one faying surface with a roller, an extrusion gun, or a spatula.
Spread the sealant over the entire surface to obtain a uniform coating.
(6) Removable seals shall be applied with the use of a parting agent. The parting agent shall be applied to one surface. Paint shall be omitted from this surface. When the parting agent is dry to the
touch, the parts may be assembled with a faying surface seal. If the part is removed, the sealant
shall be removed, new parting agent applied, and resealed.
NOTE:

LigMning Strike and Leak Preventive Seal Application


wing fuel access covers, refer to Chapter 57.

For
to

on

removable seals

applied

(7) Assemble parts within sealant work life.


(8) Fair out extruded sealant to leave a smooth fillet along joint.
NOTE:

joint

EFFECTIVITY:

SRM-4

ALL

applied to ensure a continuous


assembly of the faying surfaces.

Sufficient sealant must be

after

extrusion

on

both sides of the

51-30-02

Page 9
Jun1/95

Learjet I

STRUCTURAL REPAIR MANUAL

Injection Sealing
Figure 3

Page

10

Jun 1/95

Learjet
Leariet

STRUCTURAL REPAIR MANUAL

Sealant
Sealant

(ASSEMBLED)

(BEFORE ASSEMBLY)
(PERMANENT SEAL)

Sealant

Thin coat oi

parting agent

(A SSEMBLED)

(BEFORE ASSEMBLY)
(REMOVAL SEAL)

Faying Surface Sealing


Figure 4

Repro

EFFECTIVITY:

ALL

51-30-02

Page
SRM-4

11

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


11. PRE-PACK SEALING

A.

Failed

pre-pack

and

faying

surface seals

normally repaired by raising the seal plane to isolate the


option,
surrounding the faulty seal can be disassembled, a
new seal applied, and the structure reassembled. To replace a failed pre-pack seal, proceed as follows:
(1) Disassemble structure surrounding seal.
(2) Remove all sealant from pre-packed cavity with sealant cutting tools and suitable plastic scrapfailed seal from fuel. As

are

the structure

an

ers.

(3) Complete all preassembly operations such as hole drilling and deburring. Use Shell L-73101 or
Mobil Jet 35, or equivalent lubricants for preassembly drilling or deburring operations.
(4) Clean parts with cleaning solvent.
(5) Apply a coat of Type B sealant to one of the parts. Shape sealant with a fairing tool to the general
contours of the

cavity.

Sufficient sealant must be

NOTE:

applied

to

ensure

complete filling of the cavity.

(6) Assemble parts within sealant work life.


12. HOLE SEALING

A.

SealToolingand CoordinationHoles
(1) Plug tool and coordination holes with soft rivets.
(2) Clean area to be sealed.
(3) Apply Type A sealant over rivet and/or head. Sealant may also be applied

brushing

in two directions until

coating

to structure.

Apply by

of 0.005- to O.Oli-inch thickness is obtained.

13. FASTENER SEALING

A.

Seal

Nutplates, Nuts, Bolts, and Rivets as follows: (See Figure 5.)


(1) Clean fastener and area around fastener.
(2) Using an extrusion gun or spatula, apply Type B sealant around fastener. When sealing

plates,

ensure

that

attaching

rivets

are

nut-

sealed.

(3) Work sealant with a fairing tool to obtain fillet seal dimensions shown.
(4) Use extreme care to eliminate any visible voids or bubble areas around base of fastener.

EFFECTIVITY:

ALL

51-30-02

Page 12
SRM-4

Tun1/95

Learjet I

STRUCTURAL REPAIR MANUAL

0.005 to 0.015-Inch

0.060-inch
0.060-Inch

Rivet

(DOME TYPE NUTPLATE)

(RIVET)

0.060-Inch

_L
I~i

\T
0.060-Inch

0.060-Inch

(NUT GND THREAD)

Repro

EFFECTNITY:

SRM-4

(BOLT HEAD)

Sealing
Figure 5

Fastener

ALL

51-30-02

Page 13
Tun1/95

Learjet
Ledliet
STRUCTURAL REPAIR MANUAL
STRUCTURAL IDENTIFICATION

CKARTS AND TABLES


i.

CHARTSAND TABLES
A.

Chartsand Tables
Charts and tables that

parts are presented


(1)
(2)
(3)
(4)
(5)
(6)
B.

as

provide

the necessary data to

Minimum Bend Radii Chart

Figure
Figure 2

Bend Allowance Chart


Setback Chart

accomplish

the

layout

and fabrication of

repair

follows:

Figure

Equivalents Figure 4
Circumference Table Figure 5
Shop Mathematics Figure 6
Special Tools
Locally manufactured special tools, and/or methods and procedures, are shown in Figures 7 through
10. The special tools/procedures provide methods of reducing the head size of flush rivets, picking
and using drilled
up the location of blind or hidden fastener holes, locating hidden skin trim lines,
countersunk
holes.
in
for
fillers
out heads of flush fasteners
dimpled or
Drill Sizes and Decimal

EFFECTIVITY:

ALL

51-30-03

Page 201
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ALUMINUM
THICKNESS

20240

0.016

1/32

0.020

1/32

0.025

1116

2024-74

5052-0

5052-Hs4

60614

8061-74

6061-76

70750

7075-T6

1116

1/8
118

1/32

1116

1116

118

1/16
1/32

1/16

1/32

1116

1/32

71780

7178-76

1116

1/8

1H6

1/8

1/16

1/8

111

SHEET

0.040

1/16

3/32

1116

1/18

3/32

3/16

3/32

7/32

0.051

1116

1/8

1116

3/32

1/16

1/16

3/32

3/32

114

1/8

9/32

0.~4

3/32

5/32

1116

3/32

1118

3/32

1/8

3/32

5/16

1/8

11/32

0.091

1/8

9/32

13/32

3/16

112
1

0.188

11/32

0.250

2T1

1/4

5/32

7/32

9/32

3/4

15/32

17/32
13/16

1-1/8

19/32

1-3116

6T*

3-1/2T*

6-1/2T*

PLATE
5T*

1-1/2Tt

2T1

2-1/2TI

3T*

STEEL
CARBON STEEL

4137. 4340 AND 8630

THICKNESS
0.012

1/32

1118

0.016

1/32

1116

1116

3/32

1/32

1/16

1132

1116

1132

1116

0.035

1/16

1/8

0.036

1/16

1/8

0.018

0.020

0.024
0.025
0.030

1116

3/32

1H6

3/32

1/8

3/16

0.032
1/16

118

0.040
1
0.045
0.048

1/16

118
3/32

0.049

1/8
3/16

0.060

SHEET

1116

118

0.063
0.065

0.072
0.075

3/32

3/32

1/8

1/8

3/16

1/8

3/16

3/16

1/4

31t6

114

1/8

3/16

5/32

114

Y16

3/8

3/32

7132

7116

118

1/4

1/2

1/8

5/8

5/32

1/4

3/8

3/4

3/16

9/32

1-1/2T*

2T

Y16

0.078

0.080
0.083
0.093
0.095
0.

1/8

1/4

1/8

114

Y32

0.112

0.119
0.120

3/16

0.125
0.134

3/16

114

318

0~56

1/4

3/8

0.188

5/16

3/8

0.250

PLATE

3/8

Y16

3/8

OVER
0.250

YT

3/8

1-1/2T"

material thickness (round off bend radius

to next

2T*

I-lnT*

5T*

largest 1/32.)

Minimum Bend Radii Chart

Figure
EFFFCTIVITY:

ALL

1 (Sheet 1 of 2)

51-30-03

Page 202
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


CRES, INCONEL,

AND TITANIUM
PURE

ALLOY

AISI-302
AIS1321
AiS1347

AIS1302

350

INCONEL

IksDL

IgDL

AMS0901

AM54908

17=7PH

INCONEL X

19-9DX

I9-9DX

NAS7123

NAS7125

1RHARD

THICKNESS

9~

90"

0.010

1/32

1118

0.012

1132

1/32

1/32

1/16

0.016

1/32

1/32

1M2

1/18

0.020

1132

1116

1/16

3/32

1116

1/32

1118

1/16

1118

0.025

1/32

1118

1/16

3/32

1/16

1132

1116

1HB

Y32

118

Y32

5/32

1/16

0.018

1/16

0.028
0.030

1132

1116

1118

3/32

1/16

1/32

1/16

3/32

1/8

5/32

0.036

1118

1/8

1/8

3/16

3/32

1116

3/32

3/32

1/8

5/32

0.040

1/16

1/8

1/8

3/16

3/32

1116

3/32

1/8

1/8

3/16

1118

1/6

5/32

3/16

1118

1/8

5/32

7/32

Y16

1/4

Y16

9/32

1/4

3/8

0.032
0.035

0.042
0.045

3/18

0.048
0.049
0.050

1/8

3/16

1/8

1116

1/8

1/8

0.056
0.060
0.063

1/16

1/8

1/8

3/18

1/8

1116

118

5/32

0.065
0.071

SHEET

0.072
0.075

0.078
0.080

3/32

3/18

3/16

5/16

3/16

3/32

1/4

9/32

9r32

13/32

3/32

3/16

3/16

5/16

3/16

3/32

9/32

5/16

Y16

15/32

3/8

1/2

0083

0.090
0.093
0.095
0.100
0.104
0.109

0.112

1/8

1/4

114

3/8

1/4

1/8

318

13/32

13/32

9/16

1/8

1114

1/4

3/8

1/4

118

318

7/16

7/16

5/8

1/2

23/32

0.119
0.120
0.125

0.140

0.156
0.180
0.180
0.188

3/16

3/8

3/8

3/16

9/16

11/16

13/32

3/18

5/8

11/16

1/2

1/2

1/4

3/4

7/8

2T

2r

lr

0.190

PLATE

0.250

1/4

2r

9/16

13/16

21132

29/32

OVER
0.250

material thickness (round off bend radius to next

largest 1/32.)

Minimum Bend Radii Chart

Figure
EFEECTIVITY:

ALL

(Sheet 2 of 2)

51-30-03

Page 203
SRM~

May 15/92

Learjet
STRU~TURAL REPAIR MANUAL
empirical formula for finding the allowance

The

for

material

required

(0.0078

thickness).

This

bend

radius)

of

i.

Multiply the numbers in the

table

by the degrees

of bend to determine the amount of material

required for the bend.


Example:

the material

equals

(0.01743

required

for

one

degree

of

95

deg bend, 1/8

0.00249

bend.
2.
Mold Lines

Degree

For bends

calculated

as

which is taken

Bend Lines

Example:
90 deg bend,
(R)

the

are

one

required
of

1 in.

of the material.

radius, 0.064 in. material.

Radius to center of material

Rx

Circumference of are

BEND ALLOWANCE COEFFICIENTS FOR ALUMINUM

bend radius ~1 in.)


0.032

1.032 in.

degreeof bend

360 (total

(T)

inch radius, the


for the bend is

circle, the radius of

to the center

1/2 material thickness

Thicltness

O.aQO in, material

radius,

than

larger

amount of material

of Bend

Radius

in,

0.2365 in.

95

degrees in circle)

ALLOYS, BASED ON ONE-DEGREE ANGLE

METAL THICKNESS
RADII

0.018

0.020

0.022

0.025

0.092

0.040

0.0~0

0.063

0.080

OAgO

0.125

0.180

1132

0.00067

9.90976

O.MX)72

0.00074

O.MX)79

0.00086

0.00094

0.00104

0.00117

0.00125

O.M)154

0.00200

1H6

0.00121

0.00125

0.001 26

9.99129

0.00135

0.00140

0.00149

0.00159

0.00171

O.M)180

0.00209

0.00255

3/32

0.00176

0.00179

0.00180

0.00183

9.90188

0.00195

0.00203

0.00213

0.00226

0.00234

0.00263

0.00309

1/8

0.00230

0.96234

0.00235

0.99238

0.90243

0.00249

0.00258

0.99268

0.00281

9.96289

0.00317

0.00364

5/32

0.00285

0.99288

0.00290

0.00292

0.96297

0.00304

0.00312

0.00322

0.99335

0.90343

9.99372

O.M)418

3/16

0.00339

0.00342

0.00344

0.a0347

0.00352

0.M)358

0.00387

0.00377

0.00390

0.00398

0.00426

0.00473

7/32

0.00394

0.00397

0.00398

0.00401

0.004108

O.W412

0.00421

0.00431

0.00444

0.00452

9.99481

0.00527

1/4

0.00448

0.0045~

0.00454

0.00458

a.00461

0.00467

0.00476

9.99486

0.00499

0.00507

0.00535

0.00582

9/32

0.00503

9.96506

0.00507

0.00510

0.00515

0.00521

0.00530

0.00540

0.96553

0.00561

0.00580

0.00636

5/16

0.00557

0.00560

0.99562

0.00564

9.99579

0.00578

0.00584

0.00595

0.00608

OX~0816

0.M)644

0.00691

11132

0.00612

0.00615

9.80616

0.00619

0.00624

0.00630

9.96639

0.00649

0.00662

0.00670

0.00699

0.00745

3/8

0.00666

0.00869

0.00671

0.00673

0.00679

0.00685

0.00693

O.M)7W

O.W717

0.00725

0.00753

0.00800

13/32

0.00721

0.00724

0.00725

0.M)728

0.00733

0.00739

0.00748

0.00758

0.00771

0.96779

8.90898

0.00854

7/16

0.00775

o.oons

9.90783

o.oo7eg

0.00787

0.00794

0.00802

0.00812

0.00826

0.99834

0.00862

0.00908

15/32

6.99829

0.00833

0.00834

0.00837

6.80842

0.00848

0.00857

0.00867

0.00880

0.00888

0.00917

0.00963

112

0.00884

0.00887

0.00889

0.69891

0.M)896

0.00903

0.00911

0.00921

0.00935

0.00943

0.00971

0.01017

17/32

0.00938

0.M)942

0.00443

9.86016

0.00951

0.00957

0.00966

0.00976

0.00989

O.M)997

0.01925

0.01072

9/16

0.00993

0.00996

0.00998

0.01000

0.01095

0.01012

0.01020

0.01030

0.01043

0.0~051

0.0108D

0.01126

19/32

0.01047

0.01051

0.01052

0.01055

0.010M)

0.01065

0.01073

0.01083

0.01098

0.01105

0.01133

0.01179

518

0.0\\02

0.01~05

0.0~\07

0.01\09

0.01~14

0.01121

0.01129

O.Dt139

0.01152

0.01160

9.91189

0.01235

21132

0.01158

0.01160

0.01161

0.01164

0.01170

0.01175

0.01183

0.01193

0.01207

0.a1214

0.01245

0.01289

11116

0.01211

0.01214

0.01216

0.01218

0.01223

0.01230

0.01238

0.01248

0.01261

0.01269

0.01298

0.01344

23/31

0.01265

0.01268

0.01269

0.01273

0.01276

0.01283

0.01291

0.01301

0.01316

0.01322

0.01351

0.01397

3/4

0.01320

0.01323

0.01324

0.01327

0.01332

0.01338

0.01347

0.01357

0.01370

0.01378

0.01407

0.01453

25/32

0.01374

0.01378

0.01379

0.01381

0.01386

0.01392

0.01401

0.01411

0.01425

0.01432

0.01461

0.01507

13/16

0.01429

0.01432

0.01433

0.01436

0.01441

0.01447

0.01456

0.01466

0.01479

0.01487

0.01516

0.01562

27/32

0.01483

0.01488

0.01487

OA1490

0.01494

0.01501

0.01509

0.01519

0.01534

0.01 510

0.01569

0.01615

7/8

0.01538

0.015H

0.01542

0.01545

0.01 550

0.01556

0.01565

0.01575

0.01588

0.01 596

0.01625

0.01671

29/32

0.01592

0.01595

0.01596

0.0159g

0.01804

0.01610

0.01619

0.01629

0.01643

0.01650

0.01679

0.01 727

15H6

0.01848

0.01850

0.01651

0.01654

0.01859

0.01885

0.01674

0.01684

0.01697

0.01705

0.01734

0.01780

31/32

0.01701

0.01704

0.01705

0.01708

0.01712

0.01718

0.01727

0.01737

0.01752

0.01758

0.01787

0.01833

0.01755

0.01759

0.01760

0.01763

0.01768

0.01774

0.01783

0.01793

0.01806

0.01814

0.01843

0.01888

Bend Allowance Chart

Figure 2
EFFECTIVITY:

ALL

51-30-03

Page 204

May15/92

Learjet
STRUCTURAL REPAIR MANUAL
Example:

Angle of bend ~A)

deg

Radius (R)= 0.125 in.


K from table
2.7475
SETBACK

_t
L,-

1-

140

Material thickness (T)= 0.064 in.

2.7475

(0.064

2.7475

0.189

SETBACK

(T

R)=

0.125)=
0.509

0.509 in.

SETIICK

ANGLE

ANGLE

ANGLE

ANGLE

ANGLE

ANGLE

DEGREE

DEGREE

DEGREE

K.

DEGREE

DEGREE

DEGREE

0.00873

31

0.27732

61

0.58905

91

1.0176

121

1.7675

151

3.8667

0.01745

32

0.28874

82

0.60086

92

1.0355

122

1.8040

152

4.0108

0.02618

33

0.29621

83

0.61208

93

1.0538

123

1.8418

153

4.1653

0.03493

31

0.30573

64

0.62487

94

1.0724

124

1.8807

154

4.3315

0.04368

35

0.31530

65

0.63707

95

1.0913

125

1.9210

155

4.5107

0.05241

36

0.32492

86

0.&1941

96

1.1106

126

1.9626

156

4.7046

0.06116

37

0.33459

67

0.66188

97

1.1303

127

2.0057

157

4.9151

0.06993

38

0.34433

68

0.87451

08

1.1504

128

2.0503

158

5.1455

0.07870

39

0.35412

89

0.88728

99

1.1708

129

2.0965

159

5.3995

10

0.08749

40

0.36397

70

0.70021

100

1.1917

130

2.1445

160

5.6713

11

0.09629

41

0.37388

71

0.71329

101

1.2131

131

2.1943

161

5.9758

12

0.10510

42

0.38386

72

0.72654

102

1.2349

132

2.2460

162

6.3137

13

0.11393

43

0.39391

73

0.73996

103

1.2572

133

2.2998

163

6.6911

14

0.12278

44

0.40403

74

0.75355

104

1.2799

134

2.3558

164

7.1154

15

0.13165

45

0.41481

75

0.76733

105

1.3032

135

2.4142

165

7.5957

16

0.14051

46

0.42447

76

0.78128

106

1.3270

136

2.4751

166

8.1443

17

0.14945

47

0.43481

77

0.79543

107

1.3514

137

2.5386

167

8.7769

18

0.15838

48

0.44523

78

0.80978

108

1.3764

138

2.8051

168

19

0.16731

49

0.45573

79

0.82434

109

1.4019

139

2.6746

169

10.385

20

0.17633

50

0.46631

80

0.83910

110

1.4281

140

2.7475

170

11.430

21

0.18534

51

0.47697

81

0.85408

111

1.4550

141

2.8239

171

12.706

22

0.19438

52

0.48773

82

0.86929

112

1.4826

142

2.9042

172

14.301

23

0.20345

53

0.49858

83

0.88472

113

1.5108

143

2.9887

173

16.350

24

0.21256

54

0.50952

84

0.90040

114

1.5399

144

3.0777

174

19.081

25

0.22169

55

0.52057

85

0.91633

115

1.5897

145

3.1718

175

22.904

26

0.23087

56

0.53171

86

0.93251

116

1.6003

148

3.2708

176

26.636

27

0.24008

57

0.54295

87

0.94896

117

1.6318

147

3.3759

177

38.188

28

0.24933

59

0.55431

88

0.96569

118

1.6643

148

3.4874

178

57.290

29

0.25862

59

0.56577

89

0.98270

119

1.8977

149

3.6059

179

114.590

30

0.28795

80

0.57735

90

1.00000

120

1.7320

150

3.7320

180

INFINITE

9.5144

Setback Chart

FigureJ
EFFECTIVITY:
swc4

ALL

51-30-03

Page 205
May 15/92

Learjet
E~ Learjet]

STRUCTURAL REPAIR MANUAL


DECIMAL
EaU\VALENTS

TAP
DRILLSIZES
I

NC

SCREW

TAP

SCREW

7/16-14

TAP

NUMBER, LETTER, AND FRACTIONAL SIZE DRILLS

SIZE
DRILL

SIZE

DECIMAL

DRILL

SIZE
DRILL

I
DECIMAL

DECIMAL

DRILL

7/16-20

25/64

1/2-20

29/64

27/64

1/2-13

SIZE

DRILL

SIZE

NF

9/16-12

31/64

9/16-18

33/64

5/8-11

17/32

5/8-18

37/64

11/16-11

19/32

5/8

11/16-11

79

0.0145

30

0.1285

1/M

0.0156

29

0.1360

0.3390

78

0.0160

28

0.1405

11/32

0.3437

omeo

9164

0.3480

76

O.OMO

27

0.1440

0.3580

75

O.M10

26

0.1470

23/64

0.3580

0.\406

0.3320

3/4-10

21/32

3/4-16

11/16

74

o.om

25

0.1495

13/16-10

23/32

7/8-14

13/16

73

0.0240

24

0.15X)

318

7/8- 9

49/64

1-14

15/16

72

0.0250

23

0.1540

0.3770

15/16- 9

53/64

1-1/8-12

1-3/64

71

0.0260

632

0.1562

0.3860

7/8

1-14/-12

1-11/64

1-112-12

1-27/64

1- 8

1-1/8- 7

63/64

1-1/4- 7

1-7/64

1-1/2- 6

1-11/32

MACHINE SCREW
SCREW

DRILLS FOR

SIZE

0.3680

9.8759

70

0.0280

22

0.1570

25154

0.3906

89

0.029~

21

0.1590

0.3970

88

0.0310

20

0.16~0

1/32

0.0313

19

0.1660

0.4040

13/32

9.4989

67

0.0320

18

0.1695

0.4130

68

0.0330

11/64

0.1719

27/64

0.4219

65

0.0350

17

0.1730

7/16

0.4375

64

0.0360

16

0.1770

89/54

0.4531

0.0370

15

0.1800

15/32

0.4687

82

0.0380

14

9.1889

31/64

61

0.0390

13

0.1850

112

0.4843

9.5009

No.50

No. 43

No. 47

No. 40

se

0.0410

12

o.lseo

17/32

No.43

No. 32

58

9.9499

11

0.1910

35/64

6-32

No.36

No. 28

57

0.0430

10

0.1935

9116

8-32

No.ZS

No. 19

56

00465

0.1960

37/64

0.5781

10-24

No. 25

No. 10

3/64

0.0489

0.1990

19/92

0.5937

No.21

No. 10

55

0.0520

0.2010

39/64

0.6094

10-32

54

0.0550

0.203~

518

0.8259

7/32

0.6406

2-56

3-48
4-40

12-24

No.16

1/4-20

No.

1/4

1/4-28

No.

114

5/16-18

5/16-24

3/8-16

5/16

3/8-24

DIAMETER

PIPE
I

7
1Y64

0.5469

0.5625

53

0.0595

0.2040

41~4

1/18

0.0625

9.9955

21/32

9.8589

52

0.0635

0.2090

43/64

0.6719

5/16

51

9.9879

0.2130

11/16

0.8875

5/16

50

0.0799

1/32

0.2187

45/&1

0.7031

49

0.0730

0.2210

23612

0.7187

48

0.0760

0.2280

47/64

9.7314

5/64

0.0781

0.2340

3/4

0.7500

47

0.0785

15/64

0.2344

49164

0.7656

46

0.OB10

O.nBO

25/32

0.7812

3/8

45

0.0820

0.2429

51164

0.7969

44

0.0860

0.2480

13/16

0.8125

CLEARANCE I

43

9.9890

114

9.2599

5384

0.8281

42

0.0815

0.2570

27/32

0.8437

3/32

0.0837

0.2610

55/64

0.8594

41

0.0960

17/64

0.2656

7/8

0.8750

40

0.0980

39

0.0995

DRILLS FOR

OF TAP

TAp

1/8-27

11/32

7/16

0.5312

318

1/4-18

7/16

7/16

3/8-18

37/64

314

1/2-14

23/32

7/8

57164

57/64

0.8906

0.2720

29/32

0.9062

3/4-14

59/64

1-3/16

38

0.1015

0.2770

59/64

0.9219

1-11-1/2

1-5/32

1-7/16

37

0.0140

0.2811

15118

0.9375

1-1/4-11-1/2

1-1/2

1-3/4

38

0.0165

9132

0.2812

8~164

0.9531

1-1/2-11-1/2

1-47/64

7/54

0.1093

9.2999

31/32

0.9687

2-7/32

2-112

35

0.1100

0.2950

89/84

0.9844

34

0.1110

19/84

0.2968

1.M)O

33

0.1130

0.3020

32

0.1160

615

9.3125

31

0.1200

0.3160

0.3230

2-112-8

2-5/8

3-8

3-114

3-3/4

3-1/2-8

3-314

4-1/4

4-8

4-1/4

4-3/4

Drill Sizes and Decimal

Equivalents

Figure 4
EFFECTNITY:
sI~M-a

ALL

51-30-03

Page 206
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
INCHESORFEET

OFONEINCH
DIAMETER
FRACTION

DECIYAL

1/64

0.015625

AREA

0.04909

0.00019

3.1416

0.7854

64

201.06

3216.99

CIRCUM.

DIA.

CIACUIM.

AREA

CIRCUM.

DIA.

AREA

1/32

0.03125

0.09818

0.00077

6.2832

3.1416

65

204.20

3318.31

3/64

0.046876

0.14726

0.00173

9.4248

7.0686

68

207.35

3421.19

1116

0.0625

0.19635

O.M)306

12.5864

12.5664

67

210.49

3525.85

5/64

0.078125

0.24545

0.00479

15.7080

19.635

68

213.63

3631.88

3/32

0.09375

0.99452

0.00690

18.850

28.274

69

218.77

3739.28

7/64

0.109375

0.34383

0.00939

21.991

38.485

70

219.91

3848.45

50.266

71

63.617

72

0.125

0.38270

0.01227

25.133

9/64

0.140625

944161

0.01553

28.274

5/32

1/8

223.05

3958.19

228.19

4071.50

229.34

4185.39

232.48

4300.84

0.15625

0.49087

0.01917

10

31.418

78.540

73

11~64

0.171875

0.53999

0.02320

11

34.558

95.033

74

3/18

0.1875

0.58905

0.02761

12

37.699

113.1

75

235.62

4417.88

13/84

0.203125

0.63817

0.03241

13

40.&11

132.73

78

238.78

4538.48

7/32

0.21875

0.68722

0.03758

14

43.982

153.64

77

241.90

4656.63

15/64

0.234375

0.73635

O.M314

15

47.124

176.71

78

245.04

4778.36

0.25

0.78540

0.04909

18

50.265

201.08

79

248.19

4901 .67

17/64

0.265625

0.83453

0.05542

17

53.407

226.98

80

251.33

5026.55

9/32

0.28125

0.88357

0.06213

18

56.549

254.47

B1

254.47

5153.

19/64

0.296875

0.93271

0.06822

19

59.690

283.53

82

257.81

5281.02

0.3125

O.gS175

0.07670

20

62.832

314.18

83

260.75

5410.81

0.328125

1.0309

0.08456

21

85.873

348.38

84

283.89

5541.77

11/32

0.34375

1.0789

0.09281

ss.l 15

380.13

85

267.04

5674.50

23/64

0.359375

1.1291

0.10144

23

72.287

415.48

86

270.18

5808.80

0.375

1.1781

0.11045

24

75.398

452.39

87

273.32

5944.68

25/84

0.390825

1.2273

0.11984

25

78.540

490.87

B8

276.46

8082.12

13/32

0.40625

1.2763

0.12962

26

81.681

530.93

89

279.60

8221.14

27/64

0.421875

1.3254

0.1397g

27

84.823

572.58

80

282.74

6361.73

0.4375

1.3744

0.15033

28

87.985

815.75

91

285.88

65W.8B

0.453125

1.4236

0.16126

29

91.106

660.52

82

289.03

6647.81

15/32

0.46875

1.4728

0.17257

30

94.248

706.88

93

292.17

6792.91

31/64

0.4&1375

1.5219

0.18427

31

97.389

754.77

94

295.31

6939.78

0.5

1.5708

0.19635

32

100.53

8W.25

95

298.45

7088.22

33/64

0.515625

~.6199

0.20880

33

108.67

855.30

86

301.59

7288.29

17/32

0.53125

1.8890

0.22166

34

106.81

907.92

97

304.73

7389.81

35/64

0.546875

1.7181

0.23489

35

109.96

98

307.88

7542.96

0.5825

1.7871

0.24850

36

113.10

1017.88

99

311.02

7897.69

0.678125

1.8163

0.28248

37

118.24

1075.95

1M)

314.16

7853.98

1134.11

101

317.30

8011.85

1184.59

102

320.44

8171.28

103

323.58

8332.29

1/4

5/16

3/8

7/16

29/64

In

9/16
37/84
19/32

0.27688

1.8653

0.59375

38

0.30680

i
1

40

2.0127

0.32232

41

128.81

1320.25

104

326.73

8491.87

0.65625

2.0617

0.33824

42

131.95

13B5.M

105

329.87

8659.01

43/64

0.671875

21108

0.35453

43

135.09

1452.20

108

333.01

8824.73

11/18

0.6875

2.1598

0.37122

44

138.23

1520.53

107

338.15

8992.02

45/&0

0.703125

2.2090

0.38828

45

141.37

1590.43

108

339.29

9160.88

23/32

0.71875

2.2580

0.40574

48

144.51

1661.90

109

342.43

47/64

0.734375

2.3072

0.42356

47

147.65

1734.94

110

345.58

0.75

2.3562

0.44179

48

150.80

1809.56

111

348.72

49/64

0.765625

24054

0.46038

49

153.94

1885.74

112

351.88

9852.03

25/32

0.78125

24561

0.47937

50

157.08

1963.M)

113

355.00

10028.75

51/64

0.796875

2.5036

0.49872

51

180.22

2042.82

114

358.14

10207.03

13/16

0.8125

25525

0.51848

52

163.36

2123.72

115

381.28

10386.89

53/64

0.828125

2.6017

0.53862

53

166.50

2208.18

116

364.42

10568.32

27/32

0.84375

2.6507

0.55914

54

169.65

2290.22

117

367.57

10751.32

55/64

0.859375

2.6999

0.58003

55

172.79

2375.83

llS

3M.71

10935.88

0.875

2.7489

0.60132

175.93

2463.01

119

373.85

1112.02

57164

0.880625

27981

0.62298

57

179.07

2551.76

120

376.99

11309.73

29132

0.90625

28471

0.64504

58

182.21

2642.08

121

380.13

11499.01

59/64

0.921875

2.8959

0.66748

59

185.35

2733.97

122

383.27

11689.87

15/16

0.9375

2.9452

0.69029

60

188.60

2827.43

123

386.42

11882.29

61164

0.953125

29945

0.71349

61

191.64

2922.07

124

389.58

3102

0.06875

3.0434

0.73708

62

194.78

3019.07

125

392.70

63/&1

0.984375

3.0928

0.76097

63

197.92

3117.25

126

395.84

0.609375

1.8145

0.29164

0.625

1.9635

41/84

0.640625

21/32

39/64
5/8

3/4

7/8

Diameter

multiplied by

39

1
1

119.38

1P.52
125.68

1258.64

equals circumference. Circumference multiplred by


Square of the diameter multiplied by 0.7854 equals area.

3.1416

0.3183

9331.32

9503.32
9878.89

12076.28
1

12271.85

12468.98

equals diameter.

Circumference Table

Figures
EFFECTIVITY:

ALL

51-30-03

Page 207
SRML

May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


SPHERE
4

4 Tr

VOLUME

Ir

AREA

CONE

d3

nr3

VOLUME

AREA OF

SURFACE

r2 :Xd2

AREA

nr2L

~r2h

CYLINDER

VOLUME

(OF EITHER)

O.7854D2L

(OF

n DL

~ZTrs

a3

DIAGONAL

CYLINDRZCAL

CONE)

CUBE
VOL UME

RIGHT

J-;-

6a2

TOTAL AREA

RECTANGULAR PRISM
CYLINDER
VOLUME
AREA OF

SURFACE

(area base)

h:

CYLINDRICAL

(perimeter base)

f--j-i-

VOLUME

I
I

(area of end)

DIAGONAL

TOTAL AREA

CONVERSION OF DECIMAL FRACTION TO

abe

2(ab

ca)

be

CONVERSION OF FRACTION TO DECIMAL

COMMON FRACTION
To convert fraction to decimal
To convert decimal to

common

fraction

Divide numerator

(top) by denominator (bottom)

Multiply the denomminator (bottom) of fraction


desired

Bxamp~:

0.678 (decimal fraction)

5/8

8~2:

5/8

0.625

48

64 (denominator desired)

20

2712

16

4068

40

43.392

Result: 43

40

64

Shop Mathematics
Figure 6 (Sheet 1 of 2)
EFFECTTVITY:
SRM~I

ALL

51-30-03

Page 208
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
8

TRAPEZOID

(a parallel

b)

to

AREA

bh

Ih
h

AREA

\lbZ+

2
is

RECTANGLE

/1

a+b

perpendicular

to

h2

and b

RIGHT

TRIANGLE

ba
AREA

CIRCLE
nd

CIRCUMFERENCE

AREA=~Tr

2n

circumference

(n=

HYPOTENUSE:

1F

qd2

b/

A.*B.+C.1BOdegrees

I/\B
d

=0.7854d2

diameter

n=

ANY TRIANGLE

3.1416

bh
ELLIPSE
AREA:

AREA=

~(DA)x(OC)
n
(AB) x (CD)

I_C-l_~

is

AO

perpendicular
BO

C"

180

~o

h;

b)

degrees

I PARALLELOGRAN

SECTOR

AREA

l(h

r(arcAB)

(opposite

2
IT~

r2(angleA08)

360

degrees

parallel)

AREA= bh

(h

sides

AO

is

perpendicular
BO

FUNCTIONS OF ANGLES

CO

360

SINE

to

b)

degrees

Side

Opposite

Hypotenuse
TANGENT

SIDE

HYPOTENUSE

SECANT

SideOpposite
Side Adjacent
=Hypotenuse

OPPOS I IE

COSINE

iSIDE

ANGLE

Side

Adjacent

Side

Adjacent

Hypotenuse
COTANGENT

Side

ADJACENT

COSECANT

ediStncajAOpposite

Hypotenuse
Side

Opposite

Shop Mathematics
Figure 6 (Sheet 2 of 2)
EFFECTIVITY:
SRM4

ALL

51-30-03

Page 209
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


Dimple

or

countersunk

Dimple

to

filled

be

install

filler,

flush

heat-treated

Select

drill

Drill

through

same

diameter

rivet.
as

rivet.

Typical application

head.

Filling Dimpled

ad Countersunk Holes

Couotersink to match

existing fastener.
Steel

block
ill

where a dimpled or countersunk


hole has become enlarged, and it is not

In

case

possible
next

to

size

countersink for the

redimple
larger fastener,
or

the

size

Aedrill
size

larger

fastener.

fastener
before

Drill
size

2.

as

hole in
the

steel block the

Fastener

existing

so

size fastener head is flush

Redrill hole to next size

larger fastener

trimming.

after

that

with the surface of the steel block.


3.

trimming.

same

existing fastener.

CounteISillk the drilled hole


the

existing

method may be used to trim the next size


larger fastener head to match the existing

1.

match

fastener.

match next

to

following

dimples or countersinks.

to

of

Note
This method to be used
the next

larger

only

for

fastener.

diameter.
4.

Place the fastener to be used in the


countersunk hole in the steel block,
and file or grind off head flush with

5.

the surface of the block.


Install the fastener to be used in redrilled holes. ~ter installation, coat

head of fastener with epoxy primer,


and paint to match surrounding area.
~C

Tr

ring

Fastener Heals

Trimming Fastener Heads and Filling Countersunk Holes


Figure 7
EFFECTIVITY:
SRM-4

ALL

51-30-03

Page 210
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


NOTES:

fastening operations on covers and doors,


secure part firmly in place before trimming.
Use radius gage or disk to duplicate radius.
Radius

First

Perform all

of

Edge

~ICCLCOCC

Opening

Tape (Ref)

Second

and

(Refer

Note)

to

(Ref)

OO

CDL16U

Tape (Ref)

Oversize Filler

gC,

oi:

Edge

of Cutout

I,

CCi

cc

go

II

i~

c
c

cc

Repair
or

Doubler

Door Frame

c~

c~

Place second

tape

cover,

over

matching

it

accurately

with

outer

edges of

first

tape.

Oversize

filler

Trace trim line

material

placed

inside outer

over

taped

cutout.

(second) tape.

WITH MASKING TAPE

NOTES:
Trim out

area.

Cut filler

over-

cutout, and insert


skin scribe. Hold filler firmly in place,

------~f

r-

damaged

size. Place filler

over

and slide scribe around cutout.


o

This trim

marking method is not recomfitting covers and doors.

mended for

1/2
Skin Scribe

ribe Line

Oversize Filler

Spacer

Any Alloy Steel

(Approx.
or

0.040

in.)

Scribe

(Ref)

Hacksaw Blade

I
WITH SKIN 9CRIBE

Locating Skin Trim Lines


Figure 8

EFFECTIVITY:
SRM-4

ALL

51-30-03

Page 211
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


5/8 (Approx.)
30

No.

Peen Probe Stem

0.050

Material
Steel

40 Drill

No.

Spacer -0.050
(or as required)

(Approx.)

Heat-Treated

or

Bu:7

Probe
SCREW LOCATOR
This variation of

Aluminum Alloy

Either
be

member

may

formed to clear

obstructions

~1

the

sizes,

such

J(;-;---==jSweat
or

as

\LAS required
mid-panel

or

far

holes

screw

doors

of

holes in

and

covers.

50

No.

Solder

Stake

finder may be

hole

locating larger

undrilled structural

as

HOLES

various

Peen

necessary.

LOCAIIH; BLIH)

for

used

or

40

or

Bushing

3j8

Sweat Solder

Flush--\

Drill

Drill Bushing

1/8 Rivet

1/$

i-

edge

holes

I/iii

WITH HME

Probe

CAHLOC STUD LOCATOR


NOTE:

shapes of

The

hole

the

only examples.

Other

finders

shown

configurations

are

This variation of the hole

will

required for accomplishing many jobs.


The main points to keep in mind when

be

making

hole

drill
be
To

finder

snugly

fit

must

in

the

probe

and

:2)

transfer

bushing
accurately

or

accomplish

the

should be

(1)

hole,

are

the

centered

punch

over

latter,

the

the

series)
When

the

and

hole must

probe.

in undrilled

is

shown

in

assembly

center

of

rivet.

selected distance

on

line

With

from

to

figure

of blank
a

set

the Camloc
10

is

covers

of
stud

locating
locator

recommended.

repair sheet in place, align

scale

along

line;

then

of rivet.
e

sheet.
tance.

To locate center,
insert AD rivet

uncovered

project

portion of

line

onto

repair

Carefully mark chosen disCenter-punch and drill hole.

in hole.

g~

~ETHOO
Draw two

MTHOD

lines

intersecting
center

expected,

(4002

and doors.

covers

frequent fitting
doors

finder may be

studs

line-drilled.

through

centerline

Camloc

)ETHOD

Draw line
Mark

locating

tools similar

METHOD

for

used

at

of rivet,

Install

repair

scale

sheet.

Accurately

portion
along
project lines onto
repair sheet.
Center-punch at
drill pilot hole.
and
intersection,
align

uncovered

of lines and
LOCATING BLIND HOLES IILTH
A SCALE

TW0 MTHODS

Locating Blind Holes


Figure 9

EFFECTIVITY:
SRM-4

ALL

51-30-03

Page 212
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

NOTE:
This

type
and

doors
tool

Camloc

of

when

recommended

covers

receptacle

under

1-1/4

the door

Camloc

each

in

cover

or

A locator

expected.

is

installed

be

can

is

locator

stud

regular replacement of

being

11 1/4

__i__\

fitted.
r~-lc.nol

LDrill 1/2-CSK

Fabricate all parts from 0.050-inch

2024-74

7075-16 clad material.

or

5/32

Cut

Joggle loner (collar-retaining)


strip.
Align and clamp strips and 0.050-inch
spacer in drill vise, and insert a

sheet-metal

strips

and spacers.

Rig

140

Rivet

/\--cxiii

(Typ)

all

rivet

hole,

and

No.

Remove

Rig-Pin

end.

30

upper

Pin

Rig
parts, drill
a

No.

21

transfer-punch
strip

21

No.

Rivet

rig-pin hole,

and

Hole

No.

(Typ)

Transfer-Punch Hole

(loosely

From

Reclamp lower strip; drill and


countersink 1/2-inch Camloc collar
vise.

0.050 Spacer
Camloc Grommet

hole.
7

Install Camloc collar.

Assemble
ensure

in

parts,

and

rivet

alignment, rig pin

them.

Camloc

Rig

Pin in

with

Place~

Tape

door

securely
:P:

(Typ)

inplsce.

(Typ

Untrimmed Door
amloc Grommet

loc

and Stud

1/8 in.

transfer punch.

Camloc Stud Locator Ali

Camloc Stud
Locator

Ring

Mark hole center

should be

Receptacle (Typ

and

CA~LOC STUD LOCATOR

To

place during riveting operation.

(Typ)

Receptacle (Typ)

Door Frame

LOCATI~ CAIUOC STUDS


1

Install Camloc stud locator in eaCh

receptacle
2

around

opening.

Align mtrimmed door


and securely tape it

Skin

opening,
place.

in

each

Door Frame (Ref

and

Align locator, install rig pin,


on

(Ref

over

mark center of stud location.

procedure
opening.

Repeat

locator around

Locating Access Door Fastener Locations


Figure 10

EFFECTTVITY:
SRM-4

ALL

30

(5/32 Rivet)

hole.

spacers

5/8

Pin Hole

Drill No. 21

0.100-inch spacer between strips at

joggled
Through

Deg.

Drill No.

51-30-03

Fage 213
May 15/92

Leariet

STRUCTURAL REPAIR PIIANUAL


PROTECTIVE TREATMENT OF STRUCTURAL MATERIALS
i.

GENERAL
A.

B.

2.

Any repair process which breaks the surface of the original structure requires a protective treatment.
The treatment acts as a paint base and corrosion protection when applied prior to the installation of
repair parts.
Structural components whose surfaces have not been damaged beyond the limits of allowable dam
age or whose surfaces have been damaged by corrosion must be protective treated. Final aircraft exterior finish is described in the appropriate Leajet Maintenance Manual.

FINISH SPECIFICATIONS AND CODE NUMBER (See Figure 1.)


A. The finish specifications are listed in tabular form using code numbers that
or

three dash numbers

as

are

composed of one, two,

required to finish a part.

(1) The order of the dash numbers specifies the sequence of application.
(2) Finish code numbers also are listed in each table.
Finish

B.

Specifications

NON-

ALUMINUM

Wings

CORROSIONRESISTANT
STEEL

FIBERGLASS

Tip Tanks

Exterior of skins
as

CORROSIONRESISTANT
STEEL

except

F4

(1)

noted

Interior of skins except


as noted

F4-4

Exterior surface of upper


and lower skin between

F4-6

(6)

fuselage fairings
Exterior surface of lower
skin under

F4-6

leading edge

fairing between

spats No. 1

and No. 2
Exterior surface of doublers
Interior surface of
between

dry bay
extension and tip tank

Tip tank casting

LE~ -1135

EFFECTIVITY:

F4-6
F4-6

F4-4

Specifications Table
Figure 1(Sheet 1)

Finish

ALL

51-30-04

Page 1
SRM-4

Jun 1/95

Learjet
~Learjetl

STRUCTURAL REPAIR MANUAL


R.

FinishSpecifications (cont.)

NON-

CORROSION-

CORROSION-

RESISTANT

RESISTANT

STEEL

STEEL

ALUMINUM
Area between spars 7 and 8

F4-6

Wing Spar No.

F4-4

FIBERGLASS

Parts
In fuel

Attach

F4-4

area

In non-fuel

F8-4

F4-6

area

fittings

F4-6

Plumbing (3)
In fuel

F4-4 Ext

area

F4 Int.
In non-fuel

Throughout

F4-6

area

Aircraft

F17, F17-6,
orF20

Main Gear Wheel Well

F4-4

Battery Area

F4-4

F8-4

Structure Not Visible

F4-6

F8-6

Horizontal Stabilizer

F4-6

Tubing in Structure
Open

(2)

(2)

F4-6 Int.

F1-2 Int. 8

(4)

8 Ext.
Closed

F8-6 Ext.

Fl Int. 8
F4-6 Ext.

Fuselage

Fuel Cell

Engine Nacelle

(8)

F15 Int. 8
F8-6 Ext.

F4-6
F4-6 Int.

F8-6 Int.

Finish

Specifications Table
Figure 1 (Sheet 2)

EFFECTIVITY:

ALL

51-30-04

Page2
SRM-4

Jun 1/95

Learjet
STRUCTLIRAL REPAIR WIANUAL
FinishSpecifications (cont.)

B.

NONCORROSIONALUMINUM

RESISTANT
STEEL

F1 Ext. 8

FO-0-7

CORROSIONRESISTANT
STEEL

FIBERGLASS

Landing Gear Doors


Skin

F14-6 Int.
F8-6

F4-6 Ext.

Pan

8 Int.
Inside

Assembly

F8-6

FO-0-7

Tailcone Access Door


Skin

F4 Ext. 8

Pan

F4-6

Inside Assembly

FO-0-7

F4-6 Int.

Other

Hinged

Access

F4-6

F0-0-7

Doors

F4-6 Int. 8

Exterior Skins

F4 Ext.
Covered

fairings,

by attach angles

F4-1

(5)

F4a

(7)

etc.

Fuselage Area
Over wing, under floors,

F8-6

(9)

between frames 15 and 22

Specifications Table
Figure 1 (Sheet 3)

Finish

EFFECTIVITY:

ALL

51-30-04

Page
sRM-4

Jun 1/95

STRUCTURAL REPAIR MANUAL


NOTES:

(1) Add aircraft exterior finish per the appropriate Learjet Maintenance Manual.
(2) No interior finish is required on tubing closed by welding
(3) Except on plumbing lines that are beaded on the end, omit primer from exterior surfaces of plumbing
lines for

(a)
(b)
(C)
(d)

distance of 1 inch from end. Prime beaded lines end to end.

primer from connecting surfaces of welded bosses.


Where possible, protect to avoid removing anodized finish of fittings.
Omit primer from interior surfaces of oxygen lines and fire extinguisher lines.
Omit primer from plumbing lines less than 6 inches in length, unless they ate exposed
ceive a top coat.
Omit

(e) Omit primer from exterior surfaces of 1100-0 and 3003-0 aluminum

and

te-

tubing. Chemically clean in-

terior and exterior.

(4) Finish major structural parts

to F4-4.

Brackets, plumbing, and other easily replaced parts may be fin-

ished to F4-6.

(5) Mask off, clean, and prime surface


removable

fairings

that

are

not

fay

areas

of skin that

sealed in

are

to be covered

by

removable attach

angles or

place.

(6) Finish areas for lightning strike protection to Fl.


(7) As an option, apply Pro-Seal 890 (MIL-S8802) to fasteners that may

not need to be corrosion

proted-

by only using epoxy primer.


(8) Major structural parts installed in the battery area shall be finished to F8-4. After installation, all rivet
heads and any damaged areas shall be touched up with epoxy primer.
(9) After installation, all bolt heads and nuts and any damaged areas shall be touched up with epoxy
primer.
ed

EFFECTNITY:

ALL

51-30-04

Page 4
SRM~

Jun 1/95

Learj~t
~Learptl
STRUCTURAL REPAIR MANUAL
C.

FinishCode Number

DASH NUMBERS
Ist

I 2nd

I 3rd

DESCRIPTION
this part of finish given before (Assemblies).

Fo

No finish required (Detail Parts)

F1

Chemically

F2

(a)F1,

(b)Gritblast

F3

(a) F1,

(b) Anodize (Chromic Acid)

F4

(a) F1,

(b) Chemical Film

Colored Chemical Film

F5

(a) Fl,

(b) Chemical Film

Clear Chemical Film

F6

Apply Sanding

F7

(a) Fi,

(b) DichromateTreatment

F8

(a) F1,

(b) Cadmium Plate 0.0003

F9

(a) F1,

(b) Cadmium Plate

F10

(a) F1,

(b) Hard Chromium Plate

F11

(a) F1,

(b)

F12

(a) F1,

(b) Apply Manganese Phosphate Coating

F13

(a) Fl,

(b) Apply Zinc Phosphate Coating

F14

(a) Solvent Clean,

F15

(a) F1,

F16

Apply Hard Anodize

F17

(a) Fl,

F18

Natural Satin Finish (Stainless Steel)

F19

Natural Satin Finish

F20

or

clean.

Surfacer

to 0.0005

0.0002 to 0.0003

Decorative Chromium Plate per QQ-C320 Class

1.Type

(b) Apply Pretreatment Primer

(b) Apply corrosion preventive to interior surface


per Mll-A-8625,

Type

of closed end steel assemblies.

111

(b) Pickle and Passivate (300 Series Stainless Steels.)

(Aluminum Alloys)

(a) F1, Passivate Only

F21

Non-Directional Satin Finish

(Stainless Steel)

F22

Non-Directional Satin Finish

(Aluminum Alloys)

S100AR

(Low Electrical Resistance)

Finish Code Numbers

Figure 2 (Sheet 1)
EFFECTIVITY:

ALL

51-30-04

Page
sRM-4

Jun 1/95

Learjet
STRUCTURAL REPAIR MANUAL
C.

FinishCodeNumber (cont.)

DASH NUMBERS
Ist

2nd

3rd

DESCRIPTION

F23

Chemical Treatment of Lead

F24

Chemical

F25

(a) Fl,

(b)

F26

(a) Fl,

(b) Zinc Plate

F27

Pickle

only. (300 Series Stainless)

F28

Pickle

only. (Low Alloy Steel)

F29

(a) F1,

(b) Electropolish (Corrosion Resistant Steels)

F30

(a) Fl,

(B) Zinc-Nickel

F31

(a) Fl,

(B) Zinc-Nickel Plate

F32

(a) F1,

(B) Applly Non-Chromic Acid Anodize Per MIL-A-8625, Type IC

-O

This

Cleaning

and

Etching

of Aluminum Parts for

Bonding

Zinc Plate 0.0003 to 0.0005


0.0002 to 0.0003

Plate 0.0003 to 0.0005


0.0002 to 0.0004

part of finish previously indicated.

(Not Used)

-2

(Not Used)

(Not Used)

-4

Epoxy

-5

Apply

-6

Epoxy

-7

Corrosion

-8

Epoxy Primer (Light Green)

-10

No additional finish

Fuel Resistant and Corrosion Protection Finish


Solid Film Lubricant
Primer

Inhibiting

Metal Bond Primer

Flat Black

Topcoat (Urethane)

(Color

-2

Flat White

Topcoat (Urethane)

(Color No. 37875)

-3

Flat Red

Topcoat (Urethane)

(Color

No.

No.

37038)

31136)

Finish Code Numbers

Figure 2 (Sheet 2)
EFFECTIVITY:

ALL

51-30-04

Page 6
SRM-4

Tun1/95

STRUCTURAL REPAIR MANUAL


C.

FinishCodeNumber (cont.)

DASH NUMBERS
2nd

Ist

DESCRIPTION

3rd

-4

GlossBlack

-5

FlatBlack

-6

GlossGreen

(Color No. 17038)

Topcoat(Urethane)

Topcoat(Urethane)
of

(Identifioation

No.

37038)

(Color No.

141 1 0)

(Color

Epoxy EnamelTopcoat

Prototype Parts)

-7

GlossAluminum Topcoat (Urethane)

(Color

No.

17178)

-8

FlatGrey Epoxy EnamelTopcoat

(Color

No.

36118)

-9

Gloss Omaha

Orange Topcoat (Urethane) (Color


Parts)

No.

12473)

(Identification

of Slave

-10

No additional finish

-11

Gross White

-12

Gloss Red Topcoat (Urethane)

-13

Gloss Yellow

-14

Gloss Blue

(Color No. 17875)

Topcoat (Urethane)

(Color No. 11136)


(Color

Topcoat (Urethane)

No.

13655)

(Color No. 15180)

Topcoat (Urethane)

Finish Code Numbers

Figure 2 (Sheet 3)
3.

VAPOR DEGREASING
A.

Materials:

(1) 1,1,1
B.

Degreaser

trichloroethane

(methyl chloroform) inhibited, vapor degreasing (MIL-T-81533).

Procedure

(1) Rack parts so condensed solvent can drain freely from surfaces.
NOTE:

Parts shall be

(2) Parts shall

dry when introduced into degreaser to

not be introduced into

degreaser

Parts shall be left in vapors until clean

or

avoid water contamination.

unless the vapor level is up to the condensing coils.


no longer any condensation on the surfac-

until there is

es.

(3) Parts may be subjected

ing heavy

(4) Parts which


the

are

scrubbing

not clean shall be

action

or

sprayed

with cold solvent to aid in

dislodg-

recycled. Cooling

the

parts prior

to the second

cycle

increases

cleaning efficiency.

(5) Parts which require

EFFECTIVITY:

to some

films.

ALL

no

further

cleaning prior to painting shall not be handled with bare hands.

51-30-04

Page 7
SRM-4

Jun 1/95

Learjet
~Leariet

STRUCTURAL REPAIR MAMUAL


4.

SOLVENT CLEANING
A.

Use this

procedure to

clean the

(1) Parts covered with


(2) Parts
(3) Prior
(4) Prior
B.

following:
significant quantities of oil or grease.

to receive brush chemical film treatment.

application of top coat or touch-up, primed parts which have been sanded.
to application of wash primer, aluminum honeycomb parts, spot welded assemblies, anodized parts, and predominantly aluminum assemblies which include one or more steel parts.
Cleaning Procedure
(1) Wipe off excess oil and grease.
(2) Apply methyl ethyl ketone (MEK) (TT-M-261) from safety cans with clean, oil-free, absorbent
to

cloths.

(3) Scrub surface with a clean cloth, if necessary, to loosen the soil.
(4) Repeat applications of clean solvent as necessary to remove all soil.
(5) Wipe off solvent with clean, absorbent cloths. Do not allow solvent

to

dry

on

surface,

as a

resi-

due will remain.

(6) Blow assembled faring surfaces free of solvent with oil-free air.
(7) Solvent cleaned surfaces shall be dry and free of all visible soils. Iridescent surfaces
of
5.

improper cleaning and

shall be cleaned

are

evidence

again.

ABRASIVECLEANING OFMETALS
A.

General

Requirements

(1) Oily
sive

or

greasy parts shall be vapor

degreased

per

paragraph 3, Vapor Degreasing, prior

to abra-

cleaning.

(2) Parts shall be abrasively cleaned only immediately preceding final finishing to prevent corrosion.
(3) Significant surface defects shall not be removed by abrasive cleaning.
(4) Where a significant loss of metal cannot be tolerated and/or a smooth finish is required, a size
180 grit or finer abrasive shall be used. When heavy layers of dirt, scale, or oxides are to be removed and the surface is to receive

subsequent finishing

or

processing,

abrasive may be used for cleaning.


grit
be
used with either hand or power tools.
All
abrasives
(5)
may
their
within
be
Parts
must
(6)
original permissible tolerances after abrasive
150

metallic brush

or

size

or coarser

cleaning.

(7) Compressed air used for blowing off dust, drying parts, or for abrasive blast cleaning shall be essentially free from moisture, oil, and other foreign solid particles.
loose particles shall be removed from parts by a jet of air immediately upon completion of
All
(8)

cleaning. Care shall be exercised that surfaces adjoining the surface to be abrasively
are not impaired by any phase of the cleaning process.
Abrasive Cleaning with Papers, Cloths, Wools, and Brushes
(1) Abrasive cleaning of small areas shall be accomplished by using one of the applicable abrasives
indicated in Figure 1.
(2) During the life of an abrasive material, the abrasive material shall be used for the cleaning of one
class of materials only. The following classes of metals shall be used:
(a) Carbon and low alloy steel.
abrasive

cleaned

B.

(b) Corrosion resistant steels.


(c) Aluminum and aluminum alloys.
(d) Copper and copper alloys.

EFFECTIVITY:

ALL

51-30-04

Page 8
SRM-4

lun 1/95

Leariet
~j Learjet

STRUCTURAL REPAIR MANUAL


6.

CHEMICAL FILM TREATMENT OF ALUMINUM AND ALUMINUM ALLOYS

NOTE:
A.

Equivalent processes meeting the requirements of MIL-C-5541, Class 1A,

may be used.

Materials

(1) Turcoat Accelagold manufactured by Turco Products, Wilmington, California: 0.5

ounce per galTurcoat


of
2.0
0.5
to
ounce
lon of water. Maintain aging solution in the range
Accelagold per gallon of water with pi-I of 1.7 to 1.9. When the pH cannot be maintained in the specified range with

the addition of

required Turcoat Accelagold:

(a) Raise the pH by adding ammonium hydroxide.


(b) Lower the pH by adding nitric acid.
B.

Procedure
NOTE:

apply chemical film treatment to parts or assemblies having joints or crevices or any
type of configuration that will entrap solution unless those areas are positively

Do not

other

masked off.

(1) Vapor degrease all parts covered with significant quantities of oil

or

grease per

paragraph 3,

Va-

por Degreasing, or solvent clean per paragraph 4, Solvent Cleaning.

(2) Immerse parts in solution per step A. for 0.5 to 6.0 minutes at 400 to 1000F (4.40 to 370C).
(3) Rinse parts in room temperature water (40" to 1000F [4.4" to 370C1) and then in warm water (100"
to 1400F [370 to 600C1).
(4) Dry parts in still or circulating air in the temperature range of 60" to 1400F (15" to 600C).
CAUTION:

DO NOT WIPE PARTS FOR ANY REASON UNTIL THEY HAVE DRIED 24

HOURS.

(5) Apply required paint


CAUTION:

to treated surfaces within 12 hours after

drying.

HANDLE TREATED PARTS SO AS TO AVOID FINGERPRINTING PRIOR


TO PAINTING.

(6) Scratched or otherwise impaired small areas may be touched up as follows:


(a) Strip chemical film from area with a Scotch-Brite pad, or equivalent.
(b) Swab or brush small quantities of Turcoat Accelagold solution over the
duce

satisfactory

the chemical film, along the


produce a continuous film.

(c) Apply the solution


far

as

necessary to

(d) Using a sponge


(e) Dry the treated
600C).

EFFECTIVITY:

ALL

or

stripped

area

to pro-

chemical film.
over

brush rinse treated

area

in still

or

area

circulating

periphery

of the

stripped

area,

only

as

thoroughly with water.


air in the

temperature

range of 60" to 1400F (150 to

51-30-04

Page 9
SRM-4

Jun 1/95

STRUCTURAL REPAIR MANUAL


MATERIALS TO BE CLEANED
Carbon

Aluminum

Corrosion

Low

Alloy Steel

ABRASIVES

Its

Resistant Steel

Magnesium
Its Alloys

Alloys

Copper
Its Alloys

Acceptable

Acceptable

Acceptable

Acceptable

Acceptable

Recommended

Acceptable

Acceptable

Acceptable

Acceptable

Acceptable

Recommended

Recommended

Recommended

Recommended

Steel Wool

Acceptable

Prohibited

Prohibited

Prohibited

Prohibited

Aluminum Wool

Prohibited

Prohibited

Acceptable

Prohibited

Prohibited

Acceptable

Recommended

Acceptable

Prohibited

Acceptable

Recommended

Prohibited

Prohibited

Prohibited

Prohibited

Steel Brush

Acceptable

Recommended

Acceptable

Acceptable

Acceptable

Monel Brush

Acceptable

Acceptable

Recommended

Recommended

Recommended

Sandpaper
Emery Paper
or

Cloth

Aluminum Oxide

Paper

or

Cloth

Stainless
Steel Wool

Carbon Steel
Brush
Stainless

Abrasives and Their

Figure

Usage

MATERIALS TO BE CLEANED
Carbon

Corrosion

Low

Resistant Steel

Alloy Steel

TYPE OF GRIT

Aluminum

Aluminum

Alloys

Magnesium
Magnesium Alloy

Steel

Recommended

Prohibited

Prohibited

Prohibited

Silica

Acceptable

Acceptable

Acceptable

Acceptable

Garnet

Acceptable

Acceptable

Acceptable

Acceptable

Aluminum Oxide

Acceptable

Recommended

Recommended

Recommended

**Blast

cleaning permitted only

on

aluminum

or

magnesium alloy castings.

Blast

EFFECTIVITY:

SRM-I

ALL

Cleaning Grits
Figure 2
51-30-04

Page 10
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
7.

APPLYING SANDING SURFACER TO LAMINATED FIBERGLASS PARTS


A.

Materials

(1) Andrew Brown Co. system:


(a) P-900 Skyspar Surfacer
(b) C-903 Converter
(c) T-262 Thinner
(2) Bostik system:
(a) No. 464-3-1 Cat-A-Lac Hi-Build
(b) CA-142 Catalyst

Primer Surfacer

(c) TL-52 Thinner or methyl ethyl ketone (MEK)


(3) No. 49)(2 Neutral Patching Paste, Presto Chemicals Inc., Sun Valley, CA
(4) Toluene(TT-T-548)
(5) 320 grit abrasive paper (wet or dry)
B.

Surface

(1)
(2)
(3)
(4)
(5)
(6)
(7)

Preparation

dampened with toluene, thoroughly clean the laminated fiberglass surface.


produce a slightly roughened surface.
Clean sanding residue from the area with a clean cloth dampened with toluene.
Dry surface thoroughly.

With

clean cloth

Scuff sand the surface to

Mask off areas not intended to receive surfacer.

patching paste per manufacturers instructions.


Apply patching paste to surface with a plastic scraper to fill pin holes, dents, abrasions, scratches.
Squeegee away excess patching paste, leaving depressions filled flush with the surface.
(8) Allow patching paste to dry thoroughly.
(9) Sand patching paste smooth with 320 grit abrasive paper.
(10) Thoroughly clean the filled surface with a clean cloth dampened with acetone to remove sanding
Mix

residue.

(11) Dry surface thoroughly.


C.

Applicationof Sanding Surfacer


(1) Andrew Brown Co. System
one part converter. Stir thoroughly and allow mixture to
using.
(b) Thin as required with thinner for spraying.
(c) Spray a crosscoat of sanding surfacer on the prepared laminated fiberglass surface.

(a) Mix four parts surfacer with

sit

one

hour before

NOTE:

pot life of the mixed sanding surfacer is approximately


only the amount of material that can be used within this time.

The

(2) Bostik System


(a) Mix three parts surfacer with one part catalyst. Stir thoroughly.
(b) Thin catalyzed material to a viscosity of 25 seconds (No. 2 Zahn

24 hours.

Catalyze

cup) using Bostik thinner

or

MEK.

(c) Strain thinned material through suitable paint strainer prior to spraying.
(d) Spray a crosscoat of sanding surfacer on the prepared laminated fiberglass surface.
NOTE:

EFFECTIVITY:

SRM-4

ALL

The

pot life of the mixed sanding surfacer is approximately eight


only the amount of material that can be used within this time.

hours.

Catalyze

51-30-04

Page 11
Jun1/95

~Learjetl
STRUCTURAL REPAIR MANUAL
(3) Cure Andrew Brown Co. surfacer
Cure Bostik surfacer at

sanding.
can

be accelerated

by heating
sanding

(4) Wet sand the cured

at

temperature (60"F [15"C] or above) for 12 hours before


temperature for two to six hours before sanding; the cure

room

room

to 1000 to 1500F

surfacer in the

(370

to

650C) for

general

two to three hours.

direction of air flow with 320

grit

abrasive

paper.

(5) All surface imperfections, blemishes, and the


additional
to

8.

an

sanding

surfacer must be

absolute minimum while

applied

weave

to

completely obscured or
sanding surfacer thickness

of the fabric must be

imperfect

meeting the requirements

areas.

of this

Hold

step.

APPLYING EPOXYPRIMER
A.

Precautions

(1) The following precautions shall be adhered to when applying epoxy primer.
(a) Clean and proper equipment shall be used.
(b) The coating material shall be uniform, free of skins, lumps, gelled, or coarse particles.
(c) Suitable ventilation and safety precautions shall be provided in the work area.
(d) The finish area shall be free of dust and severe temperature change which will adversely af-

application and cure of the coating.


requirements listed for the coating shall be strictly maintained.
(f) Every attempt shall be made to produce a lint free, smooth, good quality finish.
fect the

(e) Thickness
B.

Material

(1) Super Koropon Fluid Resistant Primer, Green; Mfg.: Desoto, Inc., Garland, TX
(a) 515)(400 Primer Base
(b) 910)<350 Curing Agent
Resistant Primer, Green; Mfg.: Akzo Coatings, Inc., Orange, CA
Corrosion
(2)
Primer Base
463-12-8
(a)
CA-116
(b)
Catalyst
(c) TL-52 Reducer (Normal Temperature) (Ambient temperature of 90"F [32.2"C] or lower)
(d) TL-65 Reducer (High Temperature) (Ambient temperature of 90"F [32.2"C] or higher)
C.

Surface

Preparation

(1) Treat detail aluminum parts with anti-corrosion chemical film.


(2) Touch-up anti-corrosion chemical film on aluminum surfaces.
(3) Treat welded (spot or fusion) assemblies with exposed or unsealed faying surfaces, assemblies
with parts that were not chemical filmed, anodized parts over 24 hours old, parts which are inconvenient to chemical film treatment,

or

treatment

primer.

NOTE:

Epoxy primer must be applied

parts and assemblies that might trap solution with pre-

within four (4) hours after

pretreatment primer applica-

tion.
D.

Application
(1) Thoroughly mix curing solution into primer and allow to stand a minimum of 30 minutes before
applying or thinning.
(a) Mixing Green Super Koropon Fluid Resistant Primer by Desoto, Inc.
1) Mix one (1) volume of curing agent into one (1) volume of primer base.
2) Thorough stirring with a paddle is sufficient agitation after mixing base and curing
agent.
3)

Methyl ethyl
sprayability.

ketone (MEK) may be used

as a

thinner. Thin up to 10%

(by volume)

for

LES1091U

EFFECTIVITY:

ALL

51-30-04

Page
SRM-4

12

Jun 1/95

~j Learjet
STRUCTURAL REPAIR IVIANUAL
(b) Mixing Green Corrosion Resistant Primer by Akzo Coatings, Inc.
1) Mix one (1) volume of catalyst into one (1) volume of primer base.
2) Thorough stirring with a paddle is sufficient agitation after mixing base and catalyst.
3) Reducer may be used as a thinner. Thin up to 10% (by volume) for sprayability.
(2) Unused mixed material over eight (8) hours old must be discarded.
(3) All surfaces shall be thoroughly dry before receiving primer.
(4) Apply a spray coat of mixed primer to give a dry film thickness of 0.0006 to 0.0012 inch (0.6 to 1.2

mils).
Film thickness may be measured by masking and test painting a bare piece of aluminum and measuring the difference in thickness between bare and painted areas

NOTE:

with

precision micrometer.

Adjust spray pattern or primer viscosity to adjust dry film thickness.


(5) Allow primer
NOTE:

to air

Drying

dry a minimum of two (2)

time

minutes (to

can

be reduced

hours before

applying top coat.

by, allowing primer

prevent flash-off).

to

dry

at

room

Then bake at 1300 to 1500F for

temperature

approximately

for 20

30 min-

utes.

(6) Primer Appearance


a) The cured primer shall be continuous and have a smooth and uniform appearance, free from
soils and contamination, sags, runs, blisters, overspray, and orange peel when visually in-

spected without magnification.


NOTE:

b)

Coatings Corrosion Resistant Primer at ambient temperatures of 90"F (32.2"C) or higher, excess surface roughness caused by too rapid drying of primer may be eliminated by using high temperature reducer TL-65.
When

applying

Akzo

Slight roughness, silking, beads,

sags, and orange peel are not a cause for rejection on


factor. Thickness in local area of such beads, runs, or sags

runs,

surfaces where appearance is not a


shall not exceed the maximum allowable film thickness
9.

by more than 0.001 inch (1 mil).

APPLYINGSOLID DRYFILMLUBRICANT
A.

Materials

(1)
(2)
(3)
(4)
B.

Everlube 620-C manufactured

Ethyl

by Everlube Corp., North Hollywood, CA

alcohol

TuIuol(TT-T-548)

Methyl.ethyl ketone (MEK)


Surface Preparation
(1) Aluminum and aluminum alloys: apply chemical film

treatment per

paragraph 6,

Chemical Film

Treatment.

(2) Ferrous alloys:


(a) Stainless steels: vapor degrease per paragraph 3, Vapor Degreasing,
agraph 6, Chemical Film Treatment.

EFFECTIVITY:

ALL

or

abrasive clean per par-

51-30-04

Page 13
SRM-4

Jun 1/95

STRUCTURAL REPAIR MANUAL


C.

Application
(1) Apply dry

dry surface immediately following surface preparation per step B.


handling parts.
gloves
(2) Dry film lubricant can be applied by spraying, brushing, or dipping. Prepare Everlube 620 for
spraying by thinning one part 620 with three parts thinner. Prepare Everlube 620 for brushing or
dipping by thinning one part 620 with two parts thinner. Prepare thinner by mixing 50 percent
ethyl alcohol with 50 percent toluol prior to introducing thinner into Everlube 620.
(3) Apply dry film lubricant to achieve an even film thickness of 0.0002 to 0.0005 inch (mm) that is
smooth, free of runs, lumps, blisters, and dirt particles, and is continuous over its entirety.
Touching up scratches or areas not having the required thickness is not permissible.
Baking
(1) Air dry parts a minimum of 15 minutes prior to baking. Baking is required to make the finished
coating insoluble in solvents. Bake aluminum and aluminum alloy parts for one hour at 3000F
(149"C). Bake ferrous alloys, stainless steels, and cadmium plated steel one hour at 3750F (190"C).
Stripping
(1) Parts which have had the dry film lubricant application and have not been baked can be stripped
of the dry film lubricant by immersing the part in MEK and scrubbing with a non-metallic brush.
(2) Parts which have had the dry film lubricant application and have been baked can be abrasively
stripped per paragraph 5, Abrasive Cleaning of Metal, and pretreated per step B.
him lubricant to

Wear clean, cotton

D.

E.

while

10. APPLYING FUEL RESISTANT AND CORROSION PROTECTION FINISH

A.

Materials

(1) Epoxy Fuel Resistant and Corrosion Protection Coating Bostik-Finch


(a) No. 454-4-1 Base
(b) CA-109 Catalyst
(c) TL-52 Thinner
(2) Polyurethane Fuel Resistant and Corrosion Protection Coating DeSoto Chemical
(a) 823-707 Coating

Coatings, Inc.

(b) 910-702 Catalyst


(c) 020-707 Solvent Reducer
(3) Spray Guns and Accessories
(a) Binks Model 18 with 66SD Air Cap, 66 Fluid Tip, and 65 Needle

Cap, 66 Fluid Tip, and 65 Needle


Cap, 67A Fluid Tip, and 18 Needle
(b) Binks Model 19 with 66SE Air Cap, 66 Fluid Tip, and 15 Needle
66SD Air Cap, 66 Fluid Tip, and 15 Needle
67SA Air Cap, 67A Fluid Tip, and 18 Needle
Surface Preparation
(1)
alloy surfaces: apply chemical (ilm heatment per paragraph 6,Chemical
66SE Air

67SA Air

B.

Film Treat-

L~S1079

EFFECTIVITY:

ALL

51-30-04

Page 14
SRM-4

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


C.

Coating Preparation
(1) Epoxy Coating Preparation
(a) Stir base component with a paddle to reincorpoate settled pigment.
(b) Agitate base for at least 10 minutes on a vibrating paint mixer or box the base component
times to

ensure a

homogeneous solution.

One "box" is defined

NOTE:

six

as

pouring

the entire contents of

container into another

empty container.

Properly agitated base component will remain homogeneous for approximately three hours. If the base component is not used immediately after the recommended initial agitation, but is used within three hours, the base component
shall be thoroughly stirred with a paddle to reincorpoate any pigment or material that has settled. After three hours settling, stirring is not sufficient agitation; repeat the recommended initial agitation.
(c) Shake catalyst vigorously by hand
CAUTION:

to achieve sufficient

agitation.

DO NOT USE ANY TYPE OF CONTAINER WHICH IS LINED WITH AN

ORGANIC COATING FOR MEASURING BASE, CATALYST, OR THINNER. USE OF PAPER CONTAINERS IS STRICTLY PROHIBITED.

(d) Mix three volumes of base and one volume of catalyst, thoroughly stirring with a paddle.
(e) If thinning is absolutely necessary, thin as required up to one part thinner to one part mixed

coating.
After mixing and thinning, age mixture a minimum of 45 minutes before use.
(g) Discard unused mixed material over eight hours old.
(2) Polyurethane Coating Preparation
(a) Agitate base for at least 10 minutes on a vibrating paint mixer.
(f)

NOTE:

Properly agitated coating will remain homogeneous for approximately three hours.
If the coating is not used immediately after the recommended initial agitation, but
is used within three hours, the coating shall be thoroughly stirred with a paddle to
reincorpoate any pigment or material that has settled. After three hours settling,
stirring is not sufficient agitation; repeat the recommended initial agitation.

(b) Shake catalyst vigorously by hand


CAUTION:

to achieve sufficient

agitation.

DO NOT USE ANY TYPE OF CONTAINER WHICH IS LINED WITH AN

ORGANIC COATING FOR MEASURING COATING, CATALYST, OR


SOLVENT REDUCER. USE OF PAPER CONTAINERS IS STRICTLY PROHIBITED.

(c)
(d)
(e)
(f)

EFFECTIVITY:

catalyst to four volumes of coating, thoroughly stirring with a paddle.


required up to one part solvent reducer to one part mixed coating.
After mixing and thinning, age mixture a minimum of 30 minutes before use.
Discard unused mixed material over eight hours old.

Add

one

Thin

as

ALL

volume of

51-30-04

Page
SRM-I

15

Jun 1/95

STRUCTURAL REPAIR MANUAL


D.

Application
(1) Using the
at

recommended spray gun air cap, fluid tip, and needle, apply coating with air pressure
psi (206 to 344 kPa) to achieve a dry film thickness of 0.0008 to 0.0012 inch (mm).

gun of 30-50

Ambient

NOTE:

85

temperature

percent

or

All surfaces shall be


To

ensure

soon as

shall be 60"F t15"C)

below when

that all

possible

coating

is

or

above and relative

humidity

shall be

applied.

thoroughly dry before receiving finish coating.

areas

to be coated are

after surface treatment

free from

foreign

matter,

apply coating

as

operations.

(2) Cure the finish prior to subjecting the part to service. Cure finish a minimum of 24 hours at a
temperature above 73"F t22"C) or as follows:
(a) Allow finish to dry a minimum of six minutes at room temperature to allow solvent flash-off.
Bake polyurethane finish at 1300 to 2300F (54" to llO"C) for approximately 20 minutes.
finish to dry a minimum of six minutes at room temperature to allow solvent flash-off.
Allow
tb)
Bake epoxy primer at approximately 120"F (48"C) for approximately eight hours.
(3) Measure for ultimate cure by rubbing the coating with a gauze pad wet with MEK for 50 double
strokes with moderate pressure. No bare metal is to be

exposed.

11. PROTECTION FOR DISSIMILAR METAL CONTACT


A.

Dissimilar metals

(1) Group
(2) Group

I
II

are

defined

as

follows:

Magnesium alloys; aluminum alloys 5052, 5056, 5356, 6061, and 6063; tin.
Aluminum, aluminum alloys tall), zinc, cadmium tin, stainless steel tactive),

tin lead

tsolder), and titanium.


(3) Group III Zinc, cadmium, steel, lead, tin, stainless steel tactive), nickel and its
tsolder), and titanium.
(4) Group IV Copper and its alloys, nickel and its alloys, chromium, stainless steel
silver, and titanium.
Metals classified in the

NOTE:

same

group

are

considered similar to

sified in different groups are considered dissimilar to


to is the metal on the surface of the part.
B.

one

one

alloys,

tin lead

(passive), gold,

another. Metals clas-

another. The metal referred

Procedure

(1) Dissimilar metal mating parts used in


tion

as

faying

surface

application

shall receive corrosion

protec-

follows:

ta) Faying surface mating parts that have been epoxy primed require
NOTE

Epoxy primer

used for

no

further treatment.

faying surface dissimilar metal protection


a fingernail) prior to assembly.

must be cured

tcannot be indented with

tb) Apply Pro-Seal 890, tMIL-S-8802) using


ous

EFFECTIVITY:

sufficient

quantity of material to provide a continuexposed edge of the mating joint.

uniform extruded bead of sealant all around the

ALL

51-30-04

Page
SRM-4

16

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL

FASTENERS-GENERAL

1.

GENERAL
A.

The fasteners used in this aircraft are, for the most part, the conventional fixed and removable types.
However, specific instructions concerning fasteners in the repair illustrations should be strictly ob-

served. Unless otherwise noted in this manual, the minimum fastener edge distance is two fastener
diameters from the center of the hole to the edge of the material, and minimum spacing is 6 fastener
diameters.
B.

Bolts, washers, nuts, and

C.

Conventional rivets and

D.

shall be installed per 51-40-01.


fasteners shall be installed per 51-40-02.
For fastener substitutions refer to 51-40-03.
screws

specially installed

countersinking of rivets and

E.

For

F.

Fastener Selection

associated hardware refer to 51-40-04.

Rivet diameter must

normally

be between three and five times the thickness of

greater than 1/4 the width of an attachment flange. In skin and


web repairs it is best to match the type and size of fastener with those in use in the general area. Blind
fasteners may be used only where repair with solid fasteners is not possible.
the thinnest material riveted and not

EFFECTIVITY:

ALL

52-40-00

Page
SRM-4

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


THREADED FASTENERS
i.

TORQUINGTHREADED FASTENERS
A.

B.

C.

D.

E.

Torquing of bolts is required to provide security of installation and prevent overstressing of components during installation. Bolts, screws, or nuts not having a specific torque requirement shall be
tightened in accordance with good aircraft practice to approximate the torque values as specified in
Figure 1.
When drag torque is referred to, it is defined as the torque required to turn a self-locking nut on the
threads of a bolt. Drag torque is added to the required torque value.
When shank friction is referred to, it is defined as the torque required to turn a bolt within a snug fitting hole. Shank friction is normally added to the required torque value when it is necessary to
torque the fastener from the head end. Measure shank friction using a torque wrench.
Wrench torques shown in Figures 1 thru 6 are for clean, non-lubricated parts. Any lubricant accumulations on threads shall be removed by suitable means. Lubricants other than that on the fastener as
purchased shall not be added unless specified in specific repair procedures. When threads are
greased, decrease torque values by 10 percent. When threads are cadmium plated or lubricated with
graphite or molybdenum disulfide, decrease torque values by 15 percent.
Bolts and
bolts and

which do not have the nut accessible, are installed in nutplateq or have threads not
Figure 6 normally are not torqued, but shall be drawn down tight. Exceptions to this are

screws

included in

screws

used in the fuel

system

to

secure access

Maintenance Manual

or
appropriate Learjet
Impact tools or tools with ratcheting clutches should

H.

fied torque.
Sheet metal

screws

shall not be

panels, fuel probes, and fuelpumps.


specific torque values.

Refer

Service Manual for

F.

to the

not be used in

any installation

requiring a speci-

torqued, but shall be drawn down tight.

INSTALLING THREADED FASTENERS AND WASHERS


A.

InstallBolts

(1) Bolts 1/4-inch diameter

locking

or

less which

are

drilled for cotter

pins

shall not be installed

using

self-

nuts.

(2) When installing bolts,

ensure

that the threads are free of foreign material. Do not


in the specific instructions.

use

anti-seize

compounds or lubricants unless specified


B.

InstallNuts

(1) When installing castellated

nuts for use with

safety

wire

or

cotter

pin, align

holes

by tightening

torque range and continue to tighten until holes align. If holes cannot be aligned without exceeding the maximum torque value, a washer of different thickness may be used or another
nut to low

washer added.

self-locking nuts, always use the same type nut as removed. Self-locking nuts
shall not be substituted for castellated nuts, secured by safety wire or cotter pin. Fiber or nylon
self-locking nuts shall not be used in areas subject to high temperature. Check break away torque

(2) When installing

on

C.

used

self-locking nuts prior to use.

Install Washers (See

Figure 7.)

a lockwasher against aluminum alloy, a cadmium-plated flat washer shall be installed between lockwasher and aluminum alloy to prevent damage to the aluminum alloy. On
magnesium alloys, use an NAS1252 flat washer under the lockwasher to prevent corrosion be-

(1) When installing

tween dissimilar metals.

(2) The

use

of wrong 4pe

or

number of washers

can

result in

improper preloading

of the bolts when

torqued.

LES ImbL

EFFECTIVITY:

ALL

51-40-01

Page
sahc4

Jun 1!95

Learjet

STRUCTU RAL REPAIR MANUAL


(3) When bolts

are

used which have

radius under bolt head,

with the countersink next to the radius under the bolt head.

installing a
3.

standard washer

can

counter-sunk washer must be used

Reversing

countersunk washer

or

result in bolt failure.

INSPECTINGTHREADED FASTENERS
A.

InspectNutsand

Bolts

(1) Bolts shall extend

through

the

self-locking portion of self-locking nuts. Rounded or chamfered


Flat end bolts shall extend at least
or chamfer through nut.

ends shall extend at least full round

1/32 inch through

nuts.

(2) Drilled hole in bolts for

use

with castellated nuts shall not extend

more

than 1/2 diameter of hole

above nut.

(3) When reusing


vice.
mum

4.

self-locking nuts, ensure that gripping power is sufficient so as not to loosen in serNuts which thread onto bolt easily shall be discarded. Gripping power must meet minibreakaway torque requirements per MIL-N-25027.

TORQUE WRENCHES (See Figures 1 thru 6.)


following standard torque wrench practices shall be followed when torquing nuts and bolts.
(1) Whenever possible, the nut shall be torqued. When it is necessary to torque the fastener from the
head end, increase the maximum torque value by an amount equal to the shank friction. The
shank friction shall be measured by a torque wrench.
(2) Calibrate torque wrenches periodically per local regulations to ensure accuracy.
(3) Take final torque reading while nut is rotating. If highest torque value is reached without rotat-

USING
A.

The

ing the nut, the nut must be backed off and retorqued.
torquing requires the use of an adapter, the torque value must be computed using the formula in Figure 6 or the appropriate decimal figure in Figure 3.
(5) When an adapter and a universal socket extend the wrench length at an angle, the correct torque
is obtained by consulting Figure 4 for a torque reading which is multiplied by a factor for the
adapter obtained from Figure 3.
(6) When using a "pre-set" torque wrench, the load shall be applied gradually until the wrench gives
its indicating snap. The load must be immediately removed at this time. The snapping of the
wrench does not prevent additional torque being applied if more pressure is applied to the han(4) When

die.

EFFECTIVITY:
SRM~

ALL

51-40-01

Page 2
May 25/92

Learjet
Learjet

STRUCTURAL REPAIR IWANUAL


TORQUE RANGE

(Inch-Pounds)

SIZE OF NUT,
BOLT, OR

TENSION TYPE NUTS

SMEAR TYPE NUTS

SCREW

TYPICAL EXAMPLES:

TYPICAL EXAMPLES:

MS20365 8 MS21045

MS20384

MS20365

MS21245

OR

OR

MS20364

AN310

AN320

8-32

12-15

7-9

32

20

25

12-15

70

10

1/4-28

50

30

40

5/16

24

100

140

60

85

3/8

24

160

190

95

110

7/16

20

450

500

270

300

1/2

20

480

690

290

410

9/16-18

800

1000

480

600

5/8-16

1100

1300

660

780

2300

2500

2500

3000

3/4-16

7/8

14

1-14

3700

5500

1-1/8-12

5000

7000

1-1/4

9000

11000

12

1
1
1

1300

1500

1500

1800

2200

3300

3000

4200

5400

6600

Torque Values

Figure 1

MINIMUM BREAKWAY

SIZE OF

NUT,
BOLT, OR

TORQUE VALUE

8-32

1.5 inch-Pounds

10-32

2.0 inch-Pounds

3.5 Inch-Pounds

1/4

28

5116

24

3/8

24

9.5 Inch-Pounds

7/16

20

14.0 Inch-Pounds

1/2-20

6.5 Inch-Pounds

9/16 -18

NOTE:

LFS 1036L

EFFECTIVITY:

18.0 Inch-Pounds

24.0 Inch-Pounds

32.0 inch-Founds

5/8

16

314

16

7/8

14

70.0 inch-pounds

1-14

92.0 Inch-Pounds

50.0 Inch-Pounds

Replace nuts which fall below values shown for


unscrewing nut from bolts.

Torque Values for Self-Locking Nuts


Figure 2
ALL

51-40-01

Page 3
SRM-4

Jun 1/95

Learjet
STRUCTU RAL REPAIR MANUAL

ADAPTER LENGTHS
APPROX.
LENGTH

OVER

OVER

OVER

OVER

OVER

OVER

OF

1"

1-5/8"

2-3/8"

3-118"

3-7/8"

4-5/8"

53/8"

TORQUE

THRU

THRU

THRU

THRU

THRU

THRU

THRU

ARM

1-5/8"

2-3/8"

3-1/8"

3-7/8"

4-5/8"

5-3/8"

6"

7"

.85

.77

.71

.66

.61

.57

.54

9-1/2"

.89

.83

.78

.74

.69

.67

.64

13-1/2"

.91

.87

.83

.79

.76

.73

.70

24"

.95

.92

.90

.87

.85

.83

.81

NOTE:

Multiply the required torque by the

decimal

figures given in this

table to obtain the actual wrench

reading.

Adapter Use Torque Values


Figure 3
EFFECTIVITY:
SRM-4

ALL

51-40-01

Page 4
May 15/92

Learjet
STRUCTU RAL REPAIR MANUAL

DIAL MUST READ

WITH UNIVERSAL HELD AT THESE ANGLES

TO OBTAIN A

TORQUE OF IN. LBS.


OR FT. LBS.

100

20"

30"

40"

45"

50"

60"

10

10.2

10.7

11.5

13.1

14.1

15.6

20.0

20

20.4

21.4

23.0

26.2

28.2

31.2

40.0

30

30.6

32.1

34.5

39.3

42.3

46.9

60.0

40

40.8

42.8

46.0

52.4

56.4

62.4

80.0

60

61.2

64.2

69.0

78.6

84.6

93.6

120.0

81.6

85.6

92.0

104.8

112.8

124.8

160.0

100

102.0

107.0

115.0

131.0

141.0

156.0

200.0

120

122.4

128.4

138.0

157.2

169.2

187.2

240.0

140

142.8

149.8

161.0

183.4

197.4

218.4

280.0

180

183.6

192.6

207.0

235.8

253.8

280.8

360.0

200

204.0

214.0

230.0

262.0

282.0

312.0

400.0

220

224.4

235.5

243.0

288.2

310.2

343.5

440.0

240

244.4

256.8

276.0

314.4

338.4

374.4

480.0

260

265.2

278.2

299.0

340.6

366.6

405.6

520.0

280

285.6

299.6

312.0

366.8

394.8

436.8

560.0

300

306.0

321.0

345.0

392.0

423.0

468.0

600.0

320

326.4

342.4

368.0

419.2

451.2

499.2

640.0

340

346.8

363.8

391.0

445.4

479.4

530.4

680.0

360

367.2

385.2

414.0

471.6

507.6

561.6

720.0

380

387.6

406.6

437.0

497.8

535.8

592.8

760.0

400

408.0

428.0

460.0

524.0

564.0

624.0

800.0

420

428.4

449.4

483.0

550.2

602.2

655.0

840.0

440

448.8

470.8

506.0

576.4

620.4

686.4

880.0

460

469.2

492.2

529.0

593.6

648.6

717.6

920.0

480

489.6

512.6

552.0

628.8

676.8

748.8

960.0

500

510.0

535.0

575.0

655.0

705.0

780.0

1000.0

80

Torque Values
Figure 4

Universal Socket Use

EFFECTNITY:
SRM4

ALL

51-40-01

Page 5
May 15/92

Learjet
STRU,CTURAL REPAIR MANUAL

TORQUE WRENCH TOLERANCES

(Inch-Pounds)
APPLIED TORQUE

NOTE:

TOLERANCES

APPLIED TORQUE

TOLERANCES

4-

350

340-

363

10

9-

11

400

388-

414

15

14-

16

450

437-

465

20

19-

23

500

485-

517

25

24-

28

600

582-

620

30

29-

33

700

679-

723

40

39-

43

750

728-

775

50

49-

54

800

776-

826

60

58-

64

900

873-

929

70

68-

74

1000

80

78-

84

1100

1067

90

87-

95

1200

1164 -1238

100

97-105

1300

1261-1341

970 -1032
1135

125

121

131

1400

1358

1444

150

146

157

1500

1455

1547

200

194

208

1600

1552

1650

250

243

260

1700

1649

1753

300

291

311

1800

1746

1856

Tolerances for ft-lbs shall be

L~Slm6L

plus

or

minus 3%

plus

2 ft-lbs for all ranges.

Torque Wrench Tolerances

Figure 5

EFFECTIVITY:
sRM-4

ALL

51-40-01

Page 6
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

Wrench

Drive
Centerline

Open-End
Adapter

Torque
Wrench

Adapter

Wrench

Handgrip

Drive

Centerline

Centerline

(Predetermined)
Ek-----L

i*

Short

Open End

Wrench
FORMULA

Adapter

TxL,
L+E

EXAMPLE

(WITH "E"

AS

Torque Required

Yield

10.0

Length

Extension

135

10

135

In.-Lb.

(Adapted Torque)

DIMENSION)

PLUS

117

Unknown

Flare

In.

Nut

Wrench

Adapter

by Adapter
10

1350

1.5

11.5

1.5

In.

117.39

Spanner sJrench

In.-Lb.

Adapter

Setscrew
NOTE:

If

it

1800
comes

is
as
a

necessary

shown

to

attach

in Detail

A,

adapter drive

then

Adapter

be-

negative number.

Hose

Clamp

Adapte r

Torque Wrench Adapter Formulas


Figure 6

EFFECTIVITY:
SRM-4

ALL

51-40-01

Page 7
May 15/92

Learjet I
STRUCTURAL REPAIR MANUAL

Countersunk Washer

Countetsunk Washer

Standard Washer

Install washer with countersunk

face

next

to

bolt

head

radius

(INCORRECT)

tconnEcT)

Washer Installation

Figure

EFFECTIVITY:
SRM4

ALL

51-40-01

Page 8
May 15/92

Learjet I
E~ Ledriet

STRUCTURAL REPAIR MANUAL


RIVETS AND BLIND FASTENERS

i.

DESCRIPTION
A.

Rivets and
a

variety

specially installed

fasteners used

on

of materials suitable to the materials

this aircraft include conventional solid rivets made of

they join, mechanically expanded

blind rivets, Huck

lockbolts, Huck bolts.


(1) Rivet Failures
(a) Generally speaking, the design of riveted joints is based

on

the

theory

that the total

joint

whole group of rivets. It is then


sum
strengths
strengthis simply
obvious that, if any one rivet fails, its load must immediately be carried by others of the
group; if they are unable to carry this added load, progressive joint failure then occurs. Stress
the

concentrations will

of the individual

of

usually cause one rivet to fail first; and careful analysis of such a rivet in a
highly loaded, with the possibility that neighboring riv-

joint will indicate that it has been too


ets may have partially failed.

perhaps the most common rivet failure. It is simply a breakdown of the rivet
acting along the plane of two adjacent sheets, causing a slipping action which
by
be
severe enough to cut the rivet shank in two. If the shank becomes loaded beyond the
may
yield point of the material and remains overloaded, a permanent shift is established in the
sheets and the rivet shank may become joggled.
(C) If the rivet is excessively strong in shear, bearing failure occurs in the sheet at the edge of the
rivet hole. The application of large rivets in thin sheets brings about such a failure. In that
case, the sheet is locally crushed or buckled, and the buckling destroys the rigidity of the
joint. Vibrations, set up by engine operation or by air currents in flight, may cause the buckled portion to flutter and the material to break off close to the rivet head. If buckling occurs at
the end of the sheet, a tear-out may result. In either case, replacement of the sheet is neces-

(b) Shear failure is


shank

forces

sary.

complex loadings occurring at a joint, causing stresses of tenThe head may fail by shearing through the area cofieapplied
thicker
in
the
rivet
sheets, it may fail through a prying action which
to
shank,
or,
sponding
head distortion is cause for replacement. This
visible
itself.
head
of
the
failure
causes
Any
latter type of head failure is especially common in blind rivets.
(2) RivetInspection
(a) To obtain high structural efficiency in the manufacture and repair of aircraft, an inspection
(d) Head failure may result from
sion to be

to the rivet head.

part is put in service. This inspection consists of examinheads and the surrounding skin and structural parts for
manufactured
and
shop
ing
deformities. A scale or rivet gage can be used to check the condition of the upset rivet head
to see that it conforms to the proper requirements. Deformities in the manufactured head can

must be made of all rivets before the

both the

by the trained eye alone. However, on flush rivets, a straightedge can be used as
Figure 1.
Cb) Some common causes of unsatisfactory riveting are improper bucking, rivet set slipping off
or being held at the wrong angle, and rivet holes or rivets of the wrong size. Additional causes for unsatisfactory riveting are countersunk rivets not flush with the well; work not properly fastened together during riveting; the presence of burrs, rivets too hard, too much or too
little driving; and rivets out of line.
be detected

shown in

EFFECTIVITY:

ALL

51-40-02

Page 1
May 15/92

STRUCTURAL REPAIR MANUAL


(c) Occasionally, during

an

aircraft structural

repair,

it is wise to examine

adjacent parts

to deter-

doing so, it may be necessary to remove the


neighboring
cracked
of
The
paint around the heads may indicate shifted or
chipped or
paint.
presence
loose rivets. Look for tipped or loose rivet heads. If the heads are tipped or if rivets are loose,
rivets. In

mine the true condition of

will show up in groups of several consecutive rivets and will probably be tipped in the
same direction. If heads which appear to be tipped are not in groups and are not tipped in

they

direction, tipping may have occurred during some previous installation.


(d) Inspect rivets known to have been critically loaded, but which show no visible distortion, by
the

same

carefully punching out the shank. If, upon examination, the shank
misaligned, the rivet has failed in shear. In that
appears joggled
what
the
determine
is
shearing stress and take the necessary corrective accase, try to
causing
head
that
show
rivets
tion. Flush
slippage within the countersink or dimple, indicating either
sheet bearing failure or rivet shear failure, must be removed for inspection and replacement.
(e) Joggles in removed rivet shanks indicate partial shear failure. Replace these rivets with the
next larger size. Also, if the rivet holes show elongation, replace the rivets with the next larger size. Sheet failures (such as tear-outs, cracks between rivets, and the like) usually indicate
damaged rivets, and the complete repair of the joint may require replacement of the rivets
with the next larger size.
(f) The general practice of replacing a rivet with the next larger size (1/32 in. greater diameter) is
necessary to obtain the proper joint strength of rivet and sheet when the original rivet hole is
enlarged. If the rivet in an elongated hole is replaced by a rivet of the same size, its ability to
carry its share of the shear load is impaired and joint weakness results.
(g) Loose fasteners must be replaced. They may be shown by the following situations:
drilling

off the head and

and the holes in the sheet

1)
2)

The fastened material

moves

relative to the fastener. Skin deflection is evident.

Tipping of the fastener head may indicate its


rolled upward also indicates looseness.
A black

3)

or

loosening or slippage.

Rivet head

dark gray stain is found adjacent to or around the fastener head.


a dirt or oily streak aft of the loose fastener.

periphery

Generally,

it

takes the form of

4)

Mark

B.

When
its

removing a

red line

across

the fastener head and the

rivet for

adjacent

material. Check the line at the

of the fastener will break the line

replacement (see Figure 2), be very careful

so

as

indicated in

Figure

1.

that the rivet hole will retain

shape and replacement with a larger size rivet will not be necessary. If the rivet is
properly, the strength of the joint may be weakened and the replacement of rivets made

size and

original

not removed
more

inspection. Any loosening

next

difficult.

a rivet, work on the manufactured head. It is more symmetrical about the shank
and there will be less chance of damaging the rivet hole or the material
head,
shop
around it. To remove rivets, use hand tools, a power drill, or a combination of both. The pre-

(1) When removing


than the

ferred method is to drill


drift

punch. First, file

the flat surface for

through
flat

the rivet head and drive out the remainder of the rivet with

drilling.
depressing the metal. The dimple in 2117-T
and center punching the rivet head.

punch
avoid

(2) Select

drill

power drill,

one

on

head, while

EFFECTTVITY:

ALL

rivets

usually eliminates

the

necessity

size smaller than the rivet shank and drill out the rivet head.

set the drill on the rivet and rotate the chuck several revolutions

When

of

filing

using

This

51-40-02

Page
SRM-I

hand before turn-

by
procedure helps the drill cut a good starting spot and eliminates the
slipping off and tracking across the metal. Drill the rivet to the depth of its
holding the drill at a 900 angle. Be careful not to drill too deep because the rivet

the power.
chance of the drill

ing

the manufactured head of any non-flush rivet, and center


Back up the rivet on the upset head when center punching to

area on

May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


shank will turn with the drill and cause a tear. The rivet head will often break away and climb
the drill, which is a good signal to withdraw the drill. If the rivet head does not come loose of its
own

accord,

comes

insert

drift

into the hole and twist

slightly

to either side until the head

punch slightly smaller than the diameter of the shank.


driving out the shank. If the shank is exceptionally
bucking
Support
drill
the
rivet about two-thirds of the way through the thickhead
is
the
rivet
after
removed,
tight
ness of the material and then drive out the remainder of the rivet with a drift punch.
The procedure for the removal of flush rivets is the same as that just described except that no filing is necessary. Be very careful to avoid elongation of the dimpled or the countersunk holes.
The rivet head shall be drilled to approximately one-half the thickness of the top sheet.

(3) Drive

out the shank of the rivet with a drift

the sheet with

(4)

punch

off.

bar while

Figure 3.

C.

For details of rivet codes and blind

D.

Holes and countersinks for rivets and blind fasteners shall be created within tolerances

Figures

fasteners,

see

specified

in

4 thru 13.

(1) In repairs where edge distance has

not been established

by previous installations,

the

following

shall be not less than 1.5 times the rivet diameter


apply:
for universal head rivets and 2 times the rivet diameter minus 0.03 inch ~.0762 mm) for countersunk head rivets as measured from the rivet centerline to the closed edge.
Minimum

shall

acceptable edge distance

(2) Minimum spacing for rivets in a row is 3 times the rivet diameter. Maximum spacing for rivets is
one inch (25.4 mm). Distance between rows of rivets in a web or skin patch is 5 times the rivet diameter.

EFFECTIVITY:
SRM-4

ALL

51-40-02

Page 3
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

Straightedge

Straightedge

used

to

check

rivet

flushness

Red

Loose

Lining

of

Fasteners

Fastener

Inspection
Figure 1

Rivet

EFFECTIVITY:
SRM-I

ALL

51-40-02

Page 4
May 15/92

Learjet
~earjetl

STRUCTURAL REPAIR MANUAL

Center

File

Drift

Punch

Punch

Drill

Drift Punch

Solid Shank Rivet Removal

Figure 2
Em~CTTVITY:
SRM-4

ALL

51-40-02

Page 5
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
SKETCH OF
FASTENER

CALLOUT

MATERIAL

REMARKS

Conventional
Rivets
MS20470AD

2117-T3

MS20426AD

2117-T3

Tension Head

NAS1097AD

2117-T4

Shear Head

S-194

2117-T4

Large Head
Small Head

Crown Flush Shear Head


Attach

Order from

Skin

Learjet Spares

Blind
Fasteners

CR3212

5056

Cherry Rivet,
Cherry Rivet

100" Flush Head

Jo-Bolt Rivet

~8P

Jo-Bolt Rivet

Jo-Bolt Rivet

Huck Rivet

Huck Rivet

LES-1032

Rivet and Blind Fastener Identification

Figure 3 (Sheet
EFFECTIVITY:
SRM-4

ALL

1 of 3)

51-40-02

Page 6
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


SKETCH OF
FASTENER

CALLOUT

MATERIAL

CSR903B

Ti/Cb

CSR902B

Ti/Cb

CSR904B

Ti/Cb

CSR924F

Ti

CR3242
CR3243

5056

REMARKS

Cherry
Cherry
Cherry
Cherry

(6-4)

Rivet,
Rivet,
Rivet,
Rivet,

Cherry Rivet,
Cherry Rivet,

5056

Universal Head
100" CSK Head
1000 CSK Head

Solid,

100" Flush Head

100" Flush Head


Universal Head

CR2838CW
CR2839CW
HL18 Pin

Hi-Lok

Hi-Shear

HL79 Collar
HL19 Pin
HL79 Collar
HL19 Pin
HL86 Collar
HL19 Pin
HL82AW Collar

HL40 Pin
HL97V Collar
HL18 Pin
HL82 Collar

HL19 Pin

Hi-Lok

HL82 Collar

Hi-Shear

HL20 Pin
HL75 Collar
HL21 Pin
HL75 Collar
HL12 Pin

HL198 Collar
HL12 Pin
HL86 Collar

HL12 Pin
HL75 Collar

Rivet and Blind Fastener Identification

Figure 3 (Sheet 2 of 3)
Em~CTIVITY:

ALL

51-40-02

Page 7
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
SKETCH OF
FASTENER

CALLOUT

MATERIAL

REMARKS

HL13 Pin
HL198 Collar
HL13 Pin
HL86 Collar
HL13 Pin

HL75 Collar
HL10 Pin
HL198 Collar

HL30-10-6 Bolt
HL94-10 Collar

Rivet and Blind Fastener Identification

Figure 3 (Sheet 3 of 3)
Em~ECTNITY:
FlUvr"l

ALL

51-40-02

Page 8
May 15/92

Learjet
Learjet

STRUCTURAL REPAIR MANUAL

HOLE TOLERANCE

STANDARD

MATERIAL THICKNESS
All Thicknesses

0.050

0.103

DRILL

NOMINAL

thru

thru

thru

DIA.

SIZE

DIA.

0.049

0.102

0.1 25

1/16

52

0.064

40

1/8

30

5/32

21

3/16

11

1/4

5/16

3/8

For gas-

or

liquid-tight

5129

0.098

0.128

0.159

0.191

0.257

0.316

0.377

GAS TIGHT

MATERIAL THICKNESS

RIVET

3/32

HOLE TOLERANCE

LIQUID

0.064

0.064

0.064

0.069

0.072

0.072

0.098

0.098

0.098

0.097

0.103

0.106

0.106

0.102

0.128

0.128

0.128

0.127

0.133

0.136

0.136

0.132

0.159

0.159

0.159

0.158

0.167

0.169

0.169

0.163

0.191

0.191

0.191

0.189

0.199

0.201

0.201

0.194

0.257

0.257

0.257

0.252

0.265

0.267

0.267

0.257

0.316

0.316

0.316

0.314

0.324

0.327

0.330

0.319

0.377

0.377

0.377

0.377

0.385

0.388

0.391

0.383

areas, hole diameters for

"liquid

and gas

tight"

must be used.

Holes for all Driven Rivets

Figure 4
EFFECTn/ITY:
slad-a

ALL

51-40-02

Page 9
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

STANDARD DIA. RIVETS


REF:

1/64" OVERSIZE DIA. RIVETS

Cherrymax (Nominal) Wiredraw


Cherrylack Huck "Conical
Keystone" Huck "General
Purpose" Etc.

REF:

Cherrylock
Cherrymax (Oversize)
Bulbed

HOLE DIA.
DRILL

DIA.

SIZE

MIN.

MAX.

1/8

27

0.143

0.146

0.164

5/32

16

0.176

0.180

0.191

0.196

3/16

0.205

0.209

0.256

0.261

DRILL

DIA.

SIZE

MIN.

MAX.

3/32

40

0.098

0.100

1/8

30

0.128

0.132

5/32

20

0.160

3/16

11

114

Holes for

SRM~

ALL

HOLE DIA.
RIVET

RIVET

EFFECTIVITY:

Etc.

Mechanically Expanded
Figure 5

Blind Rivets

51-40-02

Page 10
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
COUNTERSINK

HOLE DIA.

BLIND

DIA.

MATERIAL

COUNTERSINK

THICKNESS

BOLT
DIA.

MIN.

MAX.

"D" MIN.

"D" MAX.

"r MIN.

5/32

0.164

0.167

0.329

0.339

0.080

1000

~10)

3/16

0.199

0.202

0.381

0.391

0.090

1 00"

(rtlO)

1/4

0.260

0.263

0.504

0.514

0.125

100"

~tt")

5/16

0.312

0.315

0.623

0.642

0.160

1 00"

3/8

0.374

0.378

0.764

0.774

0.180

100

ANGLE

(-lio)

/t

"D"

~Ijj

Holes and Countersinks for Huck Blind Bolts

(BP-T

or

M590354; B100T or MS90353)

Figure 6

LOCK

HOLE DIA.

BOLT
DIA.

MIN.

MAX.

5/32

0.154

0.156

3/16

0.187

114

0.247

0.249

5/16

0.310

0.312

3/8

0.372

0.374

0.189

Holes for Huck Lockbolts

Figure 7
EFFECTIVITY:
SRM-4

ALL

51-40-02

Page 11
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

TYPE

COLLAR

1/64" O.S.

COLLAR

1/32" O.S.

COLLAR

STD. DIA.

(REF)

DIA.

(REF)

DIA.

(REF)

P.H. Shear

HL18

HL70

HL62

HL79

HL218

HL84

CSK. Shear

HL19

HL70

HL63

HL79

HL219

HL84

P.H. Tension

HL20

HL86

HL64

HL87

HL220

HL93

CSK. Tension

HL21

HL86

HL65

HL87

HL221

HL93

PIN DIA.

HOLE

PIN DIA.

HOLE

PIN DIA.

HOLE

(REF)

DIA.

(REF)

DIA.

(REF)

DIA.

0.1 635

0.1640

N/A

0.1625

0.1610

0.1895

0.1 900

0.2026

0.2031

0.21 82

0.2187

0.1885

0.1870

0.2016

0.2001

0.2172

0.21 57

SIZE
-5

-6

-8

-10

-12

-14

-16

NIA

0.2495

0.2500

0.2651

0.2656

0.2807

0.2812

0.2485

0.2470

0.2641

0.2626

0.2797

0.2782

0.3120

0.3125

0.3276

0.3281

0.3432

0.3437

0.3110

0.3095

0.3266

0.3251

0.3422

0.3407

0.3745

0.3750

0.3901

0.3906

0.4057

0.4062

0.3735

0.3720

0.3891

0.3876

0.4047

0.4032

0.4370

0.4375

0.4526

0.4531

0.4682

0.4687

0.4360

0.4345

0.4516

0.4501

0.4672

0.4657

0.4995

0.5000

0.5151

0.5156

0.5307

0.5312

0.4985

0.4970

0.5141

0.5126

0.5297

0.5282

Holes for Hi-Lok Bolts

Standard and Oversize

Figure 8
EFFECTTVITY:
SRM-4

ALL

51-40-02

Page 12
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

FLUSH SMEAR HEAD RIVET

FLUSH TENSION HEAD RIVET

COUNTERSINK

COUNTERSINK
RIVET
DIA.

DIA.

MATERIAL

I THICKNESS r

"D"Max.

DIA.

"T"MIN.

"E"

"D"Mln.

1/16

0.137

0.147

0.025

3/32

0.170

0.174

0.040

0.141

0.148

1/8

0.216

0.220

0.050

0.188

5/32

0.277

0.281

0.063

3/16

0.344

0.348

0.071

1/4

0.466

0.471

0.100

Flush shear head rivets may be NAS1097

or

"D"Mln.

1000

~20)

0.025

100"

(f20)

0.196

0.032

loo

(f29)

0.240

0.247

0.040

100"

~20)

0.297

0.302

0.050

100"

(-120)

0.390

0.395

0.063

100"

(+20)

made

by driving

Countersinks and

E"

MS20426 rivets

"D"

it

MATERIAL

7 THICKNESS I COUNTERSINK
"T"MIN.
"D"Max.
ANGLE
I

high

and

shaving.

"0"

-i

I-

Dimples in Non-Fluid and Non-Gas-Tight Areas for MS20426 (Flush Tension Head) and
Having These Head Styles

NAS1097 (Flush Shear Head) Rivets and Other Rivets


Figure 9

EFFECTTVITY:
SRM4

ALL

51-40-02

Page 13
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
COUNTERSINK
MATERIAL

DIA.
RIVET

I
COUNTERSINK

ANGLE

DIA.

"D"Mln.

"D"Max.

"T" MIN.

3/32

0.182

0.192

0.040

105"

~t29)

1/8

0.235

0.245

0.050

105"

(f2")

5/32

0.295

0.305

0.063

105"

(f30)

3/16

0.369

0.381

0.080

105"

(~30)

1/4

0.503

0.515

0.112

105"

~40)

Countersinks to Receive

THICKNESS

IIDII

t~JI

Dimples for Flush Tension Head (MS20426 and 5194) Rivets


Figure 10

COUNTERSINK
MATERIAL

DIA.
RIVET

THICKNESS

COUNTERSINK
ANGLE

DIA.

"D"Mln.

"D"Max.

"T" MIN.

3/32

0.160

0.165

0.040

1000

(f1/20)

1/8

0.206

0.211

0.050

1000

~I1/20)

5/32

0.267

0.272

0.063

100"

(f1/20)

3/16

0.334

0.339

0.071

1 00"

(-11/2")

1/4

0.457

0.462

0.100

1000

(Jr1/20)

NOTE:

For

This may necessitate


(NAS1907 head style)

Countersinks for

SRM-4

/e

tl~

liquid- or gas-tight areas, countersinks for liquid- and gas-tight holes must be used.

Countersink dimensions

EFFECTIVITY:

L1

"D"

ALL

are

chosen

so

that manufactured rivet head will be

shaving depending
are not

to be used

upon flushness

"high"

after

driving.

Flush shear head rivets

requirements.
in liquid- or gas-tight applications.

Liquid- and Gas-Tight Holes for Flush Tension Head (MS20426 and
Figure 11

S194) Rivets

51-40-02

Page 14
May 15/92

Learpt

STRUCTURAL REPAIR MANUAL


FLUSH SMEAR HEAD BOLT

FLUSH TENSION HEAD BOLT


STD.

DIA.

DIA.

1/64 O.S.
DIA.

1/32 O.S.

DIA.

1/64 O.S.
DIA.

1/32 O.S.

NOMINAL
BOLT

(REF)

(REF)

(REF)

(REF)

(REF)

(REF)

DIA.

L~

STD.

DIA.

0.3280

-5

(5/32)

0.2588

-6

(3/16)

0.2991

0.2991

0.3278

0.3789

0.3789

0.3789

-8

(1/4)

0.3923

0.3923

0.4235

0.5042

0.5042

0.5042

0.471

0.471

0.5026

0.6311

0.6311

0.6311

-10(5/16)
-12

(3/8)

0.5579

0.5579

0.5891

0.7580

0.7580

0.7580

-14

(7/16)

0.6650

0.6650

0.6962

0.8848

0.8848

0.8848

0.7510

0.7510

0.7822

1.0104

1.0104

1.0104

The head height of all Hi-Lok bolts common to an aerodynamic surface must meet the installation requirements per 51-4(H)4. The head height of all Hi-Lok bolts not common to an aerodynamic surface
may deviate plus or minus 0.010 inch height from the adjacent surface.

Countersinks for 1000 mush Head Hi-Lok Bolts

Standard and Oversize

Figure 12

COUNTERSINK

"D"Mln.

"D"Max.

MATERIAL
THICKN ESS
"T" MIN.

1/8

0.167

0.173

0.020

100"

(f20)

5/32

0.210

0.216

0.025

100"

(f20)

3/16

0.252

0.258

0.032

100"

(f20)

DIA.

RIVET
DIA.

COUNTERSINK
ANGLE

Countersinks for Unisink Head

Cherry Rivets

Figure 13
EFFECITVITY:
SI~M-4

ALL

51-40-02

Page 15
May 15/92

STRU~TURAL REPAIR MANUAL


E.

Solid Shank Rivets


some
a

this aircraft

made from 2117 aluminum alloy. In


alloy are used. Rivet part numbers have
suffix denoting the material, while the actual rivet bears a head marking as listed in Table 1.

(1) The solid shank rivets in general

use on

locations rivets made from 5056

or

are

1100 aluminum

HEAD MARKING

SUFFIX

MATERIAL

2117

AD

Dimple

5056

Raised Cross

1100

None

Table 1

(2) Rivets made from 2117, 5056, and 1100 aluminum alloy

can

be stored and used at

room

tempera-

ture.

(3) Solid rivets

can

be installed

by

the

use

of

rivet gun and

bucking bar

or a

suitable squeeze rivet-

Rivet guns and bucking bars must be large enough to drive the rivets quickly. Three to
four seconds driving duration is the optimum, while seven seconds should be the maximum.

ing tool.

Bucking bars should be very smooth when driving aluminum alloy rivets.
grip ranges, shank projection before driving, and the driven head sizes for
solid shank rivets used in non-fluid-tight applications.
(5) On assemblies where the direction of driving is optional, it is desirable to form the driven head
against the thicker sheet or harder material.
(4) Figure 14 shows the

(6) The die

or

rivet set shall fit the manufactured head of the rivet.

manufactured head of universal head rivets

provided

Flat dies may be used

on

the

the head is not flattened to dimensions less

Figure 14.
completely fill the hole. Peening of
bar is not permitted since the rivet hole will not be filled.
than those listed in

(7) The driven rivet shall

(8) Aluminum rivets used

to fasten stainless

steel, monel rivets used

rivet material other than 5056 aluminum used to fasten

the driven head

by rolling

the

bucking

to fasten

magnesium,

aluminum, and any


shall be driven in wet epoxy

primer per 51-30-04, wet epoxy, or faying surface sealer (Pro-Seal 890) (MIL-S-8802).

LES-1OZ1AS

EFFECTIVITY:

ALL

51-40-02

Page

16

Jun1/95

Learjet

STRUCTURAL REPAIR MANUAL


STANDARD DRIVEN HEAD DIMENSIONS FOR RIVETS
HEAD THICKNESS
MINIMUM

RIVET
DIAMETER

I HEAD DIAMETER

MIN.

MAX.

1/16

0.081

0.025

0.040

3/32

0.122

0.038

0.050

1/8

0.163

0.050

0.070

5/32

0.203

0.062

0.092

3/16

0.244

0.075

0.105

7/32 D

0.285

0.087

0.110

1/4

0.325

0.100

0.130

9/32

0.365

0.113

0.140

5/16

0.406

0.125

0.158

0.450

0.137

0.170

0.488

0.150

0.190

0.530

0.165

0.200

11/32 D
318
13/32 D

rStandard
Driven

Diameter

Flat

Head

-tI

.-ss"

Thickness

D Oversize Replacements

GRIP RANGES FOR RIVET LENGTHS AND DIAMETERS


RIVET LENGTH
"L"

118 DIA.
GRIP "T"

5/32 DIA.

GRIP "r

3116 DIA.
GRIP "T"
Min

Max

.124

.064

.120

.187

.121

.188

.249

.176

.295

.250

.314

.296

.350

.315

-9

.351

.410

5/8

-10

.411

11/16

-11

3/4

1/4 DIA.
GRIP

"T

5/16 DIA.

318 DIA.

GRIP "T"

GRIP

Min

Max

Min

Max

.298

"T

Min

Max

.175

.091

.103

.219

.104

.175

.220

.276

.176

.216

.375

.277

.335

.217

.263

.242

.376

.426

.336

.394

.266

.339

.299

.355

.468

.429

.481

.395

.453

.340

.385

.356

.410

.188

.250

.469

.525

.482

.530

.454

.513

.386

.445

.411

.467

.251

.313

-12

.526

.597

.531

.587

.514

.569

.446

.491

.468

.524

.314

.375

13/16

-13

.598

.648

.588

.638

.570

.625

.492

.548

.525

.581

.376

.437

7/8

-14

.649

.715

.639

.702

.626

.680

.549

.602

.582

.630

.438

.500

15/16

-15

.716

.772

.703

.758

.681

.736

.603

.675

.631

.687

.501

.563

-16

.773

.840

.759

.810

.737

.791

.676

.728

.688

.744

.564

.625

Dash

Min

Max

Min

Max

5/32

-2.5

.015

.057

3/16

-3

.058

1/4

-4

.095

.094

.020

.071

.130

.072

5/16

-5

.131

.178

.125

3/8

-6

.179

.230

7/16

-7

.231

1/2

-8

9/16

Fraction

Driven Head

Dimensions for

Figure
EFFECTIVITY:
SRM~

ALL

Driving Rivets

14 (Sheet 1 of 2)

51-40-02

Page 17
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
AVERAGE NOMINAL PROJECTION BEFORE DRIVING

FOR RIVETS UP TO 1/2-INCH LONG


RIVET DIAMETER

"C"

1/16

0.093

3/32

0.120

1/8

0.156

5/32

0.156

3/16

0.180

1/4

0.250

5/16

0.256

3/8

0.406

=~i
T

MINIMUM FLATTENING DIMENSION OF

MANUFACTURED RIVET HEADS

(MS20470 UNIVERSAL

HEAD

RIVET)

RIVET DIAMETER

"C"

3/32

0.032

1/8

0.042

5/32

0.052

3/16

0.062

1/4

0.083

5/16

0.104

3/8

0.125

Dimensions for Driving Rivets

Figure
EFFECTNITY:
sRM-a

ALL

14 (Sheet 2 of 2)

51-40-02

Page 18
May 15/92

Learjet
Leari~tl

STRUCTURAL REPAIR MANUAL


(9) Flush Driven Rivets in Non-Fluid and Non-Gas-Tight Areas.
(a) When a flush tension head rivet is to be installed in material too thin for a standard countersink (see Figure 16) (a condition that would result in a knife edge of the material), install a rivet of same size and material per paragraph (9)(b) or (9)(c).
(b) It is permissible to install a flush shear head rivet and drive flush. The hole and countersink
are

to be per

Figures 4 and 9.

to install a flush tension head rivet high and shave flush. The hole size is to
Figure 4 and the countersink diameter and angle are to be per Figure 16.
(d) Dimples shall nest into other dimples or countersinks so that before riveting there is a minimum gap between adjacent sheets of 0.001 inch (.0254 mm) and a maximum gap before or after riveting of 0.005 inch (.127 mm) except that a sheet separation of 0.010 inch (.254 mm) will
be allowed adjacent to 20 percent (not consecutive) of the rivets. The sheet separation limitations described above shall be measured immediately adjacent to the dimple or countersink.
The maximum sheet separation after dimpling, measured midway between rivets, shall be
0.008 inch (.2032 mm) except that a maximum sheet separation of 0.015 inch (.381 mm) will be
permissible between 20 percent (not consecutive) of the rivets. (See Figure 17.)
(e) The projection of flush head rivets used to allow contact of faring surfaces shall not be sufficient to cause interference between parts. In no case shall the rivet head project more than

(c) It is permissible
be per

0.010 inch (.254 mm) above the sheet or be below the surface.
(10) Flush tension head rivets for liquid- and gas-tight installation shall be driven

high

and shaved

flush.

(a)
03)
(c)
(d)

Hole size, countersink diameter, and countersink angle shall be per Figures 4 and 11.
Rivets must meet surface flush requirements of 51-40-04 if applicable.

shaving shall meet requirements of Figure 16.


protrusion before and after driving shall meet requirements of Figure

Rivet head diameter after


Rivet head

(11) The manufactured head of flush tension head rivets land the driven head
must

on

18.

double flush rivets)

completely fill the countersink or dimple. The manufactured head of flush shear head rivets
tightly in the countersink or dimple. Gaps between the countersink or dimple and the

must seat

head of

gauge

are

flush shear head rivet which will allow the insertion of

unacceptable. Gaps

between the countersink

or

0.001 inch (.0254 mm) feeler

dimple

and the head of flush shear

head rivets which will not allow the insertion of a 0.001 inch (.0254 mm) feeler gauge are accepfaprovided that the gap does not extend for more than 40% of the head circumference. All flush

ble

head rivets driven below flush

EFFECTIVITY:
SRM~

ALL

are

unacceptable. (See Figure

19.)

51-40-02

Fage 19
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

2Nominal

NOMINAL MATERIAL
NOMINAL RIVET DIA.

THICKNESS

100

(Mlnimum)
1/16

0.025

3/32

0.040

1/8

0.050

5/32

0.063

3/16

0.071

1/4

0.100

Materia.l

Thickness

(Minimum)
f~20

f
i

Nominal Rivet

Diameter

-Ci

I
t~C

Minimum Material Thickness for Flush Tension Head Rivet Installation

Figure

15

NOMINAL RIVET
DIA. "E"
Countersink

3/32

1/8

5/32

3/16

1/4

0.141

0.188

0.240

0.297

0.390

"D"

"A"

,ci 1>Nominal Material


Thickness "T"

0.025

0. 032

0.040

(Minimum)
Countersink

Angle

"A"

100"

Installation

EFFECTIVITY:
sI1M~

ALL

(f2")

0.050

0.063

r,~73
nEP-1 1-

Specifications for Flush Tension Head Rivets


Installed High and Shaved Flush
Figure 16
51-40-02

Page 20
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

0.008 Maximum

0.005

Maximum Sheet

Maximum

Gap Between Rivets and Dimpled Sheets


Figure 17

3/32

1/8

5/32

3/16

1/4

Max.

0.165

0.211

0.272

0.339

0.462

Min.

0.160

0.206

0.267

0.334

0.457

Max.

0.010

0.010

0.010

0.010

0.010

Min.

0.004

0.004

0.004

0.004

0.004

Head Protrusion

Max.

0.008

0.008

0.008

0.008

0.008

After

Min.

0.002

0.002

0.002

0.002

0.002

NOMINAL RIVET DIAMETER


Countersink Diameter
Refer to

figure 11,

"Countersink for
and

Liquid-

Gas-Tight Holes"

Head Protrusion
Prior to

Driving

Driving

Countersink

Angle
100"

figure 11, "Countersinks


Liquid- and Gas-Tight Holes"

Refer to
for

(f1/20)

Flush Tension Head Rivets Protrusion Specifications For


Liquid- and Gas-Tight Installations

Figure
EEFECTIVITY:
SRM~

ALL

18

51-40-02

Page 21
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
Below Flush

Unacceptable for all Flush Head Driven


Area

Rivets

not

filled
than

Rivet

the

Countersink

completely

extends

40
head

more

percent of
circumference

Rivet:

or

Dimple

Countersink

for Plush

Rivets

not

Area

completely filled

or

Dimple

13nacceptable for Flush Shear

land the driven head

on

double

Head Rivets

flush rivets)

filled

extends

head

the

circumference

but

allo~s

insertion
inch

0.001

of

less

percent of

than 40

feeler

gauge

at

point

any

Countersink

completely

not

Area

Dimple

or

Rivet

Unacceptable for

Flush Sheer Head Rivets

Area

not

of

the

does

not

0.001

at

any

or

circumference

head

of

Countersink

completely filled
than 40 percent

less

extends

allow the
inch

and

insertion

feeler

gauge

point.

Dimple

Rivet

Acceptable

for Plush Sheer Head Rivets

Acceptance Specifications for Flush Head


Figure 19
EFFECTIVITY:

ALL

Driven Rivets

51-40-02

Page 22
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


used to attach most external skin panels on the Learjet. Before driving, S-194 rivets installed in countersinks shall appear as follows and as shown in Figure 20.
(a) Slightly exposed countersink is visible.

(12) Crown flush rivets S194

are

(b) Edge of rivet head is always low.


(C) Crown is always high (0.008 inch [.2032 mm] high, maximum).
(d) Countersink diameters are per Figure 11. After driving, S-194 rivets shall appear
and

as

shown in

Figure

(e) Visible exposed countersink is acceptable.


(f) Edge of rivet head can be same height as rivet head

(g)

Crown shall be flush to

crown to

high per 51-40-04.

All the above conditions must exist for rivet installation

1[-

Tf

S-194

dimple

S-194 RIVET BEFORE DRIVING

follows

slightly below skin surface.

(h) Rivet heads shall not be shaved.


(i) A 0.001 feeler cannot be installed between rivet head and countersink
NOTE:

as

20.

at

any

point.

acceptance.

(I

II/G3

Rivet has
in butt.

S-194 RIVET APTW

DRIVING

Acceptance Specifications for S-194 Crown Flush Rivet Installation


Figure 20

EFFECTIVITY:
SRM4

ALL

51-40-02

Fage 23
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
(13) Shaving of flush shear head rivets is

not allowed.

(14) Shaving of flush tension head rivets

to meet surface flushness

requirements

of 51-40-04 is al-

lowed.

(15) Flush tension head rivets installed in a liquid- or gas-tight area that have been driven high and
shaved flush, shall be checked for loss of tensile strength per Table 2.

Nominal Rivet Diameter


Minimum Head Diameter after

FLUSH SMEAR HEAD RIVETS

RIVET SHAVING

CHECKING DIMENSIONS

Shaving

3/32"

1/8"

5/32"

3/16"

1/4"

0.160"

0.206"

0.267"

0.334"

0.450"

Table 2

(16) Flush tension head rivets that have been driven high and shaved flush
head rivet, shall be checked for loss of shear strength per Table 3.

CHECKING DIMENSIONS

RIVET SHAVING

Nominal Rivet Diameter


Minimum Head Diameter after

Shaving

to function

as a

flush shear

FLUSH TENSION HEAD RIVETS

3/32

1/8"

5/32"

3/16"

1/4"

0.1 48"

0.196"

0.247"

0.302"

0.395"

Table 3

(17) Cracked Driven Heads


(a) Cracks in driven heads

are

2117-T4 rivets

NOTE:

undesirable and must be

are

kept to a minimum.

driven in hard condition;

therefore,

large percentage

will have

cracks if driven 1.5 times the shank diameter. For this reason, care should
be taken to keep the driven head to 1.3 times the shank diameter per Figure 14.

diagonal

(b) Cracks
caused

on

the sides of driven heads which

by upsetting the

be evaluated

1)
2)
3)

EFFECTIVITY:
SRM-I

as

rivet material

run

beyond

at

450

angle

to the flat

the limit of its

surface of the head

ductility. Diagonal

are

cracks shall

follows:

superficial cracks are allowable in all cases regardless of their numbers. Intersecting superficial cracks are also acceptable.
Rivets having as many as three diagonal cracks which do not intersect are acceptable.
Rivets with severe cracks are not acceptable and should be replaced.
Hairline

ALL

or

51-40-02

Page 24
May 15/92

Learjet I

STRUCTURAL REPAIR MANUAL


by a lap in rivet wire, and the other caused
by overheat treating the rivets. It is very important to distinguish between these two types.
1) Cracks due to lap in rivet wire appear infrequently. The surface exposed by the cracks
will be smooth and dull in appearance and will be only a few thousandths deep (0.005 to
0.015 [.0127 to .381 mm]). These cracks are acceptable.
2) When cracks from overheating appear, they are usually found in a large percentage of the
rivets being driven. This cracking is due to excessive temperatures being reached during
the heat treatment of the rivet. These cracks are not acceptable, and rivets having these
vertical cracks on either head shall be rejected. The batch which was overheated should
be segregated and scrapped because the ductility cannot be restored by reheat treatment.
(18) Bell-shaped driven heads are formed by use of too light a bucking bar or by rocking the bucking
bar. Rivets which show evidence of this condition should be rejected since the rivet hole is poorly
filled and the head has very little bearing surface on the sheet.
(19) Shanked Rivets Fart Separation
(a) A maximum of 0.015 inch (.381 mm) shanking (part separation) is permissible for the rivet adjacent to intermediate material as shown in Figure 22.
(6) Sheet separation shall be less than 0.002 inch (.0508 mm) adjacent to universal, brazier, and
(C) There

are

two

types of vertical cracks:

countersink driven rivets with

Figure

22. If

one

caused

0.008 inch (.2032 mm) maximum between rivets

0.002 inch (.0508 mm) feeler gauge

rivet shall be considered shanked and is not

can

as

shown in

be inserted to the shank of the rivet, the

acceptable~

For sheet

separation

in

dimpled

ma-

terial, see Figure 17. In the case of riveting dissimilar metals, where tape is used between the
sheets, the total separation of the metallic sheets shall not be greater than the thickness of the
tape plus the maximum separation permitted above. The allowable sheet separation of fay
F.

sealed joints is 0.004 inch (.1016 mm) at the shank of the rivet.
MechanicallyExpanded Blind Rivets
(1) Blind rivets are intended for use where access is available to only one side of the work.
(2) Blind rivets are installed with special tools in holes specified in Figure 5.
(3) Head gapping on the visible side shall be checked with a 0.002 inch (.0508 mm) feeler gage for
both countersunk and protruding head blind rivets. Rivets with more than 0.002 inch (.0508 mm)
gap on more than 40 percent of the head circumference are not acceptable.
flushness of the stem break on installed wiredraw bulbed Cherrylock blind rivets (fiush head
The
(4)
and protruding head) shall be in accordance with Figure 23.
(5) The flushness of the collar on installed wiredraw bulbed Chenylock blind rivets shall be in accordance with Figure 23.
(6) The flushness of the stem break on installed Chenymax blind rivets shall be in accordance with
Figure 24.
(7) The flushness of the stem break and collar on installed Huck "Conical Keystone" and Huck "General Purpose" (NAS 1919 and 1921) blind rivets shall be in accordance with Figure 25.
(8) A slight collar "flash" caused by the pressure necessary to install the collar is acceptable within the
limit shown in Figure 26 for all Cherry and Huck rivets.
(9) Shaving of installed blind rivets shall be limited to removal of stem and/or removal of collar
down to flush with the head of the rivet.

(10) Blind rivets

EFFECTIVITY:
SRM-4

ALL

can

be removed in

similar

The head of the rivet shall not be shaved.


manner to

that

specified

for solid rivets.

51-40-02

Page 25
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

Intermediate

Material

0.032-Inch Maximum.
No

joggle

or

shim

re-

quired by drawing.

0.015

Inch

Adjacent

Maximum Rivet

Shanking

(~ivet

Intermediate

Material

Only)

to

0.032-Inch

iLess

than

0.002

Inch

0.008

Inch

Max.

0.008

Inch

Max.

fLess

than

0.002

Inch

f
Less

Shanking and

EFFECTNITY:

Max.

ALL

than

0.002

Inch

Separation Tolerances
Figure 21

Sheet

51-40-02

Page 26
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


G.

Huck Lockbolts

(1) The lockbolt and collar used shall be

as

originally

installed. The collars

are

lubricated when

re-

ceived from the manufacturer and should be stored away from heat, dirt, and grit until used.
(2) Grip length adjustment of the lockbolts may be accomplished by the use of washers (1/32 inch
minimum thickness). For aluminum and steel material, one AN960PD aluminum washer may be
or one AN960 cadmium plated steel washer may be used under the collar.
The thickness of the washers shall not exceed 1/16 inch.
(3) Final hole sizes for lockbolts shall be as specified in Figure 7.
(4) Lockbolts shall be installed with tools recommended by the manufacturer. The swaging die for

used under the head

lockbolt collars shall not be

tipped

more

than 3

degrees from the lockbolt axis during driving.

(5) The end of the broken-off" portion of the pull pin does not require corrosion protection.
(6) Collars cracked after swaging shall be rejected.
(7) The presence of gaps which allow the insertion of a 0.004-inch (.1016 mm) feeler gage between the
countersunk or protruding head and the bearing surface shall not be accepted when more than 40
percent of the head circumference has such a gap. In all cases, the cause of the production of gaps
shall be eliminated if
NOTE:

possible.

of doubt, lockbolts may be checked for proper swaging of the collar and breakpull pin with the lockbolt inspection gage. See vendor supplied Huck catalog
for proper gage (Huck Mfg. Co., 6 Thomas, Irvine, CA 92714).

In

case

off of the

Stem

(Ref.)

.015

(Max.)

Collar

Stem Flushness

EFFECTIVITY:
sRM4

ALL

(Ref.)

Specifications for Cherrylock Blind


Figure 22

Rivets

51-40-02

Page 27
May 15/92

Learje

STRUCTURAL REPAIR MANUAL

(Ref.)

Stem

.020

.015

Max.

(Ref.)

Collar

Collar Flushness

*0.015

.010

inch

Specifications for Cherrylock


Figure 23

for

-4

(0.125 inch)

Blind Rivets

diameter

c""

1
.020

Stem Flushness Specifications for

only.

_1
1

1*.020

Cherrymax Blind Rivets

Figure 24
EFFECTIVITY:
sruur-4

ALL

51-40-02

Page 28

May

15/92

Learjet
STRUCTURAL REPAIR MANUAL

RIVET SIZE

"A"MAX.

"B"MAX.

"C"MAX.

1/8

0.012

0.016

0.008

5/32

0.015

0.020

0.010

3/16

0.018

0.024

0.012

Stem and Collar Flushness


Huck Conical

Keystone

Specifications for
Purpose Blind Rivets

and General

Figure 25

Flash

~20

Allowable Flash

EFFECTTVITY:
SRM-4

ALL

on

Inch

Max"

Cherry and
Figure 26

Huck Blind Rivets

51-40-02

Page 29
May 15/92

Learjet
STRUCTURAL REPA~R MANUAL
H.

HuckBlind Bolts

(1) Final hole size for Huck blind bolts shall be as given in Figure 6.
(2) Huck blind bolts are supplied lubricated. They shall not be degreased or re-lubricated. They
shall be stored away from heat, dirt, and grit.
(3) Dip bolt used in a wet fuel area in Pro-Seal 890 (MIL-S-8802) sealant immediately prior to installation.

(4) Huck blind bolts shall be installed with tools recommended by the manufacturer. The driving
tool shall be held

its axis coincides with the axis of the fastener and

so

to the

perpendicular

sur-

face.

(5) The end of the bolt at the break-off point shall be touched up with epoxy primer.
(6) Where possible, the blind side of the installation shall be inspected to see that proper blind head
is formed. (See Figures 27 and 28.) Touch up blind side with Pro-Seal 890 (MIL-S-8802) or ProSeal 870 (MIL-S-81733) where possible.
Use Pro-Seal 890 in wet fuel

NOTE:

(7) Gaps which allow the insertion of

protruding

head and

areas

only.

0.004 inch (.1016 mm) feeler gage between the countersunk or


acceptable when more than 40 percent of the

surface shall not be

bearing

head circumference has the gap.

(8) Gapping under the manufactured heads of fasteners is undesirable from a quality standpoint. In
all cases when gapping occurs, steps shall be taken to eliminate the cause.
(9) The flushness of the locking collar and spindle of the Huck blind bolt fastener as driven shall be
in accordance with

(10) Shaving of either the collar


ble.
I.

Fasteners with either collar

29.

Figure

quirements per Figure 30 shall

replaced.
and/or the spindle

Shaving of the fastener head

wet

fuel

spindle

not

meeting

flushness

re-

to flush with the head of the fastener is

area

pennissi-

is not allowed,

Jo-Bolt Blind Bolts (NAS 1669 and NAS 1670)


(1) The ~o-Bolt used shall be as originally installed.
(2) Jo-Bolts are supplied lubricated. They shall not
stored away from heat, dirt and grit.
(3) Dip bolt used in

or

be

in Pro-Seal 890

be

degreased

re-lubricated.

or

shall be

They

(MIL-S-8802) sealant immediately prior

to installa-

tion.

(4) 10-Bolts shall be installed with tools recommended by the manufacturer. The
held

so

driving tool

shall be

its axis coincides with the axis of the fastener.

(5) The end of the bolt

at the break-off

point shall be touched up with epoxy primer.

(6) Where possible, the blind side of the installation shall be inspected for properly driven collars.

Any

crack in

(MILS-8802)
NOTE:

collar is

or

cause

for

rejection of the

Use Pro-Seal 890 in wet fuel

(7) Gaps which allow the insertion of

protruding

fastener. Touch up blind side with Pro-Seal 890

Pro-Seal 870 (MIL-S-81733) where

head and

bearing

areas

possible.

only.

0.004 inch (.1016 mm) feeler gage between the countersunk

surface shall not be

acceptable

when

more

than 40

or

percent of the

head circumference has the gap.

(8) Gapping under the manufactured heads of fasteners is undesirable from a quality stand point. In
all cases when gapping occurs, steps shall be taken to eliminate the cause.
(9) The stem breakoff limits for flushness with the skin surface shall be per Figure 30. If stem breakoff is outside of these limits, either the fastener used is out of grip length or it did not drive prop-

erly.

Stem breakoff

the limits

EFFECTIVITY:
sRM4

ALL

too short

higher

than the limits will

generally

indicate

too

long

fastener and below

fastener. In either case, the fastener shall be removed and

replaced.
51-40-02

Page 30
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
Nom

je

Bol t

AS CLINCHED

Die.

PROTRUSION OF
BLIND HEAD

NOMINAL

MIN.

MAX.

DIAMETER OF

DIAMETER

(Inches)

(Inches)

BLIND HEAD

(5/32)
(3/16)

0.120

0.201

Max. dia.

-06

0.146

0.231

clinched blind

-08

(1/4)

0.188

0.279

head shall not

-10

(5/16)
(3/8)

0.224

0.319

exceed

0.264

0.364

dia. of

-05

-12
As

as

max.

mfg. head.

LAs Clinched

Clinched

Protrusion
of

AS CLINCHED

BOLT

Dia.

Blind

of

Blind

Head

Head

Dimensional

rJ> Allowable
or

surface

discontinuities

formed

blind head

Longitudinal

Requirements for Clinched


Figure 27

Blind Head

fractures

in
are

-0.010

area
as

of

follows:

max.

Circumferential -0.005

max.

Acceptable

(Providing requirements of
figure 29 are met)

(Anytime

the

bolt

extrudes

out

and

land

on

the

bolt

sleeve
over

the

pin)

Blind Head

Shapes
Figure 28

EFFECTIVITY:
SRM-4

ALL

51-40-02

Page 31
May 15/92

Learjet
Learietl
STRUCTURAL REPAIR MANUAL
A
A

Inspection
A...Maximum

allowable

Locking Collar Position

locking

of

distance

NOMINAL

of

collar

COLLAR POSITION

FASTENER

above

head.

"B"

(MAX)
(Inch)

(MAX.)
(Inch)

5/32

0.017

0.010

3/16

0.022

0.012

1/4

0.029

0.015

5/16

0.037

0.019

3/8

0.045

0.023

(Same inspection procedure

fastener

SPINDLE POSITION

)1A(I

DIAMETER

below

or

is used for oversize

diameter.)

BTop

Top Land

Land

s~

~I

Inspection
B...Maximum allowable

distance

Plushness

EFFE~TIVITY:
SRM-4

ALL

of

of

top of

Spindle Position
land

Requirements for Huck


Figure 29

on

pin

above

or

below

fastener

head

Blind Bolt Installation

51-40-02

Page 32
May 15/92

Learjet

STRUCTURAL REPAIR NIANUAL

NOM. DIA.
0.164

PART NUMBER
NASI 669-08

"A"

PART NUMBER

+0.000

NAS1670-08

+0.088
0.200

NAS1 669-3

NAS1 669-4

NAS1 6703

+0.010

NAS1 669-5

NAS1 670-4

+0.047

0.375

NAS1 669-6

+0.010
-0.078

NAS1 670-5

+0.043
+0. 146

+0.010
-0.073

+0.135
0.312

+0.010
-0.068

+0.098
0.260

"B"

+0.049

+0.010
-0.083

NAS1 670-6

+0.152

+0.010
-0.093

NOTE: "A" is above skin surface, "B" is below skin surface.

Flushness

EFFECTIVITY:
sIzM~

ALL

Specifications for Jo-Bolt Installation


Figure 30
51-40-02

Page 33
May 15/92

Learjet
~Learierl

STRUCTURAL REPAIR MANUAL


J.

Hi-Loks

(1) The Hi-Lok pin and collar used shall be as originally installed except as substituted. (Refer
70-00, Figure 202.)
(2) Collars as received are lubricated. Degreasing or additional lubrication is not allowed.
(3) In inaccessible areas where space or location will not permit the use of specified collars,
may be substituted

as

to 51-

nut

shown in Table 4.

SUBSTITUTED NUT

SPECIFIED COLLAR

INSTL TORQUE

(In Lbs)
HL70-5, HL90-5A, HL91-5
HL72-5, HL86-5
HL79-6, HL84-6, HL90-6A, HL94-6
HL72-6, HL86-6, HL87-6, HL87-6W, HL93-6
HL70-8, HL79-8, HL90-8A, HL94-8
HL72-8, HL87-8
HL90-10A, HL94-10, HL86-10

MS21 042-08

15

25

MS21 042-08

30

40

MS21 042-3

25

35

MS21 042-3

40

50

MS21 042-4

60

80

MS21 042-4

115

130

MS21 042-5

130

160

Table 4

(4) All Hi-Lok Bolts


ant

prior to

to be used in

wet fuel

area

shall be coated with Pro-Seal 890 (MIL-S8802) seal-

installation.

(5) Final hole size and countersink for Hi-Loks shall be as specified in Figures 9 and 13.
(6) Hi-Loks shall be installed with tools recommended by the manufacturer.
(7) Washers used for

grip adjustment

shall be AN960 cadmium

plated

steel.

(8) When installing a standard Hi-Lok collar, the use of one (1) washer, 0.032 inch (.812 mm) maximum thickness, under the collar is allowable.
When
(9)
installing the MS21042 substitute nut, with bolt head and all material in "sheared-up" condition, use washers to "cover-up" a minimum of two (2) "imperfect" bolt threads prior to installing the nut. Maximum allowable quantity of washers is two (2) per fastener. Maximum allowable thickness of individual washer(s) is 0.063 inch (1.6 mm).
(10) At all protruding head style bolt locations, prepare the edge of the hole adjacent to the bolt head
as

shown in

Figure 31.

(11) The presence of gaps which allow the insertion of a 0.004 inch (.1016 mm) feeler gage between the
countersunk or protruding head and bearing surface, shall not be acceptable when more than 40

percent of the head circumference has the gap.


(12) The pin protrusion after installation shall be within the limits specified in Figure 32.
(13) After assembly, the maximum collar gap allowables
NOMINAL DIAMETER

are

per Table 5.

COLLAR GAP (Maximum)

5/32

0.003

3!16

0.004

114

0.005

5/16

0.006

3/8

0.007

7/16

0.008

1/2

0.009

TableS

EFFECTIVITY:
SRM-4

ALL

51-40-02

Page 34
May 15/92

Leariet
Learjet

STRUCTURAL REPAIR MANUAL

pin sizes a, -6 -8
[f10] chamfer optional)

0.010 ~0.005) Radius for

(0.010

~0.005]

45"

0.015 (~0.005) Radius for

(0.010 ~0.005]

Hole

45"

pin sizes -10

thru -16

[+10] chamfer optional)

Edge Preparation Specification for Hi-Lok Installation


Figure 31
I

P1

j
HINmnn

L~Y
~I\\ \\1

GRIP

h~ \I

h\\\\\r

Y//~/1

P~XIMUM

Y~I

GRIP

t
Minimum

Grip

Maximum

(Maximum Protrusion)

Grip

(Minimum Protrusion)

MINIMUM

FASTENER

PROTRUSION

MAXIMUM

PROTRUSION
"Pt"

DASH NUMBER

NOMINAL DIAMETER

-5

5/32

0.302

0.384

-6

3/16

0.315

0.397

-8

1/4

0.385

0.467

-10

5/16

0.490

0.572

-12

3/8

0.535

0.617

-14

7/16

0.625

0.707

-16

1/2

0.675

0.757

Hi-Lok Pin Protrusion Allowables

Figure 32

EFFECTIVITY:
SRM4

ALL

51-40-02

Page 35
May 15/92

Leariet
Learjetl

STRUCTURAL REPAIR MANUAL


FASTENER SUBSTITUTION
1.

GENERAL
A.

When

adapting

necessary to

use

shown in this manual to suit actual conditions, it may be found


different fasteners than those originally used. This may be due to nonavailability of

the

typical repairs

particular fastener, restricted access, or other difficulties not foreseen in the original repair.
Make selection of substitute hardware per figures 1 thru 8.
The
following the fastener part number is used to identify the length, diameter, finish, or other fastener definitions. These identifications must be the same as the original hardware.
a

B.

C.

SPECIFIED HARDWARE
B100-T Blind Huck Bolt

(NAS523

Pt)

Code

BPT Blind Huck Bolt

(NAS523

Code

UB100-T Blind Huck Bolt

Diameter and

(NAS523 Code

length

N)

(NAS523

Code

length to

TX)

UB100-T Blind Huck Bolt

Diameter and

(NAS523 Code

length

UBP-T Blind Huck Bolt

Diameter and

TX)

(NAS523 Code

length

TX)

grip

to be the same

Diameter and

length

TY)

Diameter and grip


length to be the same

(NAS523 Code

TX)

(NAS523 Code

TX)

TX)

MS90354U
(NAS523 Code

TX)

MS90353U

8P-T Blind Huck Bolt

MS90354

same

TY)

TY)

(NAS523 Code

grip

to be the

(NAS523 Code

(NAS523 Code
MS90354U

same

B100-T Blind Huck Bolt

TY)

MS90353

same

grip

be the

TY)

TY)

grip

to be the

Diameter and

UBP-T Blind Huck Bolt

Code

(NAS523 Code

RESTRICTIONS

MS90353

(NAS523

TX)

MS90354U

(NAS523 Code

SUBSTITUTE HARDWARE

MS90353U

(NAS523 Code

grip

to be the same

Diameter and grip


to be the same

length
I

Diameter and

length

grip

to be the

same

NAS6203-()D
NAS6204-( )D
NAS6205-()D
NAS6206-( )D
NAS6207-( )D
NAS6208-()D

NAS464P3-()
NAS464P4-()
NAS464P5-()
NAS464P6-(
NAS464P7-()

NAS464P&()

Bolt and Blind Bolt Substitutions

Figure 1(Sheet 1)
EFFECTIVITY:

ALL

51-40-03

Pagel
SRM-(

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL

NAS464P9-(
NAS464P10-(
NAS464P12-(
NAS464P14-(

1
i

NAS464P17-(

NAS6209-( )D
NAS6210-( )D
NAS6212-( )D
NAS6214-()D
NAS621-( )D

NAS 1608-(

NAS 1603-( )R thru


NAS 1608-()R

1703-() thru
NAS 1708-(

NAS 1703-( )R thru


NAS 1708-()R

thru

NAS 1603-(

NAS

RESTRICTIONS

SUBSTITUTE HARDWARE

SPECIFIED HARDWARE

Diameter and

length

grip

to be the same

Diameter and

length

grip

to be the same

HT4005-(

Diameter and

grip

NAS 4703-() thru


NAS 4716-(

NAS 4803-() thru


NAS 4816-(

Diameter and

grip

HT4013-3-3

NAS 1581 A3H3

NAS

1220-(

length

Diameter and

length
NAS 1669-

NAS 1669-

to be the

NAS 1669-

DL

Diameter and

NAS 1669-(

DL

NAS 1669-

DL

Diameter and

)L()

grip

grip

to be the same

Diameter and

length

same

to be the same

Diameter and

length
NAS 1669-(

grip

to be the

length
NAS 1669-

grip

to be the same

length
NAS 1669-

same

grip

to be the same

NAS 1670-

NAS 1670-

Diameter and grip


length to be the same

NAS 1670-

NAS 1670-

DL

Diameter and

NAS 1670

NAS 1670-

length
()L()

DL

NAS 1669-(

DL(

Diameter and

length
NAS 1670-

grip

to be the same

grip

to be the same

Diameter and grip


length to be the same

Bolt and Blind Bolt Substitutions

Figure 1 (Sheet 2)

EFFECTIVITY:

ALL

51-40-03

Page 2
Jun 1/95

SRM-I

Leariet

STRUCTURAL REPAIR MANUAL


HL10

RESTRICTIONS

SUBSTITUTE HARDWARE

SPECIFIED HARDWARE

HL10(

Pin

Diameter and

Hi-Lok

length

Lubricant

HL11- i

HL11(

Pin

optional

Diameter and

Hi-Lok

length

length

HL13(

Pin

optional

Diameter and

Hi-Lok

length

HL18(

Pin

length

IPin

HL19-

HL20- i

Pin

Hi-Lok

HL19(

HL20(

Hi-Lok

)Pin

HL21(

Hi-Lok

Diameter and

(-5)-()AIC
08L.proC

Air Industries

HL70-(

Hi-Lok Collar

HL70(

HL70-(

Hi-Lok Collar

HL79-(

Hi-Lok Collar

Hi-Lok Collar

grip

to be the same

Diameter and

length

HL18-( )-()Pin

grip

to be the same

Diameter and grip


length to be the same

length
HL21-(

same

optional

Diameter and

Hi-Lok

grip

to be the

Lubricant
HLla- i

grip

to be the same

Lubricant
HL13

optional

Diameter and

Hi-Lok

HL12(

Pin

grip

to be the same

Lubricant

HL12-(

grip

to be the same

grip

to be the same

htgnelpirg

to be the same

Diameter to be the

Substitutable in

Hi-Lok Collar

HL86G-(

HL79-(

Hi-Lok Collar

HL79(

HL79-5 Hi-Lok Collar

HL82-( )Hi-Lok
HL86-(

Hi-Lok Collar

HL70-5 Hi-Lok Collar

Collar

Hi-Lok Collar

Hi-Lok Collar

)A

HL86G-(

same

same

diameter, except

HL72-(

Diameter and

-5 diameter

Diameter to be the

same

Diameter to be the

same

Lubricant

optional

II

Collar

Hi-Lok Collar

HL87-5 Hi-Lok Collar

HL86-5 Hi-Lok Collar

HL90-( )A Hi-Lok Collar

HL90(

i )A Hi-Lok Collar

Lubricant

optional

Lubricant

optional

Diameter to be the

same

Hi-Lok Substitutions

Figure 2
EFFECTIVITY:

ALL

51-40-03

Page
SRM-4

Jun 1/95

STRUCTURAL REPAIR MANUAL


SPECIFIED HARDWARE

SUBSTITUTE HARDWARE

locking feature,
length, material, and finish

Thread size,

NAS1832

SL601-(
Shur-Lok Blind Threaded
Honeycomb Insert

Shur-Lok

to be the same

locking feature,
length, material, and finish

Thread size,

NAS1833

SL602-(

Through

Threaded

to be the same

Insert

Hole size,

NASi834(

SL603-(
Shur-Lok

RESTRICTIONS

length and

material to be the

Spool Type

same

Insert

NAS1834(

SL604-(
Shur-Lok CSK Spool
Honeycomb Insert

)II.(

length and

material to be the

Type

NAS1836

Thread size,

length,

Shur-Lok Blind Threaded

SLGOI-(

NAS1832

Hole size,

same

locking feature,

material and finish

locking feature,
and finish
material,
length,

Thread size,

to be the same

SL602-

NAS1833

Thread size,

locking feature,

length, material,

and finish

to be the same

SLsa3-(

NAS1834(

locking feature,
length, material, and finish

Thread size,

to be the same

NAS1834(

)K

SL604-(

Thread size,

locking feature,

length, material, and finish


to be the same

locking feature,
length, material, and finish

Thread size,

NAS1836(

to be the same

Honeycomb Insert Substitutions


Figure 3

ALL

1/95 1-40- 3

Page 4
Jun

Learjet

STRUCTURAL REPAIR MANUAL


SUBSTITUTE HARDWARE

SPECIFIED HARDWARE

RESTRICTIONS

AN320

hns14145

Size to be the

same

AN320

MS14145L

Size to be the

same

AN340

MS35649

Material 8 size to be

same

AN345

MS35650

Material 8 size to be

same

AN364-( )C

MS21042-(

AN364-( )D

MS21083D(

MS20341-(

MS35649

Material 8 size to be

same

MS20341-(

MS35650

Material 8 size to be

same

AN364D

MS21083D(

MS20341

MS35649

Material 8 size to be

same

MS20341-

MS35650

Material 8 size to be

same

MS20364

MS21042

Size to be the

same

MS20364

MS21083N

Size to be the

same

MS20364

MS21083N

Size to be the

same

MS20364

MS21042

Size to be the

same

MS20364D

MS21083D

Size to be the

same

MS20365

MS21042

Size to be the

same

Nut Substitutions

Figure 4 (Sheet 1)

EFFECTIVITY:

ALL

51-40-03

Page5
SRM-4

Jun 1/95

Learjet
STRUCTURAL REPAIR MANUAL
SPECIFIED HARDWARE

MS20365

SUBSTITUTE HARDWARE

RESTRICTIONS

MS21044N

Size to be the

same

MS20365

MS21044N

Size to be the

same

MS20365

MS21042

Size to be the

same

MS20365B

MS21044B

Size to be the

same

MS20365D

MS21044D

Size to be the

same

MS210244N

MS21042

Size to be the

same

MS21042

Size to be the

same

MS21083N

MS21042

Size to be the

same

MS35650-3395

MS35650-3395T

Size to be the

same

MS21045

or

NAS395

NAS395

Size to be the

same

NAS396

NAS396

Size to be the

same

Size to be the

same

MS21042

NAS679

Nut Substitutions

Figure 4 (Sheet 2)

EFFECTIVITY:

ALL

51-40-03

Page 6
SRM-4

Jun 1/95

Learjet
~Learjetl

STRUCTURAL REPAIR MANUAL


SPECIFIED HARDWARE

RESTRICTIONS

SUBSTITUTE HARDWARE

MS21047

NAS 680

Material 8 size to be the

same

MS21049

NAS 681

Material 8 size to be the

same

MS21051

NAS 682

Material 8 size to be the

same

MS21053

NAS 683

Material

size to be the

same

MS21055

NAS 684

Material 8 size to be the

same

MS21057

NAS 685

Material 8 size to be the

same

MS21059

NAS 686

Material 8 size to be the

same

MS21061

NAS 687

Material 8 size to be the

same

MS21062

NAS 687

Material 8 size to be the

same

MS21069

NAS 697

Material 8 size to be the

same

MS21071

NAS 696

Material 8 size to be the

same

MS21073

NAS 698

Material 8 size to be the

same

MS21075

NAS 1068

Material 8 size to be the

same

MS21086

NAS 1067

Material 8 size to be the

same

NAS680A(

MS21047L(

NAS680C(

MS21046-(

NAS680C( )M

MS21048L(

NAS680C(

MK

MS21048L()K

NAS680X(

MS21

NAS681A(

MS21049L(

NAS681C(

MS21

NAS681C()M

MS21050L()

NAS681C(

MK

047-(

050-(

MS21050L( )K
MS21049-(

NAS681X(

Nutplate Substitutions
Figure 5 (Sheet 1)

EFFECTIVITY:

SRM-4

ALL

51-40-03

Page 7
Jun1/95

Learjet
STRUCTURAL REPAIR MANUAL
SPECIFIED HARDWARE

SUBSTITUTE HARDWARE

NAS682A(

MS21

NAS682C()

MS21052-(

NAS682C ()M

MS21052L(

NAS682C(

MK

051L()

MS21052L( )K

NAS682X(

MS21051-(

NAS683A

MS21053L(

NAS683C(

MS21054-(

NAS683C( )M

MS21054L(

NAS683C ()MK

MS21054L()K

NAS683X(

MS21053-(

NAS684A(

MS21055L(

NAS664C(

MS21056-(

NAS684C()M

MS21056L(

MK

NAS684C(

RESTRICTIONS

MS21056L()K

NAS684X(

MS21055-()

NAS685A(

MS21057L()

NAS685C

M521058-(

NAS685C()M

MS21058L(

NAS685C ()MK

MS21058L( )K

NAS685X

MS21059-()

NAS686A(~

MS21060L(

NAS686C()

MS21060-(

NAS686C()M

MS21060L(

Nutplate Substitutions
Figure 5 (Sheet 2)
EFFECTIVITY:

ALL

51-40-03

Page 8
SRM-4

Jun 1/95

Learjet
Learjet

STRUCTURAL REPAIR MANUAL


SUBSTITUTE HARDWARE

SPECIFIED HARDWARE

NAS6866C()MK

MS21060L()K

NAS686X(

MS21059-(

NAS687A(

MS21 061L(

NAS687C()

MS21062-(

NAS687C()M

MS21062L()

NAS687C ()MK

MS21062L( )K

NAS687X(

MS21061-(

NAS696A(

MS21 071L(

NAS696C()

MS21072-(

NAS696C( )M

MS21072L(

NAS696C( )MK

MS21072L( )K

NAS696X()

MS21071-(

NAS697A()

MS21069L(

NAS697C

MS21070-(

NAS697C()M

MS21070L(

NAS697X(

MS21069-(

NAS698A(

MS21073i(

NAS698C(

MS21074-(

NAS698C( )M

MS21074L(

MK

NAS698C(

NAS698X()

RESTRICTIONS

MS21074L( )K
MS21073-(

Nutplate Substitutions
Figure 5 (Sheet 3)
EFFECTZVITY:

ALL

51-40-03

Page 9
Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


SUBSTITUTE HARDWARE

SPECIFIED HARDWARE

MS21086L()

NAS1067A(
NAS1O67C(

MS21087-(

NAS1067C()M

MS21087L(
MS21087L( )K

MK

NAS1067C(

RESTRICTIONS

NAS1067X(

MS21086-(

NAS1O68A(

MS21075L(

NAS1O68C(

MS21076-(

NAS1O68C( )M

MS21076L(

NAS1068X(

MS21075-(

LHA228-

MF60O1-

Size to be the

same

LHA27M2860-

MF6331-

Size to be the

same

221HA27M22-

MF6300-

Size to be the same


("F" or "RM" prefix optional)

52LHA227-(

MF6000-(

Size to be the

MF6000-

RM52LHA227-

Size to be the

same

MF6001-

LHA228-

Size to be the

same

MF6300-

22LHA27M22-

Size to be the

same

MF6331-

LHA27M2860-

Size to be the

same

hnl4sog

M14700E

450"F Max

M146OOH

M14700HE

450"F Max

M14710E

450"F Max

hn14610H

M14710HE

4500F Max

M14620

M14720E

4500F Max

M14620H

M14720HE

450"F Max

same

("RM" prefix optional)

M1461O

Nutplate Substitutions
Figure 5 (Sheet 4)
EFFECTIVITY:

SRM-4

ALL

51-40-03

Page 10
Tun1/95

Learjet
Leariet
STRUCTURAL REPAIR MANUAL
SPECIFIED HARDWARE

SUBSTITUTE HARDWARE

RESTRICTIONS

M14635H-(

M14735HE

4500F Max

M14600H

M14700HE

4500F Max

M14640

M14740E

450"F Max

M14640H

M14740HE

450"F Max

M14700

M14700E

450"F Max

M14740

M14740E

450"F Max

14600

M14700E

4500F Max

14600H

4600H

Thread size to be the same


(approx. 3x weight penalty)

14600H

14700HE-(

450"F Max

14610H

14710HE

4500F Max

14620H-(

14720HE

4500F Max

14650H-(

14750H-( )E

4600

470E

450"F Max

4600H

4700HE

450"F Max

Nutplate Substitutions
Figure 5 (Sheet 5)
EFFECTIVITY:

ALL

51-40-03

Page 11
SRM-4

Jun 1/95

Learjet
IL~l-itl

STRUCTURAL REPAIR MANUAL


SPECIFIED HARDWARE

SUBSTITUTE HARDWARE

Avdel 1204

CR2Ei62 Widedraw

Diameter and

(NAS 523 Code

same

Cherrylock
(NAS523 CODE ADD)

CR3214

CR2245 Bulbed

CR2164

Cherrylock
AGH)

CR3245

CR2248 Bulbed

Cherrylock

CR3242

CR2249 Bulbed

CR2662

(NAS523 CODE

ARD)

CR3242

Cherrymax
(NAS523 CODE ARD)
e

CR3243

Cherrymax

Cherrymax
CODE
ARD)

CR3243

Cherrymax

the

Cherrymax

Diameter and

(NAS523 CODE

ACX)

the

Cherrymax

(NAS523 CODE

(BAC

R15FP

CR2249 Bulbed

ARO)
E(

Cherrylock

NAS1398B

CR2263 Wiredraw

(NAS523 CODE

RK)

NAS1398D

CR2163 Wiredraw

(NAS523 CODE

RL)

NAS1399C

(NAS523 CODE
CR2662 Wiredraw

(NAS523 CODE

RS)

NAS1399D

(NAS523

(NAS523 CODE

CODE

RP)

NAS17388

(NAS523 CODE

AAO)

NAS17398

AAT)

NAS17388

AAO)

NAS17398

AAT)

Cherrylock
RS)

the

Diameter and

Diameter and

Diameter and

(NAS523 CODE

(NAS523 CODE

(NAS523 CODE

Cherrylock
AAO)

the

Cherrylock
PV)

the

Cherrylock
ARE)

the

Cherrylock
ARD)

the

to be

grip length

to be

grip length

to be

grip length

to be

grip length

to be

grip length

to be

grip length

to be

grip length

to be

grip length

to be

grip length

to be

grip length

to be

grip length

to be

same

the

(NAS523 CODE

grip length

same

Cherrylock

CR2248 Bulbed

(NAS523 CODE

the

to be

same

PR)

CR2249 Bulbed

(NAS523 CODE

Cherrylock
PW)

Diameter and

(NAS523 CODE

CR2248 Bulbed

(NAS523 CODE

the

grip length

same

CR2162 Wiredraw

CR2249 Bulbed

(NAS523 CODE

Cherrylock
RK)

to be

same

Diameter and
the

grip length

same

Diameter and
the

to be

same

CR4622 Wiredraw

CR3252

grip length

same

Diameter and

to be the

same

Diameter and
the

length

same

Diameter and
the

(NAS523

Cherrylock
PZ)

Diameter and
the

Cherrymax
(NAS523 CODE ATK)

PV)

(NAS523 CODE

Cherrylock
RS)

Cherrymax
(NAS523 CODE ASK)

(NAS523 CODE

(NAS523 CODE

RESTRICTIONS

same

Diameter and
same

Diameter and
same

Diameter and
same

Diameter and
same

Rivet and Blind Rivet Substitutions

Figure 6
EFFECTIVITY:

ALL

51-40-03

Page 12
SRM-4

Jun 1/95

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


SPECIFIED HARDWARE

AN507

RESTRICTIONS

SUBSTITUTE HARDWARE

MS24693

Size and

length to be the same

AN507B

MS24693

BE

Size and length to be the

AN507C

MS24693

Size and

length

to be the same

Size and

length

to be the same

same

AN507DD

MS24693

AN507PB

MS24693

CB

Size and

length

to be the

AN507UB

MS24693

Size and

length

to be the same

Size and

length to

AN509

AN509
AN509

AN509C

AN509DD
AN515
AN515

same

be the

same

MS24694

Size and length to be the

same

MS24694

Size and

length to

be the

same

MS24694

Size and

length to be the

same

MS35206

Size and

length to

be the

same

MS35206

Size and

length to

be the

same

AN515B

MS35214

Size and

length to be the same

AN515C

MS51957

Size and

length

to be the same

MS35213

Size and

length

to be the

MS35207

Size and

length to be the same

AN515DD
AN520

be the

same

to be the

same

be the

same

Site and length to be the

same

AN520B

MS35215

Size and

length to

AN520C

MS51953

Size and

length

MS35219

Size and

length to

AN520DD
AN 530-

RF

AN 530-

Material, finish, diameter and

AN 507

MS24693

length
AN 509

MS24694

same

to be the

same

Material, finish, diameter and

grip length to

be the

same

Screw Substitutions

Figure 7 (Sheet 1)
EFFECTIVITY:

ALL

51-40-03

Page
SRM-4

13

Jun 1/95

Leariet
~Learjet
STRUCTURAL REPAIR MANUAL
SUBSTITUTE HARDWARE

SPECIFIED HARDWARE

MS27039

NAS 220

RESTRICTIONS

thru

Material, finish, diameter and

NAS 226
AN 515

MS35206-(

grip length
R

to be the

Diameter and

same

length

to be

the,

length

to be

the,

length

to be

the,

length

to be

the,

length

to be

the,

length

to be

the,

same

AN 520

MS35207

Diameter and
same

AN 5158

MS35214

Diameter and
same

AN 5208

MS35215-(

Diameter and
same

AN 515C

MS51957

Diameter and
same

AN 520C

MS51958

Diameter and
same

NAS220-( )thru

MS27039(

Diameter, grip length, and


material to be the

NAS226

same

NAS8702

NAS8702U

Grip length

to be the

same

NAS8703

NAS8703U

Grip length

to be the

same

AOL4200

NAS1221

Material, diameter and grip

length
FAS4200

NAS1221

to be the same

Material, diameter and grip

length

to be the same

Screw Substitutions

Figure 7 (Sheet 2)
EFFECTIVITY:

ALL

51-40-03

Page
SRM-4

14

Jun 1/95

STRUCTURAL REPAIR MANUAL

SPECIFIED HARDWARE

SUBSTITUTE HARDWARE

RESTRICTIONS

AN935

MS35338

Material 8 size to be the

same

AN936

M535333

Material 8 size to be the

same

AN960D-

AN960JD-

Size and thickness to be the


same

AN960JD-

AN960PD-

Size and thickness to be the


same

MS35333

AN936A

Material 8 size to be the

same

MS35335

AN936B

Material 6 size to be the

same

MS35338

AN935

Material 8 size to be the

same

Washer Substitutions

Figure 8
EFFECTIVITY:

SRM-4

ALL

51-40-03

Page 15
Jun1/95

Learjet

STRUCTURAL REPAIR MANUAL


COUNTERSINKING
i.

GENERAL
A.

For all-around purposes, the micro-stop countersink, fitted with a removable cutter, has been
the most efficient countersinking tool for use with portable equipment.

B.

micro-stop countersinking tool rotates on a bearing inside an adjustable locking


piece assembly. The foot piece (or stop, as it is often called) threads onto the ~shaft
bearing, enabling depth adjustments to be made.
Markings, indicating depth differentials in 0.001-inch increments, surround the bevelled circumference of the locking sleeve to aid in depth adjustments.
The adjustment is made by pulling the sleeve back and turning the stop to deepen or to shallow the
cut. The sleeve is then dropped back into its original position to effect a lock.

proved

The shaft of the


sleeve and foot

C.
D.

NOTE:
E.

The

Ensure that the

locking splines intermesh; only then is the adjustment securely locked.

stop countersink may be adjusted

precautions are

or

set up

on

the

part to

be countersunk

provided

the

following

taken:

(1) Ensure that the adjustable foot piece is extended far enough that the cut will not be too deep.
(2) Gradually increase the depth adjustment until the depth and diameter of the hole are the same

as

the size of the fastener head.

(3) If

at all

doubtful of the accuracy of the

adjustment, try

the countersink

piece

on a

of scrap sheet

stock before

F.

G.

using.
pilot pin guides the spinning cutter as it cuts into the material. The pilot pin should be approximately 0.002 inch less in diameter than the fastener hole. This allows the cutter to spin without binding in the hole. Cutter-pilots which are more than 0.002 inch smaller than the hole size will allow the
cutter to wobble, resulting in a lop-sided countersink.
Cutters are available in a variety of cutting angles. 100-degree cutters are most frequently used. The
cutting angle is stamped on each cutter as shown in Figure i.
The

CAUTION:

ENSURE THAT THE CUTTER IS TIGHTENED IN THE COUNTERSINK SHAFT


BEFORE USING THE STOP COUNTERSINK.

H.
I.

When the

Keep

the

stop countersinking tool

following

is used, it should be held

rules in mind when

(1) Before using, check countersink

using

the

cutter for

stop

as

shown in

Figure

1.

countersink:

pilot size, sharpness, degrees

of cutter, and true

run-

ning.
(2)
(3)
(4)
(5)
(6)
(7)
(8)

Back up the countersink to a safe depth of cut, then


Hold countersink at a 90-degree angle to material.

to

proper

setting.

Take full

depth of cut each time.


Apply pressure directly behind countersink.
Face on the stop countersink must be highly polished to prevent marring the material.
Select the size and length fastener to be installed and use it to judge depth of countersink.
Do not allow the stop to spin on the material.

EFFECTIVITY:
SRM-4

gradually increase depth

ALL

51-40-04

Page 1
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

Holding

of

Countersink

Microstop

Adjusting

Tool

of

Microstop

Countersink Tool

Countersink Cutter

Micro-Stop Countersink
Figure 1

NOTE:
Countersink dimensions in the table are given in terms
of the maximum diameter, because this is the most si~nificant dimension in order to avoid too
tersink which may produce
the riveted material.

knife-edge

Minimum countersink diameters

the

are

deep

a coun-

condition in

determined

by

1000

~r

1~

a~ i

aerodynamic flushness requirements.

practice, the proper depth of the countersink


is determined by driving a test rivet in a scrap piece of
metal. The depth adjustment of the micro-stop countersink tool is gradually increased until a countersink
depth is obtained that provides the required flushness
of a driven rivet. Once the proper countersink adjustIn actual

ment has been established in this manner, the tool

be used for

can

MAXIMUM
RIVET

COUNTERSINK

DIAMETER

DIAMETER "A"

1/8

0.200

5/32

0.250

3/16

0.305

1/4

0.405

countersinking on the actual job.

Maximum Countersink Diameter for Shear Head Rivets

Figure 2

EFFECTIVITY:

ALL

51-40-04

Page 2
SRM~

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

DIMPLING
MAXIMUM TOTAL SHEET THICKNESS FOR

COUNTERSINKING

DIMPLING WITH STATIONARY SQUEEZERS


COIN DIMPLING

Minimum

Joint
Rivet

Minimum

Thickness

Minimum

Maximum

Surface

for Sub-CSK

Thickness

Thickness

or

Sheet

When Outer

Screw

Thickness

Sheet Is

Size

For Csk

3/32
1/8
5/32

Conventional

1 or 2

Single

Two

Dimpled

Dimpling

Sheets

Sheet

Sheets

0.032

0.050

0.040

0.020

0.050

0.063

0.040

0.063

0.050

0.020

0.063

0.063

0.050

0.071

0.063

0.020

0.071

0.071

3/16

0.063

0.080

0.071

0.025

0.071

0.071

1/4

0.071

0.112

0.063

0.032

0.071

0.080

RIVETS

SCREWS
5-32

0.050

0.076

0.050

0.020

0.050

0.063

8-32

0.050

0.084

0.063

0.020

0.071

0.071

10-32

0.063

0.095

0.071

0.032

0.071

0.071

1/4-28

0.071

0.121

0.063

0.032

0.071

0.080

0.071

0.147

5/16-24

0.025 minimum sheet thickness may be countersunk for 3/32 rivets for attachment of skins

specified by repairs

as

well

as

nutplates

when

within this manual.

Maximum and Minimum

Requirements for Countersinking and Dimpling for


Flush Rivets and Screws

Figure 3
EFFECTIVITY:
SRM~

ALL

51-40-04

Page 3
May 15/92

Learjet
~LearjetJ

STRUCTURAL REPAIR MANUAL


MS20426 RIVET
DIAMETER
SHEET
GAGE

1/8

5/32

3/16

114

5/16

3/8

0.040

0.181

0.242

0.309

0.432

0.520

0.650

0.045

0.175

0.236

0.303

0.426

0.514

0.644

0.050

0.170

0.230

0.297

0.420

0.508

0.638

0.056

0.166

0.223

0.290

0.413

0.501

0.631

0.063

0.161

0.216

0.282

0.405

0.493

0.623

0.071

0.158

0.210

0.272

0.395

0.483

0.613

0.080

0.154

0.204

0.263

0.385

0.473

0.603

0.090

0.151

0.199

0.254

0.373

0.461

0.591

0.100

0.149

0.195

0.248

0.361

0.449

0.579

0.112

0.147

0.191

0.242

0.349

0.435

0.565

0.125

0.145

0.188

0.236

0.339

0.422

0.549

0.140

0.143

0.185

0.231

0.330

0.411

0.531

0.160

0.141

0.182

0.226

0.320

0.399

0.512

0.180

0.140

0.179

0.222

0.313

0.389

0.497

0.190

0.139

0.178

0.221

0.310

0.386

0.491

0.200

0.138

0.177

0.219

0.307

0.382

0.485

0.224

0.137

0.175

0.216

0.301

0.375

0.474

0.250

0.136

0.173

0.213

0.296

0.369

0.464

HEAD FLUSH WITH SURFACE

Sheet

Average

Hole

Diameter

Gage

Average Hole Diameter of Countersunk Holes


Figure 4
EFFECTIVITY:
sI1M-a

ALL

51-40-04

Page 4
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

Measure

This

NOTE:

Flushness

at

Point

Tolerance limits for the lower

portions of the wing, fuselage, and tail surfaces are the same as the
edge of stainless steel nose cup is Zone 1. The

corresponding upper surfaces. Inside nacelle to aft


interior of the inlet duct is Zone 2.
Rivets

or screw

heads

protruding

heads below the surface

Flushness
The heads of flush

on

rivets,

contour to within the

screws,

ZONE

SRM4

and Hi-Loks

on

are

considered

positive.

Rivets

or screw

negative.
as

shown:

the exterior of the aircraft shall be flush with the local skin

tolerances:

DRIVEN

BLIND

RIVETS

SCREWS

RIVETS,
HI-LOKS

CAMLOKS

+0.001

+0.002

-0.000

-0.005

+0.005

+0.002

+0.005

-0.000

-0.005

-0.010

+0.005

+0.005

+0.010

-0.000

-0.005

-0.020

Requirements and Tolerances


Figure 5 (Sheet 1 of 6)

Flushness

LES1054J

EFFECTIVITY:

above the surface

considered

sharp contours shall be measured

following

are

ALL

51-40-04

Page 5
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

Zone I

f~

Zone 2
Zone3

Requirements and Tolerances


Figure 5 (Sheet 2 of 6)

Flushness

EFFECTIVITY:

MODEL 23/24SERIESAIRCRAFT

51-40-04

Page
SRM-4

May.15/92

Learjet
~tl
STRUCTURAL REPAIR MANUAL

Zonel
Zonel

~j

ZaneBI

0000

Requirements and Tolerances


Figure 5 (Sheet 3 of 6)

Flushness

EFFECTIVITY:
SRM-4

MODEL 25 SERIES AIRCRAFT

51-40-04

Page 7
May 15/92

STRUCTURAL REPAIR MANUAL

Zone 1

~il

Zone 2

Zone3

L_I

0000

Requirements and Tolerances


Figure 5 (Sheet 4 of 6)

mushness

LESl054r

EFFECTIVITY:
SRM~

MODEL

28/29SERIESAIRCRAFT

51-40-04

Page 8
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

Zone 1
Zone 2

Zone 3

00000

LESl054r

EFFECTIVITY:

Requirements and Tolerances


Figure 5 (Sheet 5 of 6)

mushness

MODELSI SERIESAIRCRAFT

51-40-04

Page
SRM~

May 15/92

Learjet

STRUCTU RAL REPAIR MANUAL

Zone

Zone 2
Zone 3

0000

LES1054J

EFFECTIVITY:
sua~

Plushness

Requirements and Tolerances


Figure 5 (Sheet 6 of 6)

MODEL 35/36SERIESAIRCRAFT

51-40-04

Page 10
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
AIRCRAFT SUPPORT FOR ALIGNMENT AND REPAIR
ALIGNMENT AND SYMMETRY INSPECTION (See

i.

A.

STRUCTURAL IDENTIFICATION

Figure 1.)

Toolsand

Equipment

NOTE:

Equivalent substitutes may be used in lieu of the following:

PART NUMBER

NAME

Scale, 24-inch

MANUFACTURER

USE

Commercially available

Required for
point AR

Commercially available

Required for
points 3L, 3R,

Machinist type with


adapter and level

an

bubble

Scale, 48-inch
Machinist type with
an

5L, 6L, 5R, and

adapter and level

6R

bubble

Check

6226 Parts 1 thru 4

Contour Boards

2420000

Clinometer

wing and

horizontal

(Wing)

12126 Parts 1 thru 4

stabilizer

2332000-1 (Tail)

contour

2471004

Check

angle

of incidence
Steel

Tape,

25 foot

Commercially available

Measure from

points 3LU to

Lightweight Steel Tape

9L, 3RU

to

9R,

and distance
between

landing

gear

Commercially available

Plumb Bob

Marking
locations

Commercially available

Transit

Elevation

readings
Commercially available

Spirit Level

EFFECTIVITY:
SRM-4

ALL

Preliminary
leveling

51-50-00

Page 1
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


B.

alignment data can be of value in locating deformed structure after a hard landing or seturbulence and/or maneuvers. It should not, however, be considered a criterion for determining structural integrity. In some instances, field checks indicate that an aircraft is out of the tolerances
presented, but experience shows that the aircraft may be aerodynamically acceptable because its fly-

The aircraft
vere

C.

D.

ing qualities, performance, and handling characteristics meet established criteria.


A thorough and searching inspection should be made of the airframe, with particular attention given
to fittings where heavy weight masses are carried. A sampling of fasteners may be removed to be examined for evidence of shear and tension deformation. Buckling of stressed skins, which did not exist before the hard landing or high-G maneuver, is cause for careful inspection of the substructure
and of the pressurized skins for crack propagation. Skin buckling in itself is not necessarily detrimental structurally if the buckles do not cross a row of rivets and have not loosened any rivets. When adequate inspection reveals the structure to be sound and functional checks of the controls and landing
gear (after hard landings) are normal, a check flight will be made.
If the results of the structural inspection and flight test are satisfactory, the aircraft is acceptable for
flight status. If flight tests indicate the aircraft is either laterally or directionally out of tolerances, and
cannot be corrected by rerigging (within the tolerances given in the applicable maintenance manual),
a complete alignment check should be made, and results of the alignment check and the flight test
should be forwarded to Learjet Field Service for evaluation.

SURFACE ALIGNMENT INSPECTION

2.

A.

Geometry Check
(1) The geometry check as illustrated
All measurements

B.

are

in

Figure 1 can be made with the aircraft resting on the ground.


points illustrated with a steel tape.

taken from the

Elevation Check

(1) To satisfactorily perform

an

elevation check, the aircraft must be drained of all fuel. To

ensure

readings are obtained, an engineers level or transit must be used. Preliminary leveling with a spirit level may precede the actual leveling of the aircraft with a transit to place the aircraft in an approximately level position.
that correct

EFFECTIVITY:
srzM-4

ALL

51-50-00

Page 2
May 15/92

Learjet
L~arjet
STRUCTU RAL REPAIR MANUAL
3.

LEVEL AND ELEVATION INSPECTION PROCEDURES

A.

Moc~el 23/24 Series Airmaft

Alignment and Symmetry Inspection


Personnel must not be

NOTE:

permitted

on or

in the aircraft while the

alignment inspection

is

in progress.

Aircraft shall be

parked

inside

hangar and hangar

doors shall be closed

during

this in-

spection.
(1) Level aircraft laterally, longitudinally, and check aircraft elevation, as follows:
(a) Defuelaircraft. (Refer to Section I in the appropriate Leajet Service Manual for defueling instructions.)
(b) Place aircraft on jacks with landing gear fully extended and clear of hangar floor. Aircraft
door shall be closed. (Refer to Section I in the appropriate Learjet Service Manual for jacking

procedures.)
(c) Perform preliminary aircraft leveling as follows:
1) Level. laterally by placing level across inboard
of the inboard seat rails to obtain

(d) Perform final aircraft leveling


1) Position transit, mounted
Shoot

3)

Insert

top surface of

one

level.

follows:

tripod (approximately 24 inches high), at the right aft side


required to shoot all check points.
lateral leveling points 3L and 3R. Place adapter point in screw heads when hold-

of aircraft

2)

as

seat rails. Place level on

longitudinal leveling. Adjust jacks to

on a

as

ing scale at these locations.


phillips head screwdriver through

scale

adapter

and hold in

screw

head at frame

28.

4)
5)
6)

Shoot

longitudinal leveling point BR.

Remove radome

Shoot

cover

and insert scale

adapter through right tooling hole in frame

NOTE:

The

EXAMPLE:

following is an example for leveling an aircraft.

Frame Number

*Reference Point

Scale

2+3

~4

Reading

23.96
35.46

+11.00

35.46

34.96

0.50

0.50

point

37.00 (frame 28

SRM-4

NOTED

larger

than frame 1

34.96, the forward end of the aircraft (frame 1) is 0.50

Adjust nose jack as required


Reference

28

Since frame 28 measurement is 35.46 and is


ment at

EFFECTIVITY:

1.

longitudinal level point AR.

too low.

for level condition.

23.96 is the distance between WL 13.039 (frame 1


screw

measure-

tooling hole)

and WL

head).

51-50-00

Page 3
May 15/92

STRUCTURAL REPAIR MANUAL


NOTE:

Accurate elevations and


ond decimal is

7)

required.

recording of check points 5L, 5R, 6L and 6R to the secLocate all scales for large numbers to be at bottom.

Shoot and record elevations of check

NOTE:

See

1 for

Figure

points

points 5L, 6L, 5R and

to locate contour board

6R.

on

upper

wings

and horizontal

stabilizer.

8)

Place contour boards


on

wings

at

across

upper

dence at each station in

9)

wing surfaces at points referenced

points specified
degrees and
on

Place contour board

on

contour

boards;

use a

in

Figure 1. Locate
angle of inci-

clinometer and record

minutes.

stabilizer at BL 19.40. Actuate stabilizer until clinometer

board) indicates the stabilizer leading edge is 0030 down.


checks shall be made with the stabilizer in this position.
on

contour

10) Place contour boards


Locate at

across

points specified

on

upper stabilizer surface at all


contour

boards;

use a

points

(placed

All incidence

referenced in

Figure

1.

clinometer and record incidence in de-

grees and minutes.

(e) Measure and record distances from 3LU to 9L and 3RU to 9R.
(f) Drop a plumb bob from left main landing gear (LG), right main landing gear (RC), and nose
landing gear (NG) to hangar floor and mark locations on hangar floor. Remove Plumb bobs.

(g)

Measure and record distances from 3LU to 9L and from 3RU to 9R.

(h) Remove contour boards, clinometer, and levels from aircraft.


(i) Move aircraft, then measure and record distances from NG to LG, from LG

to

RG, and from

RG to NG.

(j)

EFFECTIVITY:

Remove aircraft from

jacks and secure aircraft as desired.

MODEL 23/24 SERIES AIRCRAFT

51-50-00

Page 4
SRM~

May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

I\

I II\

3RU-9R

3LU- 9L

3RU

nn

~I

~1
3LU

1:
LG

(Opposite)

SYMMETRY CHECK
ALIGNMENT
WING TO HORIZONTAL STAB.
POINTS

DISTANCE

3LU to 9L

3RU to 9R

ALIGNMENT

SYMMETRY CHECK

LANDING GEAR
POINTS

DISTANCE

NG to LG
NG

to

RG

LG to RG

(TYPICAL)
Aircraft

Alignment and Symmetry inspection


Figure 1 (Sheet 1 of 3)

MODEL23/24 SERIESAIRCRAFT
SRM4

5150-00

Fage 5
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

BL 65.60
BL 50.20
BL
BL 19.

BR

,o
WS 53.15--/

~C

WS 92.52

AR

~3

WS 157.
WS 181.1

WING
STATION

ANGLEOF

LH WING

53.15

STABILIZER INCIDENCE

INCIDENCE
RH WING

i BUFF LINE

LBL19.40

LBL34.80

92.52

157.48

LBL50.20

181.10

LBL65.60

INC.

BUTT LINE

INC.

RBL 19.40

RBL34.80

RBL50.20

RBL65.60

ELEVATION CHECK POINTS

POINTS

ACTUAL

ELEVATION

ELEVATION

DIFFERENCE

5L

5R
6L
6R

(TYPICAL)
Aircraft

EFFECTIVITY:
SRM-4

Alignment and Symmetry Inspection


Figure 1 (Sheet 2 of 3)

MODEL 23/24 SERIES AIRCRAFT

51-50-00

Page 6
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

3RU

51
I

9R

[SldnSplife)

(TYPICW

BOTTOM OF HORIZONTAL STABILIZER

CTYPICAL)

6R

6L

Opposite
TOP OF WING TIP

oo

)PylonAccess

OUTED

gR--i

5R
5L

Opposite

FWD

(TYPICAL)

ol

BOTTOM OF WING TIP

(TYPICAL)

UNDERSIDE OF RIGHT PYLON


Frame 28

(ReD

--BR
AR

(Framel
Tool Hole)

(TYPICAL)
RIGHT SIDE OF FIISELAGE

NOSE (RADOME REMOVED

Aircraft

EFFECTIVITY:

Alignment and Symmetry Inspection


Figure 1 (Sheet 3 of 3)

MODEL 23/24 SERIES AIRCRAFT

51-50-00

Page
SRM-Q

May 15/92

Learjet

SIRUCTURAL REPAIR MANUAL


B.

Mode2 25 Series Aiucraft

Alignment and Symmetry Inspection


Personnel must not be

NOTE:

permitted

in the aircraft while the

on or

alignment inspection

is

in progress.

parked

Aircraft shall be

inside

hangar

and

hangar

doors shall be closed

during

this in-

spection.
(1) Level aircraft laterally, longitudinally, and check aircraft elevation, as follows:
(a) Defuel aircraft. (Refer to the appropriate Learjet Service/Maintenance Manual for
instructions.)

(b) Place aircraft

with

jacks

on

defueling

landing gear fully extended and clear of hangar floor. Aircraft


appropriate Learjet Service/Maintenance Manual for jack-

door shall be closed. (Refer to the

ing procedures.)
(c) Perform preliminary aircraft leveling as follows:
1) Level laterally by placing level across inboard
of the inboard seat rails to obtain

(d) Perform final aircraft leveling


1) Position transit, mounted

as

seat rails. Place level

longitudinal leveling. Adjust jacks

on

top surface of

one

to level.

follows:

tripod (approximately 24 inches high), at the right aft side


required to shoot all check points.
lateral leveling points 3L and 3R. Place adapter point in screw heads when hold-

of aircraft

on a

as

2)

Shoot

3)

ing scale at these locations.


Insert phillips head screwdriver through

scale

adapter

and hold in

screw

head at frame

27.

4)
5)
6)

Shoot

longitudinal leveling point BR.

Remove radome

Shoot

cover

longitudinal

NOTE:

The

EXAMPLE:

and insert scale

level

adapter through right tooling hole in frame

following is an example for leveling an aircraft.

Frame Number

.Reference Point

Scale

2+3

64

Reading

27

35.46

+11.00

35.46

34.36

1.10

1.10

point

36.40 (frame 27

SRM-4

larger

than frame 1

34.36, the forward end of the aircraft (frame 1) is 1.10

Adjust nose jack as required

EFFECTIVITY:

23.36

Since frame 27 measurement is 35.46 and is


ment at

Reference

1.

point AR.

too low.

for level condition.

23.36 is the distance between WL 13.039 (frame 1


screw

measure-

tooling hole)

and WL

head).

MODEL25 SERIESAIRCRAFT

51-50-00

Page 8
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
NOTE:

ond

7)

recording of check points 5L, 5R, 6L and 6R to the secdecimal is required. Locate all scales for large numbers to be at bottom.

Accurate elevations and

Shoot and record elevations of check


NOTE:

See

Figure

1 for

points

points 5L, 6L, 5R and 6R.

to locate contour board on

upper

wings

and horizontal

stabilizer.
across upper wing surfaces at points referenced in Figure i. Locate
wings at points specified on contour boards; use a ciinometer and record angle of incidence at each station in degrees and minutes.
9) Place contour board on stabilizer at BL 19.40. Actuate stabilizer until clinometer (placed
All incidence
on contour board) indicates the stabilizer leading edge is 0030 down.
checks shall be made with the stabilizer in this position.
10) Place contour boards across upper stabilizer surface at all points referenced in Figure 1.
Locate at points specified on contour boards; use a clinometer and record incidence in de-

8)

Place contour boards


on

grees and minutes.

(e) Measure and record distances from 3LU to 9L and 3RU to 9R.
(O Drop a plumb bob from left main landing gear (LG), right main landing gear (RG), and nose
landing gear (NG) to hangar floor and mark locations on hangar floor. Remove plumb bobs.

(g)

Measure and record distances from 3LU to 9L and from 3RU to 9R.

(h) Remove contour boards, clinometer, and levels from aircraft.


(i) Move aircraft, then measure and record distances from NG to LG, from LG

to

RG, and from

RG to NG.

(j)

EFFECTIVITY:
SRM-4

Remove aircraft from

jacks and

secure

MODEL 25 SERIES AIRCRAFI~

aircraft

as

desired.

51-50-00

Page 9
May 15/92

Learjet

STRUCTURAL REPAIR MAMUAL


9R

111\

3RU-9R

3LU-9L

3RU

II
~Y

qi
3LU

RG
LG

(Opposite)

NC

j-/

ALIGNMENT

SYMMETRY CHECK

WING TO HORIZONTAL STAB.


POINTS

DISTANCE

3LU to 9L
3RU to 9R

ALIGNMENT

SYMMETRY CHECK

LANDING GEAR
POINTS

DISTANCE

NG to LG
NG to RG
LG to RG

Aircraft

EFFECTTVITY:
SRM~

Alignment and Symmetry Inspection


Figure 1 (Sheet 1 of 3)

MODEL25 SERIESAIRCRAFT

51-50-00

Page 10
May 15/92

E~ Learjet
~rptl
STRUCTURAL REPAIR MANUAL

BL 65.60
BL 50
BL 34.80

BL 19.40

BR

AR--\
Ws92.52---(
WS 157.
WS 181.10

WING

ANGLE OF

STATION

INCIDENCE

STABILIZER INCIDENCE

RH WING

LH WING

IBUTTLINE

BUTTLINE

RBL19.40

RBL34.80

INC.

53.15

LBL19.40

92.52

LBL34.80

157.48

LBL50.20

RBL 50.20

181.10

LBL65.60

RBL 65.60

INC.

ELEVATION CHECK POINTS

POINTS

ACTUAL

ELEVATION

ELEVATION

DIFFlERENCE

5L
5R
6L

6R

Aircraft

EFFECTNITY:
SRM~

Alignment and Symmetry Inspection


Figure 1 (Sheet 2 of 3)

MODEL 25 SERIESAIRCRAFT

51-50-00

Page 11
May 15/92

Lear

STRUCTURAL REPAIR MANUAL


i

3RU
9R

(SldnSplice)
BOTTOM OF_HORIZOIV~AL STABILrZER

bR
6L

(TYPICAL)

Opposite

TOP OF WING_TIP
ooo

~d0

Oe@b~

000

do o

~T,

OUTED

)-Py~on Access

3R

5R
SL

a,

Opposite

n,

FWD

(TMJrCAL)

ooooo

ol

(TYPICALI

BOTTOM OF WING TIP

UNDE~RSIDE: OF RIGHT PYLON


Frame 28

...:I;

(c---- BR
AR

(Rame 1
TooI Hole)

(TYPICAL)
RIGF~ SIDE OF FUSE~AGE

Aircraft

EFFECTIVITY:
SRM-P

NOSE_(RADOMB REMOVED

Aiignmenf and Symmetry Inspection


Figure 1 (Sheet 3 of 3)

MODEL 25 SERIES AIRCRAFT

51-50-00

rage 12
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
C.

Model 28/29 Series Aircraft

Alignment and Symmetry Inspection


Personnel must not be

NOTE:

permitted

on or

in the aircraft while the

alignment inspection

is

in progress.

Aircraft shall be

parked

inside

hangar and hangar

doors shall be closed

during this

in-

spection.
(1) Level aircraft laterally, longitudinally, and check aircraft elevation, as follows:
(a) Defuel aircraft. (Refer to Chapter 28 in the appropriate Learjet Maintenance Manual for defueling instructions.)

(b) Place aircraft

on

landing gear fully extended and clear


(Refer to Chapter 7 in the appropriate Learjet

jacks

door shall be closed.

with

of

hangar

floor. Aircraft

Maintenance Manual for

jacking procedures.)
(c) Perform preliminary aircraft leveling as follows:
1) Level laterally by placing level across inboard seat rails. Place level on top surface of one
of the inboard seat rails to obtain longitudinal leveling. Adjust jacks to level.
(d) Perform final aircraft leveling as follows:
1) Position transit, mounted on a tripod (approximately 24 inches high), at the right aft side
of aircraft as required to shoot all check points.
2) Shoot lateral leveling points 3L and 3R. Place adapter point in screw heads when holding scale at these locations.
3) Insert phillips head screwdriver through scale adapter and hold in screw head at frame
27.

4)
5)
6)

Shootlongitudinal levelingpointBR.
Remove radome

cover

and insert scale

adapter through right tooling hole in frame

1.

Shootlongitudinal level pointAR.


NOTE:

The

EXAMPLE:

following is an example

Frame Number

*Reference Point

Scale

2+3

44

Reading

for

leveling an aircraft.

27

23.36
35.43

+11.00

35.43

34.33

1.10

1.10

Since frame 27 measurement is 35.43 and is

larger

than frame 1

measure-

34.33, the forward end of the aircraft (frame 1) is 1.10 too low.
nose jack as required for level condition.

ment at

Adjust
Reference

point 23.36 is

36.40 (frame 27

EFFECTIVITY:
SRM-I

screw

the distance between WL 13.039 (frame 1

tooling hole)

and WL

head).

MODEL 28/29 SERIES AIRCRAFT

51-50-00

Page 13
May 15/92

Learjet
Learjet

STRUCTURAL REPAIR MANUAL


NOTE:

7)

recording of check points 5L, 5R, 6L and 6R to the secrequired. Locate all scales for large numbers to be at bottom.

Accurate elevations and


ond decimal is

Shoot and record elevations of check


NOTE:

See

1 for

Figure

points

points 5L, 6L, 5R and

6R.

to locate contour board on

upper

wings

and horizontal

stabilizer.

8)

Place contour boards


on

9)

wings

at

across

points specified

upper
on

wing surfaces at points referenced

contour

boards;

use a

in

Figure 1. Locate
angle of inci-

clinometer and record

dence at each station in

degrees and minutes.

Place contour board

stabilizer at BL 19.40. Actuate stabilizer until clinometer

on

board) indicates the stabilizer leading edge is -1030 down.


checks shall be made with the stabilizer in this position.
on

contour

10) Mace

contour boards across

Locate at

points specified

on

upper stabilizer surface at all


contour

boards;

use a

points

(placed

All incidence

referenced in

Figure

1.

clinometer and record incidence in de-

grees and minutes.


(e) Drop a plumb bob from left main landing gear (LG), right main landing gear (RG), and nose
landing gear (NG) to hangar floor and mark locations on hangar floor. Remove plumb bobs.

(f)

Measure and record distances from

point 9L to points 3LU, 4LW, 5LW, 6LW,


point 9R to points 3RU, 4RW, 5RW, 6RW, and 7RW.

Remove contour boards, clinometer, and levels from aircraft.


(h) Move aircraft, then measure and record distances from NC to LG, from LG

and nW, and

(g)

to

RG, and from

RG to NC;.

(i)

EFFECTIVITY:
SRMI

Remove aircraft from

jacks and

secure

MODEL 28/29 SERIES AIRCRAFT

aircraft

as

desired.

51-50-00

Page 14
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


-r:

9R

~r

3~9L

9R-3RU

/----9L-3LU

9R-4RW---\

J~M

/---9L-4LW

II-I\

9R-5RW----------\
9R

9R-7RW------~

I I I

/--9L-7LW

7LW
6R

5RW

5LW

iln
4RW

4LW
3RU

3LU

Re
LG

ALIGNMENT

Opposite

SYMMETRY CHECK

WING TO HORIZONTAL STAB.


DISTANCE

POINTS

ALIGNMENT

DISTANCE

POINTS

SYMMETRY CHECK

LANDING GEAR

9LtoBLU

9Rto3RU

9L to 4LW

9R to 4RW
9Rto5RW

9L to 5LW

9Lto6LW

9Rto6RW

9LtonW

9Rto7RW

POINTS

sud~

NG to LG
NG to RG

Aircraft

EFFECTIVITY:

DISTANCE

LG to RG

Alignment and Symmetry Inspection


Figure 1 (Sheet 1 of 4)

MODEL 28/29SERIESAIRCRAFT

51-50-00

Page 15
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


BL 55.

BL 50.2
BL 34.
BL 19.

BR

30

WS 53. 15
WS 92.52

WS 157.48
WS 181. 1
WS 213.60

WING

STATION

I
I

ANGLE OF

LH WING

53.15

STABILIZER INCIDENCE

INCIDENCE

I BUTF LINE

LBL19.40

RBL 19.40

RH WING

INC.

BUTTLINE

92.52

LBL34.80

RBL 34.80

157.48

LBL50.20

RBL 50.20

191.10

LBL65.60

RBL 65.60

INC.

213.60
ELEVATION CHECK POINTS
ACTUAL

LEVELING POINT ELEVATIONS

POINTS

FRAME 1 AR*

5L

FRAME 27 BR

5R

L WING 3L

6L

R WING 3R

6R

ELEVATION

I
I

ELEVATION
DIFFERENCE

LONGITUDINAL

LATERAL

Aircraft

EFFECTNITY:

Alignment and Symmetry Inspection


Figure 1 gheet 2 of 4)

MODEL 28/29 SERIES AIRCRAFT

51-50-00

Page
SRM4

16

May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

6L

Opposite

AR(Framel
01

Tool Hole)

000
010

60

oo

olo

8 o~o

Pylon

pq

Access

NOSE (RAD_OME_REMOVET))
5n

FWD

5L

Opposite

oo

Frame 28

Frame 27

(Ref)

(ReD

Sp""

Frame 26

(Iief)
(Skin splice)

Pylon

00C)00
ol

UNDERSIDE OF RIGHT PYLON


WL 36.40

BR

(Screwhead)

FWDI
RIGHT SIDE OF FUSELAGE

Aircraft

EFFECTIVITY:
SRM-4

Alignment and Symmetry Inspection


Figure 1 (Sheet 3 of 4)

MODEL28/29 SERIESAIRCRAET

51-50-00

Page 17
May 15/92

Learjet
STRU~TURAL REPAIR MANUAL
~tuo

BL 80.35

6RW

(Ref)

6LW

(Skin

Opposite
Splice)
7RW
7LW

9R

9L

(Skin

Opposite
Splice)

Opposite
Splice)

(Skin

Winglet Sta 44.87


(Ref)

CFWD

UNDERSIDE OF RIGHT
HORIZONTAL STABILIZER

Winglet Sta

17.817

(ReO
4RW

5RW

Opposite
(Skin Splice)

5LW

4LW

Opposite
Winglet Sta 6.00
(Ref)

LOOKING OUTBOARD AT
RIGHT WINGLET

WS 181.10

(Ref)
WS 181.10

(Ref)

3R

3RU
3LU

3L

Opposite

O
o

s,~NBD

rINBD

Opposite

cs

FWD

FWD

Leading Edge

Leading Edge

UPPER SURFACE OF WING

Aircraft

EFFECTIVITY:
sRM-b

~Scrupper

UNDERSIDE OF WING

Alignment and Symmetry Inspection


Figure 1 (Sheet 4 of 4)

MODEL 28/29SERIESAIRCRAFT

51-50-00

Page 18
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


D.

Model 31 Series Aircraft

Alignment and Symmetry Inspection


Personnel must not be

NOTE:

permitted

on or

in the aircraft while the

alignment inspection

is

in progress.

parked

Aircraft shall be

inside

hangar and hangar

doors shall be closed

during this

in-

spection.
(1) Level aircraft laterally, longitudinally, and check aircraft elevation, as follows:
(a) Defuel aircraft. (Refer to Chapter 28 in the appropriate Learjet Maintenance Manual for defueling instructions.)
Cb) Place aircraft

landing gear fully extended and clear


(Refer to Chapter 7 in the appropriate Learjet
with

jacks

on

door shall be closed.

of

hangar

floor. Aircraft

Maintenance Manual for

jacking procedures.)
(C) Perform preliminary aircraft leveling
1)

Level

laterally by placing

level

as

3)

inboard seat rails. Place level

longitudinal leveling. Adjust jacks

on

top surface of

one

to level.

follows:

tripod (approximately 24 inches high), at the right aft side


of aircraft as required
points.
Shoot lateral leveling points 3L and 3R. Place adapter point in screw heads when holding scale at these locations.
Insert phillips head screwdriver through scale adapter and hold in screw head at frame
on a

to shoot

2)

follows:

across

of the inboard seat rails to obtain

(d) Perform final aircraft leveling


1) Position transit, mounted

as

all check

27.

longitudinal leveling point BR.

4)

Shoot

5)
6)

Remove radome

Shoot

cover

longitudinal

NOTE:

The

and insert scale

level

point

following is an example

Frame Number

*Reference Point

Scale

2+3

Reading

5
EXAMPLE:

point

36.40 (frame 27

EFFECTIVITY:
SRM-4

in frame 1.

for

leveling an aircraft.

27

23.36
35.46

+11.00

35.46

34.36

1.10

1.10

Since frame 27 measurement is 35.46 and is larger than frame 1 measurement at 34.36, the forward end of the aircraft (frame 1) is 1.10 too low.

Adjust
Reference

adapter through right tooling hole

AR.

nose

jack

as

required

for level condition.

23.36 is the distance between WL 13.039 (frame 1


screw

tooling hole)

and WL

head).

MODEL31 SERIESAIRCRAFT

51-50-00

Page 19
May 15/92

Learjet
STRU~TURAL REPAIR MANUAL
NOTE:

7)

recording of check points 5L, 5R, 6L and 6R to the secrecluired. Locate all scales for large numbers to be at bottom.

Accurate elevations and


ond decimal is

Shoot and record elevations of check


NOTE:

See

1 for

Figure

poi"ts

points 5L, 6L, 5R and

to locate contour board

6R.

on

upper

wings

and horizontal

stabilizer.

8)

Place contour boards

across

upper

wing

surfaces at

wings at points specified on contour boards;


dence at each station in degrees and minutes.
on

9)

Place contour board

points

use a

referenced in

Figure

clinometer and record

1. Locate

angle of inci-

stabilizer at BL 19.40. Actuate stabilizer until clinometer

(placed
leading edge is -20 (+0; -15) down. All incidence checks shall be Inade with the stabilizer in this position.
10) Mace contour boards across upper stabilizer surface at all points referenced in Figure 1.
Locate at points specified on contour boards; use a clinometer and record incidence in deon

on

contour board) indicates the stabilizer

grees and minutes.


(e) Drop a plumb bob from left main landing gear (LG), right main landing gear (RG), and nose
landing gear (NG) to hanger floor and mark locations on hangar floor. Remove plumb bobs.

(f)

Measure and record distances from

(g)

point
points 3RU, 4RW, 5RW, 6RW, and 7RW.
Remove contour boards, clinometcr, and levels ~om aircraft.

point

9L to

points 3LU, 4LW, 5LW, 6LW,

and nW, and

9R to

(h) Move aircraft, then

measure

and record distances from NC to

LG, from LG

to

RG, and from

RG to NG.

(i)

EFFECTIVITY:
sr~M1!

Remove aircraft from

jacks and

secure

MODEL31 SERIESAIRCRAFT

aircraft

as

desired.

51-50-00

Page 20
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


~-----9L

II

9R-3RU

\P~

9L-3LU
9L-4LW

9R-4RW~

S)LSLW

9R-5RW~

II I

9R-6RW~

~9L-6LW

\I I I \I

9R-7RW~

7RW~

5RW/

\V

\~iT(

\IVI I

II

L_7

II

/7LW

II

V~6LW

4RW

5LW

\Il

-1

4LW

3LU

RU

RC
LG OPPOSITE

NG

SYMMETRY CHECK
ALIGNMENT
WING TO HORIZONTAL STAB.

DISTANCE

POINTS

ALIGNMENT

DISTANCE

POINTS

SYMMETRY CHECK

LANDING GEAR
9Lto3LU

9RtoSRU

9Lto4LW

9RtoQRW

9L to 5LW

POINTS

9RtoSRW

DISTANCE

NG to LG

NG to RG
9L to 6LW

9R to 6RW

9L to nw

9Rto7RW

Aircraft

EFFECTIVITY:

LG to RG

Alignment and Symmetry Inspection


Figure 1 (Sheet 1 of 4)

MODEL31 SERIESAIRCRAF~

51-50-00

Page
SRM-P

21

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

BL 65.
BL 50.20

BL
BL 19.

BR

3R

O
AR

CI

/Z~

32~

~3L

WS 53.1
WS 92.52

WS 157.

WS 181.10
WS 213.60 i

WING

ANGLE OF

STATION

INCIDENCE
LH WING

STABILIZER INCIDENCE

RH WING

I PUTT LINE

INC.

BUTTLINE

53.15

LBL19.40

RBL19.40

92.52

LBL3Q.80

RBL34.80

157.48

LBL50.20

RBL50.20

181.10

LBL65.60

RBL65.60

INC.

213.60
ELEVATION CHECK POINTS

LEVELING POINT ELEVATIONS

POINTS

FRAME 1 AR"

5L

FRAME 27 BR

5R

6R

ACTUAL

ELEVATION

ELEVATION

DIFFERENCE

LONGITUDINAL
6L

LWWG3L

LATERAL

R WING 3R

AiTrraft

EFFECTIVITY:
SRM4

Alignment and Slymmehy Inspection


Figure 1 (Sheet 2 of 4)

MODEL31 SERIESAIRCRAFT

51-50-00

Fage 22
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

(Skin

Frame28

Frame27

Frame26

(Ref)

(Ref)

(Ref)

Splice)
Pylon
(Skin

6R

/I

6~

ii

Opposite

WL36.40-

Splice)

..1..

(Ref)
ooo

oo

do

lo

BR

o
o

OUTED

1_1

(Screwhead)

Access

Pylon

RIGHT SIDE OF FUSELAGE

5R
5L

FWD

Opposite

II.

ooo~oo
ooooo

(TYPICAL)

UNDERSIDE OF RIGHT PnON

AR

(Frame 1
Tool Hole)

NOSE (RADOME REMOVED

Aircraft

EFFECTIVITY:
SRM-4

Alignment and Symmetry Inspection


Figure 1 (Sheet 3 of 4)

MODEL31 SERIESAIRCRAFT~

51-50-00

Page 23
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


3~3

BL80.35
(Ref)

6RW
6LW

(Skin

Opposite
Splice)
7RW
7LW

9R
9L

Opposite

(Skin Splice)

Opposite

(Skin Splice)

Winglct Sta 44.87


(Ref)

CFWO

UNDERSIDE OF RIGHT

HORIZONTAL STABILIZER

Winglet Sta

17.817

(Ref)

4RW

5RW

Opposite
(Skin Splice)

4LW

5LW

Opposite
Winglet Sta

6.00

(Ref)

LOOKING OUTBOARD AT
RIGHT WINGLET

WS 181.10

WS 181.10

(Ref)

(Ref)
3R

3RU
O

~o

3LU

3L

Opposite

ol~

o
O

ao
e

cs

B~e
a

rINBD

s,

INBD

FWD

FWD

Leading Edge

LeadingEdge-/

UPPER SURFACE OF WING

Aircraft

EFFECTIVITY:
SRM~I

Opposi~e

~Scrupper

UNDERSIDE OF WING

Alignment and Symmetry Inspection


Figure 1 (Sheet 4 of 4)

MODEL31 SFRIFSAIPCPAFT

51-50-00

Page 24
May 15/92

Learjet
~LBarjet

SIRUCTURAL REPAIR MANUAL


E.

Model 35/36 Series Airmaft

Alignment and Symmetry Inspection


Personnel must not be

NOTE:

permitted

on or

in the aircraft while the

alignment inspection

is

in progress.

parked

Aircraft shall be

inside

hangar and hangar

doors shall be closed

during

this in-

spection.
(1) Level aircraft laterally, longitudinally, and check aircraft elevation, as follows:
(a) Defuel aircraft. (Refer to Chapter 28 in the appropriate Learjet Maintenance Manual for defueling instructions.)
(b) Place aircraft

jacks

on

with

landing gear fully extended and clear


Chapter 7 in the appropriate Learjet

door shall be closed. (Refer to

of

hangar

floor. Aircraft

Maintenance Manual for

jacking procedures.)
(c) Perform preliminary aircraft leveling as follows:
1) Level laterally by placing level across inboard

seat rails. Place level

on

top surface of

of the inboard seat rails to obtain longitudinal leveling. Adjust jacks to level.
(d) Perform final aircraft leveling as follows:
1) Position transit, mounted on a tripod (approximately 24 inches high), at the
of aircraft

2)

Shoot lateral

ing
3)

to shoot all check

as

required
leveling points

right aft

one

side

points.

3L and 3R. Place

adapter point

in

screw

heads when hold-

scale at these locations.

Insert

phillips

head screwdriver

scale

through

adapter

and hold in

screw

head at frame

27.

4)

Shootlongitudinal levelingpointBR.

5)
6)

Remove radome

Shoot

cover

longitudinal

NOTE:

The

EXAMPLE:

and insert scale

level

point

following is an example

Frame Number

*Reference Point

Scale

2+3

~4

adapter through right tooling hole

Reading

for

leveling an aircraft.

23.36

35.46

+11.00

35.46

34.36

1.10

1.10

point

36.40 (frame 27

EFFECTIVITY:
SRM-4

larger

than frame 1

34.96, the forward end of the aircraft (frame 1) is 1.10

Adjust nose jack as required


Reference

27

Since frame 27 measurement is 35.46 and is


ment at

measure-

too low.

for level condition.

23.36 is the distance between WL 13.039 (frame 1

screw

in frame 1.

AR.

tooling hole)

and WL

head).

MODEL35/36SERIES AIRCRAFT

51-50-00

Page 25
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


NOTE:

Accurate elevations and


ond decimal is

7)

rccluired.

recording of check points 5L, 5R, 6L and 6R to the secLocate all scales for large numbers to be at bottom.

Shoot and record elevations of check


NOTE:

See

Figure

1 for

points

points 5L, 6L, 5R and

to locate contour board

6R.

on

upper

wings

and horizontal

stabilizer.

8)

Place contour boards

across upper wing surfaces at points referenced in Figure i. Locate


wings at points specified on contour boards; use a clinometer and record angle of incidence at each station in degrees and minutes.
9) Place contour board on stabilizer at BL 19.40. Actuate stabilizer until clinometer (placed
on contour board) indicates the stabilizer leading edge is -1040 down.
All incidence
checks shall be made with the stabilizer in this position.
10) Place contour boards across upper stabilizer surface at all points referenced in Figure 1.
Locate at points specified on contour boards; use a clinometer and record incidence in deon

grees and minutes.

(e) Drop

a plumb bob from left maiII landing


gear (LG), right main landing gear (RG), and nose
landing gear (NG) to hangar floor and mark locations on hangar floor. Remove plumb bobs.
(f) Measure and record distances from point 9L to 3LU, and from point 9R to 3RU.
(g) Remove contour boards, clinometer, and levels from aircraft.

(h) Move aircraft, then

measure

and record distances from NG to

LG, from LG

to

RG, and from

RG to NG.

(i)

EFFECTIVITY:
SRM41

Remove aircraft from

jacks and

secure

MODEL 35/36SERIES AIRCRAFT

aircraft

as

desired.

51-50-00

Page 26
May 15/92

Leariet
~Learptl
STRUCTURAL REPAIR MANUAL
la-- st

9R---?r;

II I\

3RU- 9R

3LU- 9L

I
3LU

RG

LG(Opposite)

F~

NG

ALIGNMENT

SYMMETRY CHECK

WING TO HORIZONTAL STAB.


DISTANCE

POINTS
3LU to 9L
3RU to 9R

ALIGNMENT

SYMMETRY CHECK

LANDING GEAR

POINTS

DISTANCE

NG to LG
NG to RC
LG to RG

Aircraft

EFFECTIVITY:
srzM~

MODEL

~Alignment and Symmetry Inspection


Figure 1 (Sheet 1 of 3)

35/36SERIESIURCRAF~

51-50-00

Page 27
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

BL 65.

si 50.20
BL
BL 19.40
BR

WS 53.15
WS 92.52"

~e

WS 157.48

AR.

WS 182.1

WS 205.1

ANGLE OF

WING
STATION

INCIDENCE
LHWING

STABILIZER INCIDENCE

RHWING

BUTL LINE

RBL19.40

RBL34.80

RBL50.20

53.15

I BUTT LINE

92.52

LBL19.40

157.48

LBL34.80

181.10

LBL50.20

LBL65.60

213.60

INC.

INC.

RBL65.60

ELEVATION CHECK POINTS

POINTS

ACTUAL

ELEVATION

ELEVATION

DIFFERENCE

5L
5R
6L
6R

Aircraft

Em~ECTTVITY:
SRM-4

Alignment and Symmetry Inspection


Figure 1 (Sheet 2 of 3)

MODEL 35/36SERTES AIRCRA~

51-50-00

Page 28
May 15/92

STRUCTURAL REPRIR MANUAL

~R
(Skin

(TYPICAL)

FWD

1~1
Splice)

BOITOM OF HORIZONTAL STABILIZER

3RU

Tip Tank
(TYPICAL)

6R
6L

Opposite

TOP OF WING TIP EXTENSION

~90@
o~o

FWD

OUTED

~Pylon Access
5R

5L

Opposite

FWD

Tip Tank
(TYPICAL)
oo

ol

BOTTOM OF WING TIP EXTENSION

(TMJICAL)

UNDERSIDE OF RIGHT PYLON


Frame 27

(Ref)

BR

~3

AR

(Frame

Tool Hole)

(TYPICAL)

g~a
~-e

NOSE (RADOME REMOVED

RIGHT SIDE OF FUSELAGE

Aircraft

EFFECTIVITY:

Alignment and Symmetry Inspection


Figure 1 (Sheet 3 of 3)

MODEL 35/36SERIES AIRCRAFT

51-50-00

Page 29
s~M-a

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
4.

SUPPORT
A.

See

EQUIPMENT FOR AIRCRAFT REPAIR

Figure 2

NOTE:

for aircraft support

equipment.

Equivalent substitutes may be used in lieu

NAME

PART NUMBER

of the

following:

MANUFACTURER

USE

Jack Pad

2370102-4 (1 ea)

Learjet Inc.

Jacking aircraft

Jack Pads

2572006-3 (2 ea)

Learjet Inc.

Jacking aircraft

Tailstand

2471016-1

Learjet Inc.

Jacking aircraft

Tailstand*

3170002

Learjet Inc.

Jacking aircraft

Tripod Tacks

02-0526-0100 (3 ea.)

Tronair

Jacking aircraft

(Minimum capacity

Holland, OH

of10,0001bs.)

Spreader Bar

2311600-500

Learjet Inc.

Aircraft

Wing Mating Dolly

2420000

Learjet Inc.

Wing support

Wing Transfer Dolly

2300001

Learjet Inc.

Wing support

Pylon Jack Adapters**

3170003 (2 ea.)

Learjet Inc.

Jacking aircraft
without wings
Or engines

Commercially available

Jacking aircraft
without wings or

Pylon Jacks
(5 ton, height 64")

support

engines
Keel Beam

Dolly

Learjet Inc.

Keel beam sup-

port

Engine Stand

PME 500006

Learjet Inc.

Engine support

Engine Hoist

04-0308-0112

Tronair

Engine lift

Holland, OH

Engine Sling

OHME 2650000

Learjet Inc.

Engine lift

Model 31 Series Aircraft only


Model 31/35/36 Series Aircraft onlu

EFFECTIVITY:
SRM-4

ALL

51-50-00

Page 30
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

~jC

Jack

lack

Nose Jack Pad

Wing Jack

Pad

(TYPICAL)

WINGIACK

NOSETACK

Aircraft

Support Equipment
Figure 2 (Sheet 1 of 5)

EFFECTIVITY:
SRM-4

ALL

51-50-00

Page 31
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

Adjusting Nut

Spreader Bar

Mounting Pad

(Install spreader bar between keel beam mounting Dads

on

fuselage)

SPREADER BAR

Jack

WING TRANSFER DOLLY

Aircraft

Support Equipment
Figure 2 (Sheet 2 of 5)

EFFECTIVITY:
SRM-4

ALL

51-50-00

Page 32
May 15/92

Learjet
Learjet

STRUCIURAL REPAIR MANUAL

Safety Pin

WING MATING DOLLY

Keel Beam

Wheel
Well
Doors

KEEL.BEAM SUPPORT DOLLY

Aircraft

Support Equipment
Figure 2 (Sheet 3 of 5)

EFFECTIVITY:

ALL

51-50-00

Page 33
May 15/92

Learjet

STRU~TURAL R~PAIR MANUAL


Engine Hoist

Engine Sling I

Forward

Sling

Arms (Attach

Sling Arms
Equally Spaced
From \Centerline)

AN6-28 Bolts

Sling Arm
(Centered on Engine

Aft

(2

Required)

Centerline) AN6-8 Bolts


(2 Required)

qli!
~ic Two holes

are

provided

for attachment of

hoist. The forward hole is for

engines

without thrust reversers and the aft hole


is for engine with thrust reversers.

Forward

Engine

Mount (Slave)

NAS1307-3H Bolt
AN960-716 Washer

(2

Required)

Engine Stand
I~F Do Not Remove

Engine

Mount from Aircraft

(TYPICAL)
Aircraft Support

Equipment
Figure 2 (Sheet 4 of 5)

EFFECTIVITY:
SRM-4

MODEL 31/35/36 SERIES AIRCRAFT

51-50-00

Page 34
May 15/92

Learjet
STRUCTURAL RE:PAIR MANUAL

Pylon Jack Pad

PYLON TACK

Aircraft

Support Equipment
Figure 2 (Sheet 5 of 5)

EFFECTIVITY:

MODEL 31/35/36SERIES AIRCRAFT

51-50-00

Page 35
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


REPAIRS-GENERAL
1.

GENERAL
A.

of the airframe structure

are similar in design and fabrication. Typical repairs to


compiled in this section to eliminate the duplication of repairs under
each applicable component. Repairs in this section apply to the member shown regardless of location
on the aircraft structure (except as limited) and will include only those parts or members necessary to
show the typical situation.
Typical repairs may be accomplished individually, or combined with other repairs for a major repair.
Technique and material variation is permissible only so far as to facilitate fabrication and ensure the
original strength and usefulness of the affected component.
It is the responsibility of the aircraft owner/maintenance facility to determine qualifications of maintenance personnel performing inspections and repair procedures as well as to ensure all aircraft log
books are properly updated following any maintenance or repair to aircraft structure. As always, a
clean environment and good general shop practices shall be exercised at all times.
Prior to, and after performing, any repairs on the aircraft structure, ensure serviceability and reliability of repair. If serviceability and/or reliability of repair remains in question or if guidance is needed
in making this determination, contact Learjet Field Service for additional information.
Repairs for structure not included in this section does not necessarily indicate that the structure involved is non-repairable, but that the application of a typical repair procedure to theoretical damage
has not yet been developed. For repair procedures pertaining to items not covered in this section, refer to that items respective chapter.
If material added in the course of a repair obstructs drainage holes, the holes must be continued
through the repaired member unless this is likely to cause structural weakness. If the original holes
cannot be used new drainage holes must be made as near as possible to the original ones. The drainage efficiency of a repaired component must be checked during the course of repair. Any drainage
holes in the original structure must be duplicated in the replacement structure.
Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds the
allowable limits. Cracks in any fitting or forging are not allowed. Fittings or forgings with bushings
shall be repaired.
All parts fabricated by the repair facility shall be identified for future reference. Marking of parts shall
be accomplished in a manner which does not effect the serviceability and reliability of the part.
Classification of Repairs
(1) Specific Repairs
(a) Repairs of this type are specifically designed for structure/components named in the appropriate Allowable Wear and Repair Data Index and/or in that structure/components specific
chapter.
(2) Typical Repairs
(a) Typical repairs are evolved from the characteristics of the materials, with no particular reference to location or class of structure. Repairs of this type may be used singly or in combination to cover a wide variety of damage within the limits given in the appropriate repair figures. Typical repairs must not be used in restricted areas, or for damaged structure for which
specific repairs are issued.
(3) Temporary Repairs
(a) With the approval of the local airworthiness regulatory authority and Learjet Inc., temporary
repairs may be made to allow the aircraft to return to base. The effect of damage on structural
strength and airworthiness characteristics such as systems operation must be considered.
Temporary repairs must be replaced by permanent repairs before the aircraft is released for
normal operational duty.

Many components

these and other items have been

B.

C.

D.

E.

F.

G.

H.

I.

EFFECTIVITY:

ALL

51-70-00

Page
SRM~

Jan 15/93

~Learjki
STRUCTURAL REPAIR
I.

MANUAi

Support of Structure During Repair


(1) Prior to, and during extensive repair operations involving the removal or replacement of large areas of skin plating, frames, stringers, struts, or other heavily stressed members, it is essential to
support the surrounding aircraft structure so that the original contours and relative positions of
components are maintained. Support must be sufficient to relieve the load on the damaged area
while maintaining the position of the surrounding structure and components.
(2) Support equipment should preferably be constructed of welded or bolted steel frame, with a suitable cushioning material applied to those parts intended to come into direct contact with the aircraft.
control surface is extensive, it is advisable to remove the control
surface and inspect for possible hidden damage. The control surface, or a suitable jig, must be
temporarily installed during repair to check the alignment and position of hinge fittings and sup-

(3) When damage

to

an area near a

porting structure.
(4) For information pertaining to lifting and shoring refer

to the

applicable Learjet Maintenance Man-

ual.

T.

K.

Checking Alignment
(1) Before repairs are started, take measurements between reference points on adjacent or opposite
parts unaffected by the damage. Compare these measurements with related points on the repair
area to determine the extent of distortion. Damage involving major components orlarge portions
of the aircraft requires alignment and /or symmetry checks of the aircraft before and after repairs.
Refer to the appropriate section, in this chapter, for additional information pertaining to aircraft
alignment and /or symmetry checks.
TypicalRepair Procedure
NOTE:

If

serviceability and/or reliability of any part or repair remains in question or if guidance is


making this determination, contact Learjet Field Service for additional informa-

needed in
tion.

(1) Investigate and assess damage.


(2) Clean up damage to a regular geometric shape.
(3) Identify material specification, heat treatment and thickness of damaged structure.
(4) Determine which parts of damaged area are loaded in tension or shear, or in combined tension
and shear. (Refer to step L)
(5) Select a typical repair applicable to the existing damage.
(6) Select the proper fasteners which correspond to the type of repair and material being used.
(7) Lay out fastener pattern, using proper edge distance, pitch and spacing between rows and deter-

required.
Prepare repair members (i.e., doubler and filler)
Apply surface treatment.
Attach repair members and seal as required.
Replace any insulation required.
mine the number of fasteners

(8)
(9)
(10)
(11)
(12)

as

required.

Restore aircraft to normal.

EFFECTTVITY:

ALL

52-70-00

Page:!
SRM-4

Jan 15/93

Learjet/
I Learjet
STRUCTURAL REPAIR MANUAL
L.

Struch~ral

Loading

(1) Caps and flanges of spars, ribs, frames and beams are considered to be in tension or compression.
(2) Skin panels, together with spar, rib, frame and beam webs, are assumed to be in shear. Addition-

ally, skins may carry tension or compression loads. In the case of compression, loads are assumed
only by a small width of skin along the line of fasteners attaching skin to sub-

to be carried
structure.

(3) Stringers may be in tension or compression.


(4) If the direction of loading cannot be established, the material must be assumed to be in tension.
For purposes of fastener requirement calculation, no distinction is made between tension and

compression.
2.

LIMITATIONS AND INSPECTIONS


A.

Limitations

DRILLING, MODIFICATIONS, OR ANY TYPE OF WORK THAT CREATES A

WARNING:

BREAK IN THE PRESSURE SECTION IS THE RESPONSIBILITY OF THE OWNER AND/OR MAINTENANCE FACILITY PERFORMING THE WORK. OBTAINING APPROVAL OF THE WORK IS, THEREFORE, THEIR RESPONSIBILITY.

(1) Repairs described in this section


manual. Before

are

to

commencing any repair,

comply

given in other sections of this


appropriate chapters of this manual for perti-

with instructions

refer to the

damage information.
applied to repairs in this section must be followed unless Learjet engineering authori-

nent structural

(2) Limitations

ty

to the

contrary is given.

(3) Repairs must perform its/their specific function, such as fuel or air tightness.
(4) Repairs must not interfere with any moving parts.
(5) Repairs must be equal to or greater in strength than the original structure.

Technique and material variation is permissible only so far as to facilitate fabrication and ensure
the original strength and usefulness of the affected component.
Inspections
(1) Following any repair or maintenance procedures on the aircraft structure/components, ensure inspection records pertaining to any specific repair-related procedure are identified, properly documented and closely adhered too.

(6)
B.

3.

MATERIALSAND PROCESSES
A.

Materials

(1) Repair materials and required

treatments

terial and treatment variation is

or

processes will be listed in the repair procedure. Mafar as to facilitate fabrication and ensure the

permissible only so

original strength and usefulness of the affected component.


B.

Processes

(1) Precautions against corrosion, such

as

chemical surface

surfaces, and insulating dissimilar metals

chapter, for chemical process and


C.

protective

treatment

priming of faying
appropriate sections, in this

treatments,

must be taken. Refer to the

specifications.

Fastener Selection

(1) Refer

EFFECTIVITY:

to the

ALL

appropriate section, in this chapter, for information pertaining to fastener selection.

51-70-00

Page 3
SRM-4

Jun 1/95

Learjet
Learjet
STRUCTURAL REPAIR MANUAL
TYPICAL REPAIR

i.

APPLICATION OF LOCTITE
A.

determining the kind of Loctite to use in a given application. Use only the
given applications.
compounds
Application of Loctite shall be accomplished at temperatures above 60"F to ensure proper curing.
Use

Figure

201

as an

recommended
B.
2.

MAINTENANCE PRACTICES

aid in

in their

APPLMNG LOCTITE
A.

Prepare Surface
(1) Clean all parts to which Loctite is to be applied. Surfaces must be clean and free of dust, grease,
condensation, moisture and other contaminants.
(2) Parts that are plated, hardened, anodized, or passivated must be treated with Locquic primer

B.

C.

grade T, prior to applying Loctite sealant or compound. The Locquic primer odor must be completely gone before applying Loctite.
Apply Loctiteto Bearings
(1) If Loctite type has not been specified, selection is to be made from Figure 201.
(2) Clean mating surfaces with 1,1,1 trichloroethane (MIL-T-81533).
(3) Apply Loctite evenly to both mating surfaces. Exercise care to keep Loctite out of the bearing. Excessive Loctite may be wiped off with a rag moistened in 1,1,1 trichloroethane (MIL-T-81533).
(4) Press bearing into bearing housing and keep aligned until Loctite cures. Assembly may be heated
for 30 minutes at 1800F to accelerate curing time.
Apply Loctite to Threaded Fasteners
(1) If Loctite type has not been specified, selection is to be made from Figure 201.
(2) Clean threaded surfaces with 1,1,1 trichloroethane (MIL-T-81533).
(3) Apply Loctite to threads by brushing, dipping, tumbling, or running applicator
NOTE:

over

the threads.

Loctite may be applied to either the nut or bolt; however, for blind hole applications,
coat the sides of the blind hole and the first two threads of the male fastener.

(4) Assemble parts and torque using normal torque.


(5) Excessive Loctite may be removed using a rag moistened with 1,1,1 trichloroethane (MIL-T81533).

EFFECTIVITY:
SRM-4

ALL

51-70-00

Page 201
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

Cure

Application
Screw

Locking

Torque

Strength

Loctile

Product

Osp
nlling
Ability

(cP)

In/Lb

Product

Color

Inehea

Mean

Brealtaway

Psi
Shear

222

Purple

0.003

2.000

40

Visco4ity

900

Tamp.
Range
OF

to

300

Cure

Speed

Recom-

~SRoomTemp.on

Steel No Primer

Steel With Primer

Fixture

-65

Screwlock

Speed

@RoomTemp.on

Full

Fixture

mended
Primer

Full

20

24

24

Minutes

Hours

Minutes

Hours

pption4

20

24

24

Minutes

Hours

Minutes

Hours

(Optional)

20

24

24

Minutes

Hours

Minutes

Hour

(Optional)

E~
EH

Nut

Locking

Stud

Locking

242

Blue

0.003

2.000

60

1.600

65

Nutlbck

to

c\l

300

271

Red

0.005

500

225

2,500

-65

Studlock

to

300

AVV

Bearing and
Bushing
Retention

RC BBO

Green

0.007

1,250

Bushing

Steel

-55

10

24

~Q

4.000

to

Minutes

Hours

Minutes

Hours

(Optional)

Mo~nt

300

Bearing

Aluminum

Mount

600

RC 35
RC10

Plastic

504

Gasket

Gasket

10

to

Eliminator

2.000,000

3[10

Orange

0.015

1,000.MN)

1.300

-65

90

12

Minutes

Hours

Not Required

None

Plastic
Gashet

ISPG

t~mse

EFFECTIVITY:

Applications af Loctite
Figure 201
ALL

51-70-00

Fal;e202
May 15/92

Leariet
Learjet
STRUCTURAL REPAIR MANUAL
3.

INSTALLING OVERSIZEFASTENERS
A.

Oversized Fasteners Installation At

Existing Holes

(1) Determine maximum diameter of existing hole.


(2) Refer to oversized charts and select closest oversized fastener that will
drilled to

specified

provide

clean hole when

tolerances.

(3) Drill out damaged hole to oversize determined in step A.(2).


(4) If original hole was cracked, dye penetrant inspect to ensure that crack is removed.
(5) Apply epoxy primer, and install new fastener of proper grip length.
B.

Limitations

(1) The number of oversized fasteners

EFFECTIVITY:
SRM4

ALL

must not exceed 20% of

original attaching pattern.

51-70-00

Page 203
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
HI-LOKS
REWORK HOLE SIZE

REPLACEMENT
HI-LOK
NOMINAL
DIA.

PART

NUMBER
HL1 8-5
HL19-5
HL20-5
HL21-5
HL50-5
HL51-5

5/32

HL18-6
HL19-6
HL20-6
HL21-6
HL50-6
HL51-6

3/16

HL1 8-8
HL19-8
HL20-8
HL21-8
1-1150-8
HL51-8

1/4

HL18-10
HL19-10

5/16

ORIGINAL
HOLE SIZE

(-o.oooo)

(+0.0010)
0.1895

(-o.oooo)

(+0.001 0)
0.2495

(-o.oooo)

HL18-14
HL19-14
HL20-14
HL21-14
HL50-14
HL51-14

7/16

HL1 8-16
HL19-16
HL20-16
HL21-16

1/2

NOTE:

If fastener fit is too

1/64

Oversize

HL62-6
HL63-6
HL64-6
HL65-6
HL56-6
HL57-6

HL218-6
HL219-6
HL220-6
HL221-6
HL68-6
HL69-6

HL62-8
HL63-8
HL64-8
HL65-8
HL56-8
HL57-8

HL218-8
HL219-8
HL220-8
HL221-8
HL68-8
HL69-8

I
I

1/32
Oversize

1
1

0.190
0.187

0.2031
0.2001

0.2187
0.2157

0.2656
0.2626

0.2812
0.2782

0.3281
0.3251

0.3437
0.3407

(+0.0010)

HL62-10
HL63-10

HL218-10
HL21 9-10

(-o.oooo)

HL64-)0
HL65-10

HL220-10
HL221-10

HL56-10
HL57-10

HL68-10
HL69-10

HL62-12
HL63-12
HL64-12
HL65-12
HL56-12
HL57-12

HL21 8-12
HL219-12
HL220-12
HC221-12
HL68-1 2
HL69-12

HL62-14
HL63-14
HL64-14
HL65-14
HL56-14
HL57-14

HL218-14
HL219-14
HL220-14
HL221-14
HL68-14
HL69-14

0.4531
0.4501

0.4687
0.4657

HL62-16
HL63-16
HL64-16
HL65-16

HL218-16
HL219-16
HL220-16
HL221-16

0.51 56
0.51 26

0.5312
0.5282

0.31 20

HL51-10
HL18-12
HL1 9-12
HL20-12
HL21-12
HL50-12
HL51-12

1132

Oversize
HL18-6
HL19-6
HL20-6
HL21-6
HL50-6
HL51-6

(+0.001 0)
0.1635

HL20-10
HL21-10
HL50-10

3/8

1/64
Oversize

(+0.001 0)
0.3745

(-o.oooo)

(+0.001 0)
0.4370

(-o.oooo)

(+0.001 0)
0.4995

(-o.oooo)

0.3906
0 .3876

0.4062
0.4032

tight, enlarge hole within specified tolerance.

Optional to use HL18 and HL19 oversize fasteners in place of specified HL50 and HL51 (respectively)
replacements, provided fasteners meet installation requirements outlined in 51-40-01.

LES1097AU

Oversized Fasteners Installation At

Figure
EFFECTIVITY:
SRM-4

ALL

oversize

Existing Holes

202 (Sheet 1 of 5)

51-70-00

Page 204
May 15/92

Learjet

STRUCTU RAL REPAIR MANUAL

STANDARD AND OVERSIZE

COUNTERSINKS FOR 1000 FLUSH HEAD HI-LOK BOLTS

FLUSH TENSION HEAD BOLT

FLUSH SMEAR HEAD BOLT

1/32 O.S.

STD. C-SK

1164 O.S.

NOMINAL

DIA.

C-SK DIA.

1/32 O.S.
C-SK DIA.

C-SK DIA.

1/64 O.S.
C-SK DIA.

C-SK DIA.

BOLT

(Ref)

(Ref)

(Ref)

(Ref)

(Ref)

(Ref)

DIA.

D
0.3280

STD.

-5

(5/32)

0.2588

-6

(3/16)

0.2991

0.2991

0.3278

0.3789

0.3789

0.3789

-8

(1/4)

0.3923

0.3923

0.4235

0.5042

0.5042

0.5042

-10

(5/16)

0.4710

0.4710

0.5026

0.6311

0.6311

0.6311

-12

(3/8)

0.5579

0.5579

0.5891

0.7580

0.7580

0.7580

0.6650

0.6650

0.6962

0.8848

0.8848

0.8848

0.7510

0.7510

0.7822

1.0104

1.0104

1.0104

-14(7/16)

D The head height of all Hi-Lok bolts

common to an

aerodynamic surface

outlined in 51-04-04. The head height of all Hi-Lok bolts not


or minus 0.010 inch height from the adjacent surface.

SRM~

aerodynamic

surface

requirements
deviate plus

can

Oversized Fasteners Installation At Existing Holes


Figure 202 (Sheet 2 of 5)

sits

EFFECTIVITY:

must meet the installation

common to an

ALL

51-70-00

Page 205
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
PART

DIA.

NUMBER

1/64 Over

3/16

NAS464-3

NAS2903

1/4

NAS464-4

NAS2904

5116

NAS464-5

3/8

1/64Over

1/32 Over

NAS3003

0.2031/0.2001

0.21 87/0.21 57

NAS3004

0.2656/0.2626

NAS2905

NAS3005

0.328110.3251

NAS464-6

NAS2906

NAS3006

0.3906/0.3876

0.4062/0.4032

7/16

NAS464-7

NAS2907

NAS3007

0.4531/0.4501

0.4687/0.4657

1/2

NAS464-8

NAS2908

NAS3008

0.5156/0.5126

0.531 2/0.5282

3/16

NAS563

NAS2903

NAS3003

0.2031/0.2001

0.2187/0.21 57

114

NAS654

NAS2904

NAS3004

0.2656/0.2626

0.281 2/0.2782

5/16

NAS655

NAS2905

NAS3005

0.3281/0.3251

0.3437/0.3407

3/8

NAS656

NAS2906

NAS3006

0.3906/0.3876

0.4062/0.4032

7/16

NAS657

NAS2907

NAS3007

0.4531/0.4501

0.4687/0.4657

1/2

NAS658

NAS2908

NAS3008

0.5156/0.51 26

0.531 2/0.5282

3/16

NASI 153

NAS1 703

NAS1 603

0.2031/0.2001

0.21 87/0.21 57

1/4

NAS1154

NAS1 704

NAS1 604

0.2656/0.2626

0.281 2/0.2782

5/16

NAS1 705

NAS1 605

0.3281/0.3251

0.3437/0.3407

3/8

NAS1155
NAS1156

NAS1 706

NAS1 606

0.3906/0.3876

0.4062/0.4032

7/16

NAS1157

NAS1 707

NAS1 607

0.4531/0.4501

0.4687/0.4657

1/2

NASI 158

NAS1 708

NAS1 608

0.5156/0.5126

0.531 210 .5282

5/32

B100-T5

3/16

BP-T5
B100-T6
e100-T8
BP-T8

1/4

NAS1202
NAS1 203
NAS1 204

#8
3/16
114

I
I
I
I
I
I

BP-TG

1/32 Over

I
I
I
I
I
I

OB1 00=r5

0.281 2/0.2782

0.3437/0.3407

0.185/0.182

1
I
I
I

1
1
1
1

OBP-T8

0.281/0.278

NAS1203

0.190/0.187

OBP-TS
OB1 00-T6
OBP-T6

0.185/0.182

0.220/0.217
0.220/0.217
0.281/0.278

osl oo-Ta

NAS1 703R

NAS1 603R

0.2031/0.2001

0.21 87/0.21 57

NAS1 704R

NAS1 604R

0.2656/0.2626

0.281 2/0.2782

NAS1 605R
NAS1 606R

0.3281/0.3251

0.3437/0.3407

0.3906/0.3876

0.4062/0.4032

NAS1 607R

0.4531/0.4501

0.4687/0.4657

NAS1 608R

0.5156/0.51 26

0.531 2/0.5282

NAS1 603
NAS1 604
NAS1 605

0.2031/0.2001

0.21 87/0.21 57

0.2656/0.2626

0.281 2/0.2782

0.3281/0.3251

0.3437/0.3407
0.4062/0.4032

3/8

NAS1 205
NAS1 206

7/16

NASI 207

1/2

NAS1 208

NAS1 705R
NAS1 706R
NAS1 707R
NAS1 708A

3/16

NAS1 503

NAS1 703

1/4

NAS1 504

el

5/16

NAS1 505

NAS1704
NAS1 705

3/8

NAS1 506

NAS1 706

NAS1 606

0.3906/0.3876

7/16
1/2

NAS1 507

NAS1 707
NAS1 708

NAS1 607
NAS1 608

0.4531/0.4501

0.4687/0.4657

0.5156/0.5126

0.531 2/0.5282

3/16

NAS2803

NAS1 703

NAS1 603

0.2031/0.2001

0.21 87/0.21 57

1/4

NAS2804

NAS1704

NAS1 604

0.2656/0.2626

0.281 2/0.2782

5/16

NAS2805
NAS2806
NAS2807

NAS1 705

NAS1 605

0.3281/0.3251

0.3437/0.3407

3/8
7/16

NAS1 706

0.3906/0.3876

0.4062/0.4032

NAS1 707

NAS1 606
NAS1 607

0.4531/0.4501

0.4687/0.4657

1/2

NAS2808

NAS1 708

NAS1 608

0.51 56/0.51 26

0.531 210 .5282

5/16

NAS1 508

Oversized Fasteners Installation At Existing Holes


Figure 202 (Sheet 3 of 5)

5129

EFFECTIVITY:
sRM-4

REWORK HOLE SIZE

REPLACEMENT

BOLT
NOMINAL

ALL

51-70-00

Page 206
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


"D" DIAMETER

THREAD

UNJF-3A

BOLT
PART

"T"

(EXCEPT
NOTED)

AS

MAX.

MIN.

REF

NAS2903

0.1900-32

0.2026

0.2016

0.338

NAS2904

0.2500-28

0.2651

0.2641

0.425

NAS2905

0.31 25-24

0.3276

0.3266

0.469

NUMBER

NAS2906

0.3750-24

0.3901

0.3891

0.578

NAS2907

0.4375-20

0.4526

0.4516

0.594

NAS2908

0.5000-20

0.5151

0.5141

0.735

NAS2909

0.5625-18

0.5771

0.5761

0.840

NAS2910

0.6250-18

0.6396

0.6386

0.902

NAS2912

0.7500-16

0.7646

0.7636

1.041

NAS2914

0.8750-14

0.8896

0.8886

1.184

NAS2916

1.000-12

1.0146

1.0136

1.309

NAS291 6A

1.0000-14

1.0146

1.0136

1.291

NAS2918

1.1250-12

1.1396

1.1381

1.458

NAS2920

1.2500-12

1.2646

1.2631

1.646

/-3
1

I!

_t

"NS-3A

Bolt, Shear

Hexagon Head,

0.0156 Oversize

Shank, Alloy Steel

160-180 KSI Ultimate Tensile

"D" DIAMETER

THREAD
BASIC

DOCUMENT

UNJF-3A

(EXCEPT
NOTED)

"T"

AS

MAX.

MIN.

REF

NAS3003

0.1900-32

0.2182

0.21 72

0.338

NAS3004
NAS3005

0.2500-28

0.2807

0.2797

0.425

0.31 25-24

0.3432

0.3422

0.469

NUMBER

NAS3006
NAS3007
NAS3008

0.3750-24

0.4057

0.4047

0.578

0.4375-20

0.4682

0.4672

0.594

0.5000-20

0.5307

0.5297

0.735

NAS3009

0.5625-18

0.5927

0.5917

0.840

NAS3010

0.6250-18

0.6552

0.6542

0.902

NAS3012

0.7500-16

0.7802

0.7792

1.041

NAS3014

0.8750-14

0.9052

0.9042

1.184

NAS3016

1.0000-12

1.0302

1.0292

1.309

NAS301 6A
NAS3018

1.0000-14*

1.0302

1.0292

1.291

1.1250-12

1.1552

1.1537

1.458

NAS3020

1.2500-12

1.2802

1.2787

1.646

.f

NS-3A

Bolt, Shear

Hexagon Head,

0.0312 Oversize Shank,

Alloy

Steel

160-180 KSI Ultimate Tensile

Oversized Fasteners Installation At Existing Holes


Figure 202 (Sheet 4 of 5)

EFFECTIVITY:

ALL

51-70-00

Page 207
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
PART NUMBER

"D" DIA., 0.0156

(NONLOCKING
UNDRILLED)

OVERSIZE SHANK

NOMINAL
0.0156

THREAD

OVERSIZE

SIZE

MAX.

MIN.

NAS4703-*~

0.1900-32

0.2026

0.2016

NAS4704-*~

0.2500-28

0.2651

0.2641

NAS470A1-~

0.2500-28

0.2651

0.2641

NAS4705-~

0.31 25-24

0.3276

0.3266

NAS4706-~

0.3750-24

0.3901

0.3891

NAS4707-~

0.4375-20

0.4526

0.4516

NAS4708-*~

0.5000-20

0.5151

0.5141

NAS4709-~

0.5625-18

0.5771

0.5761

0-^I~

0.6250-18

0.6396

0.6386

NAS471 2-~

0.7500-16

0.7646

0.7636

NAS4714-*~

0.8750-14

0.8896

0.8886

6-I~

1.0000-12

1.0146

1.0136

NAS471

NAS471

"D"

0.0312

DIA., 0.0312

OVERSIZE SHANK

OVERSIZE
NAS4703-i~

0.1900-32

0.2182

0.21 72

NAS4704-~

0.2500-28

0.2651

0.2797

NAS470AI-~
NAS4705-~

0.2500-28

0.2807

0.2797

0.31 25-24

0.3432

0.3422

NAS4706-~

0.3750-24

0.4057

0.4047

NAS4707-~

0.4375-20

0.4682

0.4672

NAS1708-~

0.5000-20

0.5307

0.5297

NAS4709-*~

0.5625-18

0.5927

0.5917

NAS471 0-~

0.6250-18

0.6552

0.6542

2-j~

0.7500-16

0.7802

0.7792

NAS471 4-~

0.8750-14

0.9052

0.9042

NAS471

1,9000-12

1.0302

1.0292

NAS471

Grip dash

number in 0.0625-inch increments

.f
14-201A

EFFECTNITY:

Existing Holes
Figure 202 (Sheet 5 of 5)

Oversized Fasteners Installation At

ALL

51-70-00

Page 208
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
4.

INSTALLING BUSHINGS IN OVERSIZED HOLES


A.

Bushings Installation At Oversized Holes


(1) Determine the original hole ID (bore) of damaged part.
(2) Refer to standard bushing chart and select bushing with

Standard

the closest ID (bore) of the

original

hole

size.

Length of required bushing will vary with application.


length and deburred when necessary.

NOTE:

(3) Refer

to standard

bushing chart,

determine the hole size (steel

ing selected in step A. (2).


(4) Drill out damaged hole to hole size determined in
(5) Install bushing with wet epoxy primer.
B.

step

Standard

or

bushing may be

aluminum)

cut to

to match the bush-

A. (3).

Limitations

procedures specified in paragraph A.,


Repair Data figures in 51-71-00.

(1) Rework of oversized holes, using the

specified

in the Allowable Wear and

are

limited to those

HOLE
STEEL

ALUMINUM

HOLE DIAMETER

HOLE DIAMETER

BUSHING
OUTSIDE DIAMETER
SIZE

NOMINAL

DASH NO.

BORE

MAXIMUM

MINIMUM

MINIMUM

MAXIMUM

MINIMUM

MAXIMUM

0.1900

0.3136

0.3131

0.3123

0.3129

0.3123

0.3129

0.2500

0.3761

0.3756

0.3748

0.3754

0.3748

0.3754

0.3125

0.4386

0.4381

0.4373

0.4379

0.4373

0.4379

0.3750

0.5013

0.5006

0.4998

0.5004

0.4997

0.5003

0.4375

0.5638

0.5631

0.5622

0.5629

0.5622

0.5628

0.5000

0.6265

0.6257

0.6248

0.6255

0.6247

0.6254

0.5625

0.6892

0.6882

0.6873

0.6880

0.6872

0.6879

10

0.6250

0.8142

0.8132

0.8122

0.8130

0.8120

0.8129

11

0.6875

0.8767

0.8757

0.8747

0.8755

0.8745

0.8754

12

0.7500

0.9393

0.9383

0.9372

0.9381

0.9370

0.9379

14

0.8750

1.0648

1.0638

1.0627

1.0636

1.0625

1.0634

16

1.0000

1.1898

1.1888

1.1875

1.1885

1.1873

1.1883

18

1.1250

1.3148

1.3138

1.3125

1.3135

1.3122

1.3132

20

1.2500

1.4399

1.4389

1.4375

1.4385

1.4372

1.4382

Interference Fit Hole Sized For NAS 75,

Standard

EFFECTIVITY:

ALL

76, 77, 537, 538 (BACBP8Y, U, W, X)

Bushings Installation for Oversized


Figure 203

Holes

51-70-00

Page 209
May 15/92

Learjet
~Learjetl

STRUCTURAL REPAIR MANUAL


REAMER
SIZE

TOL

0.0625
0.0730

+0.0010

0.0937
0.1220

-0.0010

REAMER
SIZE

TOL

0.2640*

+0.0010
-0.0010

0.1230
0.1240
0.1250
0.1260
0.1270
0.1 280

0.1406
0.1542
0.1552
0.1 562
0.1719
0.1850*
0.1855
0.1865
0.1870*
0.1 875
0.1880
0.1885
0.1890

1
1
1

I
I
I

1
1
1

0.1910
0.1920
0.1930
0.1990
0.2020*
0.2031

0.2344
0.2450*
0.2460*
0.2475*
0.2480
0.2485*
0.2490

*Piloted

reamers

0.2810
0.2812
0.2822
0.2969
0.3080*
0.3090*
0.31 05*
0.3115
0.3120
0.3125
0.3135
0.3150*
0.3240*
0.3270*
0.3281
0.3290*
0.3400
0.3427
0.3438

0.3450
0.3594
0.3710*
0.3730
0.3735*
0.3740
0.3750
0.3760
0.3890
0.3906
0.3920*

0.4020*
0.4050
0.4052
0.4062
0.4070
0.4072
0.4219
0.4360*

0.2500

0.2510
0.2520
0.2530*
0.2570
0.2620*

0.2802

1
1
1
1

I
I

1
1

1
1

+0.0010
-0.0010

1
1
1
1

+0.0020
-0.0020

I
I
I
i

1
1
1
1

0.4364

+0.0010
-0.0010

0.4375
0.4385

TOL

0.4520*

+0.0020

0.4531
0.4670*
0.4677

-0.0020

_I

1
1

1
1

+0.0020
-0.0020

1.1562

1.1250

1.1875

0.4688
0.4697
0.4844

1
1

I
I

1
1

1.2188

1.2812

0.4980*
0.4990

1
1
1
1
1
1

I
I
1
I
I
I

1
1
1
1
1
1

1.3125
1.3438
1.3750

1
1

1
1

1.5625

1.5938

0.5000

+0.0020
-0.0020
+0.0030
-0.0020

1.5000

I
I

1
1
1

0.6542

1.6875
1.7188
1.7500
1.7812

0.6719

1.8125

0.6875

1.8438

0.7031
0.7188
0.7344
0.7500

1.8750

1.9062
1.9375

0.7656
0.7812

1
1

I
I

1
1

0.8281

0.8438
0.8594
0.8750
0.8906
0.9062
0.9219
0.9375
0.9631
0.9688

1.0000
1.0156
1.0312
1.0469
1.0625

+0.0040
-0.0020

1.4062
1.4375
1.4688

1
1
1

1.2500

0.5625
0.5781
0.5938
0.6094
0.6250
0.6406

0.9844
1

1.0938

0.7969
0.8125
1

1
1

0.5140*
0.5156
0.5300*
0.5312

TOL

REAMER
SIZE

0.5678

0.3447

0.2150*
0.2180*
0.2188
0.2190*

0.3430

0.1895
0.1900

0.2656
0.2670*
0.2770

REAMER
SIZE

1.6250
1.6562

1.9688
2.0000
2.0625
2.2500

2.3125
2.3750
2.5000

+0.0040
-0.0020

+0.0030

-a.

+0.0040
-0.0020

cannot be used.

Standard Reamer Size

Figure 204

EFFECI~IVITY:
SRM-4

ALL

51-70-00

Page 210
May 15/92

Learjet
STRUCTU RAL REPAIR MANUAL
PRESS FITS FOR BUSHINGS IN ALUMINUM AND MAGNESIUM

TOLERANCE
HOLE DIAMETER

0.2501 thru 0.5000


0.5001 thru 0.7500

0.7501 thru 1.0000


1.0001 thru 1.2500

1.2501 thru 1.5000


1.5001 thru 1.7500
1.7501 thru 2.0000
2.0001 thru 2.2500
2.2501 thru 2.5000
2.5001 thru 2.7500
2.7501 thru 3.0000

3.0001
3.2501
3.5001
3.7501

thru
thru
thru
thru

3.2500
3.5000
3.7500
4.0000

(O.D.)

INTERFERENCE

Min.

Max.

Min.

+0.0005
+0.0006
+0.0006
+0.0007
+0.0007
+0.0008
+0.0008
+0.0009
+0.0009
+0.0009
+0.0009

0.0000

+0.0007
+0.0009
+0.0011
+0.0013
+0.0015
+0.0017

0.0012
0.0015

0.0002
0.0003

0.0017

0.0005

0.0020
0.0023

0.0006

0.0025

0.0009

+0.0019
+0.0021

0.0027
0.0030

0.0011
0.0012
0.0013

0.0034
0.0036
0.0038

0.0015
0.0017

0.0000

+0.0022
+0.0024
+0.0026
+0.0028
+0.0030
+0.0032
+0.0034
+0.0036

0.0032

+0.0010
+0.0010
+0.0010
+0.0010
+0.0011

+0.0012
+0.0015
+0.0017
+0.0020
+0.0023
+0.0025
+0.0027
+0.0030
+0.0032
+0.0034
+0.0036
+0.0038
+0.0040
+0.0042
+0.0044
+0.0046

0.0040

0.0042

0.0020
0.0022

0.0044
0.0046

0.0024
0.0025

Max.
0.0000 thru 0.2500

BUSHING

HOLE

0.0000
0.0000

0.0000
0.0000

0.0000
0.0000
0.0000
0.0000
0.0000

0.0000
0.0000
0.0000
0.0000
0.0000

Max.

Min.

0.0008

0.0018

PRESS FITS FOR BUSHINGS IN STEEL


TOLERANCE
HOLE DIAMETER

0.2501 thru 0.5000


0.5001 thru 0.7500
0.7501 thru
1.0001 thru
1.2501 thru
1.5001 thru
1.7501 thru
2.0001 thru
2.2501 thru
2.5001 thru
2.7501 thru
3.0001 thru
3.2501 thru
3.5001 thru
3.7501 thru

1.0000
1.2500
1.5000
1.7500
2.0000
2.2500
2.5000
2.7500
3.0000
3.2500
3.5000
3.7500
4.0000

(O.D.)

Min.

Max.

Min.

+0.0005
+0.0006

0.0000

+0.0007
+0.0007

0.0000

+0.0008
+0.0008
+0.0008
+0.0009
+0.0009
+9.0009
+0.0010
+0.0010
+0.0010
+0.0010
+0.0010
+0.0011

0.0000

+0.0011
+0.0014
+0.0016
+0.0018
+0.0020
+0.0022
+0.0024
+0.0026
+0.0027
+0.0029
+0.0031
+0.0032
+0.0034
+0.0035
+0.0036
+0.0038

+0.0007
+0.0008
+0.0010
+0.0011
+0.0013
+0.0014
+0.0015
+0.0017
+0.0018
+0.0019
+0.0021
+0.0022
+0.0024
+0.0025
+0.0026
+0.0028

Max.
0.0000 thru 0.2500

BUSHING

HOLE

0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

0.0000
0.0000
0.0000

Press Fit Hole Size for

INTERFERENCE
Max.

Min.

0.0011

0.0002

0.0014

0.0003

0.0016

0.0003

0.0018
0.0020
0.0022
0.0024
0.0026
0.0027

0.0004

0.0007
0.0008
0.0009

0.0029

0.0010

0.0031
0.0032

0.0011
0.0012

0.0005

0.0006

0.0034

0.0014

0.0035
0.0036

0.0015
0.0016

0.0038

0.0017

Bushings

Figure 205
EFFECTIVITY:
SRM4

ALL

51-70-00

Page 211
May 15/92

STRUCTURAL REPAIR WIANUAL


5.

APPLICATION AND USE OF STRUCTURAL ADHESIVES


WARNING:

ROOM TEMPERATURE ADHESIVES (REGARDLESS OF CURE TIME) SHALL NOT


BE USED TO SECURE ANY PRIMARY STRUCTURE.

A.

The

area

EFFECTTVITY:
SRM~

are used and the application of the adhesive is specified


Learjet maintenance manual.

in which adhesives

sections of the basic

ALL

in the

applicable

51-70-00

Fage212
May 15/92

Learjet
TEMPORARY REVISION NO. 51-2
Leajet Model 20/30 Series Structural Repair

MANUAL AFFECTED:

Insert

FILING INSTRUCTIONS:

adjacent

to

Manual (SRM-Q).

51-70-01, page 201, dated Jun 1/95, and retain until further

notice.
To

REASON:

clarify dent repairs to wing leading edge.


Revise

INSTRUCTIONS:

paragraph i. MINOR DENT REPAIR, as follows:

AIRCRAFT SKIN DENTS


1.

TYPICAL REPAIR

MINOR DENT REPAIR


A. Minor dents are dents in the aircraft skin or sutFstructure which do not exceed the limits
the Allowable Damage section of each chapter.
B.

Minor Dent

specified

in

Repairs

(1) Dents in the aircraft skin, where access to the dented area is restricted, can be repaired using
dynamic fairing compound. (Refer to paragraph 3., for application of aerodynamic fairing

aerocom-

pound.)
(2) Dents in the aircraft skin, where accessible, may be

repaired by bumping the skin back into conpainted surface has not fractured. Refinish
appropriate Leajet Maintenance Manual, Chapter 20,

to ensure that the

inspected
painted surface, if required. (Refer to the
for painting procedures.)
(3) Dents in the engine nacelle inlet areas shall
Chapter 54 of this manual.
tour. The

area

WARNING:

shall be

be

repaired

in accordance with the

procedures

in

DENT REPAIRS ACCOMPLISHED ON THE WING LEADING EDGE SHALL


TESTED TO VERIFY AERODYNAMIC ACCEPTABILITY AND
BE

FLIGHT

STALL SPEEDS. (REFER TO THE BASIC

LEARJET MAINTENANCE

MANU-

AL OR SERVICE MANUAL FOR APPLICABLE STALL WARNING FAULT

ISOLATION PROCEDURES).

(4) Dents in the

wing,

vertical stabilizer, and the horizontal stabilizer shall be

bumped

back into

con-

tour.

MAJOR
A.

DENT REPAIR

Major

B.

dents in the aircraft skin


Damage section of each chapter.

dents

lowable

are

or

sub-structure which exceed the limits

specified

in the Al-

Major Dent Repair


(1) Damaged areas shall be removed and repaired using the typical repairs as specified in 51-70-02.
(2) Leading edges of the wing, vertical stabilizer, and the horizontal stabilizer shall be replaced.

1EMPORARY REVISION NO. 51-2

51-70-01

Page 1 of 1
Aug15/97

Learjet

STRUCTURAL REPAIR MANUAL


AIRCRAFT SKIN DENTS
i.

TYPICAL REPAIR

MINORDENT REPAIR
dents in the aircraft skin

sub-structure which do not exceed the limits

A.

Minor dents

B.

Damage section of each chapter.


Minor DentRepairs

are

or

specified in

the Allowable

(1) Dents in the aircraft skin, where access to the dented

dynamic fairing compound. (Refer


pound.)

to

paragraph 3.,

area

for

is restricted,

application

be repaired using aeroaerodynamic fairing com-

can

of

(2) Dents in the aircraft skin, where accessible, may be repaired by bumping the skin back into

con-

inspected to ensure that the painted surface has not fractured. Refinish
painted surface, if required. (Refer to the appropriate Learjet Maintenance Manual or Service
Manual for painting procedures.)
(3) Dents in the engine nacelle inlet areas shall be repaired in accordance with the procedures in
Chapter 54 of this manual.
(4) Dents in the leading edge of the wing, vertical stabilizer, and the horizontal stabilizer shall be
bumped back into contour.
tour.

The

area

WARNING:

shall be

DENT REPAIRS ACCOMPLISHED ON THE WING LEADING EDGE SHALL


BE FLIGHT TESTED TO VERIFY AERODYNAMIC ACCEPTABILITY AND
STALL SPEEDS. (REFER TO THE BASIC

LEARJET

MAINTENANCE MAN-

UAL OR SERVICE MANUAL FOR APPLICABLE PROCEDURES).


2.

MAJOR
A.
B.

DENT REPAIR

Major dents are dents in the aircraft skin or sub-structure which exceed the limits specified in the Allowable Damage section of each chapter.
Major DentRepair
(1) Damaged areas shall be removed and repaired using the typical repairs as specified in 51-70-02.
(2) Leading edges of the wing, vertical stabilizer, and the horizontal stabilizer shall be replaced.

hi
I~"that
EFFECTIVITY:

SRM-Q

ALL

REVISI(IN
revises this page.

51-70-01

Page 201
Jun1/95

Learjet
~Learjefl

S~RUCTURAC REPAIR MANUAL


APPLICATION OF AERODYNAMIC FAIRING COMPOUND

3.

A.

Toolsand

Equipment

NOTE:

Equivalent substitutes may be used in lieu of the following:

NAME

PART NUMBER

White Streak Plastic Solder

MANUFACTURER*

USE

16522

Aerodynamic filler

DX-999

47695

Aerodynamic filler

H-1337-B-L (resin)

99384

Aerodynamic filler

and Cream Hardener


Filler

Epocast

9615A (hardener)

Sealant

Pro-Seal 890

Products Research

(MIL-S-8802)
Class B1/2

Chemical

Aerodynamic filler

Corp.

Class B-2
Class B-4
Filler

C42 No. 6372

16772

Aerodynamic filler

Filler

EC-1751

94961

Aerodynamic filler

Masking Tape

Commercially

available

General

MethylEthylKetone (MEK)

Commercially

available

General

Putty Knife

Commercially

available

General

Lint-Free Cloth

Commercially

available

General

Abrasive

Paper

No. 220

or

finer

Commercially

available

General

Abrasive

Paper

No. 320

or

finer

Commercially

available

General

Commercially

available

General

Abrasive Pad

(Nylon Wool Type)


Blow Gun and

Tip

DGD501

Scales (Calibrated in Grams)


Abrasive

No. 80

Paper

17431

General

Commercially

available

General

Commercially

available

General

*Refer to the Introduction Section of this manual for lists of manufacturers.

LFS1092F

EFFECTIVITY:

ALL

51-70-01

Page 202
SRM-4

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


B.

Filler

Preparation

(1) White Streak Plastic Solder shall be mixed with the


dener to three

pounds

of base

cream

hardener at

pounds

of base

ratio of

one ounce

har-

compound.

(2) Ditzler DX-999 plastic shall be mixed with the accelerator


three

at

ratio of

hardener to

one ounce

compound.

(3) Pro-Seal 890 (MIL-S-8802) shall be mixed per manufacturers recommendations. The ratio will
vary with different classes of sealant to be mixed.
(4) EC-1751 shall be mixed at a ratio of two parts gray and
grey and two parts amber by volume.
When

NOTE:

mixing fairing compounds,

compound.
C.

Surface
NOTE:

one

part

amber

by weight

or

three parts

folding action shall be used. Avoid trapping air in


or other foreign materials to mixture.

Do not add resins, thinners,

Preparation
The aircraft structure
namic filler in order to

temperature shall be 65"F (180C) or above when applying aerodypromote adhesion and to prevent moisture condensation.
or any other surface contaminants from
each side of area to be filled.

(1) Remove all dirt, dust, grease, pencil marks, paint,


be filled and for

CAUTION:

distance of

one

inch

along

area

to

USE EXTREME CARE WHEN REMOVING SURFACE OXIDES TO PREVENT


EXCESSIVE REMOVAL OF METAL.

(2) Use #80 grit abrasive paper

to

remove

surface oxides and wash with MEK.

Dry

surface thor-

with lint-free cloth.

D.

oughly
Application

Filler

NOTE:

aerodynamic filler shall be applied directly to the cleaned metal. No primer


type shall be applied or allowed to remain prior to application of the filler.

The

(1) Mask off area

to be sealed

distance of

one

inch

of any

along each side.

(2) Apply filler with a putty knife.


(3) Build area to be sealed to a maximum of l/&inch thickness paper application. Allow first application to

(4)
(5)
(6)
(7)

cure

completely.

Sand hardened surface and blow clean with clean, dry air. Do not
Apply second application of filler and allow to cure completely.

use

liquid cleaner.

Sand hardened surface with #220 abrasive paper to remove excess filler.
Sand hardened surface with #320 abrasive paper until smooth and flush with
Feather all edges and exercise care to prevent abrasion of adjacent metal surfaces.

(8) Blow clean dry air

over

surface until clean. Do not

use a

liquid

adjacent

cleaner. Direct air

areas.

perpendicular

pin holes.
(9) Apply a thin layer of filler to fill pin holes. Repeat sanding procedure.
(10) Refinish painted surface. (Refer to the appropriate Leajet Maintenance Manual, Chapter 20,
painting procedures.)
to the surface to

EFFECTIVITY:

ALL

remove

dust from

for

51-70-01

Page 203
SRM-4

Jun 1/95

LEARJET 20/30 SERIES

STRUCTURAL REPAIR MANUAL

TEMPORARY REVISION NO. 51-6


MANUAL AFFECTED:

Learjet

20/30 Series Structural

FILING INSTRUCTIONS: Insert


REASON: To

as

dated

May 15/92 and

retain until further notice.

for treatment of cracks.

follows:
AIRCRAFT SKIN

1.

Manual.

adjacent to 51-70-02, page 201,

incorporate procedures

INSTRUCTIONS: Revise

Repair

TYPICAL REPAIRS

SkinRepairs
A.

Repair Instruction (See Figures 201 thru 203.)


(1) Repair procedures are given in this section

for

repair

side of the pressure cabin. In the pressure cabin

of skins of the pressure cabin, and skins out-

staggered

double

row

of rivets is

required

the repair is not supported or made rigid by sub-structure.


(2) Repair material and gage must be the same as original.
(3) Rivet spacing shall be compatible with the original rivet pattern. As a general rule,
shall be six (6) times the diameter of the rivets.
(4) Drill all parts in place, remove parts, and remove burrs. (Refer to 51-40-02 for skin

rivet

when

spacing

trim

).noitanimretednoitacol

(5) Refer to 51-30-04 for protective treatment of metal.


(6) Apply sealant as required when the repair may affect
30-02 for sealing procedures.
2.

the cabin pressure

capabilities. Refer

to 51-

Treatment of Cracks

DO NOT STOP-DRILL CRACKS IN THE PRIMARY STRUCTURE UNLESS THIS IS

CAUTION:

PERMITTED IN THE ALLOWABLE DAMAGE LIMITS.

(REFER

TO

51-70-00.)

CRACKS

IN THE PRIMARY STRUCTURE THAT ARE LARGER THAN PERMITTED IN THE

ALLOWABLE DAMAGE LIMITS CAN CAUSE THE PART TO HAVE LESS THAN THE
NECESSARY STRENGTH.

A.

Stop-Drill Cracks (Refer

Figure 204.)
(1) Perform a liquid-penetrant inspection to accurately find the end
20/30/55 Series Nondestructive Inspection Manual.)
(2) Stop-drill cracks.
(a) Use a #40 (0.098 inch [0.250 cmlf diameter drill for metal
to

of the crack.

(Refer

thickness of 0.032

to the

Learjet

[0.081 cm]

or

less.

(b)

Use

#30

(0.128

inch

[0.325 cml)

diameter drill for metal thickness greater than 0.032

[0.081

cm].

(3)
(4)

Deburr the hole and

Perform

remove

all unwanted material.

liquid-penetrant inspection

to the

Learjet
(Refer
(5) Apply surface treatment protection
TEMPORARY REVISION NO. 51-6

SRM -4

to make

sure

that the hole has contained the end of the crack.

20/30/55 Series Nondestructive

Inspection Manual.)
(Refer to 51-30-04.)

to the bare metal surfaces.

51 -70-02

Page

1 of 8

Jan 15/01

LEARJET 20/30 SERIES

STRUCTURAL REPAIR MANUAL

(6) Calculate

the total

length

that the total crack

(Refer
NOTE:

to

of the crack after it is

damage

in the

a crack is in one part of a riveted assembly, remove the fasteners and put in a
temporary shield made from thin stainless steel sheet. This will prevent damage to the

can

that

go into

are

behind.

stop-drill holes,

seal the

area

with sealant

or

with surface filler.

(Refer

51-30-02.)

TEMPORARY REVISION NO. 51-6


SRM -4

permitted

diameter). Make sure


allowable damage limit.

Where

Where moisture
to

is less than the maximum

the hole

51-70-00.)

adjacent parts

(7)

stop-drilled (include

51-70-02

Page

2 of 8

Jan 15/01

LEARJET 20/30 SERIES


STRUCTURAL REPAIR MANUAL
EDGE MARGIN

2 X RIVET dia

PATCH

2024-T3 CLAD

EDGE DISTANCE

21

2 X RIVET dia

RADIUS0.5 in [1.27 cm]

CLEAN OUT DAMAGE AREA

,I

SKIN

lo

Ij

RIVET SPACING

2 X RIVET dia

A_

DOUBLER

0.5 in

o\

/O

2024-T3 CLAD

[1.27 cm]

RADIUS

EDGE DISTANCE
2 X RIVET dia

EDGE DISTANCE
2 X RIVET dia

0.5 in

[1.27 cm] RADIUS

MINIMUM

D(ISTING SKIN

PATCH

DOUBLER

View A-A

520-517W2-201-01

Typical Insert Patch (Non-Pressurized Area)


Figure 201 (Sheet 1 of 2)

TEMPORARY REVISION NO. 51-6


SRM -4

of 8
51-70-02 Page
Jan 15/01
3

LEARJET 20/30 SERIES


STRUCTURAL REPAIR MANUAL

RIVET SPACING
3 dia MAXIMUM

6 X RIVET. dia

J-

EDGE DISTANCE

RIVET
X

2 X RIVET dia

DAMAGE SKIN

FILLER

-I
REPAIR DOUBLER

FILLER

REPAIR DOUBLER

SAME MATERIAL AS,

AND ONE GAUGE HEAVIER THAN DAMAGED

SKIN MATERIAL

SAME GAGE AND MATERIAL

OR EQUIVALENT

DAMAGE SKIN

820-61 7002-201 -02

Typical Insert Patch (Non-Pressurized Area)


Figure 201 (Sheet 2 of 2)

TEMPORARY REVISION NO. 51-6


SRM -4

51-70-02

Page

4 of 8

Jan 15/01

LEARJET 20/30 SERIES

STRUCTURAL REPAIR MANUAL


EDGE DISTANCE
2 X RIVET dia

0.5 in

[1.27 cm]
PATCH

RADIUS

EDGE DISTANCE

X RIVET dia

0.5 in

2024-T3 CLAD

CLEAN OUT DAMAGE

2SUIDAR

NIKSAERA

O0O

[1.27 cm]

MINIMUM

Pb
O

3~

/O

RIVET SPACING

,4-6 X RIVET dia

oo~

Oo\,

/b

o_o

DOUBLER

0.5 in

2024

T3 CLAD

[1.27 cm]

RADIUS

EDGE DISTANCE

EDGE DISTANCE

2 X RIVET dia

2 X RIVET dia

0.5 in

SPREAD SEALANT NENLY

APPROXIMATELY 1/32 in [0.08 cm]


(REFER TO 51-30-02.)

[1.27 cm] RADIUS

MINIMUM

THICK

RIVETS

f
I-I

-n

8--cl

View A-A
Typical

TEMPORARY REVISION NO. 51-6


sRM -4

(Pressurized Area)
Figure 202

Insert Patch

51-70-02

Page

5 of 8

Jan 15/01

LEARJET 20130 SERIES


STRUCTURAL REPAIR MANUAL

DOUBLER SAME GAGE AND


MATERIAL OR EQUIVALENT

ir~

c
L

EXISTING

i:

EDGE DISTANCE
2 X RIVET DIAMETER
MINIMUM
1

ed

RIVET SPACING
6 RIVET
4

DIAMETERS

L)

~y
:o

::sr

rs

b7
0,05 in

20.127 cm] RADIUS

MINIMUM

CP/PICAL)

APPLY SEALANT IN
CONTACT AREA; SPREAD

EVENLY APPROXIMATELY
1/32 in [0.08 cm] THICK.

(REFER TO 52-30-02)

PATCH

DOUBLER

DOUBLER

PATCH

RIVETS

View A-A
520-51~002-203-01

Over Structure

TEMPORARY RE\IISION NO. 51a


SRM -4

Repair (Pressurized and Non-Pressurized Area)


Figure 203

51 -70-02

15/01

LEARJET 20/30 SERIES


STRUCTURAL REPAIR MANUAL

1!2 D

1!2 D

Y
a

CRACKS

CENTER-PUNCH TO STOP-DRILL
1/2 DRILL DIAME~ER AWAY FROM
THE ENDS OF THE CRACK AND
IN LINE WITH THE CRACK DIRECTION

(USUAL)

REFER TO THE TEXT

FOR DRILL SIZES

HOW TO STOP-DRILL CRACKS

STOP DRILL, REMOVE


THE CRACK, AND
MAKE

SMOTHL

NO DAMAGE PERMITTED

TO SHADED AREAS AT BEND


RADII OR FILLETS

r/l

STOP DRILL, REMOVE


THE CRACYAND

CRACK REMOVED
TO A CIRCULAR

MAKE SMOOTH

HOLE
20 MINIMUM

TREATMENT FOR CRACKS IN DCTRUDED

OR FORMED SECTIONS

SM517002-2W-01

Treatment of Permitted Cracks

Figure

TEMPORARY REVISION NO. 51-6

204

(Sheet

1 of

2)

of 8
51-70-02 Page 15/01
7

Jan

SRM -4

LEARJET 20/30 SERIES


STRUCTURAL REPAIR MANUAL

CRACK FROM FASTENER HOLE


TO THE EDGE OF THE SKIN

CRACK FROM THE


EDGE OF THE SKIN

CRACK REMOVED TO
A CIRCULAR HOLE

CRACKS THAT START

FROM A FASTENER HOLE

n/
CRACK BETWEEN
FASTENER HOLES

CRACKIN OPEN
SKIN AREA

TREATMENT OF CRACKS IN SKIN


NOTE

LEGEND
L

X
ED
D

REFER TO THE APPLICABLE

MAXIMUM LENGTH
MINIMUM DISTANCE
EDGE DISTANCE
DRILL DIAMETER OR
RIVET HOLE DIAMETER

ALLOWABLE DAMAGE LIMITS

FOR THE MAXIMUM DIAMETER.

S20517002-204-M

Treatment of Permitted Cracks

Figure

TEMPORARY REVISION NO. 51-6


SRM -4

204

(Sheet

2 of

2)

51-70-02

Page

8 of 8

Jan 15101

Learjet
STRUCTURAL REPAIR MANUAL
AIRCRAFT SKIN
i.

TYPICAL REPAIRS

SKINREPAIRS
A.

Repair Instruction (See Figures 201 thru 203.)


(1) Repair procedures are given in this section for repair of skins of the pressure cabin, and skins outside of the pressure cabin. In the pressure cabin a staggered double row of rivets is required
when the repair is not supported or made rigid by sub-structure.
~2) Stop-drill cracks, or remove damaged area and smooth edges, before application of repair. Use
#40 (0.098) stop-drill for metal thickness of 0.032 or less and #30 (0.128) stop-drill for metal thickness greater than 0.032.
(3) Repair material and gage must be the same as original.
(4) Rivet spacing shall be compatible with the original rivet pattern. As a general rule, rivet spacing
shall be 6 times the diameter of the rivets.

(5) Drill all parts in place, remove parts and remove burrs.
(6) Refer to 51-30-04 for protective treatment of metal.
(7) Apply sealant as required when the repair may affect the cabin pressure capabilities. Refer
30-02 for

EFFECTIVITY:

to 51-

sealing procedures.

ALL

NOTE: Please

see

the

TEMPORARY
RE\NSION
that revises this page.

51-70-02

May 15/92Page

201

Learjet

STRUCTURAL REPAIR MANUAL

Patch-$i

---Existing

Skin

T~Ri
STi~
1/2

I/

Doubler

/--Edge Margin
2

Rivet Dia.

Patch

Edge Margin
2

Clad

Skin)

as

Rivet Dia.

2024-T3

(Same Gage

~I
iJ

Clean

Out

AreaDamaged
Skin

e~

~,,-Rivet Spacing
6

Doubler

2024-T3

(Same Gage

as

Rivet

Dia.

Alclad

Skin)

Edge
2

1/2"

Margin
Rivet Dia.

Radius

1/2"

Radius

Typical Insert Patch (Non-Pressurized Area)


Figure 201 (Sheet 1 of 2)
EFFECTIVITY:
SRM~

ALL

51-70-02

Page 202
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
3

Dia.

~------Rivet

Max

Spacing

Rivet Dia.

3
/X

Margin

r 3-t

Rivet Dia.

-t
I

\I

Damaged skin

Repair Doubler

ma;eZIaEsRepair

Doubler

heavier

as,

than

material
Filler

Same

and

one

gage

damaged skin

Rivet

Filler

gage
as

Same

damaged skin

Typical Insert Patch (Non-Pressurized


Figure 201 (Sheet 2 of 2)

EFFECTIVITY:
SRM4

ALL

iDamaged

and material

Skin

Area)

51-70-02

Page 203
May 15/92

Leariet

STRUCTURAL REPAIR MANUAL


Edge Margin
2x Rivet Dia,

Radius

1/2"

2024-T3

~--patch

(Same Gage

Edge Margin
2

as

Clad

Skin)

Rivet Dia.

Out

Clean

Damaged

Area

Skin

1/2" Radius
L--Rivet Spacing
4-6

Rivet Dia.

Edge Margin
2024-T3

Doubler

(Sane Gage

as

/2

CLad--~

Rivet Dia.

Skin)
Radius

Sp~ead Sealant
Evenly Approx.

1/32" Thick.
(Refer

to

1/2 Radius

41-30-02.)

NAS1097AD4 Rivets

i
i

U~ ~J
C----------1/2

Detail A
Typical Insert Patch (Pressurized Area)
Figure 202

EFFECTTVITY:
SRM~

ALL

51-70-02

Page 204
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

Doubler
1

same

Gage and

Material

Existing

Skin

as

Skin

Edge Margin
2

Rivet Dia.

0.50

R.

Min

Rivet

Spacing

4-6

Rivet Dia.

Min.--J
~,ii

(Typi call

Apply

sealant

contact

in

area;

spread evenly

1/32" thick.

approx.

(Refer

Doubler

or

SRM-4

NAS1097AD4 Rivets

Over Structure

EFFECTTVITY:

ALL

51-30-02.)

Patch

S-134

to

rl~i\

Double r

Patch

Repair (Pressurized and Non-Pressurized Area)


Figure 203
51-70-02

Page 205
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
FORMED SECTION

TYPICAL REPAIRS

SEVERED ORDAMAGED FORMED SECTIONREPAIR

i.

A.

RepairInstruction
(1)
(2)
(3)
(4)

same material and gage as original.


Refer to 51-40-02 for fastener removal and installation, hole sizes, and
Refer to 51-30-04 for protective treatment of metal.

Use

Restore

(5) Seal the

EFFECTIVITY:
SRM-4

edge margins.

required surface finish per Chapter 20 of the appropriate Learjet Maintenance Manual.
repair as required. (Refer to 51-30-02.)

ALL

51-70-03

Page 201
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

2024-T3

0.063

1 /,i/

/---Cut off damaged section here.

Doubler

Ai

(Same Gage and

Doubler

Material
Add

as

Bulkhead)

---~--J

:-:I

.i

MS20470AD4:sii:I~..Ij
i

::~i
i

III

i.i_:

aX~

j~

Existing

Clean
and

out

sealer

old

reseal.

i:

Structure"

(Refer

Bamaged Section Replacement

to

51-30-02.)

TYPICAL REPLACEMENT OF

BIJLRHWD

hole

as

SECTION

Detail A

netalF.deriuqerlightening

j:iii-l
MS20470AD4

Rivets
i

r
0.063

2024T3

Doub ler

Defect----J

O.C)63

Angles

TYPICAL REPAIR OF CRACKED

2024-T42

(2

Reqd.)

Detail B

BULKBWD

Typical Bulkhead Repair


Figure 201 (Sheet

EFFECTTVITY:
SRM-4

ALL

1 of 2)

51-70-03

Page 202
May 15/92

Learjet
~Learietl

STRUCTU RAL REPAIR MANUAL

NAS1097AD4

Rivets

MS20470AD4
Rivets

lo_

i,

Length to
Adjacent Stringers
Approximately 7 Inches Each

Ikhead

Extend
or

Defect

Side

of

Segment

to

Defect

.Detail A
Typical Bulkhead Repair
Figure 201 (Sheet 2 of 2)
EFFECTIVITY:
SRM-4

ALL

51-70-03

Page 203
May 15/92

Learjet
~tl

STRUCTURAL REPAIR MANUAL


EXTRUDED SECTION

i.

TYPICAL REPAIRS

EXTRUDED SECTIONREPAIR

A.

RepairInstruction
(1)
(2)
(3)
(4)
(5)
(6)
(7)

damaged portion of extrusion.


repair parts of same gage and dimensions of original extrusion.
Assemble repair parts and drill and ream fastener holes.
Prepare repair parts for sealing, if required, in accordance with 51-30-02.
Refer to 51-40-02 for fastener removal, installation, hole sizes and edge margins.
Refer to 51-30-04 for protective treatment of metals.
Restore finish in accordance with Chapter 20 of the appropriate basic Leajet Maintenance ManuCut and

remove

Fabricate

EFFECTIVITY:

ALL

51-70-04

Page 201
SRM-4

May 15/92

STRUCTURAL REPAIR MANUAL


New

Gage,

Type,
Same
Butt

to

New

(Material

Section

as

and Dimensions

Original Section)

Section

Original Section

out

Clean

old

reseal.

sealer and

Angle

(Material Type,

Gage,

and

Same

as

(Refer

Dimensions

a~

to

51-30-02.)

Original

Extrusion)

Section

Edge Margin

r~

/I

or

o
o

::s

.a~9

Angle

(Material Type,

Gage,

and

Same

5
of

Rivets

Each

as

Dimensions

Extrusion)

Side

Splice

MS20470AD4

Rivets

~Y3 ~-t-,

Detail A

NAS1097AD4

Rivets

Typical Extruded Section Repair (Pressurized and Non-Pressurized


Figure 201
EFFECTIVITY:
SRM-4

ALL

Area)

51-70-04

Page 202
May 15/92

Leariet

STRUCTURAL REPAIR MANUAL


Strip (Material Type and
Gage same as Extruded Angle)
Filler

Gage,
as

(Material Type,
and Dimension

Extruded

same

Angle)

s~ ii

Clean Out

Damaged

Area

Rivets

Each

Side

Area

3/4" Rivet Spacing

-t

Angle

(Material Type,

Gage,

and Din\ensions

Same

Detail A

Pick up

existing

skin

as

Extruded

Angle)

rivets

MS20470AD4 Rivets

Stringer

"21
Skin

Typical Stringer Repair (Pressurized and Non-Pressurized Area)


Figure 202
EFFECTNITY:
SRM-4

ALL

51-70-04

Page 203
May 15/92

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


FIBERGLASS STRUCTURES -REPAIR
i.

DESCRIPTION
A.

Fiberglass structures used

on

the

Leajet include the radome and

dorsal inlet

fairing.

(1) On early Model 20130 Series Aircraft the radomes are constructed of 2-inch wide strips of fiberglass
cloth, bonded together with a polyester-based resin. On later Model 30 Series Aircraft, and as replacement spares for the earlier model polyester-type radomes (t~er SSK 911), an epoxy-based resin, single-sandwich honeycomb-core radome is used.
screws.

An erosion boot is bonded to the

For additional information

pertaining

nose

The radome is attached to the

of the radome to

prevent

nose

by

environmental erosion.

to the radome erosion boot refer to the basic

Leajet

Main-

tenance Manual.

(2) The dorsal inlet fairs the vertical stabilizer

to the

The dorsal inlet is constructed of

heat

exchanger.
manently to the fuselage and verticalstabilizer.
and are secured to the fuselage with screws.

2.

fuselage and permits entry of ram air for the


5-ply laminated fiberglass and is attached per-

Two bulkheads

are

riveted into the dorsal inlet

RADOME -APPROVED REPAIRS

NOTE:

These

repairs apply only to

the

nose

radome.

A.

Approved repairs for the radome include the repair of minor damage to the radome skin and replacement of radome erosion boot. For radome erosion boot removal and/or replacement refer to the basic
Learjet Maintenance Manual.

B.

Prior to

radome

repair,

inside radome with

C.
D.

E.

determine which

type of resin

used in radome fabrication

by
strong light shinning
looking
polyester resin are translucent and their cores are constructed of Zinch wide strips of fiberglass cloth,
which will be visible. Radomes fabricated with epoxy resin are opaque and have one-piece cores.
As a general rule, minor damage is defined as damage to the radome skin only. This excludes any
damage which goes into or beyond the core.
Radomes which cannot be repaired per the following instructions must be replaced with a new radome per Special Spares Kit (SSK) 911. This includes any radome damaged beyond the limits set in
the following instructions.
Tools and Equipment
beginning

NOTE:

was

thru from the outside. Radomes fabricated with

Equivalent substitutes may be used in lieu of the following:

MANUFACTURER

USE

Epon 828 or
Epon 815

Shell Chemical

Bond radome

916

Shell Chemical

PART NUMBER

NAME

Epoxy Resin

Epoxy Hardener

Company

skin

Company

Hetron 92

Polyester Resin

Hardener for

epoxy resin

Epon 815

Pittsburg Plate Glass Co.

Bond radome
skin

LES1197A
LES1259A

EFEE~IVITY:
SRM-4

ALL

51-70-05

Page 201
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


PART NUMBER

NAME

6% Cobalt

Napthenate

Fed.

Spec.

TT-D-643

MANUFACTURER

USE

Commercially available

Used with

polyester resin
MEK Peroxide

Hypodermic Syringes

Lucidol Div., Novadel


Agene Co.

Used with

Commercially available

Inject adhesive

polyester resin

and Needles

F.

MixingInstructions
(1) Mix epoxy resin as follows:
(a) Mix by weight 100 parts of Epon 828
dener

just before using.

After

or Epon 815 epoxy resin and 20 to 25 parts of 916 harmixing, pot life is approximately 23 minutes at room tempera-

ture.

(2) Mix polyester resin as follows:


(a) Mix by weight 100 parts of Hetron 92 and 0.50 part of 6% cobalt

ly mixing, add by weight


G.

part of MEK peroxide.


greater than one (1) inch in diameter,

napthenate.

After

thorough-

1.0

Blisters and delaminations not


not closer than four (4) inches,
greater in number than four (4) in four (4) square feet of surface (see Figure 201) are to be repaired
follows:
(1) Drill a small hole into, but not through the skin at each end of the blister or delamination.

(2)
(3)
(4)
(5)

or
as

Fill

syringe with resin and inject the blister or delamination full of resin.
or delamination firmly into place and hold until resin has cured.
Remove any excess resin from the surface with light sanding.
Check repair for a sound bond by tapping repaired area with a coin. Any area which is not properly bonded will make a different (hollow) sound when tapped.
(6) Repaint affected area of radome in accordance with Chapter 20 of the appropriate basic Learjet
Press the blister

Maintenance Manual.
H.

Scratches

limited to those not

more than l/&inch wide, 1/16-inch deep and 4-inches long.


(See
depressions are limited to those not more than I/2-inch in diameter and not
more than l/lbinch deep. These defects must not be any closer than one (1) inch and there shall be
no more than three defects per on~j(l) square foot of surface area. Repair the defects as follows:
(1) Fill defect with resin and allow to fully cure.
(2) Carefully sand the resin to auniform smoothness, blending with the contour of the radome.
(3) Repaint affected area of radome in accordance with Chapter 20 of the appropriate basic Leajet

are

Figure 202.)

Pits and

Maintenance Manual.

EFFECTIVITY:
SRM~

ALL

51-70-05

Page 202
May 15/92

Learjet
~I
STRUCTURAL REPAIR MANUAL
in.

or

dia.

or

less

Drill

small

hole

at

each end of blister

rmmmmmmmrn

Pump resin into


blister with

syringe

Resin

-1

Resin

should

hole at

Press

into

until

resin

Lightly
excess

Blister and Delamination

come

opposite

sand

out

end

place and hold


fully cures

off

resin

Repair

Figure 201
EFFECTTVITY:

ALL

51-70-05

Page 203
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

4 in.

max.

length

;t

1/16 in. max. depth


1/8 in. max. width

Fill with
and

in.

sand

Dia

resin
smooth

max.

1/16 in.

max

depth

Fill with resin


and

sand

smooth

Scratch, Pit, and Depression Repair

Figure 202
EFFECTIVITY:
sRM-4

ALL

51-70-05

Page 204
May 15/92

Learjet
Learjet

STRUCTURAL REPAIR MANUAL


3.

APPROVED REPAIRS

DORSAL INLET
A.
B.

C.

Approved repairs for the dorsal inlet include minor and major damage to the dorsal inlet fairing.
Damage to the dorsal inlet forward structure shall require replacement of the dorsal inlet fairing.
Toolsand Equipment
Equivalent substitutes may be used in lieu of the following:

NOTE:

PART NUMBER

NAME

181

Glass Fabric

120

weight and
weight

MANUFACTURER

USE

J.P. Stevens Co., Inc.


New York, NY

Replace damaged skin

Epoxy Resin

Epon 828 or
Epon 815

Shell Chemical

Company

Bond skin

Epoxy Hardener

916

Shell Chemical

Company

Bond skin

Clean Cloth
or

or

Commercially available

Remove residue

Commercially available

Remove residue

Cheesecloth

Acetone

or

Ketone

D.

Repair blisters and delaminations, scratches, pits and depressions per instructions in step 2, except
that damaged area in excess of size and depth limits given in step 2 shall be repaired as follows:
NOTE:

Damage

(2) Cut

excess

of limits in

step

2 shall be combined

larger on all sides than


number of plies affected minus 1.

(1) Mark off


the

in

an

an area

X in the center and

NOTE:

remove

the

the first

area

to be

as one

repaired by

repair area.
an

amount in inches

ply, being careful not to cut into

the

equal

remaining plies.

Rectangular cut-out area or other cut-out area having sharp comers shall
whenever possible and the outside ply shall be avoided whenever possible.

be avoided

(3) Move in one (1) inch on all sides and remove second ply (if affected).
(4) Proceed in this fashion until all damaged plies have been removed.
(5) Sand exposed plies and wipe with a clean, lint-free cloth or cheesecloth moistened with
or

acetone

ketone.

181-weight glass fabric for inner plies and 120-weight glass fabric for outer ply to lap
new ply of skin 0.5 to 0.75 inch (12.7 to 19.5 mm) over corresponding ply of original skin.

(6) Cut

(7) Mix resin per step 2. F.


(8) Impregnate new plies with mixed resin.
(9) Place impregnated plies in damaged area, working each ply
to the

EFFECTIVITY:

to

preceding ply as possible,

ALL

and to

remove excess

to make it as wrinkle-free and

each

tight

resin and air from the laminate.

51-70-05

Page 205
SRM~

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
NOTE:

The outermost

bridging
(10) Laminate will
ened

(11) Sand

cure

by heating

ply

of the

at the

original
repair line.

or

gaps

in

approximately two (2)

to 1400 to 1600F

to contour with 150

grit or

outer skin must be faired to

hours at

room

fine

edge

temperature. Cure time

to

can

using heat gun or infrared lamps.


finer abrasive paper, being careful not to sand into the

(60"C

to

710C)

prevent

be short-

glass

fab-

ric.

(12) Check repair for

erly

(13) Repaint affected

jet

EFFECTIVITY:
SRM-4

sound bond

area

by tapping repaired area with a coin. Any area which is not proptapped.
Chapter 20 of the appropriate basic Lear-

different (hollow) sound when


of dorsal inlet in accordance with

bonded will make

Maintenance Manual.

ALL

51-70-05

Page 206
May 15/92

Learjet I
STRUCTURAL REPAIR MANUAL
CORROSION- REPAIR
1.

APPROVED REPAIRS
A.

depth gauge (or equivalent), determine the extent of corrosion (material


damage exceeds the allowable material thickness, as specified in the allowable
age limits section of each chapter, the structural component must be replaced. (See Figure 201.)
Using

age).

dial indicator

If material

NOTE:

Light

Corrosion

Structure is discolored

or

pitted

to

depth

of

approximately

damdam

0.001

inch (.0254 mm) maximum.

scaling, flaking, and pitting to a depth


0.010 inch (.254 mm). Requires structural repairs after rework of corroded areas.

Moderate Corrosion

Severe Corrosion

Structure has blisters,

Structure has

depth greater than 0.010 inch (.254

blisters, exfoliation, scaling, and pitting


Requires structural repairs or replaced.

light or moderate corrosion is found, rework area per paragraph D.


severe corrosion is found, the structural component must be repaired or replaced.
Rework lightly or moderately corroded areas on structure as follows: (See Figures 202

B.

If

C.

If

D.

severe

mm),

CAUTION:

of

to a

and 203.)

DO NOT USE STEEL WOOL OR STEEL WIRE BRUSHES OR SEVERE ABRASIVES WHEN REWORKING STRUCTURE FOR CORROSION. USE 240 GRIT OR
FINER ALUMINUM OXIDE ABRASIVE PAPER. FINISH WITH 400 GRIT PAPER.

(1) Sand corroded areas using 240 grit or finer aluminum oxide abrasive paper.
(2) Blend out pits in structure as shown.
WARNING:

WEAR PROTECTIVE hlZC~SK AND ENSURE THAT WORK AREA IS


WELL VENTILATED WHILE CLEANING STRUCTURE WITH METHYL
ETHYL KETONE (MEK).

ENSURE

THAT

MANUFACTURERS

PUBLISHED

INSTRUCTIONS

ARE FOLLOWED WHEN USING CLEANING AGENTS AND METAL

FINISH.

(3) Clean sanded surfaces with a clean cloth soaked with methyl ethyl ketone (MEK). Immediately
wipe surfaces dry using a clean, dry cloth. Do not allow solvents to be "wicked" under adjacent
structure.

(4)

Apply chemical film treatment on reworked surfaces as follows:


(a) Obtain Turcoat Accelagold chemical film treatment, manufactured by
pany, Wilmington, CA.
NOTE:

Any equivalent chemical film treatment for aluminum alloy


ing it complies with MIL-C-5541 Class 1 metal finish.

Turco Products Com-

may be used

provid-

03) Brush chemical film over sanded surfaces until a satisfactory chemical film is obtained.
(c) Gently sponge over chemically treated surfaces using warm water. Do not rub surfaces. Allow surfaces to air

EFFECTTVITY:
sI1M~

ALL

dry.

51-70-06

Page 201
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
(5) Apply

brush coat of epoxy

NOTE:

Use either of the

primer on chemically treated

surfaces

as

follows:

primer systems described below:

Thoroughly mix

one volume of base primer #515-344 and one volume of curing solution #910-350, Super Koropon Fluid Resistant Primer available from: Desoto, Inc.,
P.O. Box 401268, Garland, TX 75040. Telephone (214) 276-5181.

Thoroughly mix one

volume of primer base #463-12-8 and one volume of Catalyst


CA-116 Cat-A-Lac corrosion resistant primer available from: Bostik Div. Emhart
Corp., 20846 S. Nortnandie Ave., Torrance, CA 90502. Telephone (213)320-6800

Thoroughly

mix

one

volume of

primer

base #438-660 and

agent #120-650 available from: Wichita Division, Pratt


Wichita, KS 67201. Telephone(316) 733-1361.
(a) After

of the

one

volume of

primer systems described above has been thoroughly mixed, apply


over
prepared surfaces.
(b) Allow primer to dry at room temperature for a minimum of two hours.
(6) Install all previously removed equipment.
coat

one

sI~M-a

ALL

brush

the

(7) Return aircraft

EFFECTIVITY:

curing

Lambert, P.O. Box 2153,

to service.

51-70-06

Page 202
May 15/92

Learjet
~Learjet
STRUCTURAL REPAIR MANUAL

Adjustable
Dial
in

Dial Face Lock

Indicator Marked

Increments of O.ODOS

Base

Point "A"

Point "B"

Corrosion Pit

Point

Conical

"C"

Point

DETAIL I

Take

readings

at

various points.

NOTE:

Depth

dial

gage

to

0.500

inch

range.
O

Take

measurement

adjacent

readings

on

edges

corrosion

~1

damage or
blended depression (Points "A" and
"B"). Take several readings around
of
corrosion
center
or
damage
blended depression (5ee Detail II)
and
be

to

consider

Point

"C".

the

DETAIL II

deepest reading to
Determine

depth

as

follows:

Depth =C

(A

B)

Corrosion

EFFECTIVITY:
SRM-4

ALL

Damage and Rework Measurement


Figure 201
51-70-06

Page 203
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

Pit has been cleaned


all

loose

corrosion

to

up

ertent

the

have

products

been

that
removed.

~LD

CORROSION DAMAGE BE~OAE RDJORK

Rough edges

have

corrosion has

depression

has

been

been
not

smoothed

removed.
been

and

all

However,

shaped.

DEPRESSION ARER CORROSION REMOVAL

Blending
ratio

has

and

been

accomplished

direction shown

in

in

the

figure

203.

DISH-GOT AFTER RLENOING

Blendout of Corrosion of

Single Depression
Figure 202

EFFECTIVITY:
sIiM~

ALL

51-70-06

Page 204
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

100-

CORROSION DANA(r BEFORE RMOVAL

SD

Min

09

Bottom of Dep ression


After Corrosion Removal

REMOVED AND SURFACE S(OOTHED


WITH SHALLOW ELLIPTICAL DISH-OUT

Generous Radius

(Typical)

Run-Out

Generous Radius
NOTE:
D

(Typical)
of

Depth

Refer

Depression

specific

to

allowable

limits for maximum allowable


D

Since

maximum

different

The

all

at

in

specified
O

See

also

blending

tained

Detail

varies

depth

locations,

dish-out will

damage

EXAC(PLE a

depth.

1:5 BLEM)IH; RATIO


DETAIL

at

maximum size

of

vary.

ratio

shall

times

unless

be

main-

otherwise

specific repair.
for

example

of

blend-

ing.

Multiple Pits in Corroded


Figure 203 (Sheet 1 of 2)

Blendout of

EFFECTIVITY:
s~ur-4

ALL

Area

51-70-06

Page 205
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

CAUTION:

W NOI

USE STEEL

WIRE

WOOL,

STRUCTURE FOR CORROSION.


SIVE PAPER.

BRUSHES,
USE

OR SEVERE

210 GRIT

ABRASIVES WHEN REWDRKING

OR FINER

ALUMINUM OXIDE ABRA-

FINISH WITH 400 GRIT PAPER.

Location of

Width of Cleaned

Corrosion Pits

Up

Area

(10 limes Depth Min)

iii
i

ij

c)

:j

r::
j
VIEW LOOKIK; DOWN

VIEW IN TRUE PERSPEICTIM

Depth

~ength of Cleaned Up
(ZO rimes Depth Min)

of Clean

Up

of Corrosion

Atee

CROSS SECTION VIEW

NOn

AC6PTABLE.

ACCEPTABLE

Blendout of

Multiple Pits in Corroded Area

Figure 203 (Sheet 2 of 2)

EFFECTIVITY:
SRM~

ALL

51-70-06

Page 206
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


HONEYCOMB INSERT- REPAIR
i.

APPROVED REPAIRS

NOTE:
A.

If inserts

are

being installed

in

new

honeycomb panels,

omit

paragraph A.

RemoveDamagedInsert
(1) Determine part number and maximum diameter of damaged insert.
(2) Drill out insert. Clean hole with clean cloth and MEK. If old epoxy remains around perimeter of

integrity. Any epoxy not adhering to honeycomb must be removed.


Requirements
(1) Storage of Epoxy Potting Compound
(a) All unmixed epoxy potting compound shall be stored at 450 to 800F (7.2" to 26.70C). Epoxy
potting compound has a storage life of 9 months at 800F (26.70C) when maintained in unopened original package.
(b) Materials stored at temperatures exceeding 800F (26.7"C) shall be used within 2 weeks.
(c) Stocks shall be rotated to eliminate storage stability problems and retesting of the epoxy potting compound.
(2) Mixing of Epoxy Potting Compound
(a) The scales and weighing procedure shall be controlled so that the hardener is within +2%, to
be sure of uniform quality.
(b) Weigh into a clean, wax-free container 100 parts by weight of SLE3009 resin. Add 25 parts by
weight of SLE3009 hardener.
(c) Weigh into a clean, wax-free container 100 parts by weight of EA9321 Part "A". Add 50 parts
by weight of EA9321 Part "B".
(d) Weigh into a clean wax-free container 100 parts by weight of SLE3006 resin. Add 27.5 parts
by weight of SLE3006 hardener.
(e) Mix components until the color is uniform, taking care not to trap air in epoxy potting compound. Entrapped air creates porosity, thereby reducing potting strength and also causes
potting material to slump as entrapped air outgasses.
(f) Mix only amount of epoxy potting compound that can be used in 30 minutes. Mixed epoxy
potting compound has a pot life of 30 minutes at 750F (23.90C). Excessive agitation during
mixing, higher ambient temperature, or large masses of material being mixed, will reduce
installation hole check it for

B.

General

pot life.

(g)

Load mixed epoxy

potting compound into a polyethylene cartridge.


a sealing gun and install a 1/16-inch orifice nozzle.

(h) Load polyethylene cartridge into

LES1228E

EFFECTTVITY:
SRM~

ALL

51-70-07

Page 201
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
Installationof

C.

Honeycomb Inserts

(1) Tools and Equipment


NOTE:

Equivalent

substitutes may be used in lieu of the

PART NUMBER

NAME

Epoxy
Potting Compound

Insert

SLE3009 Bulk Kit

following:

MANUFACTURER

USE

Dalco Industries
2230 Gladwick

Compton, CA 90220
Insert

Epoxy
Potting Compound

Hysol EA9321

The Dexter

Corp. Hysol

Div.

15051 E. Don Juiian Road

Industry, CA 91749
Insert

Epoxy
Potting Compound

SLE3006 Bulk Kit

Dalco Industries
2230 Gladwick

Compton, CA 90220
Semco

Sealing Gun

Sealant Gun Nozzles

No. 250

(for

use

with

Sealing Gun)

Polyethylene Cartridges
Scales

Accuracy +2%

Solvent

EFFECTIVITY:
SRM4

Methyl Ethyl Ketone (MEK)


per Fed. Spec. TT-M-261

ALL

51-70-07

Page 202
May 15/92

STRUCTURAL REPAIR MANUAL


(2) Honeycomb panel preparation for blind threaded inserts.
(a) Drill installation hole per Figure 201 to a depth slightly greater than the length of the blind
threaded insert.

(b) Refer

to

step C.5, C.6 or

C.7 for installation

procedures of insert.

Honeycomb Panel (Ref,)


Installation Hole
Part

way

thru

Honeycomb Panel.

or

Installation
Hole

extends

surface

of

to

upper

lower

Honeycomb Panel

skin.

(Ref.)

Installation Hole Size (Dia


First Dash
No. per
NAS 18XX

NAS 1832-(
Insert

NAS 1835-(

Thread Size
and Class

[Ref SL601-( )1

[Ref SL606-( )1

Insert

Inches)
NAS 1836-(
Insert

[Ref SL607-( )1

-06

0.1380-32

UNJC

0.561

0.566

0.452

0.457

-08

0.561

0.566

0.686

0.691

0.452

0.457

-3

0.1640-32 UNJC
0.1900-32 UNJF

0.561

0.566

0.686

0.691

0.452

0.457

-4

0.2500-28

0.686

0.691

0.749

0.755

0.499

0.504

0.686

0.691

0.811

0.817

0.842

0.847

0.874

0.880

-5
-6

UNJF
0.3125-24 UNJF
0.3750-24 UNJF

Blind Threaded Insert Installation

Figure 201
EFFECTIVITY:
SRM~

ALL

51-70-07

Page 203
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
(3)

Honeycomb panel preparation for spool-type inserts thru clearance hole type.
(a) Drill installation hole per Figure 202 to the bottom honeycomb face sheet at locations.
(b) Drill bolt or screw hole through the bottom honeycomb face sheet per Figure 202.
(c) With a counterbore tool, clean honeycomb core and adhesive from the bottom honeycomb
face sheet.

(d) Refer

to

step C.8 for installation procedures of spool-type inserts.

:r

Installation
to

upper

Holt/Screw
Hole

[Ref SL603-(
Per NAS

)1

Bolt

or

Hole

extends

lower

skin.

(Ref.)

(Ref.)

Installation Hole Size

1834

of

Honeycomb Panel

First Dash No.


Per NAS

Hole.

surface

or

Screw

Hole Diameter

(Inch)

(Inch)

1833

[Ref SL602-(

)1

-06

0.561

to

0.566

No.

28

0,561

to

0.566

No.

19

(0.140 +0.005/-0.001)
(0.166 +0.005/-0.001)

Hole

-08
-3

0.561

to

0.566

No.

12

(0.189

Hole

-4

0.686

to

0.691

-5

0.686

to

0.691

-6

0.842

to

0.847

1/4
5/16
3/8

+0.005/-0.001)
(0.250 +0.005/-0.001)
(0.312 +0.006/-0.001)
(0.374 t0.006/-0.001)

Hole

Hole
Hole
Hole

Spool-Type Insert Installation


Figure 202
EFFECTIVITY:
SRM-4

ALL

51-70-07

Page 204
May 15/92

Learjet I
STRUCTURAL REPAIR MANUAL
(4)

Honeycomb Panel Preparation for Spool Type Inserts Countersunk Clearance Hole.
(a) Drill Installation hole per Figure 203 thru core and both skins (upper and lower).

Installation

Completely

Hole----~

mru

Honeycomb Panel

Panel

Upper

(Ref.)

Skin

Honeycomb Panel
Skin (Ref,)

Lower

First Dash No.


Per NAS

)k(

1834-(

[Ref SL604-(

)1

Nom.

Of Insert

SRM-4

Hole Diameter

(Inch)

(Inch)

-06

0.140

0.561

to

0.566

-08

0.169

0.561

to

0.566

-3

0.196

0.561

to

0.566

-4

0.257

0.686

to

0.691

-S

0.316

0.686

to

0.691

-6

0.377

0.842

to

0.847

Spool-Type Insert (Countersunk Clearance Hole)


Figure 203
EFFECTIVITY:

Installation

Clearance

Hole Diameter

ALL

Installation

51-70-07

Page 205
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
(5) Installing blind inserts using tab method. (See Figure 204.)
(a) Remove paper backing from tab. Press adhesive side of tab
up holes. Press tab down
NOTE:

Tab is not

firmly so

required

onto insert

being careful

to line

that it sticks to insert.

when bottom end of blind insert is seated.

a sufficient quantity of epoxy potting compound into counterbored hole to completely fill bottom portion of hole to insure that all cells underneath insert and bottom of insert are
coated with the epoxy potting compound when insert is installed. (See Detail B.)
(c) Insert prepared insert assembly into honeycomb panel installation hole. Apply adequate
force to ensure that the tab will adhere to top skin of honeycomb panel.
(d) After all inserts have been positioned in honeycomb panel, the inserts shall be potted. Inject
epoxy potting compound through one potting hole.The cavity is filled when epoxy potting
compound appears in the second potting hole. All honeycomb panel inserts shall be potted

(b) Extrude

in this manner. (See Detail C.)


(e) Excess epoxy potting compound may be wiped away prior

dampened
(f)

(6)

to

cure

using

clean cotton cloth

with MEK solvent.

After epoxy potting compound has cured for a minimum of 24 hours at room temperature,
the tab shall be removed and discarded. Cure may be accelerated by baking at 1400F (600C)

for three hours. Full cure required approximately 5 days at room temperature.
Installing blind inserts using no tab (See Figure 205.)
NOTE:

Bottom end of blind insert must contact inside surface of the lower face sheet of

honeycomb panel.
Refer to

Step 7 for alternate shimming method


ing tab method.

for installation of inserts without

(a) Extrude sufficient quantity of epoxy potting compound into counterbored hole
inside surface of lower skin and underneath side of insert

us-

to ensure that

coated with epoxy

potting compound when insert is installed.


03) After all inserts have been positioned in honeycomb panel, inserts shall be potted. Inject potting compound through one of the potting holes until cavity fills and potting compound
starts to extrude through the second hole. Close off extrusion of potting compound from second hole and continue injection. The cavity is properly filled when potting compound extrudes through hole in skin all around circumference of upper flange of insert. All inserts
shall be potted in this manner.
(c) Repeat step (5)(e).
(d) Repeat step (5)(f).

EFFECTIVITY:
SRM-4

ALL

are

51-70-07

Page 206
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


Insert

Tab

Insert

(Ref)

Detail A
Insert

Insert

in

(Positioned

Tab

Honeycomb

Panel

(Ref)

panel.)

Epoxy Potting
Compound

Detail B
Potting
Sealing

Gun

(Ref)--,

Holes

~d

(Ref)
Insert

..e

Epoxy Potting
Compound

Tab

(Ref)

Honeycomb Panel

(Ref)

Detail C
Insert Installation

Using Tab Method


Figure 204

EFFECTTVITY:
SRM-4

ALL

51-70-07

Page 207
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

~-Masking tape optional.


If used, punch holes
thru

to

holes

Potting

Holes

in

match

potting

insert.

(Ref.)

Honeycomb Panel

Insert

(Ref.)

Insert Installation

Figure
EFFECTIVITY:
SRM-4

(Ref.)

ALL

Using No

Tab

205

51-70-07

Page 208
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


(7) Alternate Shimming Method (See Figure 206.)
(a) It is permissible to use clean AN960 washers in bottom of hole

to shim insert flush with

upper surface of the honeycomb panel skin.


Cb) Determine combination of washers required.
(c) Remove and clean washers by wiping with clean cotton cloth dampened with MEK solvent.
(d) Extrude a sufficient quantity of epoxy potting compound into the counterbored hole to com-

pletely fill bottom portion of hole to ensure that all cells underneath insert are coated with
potting compound.
(e) Apply potting compound to all surfaces of each washer to be used for shims and position in
installation hole.

(f) Position insert into

honeycomb panel installation hole. Apply sufficient force to extrude potflange of insert as insert is pressed into its "seated" position.

up around base

ting compound
(g) Repeat step (6)(b).
(h) Repeat step (5)(e).
(i) Repeatstep(S)(f).

or

AN

960 WASHERS

Insert Installation

Alternate

Figure
EFFECTIVITY:
s~M-a

ALL

Shimming Method

206

51-70-07

Page 209
May 15/92

STRUCTURAL REPAIR MANUAL


(8) Installing Spool Inserts
(a) Apply masking tape to cover hole in honeycomb panel skin.
(b) Install insert to contact tape
(c) Insert tab, masking tape, or no covering at all, may be used on upper side of inserts. If tab is

used, holes in tab must be lined up with insert holes. If masking tape is used, punch holes
thru tape at potting insert hole locations.
(d) Repeat step (5)(6).
(e) Repeat step (5)(e).
(f) Repeat step (5)(f).
(9) Voids at either or both

potting hole locations caused by slumping or sagging of the epoxy potting


compound shall be permissible providing the limits of acceptability as noted below are met.
(a) Acceptable voids must be contained to the local area of each respective potting hole and shall
extend all the way around the insert.
allowable depth of voids, as measured thru
Maximum
(b)
not

potting holes,

shall be 0.35 inch.

or

MASKIErG

TAPE

Insert Installation-

Spool Type

Figure 207

EFFECTIVITY:
SRM-4

ALL

51-70-07

Page 210
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
SEAT RAIL

REPAIR

APPROVED REPAIRS

i.

All dimensions

NOTE:
A.

Seat Rail

are

in inches unless otherwise

specified.

Repair (See Figure 201.)

NOTE:

(1) Tools and


NOTE:

Repair procedures
wise specified.

for both inboard and outboard seat rails

are

identical unless other-

Equipment
Equivalent substitutes may be used in lieu
PARTNUMBER

NAME

of the

following:

MANUFACTURER

Commercially available

Countersink (0.339x100O)

USE
Countersink

splice

strips
#12

Drill

Commercially available

Drill holes for

screws

matching nutplates
Drill

#40

Commercially available

Drill holes for rivets

matching nutplates
Drill

#30

Commercially available

Drill holes for rivets

Drill

#21

Commercially available

Drill holes for rivets

(2) Parts and Materials


NOTE:

Equivalent substitutes may be used in lieu

of the

following:

NAME

PART NUMBER

MANUFACTURER

Segment,

S-537

Learjet Inc.

Rail

Replace damaged
rail

Inboard
Rail

USE

S-713

Segment,

Learjet inc.

Replace damaged
rail

Outboard
2384042-6

Strap

Fabricate
0.080

2384042-4

Splice

Fabricate
0.080

locally from

2024-T3 clad

locally from

2024-0 clad

Strengthen

structure

at seat rail union

Strengthen structure
at seat rail union

heat treat to T42

2384042

EFFECTIVITY:

ALL

51-70-08

Page 201
SRM-4

Jun1/95

Learjet
~3L-i

STRUCTURAL REPAIR MANUAL


NAME

Rivet las

required)

PARTNUMBER

MANUFACTURER

MS2aQ70AD5

Commercially available

USE

Secure seat rail and

strap
Rivet las

required)

MS20426AD5

Commercially available

Secure

Rivet las

required)

NAS1398B4

Commercially available

Secure diffuser/foot-

splice strip

rest

Rivet las

(3)

Commercially available

MS20426AD3

required)

Repair Procedure: (See Figure 201.)


(a) Remove interior equipment and furnishings, carpet,
gain access to seat rail.
CAUTION:

Attach

nutplates

diffusers and floorboards

as

required

to

SEAT RAIL SEGMENT BEING REPLACED SHALL BE A MINIMUM OF


EIGHT BMSTING FASTENER LOCATIONS IN LENGTH.

Cb) For inboard mounted seat rail,


(c) For

cut

existing rail

between fasteners in the vertical

flange.

existing fastener locations may be picked up at each splice.


outboard mounted seat rail, cut existing rail between frames preferred, at location

that

Ensure

minimum of four

between

flange and between seat locking holes in top of flange. Ensure that
minimum of four existing fastener locations may be picked up at each splice.
(d) Using a #30 drill, drill out rivets securing damaged rail segment to web.
(e) Remove damaged seat rail segment.
(f) Using a #30 drill, drill out four existing rivets adjacent to forward and aft union locations.
(g) Cut new rail segment (S537 or S-713) to fit.
fasteners in the vertical

NOTE:

Final trim rail segment to obtain

0.060 inch maximum gap at each end of rail seg-

ment.

(h) For outboard mounted seat rails, drill 5/16 holes (1.00 spacing) for seat stops in top of vertical
flange. (See Detail B,Section B -B.)
For
inboard mounted seat rails, using measurements from removed seat rail, drill #12 holes in
(i)

segment for nutplates to match floorboard attachment hole pattern.


Drill #21 holes in vertical flange of rail segment to match rivet holes in web. Cleco holes
new

(j)

seat rail

as

drilling progresses.
(k) Fabricate

two 2384042-4

tener locations in

splice strips.

splice strip shall be a minimum

of

eight existing fas-

length.

MATERIAL NOTE:

Splices

shall be fabricated from 0.080

2024-0 clad aluminum, final

heat treated to T-42 and final finished to F4-1.

EFFECTlVITY:

ALL

51-70-08

Page 202
SRM~

Jun 1/95

Learjet
STRUCTURAL REPAIR MANUAL
(1)

Fabricate two 2384042-6 straps. A strap shall be


tions in length.
MATERIAL NOTE:

Straps

minimum of

shall be fabricated from 0.080

eight existing

fastener loca-

2024-T3 clad aluminum, and fi-

nal finished to F4-1.

(m) Chemically

treat

splice strips

and straps per F4-1 (refer to 51-30-04), and

identify

for future

reference.

(n) Position splice strips


on

across

seat rail

joint

so

slice

strips

cover

four

existing

existing

(O) Drill four (two

strip

fastener locations
strips to match

joint. Drill #21 holes in upper leg of 2384042-4 splice


rivet holes in web and seat rail. Cleco holes as drilling progresses.

each side of seat rail

on

each side of seat rail

splice)

#21 holes

through lower leg of 2384042-4 splice

and web.

Countersink rivet holes in splice strips, as required.


Secure splice strips to web with MS20426AD5 and MS20470AD5 rivets.
inboard mounted seat rail, position and clamp -6 straps across seat rail unions on lower surFOY
(r)
face of seat rail horizontal flange. Ensure that straps cover four existing fastener locations on

(p)
(q)

each side of seat rail unions.

(s) For outboard mounted seat mil, position and clamp -6 straps

across

four

seat rail unions

surface of seat rail horizontal flange. Ensure that straps cover


existing
each side of seat rail unions.
For inboard mounted seat rail, drill #12 holes in straps to match floorboard

on upper
fastener locations

on

(t)

seat rail, refer to step (i).


(u) For inboard mounted seat rail,

nutplate

holes in

straps for floor- I


board nutplates. Counter sink holes and attach floorboard salvaged nutplates to straps using
MS20426AD3 rivets. Clamp straps to seat rail as described in step (r).
(v) Drill #21 rivet holes through strap to match existing rivet holes in seat rail. Drill new holes I
(0.75 typical spacing) through strap and new seat rail segment.
(w) Secure straps to seat rail with MS20426AD5 or MS20470AD5 rivets.
I
remove

straps from

seat rail. Drill #40 holes in

(x) Remove clamps.


Install diffusers, floorboards, carpet and other previously removed equipment and fumish-

(y)

ings.
(z) Restore aircraft to normal.
(aa) Update all aircraft log books.

EFFECTIVITY:

SRM-4

ALL

51-70-08

Page 203
Tun1/95

STRUCTURAL REPAIR MANUAL


NOTES:
1.

r- Denotes existing fastener locations.

I~ Length to be determined at installation.


I~ No finish on these surfaces.
I~ Rail Configurations, notches (if any) and
length to be determined
specific aircraft at installation.

detail

for each

For aircraft with diffuser and footrest in-

stalled.
Minimum 4 fasteners each and

I~Strap

through

splice, existing nutplate, and/or

added

2384042-6

rivets. (MS20426AD5)

j~
23840423
No. 12 (0.198 Dia.) holes
required to match floorboards

as

salvaged nutplates

MS20426AD3 Rivets (2 ea.)

cS\YI

~qaP

~I

Web

(Ref)

I~>Strap

Dspsce

Rivet MS20470AD5

2384042-4

(Min. 2 required each


side of gap in lower

leg and web, typical)

st
6.1

Rail

~Splice

(Ref)
MS20426AD5

2384042-4

(Typical both sides)

0.80
Riveted MS20470AD5

(Minimum 4 places each end through splice)

1.63
0.80

032 Jog

Spiice
(Ref)

Section A A
(TYPICAL INBOARD MOUNTED SEAT RAIL)

Detail A
Repro

EFFECTNITY:

Seat Rail Repair


Figure 201 (Sheet 1 of 2)

ALL

51-70-08

Page 204
SRM-4

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


Co

,0,41

B~J
aP
2384042-6

~Rail
2384042-5

~Strap

_0~3P

Min. 0.47

;1

2384042-6

~l;le

CTyp)
i

D75

r~

sOaC

Rivet MS20470AD5

0~0

Rivet MS20470AD5

(Min. 2 required each

(Min, 4

side of gap in lower

end

leg and web,

places each
through splice)

~Splice
23&4042-4

~Splice

Web

2384042-4

(Ref)

Rivet MS20470AD5

existing locations each end of -4


existing locations through web and 6)

(Min. 4
and

5/16 (0.312 +0.005 /-0.000)--7


Dia. Holes

Rail

.(ReO

1.000

spacing

0.47

0.50 from EOP

~--Strap CTyp)
Rivet MS20470AD5

0.16

i,

Splice

(Min. 4 existing or
ran and

new

locations each end of -6

through

strap. pick up existing web locations through -5)

(Ren
0.75

RivetMS20426AD5jl
OUTED

Section B- B
(TYPICAL OUTBOARD MOUNTED SEAT RAIL)

Detail B
Repro

Seat Rail

Repair

Figure 201 (Sheet 2 of 2)


EFFECTIVITY:

ALL

51-70-081

Page 205
SRM-B

Jun 1/951

Learjet

STRUCTURAL REPAIR MANUAL


ALLOWABLE WEAR AND REPAIR DATA
1.

GENERAL

General
A.

B.

C.

D.

E.

The information in this section is

provided

determining the extent of wear in a


providing procedures for specific component/structural

to aid the mechanic in

particular system or component, as well as


repair. Original hole sizes, bushing sizes, bolt diameters, and manufactured allowable tolerances as
well as repair materials and required treatments or processes will be listed in the appropriate repair
procedure. Material and treatment variation is permissible only so far as to facilitate fabrication and
ensure the original strength and usefulness of the affected component.
It is the responsibility of the aircraft owner/maintenance facility to determine qualifications of maintenance personnel performing inspections and repair procedures as well as to ensure all aircraft log
books are properly updated following any maintenance or repair to aircraft structure. As always, a
clean environment and good general shop practices shall be exercised at all times.
Prior to, and after performing, any repairs on the aircraft structure, ensure serviceability and reliability of repair. If serviceability and/or reliability of repair remains in question or if guidance is needed
in making this determination, contact Leajet Field Service for additional information. Repairs must
be equal to, or greater in strength, than the original structure. Technique and material variation is permissible only so far as to facilitate fabrication and ensure the original strength and usefulness of the
affected component. Limitations applied to repairs and tolerances must be followed unless Leajet engineering authority to the contrary is given.
Repairs for structure not included in this section does not necessarily indicate that the structure involved is non-repairable, but that the application of a typical repair procedure to theoretical damage
has not yet been developed. For repair procedures pertaining to items not covered in this section, refer to that items respective chapter.
Refer to the following sections for allowable wear and repair data:
51-71-01
51-71-02
51-71-03

51-71-04
51-71-05
51-71-06

51-71-07
51-71-08
51-71-09
51-71-10
51-71-11

51-71-12
51-71-13

51-71-14
51-71-15

EFFECTIVITY:

ALL

Passenger/Crew Upper Door

Wing-to-Fuselage Fittings
Flap Fittings
Spoiler Fittings
Aileron System
Tip Tank Fittings
Landing Gear Fittings
Engine Mount Fittings
Rudder Control System
Horizontal Stabilizer Fittings
Elevator Control System
Keelbeam Assembly
Mach Trim System
Control Column Assembly
Passenger/Crew Upper Door

51-71-16

51-71-25

Nose Gear Actuator

(36-Inch)

51-71-26

Nose Gear

Passenger/Crew Lower Door

51-71-27

Nose Gear Door Mechanism

(36-Inch)

51-71-28

Flap

(24-Inch)
51-71-17

Passenger/Crew Lower Door

51-71-18

(24-Inch)
Quadrant Assembly

51-71-19

MLG Fewer Brake Valve Link-

age

Uplatch

51-71-20

Main Gear Door and

51-71-21

Main Gear Shock Strut

51-71-22

Nose Gear Shock Strut

51-71-23

Main Gear Actuator

51-71-24

Main Gear Door

Uplatch Mech-

anism

Uplatch

Preselect

Assembly

51-71-00

Pagel
SRM-4

Jun 6/98

Lenrjet
~L-il
STRUCTURAL REPAIR MANUAL
ALLOWABLE WEAR AND REPAIR DATA

WING-TO-FUSELAGE FITTINGS

.-,-s~
/I

C
B

Be

(TYPICAL)

Detail A
Wing-to-Fuselage Fittings
Figure
EFFECTNITY:

ALL

Allowable Wear and


I (Sheet I of

Repair Data

9)

51-71-01

Pagel
SRM-4

Jun 6/98

Learjet
LRarjet

STRUCTURAL REPAIR MANUAL


WING-TO-FUSELAGE FITTINGS

o~

I 1I~P ii

ALLOWABLE WEAR AND REPAIR DATA

/12

U~

~F

\E
I

1D

(On All Excent Aircraft 28-001 and Subseauent;


a

29-001 and Swbseauent: 31-001 thru 31-020

IC II

/F

13
10

~3

~L
9

(On Aircraft 28-001 and Subseauent: 29-001


and Subseauent: 32-021 and Subseauent)

Detail B
4-66A

EFFECTIVITY:

Wing-to-Fuselage Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 2 of 9)

NOTED

51-71-01

Page 2
SRM-I

Jun 6/98

Learjet
~Learjet(
STRUCTURAL REPAIR MANUAL
WING-TO-FUSELAGE FITTINGS

ALLOWABLE WEAR AND REPAIR DATA

/kqi7
H

15

24

Detail C

22

Detail D
4-66A

EFFECTIVITY:

Wing-to-Fuselage Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 3 of 9)
ALL

51-71-01

Page3
sRM-4

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

NO.

DESCRIPTION

Fitting, Soar

Bushing

NAS75-10-016

NAS75-9-016

Bushing-

MFD
SHAFT
OD

EFF.

HOLE

ID

18

0.5620

12

0.6250

MFD

ALLOWANCE

ID

NAS75-8-026

ID

ALLOWANCE
OD

i f0.0100
0.8142

+0.0015/

+0.0000/

-0.0000

-0.0010

11

0.5625

0.6892

+0.0015/

+0.0000/

-0.0000

-0.00010

12

0.5000

0.6265

+0.0015/

+0.0000/

NAS75-7-026

11

Bolt- NAS6208-22

12

0.4375

0.5638

-0.0000

-0.0008

+0.00151

+0.00001

-0.0000
4

OD

WEAR

No. 2

2322275-1,-2, -3, -4
2

MFD
HOLE

-0.0007

0.4995

1 +0.00011

0.4330

1 +0.00041

-0.0010
AN7-1 7A

11

12

0.4991

1 +0.00151

0.7500

1 ~0.0005

0.4370

1 +0.0010/
-0.0000

0.6875

0.4991

-0.0000

Fitting- 2311161-23

-0.0000

2311161-8

11

Bushing-

2311161-20

1 ~0.0005
0.6219

+0.0015/

~0.0005

-0.0000

2311161-6
7

Bushing-2311161-21
2311161-9

0.4875

0.5608

f0.0005

M.0005

0.6236

0.7514

+0.0000/

+0.00001

-0.0050

-0.0007

0.5625

0.6889

+0.0000/

+0.0000/

-0.0050
8

Bolt- NAS464P7L29

11

Bolt- NAS464P8L29

-0.0007

0.4367

1 +0.0000/

0.4991

1 +0.0000/

-0.0009
-0.0009
9

Fitting, Spar

No. 5

2822172-1, -2

12

0.5620

1 +0.0040/

2322278-6, -9
2322278-7, -11

0.4375

1 ~0.0005

0.4370

1 +0.0040/

13

0.4375

I rt0.0005

14

0.4370

i +0.0040/

-0.0000

-0.0000

2322278-3, -5, -9
-4,-6,-10
2322278-11,-12

-0.0000

Wing-to-Fuselage Fittings
Figure
EFFECTIVITY:

ALL

Allowable Wear and


1

Repair Data

(Sheet 4 of 9)

51-71-01

Page 4
SRM-I

Jun 6/98

Learjet
~i
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I
NO.

10

I
HOLE

EFF.

DESCRIPTION

MFD

MFD

HOLE

SHAFT

ID

OD

MFD

ALLOWANCE

ID

OD

1 0.5616

1+0.00001

EWSB26-9-30

i 0.5616

1+0.00001

EWSB22-7-A30

1 0.4367

1+0.00001

(Alt. EWSBM26-7-30)

i 0.4367

1+0.00001

AN7-22A

10

i 0.4370

1-0.00001

0.5620

1+0.0040/

0.5616

1+0.001 5/

0.4370

1+0.0040/

0.5620

1+0.0040/

1 Bolt- EWSBM22-9-30

WEAR
ID

ALLOWANCE
OD

-0.0009
-0.0009
-0.0009
-0.0009

+0.0004
11

I Fitting- 2311181-7,

-8

-0.0000

2311181-3, -4

-0.0000

2311181-1,-2, -5, -6

11

2311181-7, -8

-0.0000
-0.0000
12

1 Drag Block,

Aft-

2311370-33 LH

RH

15

-39 LH 8 RH
241 1 371-3 LH 8 RH

16

(Alt. 2411371-17, -18)

13

2411371-5, -6
(Alt. 2411371-15, -16)
2411371-15, -16
1 Drag Block, Fwd
2311370-34 LH 8 RH
-38 LH 8 RH

(Alt. 2411371-11)
241 1 371-2066-1 -2

(Alt. 2411371-9, -10)


2411371-1, -9, -10
(Alt. 2411371-11)
14

1 Fitting, Spar

0.4680

I
1

1+0.0060/

1 -0.0010

0.4680

1 ~0.0100

0.5938

IIH).0100

0.5938

lf0.0100

0.5938

IM.0100

0.5938

I f0.0100

0.4680

1+0.0060/

0.5938

I
1

1 -0.0010
lf0.0100

0.5938

IM.0100

0.5938

1~0.0100

0.5938

I f0.0100

0.5938

I f0.0100

0.5938

I f0.0100

0.5620

1+0.0080/

15

I
17

2411371-1

No. 7-

2822171-3, -4

18

-0.0010

Wing-to-Fuselage Fittings
Figure
EFFECTIVITY:

ALL

Allowable Wear and

Repair

Data

1 (Sheet 5 of 9)

51-71-01

Page 5
SRM-I

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I
NO.

15

16

I
DESCRIPTION

EFF.

Bushing- NAS75-1 0-016

Bushing-

MFD
SHAFT

ID

OD

0.6250

MFD
I

0.81 42

ID

+0.0015/

ALLOWANCE
OD

-0.0010

+0.0000/

0.5000

0.6265

+0.0015/
-0.0000

-0.0008

0.5000

0.6265

+0.0015/

+0.0000/

-0.0000
17

i Bolt-NAS6208-22

18

18

1 Fitting, Aft-2311201-3, -4,

18

0.5000

19

1 Fitting, Fwd-2311201-1,-2,

18

0.5000

1 0.4995

1+0.0040/

1-0.0000

1+0.00401

WEAR
ID

ALLOWANCE
OD

+0.0000/

-0.0000

19

NAS75-8-026

MFD
HOLE

HOLE

18

NAS75-8-021

-0.0008

1+0.0001/
-0.0010

-7, -8, -15, -16

-5, -6, -13, -14


20

Fitting, Soar No.

21

Bushing- NAS75-10-016

2322281-1,

1-0.0000

-2

22

Bushing-

23

Bolt- NAS6208-22

24

Fitting, Aft-

NAS75-8-021

18

0.5625

18

0.6250

18

I M.0100

0.8142

0.5000

+0.0015/

0.6265

-0.0010

+0.0015/

+0.0000/

-0.0000

18

1 0.4995

+0.0000/

-0.0000

-0.0008

1+0.0000/
-0.0010

2311211-1, -2, -3, -4, -5,


-6, -7, -8, -9, -10
25

0.5040

1+0.0000/

1-0.0040

1+0.0000/

1-0.0040

Fitting, Aft2311212-1, -2, -3, -4, -5,


-6, -7, -8, -9, -10

26

18

Bushing

NAS537-9- 50

18

I
3

0.5040

I
L

0.5620

i +0.0015/

0.5620

i +0.001 5/

-0.0000

(Alt. NAS75-9-01 6)

-0.0000

Wing-to-Fuselage Fittings
Figure
EFFECTIVITY:

ALL

Allowable Wear and


1

Repair Data

(Sheet 6 of 9)

51-71-01

Page 6
SRM-I

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
REPAIR DATA

ITEM

DESCRIPTION

NO.

Fitting, Spar No.

-3,

2322275-1, -2,

Bushing- NAS75-8-026
NAS75-7-026

Bolt

NAS6208-22

AN7-17A

2311161-23

Fitting

Replacewompart. ReamholeAto0.8125

(I~to.ooos).
NAS75-10-016

NAS75-9-016
3

18

-4

Bushing

REPAIR

HOLE

EFF.

2311161-8

12

Replace worn part.

11

Replace

12

11

12

11

Replace worn part. Install new bushing with


light coat of petrolatum (VV-P-236).
Replace worn part. Install new bushing with
light coat.of petrolatum (VV-P-236).
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part. Install new bushing with
wet primer on exterior surface. Ream bushing
(7) to 0.6236 (+0.00051-0.0002) after assembly
in fitting (5).
Replace worn part. Install new bushing with
wet primer on exterior surface. Ream bushing

12

12

11

11

Bushing

-2311161-20

2311161-6
Bushing- 2311161-21

2311161-9

worn

part.

(7) to 0.5625 (+0.0005/-0.0002) after assembly


fitting (5).
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.

in
11

12

13

14

EWSB26-9-30

EWSB22-7-A30

(Alt. EWSBM26-7-30)

AN7-22A

10

11

Bolt

NAS464P7L29

NAS464P8L29

Fitting, Spar

No. 5

2822172-1, -2

2322278-6, -9
2322278-7, -11
2322278-3, -5, -9, -4, -6, -10
2322278-11, -12
Bolt

10

11

EWSBM22-9-30

Fitting-2311181-7,

-8

2311181-1,-2, -5, -6
2311181-3, -4, -7, -8

Wing-to-Fuselage Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 7 of 9)

EFFECTIVITY:

ALL

51-71-01

Page 7
SRM-I

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM
NO.
12

DESCRIPTION

EFF.

REPAIR

Drag Block,Aft2311370-33, -39

15

2411371-3

16

Replace worn part.


Replace worn part.

Replace worn part.

Replace worn part.

2311370-34, -38

15

2411371-1

17

Replace worn part.


Replace worn part.

Replace

Replace worn part.

18

18

19

18

18

18

(Alt. 2411371-17, -18)


2411371-5, -6
(Alt. 2411371-15, -16)
2411371-15, -16
13

HOLE

DragBlock,

Fwd-

(Alt. 2411371-11)
2411371-2066-1,-2
(Alt. 2411371-9, -10)
2411371-1,-9, -10

(Alt. 2411371-11)
Fitting, Spar No. 7 2822171-3,

14

-4

Bushing -NAS75-10-016

15

16

1 Bushing-NAS75-8-021

worn

part.

Replacewompart. ReamholeGto0.8125
(~0.0005).
Replace worn part. Install new bushing with
light coat of petrolatum (VV-P-236). Ream
bushing (15) to 0.6273 (f0.0005) after installation.

NAS75-8-026
17

Bolt

18

Fitting, Aft 2311201-3, -4, -7, -8,

19

20
21

NAS6208-22

-15,-16
Fitting, Fwd-2311201-1,-2, -5, -6,
-13,-14
Fitting, Spat No. 8 2322281-1, -2

Bushing-

NAS75-10-016

18

18

Replace worn part. Install new bushing


light coat of petrolatum (VV-P-236).
Replace worn part. Install new bushing
light coat of petrolatum (VV-P-236).
Replace worn part.
Replace worn part.

with
with

Replacewompart.
Replace worn part.

Ream hole J to 0.8125

(~0.0005).
Replace worn part. Install new bushing with
light coat of petrolatum (VV-P-236). Ream
bushing (21) to 0.6273 (f0.0005) after installation.

22

Bushing- NAS75-8-021

18

23

Bolt

18

NAS6208-22

Replace worn part. Install new bushing


light coat of petrolatum (VV-P-236).
Replace worn part.

with

Wing-to-Fuselage Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 8 of 9)

EFFECTIVITY:

ALL

51-71-01

Page 8
SRM-I

Jun 6/98

Learjet
~Leariet/
STRUCTURAL REPAIR MANUAL
REPAIR DATA

ITEM

25

Fitting 2311211-1, -3, -5, -7,


Fitting 2311212-1, -3, -5, -7,

26

Bushing

24

EFF.

DESCRIPTION

NO.

REPAIR

HOLE

-9

18

-9

Replace
Replace

worn
worn

part.
part.

-2, -4, -6, -8, -10


NAS537-9-050

CODES

Replace worn part. Ream bushing (26) to


(+0.0004/-0.0000) after installation.

0.5620

(Alt. NAS75-9-016)

EFFECTIVITIES

Subsequent; 35-001 and Subsequent; 36-001 and Subsequent


Subsequent
Subsequent; 29-001 and Subsequent; 31-001 thru 31-020
Subsequent and Prior Aircraft Equipped With EWSBM26-9-30 Bolt
Subsequent; 36-001 and Subsequent

31-001 and

31-001 and

28-001 and

31-021 and

35-001 and

35-001 thru 35-009; 36-001 thru 36-005


35-010 and Subsequent; 36-006 and Subsequent; and Prior Aircraft

Equipped

With 232227&11

Spar

Fitting
8

28-001 and

28-001 and

10

23-001 and

11

23-001 and

36-001 and

Subsequent; 29-001
Subsequent; 29-001
Subsequent; 24-100
Subsequent; 24-100
Subsequent
Subsequent; 29-001

and

Subsequent
Subsequent; 31-001 and Subsequent
and Subsequent; 25-001 and Subsequent
and Subsequent; 25-001 and Subsequent;
and

and

Subsequent;

31-001 and

12

28-001 and

13
14

23-001 thru 23-099; 24-100 thru 24-299; 25-001 thru 25-183


24-300 and Subsequent; 25-1 84 and Subsequent

15

23-001 thru 23-099; 24-100 thru 24-229,

16

Subsequent;

Subsequent

Except 24-218; 25-001 thru 25-066, Except 25-061


24-218, 24-230 and Subsequent; 25-061,25-067 and Subsequent; 35-001 and Subsequent; 36-001
and

Subsequent

17

24-218, 24-230 and Subsequent; 25-061, 25067 and Subsequent

18

23-001 and

24-100 and

29-001 and

31-001 and

23-001

24-100 and

19

35-001 and

29-001

Subsequent;
Subsequent;
and Subsequent;
and Subsequent

Subsequent;
Subsequent;
Subsequent;

25-001 and
35-001 and
25-001 and

Subsequent;
Subsequent;
Subsequent;

2&001 and

Subsequent;

36-001 and

Subsequent
Subsequent;

2&001 and

Wing-to-Fuselage Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 9 of 9)

EFFECTIVITY:

ALL

51-71-01

Page9
SRM-I

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
FLAP FIT~INGS

ALLOWABLE WEAR AND REPAIR DATA

B
D

E
A:

33

?9 3r0

,35

i 30

31

34

38
37

Detail A

DetailB

(TYPICAL)

Flap Fittings

8188

EFFECTIVITY:

Allowable Wear and

Figure 1(Sheet

84A

ALL

1 of

Repair

Data

14)

51-71-02

Pagel
SRM-I

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


FLAP FII~TINGS

ALLOWABLE WEAR AND REPAIR DATA

41

)CsP~
P

42

Detail C
44
56

T
45,

D
el

55

54

Ij
a

46

57----

Detail D

58

R
47

52

I~
61

~-I
53

Detail E
(TYPICAL)

Flap Fittings Allowable Wear and Repair Data


Fi~ure 1 (Sheet 2 of 14)

JEFFECTIVITY:

ALL

51-71-02

Page2
SRM-I

Tun 6/98

Leariet
STRUCTURAL REPAIR MANUAL
13

11

~8-

10

12

:~CB

.D
8

C~k;n

Bu

A~

(INBOARD)

22

2,5
d

~27

20

15~cjlE

23

19

i
(OUTBOARD)

(TYPICAL)
Ag6C-2
8833C
C8116A

Flap Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 3 of 14)

DBJX

urasa

EFFECTIVITY:
SRM-4

ALL

51-71-02

Page3
Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

I
DESCRIPTION

NO.

MFD

MFD

HOLE

SHAFT
OD

IUIFD

ALLOWANCE

EFF.

HOLE I

ID

0.4390

1 +0.0020/

0.430

1 +0.00201

0.4390

1 +0.0020/

1 -0.0000

1 +0.0020/

ID

OD

WEAR
ID

ALLOWANCE
OD

SupportInner (LH)-2322511-15,

-23, -31, -41,-55

-0.0000
-0.0000

Inner (RH)-2322511-16,
-24, -30, -42, -56
1

I
B

0.430

-0.0000

Outer

(LH)-2322511-17,

-25, -29, -39, 63

0.4390

I
B

1 +0.0020/

1 -0.0000

1 +0.00201

0.4390

-0.0000

Outer (RH)-2322511-18

-26, -28, -40, -54

0.4390

1 +0.0020/

1 -0.0000

0.4390

1 +0.0020/
-0.0000

Cap-2322511-9,-45

0.4390

1 +0.0020/

Cap-2322511-8,-43

0.4390

-0.0000
1 +0.0020/

Cam Follower- CF-1-S-CP

-0.0000
4

A,
A,
A,
A,
A,
A,
A,
A,
A,

(Alt. CRS-1GCP)
(Alt. CTA-31X-85)
(Alt. CR-1X-65)
CF-7/8-S-CP

(Alt.
(Alt.
(Alt.
(Alt.

CRS-14CP)
CTA-27X-41)
CR-7/8-27X-41)
CR-7/8-X-41)

Button- 232251 3-1, -2

Nose Track

B
B
B

B
B
B
B
B
B

0.1900

1 +0.0020/
-0.0000

2322511-7, -27, -44, -46,


7

Bushing-

NAS76A4-21

Roller- 2325000-3

-57

I
1

0.7550

I
C

1 +0.0050/

i
0.2500
0.3800

1
0.3761
0.7500

-0.0020
+0.0015/

+0.0000/

-0.0000

-0.0005

+0.0000/

~0.0010

-0.0020

Flap Fittings Allowable Wear and Repair


Figure 1 (Sheet 4 of 14)

(EFFECTIVITY:

ALL

Data

51-71-02

Page 4
SRM-4

Jun 6/98

Learjet
~LearjetJ

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

I
DESCRIPTION

NO.

Bolt- NAS334CP12-5

MFD

MFD

MFD

HOLE

SHAFT

ID

OD

ALLOWANCE

ID

OD

EFF.

HOLE

0.2492

1 +0.00001

0.2492

1 +0.00001

WEAR
ID

ALLOWANCE
OD

-0.0009

NAS334CP13

-0.0009

101 TrackAssy.
2325022-5;-9, -14, -16
11

I Bearing-

BSSR-6530

0.8140

0.3750

1
0.81 25

i f0.0010
+0.0000/

-0.0005

+0.0000/

(Alt. MS21231-6)

0.3750

0.81 25

+0.0000/
-0.0005

-0.0005

(Alt. ADW-6)

0.3750

0.81 25

+0.0000/

+0.0000/

-0.0005

121

14 1

Bushing-

0.3710

NAS72-6-005

Bolt-ANG-1Ci
AN6-12

13

+0.0000/

-0.0005

1 -0.0000

I
0.5605

0.3750

-0.0005

1 +0.0030/

1
+0.0010/

+0.0000/

-0.0005

-0.0010

InboardTrack Attach

Fitting (LH)-2625023-7, -9,

-11,-15, -17, -21


2492007-1

0.5625

1 +0.0010/

-0.0000

0.5625

1 +0.0010/

0.5625

1 +0.0010/

1 -0.0000

1 +0.0010/

-0.0000

(RH)-2625023-8, -10, -12,

-16, -18, -22

I
D

2490007-2

0.5625

-0.0000

151 SupportInner

(LH)- 2322512-6, -17,


1

-19, -51

0.4390

1 +0.0020/

1 -0.0000

0.4390

1 +0.0020/

0.4390

-0.0000

Inner

(RH)-2322512-5, -16,

-39, -52

1 +0.0020/
1 -0.0000

0.4390

1 +0.0020/

0.4390

1 +0.0020/

-0.0000

Outer (LH)- 2322512-4, -15,


-27, -49
1

1 -0.0000

0.4390

1 +0.0020/

0.4390

i +0.0020/

1 +0.0020/

-0.0000

(RH)-2322512-3, -14,1
1
-28, -50

Outer

I
F

0.4390

-0.0000

-0.0000

Flap Fittings

Allowable Wear and

Figure

EFFECTIVI~:

ALL

Repair Data

1 (Sheet 5 of 14)

51-71-02

Page
SRM-4

Jun 6/98

Learjet i

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

I
DESCRIPTION

NO.
16

Cap-2322512-9, -31,

171

Cap-2322512-8

18 1

Cam Follower-

-32

MFD

MFD

HOLE

SHAFT

OD

MFD

ALLOWANCE

EFF.

HOLE

ID

0.3760

1 +0.00201

0.3760

1 +0.0020/

ID

OD

WEAR
ID

ALLOWANCE
OD

-0.0000

-0.0000

CF-7/8-S-CP

(Alt. CRS-14CP)

(Alt. CTA-27X-41)

(Alt. CR-7/8-27X-41)

(Alt. CR-7/8-X-41)

Button-2322513-2

19

(Alt. 2322513-1)

1 +0.0020/

1 -0.0000

i +0.0050/

0.1900

Nose Track

20

2322512-7, -13, -37

0.7550

Bushing-NAS76A4-021

0.2500

-0.0020

211
22

Roller- 2325000-3

23

Bolt- NAS334CP12-5

0.3761

0.3800

+0.0015/

0.7500

+0.00001

-0.0000

-0.0005

+0.00001

f0.0010

-0.0020
0.2492

1 +0.0000/

0.2492

1 +0.0000/

-0.0009

NAS334CP13

-0.0009

241

TrackAssy.
2325022-1, -10, -13, -15

25
26

Bearing-BSSR-5235
(Alt. MS21231-5)
Bolt- AN5-11

0.6890

0.3125

f~0.0010

+0.0000/

0.6875

-0.0005

+0.0000/
-0.0005

0.3108

1 +0.0009/

0.3108

1 +0.0009/

-0.0000
NAS464P5-17

-0.0000
27

Bushing- NAS72-5-005

0.3125

0.4980

+0.001 0/

-0.0005

-0.0001

+0.000/

Flap Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 6 of 14)

(EFFECTIVITY:

ALL

51-71-02

Page 6
sRM-4

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I
NO.
28

I
EFF.

DESCRIPTION

MFD

MFD

MFD

HOLE

SHAFT

HOLE

ID

OD

0.5000

ALLOWANCE

ID

OD

WEAR
ID

ALLOWANCE
OD

Outboard Track Attach


1

Fitting (LH)- 2625024-3,


1

-5,-7

(RH)

I
H

2625024-4, -6, -8

0.5000

i +0.0010/

1 +0.0010/

-0.0000
-0.0000

29

Sector6

2625031-1,-2, -6

0.3747

1 +0.0015/

1.2500

1 +0.0050/

0.7500

1 +0.0100/

0.3747

i +0.0015/

1.2500

1 +0.0050/

0.7500

1 +0.0100/

0.3747

i +0.0015/

1.2500

i +0.0050/

0.7500

1 +0.0100/

0.3747

1 +0.001 5/

1.2500

1 +0.0050/

0.7490

1 +0.0100/

-0.0000
-0.0000
-0.0000
7

2625031-9, -10

-0.0000
K

-0.0000
-0.0000

2625031V1-1, -2

-0.0000
K

-0.0000

-0.0000
9

2625031-13, -14

-0.0000
K

-0.0000
L

-0.0000
30

311
32

Bearing- AN200KP5
(Alt. MS27640-5)
Spacer-NAS43DD5-79
Bolt- NAS1305-42H

0.3125

I
K

10

1.2500

0.3200

1
0.4280

+0.0000/

+0.0000/

-0.0005

-0.0005

+0.0400/

+0.020/

-0.0000

-0.0000

0.3110

1 +0.0010/

0.3110

1 +0.0010/

-0.0000
NAS6605-44

11

-0.0000

Flap Fittings

Allowable Wear and

Figure

EFFECTIVITY:

ALL

Repair Data

(Sheet 7 of 14)

51-71-02

Page
SRM-I

Jun 6/98

Learjet
~Learjetl

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

NO.

I
DESCRIPTION

Bearing- MS21233-5

33

MFD

MFD

HOLE

SHAFT

MFD

ALLOWANCE

EFF.

HOLE

ID

OD

ID

OD

0.3125

0.7500

+0.00001

+0.00001

-0.0005

WEAR
I

ID

ALLOWANCE
OD

-0.0005

34 1

Bolt- NAS464P5-10

0.3108

1 +0.00001

35

Bolt- NAS464P6-28

0.3742

1 +0.00001

36

Bolt- NAS464P4-11

0.2492

1 +0.00001

37

Bracket

-0.0009

-0.0009
-0.0009

Assy.

2325079-3, -4, -11,-12,


-17,-18

38

Bracket

39

Pulley- MS20221-A1

Assy.

0.0250

1 +0.00051

1 -0.0000

1 f0.0100

0.3120

2425081-1,-11
0.3125

2.6250

+0.0000/

f0.005

-0.0005

Bolt- NAS1305-19H

40

0.3120

0.3125

0.3110

+0.001 0/
-0.0000

41

BracketAssy.-

1 +0.0100

2325080-1,-11
42

Pulley

MS20221-A1

2.6250

+0.0000/

~0.005

-0.0005
43

Bolt- NAS464P5-15

44

Bracket

45

Pulley- MS20221-A1

12

0.3120

13

Q
Q

0.3120

0.3117

1 +0.0000/
-0.0009

Assy.

2625040-57

2625038-1,-2

14

0.3125

I ~t0.0100
I f0.0100

+0.0000/

2.6250

rt0.0050

-0.0005
46

Screw- NAS335CP20

14

47

Bracket- 2325080-19

14

0.3120

48

Pulley- MS20221-A1

14

0.3125

0.3117

1 +0.00001
-0.0009

1 +0.0006/

-0.0001
2.6250

+0.0000/

f0.0005

-0.0005

49

Bolt- NAS464P5-12

14

50

Bracket- 2325080-20, -44,


-52

14

51

Plate-2325080-21

14

0.3117

1 +0.0000/
-0.0009

1
1

0.3120

I
S

0.3120

0.3125

1 +0.0006/

0.0001

+0.006/
-0.0001

52

Pulley-

MS20221-A1

14

2.6250

+0.0000/

~0.0005

-0.0005

Flap Fittings Allowable Wear and Repair


Figure 1 (Sheet 8 of 14)

1EFFECTIVITY:

ALL

Data

51-71-02

Page8
SRM-I

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

I
DESCRIPTION

NO.

MFD
SHAFT

ID

HOLE

EFF.

MFD
HOLE

OD

0.3117

MFD

ALLOWANCE

ID

53

Bolt- NAS464P5-17

14

54

Bracket- 2825082-4, -6

15

0.3160

1 +0.00001

Pulley-2815086-1

15

0.9370

1 +0.0000/

15

T, V

0.3125

OD

WEAR
ID

ALLOWANCE
OD

1+0.0000/
-0.0009
-0.0000

55

56

1 Bearing-

-0.0005

PD5K-FS464

+0.0000/

0.9370

-0.0005
57

Bolt-NAS464P5-24

15

58

Bracket-2825082-1, -3

15

0.3117

+0.0000/
-0.0005

1 +0.0000/
-0.0009

0.3160

0.31 25

1 +0.0000/
-0.0000

Pulley-

59

MS20221-A1

15

+0.0000/

2.6250

f0.0005

-0.0005
60

Bolt-NAS464P5-24

15

61

Bracket-2825083-7

15

Bolt- NAS464P5-13

15

0.3117

i +0.0000/
-0.0009

0.3160

1+0.0000/
-0.0000

62

0.3117

1 +0.0000/
-0.0009

Flap Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 9 of 14)
EFFBCTnTrry:

ALL

51-n-o2

Page9
SRM-4

Jun 6/98

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

NO.

DESCRIPTION

EFF.

SupportInner (LH) 2322511-15, -23, -31,

A, B

Replace

worn

part.

A, B

Replace

worn

part.

A,

Replace worn part.

HOLE

REPAIR

-41,-55
Inner

(RH) 2322511-16, -24, -30,

-42, -56
Outer (LH) 2322511-17, -25, -29,

-39,-53
Outer

(RH)

2322511-1 8, -26, -28,

A, B

Replace worn part.

-40, -54
Cap 2322511-9, -45
Cap 2322511;8, -43

Cam Follower

A, B

Replace worn part.


Replace worn part.
Replace worn part.

A, B

Replace worn part.

CF-1-S-CP

(Alt CRS-1GCP)
(Alt CTA-31X-85)
(Alt CR-1 X-65)
CF-7/8-S-CP

(Alt
(Alt
(Alt
(Alt

CRS-14CP)
CTA-27X-l1)
CR-7~27X-41)
CR-7~X-41)

Button

2322513-2

(Alt. 2322513-1)

If

spanwise

cam

Nose Track

Bushing

2322511-7, -27, -44, -46, -57

NAS76A4-21

Roller

Bolt

2325000-3

NAS334CP12-5

NAS334CP13
Track

Assy. 2325022-5, -9, -14,


Bearing BSSR-6530
(Alt. MS21231-6)
(Alt. ADW-6)

10
11

12

-16

Bolt-ANG-16
AN6-12
NAS72-6-005

13

Bushing

14

Inboard Track Attach

tend play) of flap exmaximum, replace buttons


followers (4).
movement

ceeds 0.34 inch

Fitting -2625023-7, -9, -11,-15,


-17,-21

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.

part.
part.
part.

part.
part.
part. Secure with Loctite.

Replace
Replace
Replace

Replaceworn part.
Replace worn part.
Replace worn part.
Replace worn part.

2492007-1

2625023-8, -10, -12, -16, -18, -22

2492007-2

worn
worn

worn

on

Flap Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 10 of 14)

JEFFECTIVITY:

ALL

51-71-02

Page
SRM-I

10

Tun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

DESCRIPTION

NO.
15

Inner

Inner

17

18

Cam Follower-

CF-7/8-S-CP

E,
E,
E,
E,

1
1

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

F
F
F

E, F

Replace worn part

2322513-2

Button

21

Nose Track

Bushing

22

Roller

23

Bolt

2322512-7, -13, -37

NAS76A4-21

2325000-3

NAS334CP12-5

NAS334CP13
24

Track

Assy.

If

spanwise

movement

tend play) of flap

ceeds 0.34 inch maximum,


cam followers (18).

(Alt. 2322513-1)
20

part.
part.
part.
part.
part.
part.

CRS-14CP)
CTA-27X-41)
CR-7/8-27X-41)
CR-7/8-X-41)

(Alt.
(Alt.
(Alt.
(Alt.
19

REPAIR

HOLE

1 Support(LH) 2322512-6, -17, -19, 61


(RH) 2322512-5, -16, -30, -52
Outer (LH) 2322512-4, -15, -27, -49
Outer (RH) 2322512-3, -14, -28, -50
Cap 2322512-9, -31, -32
Cap 2322512-8

16

EFF.

2325022-1, -10, -13,

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

replace

ex-

buttons

on

part.
part.
part.
part.
part.
part.

-15

25

Bearing BSSR-5235
(Alt. MS21231-5)

26

Bolt

AN5-11

NAS464P5-17

NAS72-5-005

27

Bushing

28

Outboard Track Attach

Fitting
29

30
31

(LH) 2625024-3, -5, -7


(RH) 2625024-4, -6, -8

1 Sector 2625031-1, -2, -6

2625031-9, -10

2625031V1-1,-2
2625031-13, -14

Bearing AN200KP5
(Alt. MS27640-5)
1 Spacer MS43DD5-79

J,
J,
J,
J,

K,
K,
K,
K,

I Replace worn part.


Replace
Replace
Replace

L
L

L
L

worn
worn
worn

Replace worn
Replace worn
Replace worn
Replace worn
Replaceworn
Replace worn
Replace worn

ALL

part.
part.
part.
part.
part.
part.
part.
part.
part.
part. Secure with Loctite.

I Replace worn part.

Flap Fittings Allowable Wear and Repair


Figure 1(Sheet 11 of 14)
EFFECTNITY:

Secure with Loctite.

Data

51-71-02

Page
SRM-4

11

Jun 6/98

Leariet
STRUCTURAL REPAIR MANUAL
REPAIR DATA

ITEM

32

EFF.

DESCRIPTION

NO.

Replacewompart.

11

NAS6605-44
33

10

Bolt- NAS1305-42H

REPAIR

HOLE

Bearing- MS21233-5

Replace

worn

part.

Secure with Loctite and

stake.
34

Bolt

NAS464P5-10

35

Bolt

36

Bolt

NAS464P6-28
NAS464P4-11

37

Bracket

39

Assy. 2325079-3, -4, -11,


-12,-17,-18
Bracket Assy. 2425081-1, -11
Pulley MS20221-A1

40

Bolt

41

Bracket

Assy.

42

Pulley

MS20221-A1

43

Bolt

38

44

NAS1305-19H

2325080-1, -11

NAS464P5-15
Bracket Assy. 2625040-57

2625038-1,-2

12

13

14

MS20221-A1
NAS335CP20

14

Q
Q

2325080-19

14

45

Pulley

46

Screw

47

Bracket

48

Pulley MS20221-A1

49

Bolt

50

Bracket- 2325080-44

NAS464P5-12

14

14

14

14

14

Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.
part.
part.
part.
part.
part.
part.
part.
part.
part.

Replace

worn

Replace worn
Replace worn
Replace worn
Replace worn
Replacewompart.

(Alt. 2325080-44)
51

Plate

2325080-21

MS20221-A1

52

Pulley

53

Bolt

54

Bracket

55
56

Pulley 2815086-1
Bearing PD5K-FS464

NAS464P5-17

2815082-4, -6

NAS464P5-24

57

Bolt

58

Bracket

59

PJ~ey- MS20221-A1

60

Bolt

61

Bracket

62

Bolt

2825082-1, -3

14

15

15

15

T, V

15

15

VV

15

NAS464P5-24

15

2825083-7

15

NAS464P5-13

15

Flap Fittings

EFFECTIVITY:

ALL

worn
worn

part.
part.

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn pact.
Replace worn part.
Replacewompart.
Replace worn part.
Replace worn part.
Replace worn part.

Allowable Wear and

Figure

Replace
Replace

Repair Data

(Sheet 12 of 14)

51-71-02

Page
SRM-I

12

Jun 6/98

Learjet
I~ritl
STRUCTURAL REPAIR MANUAL
CODES
1

EFFECTIVITIES
23-001 thru 23-099; 24-100 and

Subsequent; 25-001 and Subsequent; 28-001 and Subsequent; 29Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
23-003 thru 23-099 Except When Modified by SSK 934 "Replacement of Wing Flap Assembly"; 24110 thru 24327 Except When Modified by SSK 934 "Replacement of Wing Flap Assembly"; 25-001
thru 25-204 Except 25-135 and 25-188 and Except When Modified by SSK 934 "Replacement of
Wing Flap Assembly"; 35-001 thru 35-059 Except When Modified by SSK 934 "Replacement of Wing
Flap Assembly"; 36-001 thru 36-017 Except When Modified by SSK 934 "Replacement of Wing Flap
Assembly"
23-003 thru 23-099 When Modified by SSK 934 "Replacement of Wing Flap Assembly"; 24-328 and
Subsequent and Prior Aircraft Modified by a SSK 934 "Replacement of Wing Flap Assembly"; 25-205
and Subsequent and Prior Aircraft Modified by SSK 934 "Replacement of Wing Flap Assembly"; 28001 and Subsequent; 29-001 and Subsequent; 31-001 and Subsequent; 35-060 and Subsequent
and Prior Aircraft Modified by SSK 934 "Replacement of Wing Flap Assembly"; 36-018 and Subsequent and Prior Aircraft Modified by SSK 934 "Replacement of Wing Flap Assembly"
31-001 thru 31-049; 35001 thru 35673; 36-001 and Subsequent; Except Aircraft With 2625023-9 or
2492007-1 Inboard Track Attach Fitting Installed
31-050 and Subsequent; 35-674 and Subsequent; Except Aircraft With 2625023-9 or 2492007-1 Inboard Track Attach Fitting Installed
23-001 thru 23-099; 24-100 and Subsequent; 25-001 thru 25-373; 28-001 thru 28-005; 29-001 thru
29-004; 35-001 thru 35-055; 36-001 thru 36-605, Except 36-060 and 36-061
25374 and Subsequent; 2&006 and Subsequent; 29-005 and Subsequent; 31-001 thru 31-032; 35056 and Subsequent; 36-606 thru 36-664
001 and

6
7

31-033 thru 31-047; 35-665 thru 35-672

31-033 and

10

23-011, 23-012, 23-015, 23-019, 23-031, 23-039, 23-050a and Aircraft Modified Per ECR 392; 23090 and Subsequent Except When Modified by SE 23/24/25/25-57-1, "Replacement of Spoiler Actuator and Flap Sector Support Brackets"; 24-100 and Subsequent Except When Modified by SE 23/
24/25/25-57-1, "Replacement of Spoiler Actuator and Flap Sector Support Brackets"; 25-001 and
Subsequent Except When Modified by SE 23/24/25/25-57-1, "Replacement of Spoiler Actuator and
Flap Sector Support Brackets"; 28-001 and Subsequent Except When Modified by SE 23/24/25/2557-1, "Replacement of Spoiler Actuator and Flap Sector Support Brackets"; 29-001 and Subsequent
Except When Modified by SE 23/24/25/25-57-1, "Replacement of Spoiler Actuator and Flap Sector
Support Brackets"; 31-001 thru 31-129 Except When Modified by SE 23/24/25/25-57-1, "Replacement of Spoiler Actuator and Flap Sector Support Brackets"; 35-001 thru 35-676 Except When Modified by SE 23/24/25/25-57-1, "Replacement of Spoiler Actuator and Flap Sector Support Brackets";
36-001 thru 36-063 Except When Modified by SE 23/24/25/25-57-1, "Replacement of Spoiler Actua-

Subsequent Except When 2625031\11-1 or 2625031\/1-2 Sector Is Installed; 35-673 and


Subsequent Except When 2625031V1-1 or 2625031V1-2 Sector Is Installed; 36-060, 36-061 and 36665 and Subsequent Except When 2625031V1-1 or 2625031V1-2 Sector Is Installed

tor and

Flap

Sector

Support Brackets"

Flap Fittings Allowable Wear and Repair


Figure 1 (Sheet 13 of 14)
EFFECTIVITY:

ALL

Data

I
51-71-02

Page
SRM-I

13

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
CODES
11

EFFECTIVITIES
23-090 and

Subsequent When Modified by SE 23/24/25/25-57-1, "Replacement of Spoiler Actuator


Flap
Support Brackets"; 24-100 and Subsequent When Modified by SE 23/24/25/25-57-1,
"Replacement of Spoiler Actuator and Flap Sector Support Brackets"; 25-001 and Subsequent When
Modified by SE 23/24/25/25-57-1, "Replacement of Spoiler Actuator and Flap Sector Support Brackets"; 28-001 and Subsequent When Modified by SE 23/24/25/25-57-1, "Replacement of Spoiler Actuator and Flap Sector Support Brackets"; 29-001 and Subsequent When Modified by SE 23124/25/2557-1, "Replacement of Spoiler Actuator and Flap Sector Support Brackets"; 31-130 and Subsequent
and Prior Aircraft When Modified by SE 23/24/25/25-57-1, "Replacement of Spoiler Actuator and
Flap Sector Support Brackets"; 35-677 and Subsequent and Prior Aircraft When Modified by SE 231
24/25/25-57-1, "Replacement of Spoiler Actuator and Flap Sector Support Brackets"; 36-064 and
Subsequent and Prior Aircraft When Modified by SE 23/24/25/25-57-1, "Replacement of Spoiler Acand

Sector

tuator and
12

13
14

15

Flap Sector Support Brackets"

24-329 thru 24-348; 25-206 thru 25-224; 35-067 thru 35-115; 36-018 thru 36-032
24-349 and Subsequent, 25-225 and Subsequent; 28-001 and Subsequent; 29-001 and
31-001 and Subsequent; 35-116 and Subsequent; 36-033 and Subsequent

23-001 thru 23-099; 24-100 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
25-001 and Subsequent; 28-001 and Subsequent; 29-001 and Subsequent; 31-001 and Subsequent

Flap Fittings

Allowable Wear and

Figure

EFFECTTVITY:

Subsequent;

ALL

Repair Data

(Sheet 14 of 14)

51-71-02

Page
SRM-4

14

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
SPOILER FITTINGS

I Y~ )i

ALLOWABLE WEAR AND REPAIR DATA

18

,G
17

15

4
12
7

21

11

20

.i

8
18

Spoiler:Fittings Allowable Wear and Repair


Figure 1 (Sheet 1 of 5)

EFFECTIVITY:

ALL

19

Data

51-71-03

Pagel
SRM-4

Jun 6/98

Leariet
~Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

I
EFF.

DESCRIPTION

NO.

Hinge Arm,

Inboard

Sleeve- 2322510-65

I
HOLE
A

2322510-2 thru -144


2

MFD
SHAFT

ID

OD

0.5620

I
A

MFD
HOLE

ALLOWANCE

ID

OD

WEAR
ID

ALLOWANCE
OD

i +0.00501
1 -0.0010

1
I

0.4410

MFD

0.5600

+0.00301

It0.0010

-0.0000

Bearing-

PB-814-14

0.2520

+0.0000/

0.4400

+0.0000/

-0.0010
4

Bolt-AN4-13A,-14A

Hinge Bracket

Fitting 2422513-1(Hole C

0.2490

-0.0010

1 +0.0000/
-0.0030

2322514-5,-11,-6,-12
Inbd side, Hole D Outbd

0.250

0.4375

side)

0.3755

0.2500

1 +0.0050/

1 -0.0010

1 +0.00001

1 +0.00001

-0.0010

-0.0005
7

Bushing-NAS77-4-06

Bushing- NAS724-002

Bolt- BACBSONJ4D10

+0.0015/

0.3761

0.2500

0.4355

+0.0000/

-0.0000

-0.0005

+0.00101

+0.0000/

-0.0005

BACB30NJ4D12
10

Arm

Assy -2422511-8,-13

I
2

0.2495

-0.0010

1 +0.0000/

0.2492

I
1

I
1 -0.0010
1 +0.0010/

0.4410

1 +0.0030/

0.2500

1 +0.0020/

0.2492

1 +0.001 0/

0.4410

1 +0.0030/

0.3120

1 +0.0020/

-0.0000
-0.0000
-0.0010
3

2422511-18, 31,-32

-0.0000

-0.0000
-0.0000
11

Bolt-NAS464P4-13

NAS464P4A11
12

Bearing- PB1014-14
(Alt. AA401-12)

13

Bolt- NAS464P5-20

I
F

NAS464P5-17
14

0.3145

0.2492

1 -0.0009
+0.0000/

0.4400

1 +0.0000/

1
0.3117

-0.0010

1 +0.0000/
1 -0.0009

Hinge Bracket-2422514-1,
-2 thru

-43,

-44

0.3120

0.3756

+0.0060
-0.0000

2422514-57,-58, -60,-61

1 +0.0015
-0.0000

Spoiler Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 2 of 5)
EFFECTIVITY:

ALL

51-71-03

Page2
SRM-I

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

DESCRIPTION

NO.

15

1 Bushing-2422514-63

MFD

MFD

HOLE

SHAFT

ALLOWANCE

MFD

EFF.

HOLE

ID

OD

ID

OD

0.31 20

0.3761

+0.0060/

+0.0000/

Bolt- NAS464P5A14

ID

ALLOWANCE
OD

-0.0005

-0.0010

16

WEAR

0.3117

1 +0.0000/

0.2492

+0.0000/

0.3120

1 +0.0020/

0.2500

1 +0.00201

0.3120

1 +0.0020/

-0.0009

NAS464P4A13

-0.0009
17

HingeArm-2422541-2

-0.0000
2422541-1

-0.0010

Angle-

2322510-29, -30

-0.0000
18

1 HingeBracket1

Bolt-AN4-14A

Bearing- PB-814-14

0.2520

0.5620

0.4410

2322514-7, 8

0.2500

1 +0.0050/
-0.0010

19

0.2490

1 +0.0000/

-0.0030
20
21

1 Hinge

Arm-2322510-143

0.4400

+0.0000/

+0.0000/

-0.0010

-0.0010

1 +0.0050/

-0.0010
22

Sleeve- 232251 0-65

0.5600

+0.0030/

~0.0010

-0.0000

Spoiler Fittings Allowable Wear and Repair


Figure 1 (Sheet 3 of 5)
EFFECTNITY:

ALL

Data

51-71-03

Page3
SRM-I

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

NO.

DESCRIPTION

Hinge Arm, Inboard

1 Sleeve-2322510-65

2322510-2 thru -144

EFF.

HOLE

REPAIR

Replace worn part.


Replace worn part.

Install

new

sleeve with

Loctite.
3

Bearing

Bolt

Hinge

PB-814-14

AN4-14A

Fitting
Bushing-

-12

2422513-1

Replace worn part.


Replace worn part.

Bracket-

2322514-5,11,-6,
6

NAS77-4-06

Replace worn part.


Replace worn part.
Replace worn part.

Install new bushing with


primer. No substitution of parts.
I Replace worn part. Install new bushing with
wet primer. No substitution of parts.
Replace worn part. No substitution of parts.
wet

Bushing- NAS72-4-002

Bolt

C,D

-13

2422511-18 thru -31, -32

E, F,G
E, F,G

BACB30NJ4D10

BACB30NJ4D12
10

Arm

Assy. -2422511-8,

Replacewornpar.
Replacewompart.

11

Bolt

12

Bearing PB1014-14
(Alt.AA401-12)

13

Bolt

Replace worn part.

14

Hinge, Bracket2422514-1 thru -44

2422514-57, -58, -60, -61

Replace worn part.


Replace worn part.
Replace worn part.
wet primer.
I Replace worn part.

NAS464P4-13, NAS464P4A11

15

1 Bushing-2422514-63

16

1 Bolt

17

1 Hinge

NAS464P5A14, NAS464P5A13
2422541-1

2422541-2

Angle 2322510-29,

new

bearing with

Loctite.

NAS464P5-20, NAS464P5-17

Arm

Replace worn part.


Replace worn part. Install

-30

Install

Replace worn part.


Replace worn part.
Replace worn part.
Ream hole G in angle (17)

new

bushing with

to 0.312

(+0.002/-0.000) after installation.


18

Hinge Bracket

19

Bolt

20
21

22

2322514-7, -8

Bearing PB-814-14
Hinge Arm 2322510-143

Sleeve

AN4-14A

2322510-65

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.
part. Install

new

sleeve with Loc-

tite.

Spoiler Fittings Allowable Wear and Repair


Figure 1 (Sheet 4 of 5)
EFFECTIVITY:

ALL

Data

51-71-03

Page$
SRM-I

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
CODES

EFFECTIVITIES

23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 28-001 and Subsequent; 29001 and Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent

23-001 thru 23-099; 24-100 thru 24-302, 24-309 thru 24317; 25-001 thru 25-194; 35-001 thru 35-

24-303 thru

032; 36-001 thru 36-013


24-308, 24-318 and Subsequent; 25-195 and Subsequent; 31-001 and Subsequent; 35033 and

Subsequent;

36-014 and

Subsequent

Spoiler Fittings Ailowable Wear and Repair Data


Figure 1 (Sheet 5 of 5)
EFFECTIVITY:

ALL

1
51-71-03

Page 5
SRM-4

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
AILERON SYSTEM FITTINGS

ALLOWABLE WEAR AND REPAIR DATA

~C

W
(TYPICAL)
813B2

Aileron

EFFECTIVITY:

System Fittings
Figure

ALLORAS NOTED

Allowable Wear and


1

Repair Data

(Sheet 1 of 28)
51-71-04

Page
SRM-4

Jun 6/98

Learpt

STRUCTURAL REPAIR MANUAL


ALLOWABLE WEAR AND REPAIR DATA

AILERON SYSTEM FITTINGS

.6

P ~f
q

Bj
D

Wing

Detail A
(TYPICAL)
Aileron

86B
4-4C-2

(EFFECTIVITY:

System Fittings
Figure

Allowable Wear and


1

(Sheet

2 of

Repair

Data

28)

51-71-04

ALL
_

Page2
SRM-4

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


AILERON SYSTEM FITTINGS

ALLOWABLE WEAR AND REPAIR DATA

Q~P

a.

16

178

15

14

13

F
.z~s

Detail B
Aileron

4-4C-2

EFFECTIVITY:

ALL

System Fittings
Figure

Allowable Wear and


1

Repair Data

(Sheet 3 of 28)
51-71-04

Page3
SRM-4

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


AILERON SYSTEM FITTINCS

ALLOWABLE WEAR AND REPAIR DATA

21

25

22

G
28

i
23

gC

~9

Detail C

~30

(TYPICAL)
Aileron

B810C
B46A
C4-5B1

(EFFECTIVITY:

ALL

System Fittings
Figure

Allowable Wear and


1

Repair Data

(Sheet 4 of 28)

51-71-04

Page4
SRM-I

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
ALLOWABLE WEAR AND REPAIR DATA

AILERON SYSTEM FITTINGS

33

(AII Excetlt Model 31 Series Aircraft)

Detail E
M
37

M
37
i

35

Detail F
3,8

3Q

;I

38

40

Detail G
Aileron

EFFECTIVITY:

System Fittings
Figure

ALL ORAS NOTED

Allowable Wear and

Repair

Data

1 (Sheet 5 of 28)

51-71-04

Page 5
SRM-I

Jun 6/98

Learjet

STRUCTURAL REPAIR NIANUAL


AILERON SYSTEM FITTINGS

ALLOWABLE WEAR AND REPAIR DATA

P
41

43

i
d~

Detail H

44k

49

48~

(All Excetlt Model 31 Series Aircraft)

(All Excetlt Model 31 Series Aircraft)

Detail J

Detail K
(TYPICAL)

Aileron

EFFECTIVITY:

System Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 6 of 28)

AU ORAS NOTED

51-71-04

Page 6
SRM-4

Jun 6/98

Learjet
~Learpt

STRUCTURAL REPAIR MANUAL


AILERON SYSTEM FITTINGS

59

ALLOWABLE WEAR AND REPAIR DATA

AM

S
a

51

53

~d

50
r

52

50

AM

D eta i I L

58

55

60

57

.ig
(AIl Excetlt Model 31 Series Aircraft)

(All Excetlt Model 31 Series Aircraft)

DetailM

Detail N
(TYPICAL)

Aileron

EFFECTMTY:

System Fittings
Figure

ALL ORASNOTED

Allowable Wear and


1

(Sheet

7 of

Repair Data

28)

51-71-04

Page 7
SRM-4

Jun 6/98

Learjet I
C~ Learjet

STRUCTURAL REPAIR MANUAL


AILERON SYSTEM FITTINGS

ALLOWABLE WEAR AND REPAIR DATA

a
(AIl Excetlt Model 31 Series Aircraft)

Detail P

65

64

e
66

63

~79
gc~

(A12

Model 31 Series Airmaft)

DetailQ

Detail R
(TYPICAL)

Aileron

EFFECTIVITY:
SRM-4

System Fittings
Figure

ALL ORAS NOTED

Allowable Wear and


1

Repair Data

(Sheet 8 of 28)
51-71-04

Page 8
Tun 6/98

Learjet
Ledrptl
STRUCTURAL REPAIR MANUAL
AILERON SYSTEM FITTINGS

ALLOWABLE WEAR AND REPAIR DATA

~U"I

Eletail S
~lY3 72

e3~1;
"ai

76

75

DetailT

78

i/

Detail U
(TYPICAL)
Aileron

EFFECTIVITY:

NOTED

System Fittings Allowable Wear and Repair


Figure 1 (Sheet 9 of 28)

Data

51-71-04

Page9
sRM-a

Jun 6/98

Learjet i

STRUCTURAL REPAIR MANUAL


AILERON SYSTEM FITTINGS

ALLOWABLE WEAR AND REPAIR DATA

AK
85

79/ ~3h, I AL

sp

82

AJ

,AG
AB

AH

,88

AF _

AD

1
AE

DetailV

,81

AA

a;e

90

~1

,92
93

91r

AA

AB

Detail W

Aileron

(EFFECTNITY:

NOTED

System Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 10 of 28)
51-71-04

Page
SRM-I

10

Jun 6/98

Learjet
~Learjetl
STRUCTURAL REPAIR MANUAL
AILERON SYSTEM PITTINGS

ALLOWABLE WEAR AND REPAIR DATA

uh
99~

BJ

38--

AQ
97

r i

~i

99~AM

Detail B

r~ n

AC

Detail C

Aileron

EFFECTIVITY:

NOTED

System Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 11 of 28)
51-71-04

Page
SRM-I

11

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

NO.

I
EFF.

DESCRIPTION
Inboard

I
HOLE I

MFD

MFD

HOLE

SHAFT

MFD

ID

ID

0.9005

1 +0.00051

1 -0.0000

OD

WEAR

ALLOWANCE
OD

ID

ALLOWANCE
OD

Hinge Bracket

2322530-3, -39, -40, -55,


-56, -59, -60, -67, -68, -81, i

-82

Bearing-

BP-4

0.9014

1 +0.0000
-0.0005

KSP-4

0.9014

1 +0.0000

MS27645-4

0.9014

1 +0.0000

Bolt- AN4H1IA

0.2460

1 +0.0030/

0.2460

1 +0.0030/

-0.0005
-0.0005
3

-0.0000
AN4H12A

-0.0000

Middle

Hinge

Bracket
B

2322530-19, -20, 27, -28,


-51, -52, -89, -90
1

MS27645-4

Bearing-

Bolt- AN4H13A

Angle and Plate

Stud- 2322530-33, -53

Outboard

0.9005

1 +0.0005/

1 -0.0000

0.2460

1 +0.0030/
-0.0000

2322530-29, -30, -31, -32

Hinge

Bearing- N1827645-4
Bolt- AN4H11A

11

1 +0.0010/
1 -0.0000
0.2492

1 +0.00001
-0.0009

Bracket

2322530-41, -42, -63, -64,


-75,-76,-79,-80
1
10

0.2492

1 +0.0005/

0.9005

1 -0.0000

0.2460

1 +0.0030/

0.2460

1 +0.0030/

-0.0000
AN4H12A

-0.0000

121

Horn-

2324011-28

0.6560

1 +0.0020/

2324011-235

0.6560

1 +0.0020/

-0.0000
-0.0000

13

Bearing- ABT4-105

Aileron

EFFECTIVITY:

ALL

System Fittings
Figure

Allowable Wear and


1

Repair Data

(Sheet 12 of 28)

51-71-04

Page
SRM-4

12

Jun 6/98

Leariet
~Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

141

I
HOLEI

EFF.

DESCRIPTION

NO.

MFD

MFD

HOLE

SHAFT
OD

ID

MFD

WEAR

ALLOWANCE

ID

OD

Bolt-AN4-7

0.2490

1 +0.0010/

NAS464P4-8

0.2483

1 +0.0009/

ID

ALLOWANCE
OD

-0.0000
-0.0000

Clevis Rod End

15

2433003-2

0.2492

1 +0.001 0/

2333001-7

10

0.2492

1 +0.00101

-0.0000

-0.0000
16

1 Bearing

Rod End-

HFV-L1

(Alt. TR-4)
(Alt. REF-4)
17

BoR-AN4-I1

0.2460

1 +0.0030/
-0.0000

17A

0.2500

1 +0.0050/

12

0.2500

1 +0.0050/

13

0.2500

1 *0.0050/

0.9015

I f0.0010

0.9015

Actuator- 2380027-10

11

ActuatorArm-233300&3

-0.0010

181

-0.0010

23330086

-0.0010
19

Yoke- 232451 &1

14

15

20

2324511-5
BoR- NAS464P3-33

G, H
G, H

14

1
1

0.2485

I rt0.0010
1
1 +0.0010/

0.2485

-0.0000
15

NAS1 304-34H
NAS11 04-380

211 Bearing-MS27644-4

22

(Alt. DDP4)
(Alt. BP4)
(Alt. BR4)
Bushing-

I
G

NAS75-4-009

I
1

(Alt. MS27645-4)
(Alt. KSPQ)

0.2500

0.3761

0.2500

Bolt- NAS464P4-12

0.2492

1 -0.0000
+0.0000/

+0.0000/

-0.0005

-0.0005

+0.0015/

+0.0000/

1 -0.0000
0.7500

I
1

1 +0.0010/

I
0.9014

231 Bearing-BP-l

I
0.2500

NAS75-4-008

24

-0.0005

+0.0000/

+0.0000/

-0.0005

-0.0005

1 +0.0000/
-0.0009

Aileron

EFFECTIVITY:

AU

System Fittings
Figure

Allowable Wear and


1

Repair Data

(Sheet 13 of 28)

51-71-04

Page
SRM-4

13

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

NO.I

I
DESCRIPTION

I
EFF.

I
HOLE I

MFD

MFD

HOLE

SHAFT

ID

OD

MFD
I

ALLOWANCE

ID

OD

WEAR
I

ID

ALLOWANCE
OD

Aileron Drive Clevis

25

2324512-3, -5

16

0.2492

1 +0.0010/

0.4991

0.2492

1
1

1 +0.0005/
1 +0.0010/

0.4991

1 +0.0005/

0.5000

-0.0000

2324517-1,-3

17

-0.0000
-0.0000

1 Bearing-AN201KP8A

26
27

1.1250

+0.0000/

+0.0000/

-0.0005

-0.0005

Pulley Shaft
2324513-3, -13

0.4986

1 +0.0005/
-0.0000

0.9986

1 +0.0005/
-0.0000

Pulley-

28

2324513-9, -10
232451 3-15, -16

1 +0.0000!

1 -0.0009

1 +0.0050/

0.9985

Arm Link-

29

2324011-111, -223

18

0.2490

1 +0.0000/

19

0.2492

1 +0.0000/

0.2500

-0.0010

Bolt- AN4-7

30

-0.0030

NAS464P4-8

-0.0009
31

1 Bearing Rod
(Alt. TR-4)

End- HFV-4

(Alt. REF -4T)


(Alt. HFR -4M)
32

Pulley-MS24566-3B

H,
H,
H,
H,

C
C
C
C

0.2500

2.0000

+0.0000/
-0.0005

33

Bolt- AN4H1OA

34

Bracket- 2424034-1

0.2500

35

Pulley-

0.3125

0.2460

+0.0000/
-0.0100

1 +0.0030/
-0.0000

MS20220A1

I IK).0100
1.7500

+0.0005/

f0.0050

-0.0000
36

Bolt- AN5H16A

0.3090

1 +0.0030/
-0.0000

Aileron

EFFECTNTT"Y:
SRM-P

ALL

System Fittings Allowable Wear and Repair


Figure 1 (Sheet 14 of 28)

Data

51-n-04

Page 14
Tun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM
NO.

371

38

MFD

MFD

HOLE

SHAFT
OD

MFD
ID

EFF.

HOLE

ID

2324505-29, -30, -39, -40


2324505-67,-68

20

0.3120

1 ~0.0100

0.3120

I f0.0100

5425013-4, -5

21

0.3120

0.3125

DESCRIPTION

ALLOWANCE
OD

WEAR
ID

ALLOWANCE
OD

Bracket-

Pulley- MS20220A1

I M.0100
+0.0005/

1.7500

IH).0050

-0.0000

Bracket- 2324505-6

20

0.3120

5425014-4, -5
MS20221A1

21

0.3120

0.3125

39

Bolt- AN5-17

40

0.3090

1 +0.00301
-0.0000

411 Pulley-

I f0.0100
I f0.0100
+0.0000/

2.6250

f0.0050

-0.0005
42

Bolt- AN5H16A

43

Bracket- 2324505-23

20

0.3090

1 +0.0030/
-0.0000

5425010-1
44

Pulley-

MS20221A1

21

20

+0.0000/

2.6250

0.3125

~0.0050

-0.0005
45

Bolt- AN5-12

46

Bracket-

20

0.3090

1 +0.0030/

-0.0000

Upper LH
Q

20

2315159-1,-5, -6

0.3120

1 +0.0060/

-0.0010

Lower LH
20

2315159-2, -3

0.3120

0.3125

1 +0.0060/
-0.0010

47

Pulley- MS20221-1
(Alt. MS20221A1)

20

48

Bolt- AN5-12

20

49

Bracket- 2315157-1, -2,

20

50

Bearing- AN201 KP-5-A


Upper- MS27642-16

2.6250

+0.0000/

1
0.3090

lt0.0050

-0.0005

1 +0.0030/
-0.0000

-3, -4

Lower- MS27648-16

511 Spacer-23151256
5415136-19

20

21

AM

0.3120

1 +0.0060/

1.0000

1.7500

-0.0010

+0.0000/

+0.0000/

-0.0005

-0.0010
+0.0000

AM

1.0000

1.9375

+0.0000

-0.0010

-0.0010

20

0.3350

0.4380

M.01 50

M.01 00

21

AM

1.000

21

1 +0.0100/
-0.0000

Aileron

EFFECTIVITY:

ALL

System Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 15 of 28)
51-n-o4

Page
SRM-4

15

Jun 6/98

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

MFD

MFD

HOLE

SHAFT

MFD

ALLOWANCE

ITEM I
NO.

DESCRIPTION

EFF.

HOLE

52

Bolt- AN5H22A

20

53

Sector- 2315125-6

22

0.8118

3.8800

+0.0000/

23

0.8118

3.8800

+0.0000/

ID

OD

0.3090

ID

OD

WEAR
ID

ALLOWANCE
OD

1 +0.00301
-0.0000

~0.0030

-0.0005
2315124V1-2

f0.0030

-0.0005
2315125-7

24

0.8118

3.8800

+0.00001

M.0030

-0.0005
5415125-3

25

AM

1.0060

3115102-1

26

AM

1.9000

1 +0.0000/
-0.0010

54

Bracket- 2315158-1, -5, -9

20

0.3120

55

Pulley- M520221A1

20

0.3125

1 +0.00601
-0.0010

2.6250

+0.00001

f0.0050

-0.0005
56

Bolt- AN5-12

20

57

Bracket- 2315159-1, -2, -3,

20

58

Pulley- MS20221-1
(Alt. MS20221A1)

0.3090

1 +0.0030/
-0.0000

-5, -6

0.3120

I
20

0.3125

1 +0.00601

59

Bolt- AN5-12

20

60

Bracket- 2315157-3, -4

20

0.3120

Pulley-MS20219A1

20

0.2500

-0.0010
2.6250

+0.00001

1
0.3090

~0.0050

-0.0005

1 +0.0030/
-0.0000

1 +0.0060/

-0.0010
61

1.3120

+0.0000/

f0.0050

-0.0005
V

62

Bolt- AN4-10, -13

20

63

Bracket- 2315128-4, -5
Pulley- MS20219A1

20

0.2500

20

0.2500

0.2460

1 +0.0030/
-0.0000

64

I f0.0100
1.3120

+0.0000/

f0.0050

-0.0005

651

Bolt-ANC10

20

WI

66

Bracket- 23151288

20

0.2500

1 ~0.0100

67

Pulley-

28

0.3125

1 +0.0000/

29

0.3125

1 +0.0000/

0.2460

1 +0.0030/
-0.0000

MS20220-2

-0.0005

2615177-1

-0.0005
68

Bolt- AN5-24, -25

0.3090

1 +0.0030/
-0.0000

Aileron

ALL

System Fittings
Figure

Allowable Wear and


1

Repair Data

(Sheet 16 of 28)

51-71-04

Page
SRM-4

16

Jun 6/98

Learjet
~Learjetl
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM

NO.I
691

I
DESCRIPTION

71

72

MFD

MFD

HOLE

SHAFT
OD

EFF.

HOLE

ID

0.3125

MFD

ALLOWANCE

ID

OD

WEAR
ID

ALLOWANCE
OD

Bracket-

2315120-11, -12, -33, -34,


-37, -39, -40, 111
70

Pulley
Pulley
Pulley- MS20219A1

I
1

1 +0.001 01

-0.0000

+0.0000/

1.3120

0.2500

f0.0050

-0.0005
73

Spacer- NAS43DD4-20

+0.0210/

0.3750

0.2760

M.0100

-0.0200
74

Bolt- AN4-13

75

Bracket- 261 5105-7, -8,

0.2460

1 +0.0030/

27

0.2500

I M.0100

47

0.2500

0.3125

1
1

I f0.0100
I M.0005

-0.0000

-14, -15, -16, -17, -18


261 51 05L96-1, -2
76

1 Pulley-MS20220-2

(Alt. MS20220A2)
77

Bolt- AN5-12

78

Bracket- 2315120-7, -8
Yoke Assembly

0.3125

1
1

0.3090

I f0.0005
1
1 +0.0030/
-0.0000

79

AA

39

2415152-1

(Alt. 2415152-3, -5)

0.3120

0.4393

1 +0.0005/

M.010

-0.0007

AB

0.4393

1 +0.0005/

AC

0.4995

1 +0.0010

-0.0007

-0.0000
AD
AE

AF

0.5000

I ~t0.0100

AG

0.3773

I rt0.0005

AK

0.8760

1 +0.0015/

AL

1.1880

1 +0.00201

AH
AJ
-0.0000
-0.0000

Aileron System

EFFECTIVITY:

ALL

Fittings Allowable Wear and Repair


Figure 1 (Sheet 17 of 28)

Data

51-71-04

Page
SRM-P

17

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

NO.I

MFD

MFD

HOLE

SHAFT

IIIFD

ALLOWANCE

DESCRIPTION

EFF.

HOLE

ID

2615270-1

40

AA

0.4393

1 +0.0005!

AB

0.4393

1 +0.00051

AC

0.4995

1 +0.0010

OD

ID

OD

WEAR
ID

ALLOWANCE
OD

-0.0007

-0.0007
-0.0000
AD

AE
AF

0.5000

I f0.0100

AG

0.3773

I M.0005

AK

0.8760

1 +0.0015/

AL

1.1880

1 +0.0020/

AC

0.5000

AH

AJ
-0.0000

-0.0000
80

Bearing-MS27641KP8A
(Alt. AN201KP8A)

81

Pin-2315152-33

82
83

1.1250

+0.0000/

+0.0000/

-0.0005

-0.0005

AC

Bearing- MS20200KP4

33

AG

0.2500

0.9014

+0.0000/
-0.0005

-0.0005

1 Bushing-NAS75-4-015

33

AG

0.2500

0.3761

+0.0015/

+0.0005/

33

AG

AK

(Alt.

231

5152-9)

0.4986

1 +0.0005/

-0.0000
84

Bolt- MS20004H15

85

Bearing- MS27641 KPGA

86

(Alt. AN201 KPGA)


Bearing- B-539-ZZ
(Alt. B-539-DD)

87

Shaft- 2315153-28

0.2477

-0.0000

+0.0000/

-0.0000

1 +0.0015/
-0.0000

0.3750

AL

0.7500

I
30

0.8750

+0.0000/

1
1.1850

+0.0000/

-0.0005

-0.0005

+0.0007/

+0.0000!

AK

0.3740

1 +0.0003/

AL

0.7490

1 +0.0000/

AK

0.3740

1 +0.0003/

-0.0007

-0.0010
-0.0002
-0.0010

2615153-5

31

(Alt. 2315153-49)

AL

I
I

0.7490

1 +0.0000/

AK

0.3739

1 +0.0003/

-0.0002

-0.0010
231 5271-1

32

-0.0002

AL

0.7485

1 +0.0005/
-0.0005

Aileron

EFFECTIVITY:

ALL

System Fittings
Figure

Allowable Wear and


1

Repair Data

(Sheet 18 of 28)

51-71-04

Page
SRM-4

18

Jun 6/98

Learjet
~earptl
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM

NO.
88
89

90

DESCRIPTION

Pulley- 2315152-21
Bushing- NAS75-5-010

EFF.

HOLE

AA

44

AA

MFD

MFD

HOLE

SHAFT

ID

OD

1.7550

MFD
ID

-0.0005
+0.00001

45

AA

0.3125

0.4386

+0.0015/
-0.0000

-0.0005

NAS75-5-114

46

AA

0.3125

0.4386

+0.00151

+0.0000/

-0.0000

-0.0005

45

AA

0.3125

0.4386

+0.0015/

+0.0000/

-0.0000

-0.0005

46

AA

0.3125

0.4386

+0.0015/

+0.00001

43

AA

0.3120

1 +0.0000/

NAS464P5-15

44

AA

0.3117

1 +0.0000/

NAS464P5-38

45

AA

0.3117

1 +0.0000/

NAS464P5-41

46

AA

0.3117

1 +0.00001

AB

1.7550

I f0.0100

45

AB

1 Bushing-NAS75-5-016

-0.0000
Bolt- NAS1305-15D

ID

ALLOWANCE
OD

+0.0000/

-0.0000
NAS75-5-1 09

NAS77-5-34
91

OD

WEAR

I M.0100
+0.00151

0.4386

0.31 25

ALLOWANCE

-0.0005
-0.0010
-0.0009
-0.0009
-0.0009

92
93

Pulley- 231 5152-21


Bushing- NAS75-5-014

-0.0005

+0.0000/

AB

0.3125

0.4386

+0.0015/
-0.0000

-0.0005

45

AB

0.3125

0.4386

+0.0015/

+0.00001

-0.0000

-0.0005

46

AB

0.3125

0.4386

+0.0015/

+0.0000/

44

AB

0.3120

1 +0.0000/

NAS464P5-22

45

AB

0.3117

1 +0.0000/

NAS464P5-23

46

AB

0.3117

1 +0.00001

34

1.9050

1 +0.00001

Bushing-

NAS77-5-007

NAS77-5-013

-0.0000
95

+0.0000/

-0.0000
46

NAS77-5-24
94

+0.0015/

0.4386

0.3125

Bolt- NAS1305-15D

-0.0005

-0.001 0/
-0.0009
-0.0009

96

Torque Tube

97

Block

2315151-2

-0.0020

Assy., Bearing

2315151-6

34

2.6250

34

K,L

2.0610

1 +0.0010/

-0.0000
98

Bearing- 8-545-ZZ
(Alt. 85-545-DD)

Aileron

EFFECTIV~Y:

ALL

2.6250

+0.0005/

-0.0010

-0.0005

-0.0000

System Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 19 of 28)
51-71-04

Page
SRM-4

19

Jun 6/98

Learjet i
Leariet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

NO.
99

MFD

MFD

MFD
HOLE

ALLOWANCE

ID

EFF.

HOLE

ID

35

1.9050

1 +0.00001

23151 54-1

36

1.9050

1 +0.00001

231 521 6-1

37

1.9050

1 +0.00001

38

2.2500

DESCRIPTION
Bellcrank- 2315151-4, -7

WEAR

ALLOWANCE

I SHAFT
OD

OD

ID

OD

-0.0020
-0.0020
-0.0020
100

Bearing-

LS4

Aileron

EFFECTIVITY:

ALL

0.7500

System Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 20 of 28)
51-71-04

Page 20
SRM-C

Tun 6/98

Learjet
~jLeariet/

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM
EFF.

DESCRIPTION

NO.
Inboard

Bearing-

BP-4

Replace worn part.


primer or secure with
Replace worn part.
primer or secure with
Replace worn part.
primer or secure with
Replace worn part.
Replace worn part.
Replace worn part.
Replacewompart.

A
A

I
I

bearing

in wet

Stake

new

bearing

in wet

Loctite. Refer to 51-70-00.

Stake

new

bearing

in wet

Loctite. Refer to 51-70-00.

Bearing-MS27645-4

AN4H13A

Replace worn part. Stake new bearing in wet


primer or secure with Loctite. Refer to 51-70-00.
Replace worn part.
Replace worn part. Drill holes in line in angle and
plate prior to final attachment to allow installation
of stud (8).
Replacewompart.

Replacewompart.

Bearing-MS27645-4

Bolt- AN4HIIA

Replace worn part. Stake new bearing in wet


primer or secure with Loctite. Refer to 51-70-00.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part. Secure with Loctite. Refer to
51-70-00. Bearing outer race must project equally

HingeBracket-

Bolt

Angle and Plate 2322530-29, -30,


-31, -32
Stud- 2322530-33, -53
Hinge Bracket

Outboard

2322530-41, -42, -63, -64, -75, -76,


-79,-80
10
11

new

Loctite. Refer to 51-70-00.

2322530-19, -20, -27, -28, -51, -52,


-89,-90

Stake

Middle

Replacewornpat.

AN4H11A

AN4H12A

Bolt

MS27645-4

KSP-4

REPAIR

Hinge Bracket

2322530-3, -39, -40, -55, -56, -60,


-67,-68,-81,-82
2

HOLE I

AN4H12A

Horn

12

2324011-28

2324011-235

Bearing

13

-ABT4-105

from both sides of horn.


14

Bolt-AN4-7
NAS464P4-8

15

Clevis Rod End

2433003-2

2333001-7
16

1 Bearing

Rod End

HFV-4

F
F

Aileron

ALL

(Alt. TR-4)
(Alt. REF-4)

EFFECTIVITY:

9
10

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.
part.
part.
part.

System Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 21 of 28)
51-71-04

Page 21
SRM-I

Tun 6/98

Learjet
~Learjet/

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

EFF.

DESCRIPTION

NO.
Bolt

17

11

2380027-10

Actuator Arm

18

AN4-11

Actuator

17A

12

2333008-3

13

2333008-6
19

2324511-5

15

NAS464P3-33
NAS1 304-34H
NAS1104-380

14

Bolt

20

21

14

Yoke -232451&1

Bearing-

15
15

MS27644-4

REPAIR

HOLE

Replace worn part.


Replace worn part.
F
Replace worn part.
F
Replace worn part.
G, H
Replace worn part.
G, H
Replace worn part.
G
Replace worn part.
G(Replacewompart.
G
Replace worn part.
G
Replace worn part.
F
F

NAS75-4-009

22

Bushing

23

NAS75-4-008
Bearing BP-4

51-70-00.

Bolt- NAS464P4-12
Aileron Drive Clevis

25

2324512-3, -5
2324517-1,3

16
17

H, J
H, J

J, K

H
H

Bearing- AN201KP8A

27
28

Pulley Shaft 2324513-3,


Pulley 2324513-9, -10

29

2324513-15, -16
Arm Link 2324011-111, -223

30

Bolt

AN4-7

18

19

31

NAS464P4-8
Bearing Rod End

HFV-4

32

(Alt. TR-4)
(Alt. REF-4T)
(Alt. HFR-4M)
Pulley MS24566-3B

33

Bolt

34

Bracket

H,
H,
H,
H,

C
C
C
C

20

AN4H1OA

20

35

Pulley

36

Bolt

2424034-1

MS20220A1

ANSH1GA

Aileron

EFFECTIVITY:

-13

26

ALL

Replaceworn parts. Pressfitnewbushings in


primer.
Replaceworn part. Securewith Loctite. Referto

wet

(Alt. MS27645-4)
(Alt. KSP4)
24

Secure with Loctite. Refer to

51-70-00.

(Alt. DDP4)
(Alt. BP-4)
(Alt. BR4)

20

Replacewompart.
Replace worn part.
Replace worn part.
Replace worn part. Stake new bearing in wet
primer or secure with Loctite. Refer to 51-70-00.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.

System Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 22 of 28)
51-71-04

Page 22
SRM-I

Jun 6/98

Learjet
Learjet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

37

EFF.

DESCRIPTION

NO.

Bracket- 2324505-29, -30, -39, -40,

REPAIR

HOLE

20

M/Replacewompart.

21

-67, -68
5425013-4, 6
38

Pulley MS20220A1

39

Bolt

40

Bracket

AN5-17
2324505-6

5425014-4, -5
41

1 Pulley

42

Bolt

43

-MS20221A1

ANSH1GA
2324505-23

Bracket

5425010-1

20

21

20

21

44

Pulley MS20221A1

20

45

Bolt

AN5-12

20

Q
Q

46

Bracket20

20

Upper LH 2315159-1, -5,


Lower LH

-6

2315159-2, -3

47

Pulley MS20221-1
(Alt. MS20221A1)

20

48

Bolt

20

49

Bracket

20

50

Bearing- AN201KP-5-A

20

AN512

2315157-1, -2, -3, -4

20

20

22

2315124V1-2

23

2315125-7

24

20

51

Spacer 2315125-5

52

Bolt

53

Sector

AN5H22A
2315125-6

2315158-1, -5, -9

54

Bracket

55

Pulley MS20221A1

20

56

Belt

20

57

Bracket

20

58

Pulley MS20221-1
(Alt. MS20221A1)

20

59

Bolt

AN5-12

20

60

Bracket

61

Pulley MS20219A1

62

Bolt

63

Bracket

AN5-12

2315159-1, -2, -3, -5, -6

2315157-3,

U
-4

AN4-10, -13
2315128-4, -5

64

Pulley

65

Bolt

66

Bracket

MS20219A1

AN4-10

2315128-9

Aileron

EFFECTIVITY:

ALL

20

20

20

20

20

20

20

System Fittings
Figure

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
primer or secure with
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.

Allowable Wear and


1

Repair

Stake

new

bearing in

wet

Loctite. Refer to 51-70-00.

Data

(Sheet 23 of 28)

51-71-04

Page 23
SRM-4

Jun 6/98

Leariet
~gLearjetl

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

NO.
67

DESCRIPTION

1 Pulley

MS20220-2

2615177-1

EFF.

HOLE

28

29

68

Bolt

69

Bracket

70

73

Pulley
Pulley
Pulley MS20219A1
Spacer- NAS43DD4-20

74

Bolt

75

Bracket

71
72

AN5-24, -25
231512~11,-12, -33, -34,
-37, -39, -40, -41

AN4-13

2615105-7, -8, -14, -15,


-16,-17,-18
2615105L96-1,-2

76

1 Pulley

77

Bolt

78

Bracket 2315120-7, -8
Yoke Assembly 2415152-1

MS20220-2

REPAIR

Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.

worn

worn

part.
part.
part.
part.

Replace
Replace
Replace

27

Replace

47

Replace worn part.


Replace worn part.

worn

worn

(Alt. MS20220A2)
AN512

39

AA,AB
AC, AD
AE, AF
AG,AH
AJ, AK

40

AA,AB
AC,AD
AE, AF
AG,AH
AJ, AK

AC

231515233

AC

82

(AR.23151528)
1 Bearing-MS202000KP4

33

83

1 Bushing

79

(Alt. 2415152-3, -5)

Replace worn part.


Replace worn part.
Replaceworn part.

AL

2615270-1

Replaceworn part.

AL
80

1 Bearing

MS27641 KPBA

AN201 KP8A
81

Pin

NAS75-4-015

AG

33

AG

33

AG

AK

AL

Replace worn part. Stake new bearing in wet


primer or secure with Loctite. Refer to 51-70-00.
Replace worn part.

Replace worn part. Stake new bearing in wet


primer or secure with Loctite. Refer to 51-70-00.
Replace worn part. Install bushing with wet primer on

84

Bolt

MS20004H15

85

Bearing

MS27641 KPGA

AN201 KPGA
86

1 Bearing

51-70-00.

B-539-ZZ

(Alt. B-539-DD)

EFFECTIVITY:
SRM-4

ALL

Replace worn part. Secure with

Loctite. Refer to

51-70-00.

Aileron

exterior surface.

Replace worn part.


Replace worn part. Secure with Loctite. Refer to

System Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 24 of 28)
51-71-04

Page 24
Jun 6/98

Learjet
Lsarjet
STRUCTURAL REPAIR MANUAL
REPAIR DATA

ITEM

DESCRIPTION

NO.

87

Shaft- 2315153-28
2615153-5

REPAIR

EFF.

HOLE

30
31

AK,AL
AK,AL

Replaceworn part.
Replaceworn part.

32

AK, AL

AA

44

AA

Replaceworn part.
Replace worn part.
Replace worn part.

(Alt. 2315153-49)
2315271-1
88
89

Pulley 2315152-21
Bushing- NAS75-5-010

er on

45

NAS75-5-109

AA

Replace
er on

46

NAS755-114

AA

bushing with

wet

prim-

part. Install bushing with

wet

prim-

wet

prim-

bushing with

wet

prim-

part. Install bushing with

wet

prim-

with wet

prim-

Install

exterior surface.
worn

exterior surface.

Replace

worn

part. Install bushing with

exterior surface.
Replace worn part. Install

er on

90

45

NAS75-5-016

Bushing

AA

er on

46

NAS77-5-34

AA

Replace
er on

91

92

93

1 Bolt NAS1305-15D
NAS464P5-15
NAS464P5-38

43

AA

44

AA

45

AA

NAS464P5-41

46

AA

AB

45

AB

Pulley 2315152-21
Bushing- NAS75-5-014

46

AB

1 Bushing-

45

NAS77-5-007

AB

45

AB

95

44

AB

NAS464P5-22

45

AB

NAS464P5-23

46

AB

34

Bolt

NAS1305-15D

98

Torque Tube 2315151-2


Block Assy., Bearing 2315151-6
Bearing 8-545-22

99

Bellcrank

96
97

100

34

34

K, L

35

2315154-1

36

2315216-1

37

Bearing LS4

38

2315151-4, -7

Aileron

EFFECTIVITY:

ALL

part. Install bushing with

wet

prim-

worn

part. Install bushing with

wet

prim-

wet

prim-

exterior surface.

Replace
er on

worn

exterior surface.

Replace
er on

NAS77-5-013

exterior surface.

Replace
er on

94

worn

exterior surface.

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part. Install bushing
er on

NAS77-5-24

exterior surface.

worn

part. Install bushing with

exterior surface.

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.
part.
part.
part.
part.
part.
part.

System Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 25 of 28)
51-71-04

Page 25
SRM-4

Jun 6/98

Learjet I

STRUCTURAL REPAIR MANUAL


CODES

EFFECTIVITIES

23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 2&001 and Subsequent; 29001 and Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent

23-002 thru 23-099; 24-100 thru 24-302, 24-309 thru 24-314; 25-001 thru 25-186; 35-001 thru 35019; 36-001 thru 36-044

24-303 thru 24-308, 24-315 thru 24-357; 24-100 thru 24-302, 24-309 thru 24-314; 25-187 thru 25364; 28-001 and Subsequent; 29-001 and Subsequent; 31-014 and Subsequent; 35-020 thru 35-

504; 35-654 and Subsequent; 36-013 thru 36-053, 36-059 and Subsequent
25-365 and Subsequent; 31-001 thru 31-013; 35505 thru 35-653; 36-054 thru 36-058

28-001 and

23-001 thru 23-099; 24-100 and


001 and Subsequent

23-001 thru 23-034

Subsequent;

Subsequent; 31-001 and Subsequent


Subsequent; 25-001 and Subsequent; 35-001

29-001 and

Except 23-011, 23-012, 23-015, 23-019,

and

Except

23-031 and

Subsequent;

36-

Aircraft Modified

by

ECR 392
8

23-011,23-012, 23-015, 23-019, 23-031,23-035 and Subsequent and Prior Aircraft Modified by ECR
392

23-011,23-012, 23-015, 23-019, 23-031,23-035 and Subsequent and Prior Aircraft Modified by ECR
392; 24-100 thru 24-351; 25-001 thru 25-229; 35-001 thru 35-133; 36-001 thru 36-034

10

24-352 and

Subsequent;

25-230 and

31-001 and

Subsequent;

35-134 and

11

23-001 thru 23-034

12

23-035 thru 23-049

13

23-050 and

14

23-001

Subsequent;
Subsequent;

28-001 and

36-035 and

Subsequent;
Subsequent

29-001 and

Except 23-039, 23-043 and Except Aircraft Modified by ECR


Subsequent and Prior Aircraft Modified by ECR 392
thru 23-099; 24-100 and Subsequent; 25001 and Subsequent; 35-001

Subsequent;

392

thru 35465; 36-001

thru 36-050
15

28001 and
36-051 and

Subsequent;
Subsequent

29-001 and

16

23-001 thru 23-099; 24-100 and


thru 36-022

17

2&001 and

Subsequent;

Subsequent;

31-001 and

25001 and

Subsequent;

Subsequent;

35466 and

Subsequent;

35-001 thru 35092; 36-001

Subsequent; 29-001 and Subsequent; 31-001 and Subsequent; 35093 and Subsequent;
Subsequent
23-001 thru 23-049 Except 23-011, 23-012, 23-015, 23-019, 23-031 23-039, 23-043 and Except Aircraft Modified by ECR 392
23-011,23-012, 23-015, 23-019, 23-031,23-039, 23-043, 23-050 and Subsequent; 24-100 and Subsequent; 25-001 and Subsequent; 28-001 and Subsequent; 29-001 and Subsequent; 31-001 and
Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 28-001 and Subsequent; 29001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
31-001 and Subsequent
23-001 thru 23-099; 24-100 and Subsequent; 25-001 thru 25-364; 2&001 and Subsequent; 29-001
36-023 and

18
19

20
21
22

24

thru 29-003; 35-001 thru 35501


25-365 thru 25373; 29-004; 35-502 thru 35-505, 35-509 thru 35-531, 35-589 thru 35692
25-374 and Subsequent; 29-005; 35-506 thru 35-508, 35-532 thru 35-588, 35-593 and Subsequent;

25

31-001 and31-034

26

31-035 and

23

36-001 and

Subsequent
Subsequent

Aileron

EFFECTNITY:

ALL

System Fittings Allowable Wear and Repair


Figure 1 (Sheet 26 of 28)

Data

51-71-04

Page 26
SRM-4

Jun 6/98

Learjet
~rj

STRUCTURAL REPAIR MANUAL


CODES

27

EFFECTIVITIES

23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 28-001 and Subsequent; 29001 and Subsequent; 31-001 and Subsequent; 35-001 thru 35-370, 35-399 and Subsequent; 36-001

28

thru 36-040, 36-042 and Subsequent


23-001 thru 23-099; 24-100 and Subsequent; 25-001 and

29

28001 and

30

31

Subsequent
Subsequent; 29-001 and Subsequent; 31-001 and Subsequent; 35-001 and Subsequent;
36-001 and Subsequent
23-001 and Subsequent Except Aircraft Modified by SSK 947A, "Replacement of Control Column
Pulley and Shaft Assembly"; 24-100 and Subsequent Except Aircraft Modified by SSK 947A, "Replacement of Control Column Pulley and Shaft Assembly"; 25-001 thru 25-081 Except Aircraft Modified by SSK 947A, "Replacement of Control Column Pulley and Shaft Assembly"
23-001 and Subsequent When Modified by SSK 947A, "Replacement of Control Column Pulley and
Shaft Assembly"; 24-100 and Subsequent When Modified by SSK 947A, "Replacement of Control
Column Pulley and Shaft Assembly"; 25-001 thru 25-081 and Subsequent When Modified by SSK
947A, "Replacement of Control Column Pulley and Shaft Assembly"; 35-018 thru 35-487; 35-500,
35-502, 35-503, 35-505, 35509 thru 35567; 36-009 thru 36-060 and Prior Aircraft With 2315153-49
Shaft

Subsequent Except Aircraft Modified by SSK 947A, "Replacement of Control Column


Pulley and Shaft Assembly"; 24-100 and Subsequent Except Aircraft Modified by SSK 947A, "Replacement of Control Column Pulley and Shaft Assembly"; 25-001 thru 25-081 Except Aircraft Modified by SSK 947A, "Replacement of Control Column Pulley and Shaft Assembly"; 2&001 and Subse-

32

23-001 and

33

quent; 29-001 and Subsequent; 31-001 and Subsequent; 35488 thru 35-499, 35-501, 35-504, 35506 thru 35-508, 35568 and Subsequent; 36-061 and Subsequent
24-247 and Subsequent and Previous Aircraft Modified by AAK 76-04A, "Reduced Approach Speed

34

35
36
37

System"; 25-082 and Subsequent; 28-001 and Subsequent; 29-001 and Subsequent; 31-001 and
Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
23-001 thru 23099; 24-100 thru 24-246 Except When Modified by AAK 76-04A, "Reduced Approach
Speed System"; 25-001 thru 25-081 Except When Modified by AAK 76-04A, "Reduced Approach
Speed System"
23-001 and Subsequent
24-100 thru 24-152; 25-001 thru 25-016
23-011, 23-012, 23-015, 23-019, 23-031, 23-043, 23-050, 23-051, 23-060, 23-06;5, 23-087, 23-096;
24-153 and

Subsequent; 25017 and Subsequent


Subsequent Except 23-011, 23-012, 23-015, 23-019, 23-031, 23-043, 23-050, 23-051,

38

23-001 and

39

23-060, 23-065, 23-087, 23-096


23-00 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 28-001 and Subsequent; 29-

40

24-247 and

Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
Subsequent and Previous Aircraft Modified by AAK 76-04A, "Reduced Approach Speed
System"; 25082 thru 25360 and Previous Aircraft Modified by AAK 76-04A, "Reduced Approach
Speed System"; 2&001 thru 28005; 29-001 thru 29-003; 35-001 thru 35-487; 36-001 thru 36-050
001 and

41

23-001 thru 23-029

42

23-030 thru 23-099

43

23-001 and

44

23-001 thru 23-099; 24-100 thru 24-246; 25-001 thru 25-081


25-082 thru 25-360; 28-001 and Subsequent; 29-001 and Subsequent; 35-001 thru 35-487; 36-001
thru 36-050

45

Subsequent

Aileron

EFFECTIVITY:

AU

System Fittings Allowable Wear and Repair


Figure 1 (Sheet 27 of 28)

Data

51-71-04

Page 27
SRM-4

Jun 6/98

Leariet
Learjetl

STRUCTURAL REPAIR MANUAL


CODES

EFFECTIVITIES

25-361 and

46

Subsequent; 29-004;

31-001 and

Subsequent;

35488 and

Subsequent;

36-051 and

Subsequent
35-371 thru 35-398; 36-041

47

Only

NOTES:

Refer to Rudder

System for

Refer to Elevator

System

Part Number, Allowable Wear and

for Part

Aileron

I
(EFFECTIVITY:

ALL

Repair

Data.

Number, Allowable Wear and Repair Data.

System Fittings
Figure

Allowable Wear and


1

(Sheet

28 of

Repair Data

28)

51-71-04

Page 28
sRM-4

Jun 6/98

Learjet

STRUCTURAL REPAIR WIANUAL


TIP TANK FITTINGS

ALLOWABLE WEAR AND REPAIR DATA

,C

D
At

WS205.14

WS 157.48

,,12,.,

/i

S~;1
4

,ic

ii
A

C5

~21O

Detail A

si
B

Detail B
4~26C-1
4-34A

EFFECTIVITY:

Tip Tank Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 1 of 4)
23-001 THRU 23-099; 24-100 AND

SEQUENT;
SRM-I

35-001 AND

SUBSEQUENT; 25001 AND SUBSUBSEQUENT; 36-001 AND SUBSEQUENT

51-71-05

Page

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


TIP TANK FITTINGS

ALLOWABLE WEAR AND REPAIR DATA

c,

Detail C

Detail D
Tip Tank Fittings Allowable Wear and Repair Data
Figure 1 (Sheet 2 of 4)
EFFECTIVITY:
SRM-I

23-001 THRU 23-099; 24-100 AND SUBSEQUENT; 25001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

51-71-05

Page 2
jun 6/98

Learjet
~Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM

NO.
1
2

3
4

DESCRIPTION

Fitting- 2322372-1, -2, -7, -8

1 Bushing-NAS75-7-009
Bolt, Fwd-NAS464P7A21

1 Fitting-2322373-1,-2

MFD
SHAFT
OD

EFF.

HOLE

ID

0.5625

0.4375

0.5625
0.4375

Bushing- NAS75-7-009

Bolt, Aft-NAS464P7Ai4

MFD
HOLE

MFD

ALLOWANCE

ID

OD

WEAR
ID

ALLOWANCE
OD

+0.0000
-0.0010
0.5638

+0.0015/
-0.0000

+0.0000/
-0.0007

+0.0009/
-0.0000

0.4358

+0.0000/
-0.0010
0.5638

+0.0015/
-0.0000

0.4358

+0.0000/
-0.0007

+0.0009/
-0.0000

1 MountingAssembly2423160-3 thru 36

0.5631

+0.0000/

0.5631

+0.0000/
-0.0010

-0.0010
D

Bushing- NAS75-7-017

0.4375

0.5638

+0.0015/
-0.0000

+0.0000/
-0.0007

Bushing-

NAS75-7-017

0.4375

0.5638

+0.0015/
-0.0000

+0.0000/
-0.0007

Tip Tank Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 3 of 4)
EFFECTIVITY:

23-001 THRU 23-099; 24-100 AND SUBSEQUENT; 25-001 AND SUBAND SUBSEQUENT; 36-001 AND SUBSEQUENT

SEQUENT; 35001
SRM-I

51-71-05

Page 3
Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

NO.

DESCRIPTION

Fitting 2322372-1, -2, -7,


Bushing -NAS75-7-009

Bolt

Fitting 2322373-1, -2
Bushing -NAS75-7-009

EFF.
-8

NAS464P7A21

NAS464P7A14

Bolt

Mounting Assembly 2423160-35,


-36

HOLE

Replace

Replace worn part.


primer.
Replace worn part.
Replace worn part.
Replace worn part.

primer.
Replace

Bushing -NAS75-7-017

Bushing-

NAS75-7-017

CODES
1

REPAIR

worn

worn

EFFECTIVITY:

Install

new

bushing

in wet

Install

new

bushing

in wet

Install

new

bushing

in wet

Install

new

bushing

in wet

part.

Replace worn part.


Replace worn part.
Replace worn part.
primer.
Replace worn part.
primer.

EFFECTIVITIES
23-001 THRU 23-099; 24-100 AND SUBSEQUENT; 25-001 AND
35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

Tip Tank Fittings Allowable Wear and Repair


Figure 1 (Sheet 4 of 4)

I,

part.

SUBSEQUENT;

Data

23-001 THRU 23-099; 24-100 AND SUBSEQUENT; 25-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

51-71-05

Page 4
Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
LANDING GEAR FII~TINCS

ALLOWABLE WEAR AND REPAIR DATA

A,

.i-

"_I*rclWS 92.52
WS 0.001

(TYPICAL)

31

01

Main Gear Actuator

Detail A

426C-1

Detail B

Landing Gear Fittings Allowable Wear and Repair Data


Figure 1(Sheet 1 of 11)

A63C-1
B43ac

EFFECTIVI~Y:

ALL

n-71-os

PageZ
SRM-4

Jun 6/98

Learjet I

STRUCTURAL REPAIR MANUAL


LANDING GEAR FITTINGS

ALLOWABLE WEAR AND REPAIR DATA

(31-001 and Subseauent)


Shim

E
D

17

Shim

15

Detail C
20

qll
:f

Shim

;-I
I

QDetail D*s~

IQ
Main

Nose

Landing Gear

Landing Gear

Detail E
C63B

EFFECTIVITY:

Landing Gear Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 2 of 11)
ALL

51-71-06

Page2
SRM-I

Jun 6/98

~j Learjet
STRUCTURAL REPAIR MANUAL
LANDING GEAR FITTINGS

ALLOWABLE WEAR AND REPAIR DATA

23

22

Deta i I F
M

30

-i25

P
32

31

26

Detail G

31

Detail H

Landing Gear Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 3 of 11)

EFFECTIVITY:

ALL

51-71-06

Page 3
SRM-I

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

NO.

I
DESCRIPTION

MFD

MFD

HOLE

SHAFT
OD

MFD

EFF.

HOLE

ID

2.0079

1.0000

1.1000

f0.01 00

1.0000

1.1000

f0.0100

1.7550

2.0360

~0.0010

ALLOWANCE

ID

OD

WEAR
ID

ALLOWANCE
OD

Doubler-

2322203-9, -10, -13,

-14

1 +0.00121
-0.0000

Spacer-

2441001-1

2441 007-1

Bushing- 23221 87-1,

-2

+0.02001
-0.0000
+0.02001
-0.0000
+0.00081
-0.0000

PillarAssy. -2341123-1, -14,


1

-17, -18, -23

0.9990

1 +0.0000/

1 -0.0005

1.7450

1 +0.0000/

0.8000

I f0.0100

1
1

1 ~0.0100
I fO.Oi 00

I f0.0300
1 ~0.0300

-0.0100
5

1 SparNo.8
2322212-1, -2, -39, -40,
-43, -44,-49,-50,-58,-59,
-65, -66, -69, -70, -76, -77
122250016-273, -274

Bearing Plate

2322222-1
2441 007-2, -5, -6
Bearing Plate

2322221-1, -2, -3, -4, -5,


-6, -7
Support- 2322204-1, -2
5420000L-1 437-1, -2

0.8750

0.8750

C
C

1.0200
1.0200

0.6265

1.3130

1.3130

2822163-17

(LH Only)

1.3130

2822163-18

(RH Only)

10

1.3130

11

1.3130

1 +0.0015/
1 -0.0000
1 +0.0000/
-0.0010
1 +0.0000/
-0.0010
1 +0.0000/
-0.0010
1 +0.0000/
-0.0010

122250011V1-2

(RH Only)

1 +0.0000/
-0.0010

Landing Gear Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 4 of 11)

IEFFECTIVITY:

ALL

51-71-06

Page 4
SRM-I

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

EFF. I HOLE I
D

Bushing- 23221 97-1

9
10

I
DESCRIPTION

NO.

1 Bushing-232219&1

OD

ID

OD

ID

1.1240

1.3160

+0.00201
-0.0000
+0.0020/

+0.0000/

1.128

-0.0000

-0.0020

1.3160

1.1200

2322146-3, -4, -5, -6

12

1.9685

2322146-7, -8

13

1.9685

5420000\/5-1

14

1.9685

28221 59-21, -22

15

1.9685

E
E
E

12

1 Fitting,MainGearFwd-

Pin-2341110-1,-2,-003

WEAR

ID

ALLOWANCE

MFD
SHAFT

11

#FD

MFD
HOLE

1.1245

OD

-0.0020

+0.0000/

1 +0.0000 1
-0.0020

ALLOWANCE

1.128

1.121

1 +0.0002/
-0.0008
1 +0.0002/
-0.0008
1 +0.0002/
-0.0008
1 +0.0002/
-0.0008

13

1 Bearing.-BLS-32
I

(Alt. VTB08160)
(Alt. 16-577)
14

FwdTrunnionPin2341111-1

16

0.7500

1.2593

M.0002

+0.0002/

2341111-2

17

0.7500

1.2588

f0.0300

-0.0015
+0.0002/

6041113-001

0.6000

1.2588

0.8125

0.6090

0.81 45

1 ~0.0005
+0.0080/

-0.0015

15

1 BearingPlate

16

1 Bearing-2311580-5,

2311580-4, -9, -13, -15


-6

1 +0.0002/
-0.0015

-0.0010
17

Pin-23421081

0.6240

+0.0000/
-0.0010

1 +0.0000/
-0.0015

18

1 Bearing Plate-2311580-3,

19

1 Bearing-2311580-5, -6,

20
21

G
G

-12,-14

Pin-2342108-1

1 Fitting-2411243-1,3

-11

0.8125

0.6090

0.81 45

1
0.4375

0.6240

I f0.0005
+0.0080/ +0.0000/
-0.0010
-0.0010
1
1 +0.0000
-0.0015
I f0.0005

Landing Gear Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 5 of 11)
ALL

51-71-06

Page 5
SRM-4

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I
NO.

I
DESCRIPTION

22

I
EFF.

I
HOLE I

MFD

MFD

HOLE

SHAFT

ID

OD

MFD

ALLOWANCE

ID

OD

Bolt- NAS464P7L53

0.4367

1 +0.00001

NAS464P5LA7

16

0.4367

1 +0.00001

WEAR
ID

ALLOWANCE
OD

-0.0009

-0.0009
23

j Spacer-NAS43DD7-25

24

Nose Gear Actuator

25

Bracket- 234211 1 -1, -3

0.4900

0.5780

+0.0000/

+0.0000/

-0.0500

-0.0300

0.4367

1 +0.0000/

0.5620

1 +0.0010/

0.5000

1 +0.0010/

0.4375

-0.0009

-0.0000
-0.0000

Bushing-

26

NAS77A7-28

0.5638

+0.0015/

+0.0000/

-0.0000
27

Bolt- NAS464P7L20

28

Clevis- 2317103-1

18

0.4380

1 +0.0000/

19

0.4390

1 +0.0000/
-0.0010

0.4367

-0.0007

i +0.0000/

-0.0009
-0.0010
Clevis- 2417012-1
29

Bolt- NAS464P833

30

Actuator Attach Pin

0.4991

1 +0.0000/
-0.0009

2341109-2, -4, -5

20

0.6872

1 +0.0010/
-0.0000

(Shank Diameter)
5441101-2

I
21

I
N

1
0.6872

1.1220

+0.0000/
-0.0010

1
1

+0.0000/
-0.0010

i +0.0010/
-0.0000

31

(Shank Diameter)
(Finish 63 RMS)
ActuatorPinBushing2341112-1, -2

I
I
22

1
I
P

1.1250

1.1240

1.2520

1
I
+0.0015/

+0.0000/

-0.0000

-0.0000
+0.0000/

-4

23

1.1250

1.2520

+0.0015/

2341130-3, -4

24

1.1250

1.2520

-0.0000
+0.0015/
-0.0000

+0.0000/
-0.0010

20

0.5625

0.6892

+0.0015/

+0.0000/

5441101-3,

32

I
I

Bushing- 23411 09-3


5441101-3

21

0.5625

0.6892

-0.0010

-0.0000

-0.0010

+0.0015/
-0.0000

+0.0000/
-0.0010

Landing Gear Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 6 of 11)

JEFFECTIVITY:

ALL

51-71-06

Page 6
SRM-I

Jun 6/98

Leariet
Learjet I
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

DESCRIPTION

NO.
33

Bolt-NAS464P9-20

EFF.

HOLE

MFD

MFD

HOLE

SHAFT

ID

OD

0.5616

MFD

ALLOWANCE

ID

OD

WEAR
ID

ALLOWANCE
OD

1 +0.00001

-0.0009
34

Cylinder Assy.
2341101-1,-2

25

1.2500

1 +0.0010/

2441 011-1,-2

26

1.2500

1 +0.00101

-0.0000
-0.0000

2341100-2045-1L, -1 R,
-2R, -3L, -4L, -5L,
-6L, -7L, -8L, -9R, -10R

27

1.2500

1 +0.00101
-0.0000

2441011-13, -14, -37,


-38, -39, -40

28

1.2500

1 +0.001 01
-0.0000

Landing Gear Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 7 of 11)
EFFECTNITY:

ALL

51-71-06

Page 7
SRM-I

Jun 6/98

Learpt
IL~jtl

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

NO.

DESCRIPTION

EFF.

Doubler

Spacer

3
4

Bushing 2322187-1, -2
Pillar Assy. 2341123-1, -14, -17,

Spar No. 8 2322212-1, -2, -39, -40,

2322203-9, -10, -13, -14


2441001-1

2441007-1

HOLE

REPAIR

3
1

A, B,C

I Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replacewompart.

-18, -23
-43, -44, -49, -50, -58, -59,
-65, -66, -69, -70, -76, -77
12225-0016-273, -274

2441007-2,-5
Plate- 2322221-1, -2, -3,
-4, -5, -6, -7
Support 2322204-1, -2

C
D

9
10

5420000L1437-1, -2
2822163-17 (LH Onlyj
2822163-18 (RH Only)
122250011V1-2 (RH Only)
Bushing 2322197-1

Bearing

1 Bearing

Plate

2322222-1

D
D
D

232219&1

2341110-1,-2, -003

12

15

E
E
E
E

10

Bushing

11

Pin

12

Fitting, Main Gear

11

13

5420000\/5-1
13

1 Bearing

14
-22

BLS-32

(Alt. VTB08160)
(Alt. 16-577)
14

1 Pin

2341111-1

2341111-2
6041113-001

16

17

E
E

ream on
ream on

installation.
installation.

Repair or replace worn part.


Repair or replace worn part.
Repair or replace worn part.
Repair or replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.

Plate-

15

Bearing

16

2311580-4, -9, -13, -15


Bearing 2311580-5, -6

17

Pin

18

Bearing Plate 2311580-3, -12,


Bearing 2311580-5, -6, -11

19

part.
part.
part.
part.
part.
part.
part. Line
part. Line
part.

Fwd

2322146-3, -4, -5, -6


2322146-7, -8

2822159-21,

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

2342108-1

F
F

20

Pin

21

Fitting 2411243-1,

22

Bolt NAS464P7L53
NAS464P5LA7

2324108-1

-14

1
1

G
G
H

16

-3

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.

Landing Gear Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 8 of 11)

(EFFECTIVITY:

ALL

51-71-06

Page 8
SRM-I

Jun 6/98

Leariet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM
HOLE

EFF.

NO.

DESCRIPTION

23
24

Spacer NAS43DD7-25

Nose Gear Actuator


Bracket 2342111-1
Bushing NAS77A-7-28
Bolt NAS464P7L20
Clevis 2317103-1
2417012-1
Bolt NAS464P&33
Actuator Attach Pin
2341109-2, -4, -5

25

26
27
28

29
30

5441101-2
31

Actuator Pin

K, L

18

19

20

21

22

23

REPAIR

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.

Replace worn part.


Replace worn part.

Bushing

2341112-1, -2
5441101-3, -4
2341130-3, -4

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.

24

20

21

25

2441011-1, -2

26

2341100-2045-1 L, -1 R, -2R, -3L,


-4L, -5L, -6L, -7L, -8L, -9R, -fOR

27

Replace worn part.


Replace worn part.
Replace worn part.

2441011-13, -14, -37, -38, -39, -401

28

Replace worn part.

32

Bushing 23411093

33

Bolt

34

Cylinder Assy. 2341101-1,

5441101-3

NAS464P9-20
-2

Landing Gear Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 9 of 11)
EFFECT(V~DI:

ALL

51-71-06

Page9
SRM-4

Jun 6/98

Learpt

STRUCTURAL REPAIR MANUAL


CODES

EFFECTIVITIES

23-001 thru 23-099; 24-100 and Subsequent; 25001 and Subsequent; 28-001 and Subsequent; 29-001
and Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent

23-003 and

5
6

8
9
10
11
12

13

14

15
16

17

18
19
20

Subsequent Except Aircraft Modified by AMK 71-03A, "Main Landing Gear Actuator Bearing
Retainer Kit"; 24-100 thru 24-229 Except Aircraft Modified by AMK 71-03A, "Main Landing Gear Actuator Bearing Retainer Kit"; 25-001 thru 25-069 Except Aircraft Modified by AMK 71-03A, "Main Landing
Gear Actuator Bearing Retainer Kit"
23-003 thru 23-099 When Modified by AMK 71-03A, "Main Landing Gear Actuator Bearing Retainer Kit";
24-230 and Subsequent and Prior Aircraft Modified by AMK 71-03A, "Main Landing Gear Actuator Bearing Retainer Kit"; 25-070 and Subsequent and Prior Aircraft Modified by AMK 71-03A, "Main Landing
Gear Actuator Bearing Retainer Kit"; 2&001 and Subsequent; 29-001 and Subsequent; 31-001 and
Subsequent; 35001 and Subsequent; 36-001 and Subsequent
23-001 thru 23-099; 24-100 and Subsequent; 25001 and Subsequent; 2&001 and Subsequent; 29-001
and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
31-001 and Subsequent
23-001 thru 23-099 When Modified by AMK 71-03A, "Main Landing Gear Actuator Bearing Retainer Kit";
24-230 and Subsequent and Previous Aircraft Modified by AMK 71-03A, "Main Landing Gear Actuator
Bearing Retainer Kit"; 25-070 and Subsequent and Previous Aircraft Modified by AMK 71-03A, "Main
Landing Gear Actuator Bearing Retainer Kit"; 2&001 and Subsequent; 29-001 and Subsequent; 35-001
and Subsequent; 36-001 and Subsequent
23-001 thru 23-099; 24-100 and Subsequent; 25001 and

Subsequent; 35-001 and Subsequent; 36-001


and Subsequent
2&001 and Subsequent; 24001 and Subsequent; 31-001 thru 31-014
31-015 and Subsequent
31-015 thru 31-042; 31-058 and Subsequent
31-043thru31-057
23-001 thru 23-099 When Used With 2322146-1, -2 Fwd Main Gear Fittings; 24-100 and Subsequent
When Used With 2322146-1, -2 Fwd Main Gear Fittings; 25-001 and Subsequent When Used With
2322146-1,-2 Fwd Main Gear Fittings; 35-001 thru 35-549; 36-001 thru 36-053
23-001 thru 23-099 When Used With 2322146-4, -5 or -6 Fwd Main Gear Fittings; 24-100 and Subsequent When Used With 2322146-4, -5 or -6 Fwd Main Gear Fittings; 25-001 and Subsequent When
Used With 2322146-4, -5 or -6 Fwd Main Gear Fittings; 2&001 and Subsequent; 29-001 and Subsequent; 35650 and Subsequent; 36-054 and Subsequent
31-012 Only
31-001 and Subsequent Except 31-012
23-001 thru 23-099 When Used With 2322146-1, -2 Fwd Main Gear Fittings; 24-100 and Subsequent
When Used With 2322146-1, -2 Fwd Main Gear Fittings; 25-001 and Subsequent When Used With
2322146-1,-2 Fwd Main Gear Fmings
23-001 thru 23-099 When Used With 2322146-4, -5 or -6 Fwd Main Gear Fittings; 24-100 and Subsequent When Used With 2322146-4, -5 or -6 Fwd Main Gear Fittings; 25-001 and Subsequent When
Used With 2322146-4, -5 or -6 Fwd Main Gear Fittings; 2&001 and Subsequent; 29-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
23-00 thru 23-099; 24-100 thru 26357; 25011 thru 25-277; 2&001 thru 2&005; 29-001 thru 29-002;
35001 thru 35-249; 36-001 thru 36-044
24-358 and Subsequent; 25278 and Subsequent, 28006 and Subsequent; 29-003 and Subsequent;
31-001 and Subsequent; 35-250 and Subsequent; 36-045 and Subsequent
23-001 thru 23-099 Except When Modified by SSK 973 "Replacement of Main Landing Gear Bushing
and Pin"; 24-100 and Subsequent Except When Modified by SSK 973 "Replacement of Main Landing
Gear Bushing and Pin"; 25-001 and Subsequent Except When Modified by SSK 973 "Replacement of
Main Landing Gear Bushing and Pin"; 28-001 and Subsequent Except When Modified by SSK 973 "Re~
placement of Main Landing Gear Bushing and Pin"; 29-001 and Subsequent; 35~X)1 thru 35-611; 36001 thru 36055

Except 36-054

Landing Gear Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 10 of 11)

(EFFECTIVITY:

ALL

51-71-06

Page 10
SRM-4

Jun 6/98

Learjet
Leariet I

STRUCTURAL REPAIR MANUAL


EFFECTIVITIES

CODES

by SSK 973 "Replacement of Main Landing Gear Bushing and Pin";


Subsequent When Modified by SSK 973 "Replacement of Main Landing Gear Bushing and
Pin"; 25-001 and Subsequent When Modified by SSK 973 "Replacement of Main Landing Gear Bushing
and Pin"; 2&001 and Subsequent When Modified by SSK 973 "Replacement of Main Landing Gear
Bushing and Pin"; 31-001 and Subsequent; 35-612 and Subsequent; 36-054, 36-056 and Subsequent
23-001 thru 23-099 Except When Modified by SSK 973 "Replacement of Main Landing Gear Bushing
and Pin"; 24-100 and Subsequent Except When Modified by SSK 973 "Replacement of Main Landing
Gear Bushing and Pin"; 25-001 and Subsequent Except When Modified by SSK 973 "Replacement of
Main Landing Gear Bushing and Pin"; 2&001 and Subsequent Except When Modified by SSK 973 "Replacement of Main Landing Gear Bushing and Pin"; 31-001 thru 31-055; 35-001 thru 35-672; 36-001
23-001 thru 23-099 When Modified

21

24-100 and

22

thru 36-063

31-056 and Subsequent Except When Modified by SSK 973 "Replacement of Main Landing Gear Bushing and Pin"; 35-672 and Subsequent Except When Modified by SSK 973 "Replacement of Main Landing Gear Bushing and Pin"; 36-063 and Subsequent Except When Modified by SSK 973 "Replacement
of Main Landing Gear Bushing and Pin"
23-001 thru 23-099 When Modified by SSK 973 "Replacement of Main Landing Gear Bushing and Pin";
24-100 and Subsequent When Modified by SSK 973 "Replacement of Main Landing Gear Bushing and
Pin"; 25-001 and Subsequent When Modified by SSK 973 "Replacement of Main Landing Gear Bushing
and Pin"; 2&001 and Subsequent When Modified by SSK 973 "Replacement of Main Landing Gear
Bushing and Pin"; 31-001 and Subsequent When Modified by SSK 973 "Replacement of Main Landing
Gear Bushing and Pin"; 35001 and Subsequent When Modified by SSK 973 "Replacement of Main
Landing Gear Bushing and Pin"; 36-001 and Subsequent When Modified by SSK 973 "Replacement of

23

24

Main Landing Gear Bushing and Pin"


23-001 thru 23-099; 24-100 thru 24329; 25-001 thru 25205; 35-001 thru 35-066; 36-001 thru 36-017
24-330 and Subsequent; 25206 and Subsequent; 35067 thru 35-135; 36-018 thru 36-034

25
26

35136 thru 35250; 36-035 thru 36-044


28001 and Subsequent; 29-001 and Subsequent; 31-001 and

27

28

38045 and

Subsequent;

35-251 and

Subsequent;

Subsequent

NOTES:

Install

new

bushing

with wet

primer.

Seal

edges carefully.

primer.

Seal

edge carefully.

Line

ream

bushing

to 1.1265

(+0.00051-0.0000) inch af-

ter installation.

Install

new

bushing with

wet

bearing with light coating of corrosion preventative per MIL-C-16173, Grade


race is facing aft and is horizontal within ~15".
assembly
Install

new

1. Install

bearing

so

that

slot in outer

Align

oil hole in

Install

new

bearing outer

bushing

race

with

fitting

on

forward

edge of bearing plate.


bushings to

0.437

Landing Gear Fittings Allowable Wear and Repair


Figure 1(Sheet 11 of 11)

Data

with wet

primer.

Seal

edges carefully. Line

ream

(+0.001/-0.000) inch after

installation.

EFFECTIVITY:

ALL

51-71-061
Page 11

SRM-4

Jun 6/98

Learjet
~Learjet(
STRUCTURAL REPAIR MANUAL
LANDING GEAR FITTINGS

1.

General
A.

B.

C.

responsibility of the aircraft owner/maintenance facility to determine qualifications of maintenance personnel performing repair procedures. As always, a clean environment and good general
shop practices shall be exercised any time repairs are performed on the aircraft.
Prior to, and after performing, any repairs on the Landing Gear Fittings, ensure serviceability and reliability of part. If serviceability and reliability of any part or repair remains in question or if guidance
is needed in making this determination, contact Learjet Field Service for additional information.
Repairs must be equal to, or greater in strength, than the original structure. Technique and material
variation is permissible only so far as to facilitate fabrication and ensure the original strength and useIt is the

fulness of the affected


D.

F.

G.

H.

yet been developed.

repair procedures pertaining to items not covered in this section, refer to that items respective
chapter.
Following any repair or maintenance procedures on the aircraft structure/components, update all aircraft log books as required.
Following any repair or maintenance procedures on the aircraft structure/components, ensure inspection records pertaining to any specific repair-related procedure are identified, properly documented and closely adhered too.
All parts fabricated by the repair facility shall be identified for future reference. Marking of parts shall
be accomplished in a manner which does not affect the serviceability and reliability of the part.
For

Limitationsand
A.

component.

for structure not included in this section does not necessarily indicate that the structure involved is non-repairable, but that the application of a typical repair procedure to theoretical damage

Repairs
has not

E.

2.

REPAIR

Inspections

Limitations

(1) Learjet engineering approved repairs to landing gear fittings are limited to those items/areas as
outlined in step 4., REPAIR PROCEDURES.
(2) Limitations applied to repairs in this section must be followed unless Leajet engineering authori-

ty

to the

(3) Fittings

contrary is given.
or

forgings

must be

replaced if cracked or if fitting hole (non-bushed) tolerance exceeds


fitting or forging are not allowed. Fittings or forgings with

the allowable limits. Cracks in any


bushing shall be repaired.
B.

Inspections
(1) Following

Forward Trunnion Mount

Fitting Repair (PINs

2322146-1 thru -8, 2822259-21 b -22, and

5420000V5-1~ -2):
(a) Forward trunnion mount fitting retainer
for

security

of retainer

(b) Forward trunnion

landing
3.

must be

mount

gear is removed

inspected

every 600 hours

and for cracks in the

fitting.
fitting retainer (PIN 12224-005-3) must be removed each
and fitting must be inspected for any structural damage.

screws

time main

Materials andProcesses
A.

Materials

(1) Repair materials and required

treatments

processes will be listed in the repair procedure. Maonly so far as to facilitate fabrication and ensure the

or

or
permissible
original strength and usefulness of the affected component.

treatment variation is

terial
B.

Frocesses

(1) Refer

to the

appropriate sections,

in this

chapter,

for chemical process and treatment

speci~ica-

tions.

EFFECTIVITY:

NOTED

51-71-06

Page 201
SRM-I

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


LANDING GEAR FITTINGS

REPAIR

Repair Procedures

4.

All dimensions

NOTE:
A.

are

in inches unless otherwise

Forward Trunnion Mount

and -2) (See


NOTE:

Fitting Repair (PINs

specified.

2322146-1 thru -8, 2822159-21 and -22, and 5420000V5-1

Figure 201.)

Repair procedures

for both LH and RH forward trunnion mount

thru -8, 2822159-21 and -22, and 5420000V5-1 and -2,

are

fittings,

PIN 2322146-1

identical unless otherwise

specified.

(1) Tools and Equipment


NOTE:

Equivalent substitutes may be used in lieu of the following:


PART NUMBER

NAME

Countersink (1000)

MANUFACTURER

USE

Commercially available

Countersink retainer.

Drill

#19

Commercially available

Drill retainer.

Drill

#29

Commercially available

Drill tnmnion mount

fitting.
8-32 UNC-3A

Tap

Commercially available

Tap retainer screw


holes in trunnion
mount

fitting.

(2) Parts and Materials


NOTE:

Equivalent substitutes may be used in lieu of the following:


PART NUMBER

MANUFACTURER

Retainer (1 ea.)

12224-005-3

Fabricate

Screw (6 ea.)

MS24694-S5

Commercially available

NAME

USE

Repair fitting.

locally

Secure retainer to

fitting.
222

Loctite

(Refer

Trunnion Mount

Loctite Corp.
Newington, CT
to the

Screw lock.
06111

applicable Leajet IPC.)

Bearing

12224005

EFFECTNITY:

NOTED

51-71-06

Page 202
SRM-4

Jun 6/98

LBarjet
Learjet

STRUCTURAL REPAIR MANUAL


LANDING GEAR FITTINGS

REPAIR

(3) Repair Procedure: (See Figure 201.)


(a) Remove main landing gear strut assembly from aircraft. (Refer to the applicable Learjet Maintenance Manual.)
(b) Remove internal retainer ring and forward trunnion mount bearing.
(c) Clean and rework surrounding area where material has been broken (or cracked) at snap ring
flange to remove all damaged flange material. (See Details A and B.) Ensure maximum allowhas not been exceeded.
able dimension of 2.125 inch, as shown in Detail A, flag
(d) Inspect area with dye penetrant and/or Eddy current method for possible crack extension.
(Contact Learjet Field Service if more cracks are found.)

(e) Fabricate 12224-005-3 retainer per Detail C. Do

not drill

screw

hole locations in retainer at this

time.
MATERIAL NOTE:

(Preferred)

Fabricate 12224-005-3 retainer out of #300 Series A151 Stain-

less Steel, 1/2 hard

or

harder.

(Alternate) 4130 Steel, heat

paint
(f)

(g)
(h)
(i)

(j)
(k)
(I)

after

treat 140-160

KSI, cadmium plate and epoxy

machining.

Providing maximum edge distance obtainable, locate and mark six (6) hole locations on forward fitting. Check hole locations for a minimum edge distance of 0.20 inch on fitting.
Transfer hole locations to -3 retainer and drill retainer to match fitting. (See Detail C.)
Using a drill stop on drill, drill six (6) holes in fitting not less than 0.450 inch and not more
than 0.050 inch deep.
Tap screw holes in fitting using 8-32 UNC-3A tap.
Chemically treat reworked area for corrosion and touch-up prime exterior surface of fitting.
Identify -3 retainer for future reference.
Using a new trunnion mount bearing, install bearing with a light coating of corrosion preservative per MIL-C-16173 Grade 1. Install bearing so assembly slot in outer race is facing aft
and is horizontal within +15".

(m) Install -3 retainer. Add Loctite 222, or equivalent, to retainer screw threads.
(n) Install main landing gear strut assembly. (Refer to the applicable Learjet Maintenance

).la-unaM

(O) Update all aircraft log books.


(4) Limitations and Inspections Requirements:
(a) Forward trunnion mount fitting retainer (PIN 12224-005-3)

must be

inspected

every 600 hours

fitting.
fitting retainer (PIN 12224-005-3) must be removed each time main
landing gear is removed and fitting must be inspected for any structural damage.
for

security

of retainer

(b) Forward trunnion

EFFECTNITY:

NOTED

screws

and for cracks in the

mount

51-71-06

Page 203
SRM-4

Jun 6/98

~j Learjet
STRUCTURAL REPAIR MANUAL
LANDING GEAR FITTINGS

REPAIR

&32 UNC-3A

Trunnion

(Ref)

Fitting
Web #5

(ReD
-----;f-

&32 UNC3A Thread

UP

iI

FWD

Web #5

(6 Places)

(ReO

INBD
~Trunnion

INBD

(Section

C)

Fitting

(-3 RETAINER NOT SHOWN FOR CLARITY)

Detail A
damaged portion
ring location.

Remove this

edge

of lock

around

(-3 RETAINER NOT SHOWN FOR CLARITY)

I~

Check hole location for minimum


distance of 0.20 inch

on

edge
trunnion fitting.

Detail B

2.125 maximum allowable dimension af-

information is

ter

Maximum hole

Add Loctite 222,

applied.

depth

not to exceed 0.500

inch, minimum depth

not less than 0.450

equivalent,
to

on screw

51-70-00.)

This dimension may change after preliminary location of six (6) holes in trunnion

inch. Locate to match -3 retainer.

0.23

or

only (6 places). (Refer

fitting.
No. #19 (0.166) Dia. Hole (thru 3)
CSK 1000

0.310/0.320

Dia.0.212

(6 Places) (this side)

~n r

12224-0053
Retainer

30"(Typ)

2110 (f 0.005)

1QI
~e 0.112

1.60 Dia.
3.00 Dia.

Detail C
Forward Trunnion Mount

Figure

EFFECTIVITY:

NOTED

Fitting Repair

201 (Sheet 1 of 2)

51-71-06

Page 204
SRM-I

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
LANDING GEAR FITTINGS

REPAIR
Tnu~nion

i_L""Web
I

FWD

-t,

MS 24694-55

Rtting

#5 (Ret)

ScrewI~

(ReO
INBD
12224-005-3
Retainer

(Section A A)
-r

Trunnion

ij

III I
/r I i
rli I I
Detail
B

-C-

II

--;-1222P005-3
Retainer

II I

-1

Rtting

I I

---111I

-i,-I-

-i--i~l

i~2-

Web #5 (ReD

VP

t,l,

MS 24694-55 Screw

(6 Places)

(VIEW LOOKING FORWARD AT SPAR #5)


(BEARING NOT SHOWN FOR CLARITY)

Detail D
Fitting Repair
Figure 201 (Sheet 2 of 2)

Forward Trunnion Mount

EFFECTIVITY:

NOTED

51-71-06

Page 205
SRM-I

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


ENGINE MOUNT FITTINGS

ALLOWABLE WEAR AND REPAIR DATA

r----I

:i i....i
A

B
8.

O
-9

1
k

G
lo

2\

DH11
I

5
A

Detail A

J/

\13

K/
15~

Detail B
A75C-1
87-6A

EFFECTIVITY:
SRM-I

Engine Mount Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 1 of 4)
23-001 THRU 23-099; 24-100 AND SUBSEQUENT; 25-001 AND SUBSEQUENT; 28-001 AND SUBSEQUENT; 29-001 AND SUBSEQUENT

51-71-07

Page 1
Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

NO.

DESCRIPTION

Engine Mount,

EFF. I HOLE I

MFD

MFD

HOLE

SHAFT

ID

0.0000

OD

MFD
I

ALLOWANCE

ID

OD

WEAR
ID

ALLOWANCE
OD

Fwd

LM30&19

1 +0.0000/
-0.0000

Bolt-Fwd
NAS464-6A37

0.3734

1 +0.0000/

0.3742

1 +0.0000/
-0.0009

-0.0005

NAS464P6A39

Fitting Engine Support

2351 005-1, -2

2351005-3, -4

0.3750

1 +0.00201

0.3750

-0.0000
1 +0.0020/
-0.0000

EngineMount-LowerAft

LM30&33

0.0000

1 +0.0000/
-0.0000

Lower Aft
NAS464P8A64

Bolt

C,D I

0.4991

1 +0.0000/

-0.0009

Mount

Assy Engine Shock


O

2451 004-1

0.5000

1 +0.0015/

0.7490

1 +0.0000/

-0.0000
E

-0.0005
7

1 YokeAssembly-Engine
F

2351 03&40

0.3747

1 +0.0015/
-0.0000

Bolt

Upper Aft
F,G I

NAS464P6L20

0.3742

1 +0.00001
-0.0009

Spacer Upper Aft


NAS43HT6-16

F, G

0.4020

0.5000

+0.0250/
-0.0250

Rod End Engine Mounting


REM-GTH

10

G, H

0.0000

0.0000

+0.0000/
-0.0000

11

I Mount-Top

+0.0015/
-0.0015
+0.0000/
-0.0000

Half
H

LM30821

0.0000

1 +0.0000/

-0.0000

121

13

Sleeve-Mount
LM30&23

H, 1

Pad Engine Mount,


2351 031-3

0.0000

0.0000

+0.0000/
-0.0000

+0.0000/
-0.0000

Upper
1

1.4000

1 +0.0000/
-0.0000

Engine Mount Fittings Allowable Wear and Repair


Figure 1 (Sheet 2 of 4)
EFFECTIVITY:
SRM-4

Data

23-001 THRU 23-099; 24-100 AND SUBSEQUENT; 25-001 AND SUBSEQUENT; 28-001 AND SUBSEQUENT; 29-001 AND SUBSEQUENT

51-71-07

Page 2
jun 6/98

Learjet
Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

NO.I
14

15

Mount- Bottom Half


LM30&22

Bolt-2351032-6

MFD

MFD

HOLE

SHAFT

ID

OD

HOLE I

EFF.

DESCRIPTION

0.0000

ALLOWANCE

ID

OD

WEAR
ID

ALLOWANCE
OD

1 +0.00001
-0.0000

MFD

0.4991

1 +0.0000/
-0.0009

Engine Mount Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 3 o~ 4)
EFFECTIVITY:

SEQUENT;
SRM-4

AND SUB-

51-71-07

28-001 AND SUBSEQUENT; 29-001 AND SUBSEQUENT

Page 3

23-001 THRU 23-099; 24-100 AND

SUBSEQUENT; 25-001

Tun 6/98

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

NO.

DESCRIPTION

EFF.

HOLE

REPAIR

Aft

Engine Mount,

LM30&19
Bolt FWD NAS464-6A37
NAS464P6A39

Fitting

Replace worn part.


Replace worn part.

I Replaceworn part.

C, D

I Replaceworn part.

Replace worn part.

E, F

Replace worn part.

1
1

E, F
F, G

Replace worn part.


Replace worn part.

Replace worn part.


Replace worn part.
Replace worn part.

Engine Support

25510005-1, -2
23510005-3, -4
Mount Lower Aft
LM308-33
Bolt Lower Aft
NAS464P8A64
Mounting Assy Engine Shock
2451004-1
Yoke Assy Engine
235103&40
Bolt Upper Aft
NAS464P6L201
Spacer Upper Aft
NAS43HT6-16
Rod End Engine Mounting
Mount- Top Half
LM30&21
1 Sleeve- Mount
LM30&23
1 Pad Engine Mount, Upper
23510313
1 Mount- Bottom Half
LM30&22
1 Bolt 2351032-6

Engine

5
6
7

8
9
10
11
12

13
14
15

CODES

1
1

worn

part.

I Replaceworn part.
H

Replace worn part.

I Replaceworn part.

J
I

Replace worn part.


I Replaceworn part.

EFFECTIVITIES
23-001 thru 23-099; 24-100 and
29-001 and Subsequent

23-001 thru 23-069

23-070 thru 23-099; 24-100 and


001 and Subsequent
23-001 thru 23049

G,

Replace

Subsequent;

23-050 thru 23-099; 24-100 and

29-001 and

Subsequent; 25-001 and Subsequent; 2&001 and Subsequent;

Subsequent;

25-001 and

Subsequent;

25-001 and

2&001 and

Subsequent;

Subsequent; 29-

2&001 and

Subsequent;

Subsequent

Engine Mount Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 4 of 4)
EFFECTIVITY:

23-001 THRU 23-099; 24-100 AND

SEQUENT;
SRM-I

28-001 AND

SUBSEQUENT; 25-001 AND SUB


SUBSEQUENT; 29-001 AND SUBSEQUENT

51-71-07

Page 4
Jun 6/98

STRUCTURAL REPAIR MANUAL


ENGINE MOUNT FITTINGS

A~

ALLOWABLE WEAR AND REPAIR DATA

~dls

?Ir

i,

~i;p
H

i!

~o

lo
d

20

20

d,

sti
20

i:

L
19

Detail A

-i-:

I;

D
E

Detail B

A7-29C-1
A7-29C-2
B7-29C-1
14-115C

EFFECTIVITY:

Engine Mount Fittings Allowable Wear and Repair


Figure 2 (Sheet 1 of 8)
31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;
36-001 AND SUBSEQUENT

SRM-I

Data

51-71-07

Page 5
Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM

NO.
1

I
DESCRIPTION

IEFF.

I
HOLE

MFD

MFD

HOLE

SHAFT

ID

OD

MFD

ALLOWANCE

ID

OD

WEAR
ID

ALLOWANCE
OD

Engine Mount, Aft


26510216

0.4997

1 +0.00101

0.3117

1 +0.00101

0.4997

1 +0.00101

0.3117

1 +0.00101

0.4997

0.3117

1 +0.00101

0.4997

1 +0.00101

0.3117

1 +0.0010/

0.4997

1 +0.001 01

0.3117

0.4997

1 +0.001 01
-0.0000
1 +0.0010/

0.3117

0.4997

1 +0.00101
-0.0000
1 +0.0010/

0.3117

1 +0.0010/

0.4997

1 +0.00101

0.3117

0.4997

1 +0.001 0/
-0.0000
1 +0.001 0/

0.3117

1 +0.0010/

0.4997

0.3117

1 +0.00101
-0.0000
1 +0.001 0/

-0.0000
B

-0.0000

2651031-3, -4

-0.0000
-0.0000

(Alt. 2651031-5, -6)

1 +0.00101
-0.0000
-0.0000

2651031-5, -6

-0.0000
-0.0000

(Alt. 2651031-7, -8)

-0.0000
B

2651 031-7, -8

-0.0000

(Alt. 2651031-11, -12)

-0.0000
B

-0.0000

2651 031-11, -12

-0.0000

(Alt.

2651 031-13,

-14)

-0.0000
B

-0.0000

2651031-13, -14

-0.0000

Engine Mount Fittings Allowable Wear and Repair Data


Figure 2 (Sheet 2 of 8)
EFFECTIVITY:

31-001 AND

SUBSEQUENT; 35-001 AND SUBSEQUENT;

36-001 AND SUBSEQUENT


SRM-I

51-71-07

Page 6
Jun6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

MFD

MFD

HOLE

SHAFT

ID

OD

MFD

ALLOWANCE

ID

OD

DESCRIPTION

IEFF.

HOLE

Bolt-2651027-1

0.4995

i +0.0000/

Bolt- NAS335CP23

0.3117

1 +0.00001

Isolator,Aft- LM833-SA4

NO.I

WEAR
ID

ALLOWANCE
OD

-0.0010
-0.0009
4

0.3130

1 +0.00001

0.3125

1 +0.00001

-0.0005
D

-0.0005
Mount

Flange

Engine

Bolt- 2652002-2

10

0.3115

Bolt- 2652002-3

11

0.3115

12

0.5000

0.5000

0.5000

0.5000

0.5000

0.5000

0.5000

1 0.5000 1

0.1895

1 +0.0000/
-0.0005
1 +0.0000/
-0.0005

Fitting, Aft Eng. Support

2612056-5, -6

(Alt. 2612056-7, -8)


2612056-7, -8

13

(Alt. 2612056-9, -10)


14

2612056-9, -10

1 +0.0010/
-0.0000
1 +0.00101
-0.0000
i +0.00101
-0.0000
1 +0.00101
-0.0000
1 +0.0010/
-0.0000

(Alt. 2612056-13, -14)


261 2056-13, -14

15

2612056-1 7,-18

Support Beam Assy.

Aft

Bolt, Aft Side

11
12

HLI&6-5
10

16

I
I

i
i

0.1895

Bolt,TopAft-HL1S-Gd

0.1895

Bolt,TopFwd-HL1&6-4

0.1895

Bolt, FwdSide-HL1&66

0.1895

1 +0.0010/
-0.0000
1 +0.00101
-0.0000
+0.0010/
-0.0000
i +0.0010/
-0.0000
1
1 +0.0000/
I
1 -0.0010
1
1 +0.0000/
-0.0010
i
1 +0.0000/
-0.0010
1

Engine Mount Fittings Allowable Wear and Repair


Figure 2 (Sheet 3 of 8)
EFFECTIVITY:

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT

SRM-4

1 +0.0000/
-0.0010

Data

51-71-07

Page

Jun 6/98

E~ Learjet
Ledlietl
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

I
DESCRIPTION

NO.

Bolt,Bottom-HL1&6-4

13

EFF.

HOLE

MFD

MFD

HOLE

SHAFT

ID

OD

0.1895

MFD

ALLOWANCE

ID

OD

WEAR
ID

ALLOWANCE
OD

1 +0.0000/
-0.0010

14

Fitting, FwdEng.Support

261 2042-5,-6

17

0.6255

1 +0.0000/

0.3120

0.6255

0.3120

1 +0.0010/
-0.0000
1 +0.0000/
-0.0010
1 +0.0010/

0.6255

1 +0.0000/

0.3120

0.6255

1 +0.00101
-0.0000
1 +0.0000/

0.3120

1 +0.001 0/

0.6255

1 +0.0000/

0.3120

i +0.0010/

0.6255

1 +0.0000/

0.3120

-0.0010

261 2042-7,-8

18

-0.0000

(Alt. 2612042-9,-10)

-0.0010

261 2042-9,-10

19

-0.0010
-0.0000

(Alt. 2612042-13,-14)

-0.0010
-0.0000
20

261 2042-1 3,-14

-0.0010

15

Bolt-HL30-10-6

16

EngineMount,Fwd-

0.4367

0.6245

0.4367

1 +0.0015/

0.6245

0.4367

1 +0.0010/
-0.0000
1 +0.001 5/
-0.0000

22

2651 011-8

1
I

21

0.6245

2651011-6

1 +0.001 0/
-0.0000
1
1 +0.0005/
-0.0000
1 +0.0010/
1 -0.0000
1 +0.0015/
-0.0000
1 +0.001 01

0.3120

-0.0000
-0.0000
23

2651011-10

Engine

EFFECTIVITY:

Mount

Fittings Allowable Wear and Repair


Figure 2 (Sheet 4 of 8)

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT

SRM-I

Data

51-71-07

Page 8
Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I
NO.

I
DESCRIPTION

2651 011-12

MFD

MFD

HOLE

SHAFT

MFD
ID

EFF.

HOLE

ID

24

0.6245

1 +0.00101

0.4367

1 +0.00151

0.6245

1 +0.001 01

0.4375

1 +0.00151

0.6245

1 +0.001 01

0.4375

1 +0.0015/

0.625

1 +0.00101

0.4375

1 +0.00151

0.6245

0.4375

0.6245

1 +0.00101
-0.0000
1 +0.0015/
-0.0000
1 +0.001 01

0.4375

1 +0.00151

OD

ALLOWANCE
OD

WEAR
ID

ALLOWANCE
OD

-0.0000
-0.0000
25

2651 011-13

-0.0000
-0.0000
26

2651011-15

-0.0000
-0.0000
27

2651011-18

-0.0000
-0.0000
28

2651 034-1

29

2651 0343

-0.0000
-0.0000
17

30

0.6240

i +0.00001

2651 026-3

31

0.6240

1 +0.00001

2651 026-4

32

0.6240

1 +0.0000/

L,M

0.4370

1 +0.0000/

0.4375

0.3935

Bolt-2651026-1

-0.0010
-0.0010
-0.0010

NAS1307-3H

18

Bolt

19

MountAssy.

20

Bolt

LM-833-SA5

80917-6-10

1
1
1

0.3882

-0.0010
I f0.0010
1 +0.0000/
-0.0005
1
1 +0.0000/
-0.0002

Engine Mount Fittings Allowable Wear and Repair


Figure 2 (Sheet 5 of 8)
EFFECTIVITY:

31-001 AND

SUBSEQUENT; 35-001

36-001 AND SUBSEQUENT


SRM-I

AND

SUBSEQUENT;

Data

51-71-07

Page 9
Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

DESCRIPTION

NO.
1

Engine Mount,

EFF.

HOLE

Aft

2651021-5

2651031-3, -4

B
A
B

(Alt. 2651031-5, -6)


2651031-5, -6

A
B
A

(Alt. 2651031-7, -8)

2651031-7, -8

A
B

(Alt. 2651031-11, -12)

2651031-11,

-12

A
B
A

(Alt. 2651031-13, -14)


2651031-13, -14

B
2651027-1

NAS335CP23

Isolator, Aft-LM833-SA4

A
B
C, D

Bolt
Bolt

Engine Mount Flange

Bolt

2652002-2
2652002-3

Fitting,

Aft

REPAIR

10

11

12

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.
part.
part.
part.

Replace
Replace
Replace
Replace
Replace

part.
part.
part.
part.
part.
part.

worn
worn

worn
worn

worn

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.
part.

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part. (Refer to applicable basic
Learjet Maintenance Manual for complete inspection requirements.)

Replace worn part.


Replace worn part.

Eng. Support-

2612056-5, -6
(Alt. 2612056-7, -8)
2612056-7, -8
(Alt. 2612056-9, -10)
2612056-9, -10
(Alt. 2612056-13, -14)
2612056-13, -14
2612056-17, -18

13

F
F

14

F
F

15

16

G
G

Aft

Assy.

Bolt, Aft Side HL1&6-5

Support

Beam

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Refer to Chapter 53.
Replace worn part. Install oversized fastener if
hole "G" is worn past tolerance. (Refer to 5170-00.)

Engine Mount Fittings Allowable Wear and Repair Data


Figure 2 (Sheet 6 of 8)
EFFECTIVITY:

31-001 AND SUBSEQUENT; 35001 AND SUBSEQUENT;


36-001 AND

SRM-B

SUBSEQUENT

51-71-07

Page

10

Jun 6/98

Learjet
~Lenrjet
STRUCTURAL REPAIR MANUAL
REPAIR DATA

ITEM

DESCRIPTION

NO.
10

1 Bolt, Top Aft

HL19-6-5

EFF.
1

REPAIR

HOLE

Replace

worn

hole "G" is

part. Install oversized fastener if


past tolerance. (Refer to 51-

worn

70-00.)
11

Bolt, Top Fwd

HL186-4

Replace

worn

hole "G" is

part. Install oversized fastener if


past tolerance. (Refer to 51-

worn

70-00.)
12

Bolt, FwdSide-HL1SG-6

Replace

worn

hole "G" is

part. Install oversized fastener if


past tolerance. (Refer to 51-

worn

70-00.)
13

HL18-6-4

Bolt, Bottom

Replace

worn

hole "G" is

part. Install oversized fastener if


past tolerance. (Refer to 51-

worn

70-00.)
14

1 Fitting,

Fwd

Eng. Support-

2612042-5, -6
2612042-7, -8
(Alt. 2612042-9, -10)
2612042-9, -10
(Alt. 2612042-13, -14)
2612042-13, -14
15

Bolt- HL30-10-6

17

18
19
20
1

H,
H,
H,
H,
H,
H,

J
J
J

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part. Install

J
J

hole "J" is

worn

oversized fastener if

past tolerance. (Refer to 51-70-

00.)

Engine Mount, Fwd

16

17

2651011-18

25
26
27

2651034-1

28

2651034-3

29

K, L
K, L
K, L
K,L
K, L
K, L
K, L
K, L
K, L

2651011-6

21

2651011-8

22

2651011-10

23

2651011-12
2651011-13
2651011-15

24

30

2651026-3

31

2651026-4

32

Bolt

2651026-1

19

Bolt NAS1307-3H
Mount Assy. LM-833-SA5

M, N

20

Bolt- 6600187-4

18

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replacae worn part.
Replace worn part. (Refer to Chapter 71 of basic Learjet Maintenance Manual for complete
inspection requirements.)
Replacewornpar.

Engine Mount Fittings Allowable Wear and Repair


Figure 2 (Sheet 7 of 8)
EFFECTIVITY:

31-001 AND
36-001 AND

SRM-4

SUBSEQUENT; 35001 AND SUBSEQUENT;


SUBSEQUENT

Data

51-71-07

Page

11

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


CODES
1
2

EFFECTIVITIES
31-001 and
Deleted

Subsequent; 35-001 and Subsequent; 36-001 and Subsequent

Deleted

35-001 thru 35-027, 35-029 thru 35-032, 35-035; 36-001 thru 36-013, 36-015, 36-016
35-028, 35-033, 35-034, 35-036 thru 35-052; 36-014 and 36-017

35-053 thru 35-499, 35-501 thru 35-503, 35-506 thru 35-508; 36-018 thru 36-053 and Prior Aircraft
Equipped With 2651031-5, -6 Aft Engine Mount

35-500, 35-504, 35-505, 35-509 thru 35-654; 36-054 thru 36-059, 36-062, 36-063; 31-001 thru 31013; and Prior Aircraft Equipped With 2651031-7, -8 Aft Engine Mount
31-014 thru 31-048; 35-655 thru 35-674; 36-060, 36-061 and Prior Aircraft Equipped With 265103111,-12 Aft Engine Mount

8
9

31-049 and

10

35-001 thru 35-020; 36-001 thru 36-013


35-021 and Subsequent; 35-014 and Subsequent; 31-001 and

11

Subsequent; 35-675 and Subsequent;


Equipped With 2651031-13, -14 Aft Engine Mount

36-064 and

13

35-001 thru 35-141; 36-001 thru 36-034


35-142 thru 35-295; 36-035 thru 36-044 and Prior Aircraft

14

35-296 thru

12

15

16

18
19

20

22

23
24
25
26
27

28
29

30
31
32

Subsequent

Equipped

Fitting

35-001,35-002;36-001
35-003 thru 35-018; 36-002 thru 36-008
35-019 thru 35-022; 36-009 thru 36-013
35-023 thru 35-026; 36-014 thru 36-016
35-027 thru 35-340; 36-017 thru 36-045 and Prior Aircraft Equipped With 2651011-13 Engine Mount
35-355 thru 35-522, 35-529, 35-530, 35-531, 35-589; 36-046 thru 36-053
35-340 thru 35-354 and Prior Aircraft Equipped With 2651011-18 Engine Mount
35-523 thru 35-654; 36-054 thru 36-059, 36-062, 36-063; 31-001 thru 31-013
31-014 and Subsequent; 35-655 and Subsequent; 36-060, 36-061, 36-064 and

Subsequent

and

Prior Aircraft Equipped With 2651034-3 Engine Mount


31-001 thru 31-007; 35-001 thru 35-642; 36-001 thru 36-057
31-008; 35-643 thru 35-647; 36-058 and Prior Aircraft Equipped With 2651026-3 Bolt
31-009 and Subsequent and Prior Aircraft Modified Per SE 31-71-1 "Powerplant
Replacement of
Forward Engine Mount Bolts"; 35-648 and Subsequent and Prior Aircraft Modified Per SE 35/36-71-5
"Powerplant Replacement of Forward Engine Mount Bolts" Except Aircraft 35-110; 36-059 and Sut~
sequent and Prior Aircraft Modified Per SE 35/36-71-5 "Powerplant Replacement of FoMlard Engine Mount Bolts"

31-001 AND SUBSEQUENT; 35-001 AND


36-001 AND

SRM-I

Fitting

Fitting

Engine Mount Fittings Allowable Wear and Repair


Figure 2 (Sheet 8 of 8)
EFFECTIVITY:

With 2612056-7, -8

35-001 thru 35-035; 36-001 thru 36-013, 36-015, 36-016


35-036 thru 35-178; 36-017
35-179 thru 35-307; 36-039 thru 36-044 and Prior Aircraft Equipped With 2612042-9, -10 Fitting
35-308 and Subsequent; 36-045 and Subsequent and Prior Aircraft Equipped With 2612042-13,
-14

21

and Prior Aircraft

35-420; 36-045 thru 36-047 and Prior Aircraft Equipped With 2612056-9, -10 Fitting
35-421 thru 35-450 and Prior Aircraft Equipped With 2612056-13,-14 Fitting; 36-048 thru 36-051and
Prior Aircraft Equipped With 2612056-13,-14 Fitting
35-451 and Subsequent; 36-052 and Subsequent and Prior Aircraft Equipped With 2612056-17,
-18

17

Subsequent

SUBSEQUENT

SUBSEQUENT;

Data

51-71-07

Fage

12

Tun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
ENGINE MOUNT FIT~INGS

i.

General
A.

B.

C.

responsibility of the aircraft owner/maintenance facility to determine qualifications of maintenance personnel performing repair procedures. As always, a clean environment and good general
shop practices shall be exercised any time repairs are performed on the aircraft.
Prior to, and after performing, any repairs on the Engine Mount Fittings, ensure serviceability and reliability of part. If serviceability and/or reliability of any part or repair remains in question or if guidance is needed in making this determination, contact Learjet Field Service for additional information.
Repairs must be equal to, or greater in strength, than the original structure. Technique and material
variation is permissible only so far as to facilitate fabrication and ensure the original strength and useIt is the

fulness of the affected


D.

F.

G.

H.

yet been developed.

repair procedures pertaining to items not covered in this section, refer to that items respective
chapter.
Following any repair or maintenance procedures on the aircraft structure/components, update all aircraft log books as required.
Following any repair or maintenance procedures on the aircraft structure/components, ensure inspection records pertaining to any specific repair-related procedure are identified, properly documented and closely adhered too.
All parts fabricated by the repair facility shall be identified for future reference. Marking of parts shall
be accomplished in a manner which does not affect the serviceability and reliability of the part.
For

Limitationsand
A.

component.

for structure not included in this section does not necessarily indicate that the structure involved is non-repairable, but that the application of a typical repair procedure to theoretical damage

Repairs
has not

E.

2.

REPAIR

Inspections

Limitations

(1) Learjet engineering approved repairs to engine mount fittings are limited to those items/areas as
outlined in step 4., Repair Procedures.
(2) Limitations applied to repairs in this section must be followed unless Leajet engineering authori-

ty to

the

(3) Fittings

contrary is given.
or

forgings

must be

replaced if cracked or if fitting hole (non-bushed) tolerance exceeds


fitting or forging are not allowed. Fittings or forgings with

the allowable limits. Cracks in any


bushing shall be repaired.
3.

Materialsand Processes
A.

Materials

(1) Repair materials and required


terial

or

treatment variation is

original strength and


B.

processes will be listed in the repair procedure. Maonly so far as to facilitate fabrication and ensure the

treatments or

permissible

usefulness of the affected

component.

Processes

(1) Refer

to the

appropriate sections,

in this

chapter,

for chemical process and treatment

specifica-

tions.

EFFECTIVITY:

ALL

51-71-07

Page 201
SRM-B

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


ENGINE MOUNT FITTINGS

4.

REPAIR

Repair Procedures
NOTE:
A.

All dimensions

are

in inches unless otherwise

Forward

Engine Mount
(See Figure 201.)
WARNING:

specified.

and

Support Fitting (PINs

2612042-5 thru -14)

Repair

THE FOLLOWING REPAIR PROCEDURE EMPLOYS THE USE OF A DRY ICE-

ALCOHOL MIXTURE. WHEN WORKING WITH DRY ICE-ALCOHOL MIXTURE ENSURE ADEQUATE SAFETY PRECAUTIONS AND PROCEDURES ARE
CLOSELY ADHERED TO.
NOTE:

Repair procedures for both LH


unless otherwise specified.

and RH

engine mount and support fittings are identical

Bushings may be installed only in holes


ensure

that are out of tolerance. Care must be taken to


that bushed hole(s) is line reamed to match other existing bolt holes.

Due to time constraints contained in the

the

procedure

be

thoroughly

following procedure, it is recommended that


prior to performing the following

read and understood

task.

(1) Tools and Equipment


NOTE:

Equivalent substitutes may be used

NAME

ICountersink
Dry Ice

in lieu of the

following:

PART NUMBER

MANUFACTURER

9100392

Leajet Inc.

Repair engine mount

Commercially Available

Cold soak

Alcohol

USE

bushings

(2) Parts and Materials


PART NUMBER

MANUFACTURER

Bushing (4 ea.)

12135-060-1

Leajet Inc.

Repair engine mount

Bushing (4 ea.)

12135-060-2

Leajet Inc.

Repair fitting

NAME

USE

12135-060

EFFECTIVITY:

NOTED

51-71-07

Page 202
SRM-I

Jun 6/98

Learjet
~jLearpt/
STRUCTURAL REPAIR MANUAL
ENGINE MOUNT FITTINGS

REPAIR

(3) Tolerances
TOLERANCE

NAME

Engine Mount Bolt Hole

0.6255 to 0.6245

Fitting Bolt Hole

0.6255 to 0.6245

Bolt (Ref)

0.6240 to 0.6230

(4)

Repair Procedure: (See Figure 201.)


(a) Remove engine ~om aircraft. (Refer to applicable Learjet Maintenance Manual.)
(b) Remove attaching parts securing engine mount to fitting.
(c) Modify engine mount (PINs 2651034-1 thru -3) as follows:
1) Measure outside diameter of new bushing (PIN 12135-060-1).
2) Machine existing hole in engine mount to within 0.0002 to 0.0004 inch interference fit
with outside diameter of bushing.
3) Countersink hole in engine mount using a 45" countersink to a depth of 0.060 inch by
0.870 inch diameter. (See Detail D.)

4)
5)
6)

Clean

engine mount.
Inspect machined area of engine mount using Eddy current method
Cold soak bushings by placing in a mixture of alcohol and dry ice

for

possible cracks.

for

minimum of 20

minutes.

Applyepoxy primer to four (4) holes in engine mount just prior to installing new bushings.
8) Remove bushing from alcohol and dry ice mixture and install in engine mount within 14
7)

seconds.

Allowenginemountto reachroom temperature.


Measurediameter of upperengine mountbolt.
Using dimension determined in step 9), line ream opposing bushings.
Line ream inside diameter of upper bushings to provide a 0.001 inch maximum clearance
for engine mount bolt.
(d) Modify support fitting (PINs 2612042-5 thru -14) as follows:
1) Measure outside diameter of new bushing (PIN 12135-060-2).
2) Machine existing hole in fitting to within 0.0002 to 0.0004 inch interference fit with outside diameter of bushing.
3) Cleanfitting.
4) Inspect machined area of fitting using Eddy current method for possible cracks.
5) Cold soak bushings by placing in a mixture of alcohol and dry ice for a minimum of 20
9)
10)
11)
12)

minutes.

Applyepoxy primer to four (4) holes in engine mount just prior to installing new bushings.
7) Remove bushing hom alcohol and dry ice mixture and install in fitting within 14 sec-

6)

ends.

EFFECTIVITY:

NOTED

51-71-07

Page 203
SRM-I

Jun 6/98

Leariet

STRUCTURAL REPAIR MANUAL


ENGINE MOUNT FITTINGS

8)
9)
10)
11)

Allow

fitting to

reach

temperature.

Measure diameter of upper engine mount bolt.


Using dimension determined in step 9), line ream
Line

for

ream

engine

inside diameter of upper


mount bolt.

(e) Install engine mount in


(f) Align lowerboltholes.

(g)

room

REPAIR

bushings

to

opposing bushings.
provide a 0.001 inch maximum clearance

fitting using only upper bolt.

Measure diameter of lower

engine mount bolt.


bushings of engine mount and fitting to provide a 0.001
inch maximum clearance for engine mount bolt.
(i) Install lower engine mount bolt.
(j) Install engine mount in aircraft. (Refer to applicable Leajet Maintenance Manual.).
(k) Update all aircraft log books to indicate that Engine SUtll70Tt Modification Installation #12135059-1 (LH)l-2 (Rli) has been incorporated.
(h) Line

(1)

EFFECTIVITY:

ream

inside diameter of lower

Restoreaircraftto normal.

NOTED

51-71-07

Page 204
SRM-I

Jun 6/98

Learjet
~Learjetl

STRUCTURAL REPAIR MANUAL


ENGINE MOUNT FITTINGS

REPAIR

Fitting

Engine Mount

Beam

Assembly (ReD

Ball?

ii

12135-060-2

s~

Bushing

12135-060-1

Bushing

NOTES:

Bushing

to be flush

on

this side when installed.

Permissible to radius

bushing 45" flange edge

Permissible to radius

bushing edge

to

to

prevent damage

prevent damage

on

on

assembly

Dimension of hole to be 0.0002 to 0.0004 inch interference fit (4

assembly
to

to

fitting.

engine mount.

places).

(LH SHOWN, RH OPPOSITE)

Engine Mount and Fitting Repair


Figure 201 (Sheet 1 of 3)

Repro

EFFECTIVITY:

NOTED

51-71-07

Page
SRM-4

205

Jun 6/98

Learjet

REPA\RYANUAC
STFIUCfURAC
FITTINGS-REpAIR

ENGINE MO~JNT

Fitting

12135-060-2
Bushing

-i--

Typca

II

I,:
II

1~

1\

i;
t

Beam

Fitting

Assembly (ReO

(Sedion A A)

Detai\A
Mount and

Fittine,- Repab
2 of 3)

En~ne
201 (Sheet
Figure
Repro

51-71-07
page 206

Jun 6/98

EF ECTrVITY:sRM-a

NOTED

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


ENGINE MOUNT FITTINGS

REPAIR

EngineMount

Engine Mount

~II

12135-060-1

Bushing

(4 Required)
_Irr

\I

t
I/-

(Typical)

II

~cau
E,

Ic-~a

!II

r-

II

(Section

B-

B)

(VIEW LOOKING FORWARD)

Engine
Support

Detail B

Installation

I~

Engine Mount

(4Places)-\

0.870 inch Diameter

Fitting

(Countersink diameter)

(4Places)
12135-060-2

Bushing

Countersink 45"

0.060

12135-060-1

Bushing

(Section C C)

(Section

D)

(TYPICAL OF 4 LOCATIONS)

(TYPICAL OF 4 LOCATIONS)

DetailC

DetailD

Repro

EFFECTIVITY:

Engine Mount and Fitting Repair


Figure 201 (Sheet 3 of 3)
NOTED

51-71-07

Page 207
SRM-4

Jun 6/98

Learjet
Learjet

STRUCTURAL REPAIR MANUAL


RUDDER FITTINGS

ALLOWABLE WEAR AND REPAIR DATA

~H

Detail A
Rudder

EFFECTIVITY:

ALL

Fittings Allowable Wear and Repair Data


Figure 1(Sheet 1 of 16)
51-71-08

Pagel
sRM-4

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


RUDDER FITTINGS

ALLOWABLE WEAR AND REPAIR DATA

lafli

p;---

1
2

7\~!"

A$
Detail C

Detail B

I\

9
I

.j,

11

17

12

20

19

\I"

15

13/

Detail D

Detail E
Rudder

)EFFECTIVITY:

ALL

Detail F

Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 2 of 16)
51-71-08

Page 2
SRM-I

Jun 6/98

Learjet I
Learjet

STRUCTURAL REPAIR MANUAL


ALLOWABLE WEAR AND REPAIR DATA

RUDDER FITTINGS

28

22

,,P,

24

23

8/

Detail H

Detail G

30

~JZ>

31

ii
32

VV~

30

32

D eta i I J

M
35

35

Detail K
822C-1

Rudder

A515A

EFFECTIVITY:

ALL

Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 3 of 16)
51-71-08

Page
SRM-4

Jun 6/98

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


RUDDER FITTINGS

ALLOWABLE WEAR AND REPAIR DATA

36

36

41

39

e~o
o

38
37

Detail I

Detail iW

7
a
42

4s

,49

44

50

as
47
48

Detail N
C5-2B2

Rudder

DEFIC

F821C

EFFECTIVITY:

ALL

Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 4 of 16)
51-71-08

Fage4
Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
RUDDER FITTINGS

ALLOWABLE WEAR AND REPAIR DATA

51

57 V

~Y Y~

71

57

7372

58

59
ss~
6

69

AA

63

76 _~Y\\

64
78

AC;T~ tl,

67

77

80

65

81

Detail P
C52BZ

Rudder

DE5-IC

FB21C

EFFECTIVITY:

ALL

Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 5 of 16)

51-71-08)
Page5

SRM-I

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

I
DESCRIPTION

NO.
1

Horn

Bearing-

MFD

MFD

HOLE

SHAFT
OD

EFF.

HOLE

ID

0.6562

0.2500

Assy. 2333009-6

MFD

ALLOWANCE

ID

OD

WEAR
ID

ALLOWANCE
OD

1 +0.00401
-0.0000

M521233-4

0.6562

+0.00001
-0.0005

Bolt- NAS464P4-8

Clevis, Rod End


2433003-2

0.2492

0.2492

+0.00001

-0.0005
1 +0.00001
-0.0009

1 +0.00101

-0.0000

End

HFV-4

Bearing, Rod

Bolt- NAS464P4-13
NAS464P4-14
Actuator Arm

2333008-3, -4, -6, -7

I
I

1
I
0.2500

0.2492

1
I

1 +0.00001
1 -0.0009

1 +0.00501
-0.0010

Hinge Assy.

2331030-10, -12

0.7488

i +0.00051
-0.0000

9
10

Bearing- AN201 KP4A

Bolt- AN4H11A

0.2500

0.7500

0.2490

+0.0000/

+0.00001
-0.0005

-0.0005

+0.000/
-0.0030

11

HingeAssy.

2331031-8, -10, -11,-14


12

Bearing-AN201KP4A

13 i

Bolt-AN4H11A

14

15

Bearing BlockAssy.-

2312040-7
Bearing- BR-4

16

0.7488

E
1

0.2500

0.7500

1
0.8998

1 +0.0005/
-0.0000
+0.00001
-0.0005

+0.00001
-0.0005
0.0000/
-0.0030

0.2490
1 +0.0008/
1 -0.0000

1
I

(Alt DAS4-14A)

Bo~- NAS1 44A23

0.2490

1 +0.00001
-0.0030

17

1 TorqueTube Assy.
1

(AltAJ04C-125)

Fork EndTerminal-

2433002-1

0.3755

1 +0.0000/
-0.0005

18

1 Bushing- DBS-4-030

19

MS20667-6

Rudder

EFFECTIVITY:

ALL

0.3130

1 +0.0020/

1 -0.0000

Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 6 of 16)
51-71-08

Page6
SRM-I

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I
NO.
20

I
DESCRIPTION

I
HOLE

EFF.

Bolt- NAS464-4-8

MFD
SHAFT

ID

MFD
HOLE

OD

1 0.2492

MFD
I

ALLOWANCE

ID

1-

OD

WEAR
ID

ALLOWANCE
OD

1+0.0000/
-0.0009

21

1 Pulley-

MS20220A2

G,

0.3125

3.0000

+0.0005/

+0.0050/
-0.0000

22

Bracket, Upper LH
2331 510-21,-22, -23, -24,

0.3120

I f0.0100

131G

0.3120

lf0.0100

0.3120

IM.0100

1 0.3110

1-

-53, -54

24

2615116-1, -5
Bracket, Lower LH
2615117-1, -5
BoR- AN25-12, -17, -22

25

Pulley- MS20220A2

26

MS20220-2
Bracket- 2512500-23

23

G,H

J,

1+0.00001
-0.0020

2615113-1

0.3125

3.0000

+0.0005/

25

0.31 20

1+0.00601
-0.0010

26

0.3120

1+0.0100/

25

0.31 20

1+0.0060/

26

J, K

0.3120

25

0.3120

26

0.31 20

+0.0050/

1-0.0000

-0.0000
27

1 Bracket-2512500-22
2615112-2

28

Bracket- 2512500-24
2615119-1

29

1 Bolt- AN2527

J,K

30

1 Pulley-MS20220A2

0.3125

31

1 Bracket- 2512500-5, -6, -7,

0.3120

-0.0010
1+0.0100/
-0.0000
1+0.0060/
-0.0010
1+0.01 00/
-0.0000

1 0.3110

1-

1+0.0000/
-0.0020

3.0000

+0.0005/

)-0.0000

MS20220-2

-8, -11,-12, -42, -44,


-55, -56, -57, 68
32
33

34

+0.0050/

BoA- NAS464P5-44
NAS464P5-23
Pulley- MS20220A2

I
L

i Bracket-2512500-27, -28

I
I

1+0.00601
1 +0.0010

1 0.3117
I

11

0.315

0.3120

1+0.0080/

0.3120

1+0.0060/

3.0000

+0.0005/

1+0.0000/
1-0.0009
+0.0050/
-0.0000

-0.0001

2488510-4, -5

2488716-4, -5

0.3120

1+0.0060/

2512500-6, -t 7, -18, -33,


-34, -39, -40, -47

0.3120

1+0.0080/

(-0.0001

-0.0001
-0.0001

Rudder

EFFECT~VITY:

ALL

Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 7 of 16)
51-71-08

Page7
SRM-I

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

DESCRIPTION

NO.
35
36

37

EFF.

Bolt- NAS464P5-44
NAS464P5-23
Pulley- MS20220A1

ID

OD

0.3117

1
I

I
I

1
I

Bracket- 2312500-34, -35,


36

0.3120

Bolt-NAS464P5-22

1 Pulley-

M520220-2
MS20220A2

0.3120

1.7500

1
1
1

0.31 25

MFD

0.3117
3.0000

ALLOWANCE

ID

OD

WEAR
I

ID

ALLOWANCE
OD

1 +0.0000/
1 -0.0009
+0.0005/

+0.0050

-0.0000
1 +0.0006
1 -0.0010
1
1 +0.0000/
-0.0009
+0.0050
+0.0005/

1 -0.0000

1 +0.0010/
-0.0000

Bracket- 2315120-11, -12,

-33, -34, -37, -39, -40, -41


Bolt- AN5-24, -25
Bellcrank- 2315129-4

3115042-1

0.3125

Bearing- 8-546-22
(Alt. &540-0[))

1.3130

0.3754

1.3130
0.3754

0.7488

MS27646-40

R
43

MFD
SHAFT

0.3125

39

42

HOLE I

MFD
HOLE

41

38

40

0.3120

0.7488

0.3750

1 +0.0000/

-0.0030
I f0.0010
1 +0.0005/
-0.0000
I ~H).0010
1 +0.0005/
-0.0000
1 +0.0005/
1 -0.0000
1 +0.0005/

1
1

-0.0000
44

Shaft- 2315121-29, 35

0.8470

+0.0010

+0.00001

-0.0000
45

Bolt- NAS1306-601-I

46

Link- 2300003-1 31

47

Bolt- AN24-12

S
R

48

Bolt- AN25-12

49

Tumbuckle EyeNAS64846LL

-0.0010

0.3745

1 +0.0000/

1
1
1

0.2480

I f0.0100
I M.0100
1
1 +0.00001

0.3110

-0.0010
0.2500
0.3120

-0.0020

1 +0.0000/
-0.0020

50
51

Bushing- DBS-Q-030
(Alt. -AJg4C-1 25)
1 Bearing-KS4A
(Alt. -MS27645-4A)

ALL

Rudder

(EFFECTIVITY:

0.3120

0.2500
0.2500

1 +0.0020/
-0.0000

0.7500
0.7500

+0.0000/

+0.0000/

-0.0005

-0.0005

+0.0000/
-0.0005

+0.0000/

Fittings Allowable Wear and Repair


Figure 1 (Sheet 8 of 16)

-0.0005

Data

51-71-08

Page 8
SRM-I

Jun 6/98

Learjet
Leariet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

DESCRIPTION

NO.
52

2315121-14

Aft Rod End

MFD

MFD

HOLE

SHAFT

MFD

ALLOWANCE
OD

ID

EFF.

HOLE

ID

OD

23

0.2500

1 +0.0010/

24

0.2500

1 +0.0010/

WEAR
ID

ALLOWANCE
OD

-0.0000
70031 00-901

-0.0000
Bolt- AN24-15

53

0.2480

1 +0.00001

-0.0020
54

1 Connecting

Rod-

2315121-21

10

0.2500

1 +0.001 0/

2415149-4

12

0.2500

3115140V1-1

13

0.2500

3115040-2

14

0.2500

15

T, U

0.6570

0.7490

T, U

0.6570

0.7490

-0.0000
1 +0.001 0/
-0.0000
1 +0.0010/
-0.0000
1 +0.0010/
-0.0000

55 1

Bolt- NAS464P4-9

56

Bellcrank- 2315121-1

0.2492

1 +0.0000/
-0.0009

16

2315138-1, -4, -6, -8

i +0.0020/
-0.0000
1 +0.0005/
-0.0000
1 +0.0020/
-0.0000
1 +0.0005/
-0.0000

57

1 Bearing-

17

LS4

0.2500

T,U

18

T, U

Bolt- NAS464P4-9

Rod End-2315121-14

0.2500

Bearing- AN201KP4A

0.2500

MS21 233-4

0.6562

+0.0000/

-0.0005

-0.0005
+0.0000/
-0.0005

+0.0000/

0.6562

0.2500

+0.0000/

-0.0005
58

0.2492

1 +0.0000/

-0.0009
59

1 +0.0010/
-0.0000

60

0.7500

+0.0000/

+0.0000/

-0.0005

-0.0005

61

Bolt- NAS1304-32H

62

Bracket- 231 5122-1, -7, -8,

0.2495

1 +0.0000/
-0.0010

0.1890

1 ~0.0100

-17, -18, -117, -118, -122,


-133,-149

Rudder

EFFECTIVITY:

ALL

Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 9 of 16)
51-71-08

Page
SRM-I

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I
NO.
63

I
DESCRIPTION

MFD

MFD

HOLE

SHAFT
OD

EFF.

HOLE

ID

0.3125

MFD

ALLOWANCE

ID

OD

WEAR
ID

ALLOWANCE
OD

1 Bearing

Rod EndMS21 242-S05

1 +0.0000/
-0.0005

64

Pedal

Support-

2315141-17, -18, -29, -30

Bolt- NAS464P5-9

65

0.3130

0.7500

0.8690

1 +0.0010/
-0.0000
+0.0000/
-0.0020

0.5000

+0.000/
-0.001

+0.0020/
-0.0000

WI

0.3117

1 +0.0000/

0.2470

1 +0.0010/

-0.0009

66

1 SupportStud

67

Bearing- AN201KP4A

68

Sleeve Pin-2315141-12

69

Bushing- NAS77-8-25

0.5000

0.6265

+0.0015/
-0.0000

+0.0000/
-0.0008

Bushing- NAS75-4-202

0.2500

0.3761

+0.0015/
-0.0000

+0.0000/
-0.0005

19

0.6250

i +0.0000/

0.3750

0.6250

1
1

1 +0.0030/
1 +0.0000/

0.3750

0.6250

1
1

0.3750

0.6250

1 +0.0030/
1 +0.0000/
-0.0020
1 +0.0030/
-0.0010
1 +0.0000/
-0.0020

0.3750

-2315141-20

-0.0000
0.2500

0.7500

+0.0000/

+0.0000/

-0.0005

0.4980

-0.0005

1 +0.0000/
-0.0020

70
71

RudderPedal-

2315141-1,-24, -33

-0.0020
238401 0-2, -6

20

-0.0020

2415171-1, -9

2415175-1

21

22

i +0.0030/
-0.0010

Rudder

IEFFECTIVITY:

ALL

Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 10 o~ 16)
51-71-08

Page
SRM-Q

10

Jun 6/98

Learjet
~Learjetl

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

TTEIIl
NO.
72

I
IEFF.

DESCRIPTION

Link

Assy. 2315167-22,

-29

MFD

MFD

HOLE

SHAFT
OD

MFD

HOLE

ID

0.6557

1+0.0020/

AA

0.6557

1+0.0020/

ALLOWANCE
OD

ID

WEAR
ID

ALLOWANCE
OD

-0.0000
-0.0000
73

II

Bearing- AG4S
(Alt. -ABG-4)
(Alt. -LHA-4)

74

Bolt- NAS464P4-9

75

Arm

Assy. 2315166-10, -11,


-15, -16, -18, -19

AA

AA

1
1

AA
AA

AA

1 0.2492

1+0.0000/
-0.0009

0.2500

1+0.0050/

0.9390

1+0.0005/

AB

0.1890

1+0.0060/

10.1894

-0.0010
-0.0000
-0.0010
1

AB

\1

78

Lin~-23151 67-14, -27


Bushing- NAS753-011

AB
AB

0.3120
0.1 900

79

1 NutAssy.-2315167-16

AC

0.3140

80

I Bushing-

AC

0.1900

81

1 Lever-2315167-28

AC

0.1910

76

Bolt- NAS464P3-9

77

1+0.0000/
-0.0009

NAS753-004

0.31 36

1
0.3136

f0.0010
+0.0015/ +0.0000/
-0.0000 1-0.0005
1 +0.0010/
-0.0000
+0.0015/ +0.0000/
-0.0000
-0.0005

1+0.00501
-0.0010

Rudder

EFFECTIV~:

ALL

Fittings Allowable Wear and Repair Data


Figure 1(Sheet 11 of 16)
51-71-08

Page 11
SRM-4

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
REPAIR DATA

ITEM
EFF.

HOLE

Horn Assy. 2333009-6


Bearing- MS21233-4

DESCRIPTION

NO.
1
2

Bolt

NAS464P4-8
2433003-2
HFV-4
Rod
End
Bearing,

Clevis, Rod End

Bolt NAS464P4-13
NAS464P4-14
Actuator Arm 2333008-3, -4 ,-6, -7

Hinge Assy. 2331030-10,


Bearing AN201KPIA

5
6
7

8
9

-12

REPAIR

Replace worn part.


Replace worn part. Install
Loctite. (Refer to 51-70-00.)
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
or secure

Bolt

10

II

AN4H11A

2331031-8, -10,

41-,11-

Hinge Assy.
12

1 Bearing-AN201KP4A

Bolt- AN4H11A
Bearing Block Assy.

14

2312040-7
Bearing- BR-4

15

13

Stake

with Lodite.

new

(Refer

I Replace

worn

stake in

place

part. Install
or secure

F
F

Replace worn part.

Replace worn part.

G, H

Replace worn part.


Replace worn part.

G
H

24

2331510-21,-22, -23, -24, -53, -54


2615116-1,6
Bracket, Lower LH 2615117-1, -5
Bolt AN25-12, -17, -22

25

Pulley MS20220A2

G, H
J, K

26

Bracket 2512500-23
2615113-1
Bracket 2512500-22

25

26

25

J, K
J, K

NAS144A23

16

Bolt

17

Torque Tube Assy. 2433002-1


Bushing DBS-4-030
(AltAJ04C-125)

18
19
20
21
22

23

1 Fork End Terminal


MS20667-6
Bolt NAS464-4-8
Pulley MS20220A2
Bracket, Upper LH

3
1

in

place

51-70-00.)

new

bearing and

(Refer

to

51-70-00.)
I Replaceworn part.

(Alt DAS4-14A)

bearing

to

with Loctite.

bearing with

Replace worn part.


Replace worn part.

Replace worn part.


Replace worn part. Install
primer.
Replace worn part. Install
primer.
Replace worn part.

new

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.
part.

Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.

new

bearing

in wet

new

bearing

in wet

MS20220-2

27

26

2615112-2

Rudder

(EFFECTIVITY:

ALL

Fittings Allowable Wear and Repair


Figure 1 (Sheet 12 of 16)

part.

Data

51-71-08

Page
SRM-I

12

Jun 6/98

Learjet I
Learjet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

DESCRIPTION

NO.
28

Bracket

2512500-24

2615119-1
29

30
31

Bolt

AN25-27

Pulley MS20220A2
MS20220-2
1 Bracket 2512500-6, -7, -8, -11,-12,

REPAIR

EFF.

HOLE

25
26

K
K

J, K

Replace worn
Replace worn
Replace worn
Replace worn

Replace worn part.

Replace worn part.

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.

-42, -44, -55, -56, -57, -58


32
33
34

NAS464P5-44
NAS464P5-23
Pulley MS20220A2
Bracket 2512500-27, -28
2488510-4, -5
Bolt

2488710-4, -5
2512500-6, -17, -18, -33, -34, -39,
-40, -47

39
40

NAS464P5-44
NAS464P5-23
Pulley MS20220A1
Bracket 2312500-34, -35 ,-36
Bolt NAS464P5-22
Pulley MS20220-2
Bracket 2315120-11, -12, -33, -34,

41

-37, -39, -40, -41


Bolt AN5-24, -25

35
36
37
38

42

43

44

45
46
47

48
49
50
51

Bolt

Bellcrank 2315129-4
3115042-1
Bearing- 8-540-ZZ

6
7

M
M

N
P
P

1
1

Q, R
Q, R

9
8

(Alt. -B540DD)

MS27646-40

1
1

Q
Q

R, S

Shaft 2315121-29, -35


Bolt NAS1306-60H
Link 2300003-131
Bolt AN24-12
Bolt AN2512
Turnbuckle Eye NAS64&46LL
Bushing DBS-4-030
Bearing KS4A

(Alt.

MS27645-4A)

Rudder

EFFECTIVITY:

ALL

1
1

S
R
S

part.
part.
part.
part.
part.

I Replace worn part.


Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.
part.

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part. Install new bearing in wet
primer.
I Replace worn part. Install new bearing in wet
primer.
I Replace worn part. install new bearing in wet
primer.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part. Press fit into wet primer.
Replace worn part. Stake new bearing in place
or secure with Loctite. (Refer to 51-70-00.)
I Replace worn part. Stake new bearing in place
or secure with Loctite. (Refer to 51-70-00.)

Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 13 of 16)
51-71-08

Page 13
SRM-4

Jun 6/98

I Learjet
Learjeil
STRUCTURAL REPAIR MANUAL
REPAIR DATA

ITEM

NO.

52

DESCRIPTION

Aft Rod End

2315121-14

7003100-901

HOLE

10

S
T
T

53

Bolt

54

Connecting

10
12

55
56

AN24-15
Rod 2315121-21
2415149-4
3115140V1-1
3115040-2
Bolt NAS464P4-9
Bellcrank- 2315121-1

EFF.

13
14

2315138-1,-4, -6, -8
57

58
59
60
61
62

15

T, U, V
T, U, V
T, U
T, U
T, U
T, U
T, U
T, U

U
V

17

18
1

(Alt. LHSSVV-4)
(Alt. -BLFN-4)
(Alt. -BLFN-4-100)
(Alt. -RSST-4)

1
1

Bolt

NAS464P4-9
Clevis, Rod End 2315121-14
Bearing- AN201KP4A

Bolt NAS1304-32H
Bracket 2315122-1, -7, -8, -17, -18,

1
16

LS4
MS21233-4

1 Bearing

REPAIR

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.
part.
Replace worn part.
Replace worn part.
Replace worn part.
Replaceworn part.
Replaceworn part.
Replace worn part.
Replace worn part. Secure new bearing with
Loctite. (Refer to 51-70-00.)

Replace worn part.


Replace worn part.
Replace worn part.
primer.
Replace worn part.
Replace worn part.

Install

new

bearing in

wet

-117,-118,-122,-133,-149

69
70

Rod End
MS21242-205
Pedal Support 2315141-17, -18,
-29, -30
Bolt NAS464P5-9
Support Stud 2315141-20
Bearing AN201 KP4A
Sleeve Pin 2315141-12
Bushing NAS77-8-25
Bushing- NAS75-4-202

71

Rudder Pedal

63

64
65
66
67
68

72

Bearing,

1
1
1

X
Y

Y
Y

2415171-1

22

73

Assy. 2315167-22,
Bearing- AGQS

74

Bolt

EFFECTIVITY:

ALL

19
21

-29

NAS464P4-9

W
X

20

Link

W
Replace worn part.
W, X, YI Replace worn part.

2315141-24, -33
2384010-2, -6
2415171-1,-9

Rudder

Y, Z
Y, Z
Y, Z
Y, Z
Z, AA

AA

AA

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.

Secure
Loctite. (Refer to 51-70-00.)

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part. Secure
Loctite. (Refer to 51-70-00.)
Replace worn part.

with

new

bushing

new

bearing with

Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 14 of 16)
51-71-08

Page
SRM-4

14

Jun 6/98

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

75
76

EFF.

DESCRIPTION

NO.

Arm

Assy. 2315166-10, -11,-15,


-16,-18,-19

Bolt
Link

HOLE

AA, X,I

NAS464P3-9

AB

2315167-14, -27

AB

AB

80

AC

81

Lever

AC

78

CODES

2315167-28

Replace

worn

part.

AB

Bushing- NAS75-3-011
Nut Assy. 2315167-16
Bushing- NAS75-3-004

77

REPAIR

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part. Secure
Loctite. (Refer to 51-70-00.)
Repair worn part.

I
new

bushing

with

EFFECTIVITIES

23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 28-001 and Subsequent; 29-001
and Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent

23-001 thru 23-099; 24-100 thru 24-305, 24-309 thru 24322; 25-001 thru 25-201
001 thru 35-045; 36-001 thru 36-016

24-306 thru 24-308, 24-323 and Subsequent; 25-196, 25-202 and Subsequent; 35-046 and Subsequent; 36-017 and Subsequent; 2&001 and Subsequent; 29-001 and Subsequent; 31-001 and Subse-

Except 25-196;

35-

quent
4

5
6
7
8

23-001 thru 23-099; 24-100 thru 24-270 Except Aircraft Equipped With
24-100 thru 24-270 Equipped With Drag Chute
24-271 and Subsequent and Prior Aircraft Equipped With Drag Chute

Drag

Chute

25-001 and Subsequent; 2&001 and Subsequent; 29-001 and Subsequent; 31-001 and Subsequent;
35-001 and Subsequent; 36-001 and Subsequent
23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 28-001 and Subsequent; 29-001
and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent; 31-001 thru 31-054 Except Aircraft
Modified by SE 31-32-2, "lnstallation of Digital Nose Wheel Steering"
31-055 and Subsequent and 31-035 thru 31-054 When Modified by "lnstallation of Digital Nose Wheel

Steering"
10

11

12

23-001 thru 23-099; 24-100 thru 24-246 Except Aircraft Modified by AAK 76-04A, "Reduced
Speed System"; 25-001 thru 25-081 Except Aircraft Modified by AAK 76-04A, "Reduced

Speed System"
Subsequent and Prior Aircraft Modified by AAK 76-04A, "Reduced Approach Speed System"; 25-082 and Subsequent and Prior Aircraft Modified by AAK 76-04A, "Reduced Approach Speed
System"; 2&001 and Subsequent; 29-001 and Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
24-247 and Subsequent and Prior Aircraft Modified by AAK 76-04A, "Reduced Approach Speed System"; 25-082 and Subsequent and Prior Aircraft Modified by AAK 76-04A, "Reduced Approach Speed
System"; 2&001 and Subsequent; 29-001 and Subsequent; 31-001 thru 31-034; 35-001 and Subsequent; 36-001 and Subsequent
24-247 and

14

31-035 thru 31-051


31-052 and Subsequent

15

23-001 thru 23-037

16

23-038 and

13

29-001 and

Subsequent; 24-100 and Subsequent; 25-001 and Subsequent; 2&001 and Subsequent;
Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
Rudder

EFFECTIVITY:

Approach
Approach

ALL

Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 15 of 16)

1
51-71-08

Page
SRM-4

15

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
REPAIR DATA

CODES

EFFECTIVITIES

17

23-001 thru

18

Subsequent; 25-012 and Subsequent; 28-001 and Subsequent; 29-001 and Subsequent;
31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
23-003 thru 23-099 Except When Modified by AMK 81-02, "Rudder Pedal Rework and Heelplate Replacement" or AMK 81-03, "Rudder Pedal Heel Support Replacement"; 24-100 thru 24-357 Except
When Modified by AMK 81-02, "Rudder Pedal Rework and Heelplate Replacement" or AMK 81-03,
"Rudder Pedal Heel Support Replacement"; 25002 thru 25-302 Except When Modified by AMK 8102, "Rudder Pedal Rework and Heelplate Replacement" or AMK 81-03, "Rudder Pedal Heel Support
Replacement"; 28001 thru 28-005 Except When Modified by AMK 81-02, "Rudder Pedal Rework
and Heelplate Replacement" or AMK 81-03, "Rudder Pedal Heel Support Replacemenr; 29-001 thru
29-002 Except When Modified by AMK 81-02, "Rudder Pedal Rework and Heelplate Replacement"
or AMK 81-03, "Rudder Pedal Heel Support Replacement"; 35-001 thru 35-298 Except When Modified by AMK 81-02, "Rudder Pedal Rework and Heelplate Replacement" or AMK 81-03, "Rudder
Pedal Heel Support Replacement"; 36-001 thru 36-044 Except When Modified by AMK 81-02, "Rudder Pedal Rework and Heelplate Replacement" or AMK 81-03, "Rudder Pedal Heel Support Replacement"
23-001 thru 23-099 Except When Modified by AMK 81-02, "Rudder Pedal Rework and Heelplate Replacement" or AMK 81-03, "Rudder Pedal Heel Support Replacemenr; 24-100 thru 24-139 Except
When Modified by AMK 81-02, "Rudder Pedal Rework and Heelplate Replacement" or AMK 81-03,
"Rudder Pedal Heel Support Replacement"
23-001 thru 23-099 When Modified by AMK 81-02, "Rudder Pedal Rework and Heelplate Replacemenr; 24-358 and Subsequent and 24-100 thru 24-139 When Modified by AMK 81-02, "Rudder Pedal Rework and Heelplate Replacemenr and 24-140 thru 24-357 When Modified by AMK 81-02,
"Rudder Pedal Rework and Heelplate Replacement" or AMK 81-03, "Rudder Pedal Heel Support Replacement"; 25001 thru 25302 When Modified by A 2381421-1 Kit, 25303 thru 25-338 When Modified by AMK 81-02, "Rudder Pedal Rework and Heelplate Replacement" or AMK 81-03, "Rudder
Pedal Heel Support Replacement" and 25-340 thru 25-357 When Modified by AMK 81-03, "Rudder
Pedal Heel Support Replacement"; 2&001 thru 2&005 When Modified by AMK 81-02, "Rudder Pedal Rework and Heelplate Replacement"; 29-001 thru 29-003 When Modified by AMK 81-02, "Rudder
Pedal Rework and Heelplate Replacement"; 35-001 thru 35400 When Modified by AMK 81-02,
"Rudder Pedal Rework and Heelplate Replacement"; 36-001 thru 36-047 When Modified by AMK 8102, "Rudder Pedal Rework and Heelplate Replacement"
23-001 thru 23-099 When Modified by AMK 81-02, "Rudder Pedal Rework and Heelplate Replacement"; 24-140 thru 24-357 When Modified by AMK 81-02, "Rudder Pedal Rework and Heelplate Replacement"; 25339 and Subsequent When Modified by AMK 81-02, "Rudder Pedal Rework and
Heelplate Replacement"; 28-006 and Subsequent When Modified by AMK 81-02, "Rudder Pedal Rework and Heelplate Replacement"; 29-004 and Subsequent When Modified by AMK 81-02, "Rudder
Pedal Rework and Heelplate Replacement"; 31-001 and Subsequent; 35-401 and Subsequent When
Modified by AMK 81-02, "Rudder Pedal Rework and Heelplate Replacement"; 36-048 and Subse-

19

20

21

22

23-099; 24-100 thru 24-171; 25-001 thru 25-011

24-172 and

quent When Modified by


23

24

SRM-4

2384010-5 Kit

Equipped With Yaw Sensor; 29-001 and Subsequent Not Equipped With Yaw Sensor; 31-001 and
Subsequent Not Equipped With Yaw Sensor; 35-001 and Subsequent Not Equipped With Yaw Sensor; 36-001 and Subsequent Not Equipped With Yaw Sensor
23-001 thru 23-099 Equipped With Yaw Sensor; 24-100 and Subsequent Equipped With Yaw Sensor; 25-001 and Subsequent Equipped With Yaw Sensor; 28001 and Subsequent Equipped With
Yaw Sensor; 29-001 and Subsequent Equipped With Yaw Sensor; 31-001 and Subsequent
Equipped With Yaw Sensor; 35001 and Subsequent Equipped With Yaw Sensor; 36-001 and Subsequent Equipped With Yaw Sensor
Rudder

JEFFECTIVITY:

23-001 thru 23-099 Not Equipped With Yaw Sensor; 24-100 and Subsequent Not Equipped With
Yaw Sensor; 25-001 and Subsequent Not Equipped With Yaw Sensor; 28-001 and Subsequent Not

ALL

Fittings Allowable Wear and Repair Data


Fi~ure 1 (Sheet 16 of 16)
51-71-08

Page 16
Jun 6/98

Learjet I

STRUCTURAL REPAIR MANUAL


HORIZONTAL STABILIZER FIITINGS

i:

ALLOWABLE WEAR AND REPAIR DATA

AB
CA

__

i 3

/7

8
5

il

j
B

E
D

Detail A
Horizontal Stabilizer
AB7C
eec

EFFECTIVrTY:

ALL

Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 1 of 5)
51-71-09

Page 1
SRM-4

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

NO.
1

I
DESCRIPTION

EFF.

I
HOLE

MFD

MFD

HOLE

SHAFT

ID

OD

MFD

ALLOWANCE

ID

OD

WEAR
ID

ALLOWANCE
OD

Hinge Assy.
2332015-1, -2, -7, -8,
-16, -17, -20, -21

BushingNMB (A)

AJF16C-1O1

2.3000

1 +0.11001

1 -0.0000

1.2510

+0.00001

1.2510

+0.0000/
-0.0005

1.3760

+0.0000/

1.3760

+0.0000/

-0.0005

(Alt. -KJB172016B)
3

BushingNMB

(A) AJF18C-102

-0.0005

(Alt. -KJB1721188)

-0.0005
4

Pin-2331028-1, -2, -3, -4,


1

-5,-6

1
I
1

1.1280

I
I
I

1.0937

1
I
1

1 +0.0000/
1 -0.0005
1 +0.0005/

1.0320

i ~0.0100

1.0312

1 +0.0005/

1.0030

1 +0.0000/

1.1305

+0.0000/

1.0937

1 +0.0005/

1.0320

1 ~0.0100

1.0312

1 +0.0005/

1.0049

1 +0.00001

-0.0000

-0.0000
-0.0005
2430000-1 929-1, -2

-0.0010

-0.0000

-0.0000
-0.0005
5

Hinge Assy.
2331025-1,-2, -7, -8,
(Alt.2331 025-15, -16)

1.1875

1 +0.0005/

1.2500

1.1875

1 +0.0005/
-0.0000
1 +0.0005/

1.2500

I
H

2530000\/2-1,

-2

-0.0000

-0.0000

Horizontal Stabilizer

IEFFECTNITY:

ALL

1 +0.0005/
-0.0000

Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 2 of 5)

51-71-09

Page:!
SRM-I

Jun 6/98

Learjet 1

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM

NO.

I
EFF.

DESCRIPTION

6031025-1, -2, -5, -6,


-11,-12

I
HOLE
G

MFD

MFD

HOLE

SHAFT

ALLOWANCE

ID

ID

1.1875

1 +0.00051

1 +0.0005/

I
H

MFD

1.2500

OD

OD

WEAR
ID

ALLOWANCE
OD

-0.0000
-0.0000

Bushing,

LH4

2331 025-7

1.0937

1.2510

+0.0005/

+0.0005/

-0.0000

-0.0000
+0.0005/

2331025-13

1.0937

1.2510

+0.0005/
-0.0000

-0.0000

6031 025-5

1.0937

1.2510

+0.0005/

+0.0005/

-0.0000

-0.0000

Bushing,

RH-

2331 025-8

1.0312

1.1885

+0.0005/
-0.0000

+0.0005/
-0.0000

2331025-14

1.0312

1.1885

+0.0005/
-0.0000

+0.0005/

6031 025-6

1.0312

1.1885

+0.0005/
-0.0000

+0.0005/
-0.0000

E
E

1.0600

1.2500

0.9300

1.0000

~t0.0100

rt0.0100

Sleeve- 2431111-1,-2
2431111-3

Horizontal Stabilizer

EFFECTIVITY:

ALL

-0.0000

Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 3 of 5)

51-71-09

Page3
SRM-I

Jun 6/98

Leariet
~jLearjetl
STRUCTURAL REPAIR MANUAL
REPAIR DATA

ITEM

NO.
1

D ESC RI PTION

EFF.

HOLE

Hinge Assy. 2332015-1, -2, -7, -8,

I Replace worn part.

I Replace worn part.

I Replace worn part.

-16, -17, -20,


2
3
4

-21

Bushing NMB (A) AJF16C-I01


(Alt. -KJB172016B)
Bushing NMB (A) AJF18C-102
(Alt. -KJB1721188)
1 Pin 2331028-1, -2, -3, -4, -5,
2331028-1929-1,

-6

-2

Hinge Assy. 2331025-1, -2, -7,


(Alt. 2331 025-15, -16)

-8

5430000\12-1,-2
6031025-1,-2, -5, -6, -11,-12
6

LH 2331025-7
2331025-13
6031025-5
Bushing, RH 2331025-8
2331025-14
6031025-6
Sleeve 2431111-1,-2
2431111-3

Bushing,

Horizontal Stabilizer

EFFECTIVITY:

ALL

REPAIR

6
4

B, C, D,I Replace
E, F
B, C, D,I Replace
E, F
G, H
Replace

G, H
G, H
F

5
6

worn

part.

worn

part.

worn

part.

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.
part.
part.
part.
part.
part.
part.

Fittings Allowable Wear and Repair


Figure 1 (Sheet 4 of 5)

Data

51-71-09

Page4
SRM-I

Jun 6/98

Learjet
Learjet

STRUCTURAL REPAIR MANUAL


CODES
1

3
4

EFFECTIVITIES
23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 28-001 and Subsequent; 29001 and Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
23-001 thru 23-099; 24-100 and Subsequent Except 24-307 and 24-323; 25-001 and Subsequent
Except For 25-204; 28001 and Subsequent; 29-001 and Subsequent; 31-001 and Subsequent; 35001 and Subsequent; 36-001 and Subsequent
24-307 and 24-323; 25-204
23-001 thru 23-099 Except When Modified by SSK 9101, "Replacement of Horizontal Stabilizer
Hinge Assembly"; 24-100 and Subsequent Except When Modified by SSK 9101, "Replacement of
Horizontal Stabilizer Hinge Assembly"; 25-001 and Subsequent Except When Modified by SSK 9101,
"Replacement of Horizontal Stabilizer Hinge Assembly"; 28-001 and Subsequent Except When Modified by SSK 9101, "Replacement of Horizontal Stabilizer Hinge Assembly"; 29-001 and Subsequent
Except When Modified by SSK 9101, "Replacement of Horizontal Stabilizer Hinge Assembly"; 31001 thru 31-042 and Subsequent Except When Modified by SSK 9101, "Replacement of Horizontal
Stabilizer Hinge Assembly"; 35-001 thru 35-670 and Subsequent Except When Modified by SSK
9101, "Replacement of Horizontal Stabilizer Hinge Assembly"; 36-001 thru 36-063 and Subsequent
Except When Modified by SSK 9101, "Replacement of Horizontal Stabilizer Hinge Assembly"

31-043 thru 31-049

23-001 thru 23-099 When Modified by SSK 9101, "Replacement of Horizontal Stabilizer Hinge Assembly"; 24-100 and Subsequent When Modified by SSK 9101, "Replacement of Horizontal Stabilizer Hinge Assembly"; 25-001 and Subsequent When Modified by SSK 9101, "Replacement of Horizontal Stabilizer Hinge Assembly"; 28-001 and Subsequent When NModified by SSK 9101,
"Replacement of Horizontal Stabilizer Hinge Assembly"; 29-001 and Subsequent When Modified by

SSK 9101, "Replacement of Horizontal Stabilizer Hinge Assembly"; 31-050 and Subsequent and
Prior Aircraft Modified by SSK 9101, "Replacement of Horizontal Stabilizer Hinge Assembly"; 35-671
and Subsequent and Prior Aircraft Modified by SSK 9101, "Replacement of Horizontal Stabilizer
Hinge Assembly"; 36-064 and Subsequent and Prior Aircraft Modified by SSK 9101, "Replacement of
Horizontal Stabilizer Hinge Assembly"
23-001 thru 23-099; 24-100 and Subsequent; 25-001 thru 25375; 28-001 thru 28-005; 29-001 thru

29-004; 35-001 thru 35-525; 36-001 thru 36-053


8

25-376 and

Subsequent;

31-001 and

Horizontal Stabilizer

EFFECTIVITY:

Subsequent;

35-525 and

Subsequent;

36-054 and

Subsequent

Fittings Allowable Wear and Repair Data


Figure 1 (Sheet 5 of 5)

ALL

Page
SRM-I

Jun 6/98

Learjet i

STRUCTURAL REPAIR MANUAL


ELEVATOR SYSTEM

ALLOWABLE WEAR AND REPAIR DATA

AsC

2,
2,

~CLB
M

Z,N

E
J

(Model 23 Series Aircraft Only)

K\4

~o
E

Lu

i~HYi

Q\,

"G

2,
Elevator

EFFECTIVITY:

NOTED

System Allowable Wear and Repair Data


Figure 1 (Sheet 1 of 29)
51-71-10

Pagel
SRM-4

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


ELEVATOR SYSTEM

ALLOWABLE WEAR GND REPAIR DATA

/e

i-i~-

(Model 25. 28. 29. 31. 35 and 36 Series Aircraft)

K\J\H
\M

~P

N
D

P:
A ,3
4

78

B
C

Detail A
8814C-1
CB-14C

Elevator

~15C

EFFECTIVITY:

ALL OR NOTED

System Allowable Wear and Repair


Figure 1 (Sheet 2 of 29)

Data

51-71-10

Page2
sRM-4

Jun 6/98

Learjet
~Learjet
STRUCTURAL REPAIR MANUAL
ELEVATOR SYSTEM

ALLOWABLE WEAR AND REPAIR DATA

Detail B

12

Detail C

a~

16

Detail D
BB14C-1

Elevator

CB14C
Dg15C

EFFECTIVITY:

ALL

System Allowable Wear and Repair Data


Figure 1 (Sheet 3 of 29)
51-71-10

Page
SRM-4

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


ALLOWABLE WEAR AND REPAIR DATA

ELEVATOR SYSTEM

-7

103

AM

AL

~tCU/

102

AM

O ii

,1K

98

--~-t

Detail E
BS14C-l
ael4e

os-lse

EFFECTNITY:
SRM-4

Elevator

System Allowable Wear and Repair Data


Figure 1 (Sheet 4 of 29)

24SERIES AIRCRAET

51-71-10

Page4
Tun 6/98

Learlet
~Learjet(

STRUCTURAL REPAIR MANUAL


ELEVATOR SYSTEM

ALLOWABLE WEAR AND REPAIR DATA

86

88

AG

21.

20

101

C\J

AH
91~

93
94
95

15

Detail E
B&14C-1
CB14C
DB15C

EFFECTIVITY:

Elevator

System Allowable Wear and Repair Data


Figure 1 (Sheet 5 of 29)

24 SERIES AIRCRAFT AND 25 SERIES AIRCRAFT

51-71-10

Page 5
SRM-4

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
ELEVATOR SYSTEM

104~\ R

ALLOWABLE WEAR AND REPAIR DATA

le

20

21

107

AL
23

j
AM

S
105

\106

AK

Detail E
AV

27P
115

DetailT
EFB52C-1

EFFECTIVITY:

Elevator

Detail U

System Allowable Wear and Repair Data


Figure 1 (Sheet 6 of 29)

25SERIES AIRCRAFT~

51-71-10

Page6
SRM-I

Tun 6/98

Learjet
~Learjetl

STRUCTURAL REPAIR MANUAL


ELEVATOR SYSTEM

ALLOWABLE WEAR AND REPAIR DATA

107

z
93
94

95

AR
109

114

113

AQ

111

AO
108

r~

33

i;o

AU

AL

BATi
AS

AM

105

33

112
112

AH

GBI4e
H882A

EFFECTIVITY:

Detail S
Elevator

System Allowable Wear and Repair Data


Figure 1 (Sheet 7 of 29)

25 SERIESAIRCRAET

51-71-10

Page 7
SRM-I

Jun 6/98

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


ELEVATOR SYSTEM

35

ALLOWABLE WEAR AND REPAIR DATA

N 21

20

K
17

36

Q~

zs
3s

~3 1
24

0~

28

21

Detail E

31

Detail F

Is81A
KL&44B
Mg32C
Ne9e

EFFECTIVITY:

Elevator

System Allowable Wear and Repair Data


Figure 1 (Sheet 8 of 29)

28, 29, 31, 35 AND 36 SERIES AIRCRAFT

51-71-10

Page8
SRM-I

Jun 6/98

Learjet
~Learjet
STRUCTURAL REPAIR MANUAL
ELEVATOR SYSTEM

ALLOWABLE WEAR AND REPAIR DATA

CZ~;

39

kL
43

47-~

44

Detail G

50

49

d
I

JgelA

Elevator

KLg44B

Mg32C
NB9C

EFFECTIVITY:

ALL

Detail H

System Allowable Wear and Repair Data


Figure 1 (Sheet 9 of 29)
51-71-10

Page
SRM-4

Jun 6/98

Learjet
Leariet I

STRUCTURAL REPAIR MANUAL


ELEVATOR SYSTEM

ALLOWABLE WEAR AND REPAIR DATA

52

,54

Detail J

57

_r">YS

~4.

se

~ohP:
~It

58

Detail K

56

5P

60

61

Detail I
P&15C

JEFFECTIVITY:

Elevator

ALL

System Allowable Wear and Repair Data


Figure 1 (Sheet 10 of 29)
51-71-10

Page
SRM-I

10

Jun 6/98

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


ALLOWABLE WEAR AND REPAIR DATA

ELEVATOR SYSTEM

.*1

62

z
AA

B
Pa
64

Po I/~\

Detail M

Detail N

AB
AC

AD

AP

i
$8

AE
70

7~1

15~BP
Detail P

QRLF~WD

EFFECTIVITY:

Elevator

ALL

System Allowable Wear and Repair Data


Figure 1 (Sheet 11 of 29)
51-71-10

Page 11
SRM-I

Jun 6/98

I Learjet
Learjetl
STRUCTURAL REPAIR MANUAL
ELEVATOR SYSTEM

ALLOWABLE WEAR AND REPAIR DATA

AF

AG

i1/~76

77

75
it

3
77

Detail Q

Detail R
QR&43D

EFFECTIVITY:

Elevator

System Allowable Wear and Repair Data


Figure 1 (Sheet 12 o~ 29)

AIRCRAFT EQUIPPED WITH ELEVATOR BOB WEIGHT

51-71-10

Page
SRM-I

12

Jun 6/98

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

MFD
ITEM I

Bellcrank Assy.
2331 511-15, -16, -33, -34,

-45, -46, -61, -62, -83, -84, 1


-1 01, -102, -801, -802

Bearing- MS27645-4A

EFF. I HOLE

DESCRIPTION

NO.

MFD

HOLE

SHAFT

ID

OD

0.7493

MFD
ID

1+0.00001

1-0.0005

B, C

0.3140

1+0.0030/

0.7395

-0.0000
1+0.0005/
-0.0000

0.2500

0.7500

1+0.0000/
-0.0005

Pin- HL 18-8-9

BoB- 2331511-87

3
4

6
7

Bolt NAS464P4A-32
NAS464P4A30
SB41 OA4K28S
Torque Tube 2434003-7
Bearing- BLFR-4-045
Bolt- NAS464P4-14

Rod End Clevis

ALLOWANCE
OD

WEAR
ID

ALLOWANCE
I

OD

+0.0000/
-0.0005

1 0.2495

1+0.0000/

1 0.2495

1+0.0000/

-0.0010
-0.0010
4

B,
B,
B,
B,

5
6

C
C
C

C
D

0.3140

1 0.0030

1 0.2492

1+0.0000/
-0.0009

0.2492

1+0.001 01

0.2492

1+0.001 01

0.7488

1+0.00051

2331510-75

2331510-31

-0.0000
-0.0000
9

Hinge Assy. 2332918-16,


1

-20, -22

10

1 Bearing-ANPO1KP4A

11

I Bolt- AN4H11A

12

1 HingeAssy. -2332013-19,

48

1
0.2500

1-0.0000
0.7500

1 0.2490

+0.00001
-0.0005

+0.0000/
-0.0005

1+0.0000/
-0.0030

-22, -24
3532003-1, -2

+0.0005/

0.7488

1-0.0000

49

0.7488

48

0.2500

0.7500

49

0.2500

0.7500

+0.00051
-0.0000

13

1 Bearing-AN201KP4A
MS27641-4

14

1 Bolt-AN4H11A

1 0.2490

+0.0000/
-0.0005
+0.0000/
-0.0005

1-

+0.0000/
-0.0005
+0.0000/
-0.0005

1+0.0000/
-0.0030

15

Bearing Rod

End

2331 51 0-28

0.9020

1+0.0020/
-0.0000

Elevator

EFFECTIVITY:

ALL

System Allowable Wear and Repair Data


Figure 1 (Sheet 13 of 29)
51-71-10

Page 13
SRM-4

Jun 6/98

Leariet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

NO.
16

I
1
I
IEFF.
HOLE I

DESCRIPTION

1 Bearing- AN200KS-4
(Alt. MS276454)

17

Yoke-2331512-2

MFD

MFD

HOLE

SHAFT

ID

OD

ID

OD

0.2500

0.9014

+0.0000/
-0.0005

+0.00001
-0.0005

+0.00001

+0.0000/

-0.0005

-0.0005

0.2500

MFD

0.9014

ALLOWANCE

0.2492

1 +0.0010/

0.2495

-0.0000
1 +0.0010/

0.7494

0.2492

0.2495

0.7494

0.2492

1 +0.001 0/
-0.0000

0.2495

1 +0.0010/

0.7494

-0.0000
1 +0.0000/

0.2492

1 +0.0010/

0.2495

0.7494

0.2492

0.2495

0.7494

1 +0.0010/
-0.0000
1 +0.0000/
-0.0006
1 +0.0010/
-0.0000
1 +0.0010/
-0.0000
1 +0.00001
-0.0006

WEAR
I

ID

ALLOWANCE
OD

-0.0000

2331517-2

10

1 +0.0000/
-0.0006
1 +0.00101
-0.0000
1 +0.0010/
-0.0000
1 +0.00001
-0.0006

2531 533-1

11

-0.0006

2531 533-5

12

-0.0000

2631 508-2

18

13

Bolt- NAS464P4-35

Cable

0.2492

1 +0.0000/
-0.0009

19

Fitting-26315041
1

(Alt. 2631509-2)

20

1 Hinge

Bracket-2331510-17

Elevator

(EFFECTIVITY:

ALL

0.2500

0.1880

0.2500

1 +0.0050/
1 -0.0000
1 +0.0050
-0.0000
-0.0000
1 +0.0020/
-0.0000

System Allowable Wear and Repair Data


Figure 1 (Sheet 14 of 29)
51-n-10

Page
SRM-4

14

Jun6/98

Learjet
~Leariet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

NO.I

DESCRIPTION

21

22

1 Down-spring

Bolt-NAS464P48

EFF.

HOLE

MFD

MFD

HOLE

SHAFT

ID

MFD

OD

0.2492

ALLOWANCE

ID

OD

WEAR
ID

ALLOWANCE
OD

1 +0.00001
-0.0009

FrameBrM-

23

2531 539-1
Bolt- AN23-13

24

Down-spring

I
L

0.1895

1 +0.0010/

1 -0.0000
0.1860

1 +0.0000/
-0.0020

Frame-

2631 507-1, -8, -10, -12,


-16

13

0.5628

1 +0.0000/

1 -0.0004

0.2505

1 +0.0000/

0.3125

1 +0.0005/

-0.0010
-Q.0000
22

26

Bearing- F3DD
Bushing- 2631507-6

13

27

Stud-2631515-5

17

0.2492

28

Bolt-AN23-16

13

0.1860

29

Drawbar- 2631503-4, -6

13

25

0.3136

0.1560

f0.0100

0.6250

1 +0.0020/

0.3750

1 +0.0000/

0.2340

+0.0000/
-0.0005
1 +0.00001
-0.0009
1 +0.0000/
-0.0020

-0.0000
-0.0010
30
31

13

Bushing- 2631 5033

0.3760

+0.0050/

+0.0010/

-0.0000

-0.0000

1 Down-springRetainerP

13

2631 505-2
32

(Alt. 2631505-4)
Down-spring Retainer-

I
P

13
27

2631 505-1

26315053

33

Bushing-

34

Drawbolt- 2631 504-1, -2

0.6250

13

I
0.5150

I
P

1
I
0.6250

0.51 50

1
0.3160

0.5000

1 +0.0020/
1 -0.0000
1 +0.0000/
1 -0.0050
+0.0000/
-0.0005

+0.0000/
-0.0020
1 +0.00001
-0.0050

1 +0.0040/

-0.0000
35

Stud- 263151 5-5

13

0.2492

1 +0.0000/
-0.0009

Elevator

ALL

System Allowable Wear and Repair Data


Figure I (Sheet 15 of 29)
51-71-10

Page
SRM-4

15

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

MFD
ITEM I

NO.
36

37

I
DESCRIPTION
Rod End
2531538-3

I
EFF.

HOLE

17

13

HOLE

MFD

MFD

ALLOWANCE

WEAR

ALLOWANCE

I SHAFT

ID

0.2492

OD

OD

ID

ID

OD

1 Bearing

(Alt. HMK-4DA)
Bearing Rod End

HMVV-4

Clevis Rod End


2331510-32

13

39

Bolt- NAS464P4-11

13

40

SectorAssy-

38

1 +0.0010/
-0.0000

0.2492

1 +0.00001
-0.0009

2315121-24

32

231 5147-2

41

33

43

0.7788

1.4363

0.7500

1.4370

1 +0.0005/
-0.0005
1 +0.0005/
-0.0000
1 +0.0030/
-0.0000
1 +0.0030/
-0.0000

1 BearingAN201 KP-4-A
MS27645-4A

42

S
S

32
33

(Alt. -KS4A)
(Alt. -AN200KS4A)
Bearing-

0.2500

0.9014

+0.0000/
-0.0005

+0.0000/
-0.0005

8-540-22

32

DPP-6
Bolt- AN6-17

33

34

0.3742

1 +0.0000/

35

0.3742

1 +0.0000/

-0.0009

NAS464P6-21,

-22

-0.0009
44

Bracket2331 006-11, -12, -18,


-19, -25, -26, -49, 60

2331006-60, -61

41

1
1

0.3747

1 +0.0015/
1 -0.0000
1 +0.0010/

42

0.3750

-0.0010

45

Pulley- MS20220A1

36

0.3125

46

Bracket- 2615114-1, -4

36

0.3120

47

Bolt- AN25-17

36

Elevator

)EFFECTIVITY:

ALL

1.7500

1
1

0.3110

~0.0005

Jr0.0050
1 +0.0100
-0.0000
1
1 +0.0000/
-0.0020

System Allowable Wear and Repair Data


Figure 1 (Sheet 16 of 29)
51-71-10

Page 16
SRM-4

Jun 6/98

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM

I
HOLE I

EFF.

DESCRIPTION

NO.

MFD

MFD

HOLE

SHAFT

ID

OD

MFD

ALLOWANCE
OD

ID

3.0000

~0.0005
1 +0.01001

0.3110

36
36

Bracket- 2515115-1

50

Bolt- AN25-17

36

37

0.31 25

3.0000

10.0005

~t0.0050

38

0.3125

3.0000

f0.0005

~H).0050

Bracket251 2500-24

39

0.3120

1 +0.0060

2615119-1

40

0.3120

-0.0010
1 +0.0100

511

1
i

OD

-0.0000
1 +0.0000/
-0.0020

PulleyMS20220-2
MS20220A2

52

0.3125
0.3120

ID

ALLOWANCE

~0.0050

48
49

Pulley- MS20220A2

WEAR

-0.0000
53

Bracket251 2500-22

39

0.3120

1 +0.0060

2615112-2

40

0.3120

1 +0.0100

39

0.3120

40

0.3120

1 +0.0060
-0.0010
1 +0.0100/

36

WI

-0.0010
-0.0000
Bracket- 2512500-23

54

2615113-1

-0.0000

Bolt- AN25-27

55

0.3110

1 +0.0000/
-0.0020

56

Pulley- MS20220A2

0.3125

Bracket- 2512500-5, -6, -7,

0.3120

+0.0050

+0.0005/

3.0000

-0.0000

57

-8, -11,-12, -42, -44, -55, 1


-56,-57,-58

I
X

59

Bolt- NAS464P5-44
NAS464P5-23
Pulley- MS20220A2

60

Bracket- 2512500-27, -28

58

1 +0.00601

I
1

0.3117

+0.0010

1 +0.0000/

1 -0.0009
rt0.0050

M.0005

3.0000

0.3125
0.3120

1 +0.0060/

0.3120

1 +0.0060/

-0.0001

2488510-4, -5

2488710-4, -5

0.3120

1 +0.0060/

2512500-6, -1 7, -1 8, -33,
-34, -39, -40, -47

0.3120

1 +0.0060/

-0.0001
-0.0001

61

Bolt- NAS464P5-44, -23

1
1

1
0.3117

-0.0001

1 +0.0000/
-0.0009

Elevator

EFFECTIVITY:

ALL

System Allowable Wear and Repair Data


Figure 1 (Sheet 17 of 29)
51-n-lo

Page
SRM-I

17

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I
NO.

I
DESCRIPTION

Pulley- MS20220A1
Bracket- 2312500-34, -35,
-36
Bolt- NAS464P5-22

62
63

64

MFD

MFD

HOLE

SHAFT

OD

EFF.

HOLE

ID

0.31 25

0.3120

1.7500

I
1

AA

Bolt- AN5-24, -25

AA

SectorAssy. -2315147-1,-9

As

1.3125

AC

0.7500

I
I

MFD

ALLOWANCE

ID

OD

rt0.0005

~0.0050

WEAR
ID

ALLOWANCE
OD

1 +0.0060/

1 -0.0010
1
1 +0.00001

0.3117

-0.0009

65

Pulley-

MS20220-2

0.3120

1 +0.0000/
-0.0030

66

i +0.0010/
-0.0000

1 +0.0030/
-0.0000

BearingBearing-

67
68

8-540-ZZ

AB

MS21233-5

AC

0.3125

0.7500

+0.0000/

+0.0000/

-0.0005

-0.0005

801t-

69

NAS464P4-9,

-12

43

AC

0.2492

1 +0.00001

44

AC

0.3117

1 +0.0000/

-0.0009

NAS464P5-12

-0.0009
Clevis Rod End

70

2315121-14, -33

43

AC

0.2500

1 +0.0010/

2315168-5

44

AC

0.3117

1 +0.0010/

-0.0000
-0.0000
71

72

BearingRodEnd2315121-14,-33

43

RE5M6

44

AD
AD

43

AD

0.3117

1 +0.0000/

44

AD

0.3117

1 +0.0000/

44

AD

(Alt. REP5M6FS464)
(Alt. MS21151-10)
Bolt- NAS464P4-9, -12

-0.0009

NAS464P5-27,

-32

-0.0009
73

Bushing- NAS75-5-13,

74

Bushing- NAS75-5-013

-018

1
44

Elevator

EFFECTIVITY:
SRM-I

ALL

0.3125

I
AE

0.4386

I
0.3125

+0.0015/

j -0.0000
0.4386

+0.0000/
-0.0005

+0.0015/

+0.0000/

-0.0000

-0.0005

System Allowable Wear and Repair Data


Figure 1 (Sheet 18 of 29)
51-71-10

Page

18

Tun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

I
EFF.

DESCRIPTION

NO.

Yoke

75

I
HOLE I

MFD

MFD

HOLE

SHAFT

ID

OD

MFD

WEAR

ALLOWANCE

ID

OD

ID

ALLOWANCE
OD

Assembly
45

2415152-1, -3

(Alt. 2415152-5)

46

2615270-1

AD

0.4375

1 +0.0005

AE

0.4393

AF

0.3750

1
1

AG

0.3373

AD

0.4375

AE

0.4393

AF

0.3750

AG

0.3373

1
i
i
1

1 ~0.0005
1 ~0.0005
1 +0.0005/
-0.0012
i f0.0005
I f0.0005
1 ~0.0005
i +0.0005/
-0.0012

-19,-26

Bearing Rod

77

AF

48

Bolt- NAS464P4-15, -17,

76

0.2492

1 +0.0000/

-0.0009

End

SM4-6D-1

48

AF

(Alt. RM4B)
(Alt. RM4BH)
1 +0.0000/

78

Bolt- NAS464P4-10

48

AG

79

Bushing- NAS75-4-10,

48

AF

80

NAS77-4-27
I
Servo Cable 2300003-256

81

Bolt- NAS464P3-7

0.1894

1 +0.0000/

82

Bolt- NAS1104-48D

0.2495

1 +0.0000/

83

Turnbuckle- 2631511-1

0.2510

1 +0.0030/

84

Bracket- 2331516-2, -17,

17

AF

0.2500

i +0.0050/

AF

0.2500

0.2492

-0.0009

I
0.1900

+0.0015/

0.3761

0.2500

1 -0.0000

1 +0.0020/

+0.0000/
-0.0005

-0.0000
-0.0009
-0.0010
-0.0000

-18, -20, -21


85

Pulley-

MS20219-A2

j
17

-0.0010

1 +0.0000/
-0.0005

AF

0.2490

1 +0.0100/

86

Bolt- AN4-10

17

87

Bracket- 2331516-3

17

AG

0.2500

i +0.0050/

88

Pulley-MS20219-A2

17

AG

0.2500

i +0.000/

89

Bolt- AN4-10

17

AG

Fork-2331519-8, -19

17

-0.0100

-0.0010
-0.0005

0.2490

1 +0.00101
-0.0010

90

AH

0.1890

+0.0050/

-0.0010

Elevator

EFFECTNITY:

ALL

System Allowable Wear and Repair


Figure 1 (Sheet 19 of 29)

Data

57-71-10

Page
SR~-4

19

Jun 6/98

Learpt

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I
NO.

91

I
EFF.

DESCRIPTION

1 Pin, Clevis- MS20392-2C19

I
HOLE
AH

17

MFD

MFD

HOLE

SHAFT

ID

OD

1 0.1380

MFD

ALLOWANCE

ID

OD

WEAR
ID

ALLOWANCE
OD

1+0.0000/
-0.0020

92

Fork, TurnbuckleNAS645-1 6RL

29

AJ

1 0.1900

1 +0.01001
-0.0100

1+0.00101

0.1930

1 +0.0010/
-0.0010

0.1900

1
1 0.1380

1 +0.0010/
1 -0.0010
1
1+0.0000/

1+0.0015/

Eye -TurnbuckleNAS648-16RL
93

Link- 2431110-2

94

Eye-Turnbuckle-

AJ

30

(Ait. MS21254-3RL)

AJ

30

NAS64&1 6RL

30

95

(Alt. MS21254-3RL)
I
Pin, Clevis- MS20392-2C19

96

Angle,

97

Bushing- NAS77-6-22

0.1900

AJ

30

AJ

16

AK

0.3747

14

AL

0.3750

-0.0010

-0.0020

Attach- 2331006-49

-0.0000

0.5013

+0.0015/

+0.0000/

-0.0000
98

Bolt- NAS464P6-22

-0.0007

14

IAK,ALI

1 0.3742

1+0.0000/

15

IAK,ALI

1+0.0000/

14

AL

14

1 AM,

15

-0.0009

NAS464P6-17

0.3742

-0.0009
99

1 Bushing-

NAS77-6-25

0.3750

0.5013

+0.0015/

+0.0000/

-0.0000
100

Bolt- NAS464P6-23
NAS464P6-22

-0.0007

1 0.3742

1+0.0000/

AN

1 -0.0009

AM,

1 0.3742

1+0.0000/

14

AN
AM

I
1

I
1 -0.0009
1+0.0015/

101

Bracket Assy.

102

Bolt- NAS464P6-17

15

AK

1 0.3742

1+0.0000/

103

Bolt- NAS464P6-22

15

AM

1 0.3742

1+0.0000/

104

Bolt- NAS464P4-10

18

1 0.2492

1 +0.0010
-0.0010

105

Bolt- NAS464P4-9

18

AK

1 0.2492

1 +0.0010

106

Frame

2331050-1

0.3747

-0.0000
-0.0009
-0.0009

-0.0010

Assy, Down-spring

2531 542-1, -7

19

AK

0.2492

1+0.0010/

AL

0.2725

1+0.0010/

-0.0000
-0.0000

Elevator

EFFECTIVITY:

ALL

System Allowable Wear and Repair Data


Figure 1 (Sheet 20 of 29)
51-71-10

Page 20
SRM-4

Jun 6/98

Learjet
Learietl

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

NO.

I
HOLE

EFF.

DESCRIPTION

MFD

MFD

HOLE

SHAFT

ID

OD

MFD

ALLOWANCE

ID

AM

0.5650 1

1 +0.0010/

AK

0.2492

i +0.00101

AL

0.2725 1

AM

0.5626 1

OD

WEAR
ID

ALLOWANCE
OD

-0.0000

20

2531542-13, -16

AK

21

2531542-17

-0.0000
1 +0.00101
-0.0000
1 +0.00021
-0.0002
+0.00001

0.2492

-0.0009
AL

0.2725

AM

0.5626

1 +0.00101
-0.0000

AN

1 +0.0002/
-0.0002
0.1860 1
1 +0.0010/

23

AL

0.1860

24

AO
AP

0.5310
0.2485 i

AO

0.5310

AP

0.2500 i

AP

0.1870

107

Bolt- AN23-42

21

108

Bolt- AN23-15

109

Drawbar- 2531534-1

-0.0000

1 +0.00101
-0.0000

1 +0.0010/
-0.0000

25

2531 534-6

1 +0.00101
-0.0000

110

Bushing-

24

2531 534-4

2531 5346
111

Retainer, Fwd- 2531536-2


2531 54&1

112

Retainer, Aft- 2531536-2


253154&1

25

AP

0.1870

24

AQ

0.5310

26

AR

0.6250

24

26
28

+0.00051

0.2485

0.2500

+0.0010/

-0.0005

-0.0000

+0.0005/

+0.00001

-0.0000

-0.0010

1 +0.00201
-0.0000

AS

0.5310

AT

0.6250 i

1 +0.00201

AU
AO

0.2485

0.5000

+0.00101
-0.0000

0.1870

0.2485

+0.0005

-0.0000
113

Drawbolt- 2531535-1, -4

AR
114

Bushing- 2531 535-3

28

AQ
AU

+0.00101
-0.0000

-0.0005

115

Stud- 2631515-1

31

AV

0.2492

1 +0.00001
-0.0009

Elevator

EFFECTIVITY:

ALL

System Allowable Wear and Repair Data


Figure 1 (Sheet 21 of 29)
51-71-10

Page
SRM-I

21

Jun 6/98

Learjet
E~ Learjetl

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

NO.
1

3
4

DESCRIPTION

EFF.

Bellcrank

Assy. 2331511-15, -16,


-33, -34, -45, -46, -61, -62, -83, -84,
-101,-102,-801,-802

Bearing-

MS27645-4A

HOLE

A, B, C,I Replace

Pin

HL 18-8-9

Bolt

2331151 t -87

NAS464P4A-32
NAS464P4A-30

SB410F4-28S

Torque Tube 2434003-7


Bearing- BLFR-4-045

worn

part.

D
1

Bolt

REPAIR

B,
B,
B,
B,

I Replace worn part. Stake new bearing


primer or secure with Loctite. (Refer to
00.)
Replace
Replace
Replace
Replace
Replace

part.
part.
worn part.
worn part.
worn part.
Replace worn part.
Replace worn part. Stake

C
C
C
D

primer

in wet
51-70-

worn
worn

or secure

new

with Loctite.

bearing

(Refer

in wet

to 51-70-

00.)
9
8

Bolt NAS464P4-14
Rod End Clevis 2331510-75
233151031

10

Hinge Assy. 2332018-16, -20,


Bearing AN201 KP4A

11

Bolt

12

13

Hinge Assy. 2332013-19, -22,


Bearing AN201 KP4A

14

Bolt

15

Bearing Rod End 2331510-28


Bearing- AN200KS-4

16

-22

AN4H11 A

AN4H11A

(Alt. MS27645-4)

D
D

-24

G
G

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part. Secure new
Loctite. (Refer to 51-70-00.) After
assembly to a push out proof
pounds.
I Replace worn part. Secure new
Loctite. (Refer to 51-70-00.) After
assembly to a push out proof

bearing with
subject

cure,

load of 300

bearing with
subject

cure,

load of 300

pounds.
17

1 Yoke

9
10

2531533-1

11

2531533-5

12

263150&2

13

18

Bolt

19

Cable

20

2331512-2

2331517-2

H,
H,
H,
H,
H,

NAS464P4-35

Fitting 2631509-1
(Alt. 2631509-2)
1 Hinge Bracket 2331510-17

1
1

H,K
H,K

Elevator

G,
G,
G,
G,
G,

EFFECTIVITY:

ALL

J
J
J
J

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.

part.
part.
part.
part.
part.
part.
part.

System Allowable Wear and Repair Data


Figure 1 (Sheet 22 of 29)
51-71-10

Page 22
SRM-(

Jun 6/98

Learjet
~Learjetl

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

DESCRIPTION

NO.

23

NAS464P4-9
Frame Brkt
2531539-1
Bolt AN23-13

24

Down-spring

21

Bolt

22

Down-spring

Frame- 2631507-1, -8,

EFF.

HOLE

REPAIR

Replace worn part.

13

L, M,N

Replace worn part.


Replace worn part.
Replacewompart.

0, -12, -16

25

1 Bearing-F3DD

22

26

1 Bushing-2631507-6

13

Replace worn part. Install new bearing with


flange inboard and secure with Loctite. (Refer
to

51-70-00.)

I Replace

worn

flange inboard

part. Install
and

Stud

2631515-5

17

28

13

M
N

29

Bolt AN23-16
Drawbar 2631503-4, -6

13

P, Q

30

Bushing- 2631503-3

13

13

Replace worn part.

1 Down-spring

(At2631505-4)
1 Down-spring Retainer2631505-1

33

34

Bushing

26315053

Drawbolt

2631504-1, -2

2631504-2

35

Stud

36

Bearing Rod End


Bearing Rod End

37

2631515-5
253153&3
HMVV-4

41

Clevis Rod End 2331510-32


Bolt NAS464P4-11
Sector Assy. 2315147-2
Bearing MS27645-4A

42

(Alt. KSIA)
(Alt. AN200KS4A)
Bearing 8-540-ZZ

38

39
40

bushings with
(refer to

Retainer-

26315052
32

new

with Loctite

51-70-00), and line ream 0.1895 (+0.0010/


-o.oooo).
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part. Install new bushings with
Loctite (refer to 51-70-00), and ream in line after cure to 0.2500 (+0.0010/-0.0000).

27

31

secure

13

Replace worn part.

27

Replace worn part.

13

AS
AT
N, P

11

N, P

13
17

13

13

S
S

13
33

S,

32

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.

part.
part.
part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part. Secure new bearing with
Loctite. (Refer to 51-70-00.)

I Replace worn part.

Secure new bearing with


(Refer to 51-70-00.)
I Replace worn part. Secure new bearing with
Loctite. (Refer to 51-70-00.)
Loctite.

DPP-6

Elevator

EFFECTIVITY:

ALL

System Allowable Wear and Repair Data


Figure 1 (Sheet 23 of 29)
51-71-10

Page 23
SRM-I

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
REPAIR DATA

ITEM

NO.

DESCRIPTION

EFF.

43

Bolt

44

NAS464P6-21, -22
Bracket 2331006-11, -12, -18, -19,
-25, -26, -49, -50,

45
46
47

AN6-17

34

35

41

2331006-60, -61

42

Pulley MS20220A1

36

Bracket 2615114-4
Bolt AN25-17

36

MS20220A2

36

2615115-1

36

U
U
V
V

48

Pulley

49

Bracket

50

Bolt

36

54

AN25-17
Pulley MS20220-2
MS20220A2
Bracket 2512500-24
2615119-1
Bracket 2512500-22
2615112-2
Bracket 2512500-23

55

2615113-1
Bolt AN25-27

56

Pulley MS20220A2

51
52

53

59

MS20220-2
Bracket- 2512500-5, -6, -7, -8, -11,
-12, -42, -44, -55, -56, -57, -58
Bolt NAS464P5-44, -23
Pulley MS20220A2

60

Bracket

57

58

HOLE

36

37

38

39

40

39

40

39

40
36

W
W

61

2512500-27, -28
2488510-4, -5
2488510-4, -5
2512500-6, -17, -18, -33, -34, -39,
-40, -47
Bolt NAS464P5-44, -23

62

Pulley

63
64

Bracket 2312500-34, -35, -36


Bolt NAS464P5-22

Pulley MS20220-2
Bolt AN5-24-25
Sector Assy. 2315147-1, -9
Bearing- B-540-ZZ

Z
Z
AA

AA

AB
AB

Bearing MS21233-5
(Alt. LHBVV-5M)
(Alt. RSST-5)

AC

65
65A
66
67
68

MS20220A1

Elevator

)EFFECTIVITY:
SRM-I

ALL

REPAIR

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.
part.
part.

part.
part.
part.
part.
part.
part.
part.
part.

Replace worn part.


Replace worn part.
Replace worn part.

Replacewompart.
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.
part.
part.

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part. Install new bearing and
cure with Loctite. (Refer to 51-70-00.)
Replace worn part. Install new bearing and
secure with Loctite. (Refer to 51-70-00.)

se-

System Allowable Wear and Repair Data


Figure I (Sheet 24 of 29)
51-71-10

Page 24
Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM
I EFF.

DESCRIPTION

NO.

Bolt NAS464P4-9, -12


NAS464P5-12
Clevis Rod End 2315121-14, -33
231416&5
Bearing Rod End2315121-13, -33
RE5M6

69
70
71

(Alt. REP5M6FS464)
(Alt. MS21151-10)
Bolt NAS464P4-9, -12
NAS464P5-27, -32
Bushing NAS75-5-13, -018
Bushing NAS77-5-013
Yoke Assembly 2415152-1,
(Alt. 2415152-5)

72

73
74

75

77

Bolt

82
83
84

worn
worn

43

AC
AC
AD

AD

Replace worn part.


Replace worn part.
AD
Replace worn part.
AD
Replace worn part.
AD
Replace worn part.
AE
Replace worn part.
AD, AE,I Replace worn part.

44

44
44

45

AD, AE,( Replace


AF, AG

46

NAS464P4-10

Replace worn part.


I Replace worn part.

AD

43

-3

part.
part.
Replace worn part.
Replace worn part.

AD

44

NAS77-4-27
Servo Cable 2300003-256
Bolt NAS464P3-7
Bolt NAS1104-48D
Turnbuckle 2631511-1
Bracket 2331516-2, -17, -18,

81

Replace

j Replace

44

Bushing NAS75-4-10

80

AC
AC

44

1 Bolt NAS464P4-15, -17


l\lAS464P4-19, -26
Bearing Rod End SM4-6D-1
(Alt. RM48)
(Alt. RM4BH)

78
79

43

43

REPAIR

44

44

2615270-1
76

HOLE I

worn

part.

worn

part.

48

AF

Replace

48

AF

Replace worn part.

48

AG

48

AF

Replace worn part.


Replace worn part.

17

AF

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.
part.

-20, -21
86
87
88
89

90
91
92

MS20219-A2
Bolt AN4-10
Bracket 2331516-3
Pulley MS20219-A2
Bolt AN4-10
Fork 2331519-8, -19
Pin, Clevis MS20392-2C19
Fork, Turnbuckle NAS645-16RL
Eye, Turnbuckle NAS648-16RL

Pulley

85

17
17

AF

Replace worn part.

AF

I Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
I Replace wompart.

17

AG

17

AG

17

AG
AH
AH
AJ
AJ

17

17
29

30

(Alt. MS212543RL)

Elevator

EFFECTIVITY:

ALL

System Allowable Wear and Repair


Figure Z (Sheel 25 of 29)

Data

51-71-10

Page 25
SRM-4

Jun 6/98

Leariet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM
NO.

DESCRIPTION
2431110-2
Turnbuckle NAS64&16RL

93
94

Link

95

Pin, Clevis

Eye,
(Alt. MS21254-3RL)

MS20392-2C19

EFF.

HOLE

30

AJ

30

AJ

30

97

Angle, Attach
Bushing NAS17-6-22

16

98

Bolt- NAS464P6-22

14

15

105

NAS464P6-17
Bushing- NAS77-6-25
Bolt NAS464P6-23
NAS464P6-22
Bracket Assy. 2331050-1
Bolt NAS464P6-17
Bolt NAS464P6-22
Bolt NAS464P4-10
Bolt NAS464P4-9

106

Frame

96

99

100
101
102
103
104

2331006-49

Assy,

Down

14

14
14

15
14

15
15

18
18

REPAIR

Replace worn part.


Replace worn part.

Replace worn part.


Replace worn part.
AL
Replace worn part.
AK, AL Replalceworn part.
AK,AL Replaceworn part.
AK, AL Replaceworn part.
AM, AN~ Replace worn part.
AM, AN I Replace worn part.
AM
Replace worn part.
AK
Replace worn part.
AM
Replace worn part.
R
Replace worn part.
AK
Replace worn part.
AJ

AK

Spring
19

IAK,AL

Repiaceworn part.

2531542-13, -16

20

AM
AK, AL
AM

Replaceworn part.

2515542-17

21

IAK,AL

Replaceworn part.

2531542-1,-7

AM
21

110

Bolt AN23-42
Bolt AN23-15
Drawbar- 2531534-1
2531534-6
Bushing 2531534-4

25

111

25315346
Retainer, Fwd

107
108

109

23
24

25
24

2531536-2

24
26

253154&1
112

Retainer, Aft 2531536-2

24

26

113

253154&1
Drawbolt 2531535-1, -4

28

Replace worn part.


Replace worn part.
AO, AP I Replace worn part.
AO, AP I Replace worn part.
AP
Replace worn pa~.
AP
Replace worn part.
AQ
Replace worn part.
AR
Replace worn part.
AS
Replace worn part.
AT
Replace worn part.
AU, AO I Replace worn part.
AN
AL

AR, AQ
114
115

Bushing
Stud

28

2531535-3

31

26315351

Elevator

EFFECTIVITY:
sRM-a

ALL

AU
AV

Replace worn part.


Replace worn part.

System Allowable Wear and Repair Data


Figure 1 (Sheet 26 o~ 29)
51-71-10

Page 26
lun 6/98

Learjet
~LearjetJ

STRUCTURAL REPAIR MANUAL


CODES

EFFECTIVITIES

23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 28-001 and Subsequent; 29001 and Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent

23-001 thru 23-099; 24-100 and

Subsequent Except When Modified by SSK 995, "lnstallation of


Equipped for 45,000 Foot Operation"; 25-001 and Subsequent Except
When Modified by SSK 995, "lnstallation of Spare Elevator Aircraft Equipped for 45,000 Foot Operation"; 28-001 and Subsequent; 29-001 and Subsequent; 31-001 thru 31-020; 35001 thru 35-659;

Spare Elevator

Aircraft

36-001 thru 36-063


3

4
5

Subsequent When Modified by SSK 995, "lnstallation of Spare Elevator Aircraft


Equipped for 45,000 Foot Operation"; 25-001 and Subsequent When Modified by SSK 995, "lnstallation of Spare Elevator Aircraft Equipped for 45,000 Foot Operation" 31-021 and Subsequent; 35060 and Subsequent; 36-064 and Subsequent
23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 2&001 and Subsequent; 29001 and Subsequent; 35-001 thru 35-421; 36-001 thru 36-048
31-001 and Subsequent; 35-422 and Subsequent and All 23, 24, 25, 28, 29, 31 and 35 Series Aircraft Modified Per SSK 995, "lnstallation of Spare Elevator Aircraft Equipped for 45,000 Foot Oper24-100 and

ation"
6
7

23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 28-001 and
001 and Subsequent
2&001 and Subsequent; 29-001 and Subsequent; 31-001 and Subsequent
23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 35-001 and
001 and

Subsequent;

29-

Subsequent;

36-

Subsequent

10

23-001 thru 23-099; 24-100 thru 24-121, 24-123 thru 24-132 and 24-134 thru 24-139
24-122, 24-133, 24-140 and Subsequent; 25901 thru 25-060 and 25-062 thru 25-066

11

25-061, 25-067 thru 25-125

12

25-126 and
2&001 and

13

36-001 and

Subsequent
Subsequent;
Subsequent

14

24-100 thru 24-129

15

24-130 and
24-100 and

16
17

29-001 and

Subsequent;

31-001 and

Subsequent;

35001 and

Subsequent;

Subsequent
Subsequent

25-061, 25-064, 25-067 and Subsequent and Prior Aircraft Modified by AAK 70-058, "Automatic
Flight Control Stability System and Trim Augmenter Installation" or AAK 76-04A, "Reduced Approach

Speed System"; 28001 and Subsequent;


and Subsequent; 36-001 and Subsequent

29-001 and

Subsequent;

31-000 and

Subsequent; 35-001

18

25-061,25-064, 25-067 thru 25-224 and 25-226 and Prior Aircraft Modified by AAK 70-058, "Automatic Flight Control Stability System and Trim Augmenter Installation" or AAK 76-04A, "Reduced Approach Speed System" Except When Modified by AMK 77-09A, "lnstallation of Dual Elevator Upl

19

25-061, 25-067 thru 25-182

20

25-183 thru 25-224


25-225, 25-227 and

Down-spring Secondary

21

Pushrods"

Subsequent

and Prior Aircraft Modified

by AAK 70-058, "Automatic Flight Con-

Stability System and Trim Augmenter Installation" or AAK 76-04A, "Reduced Approach Speed
System" or AMK 77-09A, "lnstallation of Dual Elevator Up/Down-spring Secondary Pushrods"
25-225, 25-227 and Subsequent and Prior Aircraft Modified by AAK 70-058, "Automatic Flight Control Stability System and Trim Augmenter Installation" or AAK 76-04A, "Reduced Approach Speed
System" or AMK 77-09A, "lnstallation of Dual Elevator Up/Down-spring Secondary Pushrods"; 28
001 and Subsequent; 29-001 and Subsequent; 31-001 and Subsequent; 35-001 and Subsequent;
36-001 and Subsequent
25-061, 25-064, 25-067 and Subsequent and Prior Aircraft Modified by AAK 70-058, "Automatic
Flight Control Stability System and Trim Augmenter Installation" or AAK 76-04A, "Reduced Approach
Speed System"
trol

22

23

Elevator

EFFECTIVITY:

ALL

System Allowable Wear and Repair Data


Figure 1 (Sheet 27 of 29)
51-71-10

Page
SRM-4

27

Tun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


CODES
24

EFFECTIVITIES
25-061,25-067 thru 25-253

25

25254 and

26

25-254 and

Subsequent
Subsequent and

Prior Aircraft Modified by SSK 960, "Replacement of Elevator Up/DownDrawbolt and Retainer"
25-254 and Subsequent and Prior Aircraft Modified by SSK 960, "Replacement of Elevator Up/
Downspring Drawbolt and Retainer"; 28-001 and Subsequent; 29-001 and Subsequent; 31-001 and
Subsequent; 35001 and Subsequent; 36-001 and Subsequent
25-061,25-067 and Subsequent
24-140 thru 24-217 and 24-219 thru 24-229 Except When Modified by SE 31-32-2, Installation of
Digital Nose Wheel Steering"; 25-002 thru 25-060, 25-062 thru 25-067, 25-070, 25-074 and 25-075
Except When Modified by SE 31-32-2, Installation of Digital Nose Wheel Steering"
24-218, 24-230 and Subsequent and 24-140 thru 24-217, 24-219 thru 24-229 When Modified by SE
31-32-2, Installation of Digital Nose Wheel Steering"; 25-064, 25-071 thru 25-073, 25-076 and Subsequent and Prior Aircraft Modified by SE 31-32-2, Installation of Digital Nose Wheel Steering"

spring

27

28
29

30

31

25-225, 25-227 and Subsequent

32

23-001 thru 23-069

33

23-070 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 28-001 and Subsequent; 29001 and Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
23-001 thru 23-099; 24-100 thru 24-357; 25001 thru 25-301; 28-001 thru 28-005; 29-001 thru 29-

34

002; 35-001 thru 35296; 36-001 thru 36-044

Subsequent;

25302 and

Subsequent;

Subsequent;

35

24-358 and

36

31-001 and Subsequent; 35297 and Subsequent; 36-045 and Subsequent


24-306 thru 24-308, 24-323 and Subsequent; 25-196, 25-202 and Subsequent; 2&001 and Subse-

28-006 and

29-003 and

Subsequent;

quent; 29-001 and Subsequent; 31-001 and Subsequent; 35-046 and Subsequent; 36-017 and Subsequent
38

23-001 thru 23-099; 24-100 and Subsequent


25001 and Subsequent; 28-001 and Subsequent; 29-001 and

39

35-001 and Subsequent; 36-001 and


25-001 thru 25-201 Except 25-196

40

25-196, 25-202 and Subsequent; 28-001 and Subsequent; 29-001 and Subsequent; 31-001 and

41

23-001 thru

42

Subsequent; 31-001 thru


24-357 and Subsequent;
36-001 and Subsequent

37

Subsequent;

35-001 and

Subsequent;

31-001 and

Subsequent;

Subsequent

Subsequent;

36-001 and

Subsequent

23-099; 24-100 thru 24-356, 25-001 thru 25-372, 28-001 and Subsequent; 29-001 and
31-027
25-373 and

Subsequent;

31-028 and

Subsequent;

35-664 and

Subsequent;

43

23-001 thru 23-010, 23-013, 23-014, 23-016 thru 23-018, 23-020 thru 23-030, 23-032 thru 23-042,
23-044 thru 23-049, 23-050a, 23-052 thru 23-054, 23-056 thru 23-059, 23-061 thru 23-064, 23-065a
thru 23-086, 23-088 thru 23-095, 23-097 thru 23-099

44

23-011, 23-012, 23-015, 23-019, 23-031, 23-043, 23-050, 23-051, 23-055, 23-060, 23-065, 23-087,
and 23-096; 24-100 and Subsequent; 25-001 and Subsequent; 28-001 and Subsequent; 29-001 and

45

31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent


23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 28-001 and Subsequent; 29001 and Subsequent; 35-001 thru 35-487; 36-001 thru 36-050

46

31-001 and

47

24-122, 24-133, 24-140 and Subsequent and Prior Aircraft Equipped With Elevator Bob Weight;

Subsequent;

Subsequent;

35-488 and

Subsequent;

36-051 and

001 and Subsequent; 2&001 and Subsequent; 29-001 and


35-001 and Subsequent; 36-001 and Subsequent

Elevator

EFFECT~VITY:

ALL

Subsequent

Subsequent;

31-001 and

25-

Subsequent,

System Allowable Wear and Repair Data


Figure 1 (Sheet 28 of 29)
51-71-10

Page 28
SRM-(

Jun 6/98

Learjet
Leariet I

STRUCTURAL REPAIR MANUAL


48

23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 28001 and
001 and Subsequent; 31-001 thru 31-076; 35-001 thru 35-676; 36-001 thru 36-063

49

31-077 and

Subsequent;

35-677 and

Subsequent;

36-064 and

Subsequent; 29-

Subsequent

NOTES:

When
1.
2.

3.

replacement of the NAS464P4A-30

and the NAS464P4A-32 bolt is

required,

the

following

should be used:
NAS6604-30 or NAS6604-32 should be used when an oversized bolt is not required.
NAS6604-30X or NAS6604-32X should be used when an 1/64 inch oversized bolt is required.
NAS6604-30Y or NAS6604-32Y should be used when an 1/32 inch oversized bolt is required.

Elevator

EFFECTIVITY:

ALL

System Allowable Wear and Repair Data


Figure 1 (Sheet 29 of 29)

51-71-10(
Page 29

SRM-4

Jun 6/98

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


KEELBEAM ASSEMBLIES

ALLOWABLE WEAR AND REPAIR DATA

\4

(TYPICAL)

Detail A
(UNDERWING KEELBEAM)
4-10C

EFFECTIVITY:

Keelbeam

ALL

Assembly Allowable Wear and Repair Data


Figure 1 (Sheet 1 of 3)
51-71-11

Page
SRM-4

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM

NO.

DESCRIPTION

MFD

MFD

HOLE

SHAFT
OD

EFF.

HOLE

ID
0.3120

Fitting, Unden~ving Keelbeam

Aft LHIRH -2311611-5, -6


Bolt- MS20005-14

Fitting, Unden~ving Keelbeam

MFD

ALLOWANCE
OD

ID

WEAR
10

ALLOWANCE
OD

+0.0060/
-0.0010
+0.001 5/

0.31 02

-0.0000
Fwd LH/RH

+0.0060/
-0.0010

0.3120

2311611-7,

-8
4

Bolt- MS20005-36

Fitting, Aft Keelbeam, LH/RH

0.3120

Fitting, Fwd Fuselage

0.3120

+0.001 5/

0.31 02

-0.0000

-2312013-1, -2

Keelbeam, LH/RH-

+0.0060/
-0.0010
+0.0060/
-0.0010

2311241-1

Keelbeam

EFFECTIVITY:
SRM-I

ALL

Assembly Allowable Wear and Repair Data


Figure 1 (Sheet 2 of 3)
51-71-11

Jun

6/98Page2

Learjet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM
EFF.

DESCRIPTION

NO.

Fitting, Underwing Keelbeam,

REPAIR

HOLE

Replacewompart.

Aft LH/RH -2311 611-5, -6


2

Bolt

Fitting, Unden~ving Keelbeam,

Bolt

Fwd LH/RH 231 1611-7, -8


MS20005-36
Fitting, Aft Keelbeam, LH/RH

Fitting, Fwd Fuselage Keelbeam,

MS20005-14

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.

-2312018-1, -2

Replacewompart.

LH/RH- 2311241-1

CODES
1

EFFECTIVITIES
23-002 thru 23-099; 24-100 thru 24-357; 25-002 thru 25-373; 28-001 thru 28004; 29-001 thru 29004; 31-001 and Subsequent; 35-001 and Subsequent; 36001 and Subsequent

Keelbeam

EFFECTIVITY:

ALL

Assembly Allowable Wear and Repair Data


Figure 1 (Sheet 3 of 3)
51-71-11

Page 3
SRM-I

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


MACH TRIM SYSTEM

ALLOWABLE WEAR AND REPAIR DATA

A
0000~

,6

~-B

rc~,

r\

(TYPICAL)

Detail A
&nB

EFFECTNITY:
SRM-4

Mach Trim

System Allowable Wear and Repair


Figure 1 (Sheet 1 of 3)

Data

28-001 AND SUBSEQUENT; 29-001 AND SUBSEQUENT; 31-001 AND


SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

51-71-12

Page 1
Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

MFD
ITEM I

NO.
1

I
EFF.

DESCRIPTION
Bracket

Assy., 2605206-2,

HOLE
A

-7

Link- 2605206-5

Bolt- NAS1103-6

Bushing- NAS74A3-003

Bolt- NAS1103-4

Bushing- NAS74A3-003

Arm, Mach Trim System

HOLE

MFD

ALLOWANCE

ID

0.1895

1
I

1 +0.00101
1 -0.0000

0.3725

1 +0.00101
-0.0000

I
B

MFD

A,B I

WEAR

ALLOWANCE

I SHAFT

OD

0.1895

ID

OD

ID

OD

1 +0.0000/
-0.0010

0.1900

B,C I

+0.0010/
-0.0005

0.3730

0.1895

+0.0000/
-0.0020

1 +0.0000/
-0.0010

2605206-4

0.1900

0.3730

0.1895

0.2500

+0.0010/
-0.0005

+0.0000/
-0.0020

1 +0.0010/
-0.0000
1 +0.0040/
-0.0000

Mach Trim

I""""":
SRM-4

28-001 AND

System Allowable Wear and Repair Data


Figure 1 (Sheet 2 of 3)

SUBSEQUENT; 29-001 AND SUBSEQUENT; 31-001 AND


SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

51-71-12

Page 2
Jun 6/98

Learjet

STRUCTURAL REPAIR IlrlANUAL


REPAIR DATA

ITEM

DESCRIPTION

NO.

EFF.

HOLE

Bracket Assy.

Link

3
4

Bolt

Bushing

2605206-2, -7

2605206-5

NAS1103-6
NAS74A3-003
Bolt NAS1103-4
Bushing NAS74A3-003
Arm 2605206-4

5
6
7

CODES
1

2&001 and

Subsequent; 29-001 and Subsequent;


Subsequent

31-001 and

Subsequent;

35-001 and Subse-

36-001 and

Mach Trim

SRM-4

Install oversize bushing and ream bushing to


original hole size. (Refer to 51-70-00.)
B
I Install oversize bushing in place of bushing (4
or 6). Ream oversize bushing to original bushing l.D. (Refer to 51-70-00.)
A, B
Replace worn part.
A
Replace worn part.
B, C
Replace worn part.
B
Replace worn part.
C
Replace worn part.

EFFECTIVITIES

quent;

EFFECTIVITY:

REPAIR

System Allowable Wear and Repair Data


Figure 1 (Sheet 3 of 3)

SUBSEQUENT; 29-001 AND SUBSEQUENT; 31-001 AND


SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT
28-001 AND

51-71-12

Page 3
Tun 6/98

STRUCTURAL REPAIR MANUAL


CONTROL COL UMN ASSEMBL Y ALLOWABLE WEAR AND REPAIR DA TA

~o

B
A

~plB"b
a63e

EFFECTIVITY:

Control Column

Assembly Allowable Wear and Repair Data


Figure 1 (Sheet 1 of 7)

ALL EXCEPT MODEL 23, EARLY MODEL 24

AND EARLY MODEL 25 AIRCRAFT


SRM-(

51-71-13

Page

Jun 6/98

Learjet I

STRUCTURAL REPAIR MANUAL


CONTROL COLUMN ASSEMBLY

ALLOWABLE WEAR AND REPAIR DATA

21

B/

K~B",

L20//~i

Detail B

Detail C

Control Column

EFFECTIVITY:

Assembly Allowable Wear and Repair Data


Figure 1 (Sheet 2 of 7)

23-001 THRU 23-099, EARLY 24 AND 25 MODEL AIRCRAFT

51-71-13

Page2
SRM-I

Jun 6/98

~Learjet
S~RUCTURAL REPAIR MANUAL
ALLOWABLE WEAR AND REPAIR DATA

CONTROL COLUMN ASSEMBLY

F,

9"
11

Ilr

(TYPICAL)

Detail A
861B2

Control Column Assembly

Figure

EFFECTIVITY:

ALL

Allowable Wear and

Repair Data

(Sheet 3 of 7)

51-71-13

Page3
SRM-4

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I
NO.

I
EFF.

DESCRIPTION

I
HOLE

MFD

MFD

HOLE

SHAFT

ID

OD

0.4995

MFD

ALLOWANCE

ID

OD

WEAR
ID

ALLOWANCE
OD

Pin, Control Column Pivot

2315152-9
2

(Alt. 2315152-33)
Block Assy., Bearing

23151525, -6, 31

1 +0.00001

1 -0.0010

1 +0.01001

0.7500

0.5000

-0.0100

Bearing- MS27641 KP8A


(Alt. AN201 KP8A)
Yoke Assy.

3
4

2415152-1

I
B

(Alt. 2415152-3, -5)

261 5270-1

0.3773

I
B

0.3773

1.1250

+0.0000/
-0.0005

1 +0.0005/

+0.0000/
-0.0005

-0.0005
1 +0.0005/

-0.0005
5

Bolt- MS20004H15

Bushing-

B,C I

0.2485

1 +0.0070/
-0.0080

NAS75-4-015

Bushing-NAS75-5-013

NAS77-5-50
8

Bushing- NAS75-4-010
NAS77-4-27

Block

Assy., Bearing

11

Bearing- MS27640KP4
(Alt. MS20200KP4)
I Yoke Casting
2315153-32

0.3125

0.4386

+0.0015/
-0.0000

-0.0010

0.3125

0.4386

+0.0015/

0.31 25

0.4386

0.2500

0.3761

-0.0000
+0.0015/
-0.0000
+0.0015/

+0.0000/
-0.0005
+0.0000/
-0.0005
+0.0000/

0.3761

-0.0000
+0.0015/

+0.0000/

-0.0000

-0.0005

0.2500

0.9002

I
1

2415164-5
10

I
7

-0.0005

1 +0.0005/

I
0.2500

+0.0000/

1 -0.0000
0.9014

+0.0000/
-0.0005

0.8750

1 +0.01001

1.1865

1 +0.0020/

0.8750

1 +0.0100/

1.1865

1 +0.0020/

0.8750

1 +0.0100/

1.1865

1 +0.00201

0.8750

1 +0.01001

1.1865

1 +0.0020/

+0.0000/
-0.0005

-0.0100
-0.0000
2315153-716-2

-0.0100
-0.0000

2315153-40

-0.0100
E

-0.0000

2315153-41

10

-0.0100
-0.0000

Control Column

EFFECTIVITY:

ALL

Assembly Allowable Wear and Repair Data


Figure 1 (Sheet 4 of 7)
51-71-13

Page4
SRM-4

Jun 6/98

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I
NO.

EFF.

DESCRIPTION

11

241 5152-8-495

2415152-9-495

HOLE I

MFD

MFD

HOLE

SHAFT

ID

OD

MFD
ID

0.8750

1 +0.01001

1.1865

I
i

1 -0.0100
1 +0.0020/

0.3750

WEAR

ALLOWANCE
OD

ID

ALLOWANCE
OD

-0.0000
12

13
14
15

Bearing- MS27641KP6A
(Alt. AN201 KP6A)
I
B-539-ZZ
Bearing1
I
(Alt. B639-DD)
1 Capstan Assy. 2415160-3,
1
-5,-7
1 Shaft, Main Control Wheel

-0.0005

1.1875

+0.0007/
-0.0007

I
1

1 +0.0010/

+0.0000/

0.7500

12

0.8750

0.7500

+0.0000/
-0.0005
+0.0000/
-0.0010

-0.0000

2315153-28

13

0.3740

i +0.0002/

23151536

14

0.3740

1 +0.0002/

-0.0003

(Alt. 2315153-49)

16

15

I
0.7490

-0.0003

i +0.0000/
-0.0010

Shaft, MainControlWheel261 5271-1

17

1 Torque Tube

2315151-2

1
J

16

1
0.7485

0.3739

1 +0.0003/
-0.0002

1 +0.0005/
-0.0005

1.9050

i +0.0000
-0.0020

181 BlockAssy., Bearing2315151-6

16

2.6250

16

K,L

2.0610

1 +0.0010
-0.0000

19

1 Bearing-

B-545-22

(Alt. &545-DD)
20

Bellcrank- 2315151-4, -7

2.6250

+0.0005

+0.0010
-0.0000

-0.0005
+.0000

17

1.9050

18

1.9050

-0.0020

2315154-1

+.0000
-0.0020

231 521 6-1

19

1.9050

+.0000

-0.0020

211 Bearing-LS4

20

Control Column

EFFECTIVITY:

ALL

2.2500

0.7500

Assembly Allowable Wear and Repair Data


Figure 1 (Sheet 5 of 7)
51-71-13

Page 5
SRM-4

Jun 6/98

Learjet
t~jtl
STRUCTURAL REPAIR MANUAL
REPAIR DATA

ITEM

NO.

EFF.

DESCRIPTION

Pin, Control Column Pivot2315152-9, -33

Block

Bearing MS27641 KP8A


(Alt. AN201 KP8A)
1 Yoke Assy -2415152-1
(Alt. 2415152-3, -5)
2615270-1

10

MS20004H15
Bushing NAS75-4-015
Bushing NAS75-5-013
NAS77-5-50
Bushing NAS75-4-010
NAS77-4-27
Block Assy, Bearing 2415164-5
Bearing MS27640KP4

11

(Alt. MS20200KP4)
Yoke Casting-2315153-32

6
7

8
9

12

Replacewompart.

Replace worn part.


Replace worn part.

primer.
Replacewornpart.

B, C

D,
D,
D,
D,
D,
D,

2315153-40
2315153-41

10

2415152-&495
2415152-9-495
Bearing- MS27641KP6A

11

11

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
primer.
Replace
Replace
Replace
Replace
Replace

Replace worn

E
E
E

Install

new

bearing

with wet

part.
part.
part.
part.
part.
part. Install

new

bearing

with wet

part.
part.
part.
part.
part.
part.
part. Install

new

bearing

with wet

Install

new

bearing with

worn

part.

worn

part.
part.

worn
worn

worn
worn
worn
worn
worn

worn

worn

worn
worn

worn

12

Replace worn
primer.
Replace worn part.
primer.
Replace worn part.

2315153-28

13

2315153-5

14

G, H
G, H

Replace worn part.


Replace worn part.

14

15

Shaft, Main Control Wheel

2315153-716-2

(Alt. AN201 KP6A)


Bearing- 8-539-ZZ
(Alt. B-539-DD)
Capstan Assy 2415160-3, -5,

13

Bolt

REPAIR

Assy, Bearing

2315152-6, -31
3

HOLE

-7

wet

(Alt. 2315153-49)
16

Shaft, Main Control Wheel


2615271-1

17
18
19

20

15

G, H

Torque Tube 2315151-2


Block Assy., Bearing 2315151-6
Bearing B-545-ZZ
(Alt. B-545-DD)

16

Bellcrank

2315151-4, -7

2315154-1

2315216-1
21

Bearing

LS4

Control Column

16

16

K, L

17

18

19

20

Assembly
Figure

EFFECTIVITY:

ALL

Replace worn
Replaceworn
Replace worn
Replace worn

Replace worn part.


Replace worn part.
Repace worn part.
Replace worn part.

Allowable Wear and

(Sheet

part.
part.
part.
part.

6 of

Repair Data

7)

51-71-13

Pageb
SRM-I

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


CODES
1
2

EFFECTIVITIES
23-00 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 28-001 and Subsequent; 29.001 and Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
24-247 and Subsequent and Prior Aircraft Modified by AAK 76-04A, "Reduced Approach Speed System"; 25-082 thru 25-360 and Prior Aircraft Modified by AAK 76-04A, "Reduced Approach Speed
System"; 28-001 thru 28-005; 29-001 thru 29-003; 35-001 thru 35-487; 36-001 thru 36-050
25-361 and

Subsequent; 28-006 and Subsequent; 29-004 and Subsequent; 31-001 and Subsequent;
Subsequent; 36-051 and Subsequent
24-247 and Subsequent and Prior Aircraft Modified by AAK 76-04A, "Reduced Approach Speed System"; 25-082 and Subsequent; 28-001 and Subsequent; 29-001 and Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
24-247 and Subsequent; 25-187 and Subsequent; 28-001 thru 28-005; 29-001 thru 29-003; 35-018

thru 35-487; 36-009 thru 36-050


25-361 and Subsequent; 28-006 and

35-488 and

35-488 and

Subsequent;

Subsequent;
Subsequent
24-109 Except

23-001 thru 23-099; 24-100 thru

proach Speed System"


24-210 thru 24-169 Except Aircraft Modified by
25-001 thru 25-081 Except Aircraft Modified by

9
10

11
12

13

14

29-004 and

Subsequent;

31-001 and

Subsequent;

36-051 and

Aircraft Modified

by AAK 76-04A, "Reduced Ap-

AAK 76-04A, "Reduced


AAK 76-04A, "Reduced

Approach Speed System"


Approach Speed System"
23-001 thru 23-099; 24-100 thru 24-109 When Modified by AAK 76-04A, "Reduced Approach Speed
System"; 24-210 thru 24-169 When Modified by AAK 76-04A, "Reduced Approach Speed System";
25-001 thru 25-081 When Modified by AAK 76-04A, "Reduced Approach Speed System"
24-170 and Subsequent; 25-082 and Subsequent; 28-001 and Subsequent; 29-001 and Subsequent;
31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
23-001 and Subsequent When Modified by A 2396003 Special Spares Kit; 24-100 and Subsequent
When Modified by SSK 947A, "Replacement of Control Column Pulley and Shaft Assembly"; 25-001
thru 25-081 and Subsequent When Modified by SSK 947A, "Replacement of Control Column Pulley
and Shaft Assembly"; 2&001 and Subsequent; 29-001 and Subsequent; 31-001 and Subsequent;
35-001 and Subsequent; 36-001 and Subsequent
23-001 and Subsequent Except Aircraft Modified by SSK 947A, "Replacement of Control Column
Pulley and Shaft Assembly"; 24-100 and Subsequent Except Aircraft Modified by SSK 947A, "Replacement of Control Column Pulley and Shaft Assembly"; 25-001 thru 25-081 Except Aircraft Modified by SSK 947A, "Replacement of Control Column Pulley and Shaft Assembly"
23-001 and Subsequent When Modified by SSK 947A, "Replacement of Control Column Pulley and
Shaft Assembly"; 24-100 and Subsequent When Modified by SSK 947A, "Replacement of Control
Column Pulley and Shaft Assembly"; 25-001 thru 25-081 and Subsequent When Modified by SSK
947A, "Replacement of Control Column Pulley and Shaft Assembly"; 35-018 thru 35-487; 35-500,
35-502, 35-503, 35-505, 35-509 thru 35-567; 36-009 thru 36-060 and Prior Aircraft With 2315153-49
Shaft

17

Subsequent Except Aircraft Modified by SSK 947A, "Replacement of Control Column


Pulley and Shaft Assembly"; 24-100 and Subsequent Except Aircraft Modified by SSK 947A, "Replacement of Control Column Pulley and Shaft Assembly"; 25-001 thru 25-081 Except Aircraft Modified by SSK 947A, "Replacement of Control Column Pulley and Shaft Assembly"; 2&001 and Subsequent; 29-001 and Subsequent; 31-001 and Subsequent; 35-488 thru 35-499, 35-501, 35-504, 35506 thru 35-508, 35-568 and Subsequent; 36-061 and Subsequent
23-001 thru 23-099; 24-100 thru 24-246 Except When Modified by AAK 76-04A, "Reduced Approach
Speed System"; 25-001 thru 25-081 Except When Modified by AAK 76-04A, "Reduced Approach
Speed System"
23-001 and Subsequent

18

24-100 thru 24-152; 25-001 thru 25-016

19

23-011, 23-012, 23-015, 23-019, 23-031, 23-043, 23-050, 23-051, 23-060, 23-065, 23-087, 23-096;

15

16

23-001 and

24-153 and
20

23-001 and

Subsequent; 25-017 and Subsequent


Subsequent Except 23-011, 23-012, 23-015, 23-019, 23-031, 23-043, 23-050, 23-051,

23-060,23-065,23-087,23-096
NOTES:

Machined finish

Control Column

EFFECTIVITY:

ALL

Assembly Allowable Wear


Figure 1 (Sheet 7 of 7)

and

Repair Data

1
51-71-13

Page
SRM-4

Jun 6/98

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


PASSENGER/CREW UPPER DOOR

ALLOWABLE WEAR AND REPAIR DATA

24

CA

CL
25

i CB

i7~---

cc

CA

CP

N
3

cc

~n

7~

CC

CD3
Cc

3
S\

co

CD

cc

3~

CC

~..1

Detail N
2-19C
2-91A-3
2-7B1

EFFECTIVITY:

Passenger/Crew Upper Door Allowable Wear and Repair


Figure 1 (Sheet 1 of 24)
23-001 THRU 23-099

EQUIPPED WITH 36-INCH

PASSENGER/CREW DOOR
SRM-4

cc

;\4
cc

Data

51-71-14

Page

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
PASSENGER/CREW UPPER DOOR

ALLOWABLE WEAR AND REPAIR DATA

_-d~

c?i.

CL
25

CF
7

CG

CG

7-CJ

CH

CJ

i
9

CJ

CH
9

cJ

Ed

cJ

ck
2-19C
2-7B1

EFFECTIVITY:

SRM-4

Detail M
Passenger/Crew Upper Door Allowable Wear and Repair Data
Figure 1 (Sheet 2 of 24)

MODEL 24 AND 25 SERIES AIRCRAFT EQUIPPED WITH


36-INCH PASSENGER/CREW DOOR

51-71-14

Page 2
Jun 6/98

L~arjet
Learjet

STRUCTURAL REPAIR MANUAL


PASSENGER/CREW UPPER DOOR

ALLOWABLE WEAR AND REPAIR DATA

23

~g

,,,e

A
CL

12

11

Detai IA

Detail B
H

17

cr~-

c~B
D

8~

-L

DetailC

DetailD
M

21

J\

DetailE
2-7B1

EFFECTIVITY:

Passenger/Crew Upper Door Allowable Wear and Repair


Figure 1 (Sheet 3 of 24)
ALL MODEL 31, 35 AND 36 SERIES AIRCRAET

WJTH 36-INCH PASSENGER/CREW DOOR


SRM-I

DetailF

EQUIPPED

Data

51-71-14

Page 3
Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


PASSENGER/CREW UPPER DOOR

ALLOWABLE WEAR AND REPAIR DATA

27~

?8
29

26~

CR

CQ
CP

CN

~ad

(23-001 thru 23-059 Eauitltled with 36-Inch Door. Excetlt Modified bu


SSK 23-133. "Retllacement of Utlt~er Door Torsion Bay")

Detail Q
2-27c

EFFECTIVITY:

Passenger/Crew Upper Door Allowable Wear and Repair Data


Figure 1 (Sheet 4 of 24)
NOTED

51-71-14

Page4
SRM-4

Jun 6/98

Learjet I

STRUCTURAL REPAIR MANUAL


PASSENGER/CREW UPPER DOOR

ALLOWABLE WEAR AND REPAIR DATA

37

36
35

;X

42

CS

\1

CT

CV

33

39
40

CZ CY

CX

41

CW

with 36 Inch Door, Excetlt Modified by SSK 23-133, "Retllacement


with 36-Inch Door, Excettt ModifJed
of Ut~tter Door Torsion Bar": 24-100 thru 24-180
b; SSK23-133. "Retllacement of LIt~t7er Door Torsion Bar": 25-001 thru 25-024 Eauiotled with 36Inch Door, Excettt Modified by SSK 23-133, "Retllacement of Utlt~er Door Torsion Bar")

(23-060 thlrr 23-099

Detail R
2-36C

EFFECTIVITY:

Passenger/Crew Upper Door Allowable Wear and Repair Data


Figure 1 (Sheet 5 of 24)
NOTED

51-71-14

Page5
SRM-(

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
PASSENGER/CREW UPPER DOOR

ALLOWABLE WEAR AND REPAIR DATA

G
X

;U

Q
~B

T
46

45

(23-060 thru 23-099 EauiPtled with 36-Inch Door and t~rior Aircraft Modified by SSK23-133, "ReDoor Torsion Bar": 24-181 and Subseauent Eauitlt~ed with 36-Inch Door and
ttlacement of
tlrior Aircraft Modified bu SK 23-133, "Retllacement of Utltler Door Torsion Bar": 25-025 and Subseauent

with 36-Inch Door and tltror Aircraft Modified bu SK 23-133, "Ret~Iacement of

Door Torsion Bar": All 28, 29 31, 35 and 36 Series Aircraft

with 36-Inch Door

Detail G
BBIOC
B4-6A
C4-581

(EFFECTIVITY:

Passenger/Crew Upper Door Allowable Wear and Repair Data


Figure 1 (Sheet 6 of 24)
NOTED

51-71-14

Page6
SRM-I

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


PASSENGER/CREW UPPER DOOR

ALLOWABLE WEAR AND REPAIR DATA

58

DetailH
2-3C-1

EFFECTIVITY:

Passenger/Crew Upper Door Allowable Wear and Repair


Figure 1 (Sheet 7 of 24)

ALL AIRCRAFT

EQUIPPED WITH 36-INCH

PASSENGER/CREW DOOR
SRM-4

~59

Data

51-71-14

Page 7
Jun 6/98

6~ Learjet
Learjetl
STRUCTURAL REPAIR MANUAL
PASSENGERICREW UPPER DOOR

ALLOWABLE WEAR AND REPAIR DATA

AD

s3------IS leB
AE

Detail J
Passenger/Crew Upper Door
Figure

IEFFECTIVI?Y:
SRM-B

ALL AIRCRAFT

Allowable Wear and

Repair Data

(Sheet 8 of 24)

EQUIPPED WITH 36-INCH


PASSENGER/CREW DOOR

51-71-14

Page 8
Jun 6/98

Learjet
Learjetj

STRUCTURAL REPAIR MANUAL


ALLOWABLE WEAR AND REPAIR DATA

PASSENGER/CREW UPPER DOOR

A71

AM
13

AK

AJ
AR

e,

!18 \AN

7q

AK72

AJ
74
68

736

AL

AN
69

68

AP

AR

71

70

AL

AG
75

68

\cl
AR

as

74

DetailK

AQ

Passenger/Crew Upper Door Allowable Wear and Repair


Figure 1 (Sheet 9 of 24)
EFFECTIVITY:

ALL AIRCRAET

EQUIPPED WITH 36-INCH

PASSENGER/CREW DOOR
SRM-4

Data

51-71-14

Page 9
Tun 6/98

~9 Learjet
STRUCTURAL REPAIR MANUAL
PASSENGER/CREW UPPER DOOR

ALLOWABLE WEAR AND REPAIR DATA

AY
AZ

BA
ED

BE
BF

8~

81

s2

BG
82

"Gii-- BC

180

78

BE

AS
AX

AU
A

7s

AW

68

76

77

AS
AT

I(O

se

BH
BN

BQ

BJ

83

r.

BK

/s
78

85-----~\

BL

84

C"i--BR

BM
81

BP
86
Z1R

EFFECTIVITY:

87

sv/

Detail L

,I
87

BT

86

Passenger/Crew Upper Door Allowable Wear and Repair Data


Figure 1 (Sheet 10 of 24)
ALL AIRCRAFT

EQUIPPED WITH 36-INCH

PASSENGER/CREW DOOR
SRM-I

~les

51-71-14

Page

10

Tun 6/98

Learjet
~Leariet]

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM
NO.

I
DESCRIPTION

Plate-

Guide Assy.
-103

EFF.

2311280-75,

-83

CA

MFD

MFD

HOLE

SHAFT

ID

OD

0.5100

+0.0100/

2311281-23

CC

0.6250

2311281-33

CC

0.6400

OD

WEAR
ID

ALLOWANCE
OD

+0.0080/
-0.0010
0.6250

0.6250

ALLOWANCE

ID

I
CC

MFD

0.6250

CB

1
-82

I
HOLE

2311280-77,

Plate-2311280-67,

+0.0080/
-0.0010

-0.0000

+0.0080/
-0.0010
+0.0080/
-0.0010

1 +0.0100/
-0.0100

1 GuideAssy.

-2311280-66

CB

0.51 00

0.6250

Plate, Striker-2311295-1,-2

CE

0.5310

Plate- 2311280-83

CF

0.6250

Guide Assy.

CG

0.5100

CH

0.6250

CH

0.6250

I CH

0.6400

CJ

0.5100

+0.0100/
-0.0000

+0.0080/
-0.0010

1 +0.0060/
-0.0010

1 +0.0080/
-0.0010

2311280-77,

-103

Plate- 2311280-82

I
5

2311281-23
2311281-33

0.6250

+0.0100/
-0.0000
1 +0.0080/
-0.0010

+0.0080/
-0.0010

1 +0.0080/
-0.0010
+0.0100/
-0.0100

GuideAssy. -2311280-66,

-88, -104

2411281-10
10

0.6250

+0.0100/

CJ

0.51 00

CK

0.6250

1 +0.0080/

2411281-23, -25

CK

0.6250

1 +0.0080/

2411281-33, -35

CK

0.6400

1 +0.0100/

0.6400

1 +0.0100/

Plate- 2311280-82, -111

0.6400

+0.0080/

1
+0.0100/
-0.0000

-0.0000

+0.0100/
-0.0100

-0.0010
-0.0010
-0.010

11

Plate-2411280-33

-0.0100
12

Guide, PlateAssy.
2411281-10

0.6400

1 +0.0100/

0.6250

1 +0.0080/

0.6400

1 +0.0100/

-0.0100
13

Plate- 2411281-25

-0.0010

2411281-35

-0.0100

Passenger/Crew Upper Door Allowable Wear and Repair


Figure 1 (Sheet 11 of 24)
EFFECTIVITY:

NOTED

Data

51-71-14(
Page

SRM-a

11

Jun 6/98

Learjet I

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

I
HOLE

EFF.

DESCRIPTION

NO.

MFD

MFD

HOLE

SHAFT

ID

OD

MFD

ALLOWANCE

ID

OD

WEAR
ID

ALLOWANCE
OD

Guide, PlateAssy.

14

2411281-10

Plate- 2411281-34

15

10

0.6400

0.6400

1 +0.0100/
-0.0100
1 +0.0100/
-0.0100

16

Guide, PlateAssy.

2411281-10
17

Plate-2411281-23
2411281-33

0.6400

0.6400

0.6400

1 +0.0100/
-0.0100
1 +0.01001
-0.0100

1 +0.0100/
-0.0100

18

Guide, PlateAssy.

0.6400

1 +0.0100/

0.6400

1 +0.0100/

0.6400

1 +0.0100/

11

2411281-10

-0.0100

Plate- 2411281-23

19

-0.0100
2411281-33

-0.0100

Guide, Plate Assy.

20

2411281-10

0.6400

i +0.0100/

0.6400

1 +0.0100/

0.6400

1 +0.0100/

-0.0100
21

Plate-2411281-24

-0.0100
2411281-34

-0.0100

Guide, Plate Assy.

22

2411281-10

0.6400

1 +0.0100/
-0.0100

23

Hinge, Half-Fuselage
2311280-19, -98, -108

CL

0.0700

1 +0.0000/
-0.0050

24

Hinge, Half- Fuselage


2411283-3, -8, -11,-014

25

Hinge,

CL

0.0700

1 +0.00001
-0.0050

CL

0.0700

1 +0.0000/

Half- Door

241 1 280-20

-0.0050
26

1 Hinge,

Half-Door

2411283-2, -6, -10, -013

CL

0.0700

1 +0.00001
-0.0050

Passenger/Crew Upper Door Allowable Wear and Repair


Figure 1 (Sheet 12 of 24)

EFFECTIVITY:

NOTED

Data

51-71-14

Page
SRM-4

12

Tun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

I
DESCRIPTION

NO.

EFF.

Link-2311492-15

26

I
HOLE I

12

MFD

MFD

HOLE

SHAFT

ID

OD

MFD

ALLOWANCE

ID

CM

0.2500

1 +0.0050/

CN

0.3160

1 +0.0010/

OD

WEAR
ID

ALLOWANCE
OD

-0.0010
-0.0090
27

Pin, Clevis- MS20392-3C17

12

28

Link-2311492-21,

12

29

Plate Guide

30

PlateBearing

-22

CM

0.2480

+0.0000/
-0.0020

CM

0.2500

1 +0.0050/

12

CP

0.3750

1 +0.0060/

12

CQ

0.3750

1 +0.0060/

CR

0.5000

1 +0.0060/

-0.0010
2311492-10

-0.0000
-2311492-17

-0.0000
31

Doubler-2311492-19

32

FittingAssy.

12

-0.0000

2311280-63, -64

12

CN

0.3140

1 +0.0000/
-0.0050

Link, Lwr, Torsion Bar Arm

33

2311688-14

13

CS

0.2500

1 +0.0050/

CZ

0.3160

1 +0.0010/

-0.0010
-0.0090
34

Pin, Clevis- MS203923C17

35

Arm

36

13

CS

13

CT

0.4125

1 +0.0020/

Spacer- NAS43HT7-18

13

CU

0.4600

37

Plate

13

CV

0.4690

1 +0.0300/
-0.0200
1 +0.0060/
-0.0010

38

Torsion Bar-231168&1

13

CU

39

Angle, Torque Adj. Support

0.2480

1 +0.0000/
-0.0020

Assy.

-231168&8

-0.0000

Bearing -2311688-13

0.3750

1 +0.0060/
-0.0000

2311688-6, -7

13

CW

13

1 CW

13

CX

0.1890

1 +0.00501
-0.0000

Bolt- MS20073-03-12

40

0.1890

1 +0.00001
-0.0030

41

Plate

Bearing-2311688-9

0.5020

1 +0.0050/
-0.0000

Passenger/Crew Upper Door Allowable Wear and Repair


Figure 1 (Sheet 13 of 24)
EFFECTIVITY:

NOTED

Data

51-71-14

Page
SRM-I

13

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM i

NO.

I
EFF.

DESCRIPTION

HOLE

Link, Upper- 2311688-3, -181 13

42

MFD

MFD

HOLE

SHAFT

ID

OD

MFD

ALLOWANCE

ID

CY

0.4125

1 +0.0020/

CS

0.2500

-0.0000
1 +0.0050/

OD

WEAR
ID

ALLOWANCE
OD

-0.0010

Bushing- DBS-7-030
(Alt- AJ07C-125)
Support, Torsion Bar

43
44

Link- 2411682-1, -5, -6,


14
-17, -18, -27, -28, -31,-32 1

Link

45

11

0.4300

1 +0.0090/
1 -0.0000

Assy., Lower Arm

2411681-1

24

0.4690

1 +0.0060/

2411681-15, -21

25

0.6259

1 +0.0000/

45A

Bushing- DBS-7-30
(Alt. AJ07C-030)

24

46

Pin, Clevis-MS20392-3C17

14

P, Q

47

Link, Upper Torsion


BarArm -2311688-3,-16, 14
-17,-18
1

-0.0010

-0.0005

0.2480

1 +0.0000/
-0.0020

48

Arm

49

Angle, Torsion Bar-

Assy.

2311688-8

0.2500

I
R

14

0.4125

1 +0.0050/

1 -0.0010

1 +0.0020/
-0.0000

2311688-7

Bolt- NAS1003-12H

50

14

14

0.1890

1 +0.0050/
-0.0000

0.1880

1 +0.0015/
-0.0010

51

Plate,Bearing2311688-9

52

1 Spacer-NAS43HT7-18

14

0.5020

14

0.4650

i
0.5600

53

Plate, Bearing-231168&13

14

54

Bar, Torsion- 2311688-1

14

T, U,
V,W

0.4390

1 +0.0050/

-0.0000
+0.0250/

+0.0180/

-0.0250

-0.0120

1 +0.0050/
-0.0000

55

Bolt-NAS1003-12H

14

0.4375
0.1880

1 -0.0020

1 +0.0015/

+0.0000/

-0.0010
56

Angle, Torsion Bar2311688-6, -7

14

0.1890

I c0.0050/
-0.0010

Passenger/Crew Upper Door Allowable Wear and Repair Data


Figure 1 (Sheet 14 of 24)

)EFFECTIVITY:

NOTED

51-71-14

Page
sRM-4

14

Jun 6/98

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

NO.I

I
HOLE I

EFF.

DESCRIPTION

57

Plate- 2311271-17

58

Guide Assy., Pin


2311271-12

MFD

MFD

HOLE

SHAFT

ID

0.4950

OD

I MFD
I

WEAR

ALLOWANCE

ID

OD

ID

ALLOWANCE
OD

1 +0.0050/
-0.0000

59

62

63

0.4950

1 +0.0050/
-0.0000

AA

0.4950

1 +0.00501
-0.0000

0.4950

1 +0.0050/

1 -0.0000

1 +0.0050/
-0.0000

1 GuideAssy.
2311276-1, -2, -5, -6,
-9, -10

61

1 GuideAssy.
2311279-1, -2

60

64

65

AB

HingeArm-231127&3

AC

Bolt- AN4-27A

AD,

1 +0.0010/

AE

1 -0.0020

1 +0.0050/

0.4950

Guide-2311502-4,-12

AD

0.2500

Clevis- 2311502-5, -11,-17

AE

0.2500

AF

0.3117

Bolt- NAS464P5A12

AF

SupportAssy. -2311495-28,

AG

0.2480

-0.0010
1 +0.0050/
-0.0010
1 +0.0010/
+0.0000

0.3117

1 +0.0000/
-0.0009

66

-69, -134
67

Bearing,

1 +0.01001

-0.0100

ThrustAH

2411515-1

68

1.0100

1.2000

2.1800

+0.0300/

+0.0300/

-0.0300

-0.0300

Control Rod Assy.


15

2311288-1

AJ

1.0100

1+0.0050/
-0.0050

AK

0.1890

AS

0.1880

+0.0300/
-0.0300

1 +0.0100/
-0.0100
1 +0.0050/
-0.0010

Quadrant Assy.
16

2411513-1

AJ

1.0100

1+0.0050/
-0.0050

AK

0.1890

1 +0.0100/

AS

0.1880

1 +0.0050/

+0.0300/
-0.0300

-0.0100
-0.0010

Passenger/Crew Upper Door Allowable Wear and Repair Data


Figure 1 (Sheet 15 of 24)
EFFECTIVITY:

NOTED

51-71-141
Page

SRM-I

15

Jun 6/98

Learjet
Ledrjet/
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

MFD
ITEM I

I
DESCRIPTION

NO.

I
HOLE I

IEFF.

Bolt- 2311490-8

69

HOLE
ID

MFD

MFD

ALLOWANCE

WEAR

ALLOWANCE

SHAFT
I

OD

ID

OD

17

AK

0.1894

1 +0.00001

16

AK

0.1894

1 +0.00001

18

1 AL,

0.1860

1 +0.0000/

1 -0.0020

1
I

1 +0.0000/
1 -0.0020

ID

OD

-0.0009

2311490-12, -13

-0.0009

Pin,Clevis-AN23-34A

70

AM,

I
I

1
I

AN

MS20392-2C63

AL,
AM,

19

0.1860

AN
71

HandleAssy.,Outer2311286-3, -6, -9

20

AL

0.2504

2411286-1, -3

21

AL

0.2504

AM

0.2140

1 +0.0005/
-0.0000
1 +0.0005/
-0.0000

72

Spacer, NAS43DD3-26,

-22

0.3120

+0.0200/
-0.0200

73

Cover Assy., Outer


Handle- 2311287-3

AN

18

0.1880

+0.0100/
-0.0100

1 +0.0100/
-0.0100

AP

2311287-4, -7
2411287-2, -3, -4

0.1880

0.8600

I
AP

0.8600

AP

0.1890

0.8450

73A

Bolt- NAS221-28

18

738

Plug, Handle-

18

CZ

74

Tube Handle
2311491-19

17

AR

2311491-5

AN

19

AQ

0.1890

1 +0.0000/
-0.0050

1 +0.0100/
1 -0.0100
1
1 +0.0000/
-0.0050
1
1 +0.0000/
-0.0009
1
1 +0.0050/
-0.0050
1 +0.0000/
-0.0010

1.0000

1 +0.0300/
-0.0300

2411491-14

18

AR

0.1890

1 +0.0000/

-0.0010

AQ

1.0000

1 +0.0300/
-0.0300

2411516-1, -2, -3

16

AR

AQ

0.1890

1 +0.0000/
-0.0010

1.0000

1 +0.0300/
-0.0300

Passenger/Crew Upper Door Allowable Wear and Repair Data


Figure 1 (Sheet 16 of 24)

EFFlECTIVITY:

NOTED

51-71-14

Page
SRM-4

16

Jun 6/98

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

MFD
ITEM I

HOLE

MFD

MfD

ALLOWANCE

WEAR

ALLOWANCE

I SHAFT

NO.I

DESCRIPTION

EFF.

HOLEI

ID

75

Bolt- NAS221-23

17

AR

NAS464 P3A1 9

16

AR

OD

0.1890

1+0.0000/

1 0.1894

1+0.0000/

ID

OD

ID

OD

-0.0009

-0.0009
76

Pushrod

Assy.,

Pin
1

231149&1,3

77

Pin-2311491-18

AT

0.1900

1+0.0020/
-0.0000

AU

0.1900

1+0.00201

AV

0.1880

-0.0000
1+0.0050/
-0.0010

AW

0.4850

1+0.0000/
-0.0050

78

Rod

Assy.

2311494-1

22

AX
AY

2311490V1-004

23

AX
AY

79

1 ArmAssy.,Rocker2311277-1

AZ

0.1880

1 +0.0100/

BA

0.1880

BE

0.1880

BC

0.2504

1+0.0100/
-0.0100
1 +0.0100/
-0.0100
1+0.0005/
-0.0000

-0.0100

80

1 Pin,ClevisMS20392-2C25

BC

0.2480

1+0.0000/
-0.0002

81

1 PushrodAssy.,Pin2311496-5, -7, -9

2311490V1-002

22

23

ED

0.1900

BE

0.1900

ED

0.1900

1+0.0020/
-0.0000
1+0.0020/
-0.0000
1+0.0020/

BE

0.1900

1+0.0020/

BF

0.1880

1+0.0050/
-0.0010

1 0.4850

-0.0000

-0.0000
82

Pin- 2311491-17

BG

1+0.0000/
-0.0050

Passenger/Crew Upper Door Allowable Wear and Repair Data


Figure 1 (Sheet 17 of 24)
EFFECTIVITY:

NOTED

51-n-14/
Page

SRM-I

17

Jun 6/98

E~ Learjet
Learjetl
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

I
DESCRIPTION

NO.
83

Pushrod

MFD

MFD

HOLE

SHAFT
OD

ID

MFD

OD

ID

EFF.

HOLE

BH

0.1900 1

+0

BJ

0.1900 1

+0

WEAR

ALLOWANCE
I

ID

ALLOWANCE
OD

Pin

Assy.,

2311497-1, -3

-0.0000
-0.0000

Bellcrank

84

Assy.,

Fwd
1

2311284-1

BK

0.1880 1

+0.01

BL

0.3754 1

+0.

BM

0.1880 1

+0.01
-0.0100

BN

0.1880 1

BP

0.1880 1

+0.01
-0.0100
+0.01
-0.0100

BQ

0.1890 1

+0

BR

0.3754 1

+0

BS

0.2504 1

+0

-0.0100
-0.0000

85

Bellcrank

Assy., Aft
1

2311283-1, -3, -5

-0.0010
-0.0000

Link

86

Assy.,

Lwr Pins

2311491-1

-0.0000

BT

0.2504 1

+0.

BU

0.1880

-0.0000

Pin-2311491-16

87

-0.0010
BV

0.4850 1

+0
-0.0050

88

Pin, ClevisMS20392-2C17

AS,
AU,
AX,
AZ,
BE,
BE,

AT,I
AV~

1
I

0.1860

1
I

0.1860

1
I

I
1

+0.

I
1

+0

-0.0020

AY
ED
BF

BH

89

Pin, ClevisMS20392-2C21

BJ, BK,(
BM, BN1
BP, BS
BT, BU

Passenger/Crew Upper Door Allowable Wear and Repair


Figure 1 (Sheet 18 of 24)

1EFFECTIVITY:

NOTED

-0.0020

Data

51-71-14

Page 18
SRM-4

Jun 6/98

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

Plate 2311280-75, -83


Guide Assy. 2311280-77, -103
Plate 2311280-67, -82
2311281-23
2311281-33
Guide Assy. 2311280-66

Plate, Striker 231 1295-1,

Plate

Guide Assy. 2311280-77, -103


Plate 2311280-82
2311281-23
2311281-33
Guide Assy. 2311280-66, -88, -104
2411281-10
Plate-2311280-82, -111

2
3

10

-2

7
8

L
L

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replacewompart.
Replace worn part.
Rep\acewompart.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.

CL

Replace worn part.

CL
CL

Replace worn
Replace worn
Replace worn
Replace worn

CA

CA

CC
CC

CC
CB
CE
CF
CG
CH
CH
CH
CJ
CJ
CH
CH
CH
A
B

8
6

C
D

10

4
2

2311280-83

5
5

5
5

2311281-23, -25
2311281-33, -35

1
6

2411281-33

11

Plate

12

Guide, Plate Assy.

13

Plate

14

2411821-35
Guide, Plate Assy.

2411281-10

2411821-25
2411281-10

2411281-34

15

Plate

16

Guide, Plate Assy. 2411281-10

17

Plate 2411281-23
241128133

G
G

18

Guide, Plate Assy. 2411281-10

11

19

Plate

2411281-23

22

241128133
Guide, Plate Assy. 2411281-10
Plate 2411281-24
241128134
Guide, Plate Assy. 2411281-10

23

Hinge Half, Fuselage

24

Hinge Half, Fuselage

25

Hinge Half, Door

26

Link

27

28

Pin,Clevis- MS20392-3C17
Link 2311492-21, -22

29

Plate Guide

30

Plate

20
21

REPAIR

EFF. IHOLE

DESCRIPTION

NO.

2311280-19, -98, -108

2411280-3, -8, -11, -104


2411280-20

241 1 283-2, -6, -10, -01 3

2311492-15

CL

12

CM,

12

CM

12

CM

I
I

part.
part.
part.
part.

CN

Bearing

2311492-10
2311492-17

12

CP

12

CQ

Replacewompart.
Replace worn part.
Replace worn part.
Replace worn part.

Passenger/Crew Upper Door Allowable Wear and Repair Data


Figure 1 (Sheet 19 of 24)
EFFECTIVITY:

NOTED

51-71-141
Page 19

sRM-a

Jun 6/98

Leariet
STRUCTURAL REPAIR MANUAL
REPAIR DATA

ITEM
NO.
31

Doubler

2311492-19

12

32

Fitting Assy. 2311280-63, -64


Link, Lower Torsion Bar Arm

12

CR
CN

13

CS, CZ

13

CS

38

2311688-14
MS20392-3C17
Arm Assy. 2311688-8
Spacer NAS43H57-18
Plate Bearing 231168&13
Torsion Bar 2311688-1

39

Angle, Torque Adj. Support

40

Bolt

33
34
35
36
37

Pin, Clevis

42

MS20073-03-12
Plate Bearing 2311688-9
Link, Upper- 2311688-1, -18

43

Bushing

41

13

CT

13

CU

13

CV
CU

13

CW
CW

13

2311688-6, -7

13

DBS-7-030

REPAIR

HOLE

EFF.

DESCRIPTION

13

CX

13

ICY,CSJ

Replace worn part.


Replace worn part.
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.
part.
part.

Replace worn part.


Replace worn part.
Replace worn part.
Rep\acewompart.
Replace worn part.

44

(Alt. AJ07C-125)
Support, Torsion Bar Link

45

2411682-1,-5, -6, -17, -18, -27,


-28, 31,-32
Link Assy., Lower Arm,

14

Replace worn part.

2411681-21

24

2411681-15, -21

25

Bushing DBS-7-30

24

Replace worn part.


Replace worn part.
Replace worn part.

14

P,Q

Replace worn part.

47

(Alt. AJ07C-030)
Pin, Clevis MS20392-3C17
Link, Upper Torsion Bar Arm
2311688-3, -16, -17, -18

48

Arm

45A
46

14

Assy. 231168&8
Angle, Torsion Bar 231168&7

14

14

14

14

14

54

NAS1003-12H
Plate, Bearing 23116889
Spacer NAS43H17-18
Plate, Bearing 231168&13
Bar, Torsion 2311688-1

55

Bolt

56

Angle, Torsion Bar 2311688-6,

57

Plate 2311271-17
Guide Assy., Pin 2311271-12

49

50
51
52
53

58
59
60

Bolt

NAS1003-12H

Guide Assy.
Guide Assy.

Install

new

bushing with

Loctite.

-7

14

14

T, U,
V, W

14

14

2311279-1, -2

AA

2311276-1, -2, -5,

AB

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.
part.
part.
part.
part.

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.
part.
part.

-6,-9,-10

Passenger/Crew Upper Door Allowable Wear and Repair Data


Figure 1 (Sheet 20 o~ 24)

(EFFECTIVITY:

NOTED

51-71-14

Page 20
SRM-4

Jun 6/98

Learjet
~Learjet
STRUCTURAL REPAIR MANUAL
REPAIR DATA

ITEM

DESC RI PTION

NO.

Arm

231127&3

EFF.

IHOLE

AC

AD, AE

61

Hinge,

62

Bolt

63

AD

AE, AF

65

Guide 2311502-4, -12


Clevis 2311502-5, -11, -17
Bolt NAS464P5A12

AF

66

Support Assy. 2311495-28, -69,

AG

64

AN4-27A

REPAIR

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.
part.
part.

-134

Bearing, Thrust 2411515-1


Control Rod Assy. 2311288-1

67
68

AH

15

AJ, AK,

16

IAJ,AK,

Replace worn part.


Replace worn part.

AS

Quadrant

Assy.

2411513-1

Replace worn part.

AS

Bolt
Bolt

69

2311490-8

17

AK

2311490-12, -13

16

AK

18

AL,AM,I

19

IAL,AM,I

Pin, Clevis- AN23-34A

70

Replace worn part.


Replace worn part.
Replaceworn part.

AN

MS20392-2C63

Replacewompart.

AN
71

Handle

Assy., Outer

2311286-1,-3, -9
2411286-1,3
Spacer NAS43DD3-22, -26

72

Cover Assy., Outer Handle


2311287-3

73

2311287-4, -7
2411287-2,-3,-4

20

AL

21

AL
AM

Replace worn part.


Replace worn part.
Replace worn part.

19

AN,AP
AN,AP

Replace worn part.


Replace worn part.

18

73A

Bolt

NAS221-28

18

AP

738

Plug,

Handle

18

CZ

17

2311491-5

2411491-14

18

2411516-1,-2, -3

16

AQ, ARI
AQ, ARI
AQ, ARI

17

AR

Tube, Handle -2311491-19

74

75

Bolt

76
77

NAS464P3A219
Pushrod Assy., Pin
Pin -2311491-18

78

Rod

79

2311490V1-004
ArmAssy., Rocker-2311277-1

NAS221-23

Assy.

80

Pin, Clevis

81

Pushrod

2311494-1

MS20392-2C25

Assy.,

AR

AT, AU

AV,AWI

22

AX, AY
AX, AY
AZ, BA,I
BE, BC

23
1

part.
part.
part.
part.
part.
part.
part.
part.
part.
part.
part.

part.

BC

Replace worn part.

22

ED, BE
ED, BE
BF, BG

Replace worn part.


Replace worn part.
Replace worn part.

Pin

2311496-5, -7, -9
82

2311498-1, -3

16

Replace worn
Replace worn
Replaceworn
Replaceworn
Replaceworn
Replace worn
Replace worn
Replace worn
Replaceworn
Replace worn
Replace worn
Replaceworn

2311490V1-002
Pin 2311491-17

23
1

Passenger/Crew Upper Door Allowable Wear and Repair Data


Figure 1 (Sheet 21 of 24)
EFFECTIVITY:

NOTED

51-71-14

Page 21
SRM-I

Jun 6/98

Leariet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

DESCRIPTION

NO.

Pushrod Assy., Pin 2311497-1, -3


Bellcrank Assy., Fwd 2311284-1

83
84

EFF.

HOLE

BH, BJ
BK, BL,

REPAIR

Replace worn part.


Replace worn part.

BM
85

Bellcrank Assy., Aft

-5

Link Assy., Lwr Pins 2311491-1


Pin -2311491-16
Pin, Clevis- MS20392-2C17

86
87
88

2311283-1, -3,

1
1

BN, BP,I
I BQ, BR
BS, BT
BU, BV

AS,AT,I

Replacewompart.
Replace worn part.
Replace worn part.
Replaceworn part.

AU, AV
AX, AY
AZ,
BE, ED
BE, BF
BH
89

Pin, Clevis

MS20392-2C21

BJ, BK,
BM,
BP,BS,
BT, BU

Replace worn part.

Passenger/Crew Upper Door Allowable Wear and Repair Data


Figure 1 (Sheet 22 of 24)

(EFFECTNITY:

NOTED

51-71-14

Page 22
SRM-I

Jun 6/98

Learjet
~Learjetl

STRUCTURAL REPAIR MANUAL


CODES

EFFECTIVITIES
NOTE:

The

following effectivities

are

applicable provided

Aircraft is Eauiooed with 36-inch Pas-

senger/Crew Door
29-

Subsequent;
Subsequent

23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 28001 and
001 and Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and
23-001 thru 23-099; 24-100 thru 24-229; 25001 thru 25-066, Except 25-061

24-230 and

Subsequent; 25-061,25-067 and Subsequent; 2&001 and Subsequent;


sequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent

29-001 and Sub-

23-001 thru 23-099

24-100 thru 24-229; 25-001 thru 25-066, Except 25-061


31-001 and Subsequent; 35-001 and Subsequent; 36-001 and
35-001 thru 35-051; 36-001 thru 36-016
31-001 and Subsequent; 35-052 and Subsequent; 36-017 and

6
7
8
9
10
11

12
13

14

15

16

Subsequent
Subsequent

35-052 thru 35-510; 36-017 thru 36-053


31-001 and Subsequent; 35-511 and Subsequent; 36-054 and Subsequent
35-001 thru 35-510; 36-001 thru 36-053
23-001 thru 23-059, Except Aircraft Modified by SSK 23-133, "Replacement of

Upper Door Torsion

Bar"
23-060 thru 23-099, Except Aircraft Modified by SSK 23-133, "Replacement of Upper Door Torsion
Bar"; 24-100 thru 24-180, Except Aircraft Modified by SSK 23-133, "Replacement of Upper Door Torsion Bar"; 25-001 thru 25-024, Except Aircraft Modified by SSK 23-133, "Replacement of Upper Door
Torsion Bar"
23-060 thru 23-099 When Modified by SSK 23-133, "Replacement of Upper Door Torsion Bar"; 24180 and Subsequent and Prior Aircraft Modified by SSK 23-133, "Replacement of Upper Door Torsion
Bar"; 25-025 and Subsequent and Prior Aircraft Modified by SSK 23-133, "Replacement of Upper
Door Torsion Bar"; 2&001 and Subsequent; 29-001 and Subsequent; 31-001 and Subsequent; 35001 and Subsequent; 36-001 and Subsequent
23-001 thru 23-099 Except Aircraft Modified by AMK 78-02, "Replacement of Door Handle Mechanism"; 24-100 thru 24-356 Except Aircraft Modified by AMK 76-02, "Replacement of Door Handle
Mechanism"; 25001 thru 25-238 Except Aircraft Modified by AMK 78-02, "Replacement of Door Handle Mechanism";35-001 thru 35-167 Except Aircraft Modified by AMK 78-02, "Replacement of Door

Handle Mechanism"; 36-001 thru 36-038 Except Aircraft Modified by AMK 7&02, "Replacement of
Door Handle Mechanism"
23-001 thru 23-099 When Modified by AMK 7&02, "Replacement of Door Handle Mechanism"; 24357 and Subsequent and Prior Aircraft Modified by AMK 78-02, "Replacement of Door Handle Mechanism"; 25-239 and Subsequent and Prior Aircraft Modified by AMK 78-02, "Replacement of Door Handle Mechanism"; 2&001 and Subsequent; 29-001 and Subsequent; 31-001 and Subsequent; 35-168
and Subsequent and Prior Aircraft Modified by AMK 78-02, "Replacement of Door Handle Mechanism"; 36-039 and Subsequent and Prior Aircraft Modified by AMK 7&02. "Replacement of Door Handle Mechanism"

17

Subsequent and Prior Aircraft Modified by SSK 23-114, "Upper Door Handle ReplaceExcept When Modified by AMK 78-02, "Replacement of Door Handle Mechanism"; 24-100 thru
24356 Except When Modified by AMK 78-02, "Replacement of Door Handle Mechanism"; 25-001
thru 25-238 Except Aircraft Modified by AMK 78-02, "Replacement of Door Handle Mechanism"; 35001 thru 35-167 Except Aircraft Modified by AMK 78-02, "Replacement of Door Handle Mechanism";
36-001 thru 36-038 Except Aircraft Modified by AMK 78-02, "Replacement of Door Handle Mecha23-050 and
ment"

18

nism"
23-001 thru 23-049

Except

Except Aircraft Modified by SSK 23-114, "Upper Door Handle Replacement"


by AMK 78-02, "Replacement of Door Handle Mechanism"

Passenger/Crew Upper Door


Figure
EFFECTIVITY:

ALL AIRCRAFT

Allowable Wear and

Repair

Data

1 (Sheet 23 of 24)

EQUIPPED WITH 36-INCH

PASSENGER/CREW DOOR
SRM-4

and

When Modified

51-71-14

Page 23
Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
CODES
19

EFFECTIVITIES
23-050 and

Subsequent

and Prior Aircraft Modified by SSK 23-114, "Upper Door Handle Replaceby AMK 7802, "Replacement of Door Handle Mechanism"; 24-100 and Subsequent; 25-001 and Subsequent; 2&001 and Subsequent; 29-001 and Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
ment" and/or Modified

20
21

23-001 thru 23-099; 24-100 thru 24-241


24-242 and Subsequent and Prior Aircraft

2411287

28-001 and

and

Subsequent;
36-001 and Subsequent

22

29-001 and

31-119 and

24

23-001 thru 23-099 When Modified

25-001 and

35-001 and

Subsequent;
Subsequent;

Subsequent

by SSK 23/24/25-321, "Upper Door Torsion Bar Linkage Replaceby AMK 71-06A, "Upper Door Torsion Bar Linkage Replacement", or
AMK 71-05, "lnstallation of Anti-Friction Bushing in Upper Cabin Door Torsion Bar Links"; 24-181 thru
24-241 Except Aircraft Modified by AMK 71-05, "lnstallation of Anti-Friction Bushing in Upper Cabin
Door Torsion Bar Links", and Prior Aircraft Modified by SSK 23/24/25-321, "Upper Door Torsion Bar
Linkage Replacement", Except Aircraft Modified by AMK 71-05, "lnstallation of Anti-Friction Bushing in
Upper Cabin Door Torsion Bar Links"; 25-025 thru 25-077 Except When Modified by AMK 71-05, "lnstallation of Anti-Friction Bushing in Upper Cabin Door Torsion Bar Links", and Prior Aircraft Modified
by SSK 23/24/25-321, "Upper Door Torsion Bar Linkage Replacement" Except When Modified by
AMK 71-06A, "Upper Door Torsion Bar Linkage Replacement"
23-001 thru 23-099 When Modified by SSK 23-133, "Replacement of Upper Door Torsion Bar"; AMK
71-06A, "Upper Door Torsion Bar Linkage Replacement", or AMK 71-05, "lnstallation of Anti-Friction
Bushing in Upper Cabin Door Torsion Bar Links"; 24-242 and Subsequent and Prior Aircraft Modified
by AMK 71-06A, "Upper Door Torsion Bar Linkage Replacement"; 25078 and Subsequent and Prior
Aircraft Modified by AMK 71-06A, Upper Door Torsion Bar Linkage Replacement, or AMK 71-05, "lnstallation of Anti-Friction Bushing in Upper Cabin Door Torsion Bar Links"; 2&001 and Subsequent;
29-001 and Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
ment"

Handle;

Subsequent;

23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 28-001 and Subsequent; 29001 and Subsequent; 31-001 thru 31-118; 35-001 and Subsequent; 36-001 and Subsequent

23

25

Equipped With
Subsequent; 31-001

Except When

Modified

Passenger/Crew Upper Door Allowable Wear and Repair Data


Figure 1 (Sheet 24 of 24)

I""""":
sRM-4

ALL AIRCRAFT

EQUIPPED WITH 36-INCH


PASSENGER/CREW DOOR

51-71-14

Page 24
jun 6/98

Learjet I

STRUCTURAL REPAIR MANUAL


PASSENGER/CREW LOWER DOOR

ALLOWABLE WEAR AND REPAIR DATA

12

H
D
8.\

YI

~10

11

AI5
B

9E

AQ

np-/B

~e,
2A

(TYPICAL)

Detail A

AR
2-14C

Passenger/Crew Lower Door

Allowable Wear and

Repair Data

Figure 1(Sheet 1 of 13)


EFFECTIVITY:

ALL AIRCRAFT

EQUIPPED WITH 36-INCH

PASSENGER/CREW DOOR
SRM-I

51-71-15

Page

Tun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
PASSENGER/CREW LOWER DOOR

ALLOWABLE WEAR AND REPAIR DATA

16

,13

14

17

15

18

S
T

L
15

,13

16

"N~-n

14

19

20 S

PR
Detail B

2-14C
2-s5c

IEPPECIIYITY:
SRM-I

Passenger/Crew Lower Door Allowable Wear and Repair Data


Figure 1 (Sheet 2 of 13)
ALL AIRCRAFT

EQUIPPED WITH 36-INCH


PASSENGER/CREW DOOR

51-71-15

Page 2
Jun 6/98

Learjet
Learjet

STRUCTURAL REPAIR MANUAL


PASSENGER/CREW LOWER DOOR

ALLOWABLE WEAR AND REPAIR DATA

AF
31

AE

30

no~

CAB

AB

AC
23

U
(P

X\y

32

2~A

28

29

22

W
25
24

Detail C
2-16C-1

EFFECTIVITY:

SRM-4

Passenger/Crew Lower Door Allowable Wear and Repair Data


Figure 1 (Sheet 3 of 13)
ALL AIRCRAFT

EQUIPPED WITH 36-INCH


PASSENGER/CREW DOOR

51-71-15

Page 3
Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
PASSENGER/CREW LOWER DOOR

ALLOWABLE WEAR AND REPAIR DATA

AL

AH

AK

AJ

34

AG

Detail D
2-8C

EFFECTIVITY:

Passenger/Crew Lower Door Allowable Wear and Repair Data


Figure 1 (Sheet 4 of 13)
ALL AIRCRAFT

EQUIPPED WITH 36-INCH

PASSENGER/CREW DOOR
SRM-I

51-71-15

Page 4
Tun 6/98

Learjet
~Learjetl

STRUCTURAL REPAIR MANUAL


PASSENGER/CREW LOWER DOOR

ALLOWABLE WEAR AND REPAIR DATA

42

AQ

\44

E
=s=

i;

39

AM

AP

AN
39

pb

(TYPICAL)

AM

Detail E
2-15C-2

EFFECTIVITY:

Passenger/Crew Lower Door Allowable Wear and Repair Data


Figure 1 (Sheet 5 of 13)
ALL AIRCRAET

EQUIPPED WITH 36-INCH

PASSENGER/CREW DOOR
SRM-I

51-71-15

Page 5
Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I
NO.

I
DESCRIPTION

MFD

MFD

HOLE

SHAFT

IEFF.

HOLE

ID

Plate-2311271-17

0.4950

Housing- 2311291-2

AQ

0.6250

Bolt- 2311291-3

AR

0.5000

MFD

OD

ALLOWANCE

ID

OD

WEAR
ID

ALLOWANCE
OD

1 +0.00501
-0.0000

2A

1 +0.00061
-0.0000

Guide

Assy.,

Pin

2511278-1

A,B

0.5050

1 +0.0050/
-0.0000

Pin, Door- 2311291-6

1 +0.0100/

0.4850

-0.0000
C

0.1880

1 +0.0050/
-0.0010

Pin, Clevis-

MS20392-2C17

TurnbuckleAN165H32LS

C,D, I
E,F, I

1 0.1860 1
I
I

1 +0.0000/
1 -0.0020

22

0.1900

1 +0.0020/

23

0.1900

1 +0.0020/

-0.0000

2411242-1

-0.0000

TurnbuckleAN165H32RS

22

0.1900

1 +0.0020/

23

0.1900

1 +0.0020/

D, E

2311293-1

0.1880

1 +0.0050/

2411224-1

0.1880

1 +0.0050/

-0.0000
2411242-2

-0.0000
8

Bushing- AA226-1

Crank, Lower Door-0.0010


-0.0010

10

Pin, Door,Aft2311491-16

0.1880

1 +0.00501
-0.0010

H,J

0.4850

1 +0.0000/
-0.0050

11

I GuideAssy.,

Pin-

2311271-12

0.6310

1 +0.0000/

0.4950

1 +0.00501

-0.0050
12

Plate- 2311271-17

131

PanAssy.

-0.0000
2311229-2

0.4380

1 +0.0060/
-0.0010

Passenger/Crew Lower Door Allowable Wear and Repair


Figure 1 (Sheet 6 of 13)

IEFFECTNITI:
SRM-I

NO~D

Data

51-71-15

Page6
Tun 6/98

Learjet I
Leariet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

NO.I

MFD

MFD

HOLE

SHAFT
OD

MFD

ALLOWANCE

DESCRIPTION

EFF.

HOLE

ID

2311300-1

0.4380

1 +0.0060/

2381 403-2

0.6600

2411221-1

0.6600

2411221-3, -6

10

0.6600

1 +0.03001
-0.0300
1 +0.0300/
-0.0300
1 +0.0300/
-0.0300

ID

OD

WEAR
I

ID

ALLOWANCE
OD

-0.0010

141 Bushing-2411223-2

0.6200

1 +0.0300/
-0.0300

0.5030

1 +0.001 0/

0.3800

0.1400

1 +0.0300/
-0.0000
1 +0.0100/

-0.0000

151 Bushing-2311340-5

11

-0.0100
16

17

Pin, Spring- NAS561 P4-8


(Alt. NAS561 P4-1 0)

11

Shaft, Handle-2311302-1

12

N,P

I
P

0.1250

1 +0.0040/

1 +0.0050/

0.1310

-0.0000

-0.0000

0.3700

1 +0.0020/
-0.0000

0.1890

1 +0.0050/

0.1250

1 +0.0050/
-0.0000

-0.0010
11

24112236

0.3700

1 +0.0020/
-0.0000

R
18

Bolt- NAS464P3A16

R,S

19

Pin, Clevis- MS20392-2C55

R,S

20

Bushing- NAS77-3-31

0.1900

1 +0.0010/
-0.0000

0.1894

1 +0.00001

0.1880

1 +0.0000/

-0.0009

-0.0020
0.1900

1 +0.0015/
-0.0000

0.3136

1 +0.0000/
-0.0005

211 HandleAssy.
2311301-11, -15

2411222-1

(Alt. 2411222-2)

0.1890

1 +0.0050/
-0.0010

0.3121

1 +0.0005/

-0.0000

Passenger/Crew Lower Door Allowable Wear and Repair Data


Figure 1 (Sheet 7 of 13)
EFFECTIVITY:

NOTED

51-71-15

Page 7
SRM-Q

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I
NO.

I
DESCRIPTION
Block Assy., Bearing,
Fwd- 2311305-3, -9, -23

22

Block

23

MFD

MFD

HOLE

SHAFT
OD

MFD

WEAR

ALLOWANCE

EFF.

HOLE

ID

1.0000

1 +0.00051
-0.0005

1.0000

1 +0.00051
-0.0005

0.6870

1 +0.0030/

ID

OD

ID

ALLOWANCE
OD

Assy., Bearing, Aft

2311305-4, -10, -24


Plate, Retaining-

24

2311309-2

-0.0030
25

Eccentric, Fwd2311306-1, -2

13

IWI

0.6200

1 +0.0100/
-0.0100

14

2481108-1

0.1880

0.5000

IWI

1 +0.0050/
-0.0010
1 +0.0060/
-0.0000

0.6200

1 +0.0100/
-0.0100

0.1880

0.5000

1 +0.0050/
-0.0010
1 +0.0060/

0.1880

1 +0.0050/

0.5000

1 +0.0060/

-0.0000
15

2311306-3

0.6200

1 +0.0100/
-0.0100
-0.0010
-0.0000

16

2311306-4

0.6200

i +0.0100/
-0.0100

0.1880

1 +0.0050/

0.5000

1 +0.0060/
-0.0000

-0.0010

26

Pin, Clevis- MS20392-2C31

17

X,Z

0.1860

1 +0.0000/

18

X,Z

0.1860

1 +0.0000/

0.4900

1 +0.0050/

-0.0020
HL1 &6-14

-0.0020
27

1 Plug,

Fwd-2311305-11

-0.0000
Z

0.1880

1 +0.0050/

AA

0.2492

1 +0.00101
-0.0000

-0.0010

Passenger/Crew

Lower Door

Figure

EFFECTIV~I"Y:

NOTED

Allowable Wear and

Repair Data

(Sheet 8 of 13)

51-71-15

Page8
SRM-I

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

I
HOLE I

EFF.

DESCRIPTION

NO.

28

Tube, Torque- 2311305-22

29 1

Bolt-NAS4~4P4-15

AB

1 Plug, Aft-2311305-11,-26

19

Eccentric, Aft-2311307-1

21

22

2311307-2

MFD

0.2492

1 +0.001 01
-0.0000

1 0.2492

1 +0.0000/

1 -0.0009

1 +0.001 0/

I
0.2492

AD

0.1880

OD

ID

OD

AE

0.5000

AF

0.1880

AE

0.5000

-0.0000
1 +0.0050/
-0.0010
1
1 +0.0050/
-0.0000
1 +0.0060/
-0.0010
1 +0.0050/
-0.0010
1 +0.0060/

AF

0.1880

1 +0.0050/

0.4900

WEAR

ALLOWANCE

ID

AC

AE

311

MFD
SHAFT

AA, AB I
AC

30

MFD
HOLE

ID

ALLOWANCE
OD

-0.0010
-0.0010

32

Pin, Clevis- MS20392-2C31


HL1 &6-14

17

X,Z

0.1860

1 +0.0000/

18

X,Z

0.1860

-0.0020
+0.0000/
-0.0020

33

Fitting Assy., Torsion Bar


2311272-19

1 +0.0030/

AG

AG

0.2500

1 +0.0100/

AH

0.3160

1 +0.0100/

AJ

0.1900

1 +0.0015/
-0.0000
1
1 +0.0000/
-0.0005
1
1 +0.0015/
I
1 -0.0015
1 +0.01001
1 -0.0100
1
1 +0.0030/
-0.0000

0.2450

-0.0020
34

Link- 2311272-5, -23

-0.0100
-0.0100
35

Bushing-

NAS75-3-11

0.3136

AH, AJ I

0.1875

AK
AK

I
1
I

AK
36
37

Screw- NAS221-8
Bar

Assy., Torsion
1

2311272-20

I
AL

38

Bearing Assy.,

I
0.3160

0.2450

End
1

2311272-8

AL

0.3440

1 +0.0100/
-0.0100

Passenger/Crew Lower Door Allowable Wear and Repair Data


Figure 1 (Sheet 9 of 13)
EFFECTIVITY:

NOTED

51-71-15

Page9
SRM-4

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I
NO.
39

I
DESCRIPTION

EFF.

Arm, DoorLatch2311273-1, -2, -3, -5

(Alt. 2311273-7)
(Alt. 2311273-9)
.1

I
HOLE I

AM

MFD

MFD

HOLE
ID

SHAFT

MFD

OD

0.4950

ALLOWANCE

ID

1 +0.0050/

1 +0.0050/

OD

WEAR
ID

ALLOWANCE
OD

-0.0000

Arm, Door Latch,

40

Center Fwd

2311274-1, -3, -5, -7

(Alt. 2311274-9)
(Alt. 2311274-11)
(Alt. 231 1 274-13)
(Alt. 2311274-15)
41

AN

0.4950

-0.0000

Arm,DoorLatch,
Center Aft-

2311274-2, -4, -6, -8


(Alt. 2311274-10)
(Alt. 2311274-12)
(Alt. 2311274-14)
(Alt. 2311274-16)
Hinge Half, Fuselage

42

2311280-1 6-96

AP

0.4950

AQ

24

0.0700

1 +0.0050/

1 -0.0000

1 +0.0000/
-0.0050

43

44

HingeHalf, Fuselage2411282-4, -5, -12, -20,


-23, -024
Hinge Half, Door2311280-17

45

AQ

25

I
AQ

24

0.0700

0.0700

1 +0.0000/

1 -0.0050

1 +0.0000/

1 -0.0050

1 +0.0000/

1 -0.0050

Hinge Half, Door


2411282-3, -9, -11,-16,
-19, -21,-22, -96

25

AQ

0.0700

Passenger/Crew Lower Door Allowable Wear and Repair


Figure 1 (Sheet 10 of 13)
EFFECTIVITY:

NOTED

Data

51-71-15

Page
SRM-I

10

Jun 6/98

Learjet
~Learjetl

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

EFF.

DESCRIPTION

NO.
1

Plate

Housing 2311291-2
Guide Assy., Pin 2511278-1

AQ

Pin, Door 2311291-6


Pin, Clevis MS20392-2C17

A, B, C
C, D, E
F, G

Turnbuckle

23

AN165H32LS
2411242-1
AN165H32RS

22

Turnbuckle
Turnbuckle
Turnbuckle

22

2411242-2

23

D, E

3
4

2311271-17

Bushing

8
9

AA226-1

Crank, Lower Door

2311293-1

2411224-1

Pin, Door, Aft 2311491-16


Guide Assy., Pin 2311271-12
Plate 2311271-17
Pan Assy. 2311229-2
2311300-1
2381403-2
2411221-1
2411221-3, -6

10
ii

12
13

Bushing 2411223-2
Bushing 2311340-5
Pin, Spring NAS561 P4-8
(Alt. NAS561 P4-1 0)

14

15
16
17

2411223-5

10

K, L
M, N
N, P

2411222-1

part.
part.
part.
part.
part.
part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.

I Replace worn part.


Replace worn part.
Replace worn part.
Replacewompart.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.
part.
part.
part.

(Alt. 2411222-2)
Assy., Fwd Bearing,

22

Block

2311305-3, -9, -23


Block Assy., Aft Bearing,

23

2311305-4, -10, -24


Plate, Retaining 2311309-2
Eccentric, Fwd- 2311306-1, -2

13
14

W,X, Y
W, X, Y
W, X, Y
W, X, Y
X, Z
X, Z

24

25

24811081

26

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

2311301-11, -15

worn

Pin, Clevis

Handle Assy.

worn

P, Q, R
P, Q, R
R, S
R, S
S, T

11

Bolt

21

part.

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.

19

20

Replace

18

NAS464P3A16
MS20392-2C55
Bushing NAS77-3-31

G, H, J

12

1 Shaft, Handle 2311302-1

part.
part.
part.
part.
part.

11

Replace

Replace worn
Replace worn
Replace worn
Replace worn

11

REPAIR

HOLE

2311306-3
2311306-4
Pin, Clevis MS20392-2C31

15
16
17
18

HLI&6-14

Passenger/Crew Lower Door Allowable Wear and Repair Data


Figure 1(Sheet 11 of 13)
EFFECTIVITY:

NOTED

51-71-151
Page

SRM-I

11

Jun 6/98

Learpt

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM
NO.

DESCRIPTION

Plug,

27

Fwd

EFF.

2311305-11

HOLE

Y, Z

REPAIR

Replace worn part.

AA
28

Tube, Torque 2311305-22

29

Bolt

30

Plug, Aft-2311305-11,-26

NAS464P4-15

AB

AA, AB

19

AC,ADI

Replace
Replace

worn
worn

part.
part.

AC

Replaceworn part.

AE
31

Eccentric, Aft-2311307-1
2311307-2

Pin, Clevis- MS20392-2C31

32

HL1&6-14
33

Fitting Assy., Torsion Bar

34

Link- 2311272-5, -23

35

Bushing

36

Screw- NAS221-8

37

Bar

38

Bearing Assy.,
Arm,DoorLatch-

2311272-19

NAS75-3-11
I

20

AE,AFI

21
17

AE,AFI
AD,AFI

18

X,Z

AG

AG,AY

Replaceworn
Replaceworn
Replaceworn
Replace worn

part.
part.
part.
part.

Replace worn
Replaceworn
Replace worn
Replaceworn

part.
part.
part.
part.

AJ, AK

AH,AJ,I

AK,ALI

AL

Replaceworn part.
Replace worn part.

AM

Replace worn part.

AN

Replace worn part.

AP

Replace worn part.

24

AQ

Replace worn part.

25
24

AQ
AQ

Replace worn part.


Replace worn part.

25

AQ

Replace worn part.

AK

39

Assy., Torsion

2311272-20
End 2311272-8

2311273-1,-2, -3, -5
2311273-7
2311273-9

Arm, Door Latch, Center Fwd


2311274-1,-3, -5, -7

40

2311274-9

2311274-11
2311274-13
2311274-15
41

Arm, Door Latch, Center Aft


2311274-2, -4, -6, -8
2311274-10
2311274-12
2311274-14
2311274-16

42

Hinge Half, Fuselage-

43

Hinge Half, Fuselage

44

Hinge Half,
Hinge Half,

231 1 280-1 6, -96

2411282-4, -5, -12, -20, -23, -024


45

Door

2311280-17

Door-

2411282-3, -9, -11,-16, -19, -20,


-22,-96

Passenger/Crew Lower Door Allowable Wear and Repair Data


Figure 1 (Sheet 12 of 13)
I

EFFECTIVITY:

NOTED

51-71-15

Page
sRM-4

12

Jun 6/98

Learjet
Learjet

STRUCTURAL REPAIR MANUAL


EFFECTIVITIES

CODES

NOTE:

The

following effectivities

are

applicable provided

Aircraft is Eauiooed with 36-inch Pas-

senoer/Crew Door
1

23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 2&001 and Subsequent; 29-001
and Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent

23-001 thru 23-099; 24-100 thru 24-159; 25-001 thru 25-009


24-160 and Subsequent; 25-001 and Subsequent; 2&001 and Subsequent; 29-001 and
001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
23-001 thru 23-099; 24-100 thru 24-209; 25-001 thru 25-049
24-210 and Subsequent; 25-050 and Subsequent; 2&001 and Subsequent; 29-001 and

3
4

001 and

Subsequent;

23-001 thru 23-049

23-050 thru 23-099

35-001 and

Except

Subsequent;

Aircraft Modified

36-001 and

by

Subsequent;

31-

Subsequent;

31-

Subsequent

AMK 74-2 "Lower Cabin Door Handle Installation Im-

provement"
Except Aircraft Modified by AMK

74-2 "Lower Cabin Door Handle Installation Im-

provement"
8

10
11

23-001 thru 23-099 When Modified by AMK 74-2 "Lower Cabin Door Handle Installation Improvement";
24-100 thru 24-209 When Modified by AMK 74-2 "Lower Cabin Door Handle Installation Improvement";
25-001 thru 25049 When Modified by AMK 74-2 "Lower Cabin Door Handle Installation Improvement"
24-210 thru 24-229; 25250 thru 25-066, Except 25-061
24-230 thru 24-049; 25-061, 25-067 and Subsequent; 2&001 and Subsequent; 29-001 and Subsequent;
31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
23-001 thru 23-099 When Modified by AMK 74-2 "Lower Cabin Door Handle Installation Improvement";
24-210 and Subsequent and Prior Aircraft Modified By AMK 74-2 "Lower Cabin Door Handle Installation
Improvement"; 25-050 and Subsequent and Prior Aircraft Modified by AMK 74-2 "Lower Cabin Door Han-

12

dle Installation Improvement"; 28-001 and Subsequent; 29-001 and Subsequent; 31-001 and Subsequent; 35001 and Subsequent; 38001 and Subsequent
23-001 thru 23-099 Except When Modified by AMK 74-2 "Lower Cabin Door Handle Installation Improvemenr; 24-100 thru 24-209 Except When Modified by AMK 74-2 "Lower Cabin Door Handle Installation
Improvement"; 25-001 thru 25049 Except When Modified by AMK 74-2 "Lower Cabin Door Handle Instal-

13

lation Improvement"
23-001 thru 23-039 Except When Modified
23-001 thru 23-017 Except When Modified

14

15
16
17
18
19

20
21
22
23

by SSK 909 "Replacement of Cabin Door Lock Actuator"


by SSK 909 "Replacement of Cabin Door Lock Actuator"
23-040 thru 23-044 Except When Modified by SSK 909 "Replacement of Cabin Door Lock Actuator"
23-045 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 28001 and Subsequent; 29-001
and Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
23-018 thru 23-099 and Prior Aircraft Modified by SSK 909 "Replacement of Cabin Door Lock Actuator"
24-100 and Subsequent; 25-001 and Subsequent; 2&001 and Subsequent; 29-001 and Subsequent; 31001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
23-018 thru 23-099 Except When Modified by AAK 71-1 "Cabin Door Hook Manual Release Kit"; 24-100
thru 24-219 Except When Modified by AAK 71-1 "Cabin Door Hook Manual Release Kit"; 25-001 thru 25059 Except When Modified by AAK 71-1 "Cabin Door Hook Manual Release Kit"
23-018 thru 23-099 When Modified by AAK 71-1 "Cabin Door Hook Manual Release Kit"; 24-220 and
Subsequent and Prior Aircraft Modified by AAK 71-1 "Cabin Door Hook Manual Release Kit"
23-001 thru 23-017 Except When Modified by AAK 71-1 "Cabin Door Hook Manual Release Kit"
35-001 thru 35400; 36-001 thru 36-047
31-001 and Subsequent; 35-401 and Subsequent; 36-048 and
With 2311291-6 Door Pin

Subsequent,

and Prior Aircraft

Equipped

Passenger/Crew Lower Door Allowable Wear and Repair Data


Figure 1 (Sheet 13 of 13)
EFFECTIVITY:

ALL AIRCRAFT

EQUIPPED WITH 36-INCH

PASSENC;ER/CREW DOOR
SRM-4

51-71-15

Page

13

Jun 6/98

Lear
Learjet

STRUCTURAL REPAIR MANUAL


PASSENGER/CREW UPPER DOOR

ALLOWABLE WEAR AND REPAIR DATA

~c--A

t3 --~Qln

~eiihc-- B

L.U

~ij

i
Detail A

D--t~!

TII;

I~

1t

Detail B

o
o

~P,

~11

A
2

Detail C
219C-1

2-7C

EFFECTIVITY:

1IDetail D

Passenger/Crew Upper Door Allowable Wear and Repair Data


Figure 1(Sheet 1 of 16)
ALL AIRCRAFT

EQUIPPED WITH 24-INCH

PASSENGER/CREW DOOR
SRM-I

i cs

51-71-16

Page

Jun 6/98

Leariet

STRUCTURAL REPAIR MANUAL


PASSENGER/CREW UPPER DOOR

ALLOWABLE WEAR AND REPAIR DATA

121

B/
J.
H
11

~u

~1

h"~ai
a

1Zs

hj
Detail E
Passenger/Crew Upper Door Allowable Wear and Repair Data
Figure 1 (Sheet 2 of 16)
EFFECTIVITY:

SRM-I

ALL AIRCRAFT

EQUIPPED WITH 24-INCH


PASSENGER/CREW DOOR

51-71-16

Page 2
Jun 6/98

STRUCTURAL REPAIR MANUAL


PASSENGER/CREW UPPER DOOR

ALLOWABLE WEAR AND REPAIR DATA

21------

13

Detail F

sp~

"I

,16

Detail H

Detail G
2-3C-1
2-sc

2-3(3-2

EFFECTIVITY:

Passenger/Crew Upper Door Allowable Wear and Repair


Figure 1 (Sheet 3 of 16)
ALL AIRCRAFT

EQUIPPED WITH 24-INCH

PASSENGER/CREW DOOR
SRM-I

Data

51-71-16

Page

Jun 6/98

Learjet
~tl
STRUCTURAL REPAIR MANUAL
PASSENGER/CREW UPPER DOOR

ALLOWABLE WEAR AND REPAIR DATA

J23

27

24

X25

OAM
AA

W
AB

~4t

AL

J30

26

Detail J
BB~IOC
B4-6A
C4-5B1

EFFECTIVITY:

Passenger/Crew Upper Door Allowable Wear and Repair Data


Figure 1 (Sheet 4 of 16)
ALL AIRCRAFT

EQUIPPED WITH 24-INCH

PASSENGER/CREW DOOR
SRM-I

AC

51-71-16

Page 4
Jun 6/98

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


ALLOWABLE WEAR AND REPAIR DATA

PASSENGER/CREW UPPER DOOR

K
AR

34

3\1

AS

35

AJ
AN

AP
33

AQ

34

AQ

AK

AH

A6

AV

AV
29

AY
AE

39
37

AE
AW
AQ
34 AT 36 AT AK

AU

AF
Ax

O
AF
AZ

AU
37

2
318

AX~YV
BH
45

BJ 44

42

AT
AW

36

40

BE
BC

BE
AZ

ED

BN

BH BC

46 BM

BPBK

BE
BM

BG
BK
2-3C-1

EFFECTIVITY:

BL
46 BK 47

BQ

49

34

BQ84

416 Bg~BR

Passenger/Crew Upper Door Allowable Wear and Repair Data


Figure 1 (Sheet 5 of 16)
ALL AIRCRAFT

EQUIPPED WITH 24-INCH

PASSENGER/CREW DOOR
SRM-I

Detail K

AT

BK
46 BL 47

43
BF

AQ

51-71-16

Page 5
Jun 6/98

Leariet
STRUCTURAL REPAIR MANUAL
PASSENGER/CREW UPPER DOOR

ALLOWABLE WEAR AND REPAIR DATA

so

BS

Br

BU

Detail L
Passenger/Crew Upper Door Allowable Wear and Repair Data
Figure 1 (Sheet 6 of 16)
EFFECTIVITY:

SRM-4

ALLAIRCRAFTEQUIPFEI)WITH
PASSENGER/CREW DOOR

24-INCH

51-71-16

Page 6
Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

Plate-2511281-6,-7

Fitting Assy.,

I
HOLE I

EFF.

DESCRIPTION

NO.

MFD

MFD

HOLE

SHAFT

ID

MFD

ALLOWANCE

ID

OD

0.8280

0.5625

1 +0.0020
-0.0000

0.0700

1 +0.0000

OD

WEAR
ID

ALLOWANCE
OD

Pin Guide

2511286-9, -10, -13, -15

Hinge Assy.,

2511283-1,-6,-7,-11

-0.0050
4

1 Support,Torsion

Bar-

2411682-7, -8, -11,-12,


-19, -20, -29, -30, -33, 34

0.4300

1 +0.0090/
-0.0000

Link

Assy., Lower Arm

2411681-19, -21

Bushing- DBS-7-030
(Alt. -AJ07C-125)

Pin, Clevis- MS203923C17

0.6259

1 +0.0000/
-0.0005

0.2480

1 +0.00001
-0.0020

Link, UpperTorsion2511301-9
Arm

0.2500

1 +0.0040/
-0.0010

0.4125

1 +0.0020/

Assy., 2511301-1,

-801, -802

-0.0000
10

1 Angle,TorqueAdjustment
Support, Fwd 8 Aft
2511301-4, 3

11

Plate, Bearing-231168&9

12

Spacer-NAS43HT7-18

0.1890

0.4390

1 +0.0050/
-0.0000
1 +0.0050/
-0.0000

0.4650

+0.0250/

0.5600

-0.0250
13

1 BracketAssy.,

+0.0180
-0.0120

PinGuide-

2411294-1,-2, -3, -4, -5

0.5620

i +0.0080/

0.7500

1 +0.0050/

1 +0.0080/
-0.0010
1 +0.0050/
-0.0000

-0.0010

Plate-2411496-63, -265,
-266
14

-0.0000

1 GuideAssy.,Pin2411491-1, -5, -7

0.5620

Plate-2411496-63

0.7500

Passenger/Crew Upper Door Allowable Wear and Repair Data


Figure 1 (Sheet 7 of 16)
EFFECTIVITY:

NOTED

51-71-16

Page 7
SRM-I

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

DESCRIPTION

NO.
15

MFD

MFD

HOLE

SHAFT
OD

EFF.

HOLE

ID

0.5620

MFD
I

ALLOWANCE

ID

OD

WEAR
ID

ALLOWANCE
OD

1 GuideAssy., -2411497-1,
-2, -7, -8

1 +0.0080/
-0.0000

Guide

16

Assy., 2411493-7,

-11
17

0.4950

1 +0.0050/
-0.0010

0.4950

1 +0.0050/

Arm, Guide-231127&3, -4,


-6

-0.0000
18

Q, RI

1 +0.0010/

Bolt- AN4-27A

Guide-2311502-12

0.2500

1 +0.0050/

231 1 502-1 1

0.2500

-0.0010
1 +0.0050/

Bolt-NAS464P5A12

Cover Assy., Outer


Handle- 2311287-3, -4

0.2480

-0.0020
19

Clevis

20

-0.0010
21

22

0.1880

0.3117

1 +0.0100/
-0.0000
1
1 +0.0000/
-0.0050
1
1 +0.0000/

0.8600

0.1880

23

Pin, Clevis- MS20392-2C63

24

Spacer- NAS43DD3-26,

25

Tube, Handle- 2511293-2,

1 +0.0000/
-0.0009

-0.0020
-22

0.2140

0.31 20

+0.0200/

+0.0100/

-0.0200

-0.0100

-44

WI

1.0000

2411516-2, -4

WI

0.1890

0.1885

1 +0.0010/
-0.0000
1
1 +0.0010/

0.2492

26

Bolt- NAS1103-16, -19

27

Cover

1.1250

1 +0.0030/

28

Spacer- 2511293-62

1.0200

-0.0000
1 +0.00001
-0.0000

1.2000

1 +0.0060/
-0.0060
1 +0.0000/
-0.0010

-0.0000

Assy., 2411496-355

Bearing, Thrust- 2411515-1


-2

Passenger/Crew Upper Door Allowable Wear and Repair Data


Figure 1 (Sheet 8 of 16)

EFFECTIVITY:

NOTED

51-71-16

Page 8
SRM-I

Tun 6/98

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

29

MFD

ALLOWANCE

MFD

MFD

HOLE

SHAFT
OD

ID

OD

1.1200

+0.00001

EFF.

HOLE I

ID

2511287-1, -6, -9

AA

1.0060

2411517-1

AB

1.0050

AE

0.2492

1 +0.0050/
-0.0000
+0.0020/
-0.0000
1 +0.0010/

AF

0.1894

1 +0.0010/

AL

0.2492

AM

0.2500

DESCRIPTION

NO.

WEAR
ID

ALLOWANCE
OD

QuadrantAssy.,
1

-0.0020

-0.0000

-0.0000
1 +0.0010/
-0.0000
1 +0.0005/
-0.0001

30

Bolt- NAS1154E40P

Eyebolt- 2411520-1

AC

0.2485

1 +0.0010/

AD

0.2485

1 +0.0010/

-0.0000

-0.0000

31

BellcrankAssy., Upper1

251128&3

AG

AH

0.3160 1
nearside
0.1894 1
far side
0.4376 1

1 +0.0005/
-0.0005
1 +0.0010/

0.3160 1
nearside

1 +0.0005/
-0.0005
1 +0.0010/
-0.0000

-0.0000

1 +0.0015/
-0.0000

AJ

0.1894 1
far side

Assy., Upper

Bellcrank

32

Rod

33

2511293-78
Rod Assy., Upper Fwd
251129361

AK

AN
AP

Pin, Locking- 2511293-36

34

AQ

0.3160

0.3160

1 +0.0005/
-0.0005
1 +0.0005/

1 +0.0010/

-0.0005

nearside
0.1894

-0.0000

far side
35

RodAssy.,UpperAft2511293-50,-80,-83

AR

AS

0.3160

1 +0.0005/
-0.0005

Passenger/Crew Upper Door Allowable Wear and Repair Data


Figure 1 (Sheet 9 of 16)
EFFECTIVITY:

NOTED

51-71-16

Page9
SRM-I

Jun 6/98

Learjet
Learjet/

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

I
DESCRIPTION

NO.

Link,Pin-2511293-28

36

37

1 BellcrankAssy.,Aft2511289-3

MFD

MFD

MFD

ALLOWANCE

HOLE

SHAFT

EFF.

HOLE

ID

OD

AT

0.3160

1 +0.0005/
-0.0005

AU

0.3160

1 +0.00051
-0.0005
1 +0.0010/

far side
0.1894
near

AV
AW

1
1

OD

0.3160

1
1

side

38

RodAssy.,AftBe\bank2511293-72
Rod Assy., Fwd Bellcrank-

AX

39

2511293-73
Rod Assy., Ctr Bellcrank
2511293-77
BellcrankAssy., LwrCtr-

AY

AZ

BA

0.5000

1 +0.0005/

BE

0.3747

1 +0.0015/

BE

0.6250

40
41

2511290-1

ID

OD

1 +0.0015/
-0.0000
1 +0.0005/
-0.0005
1 +0.0010/
-0.0000

far side
0.1894

ID

ALLOWANCE

-0.0000

side

0.4376

near

WEAR

-0.0000
-0.0000

Bushing- NAS77-4-10
42
43

Rod Assy., Aft Bellcrank


2511293-74
Bellcrank Assy., Lwr Aft

+0.0015/
-0.0000

+0.0000/
-0.0010

BC

2511292-3, -5

0.81 42

ED

0.3747

BE

0.3160

BF

1 +0.0015/

far side
0.1894 1
near side
0.5000 1

-0.0000
1 +0.0005/
-0.0005
1 +0.0010/
-0.0000

1 +0.0005/
-0.0000

BG

0.3160
near

1 +0.0005/

1 +0.001 0/
-0.0000

-0.0005

side

0.1894

farside

Passenger/Crew Upper Door


Figure

(EFFECTIVITY:

NOTED

Allowable Wear and

Repair

Data

1 (Sheet 10 of 16)

51-71-16

Page
SRM-I

10

Jun 6/98

Learjet
~Learjetl
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

MFD
ITEM I

I
IEFF.

DESCRIPTION

NO.

Bellcrank

Assy.,

I
HOLE I

HOLE

MFD

MFD

ALLOWANCE I WEAR

ALLOWANCE

I SHAFT

ID

0.3770

1 +0.00051

0.3160 1
far side
0.1900 1
near side

1 +0.00051
-0.0005
1 +0.0010/

1 +0.0010/

OD

ID

OD

ID

OD

Lwr Aft
3

2511285-1

ED

-0.0000

BE

-0.0000

BF

0.5000

BG

0.3160

near

-0.0000
1 +0.0005/
-0.0005
1 +0.00101
-0.0000

side

0.1900

far side

Link, Pin-2511293-30, -37,

44

-60

BH

0.3160

1 +0.00051
-0.0005

Pin, Locking- 2511293-29,

45

-61, 36

BJ

0.3160

1 +0.0005/
-0.0005
1 +0.00101

1 +0.0010/

46

Link, Pin-2511293-30

BK

side
0.1894 1
far side
0.3160 1

47

Pin, Locking- 2511293-35

BL

0.1894

48

Rod Assy., Fwd Bellcrank


2511293-74
BellcrankAssy., LwrAft-

near

-0.0000

1 +0.00051
-0.0005
-0.0000

49

2511291-5

BM

BN

0.3747

BP

0.3160
far side

1 +0.0015/
-0.0000
1 +0.0005/
-0.0005
1 +0.0010/

0.1894 1
side

-0.0000

near

BQ
BR

0.5000

0.3160

near

1 +0.0005/
-0.0000
1 +0.0005/

side

0.1894

-0.0005

farside

Bushing-

NAS77-4-10

i~

BN

0.6250

0.8142

1 +0.00101
-0.0000
+0.0015/
-0.0000

+0.00001
-0.0010

Passenger/Crew Upper Door Allowable Wear and Repair Data


Figure 1(Sheet 11 of 16)
EFFECTIVITY:

NOTED

51-71-16

Page 11
SRM-4

Jun 6/98

IL~it
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

MFD
I

ITEM
NO. I

I EFF. I HOLE I

DESCRIPTION

51

Housing- 2411236-1
Cap- 2411237-3

52

Pin, Guide- 5415573-3, -6

BM
BN
BP

53

Sleeve- 5415578-2, -7

BQ

50

HOLE

MFD

I MFD

ALLOWANCE I WEAR

ALLOWANCE

SHAFT

rD

0.3440
0.3440
0.3230

0.3230

OD

rD

OD

ID

OD

1 +0.0005!
-0.0000
1 +0.0005!
-0.0000

Passenger/Crew Upper Door Allowable Wear and Repair Data


Figure 1 (Sheet 12 of 16)

JEFFECTIVITY:

NOTED

51-71-16

Page
sRM-4

12

Jun 6/98

Learjet
~Learjetl

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM
EFF.

DESCRIPTION

NO.

2311281-6, -7

Plate

Replaceworn part.

Replaceworn part.

1
1

C
C

Replace worn part.


Replace worn part.

Replace worn part.


Replace worn part.
Replace worn part.

Pin Guide

Fitting Assy.,

Hinge Assy.,

Support, Torsion

2511286-9, -10, -13, -15

2511283-1, -6, -7,

-11

Link

Bushing DBS-7-030
(Alt. -AJ07C-125)

2411681-19, -21

10

Upper Torsion 2511301-9


Arm Assy., 2511301-1, -801,-802
Angle, Torque Adjustment Support,
Fwd 6 Aft 2511301-4, -3
Plate, Bearing 231168&9

11

Spacer NAS43HT7-18
Bracket Assy., Pin Guide

13

14

2411294-1, -2, -3, -4, -5


2411496-63, -265, -266
GuideAssy., Pin-2411491-1,6,-7

K
L

17

Plate 241149663
Guide Assy., 2411 497-1, -2, -7, -8
Guide Assy., 2411493-7, -11
Arm Guide 2311278-3, -4, -6

18

Bolt

19

Guide

Pin, Clevis

Link

12

MS20392-3C17

Plate

15

16

AN4-27A

Q,R

2311502-12
Clevis 231 1502-11
Bolt NAS464P5A12
Cover Assy., Outer Handle

Q
S

T,U

25

2311287-3, -4
Pin, Clevis MS20392-2C63
Spacer NAS43DD3-26, -22
Tube, Handle 2511293-2, -44

26

Bolt

27

Cover

20
21
22

23
24

2411516-2, -4

28

29

Replaceworn part.

Lower Arm

Replace worn part.

Bar-

2411682-7, -8, -11,-12, -19, -20,


-29, -30, -33, -34

Assy.,

REPAIR

HOLE

NAS1103-16, -19

Assy., 2411496-355
Spacer 2511293-62
Bearing, Thrust 2411515-1, -2
Quadrant Assy., 2511287-1, -6,
2411517-1

-9

AA

AB,AE
AF,AL

Replacewompart.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.
part.
part.
part.
part.
part.
part.
part.

AM

Passenger/Crew Upper Door Allowable Wear and Repair Data


Figure 1 (Sheet 13 of 16)
EFFECTIVITY:

NOTED

51-71-16

Page
SRM-4

13

Jun 6/98

Learjet
Learjetl

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

DESCRIPTION

NO.

31

NAS1154E40P

Bolt

30

Eyebolt 2411520-1
1 BellcrankAssy., Upper-251128&3

EFF.

REPAIR

HOLE

AC

AD

AG, AH

Replace worn part.


Replace worn part.
Replace worn part.

AJ
32

Rod Assy., Upper Bellcrank


2511293-78

33

Rod

34

36

Pin, Locking 251129336


Rod Assy., Upper Aft
2511293-50, -80, -83
Link, Pin 2511293-28

37

Bellcrank

38

Rod

2511293-51
35

AK

Replace worn part.

AN, AP

AQ

Replace worn part.


Replace worn part.

AR, AS

AT

AU, AV

Assy., Upper Fwd

Assy.,

Aft

2511289-3

Replace worn part.


Replace worn part.
Replace worn part.

AW

Assy., Aft Bellcrank

2511293-72
39
40

Rod Assy., Fwd Bellcrank


2511293-73
Rod Assy., Ctr Bellcrank
2511293-77

41

1 BellcrankAssy.,

AX

Replace worn part.

AY

Replace worn part.

AZ

Replace worn part.

BA, BE

BE

Replace worn part.


Replace worn part.

BC

Replace worn part.

LwrCtr-

2511290-1
42

Bushing NAS77-4-10
Rod Assy., Aft Bellcrank

43

Bellcrank

2511293-74

Assy.,

Lwr Aft
2

1 ED, BE
BF, BG

Replace worn part.

Bellcrank Assy., Lwr Aft


2511285-1

ED, BE
BF, BG

Replace worn part.

44

Link Pin

BH

45
46

1
1

BJ
BK

47

Pin, Locking 2511293-29, -61,-36


Link, Pin 251129330
Pin, Locking 2511293-35

BL

Replace worn
Replace worn
Replace worn
Replace worn

48

Rod

BM

Replace worn part.

BN, BP
BQ,BR

Replace worn part.

BN

BM

Replace worn part.


Replace worn part.

2511292-3, -5

2511293-30, -37, -60

Assy.,

Fwd Bellcrank

2511293-74
49

1 BellcrankAssy.,

LwrAft-

2511291-5

50

part.
part.
part.
part.

Bushing NAS77-4-10
Housing 2411236-1

Passenger/Crew Upper Door Allowable Wear and Repair


Figure 1 (Sheet 14 of 16)

EFFEC~TVITY:

NOTED

Data

51-71-16

Page
SRM-I

14

Jun 6/98

Leariet
Learjet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM
DESCRIPTION

NO.

2411237-3

51

Cap

52

Pin, Guide 5415575-3, -6


Sleeve 5415573-2, -7

53

EFF.

HOLE

2
3

BN
BP

BQ

REPAIR

Replace worn part.


Replace worn part.
Replace worn part.

Passenger/Crew Upper Door Allowable Wear and Repair


Figure 1 (Sheet 15 of 16)
EFFECTIVITY:

NOTED

Data

51-71-16

Page
SRM-I

15

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
EFFECTIVITIES

CODES

NOTE:

The following effectivities


senoer/Crew Door

are

applicable provided

Aircraft is

Eouiooed

with 24-inch Pas-

24-272, 24-295 and Subsequent; 25-134, 25-168 and Subsequent; 2&001 and Subsequent; 29-001

24-272; 25-134; 2&001 and 28-002; 31-001 thru 31-091; 35-001; 36-001 and 36-002

24-295 and

and

Subsequent;

31-092 and

31-001 and

Subsequent;

35-001 and

Subsequent;

36-001 and

Subsequent

Subsequent; 25-168 and Subsequent; 28-003 and Subsequent; 29-001 and Subsequent;
Subsequent; 35-002 and Subsequent; 36-003 and Subsequent

NOTES:

I~ Apply

wet

primer

in bore

prior to bearing installation.

Passenger/Crew Upper Door Allowable Wear and Repair Data


Figure 1 (Sheet 16 of 16)
EFFECTIVITY:

ALL AIRCRAFT

EQUIPPED WITH 24-INCH

PASSENGER/CREW DOOR
SRM-I

51-71-16

Page 16
Jun 6/98

Learjet
Learjefl

STRUCTURAL REPAIR MANUAL


PASSENGER/CREW LOWER DOOR

ALLOWABLE WEAR AND REPAIR DATA

74

AM

DCq

k~o EYs

GZhC

3
2

Detail A

1
2-14C

(TYPICAL)

Passenger/Crew

Lower Door

Allowable Wear and

Figure 1(Sheet 1
EFFECTIVITY:

SRM-I

EQUIPPED WITH 24-INCH


PASSENGER/CREW DOOR
ALL AIRCRAFT

Repair

Data

of 10)

51-71-17

Page

Jun 6/98

Learjet
~Zearjetl
STRUCTURAL REPAIR MANUAL
PASSENGER/CREW LOWER DOOR

ALLOWABLE WEAR AND REPAIR DATA

.B

d:

M
11

$e

Ils

13L

15S

,41
c

~o

//I

Detail B
2-14C

2-55C

EFFECTIVITY:

Passenger/Crew Lower Door Allowable Wear and Repair


Figure 1 (Sheet 2 of 10)
ALL AIRCRAFT

EQUIPPED WITH 24-INCH

PASSENGER/CREW DOOR
SRM-(

Data

51-71-17

Page 2
Jun 6/98

Learjet
Learjet

STRUCTURAL REPAIR MANUAL


ALLOWABLE WEAR AND REPAIR DATA

PASSENGER/CREW LOWER DOOR

26

18

25
U

22

~Be
4~

AA

AC
AB
20
y

23

IU~-h

Y~

16

Detail C
2-16C-1

Passenger/Crew

Lower Door

Figure
EFFECTIVITY:

SRM-4

Allowable Wear and

EQUIPPED WITH 24-INCH


PASSENGER/CREW DOOR

ALL AIRCRAET

Repair Data

(Sheet 3 of 10)

51-71-17

Page 3
Jun 6/98

Learjet
I~rit!

STRUCTURAL REPAIR MANUAL


PASSENGER/CREW LOWER DOOR

ALLOWABLE WEAR AND REPAIR DATA

33

Ad

AE

AF

30

Detail D
Passenger/Crew

Lower Door

Figure
EFFECTIVITY:

ALL AIRCRAFT

Allowable Wear and

Repair Data

(Sheet 4 of 10)

EQUIPPED WITH 24-INCH

PASSENGER/CREW DOOR
sRM-a

AD

51-71-17

Page 4
Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
ALLOWABLE WEAR AND REPAIR DATA

PASSENGER/CREW LOWER DOOR

AH
I

36

AK

35
AJ
(TYPICAL)

AH

2-15G2

Passenger/Crew

Detail E

Lower Door

Figure
EFFECTIVITY:

SRM-4

Allowable Wear and

EQUIPPED WITH 24-INCH


PASSENGER/CREW DOOR

ALL AIRCRAFT

Repair

Data

(Sheet 5 of 10)

51-71-17

Page 5
Jun 6/98

Learjet

STRUCTURAL REPAIR IVIANUAL


WEAR ALLOWANCES

ITEM I

NO.

DESCRIPTION

Plate-251129&1

Guide

MFD

MFD

HOLE

SHAFT
OD

MFD

ALLOWANCE

EFF.

HOLE

ID

0.4950

1 +0.00501
-0.0010

0.4950

1 +0.00501

ID

OD

WEAR
ID

ALLOWANCE
OD

Assy., Pin

2511297-1

-0.0010

Pin, Door- 2311299-1

A,B I

0.4850

1 +0.0100/
-0.0000

0.1880

C,D I

1 +0.00501
-0.0000

Pin, Clevis- MS20392-2C17

Turnbuckle- 2511226-3

0.1890

Turnbuckle- MS21242S3

0.1900

Spacer-

0.6520

Bellcrank, Lower Door1

0.1890

0.6600

0.1860

1 +0.0000/
-0.0020

2511298-4

2411227-2

Pan

9
10

Assy. 2411221-3,

-6

1 Bushing-FF-520-10

1 +0.0000/
-0.0000
1 +0.0020/
-0.0000

1 +0.0000/
-0.0000
1 +0.0300/
-0.0300

0.6200

1 +0.0300/
-0.0300

111 Bushing-2311340-5

0.5030

0.3800

0.1400

1 +0.0010/
-0.0000
1 +0.0300/
-0.0000
1 +0.0100/
-0.0100

12

1 Pin, Spring- NAS561 P4-8

13

(Alt. NAS561 P4-1 0)


Shaft, Handle-24112236

N,P I

I
1

0.1250

1 +0.0040/

1 +0.0050/
-0.0000

0.1310

0.3700

-0.0000

1 +0.0020/
-0.0000

0.1900

1 +0.0010/
-0.0000

14

15

1 Bushing-NAS43HT3-16

Pin, Clevis-MS20392-2C55

1
1

R,S I
S
T

1
0.2140

0.1880

1
1

0.3120

1 +0.0000/

-0.0020
1 +0.0200/
-0.0200
1
1 +0.01001
-0.0100

Passenger/Crew Lower Door Allowable Wear and Repair


Figure 1 (Sheet 6 of 10)

I""""":
SRM-(

ALL AIRCRAFT~

EQUIPPED WITH 24-INCH

PASSENGER/CREW DOOR

Data

51-71-17

Page 6
Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

NO.I
16

I
DESCRIPTION

17

Fwd- 2511317-4

MFD

MFD

HOLE

SHAFT

HOLE

IEFF.

HandleAssy. -2411222-1
(Alt. 2411222-2)
BlockAssy., Bearing,

0.3121

1 +0.0005/

1 +0.001 0/

1.0020

ID

OD

WEAR

ALLOWANCE

ID

I
U

h(FD

OD

ID

ALLOWANCE
OD

-0.0000

-0.0000
18

1 BlockAssy., Bearing,Aft2311317-3

19

21

Plate- 231130541

1.0020

1 +0.0010/
-0.0000

0.6870

0.6900

1 +0.0030/
-0.0030
1 +0.0000/
-0.0000

Plate, Retaining2311309-2

20

Eccentric,Fwd251 1 306-2

13

0.6200

1 +0.0100/
-0.0100

0.1890

1 +0.0050/

0.5000

1 +0.0060/

-0.0010
-0.0000
22

Bolt- NAS221-20

AA

23

Bearing-81210

24

Retainer- 2511316-3

U
AB

0.1890

1 +0.0000/
-0.0009

0.7520

1 +0.0015/

-0.0015
AC

0.1960

1 +0.0050/

AC

0.1860

1 +0.0000/

2511667-2

AD

28

Boit- AN4-15A

AD

29

Bushing- NAS75-4-010

AD

0.2500

30

Link- 2511268-1

AE

0.3160

AD

0.3770

AE

0.1900

-0.0000
25

Pin, Clevis- MS20392-2C31

26

Bearing-

27

Fitting Assy.,

-0.0020
81210
Torsion Bar
0.2570

1 +0.0050/
-0.0010
0.2490

1 +0.0000/
-0.0030

0.3761

+0.0015/
-0.0005
1 +0.0050/

+0.0000/
-0.0005

-0.0000

311 Bushing-NAS75-3-007

Passenger/Crew

Lower Door

Figure
EFFECTIVITY:

SRM-I

ALL AIRCRAFT

1 +0.0050/
-0.0000
0.3136

Allowable Wear and

1 +0.0000/
-0.0005

Repair Data

1 (Sheet 7 of 10)

EQUIPPED WITH 24-INCH


PASSENGER/CREW DOOR

51-71-17

Page 7
Jun 6/98

Learjet
Learjetl
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

32

Screw- 2511269-6

33

(MS24694-54)
BarAssy., Torsion-

AF

I
HOLE

EFF.

DESCRIPTION

NO.

I
1

AG

MFD
SHAFT

MFD

ID

OD

0.1890

ID

OD

1 +0.00001

1 +0.0000/

0.1890
I

0.2180

WEAR

ALLOWANCE

AF

2511267-1

MFD
HOLE

ID

ALLOWANCE
OD

-0.0003

-0.0003

1 +0.0000/
-0.0030

34

1 Bearing Assy.,

End

2511269-3
35

AG

0.2210

1 +0.0050/
-0.0000

AH

0.4950

1 +0.0050/

Arm, Door Latch


2311273-10

-0.0000
36

Arm, Door Latch,


Center Fwd

2311274-7, -13, -15,

-17

AJ

0.4950

1 +0.0050/
-0.0000

37 1

Arm, Door Latch,


Center Aft

2311274-8, -14, -16, -18

AK

0.4950

1 +0.0050/

-0.0000

Passenger/Crew Lower Door Allowable Wear and Repair Data


Figure 1 (Sheet 8 of 10)

I""""":
sRM-4

ALL AIRCRAFT

EQUIPPED WITH 24-INCH

51-71-17

Page8
Tun 6/98

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

DESCRIPTION

NO.

EFF.

REPAIR

IHOLE

Plate 251129817
Guide Assy., Pin 2311297-1
Pin, Door 2311299-1
Pin, Clevis MS20392-2C17

A, B, C
C, D

Turnbuckle

2511226-3
Turnbuckle MS21242S3
Spacer 2511226-3
Bellcrank, Lower Door 2411227-2

F
G

Pan Assy. 2411221-3, -6


Bushing FF-520-10
Bushing 2311340-5
Pin, Spring NAS561 P4-8
(Alt. NAS561 P4-1 0)

1
1

K, L
M, N

N, P

Shaft, Handle 2411223-5


Pin, Clevis MS20392-2C55

1
1
1

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.

17

Bushing NAS43HT3-16
Handle Assy. 2411222-1
(Alt. 2411222-2)
Block Assy., Fwd Bearing,

P, Q, RI
R, S
S, T

Replace worn part.

18

1 BlockAssy., AftBearing,1

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replaceworn part.
Replace worn part.
Replace worn part.

1
2
3

6
7

8
9

10
11
12

13
14

15
16

2511317-4
2311317-3
2311309-2

19

Plate, Retaining

20

Plate

21

Eccentric, Fwd

W, X, YI

22

Bolt

NAS221-20
Bearing 81210
Retainer- 2511316-3
Pin, Clevis MS20392-2C31

AA

27

Bearing 81210
Fitting Assy., Torsion

28

Bolt

29

Bushing

NAS75-4-010

AD

30

AD,AEI

31

Link- 2511268-1
Bushing NAS75-3-007

AE

32

Screw

AF

33

Bar

AF,AGI

23
24

25
26

2311305-41
231 1 306-2

AB,ACI

AC

AD

AD

Bar

2511667-2
AN4-15A

2511269-6

(MS24694-54)
Assy., Torsion

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.

2511267-1

Replace worn
Replace worn
Replace worn
Replaceworn
Replace worn
Replace worn

part.
part.
part.
part.
part.
part.

Replaceworn part.

Passenger/Crew Lower Door Allowable Wear and Repair Data


Figure 1 (Sheet 9 of 10)
EFFECTIVITY:

SRM-I

EQUIPPED WITH 24-INCH


PASSENGER/CREW DOOR

ALL AIRCRAFT

51-71-17

Page 9
Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
REPAIR DATA

ITEM
NO.

REPAIR

DESCRIPTION

EFF.

HOLE

End

AG

Replace worn part.

AH

Replace worn part.

AJ

AK

2511269-3

34

Bearing Assy.,

35

Arm,DoorLatch-

36

Arm, Door Latch, Center Fwd


2311274-7, -13, -15, -17

2311273-10

Replacewompart.

Arm, Door Latch, Center Aft

37

2311274-8, -14, -16, -18

CODES

Replace

worn

part.

EFFECTIVITIES
NOTE:

The

following effectivities

are

applicable provided Airoraft is Eaui~ed with 24-inch

Pas-

senger/Crew Door
1

24-272, 24-295 and Subsequent; 25-134, 25-168 and Subsequent; 28-001 and Subsequent; 29-001
and Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent

Passenger/Crew Lower Door Allowable Wear and Repair


Figure 1 (Sheet 10 of 10)
EFFECTNITY:

ALL AIRCRAFT

EQUIPPED WITH 24-INCH

PASSENGER/CREW DOOR
SRM-I

Data

51-71-17

Page

10

Tun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


QUADRANT ASSEMBLY

ALLOWABLE WEAR AND REPAIR DATA

O
7
5

rA

6~

4\
3,

2~

1\B

9M
10

1.1

13

12
10

Detail A
2-12C

EFFECTIVITY:

Quadrant Assembly Allowable Wear and Repair Data


Figure 1(Sheet 1 of 11)
NOTED

51-71-181
Page

SRM-I

Jun 6/98

Learjet
Learjet/
STRUCTURAL REPAIR MANUAL
QUADRANT ASSEMBLY ALLOWABLE WEAR AND

REPAIR DATA

00~

26

AA

Lu\

23

AC

ls,V\
AB

5
a
w

Detail B
2-12C

(EFFECTIVITY:

Quadrant Assembly Allowable Wear and Repair


Figure 1 (Sheet 2 of 11)
NOTED

Data

51-71-18

Page 2
SRM-I

Tun 6/98

Learjet
~Learjet
STRUCTURAL REPAIR MANUAL
QUADRANT ASSEMBLY ALLOWABLE

WEAR AND REPAIR DATA

000

AY
c

AW

39

AQ

AX/

36

32

44

AS
AR

AJ
AP
AN

34
AL
33
30
29
AF
27

AE

Detail C
2-12C

Quadrant Assembly Allowable Wear and Repair

Figure
EFFECTIVITY:

NOTED

Data

(Sheet 3 of 11)

51-71-18)
Page3

SRM-Q

Jun 6/98

Learjet
~Learjetl

STRUCTURAL REPAIR MANUAL


QUADRANT ASSEMBLY ALLOWABLE WEAR AND REPAIR DATA

00000

55

D
so

3~
47,
BO

g~

~53

----i49
54

AZ

t:r~

\I,

1-

BE

Be

53

~j
Detail D

Z12C

Quadrant Assembly Allowable Wear and Repair

Data

Figure 1 (Sheet 4 of 11)

EFFECTIVITY:

NOTED

51-71-18

Page$
SRM-I

Jun 6/98

Learjet
~tl

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

MFD
ITEM I

I
DESCRIPTION

NO.

EFF.

HOLE

HOLE

MFD

ID

Tube-2315131-2

Handle-Park, Brake231513-80,-180

0.8750

Bushing- 23151 31-26

B, C

0.7500

MFD

WEAR

ALLOWANCE

ALLOWANCE

I SHAFT
OD

0.7490

ID

OD

ID

OD

1 +0.0000/
-0.0000

1 +0.00301
-0.0000

3
4

Lever, Throttle- 2315131-12

Wheel

1.6200

0.8740

+0.00301

-0.0000
1 +0.00001

+0.00001
-0.0000

-0.0000

Assy., Sector-

2315131-65, -72

E, F

1.0000

2315131-46, -70

0.7500

7A

Spacer- 2315131-48

Plate Lock- 2315131-7

0.7500

Spacer- 2315131-41

J, K

1.0000

10

Plate Lock- 2315131-47

0.7500

J, K

1.0000

0.8750

N, P

0.7500

0.9375

1 +0/0005/
-0.0005

Bushing- NAS76A-12-16
Spacer- 2315131-10

Plate

Assy.,

0.7500

+0.00001 +0.0100/
-0.0000 1 -0.0000

Lock

11

I Spacer-2315131-19

12

1 Handle,FlapControl2315131-74

G,

1.0000

1 +0.00301
0.7500

1
0.7500

1
0.7500

-0.0000
+0.00001
-0.0000
1 +0.0010/
-0.0000
+0.00001
-0.0000
1 +0.0010/
-0.0000
+0.0000/
-0.0000

+0.01001

-0.0000

+0.01001
-0.0000

+0.01001
-0.0000

1 +0.0030
-0.0000

13

Bushing-2315131-26

0.8740

+0.0030/

-0.0000
14

Tube-2315131-2

15

HandleAssy.,

0.7490

+0.0000/
-0.0020

1 +0.0000/
-0.0020

ParkBrake-

2315131-1 08, -141

0.8750

2415167-1

0.8750

1 +0.0030/
-0.0000
1 +0.00301
-0.0000

Quadrant Assembly Allowable Wear and Repair

Figure
EFFECTIVITY:

NOTED

Data

(Sheet 5 of 11)

51-71-18

Page5
SRM-4

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

I
DESCRIPTION

NO.
16

Spacer-2315131-26,

-137

MFD

MFD

HOLE

EFF.

HOLE

ID

SHAFT
OD

R, S

0.7500

0.8740

MFD

ALLOWANCE

ID

OD

+0.0030!
-0.0000

+0.0000/

WEAR
ID

ALLOWANCE
OD

-0.0020

Lever,Throttle-

17

2315131-101

1.6200

1 +0.0000/
-0.0000

WheelAssy.,SectorLH-

18

2315131-99, -117, -136


19

I CamAssy.,

LH2315131-85

Spacer- 2315131-88

20

0.7500

0.7500

V, W

1.0000

1 +0.0000/

0.7500

-0.0005
1 +0.0030/
-0.0000
+0.0000/
-0.0000

21

+0.0100/
-0.0000

PlateAssy.,Lock2315131-70

0.7500

X, Y

1.000

1 +0.0030/
-0.0000

22

Spacer- 23151 31-96

23

Lever, Throttle2

1.6200

1 +0.0000/
-0.0000

AA

0.7500

1 +0.0000/

AB

0.7500

1 +0.0100/
-0.0000

0.7600

2315131-101

+0.0000/
-0.0000

0.7500

-0.0100/
-0.0000

Wheel Assy., Sector RH

24

231 5131-100, -116, -135

-0.0005
25

26

1 Spacer-2315131-94

Platelock-2315131-7

AC,

AE

27

Tube- 2315131-149

28

Handle Assy., Park Brake


231 51 31-141

AF

0.8750

AF

0.8750

AF,

0.7500

24151 67-1
29

1 Spacer-2315131-137

+0.0050/
-0.0050

1.0000
0.7490

0.8740

1 +0.0030/
-0.0000
1 +0.0030/
-0.0000
+0.0030/

AG
30

-0.0000

+0.0000/
-0.0020

Lever,ThrottleLH2315164-69

31

1 +0.0000/
-0.0020

AH

1.2500

AJ

0.7510

1 WheelAssy.,SectorLH2315131-145

1 +0.00051
-0.0005

Quadrant Assembly Allowable Wear

Figure
EFFECTIVITY:

NOTED

and

Repair Data

1 (Sheet 6 of 11)

51-71-18

Page 6
SRM-4

Jun 6/98

Learjet
~jLearjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

NO.I
32

DESCRIPTION

1 CamAssy., LH-2315131-851

ID

AK

0.7500

AL

0.3160

j Spacer-231513180

AL

Screw- NAS220-6
Spacer- 2515164-51

AL

AK,
AM,
AP,

34
35
36

Trunnion-2315131-91

OD

HOLE

AL

MFD
SHAFT

EFF.

33

MFD
HOLE

1
0.3150

0.3150

1
1

MFD
I

WEAR

ALLOWANCE

ID

OD

ID

ALLOWANCE
OD

1 +0.0030
-0.0000
1 +0.00301
-0.0000
1
1 +0.0000/
-0.0030
1 +0.0000/
-0.0030

0.1640

0.7500

1.0000

+0.01 00/

-0.0000

AQ
37

1 PlateAssy.,

Lock2

2315131-70

AN

0.7500

AP,

0.7500

1 +0.0030/
-0.0000

Spacer- 2513164-51

38

1.0000

AQ
39

Wheel Assy., Sector2315131-146

AR

0.7510

AS

1.2500

AT

1 +0.0005/
-0.0005

0.7500

1 +0.01001
-0.0000
1 +0.0100/
-0.0000
1 +0.0030/
-0.0000
1 +0.0030/

Lever, Throttle RH

40

2515164-70
41

+0.01 00/
-0.0000

1 LockPlateAssy.,Flap
Switch- 2514164-75

42

Spacer- 2515164-78

AT

0.7500

43

Flap Cam

AU

0.8750

44

Lever, Flap- 251 5164-74

AV

0.8750

45

Bushing, Flap Lever

2515164-76

-0.0000

2515164-49
46

Spacer-

2315131-10

AV,
AX,

0.7500
1.0000

0.8740
0.7500

+0.0030/
-0.0000

-0.00020

+0.0000/

+0.0010/

-0.0000

-0.0000

Quadrant Assembly Allowable Wear and Repair

Figure
EFFECTIVITY:

NOTED

(Sheet

7 of

+0.0000/

Data

11)

51-71-18

Page 7
sRM-a

Jun 6/98

Leariet
Learjetl
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

DESCRIPTION

NO.

Link

47

MfD

MFD

HOLE

SHAFT
OD

EFF.

HOLE

ID

AZ

1.0623

BA

0.1920

BE

0.2520

MFD

WEAR

ALLOWANCE

ID

OD

ID

ALLOWANCE
OD

Assy, Output

2615260-3, -6

1 +0.0002/
-0.0003
1 +0.0020
-0.0020
1 +0.0020
-0.0020

Shaft, Quadrant-

48

BC

2615137-3

0.6243

1 +0.0002/

-0.0003
49

1 Spacer- 2615172-19

BC

+0.01 00

+0.0050
-0.0050

0.81 20

0.6300

-0.0100

Lever, Thrust Reverser-

50

261 5242-14

ED

0.9290

1 +0.0050

BE

0.0630

1 +0.0020/

-0.0050
-0.0010
51

BE

RollPin-MS16562-8

0.0680

1 +0.0010/

-0.0020

Output

52

Link

Stop
9

BF

0.2530

1 +0.0010/

2615290-1

10

BF

0.2530

1 +0.0010/

NAS43DD4-29

261 5266-1, -2

-0.0020

Tie
53

Strap

1 Spacer-

54 1

Bolt- NAS1104-16

55

Idle

1
BF

-0.0020
+0.0220/
-0.0190

0.3750

0.2750

0.2485

+0.0100
-0.0100

1 +0.0002/
-0.0004

Stop Assy.
1

-13
56

57

BG

2615203-7, -9, -10, -11,

0.7500

1 +0.0100/
1 -0.0100

0.3180

1 +0.0020
-0.0020

Lever, Ignition Switch


2615255-2, -7

BH

Pin- MS20392-2C11

BH

0.3110

1 +0.0000/
-0.0020

Quadrant Assembly Allowable Wear and Repair


Figure 1 (Sheet 8 of 11)
EFFECTTVITY:

NOTED

Data

51-71-18

Page 8
SRM-4

Jun 6/98

Learjet
~Learjetl

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

NO.

DESCRIPTION

EFF.

HOLE

Tube -2315131-2
Handle-Park, Brake- 2315131-80,
-180
Bushing 2315131-26
Lever, Throttle 2315131-12
Wheel Assy., Sector Bushing

2
3
4
5

7A

8
9
10
11
12

13
14

15

Spacer 2315131-10
Plate Assy., Lock 2315131-46,
Spacer 2315131-48

B, C

-70

Plate Lock 2315131-7


2315131-41
Plate Lock 2315131-47
Spacer 2315131-19
Handle, Flap Control 2315131-74
Bushing 2315131-26
Tube 2315131-2
Handle Assy., Park Brake

Spacer

NAS76A-12-16
6

E,

G, H

J, K

L, M

N, P

2315131-108, -141

2415167-1

R, S

-137

16

Spacer 2315131-126,

17

Lever, Throttle 2315131-101

18

Wheel

19

Cam

20

Assy., Sector

REPAIR

LH

Spacer 2315131-88
Plate Assy., Lock 2315131-70
Spacer 2315131-96

V, W

X, Y

24

Lever, Throttle 2315101-101


Wheel Assy., Sector RH
2315131-100, -116, -135
Plate, Lock 2315131-7

25

AA
AB

26

Spacer- 2315131-94

AC, ADI

27

Tube 2315131-149
Handle Assy., Park Brake
2315131-141

AE

AF

AF

21
22

23

28

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn
Replace worn
Replace worn
Repalce worn

part.
part.
part.
part.

Replace
Replace
Repalce

Replace worn
Replace worn
Replace worn

part.
part.
part.
part.
part.
part.

Replace worn
Replace worn
Replaceworn
Replace worn

part.
part.
part.
part.

Replace
Replace
Replace

part.
part.
part.
part.

LH

2315131-99, -117, -136

Assy.,

Replaceworn part.

2315131-85

2415167-1

worn
worn

worn

worn
worn

29

Spacer

2315131-137

AF, AG

30

Lever, Throttle LH 2515164-69

AH

Replace worn

31

Wheel

32

2315131-145
Cam Assy., LH 2315131-85

33

Trunnion

Replace worn part.


Replace worn part.
Replace worn part.

Assy.,

worn

Sector LH

2315131-91

AJ

AK, AL

AL

Quadrant Assembly Allowable Wear and Repair

Figure
EFFECTIVITY:

NOTED

Data

1 (Sheet 9 of 11)

51-71-18

Page 9
sRM-a

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

DESCRIPTION

NO.

EFF.

HOLE

REPAIR

34

Spacer

AL

35

Screw

AL

AK,AMI

AN

AP,AQ1

AR

AS

AT

AT

AU

43

2315131-90
NAS220-6
Spacer- 2515164-51
Plate Assy., Lock 2315131-70
Spacer- 2515164-51
Wheel Assy., Sector 2315131-146
Lever, Throttle RH 2315164-70
Lock Plate Assy., Flap Switch
2515164-75
Spacer 2515164-78
Flap Cam 2515164-76

44

Lever, Flap 2515164-74

36
37
38
39
40
41
42

45
46
47

AV

Bushing, Flap Lever- 2515164-49


Spacer 2315131-10
1 Link Assy., Output 2615260-3, -6

AV, AWJ
AX, AY

AZ,BA,(

Replace worn part.


Replace worn part.
Replaceworn part.
Replace worn part.
Replaceworn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replaceworn part.
Replace worn part.
Replacewompart.

BE
48

Shaft, Quadrant 2615137-3

49

Spacer

8
8
8

BC
BC
ED, BE
BE

BF

50

51
52

2615172-19
Lever, Thrust Reverser
Roll Pin MS16562-8

Output

Link

2615242-14

Stop 2615266-1,

-2

Tie Strap

55

2615290-1
Spacer- NAS43DD4-29
Bolt NAS1104-16
Idle Stop Assy. 2615203-7, -9, -10,

56

Lever, Ignition Switch 26i 5255-2,

57

Pin-MS20392-2C11

53
54

-11, -13
-7

BG

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replaceworn part.
Replace worn part.

BG
BH
BH

Replace worn part.


Replace worn part.
Replacewornpar.

BF

10
8

8
8

Quadrant Assembly Allowable Wear and Repair Data


Figure 1 (Sheet 10 of 11)
EFFECTIVITY:

NOTED

51-71-18

Page 10
SRM-II

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


CODES
1
2

EFFECTIVITIES
23-001 thru 23-010, 23-013, 23-014, 23-016 thru 23-018, and 23-020 thru 23-029
23-011, 23-015, 23-019, 23-030 and Subsequent; 24-100 and Subsequent, Except Aircraft With

Thrust Reversers Installed; 25-001 and Subsequent Except United Kingdom Certified Aircraft and Except Aircraft With Thrust Reversers Installed; 2&001 and Subsequent; 29-001 and Subsequent
3

23-011, 23-015, 23-019, 23-030 and Subsequent; 24-100 thru 24-357 Except Aircraft With Thrust Re-

Instailed; 25-001 thru 25-277 Except United Kingdom Certified Aircraft and Except Aircraft
With Thrust Reversers Installed; 28-001 thru 28005; 29-001 thru 29-002
24-358 and Subsequent; 25-278 and Subsequent; 2&006 and Subsequent; 29-003 and Subsequent
25-135 and Subsequent When Certified for United Kingdom
25135 thru 25-277 When Certified For United Kingdom
25277 and Subsequent When Certified for United Kingdom
31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
versers

5
6
7

Quadrant Assembly Allowable

Wear and

Figure 1(Sheet 11
EFFECTnTITY:

NOTED

Repair Data

of 11)

51-71-18

Page
SRM-Q

11

Jun 6/98

Learjet
Learjetj

STRUCTURAL REPAIR MANUAL


MLG POWER BRAKE VALVE LINKAGE

ALLOWABLE WEAR AND REPAIR DATA

i,

B
7111

s\

s
9

lD
(TYPICAL)

Detail A
MLG Power Brake Valve

Linkage Allowable Wear and Repair Data


Figure 1 (Sheet 1 of 3)

EFFECTIVITY:

ALL

51-71-19

Pagel
SRM-4

Jun 6/98

Learjet
Learjeti
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

NO.

MFD

MFD

HOLE

SHAFT
OD

MFD

ALLOWANCE

EFF.

HOLE

ID

2315141-24, -33

0.3750

1 +0.0030/

2384010-2, -6

0.3750

2415171-1

0.3750

i +0.0030/
-0.0010
1 +0.0030/

2415171-9

0.3750

1 +0.0030/

2415175-1

0.3750

1 +0.00301

0.6557

1 +0.00201

DESCRIPTION
Pedal

ID

OD

WEAR
ID

ALLOWANCE
OD

Assy., Rudder-0.0010

-0.0010
-0.0010
-0.0010
Link

Assy. 2315167-22
(Alt. 2315167-29)
Bolt- NAS464P439, -40

Bolt- NAS464P4-9

1 ArmAssy.,Brake-

-0.0000

A,B

1 +0.0000/

B, C, I
D,E I

1 0.2492 1
I
I

1 +0.0000/
1 -0.0009

0.2492

-0.0009

Alt. 2315166-15

2315166-19

0.2500

1
I

0.3120

1
1

Link-2315167-27

Nut

2315167-16

0.3140

Bushing- NAS75-3-004

0.1900

Lever- 2315167-3, -28

0.1910

0.1910

Assy.

1 +0.0050/
1 -0.0010
1 +0.001 0/
-0.0010
1 +0.0010/
-0.0000

(Alt. 2315167-25)

0.31 36

+0.0015/
-0.0000
1 +0.0050/
-0.0010
1 +0.0050/

+0.0000/
-0.0005

-0.0010
10

Bolt- NAS464P3-16

F,G I

0.1894

1 +0.0000/
-0.0009

MLG Power Brake Valve

Linkage Allowable Wear and Repair Data


Figure 1 (Sheet 2 of 3)

IEFFECTIVITY:

ALL

51-71-19

Page2
SRM-4

Jun 6/98

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

NO.

DESCRIPTION
Pedal
-33
Pedal
Pedal
Pedal

Assy.,

Rudder- 2315141-24

Assy., Rudder 2484010-2,


Assy., Rudder 2415171-1
Assy., Rudder 23151718
Pedal Assy., Rudder 2415175-1
Link Assy. 2315167-22

EFF.

-6

A
B

1
1

Alt. 2315167-29
Bolt NAS464P4-39, -40
Bolt NAS464P4-9

Arm

Assy., Brake 231516619


(Alt. 2315166-15)

Link

Nut

HOLE

A, B
B, C,
D, E
C, D
C, D

2315167-27

Assy. 2315167-16
Bushing NAS75-3-004

Lever

F
G
G
F, G

2315167-3, -28

(Alt. 2315167-25)
1

10

Bolt- NAS464P3-16

CODES

REPAIR

Replacewompart.
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.

part.
part.
part.
part.

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.

EFFECTIVITIES

23-001 thru 23-099; 24-100 and Subsequent; 25001 and


001 and Subsequent; 36-001 and Subsequent

Subsequent Except When Modified by AMK 81-02, "Rudder Pedal Rework and Heelplate Replacement" or AMK 81-03, "Rudder Pedal Heel Support Replacement"; 24-100 thru 24357
Except When Modified by AMK 81-02, "Rudder Pedal Rework and Heelplate Replacement" or AMK
81-03, "Rudder Pedal Heel Support Replacement"; 25-001 thru 25-302; 2&001 and Subsequent; 29001 and Subsequent; 35-001 thru 35-299; 36-001 thru 36-045
23-001 and Subsequent When Modified by AMK 81-02, "Rudder Pedal Rework and Heelplate Replacement"; 24-100 thru 24-139 When Modified by AMK 81-02, "Rudder Pedal Rework and Heelplate Replacement"
24-358 and Subsequent and Prior Aircraft Modified by AMK 81-02, "Rudder Pedal Rework and Heelplate Replacement"; 25-303 thru 25-338 and Prior Aircraft Modified AMK 81-02, "Rudder Pedal Rework and Heelplate Replacement"; 35-300 thru 35-400; 36-046 and 36-047
23-001 and Subsequent When Modified by AMK 81-03, "Rudder Pedal Heel Support Replacement";
24-100 thru 24-357 When Modified by AMK 81-03, "Rudder Pedal Heel Support Replacement"; 25001 thru 25357 When Modified by AMK 81-03, "Rudder Pedal Heel Support Replacement"; 35-401

Subsequent;

31-001 and

Subsequent;

35

23-001 and

thru 35-617; 35-621 thru 35-624; 36-048 thru 36-055


23-001 and Subsequent When Modified by AMK 81-02, "Rudder Pedal Rework and Heelplate Replacement"; 24-140 thru 24-357 When Modified by AMK 81-02, "Rudder Pedal Rework and Heelplate Replacement"; 25339 and Subsequent and Prior Aircraft Modified by AMK 81-02, "Rudder
Pedal Rework and Heelplate Replacement"; 31-001 and Subsequent; 35-618 thru 35-620, 35625
and Subsequent; 36-056 and Subsequent

MLG Power Brake Valve

Linkage Allowable Wear and Repair Data


Figure 1 (Sheet 3 of 3)

EFFECTIVITY:

ALL

51-71-19

Page 3
SRM-4

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


MAIN GEAR DOOR AND UPLATCH

ALLOWABLE WEAR AND REPAIR DATA

~5

14-90C-2

Main Gear Door and

A63C-1
A66C

EFFECTIVITY:

ALL

6~

Uplatch Allowable Wear and Repair Data


Figure 1 (Sheet 1 of 6)
51-71-20

Pagel
SRM-4

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


MAIN GEAR DOOR AND UPLATCH

ALLOWABLE WEAR AND REPAIR DATA

~6
8

11/

,10
E

23

K
22

21

13

12

,P
~20

18

J
17

Detail A
Main Gear Door and

EFFECTIVITY:

ALL

Uplatch Allowable Wear and Repair Data


Figure 1 (Sheet 2 of 6)
51-71-20

Page2
SRM~

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

I
DESCRIPTION

NO.

MFD

MFD

HOLE

SHAFT
OD

EFF.

HOLE

ID

0.2500

MFD

ALLOWANCE

ID

OD

WEAR
ID

ALLOWANCE
OD

Plate, Adjustable-

23270213

1 +0.00501
-0.0010

Bolt-NAS464P4-14

0.2492

1 +0.0000/

Bolt-AN174HC12A

0.2492

1 +0.0000/

1 ActuatorSupportPlate-

-0.0005
-0.0010
B

0.2495

0.2505

Bolt-AN174-12A

RodEnd-DREM-4-050

C
C

2311623-27, -28

1 Fitting-2322522-1

i +0.0010/
-0.0000
1 +0.0000/
-0.0010

0.2492

1 +0.0000/
-0.0005

(Alt. ARYHT4E)
Bolt- NAS464P4-23, A23
A22
Deleted
Bracket Assy.

8
9
10

2348042-1, -2
11

Bolt-AN24-36

12

Bracket

1 +0.0000/

1 -0.0009

1 +0.0050/
-0.0010
1
1 +0.0000/

0.2500

0.2492

0.2480

-0.0020

Assy.

14

Bushing- 6L6-F
Bushing- NAS75-4-122

F
G
F

15

Bolt- AN24-36

Roller-2317060-6

0.4445

Spacer-

0.2970

2348041-1, -2
13

0.4380

0.2500

0.2500

1 ~0.0010/
I ~t0.0100

1
1

+0.0015/
-0.0000

+0.0000/
-0.0005
1 +0.0000/

0.5620

+0.0000/
-0.0010

f0.0100/

0.3750

+0.0000/

+0.0000/

-0.0410

-0.0100

0.3761

0.2480

-0.0020
16

17

2317065-4

Bushing- 6L8-D
BracketAssy. -2311630-11,

-12

0.1890

1
I

1 +0.0050/
1 -0.0010

(Alt. 2311630-13, -14)


(Alt. 2311630-17, -18)
(Alt. 2311630-23, -24)

Main Gear Door and

EFFECTIVITY:

ALL

Uplatch Allowable Wear and Repair Data


Figure 1 (Sheet 3 of 6)
51-71-20

Fage3
SRM-4

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

NIFD
ITEM I

EFF.

Bolt- AN23-19

H, J I

Bushing-231162&7

H, J

Lever- 2311628-1, -2, -9


-10, -001, -002
Bolt-AN24-17

18

MFD 1 MFD
I SHAFT

ID

DESCRIPTION

NO.

HOLE

HOLE

OD

ID

OD

A1IOWAtJCE

WEAR
I

ID

ALLOWA~JCE
OD

1 +0.0000/

0.1860

0.2500

+0.0050/
-0.0010
1 +0.0050/
-0.0010

0.2480

-0.0020
19
20
21

0.1 930
0.2570

I
G

I
I

M.0100

1 +0.00001
-0.0020

22

Support, Actuator2348044-1, -2

K
K

23

Bolt-AN26-21

24

Spacer- NAS43HT6-13

Main Gear Door and

EFFECTIVITY:

ALL

0.3750

0.3730

0.4270

0.51 50

1 +0.0060/
-0.0012
1 +0.0000/
-0.0020
+0.0000/ +0.0000/
-0.0400 1 -0.0300

Uplatch Allowable Wear and Repair


Figure 1 (Sheet 4 of 6)

Data

51-71-20

Page 4
sRM-a

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
REPAIR DATA

ITEM

DESCRIPTION

NO.

EFF.

lr Plate, Adjustab\e- 2327021-3


2
3
4

Bolt
Bolt

NAS464P4-14
AN174HC12A
Actuator Support Plate

2311623-27,

IHOLE

REPAIR

Replacewompart.
Replace worn part.
Replace worn part.
Replace worn part.

-28
5

1 Fitting-2322522-1

Bolt AN174-12A
Rod End DREM-4-050

Bolt

Deleted

CJReplacewompart.

C
D

(Alt. ARYHT4E)

10
11

12

13
14
15
16

17

NAS464P4-A22, -23, -A23

Bracket Assy. 2348042-1, -2


Bolt AN24-36
Bracket Assy. 2348041-1, -1
Bushing 6L6-F
Bushing NAS75-4-122
BoR- AN24-36
Roller- 23170606

Spacer-2317065-4
Bushing- 6L8-D
1 BracketAssy-2311630-11,
(Alt. 2311630-13, -14)
(Alt. 2311630-17, -18)

E
E

F, G

G(Replacewompart.
I Replacewompart.
I Replacewompart.
I Replacewompart.

1
1

-12

I
I

20
21

Bolt

AN23-19

1 Bushing- 231162&7

Replace worn part.


Replace worn part.

H
H

H, J
H, J(

1
1

part.
part.
part.
part.
part.

Replace worn part.


Replace worn part.
Replace worn part.
Replacewompart.
Replace worn part.

Lever

Bolt- AN24-17
Actuator-

GIReplacewompart.

2348044-1,-2

2311628-1, -2, -9, -10,


-001, -002

22

Support,

23

Bolt

24

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

(Alt. 2311630-23, -24)


18
19

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.

NAS464P6-16
Spacer- NAS54HT6-13

Main Gear Door and

EFFECTNITY:

ALL

Replace worn part


Replace worn part.
Replacewompart.

Uplatch Allowable Wear and Repair Data


Figure 1 (Sheet 5 of 6)
51-71-20

Page 5
SRM-4

Jun 6/98

Learjet i

STRUCTURAL REPAIR MANUAL


CODES
1
2

3
4

EFFECTIVITIES
23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 28-001 and Subsequent; 31001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
23-001 thru 23-099 When Equipped With Goodrich Brakes
23-011 thru 23-099 When Equipped With Goodyear Brakes
24-330 thru 24-340 Except Aircraft Modified by AAK 78-03A, "Replacement of Main Landing Gear
Strut Piston Assembly for Improved Snubbing"; 25-206 thru 25-213 Except Aircraft Modified by AAK
~&OSA,"Replacement of Main Landing Gear Strut Piston Assembly for Improved Snubbing"; 35-067
thru 35-091 Except Aircraft Modified by AAK 7&03A, "Replacement of Main Landing Gear Strut Piston Assembly for Improved Snubbing"; 36-018 thru 36-023 Except Aircraft Modified by AAK 78-03A,

"Replacement of Main Landing Gear Strut Piston Assembly for Improved Snubbing"
24-100 thru 24-329, 24341 and Subsequent and 24-330 thru 24-340 When Modified by AAK 7&
03A, "Replacement of Main Landing Gear Strut Piston Assembly for Improved Snubbing"; 25-001
thru 25-205, 25-214 and Subsequent and 25-206 thru 25-213 When Modified by AAK 78-03A, "Replacement of Main Landing Gear Strut Piston Assembly for Improved Snubbing"; 2&001 and Subsequent; 29-001 and Subsequent; 31-001 thru 31-121, 31-135 and Subsequent; 35001 thru 35-066,
35092 and Subsequent and 35-067 thru 35-091 When Modified by AAK 78-03A, "Replacement of
Main Landing Gear Strut Piston Assembly for Improved Snubbing"; 36-001 thru 36-017, 36-024 and
Subsequent and 36-018 thru 36-023 When Modified by AAK 78-03A, "Replacement of Main Landing
Gear Strut Piston Assembly for Improved Snubbing"
31-122 thru 31-134

Main Gear Door and

EFFECTIVITY:

ALL

Uplatch Allowable Wear and Repair Data


Figure 1 (Sheet 6 of 6)

1
51-71-20

Page 6
SRM-4

Tun 6/98

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


ALLOWABLE WEAR AND REPAIR DATA

MAIN GEAR SHOCK STRUT

A
oi

\F

/P

/Q
Detail A

Main Gear Shock Strut

Allowable Wear and

Figure
EFFECTIVITY:

ALL

1 (Sheet 1 of

Repair Data

5)

51-71-211
Pagel

SRM-4

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

MFD
ITEM I

NO.

I
DESCRIPTION

Arm

Torque

HOLE

EFF.

HOLE

ID

0.7200

MFD

MFD

ALLOWANCE

OD

ID

OD

0.9383

+0.0050/

+0.0010/
-0.0000

-0.0000

2341126-2

0.7505

+0.0010/

0.9383

-0.0000

Torque

ALLOWANCE

ID

OD

Bushing

2341126-1

WEAR

I SHAFT

Arm

+0.0010/
-0.0000

0.7525

Bushing

2341120-1

0.7200

0.8765

+0.00501
-0.0000

lt0.0005

0.7200

0.9078

+0.00501
-0.0000

M.0003

Torque Arm Bushing


2341120-2
3

Upper Torque

Arm Pin

2341118-1

0.7500

1 +0.000011

1 0.7440

-0.0005

314111&1
4

0.5320

0.6892

+0.0050/
-0.0000

+0.0000/
-0.0005

0.7200

0.8765

+0.0050/

M.0005

0.7500

1 +0.0000/
-0.0005

Torque Arm Bushing


2341127-1, -3, -4

Torque Arm Bushing


2341120-1

-0.0000
7

234111&1

0.7500

314111&1

0.7500

2341120-2
6

Lower

Torque Arm

0.7200

+0.0050/
-0.0000

0.9078

f0.0003

Pin

1 0.7440

1 +0.0000/ 1
-0.0005
1 +0.0000/
-0.0005

Torque Arm Apex

Pin

234112&1

0.3750

0.5620

+0.0100/
-0.0000

Torque Arm Bushing


2341127-1

0.5320

0.6892

+0.0050/
-0.0000

2341127-2

0.5320

0.7045

+0.0050/
-0.0000

Main Gear Shock Strut

Allowable Wear and

Figure

1 0.5580

+0.0000/1
-0.0005

ALL

+0.0000/
-0.0005

0.5660

+0.0000/
-0.0005

0.5660

Repair Data

(Sheet 2 of 5)

51-n-21

Fage 2
SRM-I

Tun 6/98

Learjet
~jLearjetl

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I

I
DESCRIPTION

NO.

Strut Assy.
Fwd Trunnion Pin Hole

MFD
SHAFT
OD

HOLE

ID

1.2608

1.1260

125 RMS)
Bearing
(Finish 125 RMS)
Axle(Outer Ends)
(Finish 32 RMS)

MFD
HOLE

EFF.

Aft Trunnion Pin


Hole in Strut

MFD

ID

1.2620

1.1280

1 +0.0000/ 1
1
1 -0.0020
1
1 +0.0000/

3.0080

ID

OD

1 +0.00001 1
-0.0010
1 +0.00001 i
1 -0.0010

WEAR

ALLOWANCE

ALLOWANCE
OD

(Finish

10
11

1
I

12

13

32

I
N

PistonHead

(Finish

Lower

I
P

RMS)

Cylinder
(Finish 16 RMS)
Cylinder(Finish 63 RMS)

I
Q

Piston

I
1

3.0020

I
1

1 +0.0000/ 1

3.2520

1.4998
3.2480

2.9980

1 +0.0000/ i

1 +0.000/ 1

1 -0.0020

1 1.4970

-0.0010

1 3.2400

-0.0040

1 2.9945
3.2560

-0.0020

Main Gear Shock Strut

Allowable Wear and

Figure
EFFECTIVITY:

ALL

Repair Data

(Sheet 3 of 5)

51-71-211
Page 3

SRM-I

Jun 6/98

Learjet
tearjetl
STRUCTURAL REPAIR MANUAL
REPAIR DATA

ITEM

DESCRIPTION

NO.

EFF.

HOLE

REPAIR

Torque Arm Bushing

2341126-1

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.
part.
part.

2341126-2
Torque Arm Bushing

5
4

Torque Arm Bushing 2341120-2


Upper Torque Arm Pin 2341 1 18-1

314111&1
Torque Arm Bushing
2341127-1
Arm Bushing

2341120-1

2341120-2

6
7

H
H

Replace worn part.


Replace worn part.

Replace

Replace worn part.


Replace worn part.

N
P

2341120-1

Replaceworn part.

Torque

Lower Torque Arm Pin


234111&1
314111&1
Torque Arm Apex Pin
234112&1
Torque Arm Bushing
2341127-1
2341127-2
Strut Assy.
Fwd Trunnion Pin Hole
Aft Trunnion Pin

(Finish

125

10

Axle

11

Piston Head

12

Piston

13

Cylinder (Finish

Q
Q

Cylinder
63

RMS)

Main Gear Shock Strut

part.

j~

Replace wom part.


Replace worn part.
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

Allowable Wear and

Figure
ALL

worn

RMS)

Bearing
(Outer Ends)

Lower

IEFFECTnrITY:

Replace worn part. I!


Replace worn part. I!

part.
part.
part.
part.
part.

Repair Data

1 (Sheet 4 of 5)

51-71-21

PageB
SRM-4

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


CODES

EFFECTIVITIES

23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 28-001 and Subsequent; 29-001
and Subsequent; 31-001 and Subsequent; 35-0b1 and Subsequent; 36-001 and Subsequent

23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 28-001 and
and Subsequent; 31-001 thru 31-003; 35-001 thru 35-642; 36-001 thru 36-057

31-004 and

Subsequent;

29-001

Subsequent; 35-643 and Subsequent; 36-058 and Subsequent and Prior Aircraft Equipped
With 2341126-2 Bushing
23-001 thru 23-099; 24-100 and Subsequent; 25001 and Subsequent; 2&001 and Subsequent; 29-001
and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
31-001 and Subsequent
23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 2&001 and Subsequent; 29-001
and Subsequent; 35-001 thru 35-629; 36-001 thru 36-058
31-001 and Subsequent; 35-630 and Subsequent; 36-059 and Subsequent

6
7

NOTES:

Line

ream

bushings to 0.7505 (+0.0005/-0.0000) after installation.

Line

ream

bushings to

0.5625

(+0.0005/-0.0000) after installation. (Finish

Main Gear Shock Strut

Allowable Wear and

Figure
EFI:;ECTIVlTY:

ALL

32

RMS)

Repair Data

(Sheet 5 of 5)

51-71-211
Page 5

SRM-4

Jun 6/98

Learjet
~ii

STRUCTURAL REPAIR MANUAL


NOSE GEAR SHOCK STRUT

ALLOWABLE WEAR AND REPAIR DATA

~t;

Qb

:t
.~a

.F

A620C

Detail A
Nose Gear Shock Strut

Figure
EFFECTIVITY:

ALL

Allowable Wear and


1

(Sheet

Repair Data

1 of 3)

51-71-22(
Page 1

SRM-4

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I
NO.
1

I
DESCRIPTION
Axle-2342117-1

EFF.

HOLE

MFD

MFD

HOLE

SHAFT

ID

MFD

OD

1.4998

WEAR

ALLOWANCE

ID

ID

OD

1 +0.0000! 1

ALLOWANCE
OD

1 1.4980

-0.0010
2

Cylinder- 23421 02-1


2342100-2042-1 thru -12
2342101-1

Torque Block

Cam Follower-2342106-1
23421 06-3
2342100-2043-1 thru-12

Upper Cam 2342103-1

3.0000

3.0000

12200

2.5000

1
I
1

2.5000

1 +0.0020/ 1
-0.0000
1 +0.002011
-0.0000
1 +0.0010! 1
-0.0000
1 +0.00201 1
1 -0.0000
1 +0.0020/ 1
-0.0000
2.9970

3.0060

3.0060

1.2230

2.5060

2.5060

1 +0.0000/ 1

1 2.9910

-0.0020

Orifice Tube

2342113-1~

1.2180

1202-6

1.2180

2481030-2

1.2180

1 +0.00001 1
-0.0010
1 +0.0000/ 1
-0.0010
1 +0.0000/ 1

1 1.2160
1 1.2160

1 1.2160

-0.0010

1202-26A

12180

1 +0.0000/ 1

1 1.2160

-0.0010
2380032-30

1.2180

1 +0.0000/ 1

1 1.2160

-0.0010
7

Piston-2342104-1

Nose Gear Shock Strut

ALL

Allowable Wear and

Figure

IEFFECTIVITY:

2.4940

1 +0.0000/ 1
-0.0020

1 2.4950

Repair Data

(Sheet 2 of 3)

51-n-22

Page 2
slhw

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM
EFF.

DESCRIPTION

NO.
1

Axle

Cylinder

Torque Block

Cam Follower

Upper Cam

Orifice Tube

2342117-1

2342102-1

2342100-2042-1 thru -12


2342101-1

2342106-1, -3

2342100-2043-1 thru -12

1
2

G
G

12-02-6

2481030-2

1202-26A
2380032-30

5
6

J
J

Piston

HOLE

CODES

2342103-1

2342103-1

2342104-2

REPAIR

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.

EFFECTIVITIES

23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 2&001 and Subsequent; 29001 and Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent

25-001 and Subsequent; 2&001 and Subsequent; 29-001 and Subsequent; 35-134 and Subsequent
and Previous Aircraft Modified by SSK 973, "Replacement of Main Landing Gear Bushing and Pin";
36-035 and Subsequent and Previous Aircraft Modified by AAK 90-02, "Replacement of Variable Au-

thority Nose Wheel Steering Component


3

23-011, 23-012, 23-015, 23-019, 23-031, 23-043, 23-050, 23-051, 23-055, 23-060, 23-065, 23-087,

23-011, 23-012, 23-015, 23-019, 23-031, 23-043, 23-050, 23-051, 23-055, 23-060, 23-065, 23-087,

23-026 and

and 23-096 Unless Mod 2 Is Steel

Stamped On Name Plate

and 23-096 When Mod 2 Is Steel

Stamped On Name Plate


Subsequent Except 23-031, 23-043, 23-050, 23-051, 23-055, 23-060, 23-065, 23-087;
24-001 and Subsequent
24-001 and Subsequent; 25-002 and Subsequent Except Aircraft Equipped With Variable Nose
Wheel Steering
24-100 and Subsequent; 25-001 and Subsequent; 28-001 and Subsequent; 29-001 and Subsequent;
31-001 and Subsequent; 35001 and Subsequent; 36-001 and Subsequent

6
7

NOTES:

At

bearing

surface of square

parts (not diameter)

Nose Gear Shock Strut

Allowable Wear and

Figure
EFFECTIVITY:

ALL

Repair

Data

1 (Sheet 3 of 3)

51-71-22(
Page 3

SRM-4

Jun 6/98

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


MAIN GEAR ACTUATOR

ALLOWABLE WEAR AND REPAIR DATA

\G
I

Ij

/;6

D
M

(TYPICAL)

B
14-90C-2

Main Gear Actuator

A63C-1
Awc

EFFECTIVITY:

Detail A
Allowable Wear and

Figure
ALL

Repair

Data

(Sheet 1 of 3)

51-71-23

Pagel
SRM-I

Jun 6/98

Learjet
e~Learjetl
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

NO.I
1

DESCRIPTION

Cylinder- 23271 01-1, -7,

HOLE

-11,-17

Inner Piston

MFD

HOLE

SHAFT

ID

OD

2.2450

I
B

EFF.

MFD

1
C

2427110-1

2.4360

MFD

1 +0.0020/ 1

1
1.4870

ALLOWANCE
OD

1 2.4330

-0.0000
1 +0.0030/ 1
-0.0000

ID

OD

ID

1
1

WEAR

ALLOWANCE

2.2520

1 +0.0020/ 1

1 1.4840

-0.0000
2

232711 0-1

1.4870

1 +0.0020/ 1

1 1.4840

-0.0000
3

Piston- 2327102-1, -2, -5

2.2430

1 +0.0000/

1.8730

1 +0.0000/

-0.0010
-0.0020
F

1.4910

1 +0.0020/ 1

0.0050

-0.0000
4

Ball Housing24271 04-1, -2

-003

Plunger- 2427105-1, -002,

Housing- 2327108-3,

-7

2.8110

2.4380

+0.0000/
-0.0020

1.8750

2.21 70

1 +0.0020/ 1

2.2260

2.8130

1.876

-0.0000
1 +0.0020/ 1
-0.0000
1 +0.0020 1
-0.0000
1 +0.0020 1
-0.0000

Allowable Wear and


Figure 1 (Sheet 2 of 3)

Main Gear Actuator

1EFFECTIVITY:

ALL

+0.0020/
-0.0000
1 +0.0000/ 1
-0.0020

1 2.8070

2.4420

2.2350

2.8190

1.8850

Repair Data

51-71-23

Page2
SRM-4

Jun 6/98

Laarjet
Learjet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM
EFF.

DESCRIPTION

NO.

Cylinder 2327101-1, -7, -11,

1
2

Inner Piston

-17

2427110-1

2327110-1
3

Piston-2327102-1,-2, -5

A, B

D
E
F

Bail

Housing- 24271 04-1,

-2

Plunger 2427105-1, -002, -003

1 Housing-232710&3,

CODES

-7

Replace worn part.

Replacewompart.~
Replace

worn

part.

I Replacewompart.~
Replace worn part.
Replace worn part.

GIReplacewompart.~
H, J
K

REPAIR

HOLE

L, M

Replace worn part.


Replace worn part.
Replace worn part.

EFFECTIVITIES
23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 2&001 and Subsequent, 29-001
and Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 28001 and Subsequent, 29-001
and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
31 -001 and Subsequent and Aircraft Equipped With 23271 01 -1 1 or 23271 01 -1 7 Cylinder Assembly

1
2

NOTES:

I~

16RMS.
32RMS.
63RMS.
125 RMS.

Main Gear Actuator

Allowable Wear and

Repair Data

Figure 1 (Sheet 3 of 3)
EFFECTIVITY:

ALL

51-71-23

Page 3
SRM-4

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


MAIN DOOR UPLATCH MECHANISM

ALLOWABLE WEAR AND REPAIR DATA

r~

B~j
A

/i
7
5

/s

Fi
A

ii

10

Main Door

EFFECTIVITY:

ALL

Uplatch Mechanism Allowable Wear and Repair Data


Figure 1 (Sheet 1 of 3)

51-71-241
Pagel

SRM-I

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

MFD

MFD

HOLE

SHAFT

MFD

ALLOWANCE

EFF.

HOLE

ID

LH and RH Cam Bracket


Assy- 2348042-1 and-2

0.2500

Bolt- AN24-36

LH and RH

0.2500

0.2500

0.4380

Bolt-AN24-17

0.248

1 +0.0000/

Bolt- AN24-36

0.248

1 +0.0000!

Bushing- NAS75-4-122

Bushing, Nylinder-

Spacer- 2348041-10

Roller- 231 7060-6

DESCRIPTION

NO.

OD

ID

OD

WEAR
ID

ALLOWANCE
OD

1 +0.00501
-0.0010

Assy-

0.2480

1 +0.0000/
-0.0020

Cam

Uplatch

2348041-1 and-2

i +0.00501
-0.0010
1 +0.0050/
-0.0010

1+0.00101
-0.0000

-0.0020
-0.0020

8L6F

0.3716

+0.00151
-0.0000

0.250

0.313

+0.0050/
-0.0010

0.385

0.562

+0.00001

0.250

+0.0000/
-0.0005

I
~0.0100

-0.0010

10
11

1 Spacer- 2317065-4
Bushing- 6L8D

Main Door

EFF~CTIVITY:

ALL

0.375

0.297

+0.0000/
-0.0410

+0.0000/
-0.0100

Uplatch Mechanism Allowable Wear and Repair Data


Figure 1 (Sheet 2 of 3)
51-71-24

Page 2
SRM-I

Jun 6/98

Leariet
~Learjet
STRUCTURAL REPAIR MANUAL
REPAIR DATA

ITEM
EFF.

DESCRIPTION

NO.

HOLE

REPAIR

LH and RH Cam Bracket

Assy 2348042-1 and -2


Bolt AN24-36
LH and RH Uplatch Cam
Assy 2348041-1 and -2
Bolt AN24-17
Bolt AN24-36
Bushing NAS75-4-122
Bushing, Nylinder 6L6-F

Spacer

Roller

3
4
5

2348041-10

2317060-6

Spacer
Bushing

10
11

CODES

2317065-4
6L8D

Replace
Replace

worn
worn

part.
part.

Replace worn pact.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.

EFFECTIVITIES
23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 2&001 and Subsequent; 29001 and Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent

NOTES:
Product of Industrial

Bearing

Main Door

EFFECTIVITY:

ALL

Transmission, 325 N. St. Francis, Wichita, KS 67202.

Uplatch Mechanism Allowable Wear and Repair Data


Figure 1 (Sheet 3 of 3)

51-71-241
Page 3

SRM-4

Jun 6/98

Learjet i

STRUCTURAL REPAIR MANUAL


ALLOWABLE WEAR AND REPAIR DATA

NOSE GEAR ACTUATOR

B\,

~4a

f
CI~YPICAL)

1/

,3

Detail A
1

Detail E

t
E

f
A

ji~

Detail D

,_

Detail C
Nose Gear Actuator

Allowable Wear and

Figure

EFFECTIVITY:

ALL

Detail B

(Sheet

1 of

Repair Data

3)

51-71-251
Pagel

SRM-I

Jun 6/98

Ledrjet I
E~ Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

MFD
ITEM I

HOLE

MFD

MFD

WEAR

ALLOWANCE

ALLOWANCE

I SHAFT

ID

HOLE

EFF.

DESCRIPTION

NO.

OD

0.4358

ID

OD

ID

OD

Upper Attach Bolt

NAS464P7L53

1 +0.0009/ 1

1+0.43301

-0.0000

Lower Attach Bolt


NAS464P7L20
2

0.4358

1 +0.000911

1+0.4330/

-0.0009

-0.0000

CylinderAssembly2

1202-202

231 7101-12
3

(Alt. 2317101-13)
Plunger-1202-209

1.4360

1.6270

1.4360

1.6270

1
1.9900

+0.0000/

+0.0000/

-0.0020

-0.0020

+0.0000/
-0.0020

+0.0000/
-0.0020
1 +0.0000/ 1

1.4400

1.4400

1.4400

1.4400

1.9890

1.6330

1.9890

1.6330

1.4300

1.2200

-0.0020
D

1.6310

1 +0.0000/ 1
-0.0020

2317105-1, -002

1.9900

1 +0.0000/ 1

-0.0020
D

1.6310

1 +0.0000/ 1
-0.0020

Piston-1202-204

1.4340

i +0.0000/ i
-0.0020

1.1240

1 +0.0000/ i
-0.0020

2317102-1, -2, -5

i
I

1
1

1.1240

1.4340

1
1

1.1220

1 +0.0000/ 1
1 +0.0000/ 1
-0.0020
1 +0.0020/ 1

1 1.2200
i 1.4300
i 1.2200

-0.0000

1.1240

1 +0.0000/ 1

1.2200

-0.0020
5

Downlock Ball

Housing

1202-207

1.1260

2317104-1

1.1260

1.9920

1.1270

1.9920

Housing-1202-211A

2317108-1, -3, -8

1 +0.0020/
-0.0000
1 +0.0020/
-0.0000
1 +0.0020/
-0.0000
1 +0.0000/
-0.0020
1 +0.0020/

1.1300

1.1300

1.9970

1.1310

1.9970

1 +0.0000/ i

1.1310

-0.0000
A

1.1270

-0.0020

Nose Gear Actuator

Allowable Wear and

Repair Data

Figure 1 (Sheet 2 of 3)

IEFFECTnrITY:

ALL

51-71-25

Page 2
SRM-4

Jun6/98

Learjet
Learietl

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

EFF.

DESCRIPTION

NO.

Bolt

NAS464P7L53

NAS464P7L20

I
I

I Replacewompart.~
I Replacewompart.l~

Cylinder Assembly

1202-202

2317101-12

(Alt. 2317101-13)
Plunger 1202-209

2317105-1,-002

Piston -2317102-2

C
D

E
F

G
E

2317102-1, -2, -5

G
Downlock Ball Housing
2317104-1
Housing -1202-211A

5
6

REPAIR

Lower Attach Bolt

Upper Attach

HOLE

1202-207

A
B

A
B

231710&3

CODES

Replacewompart.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part. I!
Replace worn part. I!
Replace worn part.
Replace worn part. I!
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part. I!
Replace worn part. 1!
Replace worn part. I!
Replace worn part. I!
Replace worn part.
Replace worn part.

EFFECTIVITIES

23-001 thru 23-099; 24-001 and Subsequent; 25-001 and Subsequent; 2&001 and Subsequent; 29001 and Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent
23-001 thru 23-010, 23-013, 23-014, 23-016, 23-017, 23-013, 23-020 thru 23-025 Except Aircraft

23-011, 23-012, 23-015, 23-019, 23-026 thru 23099 and Aircraft Modified per SSK 23-214; 24-100

Modified per SSK 23-214


and Subsequent; 25-001 and
and Subsequent; 35-001 and

Subsequent; 2&001 and Subsequent;


Subsequent; 36-001 and Subsequent

29-001 and

Subsequent;

31-001

NOTES:
32RMS
16RMS

Nose Gear Actuator

Allowable Wear and

Figure
EFFECTIVITY:

ALL

Repair Data

(Sheet 3 of 3)

51-71-251
Page3

SRM-4

Jun 6/98

Learjet
Learjet

STRUCTURAL REPAIR MANUAL


NOSE GEAR UPLATCH

ACLOWABLE WEAR AND REPAIR DATA

00000

LA

~j

B~

(TYPICAL)

Detail A
Nose Gear

EFFECTIVITY:

ALL

Uplatch Allowable Wear and Repair Data


Figure 1 (Sheet 1 of 5)
51-71-26

Page
SXM-4

Jun 6/98

Leariet

STRUCTURAL REPAIR MANUAL


NOSE GEAR UPLATCH

ALLOWABLE WEAR AND REPAIR DATA

00000

/13

6\

d
Detail B
,1

EFFECTNITY:

Nose Gear

ALL

Uplatch Allowable Wear and Repair Data


Figure 1 (Sheet 2 of 5)
51-n-26

Page2
SRM-4

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

NO.I

DESCRIPTION

Bolt- AN4-24

IEFF.

I
HOLE I

MFD

MFD

HOLE

SHAFT

ID

OD

MFD
I

ALLOWANCE

ID

OD

0.2490

1 +0.0000/

0.2490 1

1 +0.0000/

WEAR
ID

ALLOWANCE
OD

-0.0030

AN4-34

-0.0030
2

Spacer- 2317065-1

0.2970

0.3750

+0.0000/

+0.0000/

Roller- 231 7060-2

0.4445

0.5620

+0.0100

0.4445

0.5620

+0.00001
-0.0010
+0.00001
-0.0010

0.2570

0.5620

-0.01 00
+0.0100

0.2570 1

0.1930 1

0.2500 1

1 +0.0000/
-0.0090
1 +0.0050/
-0.0000
1 +0.0100

0.2570 1

1 +0.0000/

0.1930 1

1 +0.0050/

0.2500 1

-0.0410

231 7060-5
4

Spacer- 23170653

Support- 231 7063-1,

-4

-6,-8

(Slot)

+0.0060/
-0.0010

-0.0100

-0.0100
+0.0100

-0.0100

-0.0100

2442010-1,-7

(Slot)

-0.0090
-0.0000
+0.0100
-0.0100

Bolt- NAS464P4-37

71

NoseGearPistonAssy.

C, DI

0.2492

1 +0.0000/
-0.0009

81Screw-AN509-10Rll

0.2500 1

0.1900 1

B, El

1 +0.0010/
-0.0000
1 +0.0020/
-0.0000

0.1890 1

1 +0.0000/

0.3742 1

1 +0.0000/

-0.0030
9

Bolt- NAS464P6-8

-0.0009
10

Bearing-MS21233-6

0.3750

11

RodEnd-MS21243604K

0.2500 1

12

Bolt-NAS464P4-8

0.81 25

+0.0000/
-0.0005
1 +0.0000/
-0.0005

0.2492

+0.0000/
-0.0005

1 +0.0000/
-0.0009

Nose Gear

EFFECTIVITY:

ALL

Uplatch Allowable Wear and Repair Data


Figure 1 (Sheet 3 of 5)
51-71-26

Page3
SRM-4

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

MFD
ITEM I

DESCRIPTION

NO.
13

MFD

HOLE

SHAFT
OD

EFF.

HOLE

ID

0.7491

0.3125

MFD

ALLOWANCE

ID

OD

WEAR
ID

ALLOWANCE
OD

1 +0.0010/

-17,-23

15

1 Torque Tube Assy,


Nose Gear Uplatch
231 7029-1, -11,-16,

14

Bearing- LHBV-5
(Alt. KSBG-5N)
(Alt. LHBRQ)
(Alt. MS21233-5)
Pivot-2317058-2

-0.0000

0.7500

0.3110

+0.0000/

+0.0000/

-0.0005

-0.0005

1 +0.0010/
-0.0000

Nose Gear

EFFECTIVITY:

ALL

Uplatch Allowable Wear and Repair Data


Figure 1 (Sheet 4 of 5)
51-71-26

Page 4
SRM-I

Jun 6/98

Learjet
Leariet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

DESCRIPTION

NO.

EFF.

HOLE

A
A
A
A
A

Bolt AN4-24
AN4-34

Spacer

2317065-1
Roller 2317060-2
23170606
Spacer 2317065-3

3
4

5
1

Bolt NAS464P4-37
Nose Gear Piston Assy.
Screw AN509-10R11

A, B, C
A, B, C
C, D
D, E
B, E

Bolt

Support 2317063-1, -4, -6,


Support 2442010-1, -7

5
6
7

-8

6
7
1

NAS464P6-8
Bearing- MS21233-6

10

REPAIR

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part. Install

new

bearing with

Loctite.
MS21243S04K
NAS464P4-8
Torque Tube Assy.,
Nose Gear Uplatch

11

12

13

G
G

Replace worn part.


Replace worn part.

H
H

Replace worn part.


Replace worn part. Install new bearing with wet
primer, exterior surface only.

Replace worn part.

Rod End

Bolt

2317029-23
14

1 Bearing- LHBV-5
(Alt. KSBG-5N)
(Alt. LHBR-5)

15

(Alt. MS21233-5)

CODES
1
2

Pivot -231705&2

EFFECTIVITIES
23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 2&001 and Subsequent; 29001 and Subsequent; 31-001 and Subsequent; 35001 and Subsequent; 36-001 and Subsequent
23-001 thru 23-059 Except Aircraft Modified by SK 23-129, "lnstallation of Nose Gear Uplatch Safe-

ty Cam"
3

23-060 and

Subsequent

and Aircraft Modified

by SK 23-129, "lnstallation of Nose Gear Uplatch

Safety Cam"
4

23-003 thru 23-010, 23-013, 23-014, 23-016 thru 23-018, 23-020 thru 23-030, 23-032 thru 23-038,
23-040 thru 23-042, 23-044 thru 23-049, 23-050a, 23-052 thru 23-054, 23-056 thru 23-059, 23-061

thru 23-064, 23-065a thru 23-086, 23-088 thru 23-095, 23-097 and
fied per ECR392
5

Subsequent Except Aircraft

Modi-

23-011, 23-012, 23-015, 23-019, 23-031, 23-039, 23-043, 23-050, 23-051, 23-055, 23-060, 23-065,
23-087, 23-096 and Model 23 Series Aircraft Modified by ECR392; 24-100 and Subsequent; 25-001
and

Subsequent, 2&001 and Subsequent, 29-001


Subsequent; 36-001 and Subsequent

and

Subsequent;

31-001 and

Subsequent;

35-

001 and
6
7

23-001 thru 23-099; 24-100 thru 24-223; 25001 thru 25-059


24-224 and Subsequent; 25060 and Subsequent; 2&001 and

Subsequent;

29-001 and Subse-

quent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent

Nose Gear

Uplatch

Allowable Wear and

Repair

Data

Figure 1 (Sheet 5 of 5)
ALL

51-n-26

Page 5
SRM-4

Jun 6/98

Learjet
Lenrjet

STRUCTURAL REPAIR MANUAL


NOSE GEAR DOOR MECHANISM

O [I)

ALLOWABLE WEAR AND REPAIR DATA

000

5J
/Y

1,

10

B
11

G
3
E 12
5

16

ij i

15/ 11

CA

10

16

(TYPICAL)

Detail A
I-tlC

Nose Gear Door Mechanism

Figure
EFFECTIVITY:

ALL

Allowable Wear and

Repair Data

1(Sheet lof4)
51-71-27

Pagel
SRM-4

Jun 6/98

Learjet
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

DESCRIPTION

NO.I
1

Pivot-231705&1

Channel

EFF.

HOLE

MFD

MFD

HOLE

SHAFT

ID

OD

0.3110

MFD

WEAR

ALLOWANCE

ID

OD

ID

ALLOWANCE
OD

1 +0.0010/
-0.0000

Assy.
B

0.2500

1 +0.0050/

0.4991

-0.0010
1 +0.00151

0.2500

1 +0.0000/

(Alt. MS21242S4)

0.2500

1 +0.0000/

(Alt. KBNE-4)

0.2500

1 +0.0000/

2317045-8, -9, -10

-0.0000

Rod End

MS21242-4

-0.0005
-0.0005
-0.0005
4

Bolt- AN24-32

0.2480

Bolt- AN24-15, -22

0.2480

Bolt- NAS464P8-33, -36,

0.4991

-0.0020
1 +0.0000/
-0.0020
1 +0.0000/

1 -0.0009

1 +0.0050/

1
1

-40

1 +0.0000/

Torque Tube Assy.

2317047-9,-11

0.2500

-0.0010

Bearing- LHBV-5
(Alt. RSST-5)
(Alt. LHBR-5)
(Alt. MS21233-5)

D
D

(Alt. KSBGQN)
TorqueTubeAssy.-

231 70481

0.3125

1 Bearing-LHBVd
(Alt. KSBG-5N)

12

+0.0000/
-0.0005

0.7510

1
I

0.2500

1 +0.0050/
1 -0.0000
1 +0.0050/
-0.0010

F
F

(Alt. LHBR-5)
(Alt. MS21233-5)
11

+0.0000/
-0.0005

G
10

0.7500

F
F

0.3125

0.7500

+0.0000/
-0.0005

+0.0000/
-0.0005

Rod End -2317046-9


Bolt- AN24-22

0.2480

1 +0.000/

Bolt-AN24-15

0.2480

1 +0.0000/

-0.0020

13

-0.0020

Nose Gear Door Mechanism

Figure

EFFECTIVITY:

ALL

Allowable Wear and


1

(Sheet

2 of

Repair

Data

4)

51-71-27

Page 2
SRM-4

Jun 6/98

Learjet

STRUCTURAL REPAIR MANUAL


WEAR ALLOWANCES

ITEM I
NO.
14

i
DESCRIPTION
Rod End-HMV4

EFF.

HOLE

15

Bolt- AN24-15

G
G
G
G
G

16

Bracket- 2310620-14

Rod End-HMV4
(Alt. HMV V4)

(Alt. HMV-V4)
(Alt. REM-4T)
(Alt. TRE-4T)

MFD

MFD

HOLE

SHAFT

ID

OD

0.2480

MFD

ALLOWANCE

ID

OD

WEAR
I

ID

ALLOWANCE
OD

1 +0.0000/
-0.0020

0.2500

1 +0.0050/
-0.0010

17

(Alt. REM-4T)
(Alt. TRE-4T)
18

H
H

Bolt- NAS464P4-12

0.2492

1 +0.0000/
-0.0009

Nose Gear Door Mechanism

Figure
EFFECTIVITY:

ALL

Allowable Wear and

Repair Data

1 (Sheet 3 of 4)

51-71-27

Page 3
SRM-I

Jun 6/98

Learjet
Learjet/

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

Pivot

Channel Assy. 2317045-8, -9, -10


Rod End MS21242-4

2317058-1

B, C

B
B

(Alt. MS21242S04)
(Alt. KBNE-4)

AN24-32

AN24-15, -22
NAS464P8-33, -36, -40

Bolt
Bolt
Bolt

Torque Tube Assy.


2317047-9, -11

D, E

Bearing LHBV-5
(Alt. RSST-5)
(Alt. LHBRd)
(Alt. MS21233-5)
(Alt. KSBG-SN)
Torque Tube Assy.

4
5

D
D

D
D

2317048-1
10

1 Bearing-

LHBV-5

(Alt. LHBR-5)

F, G

Rod End -2317046-9


Bolt AN24-22
Bolt AN24-15
Rod End HMV4

12
13
14

F
1

G
G
G
G
G
H

(Alt. HMV-V4)
(Alt. REM-4T)
(Alt. TRE-4T)
Bolt AN24-15
Bracket 2310620-14
Rod End HMV4

15

16
17

(Alt. HMV-V4)
(Alt. REM-4T)
(Alt. TRE-4T)
Bolt

18

CODES
1

NAS464P1-12

H
H
H

part.
part.
part.
part.
part.
part.
part.
part.

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

part.
part.
part.
part.
part.
part.

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.

23-001 thru 23-099; 24-100 and Subsequent; 25-001 and Subsequent; 28-001 and Subsequent; 29001 and Subsequent; 31-001 and Subsequent; 35-001 and Subsequent; 36-001 and Subsequent

Figure
EFFECTIVITY:

Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn
Replace worn

EFFECTIVITIES

Nose Gear Door Mechanism

(Alt. MS21233-5)
(Alt. KSBG-5N)
11

REPAIR

HOLE

EFF.

DESCRIPTION

NO.

ALL

Allowable Wear and

Repair

Data

1 (Sheet 4 of 4)

51-71-27

Page4
sRM-4

Jun 6/98

~3 Learjet I
STRUCTURAL REPAIR MANUAL
FLAP PRESELECT ASSEMBLY

ALLOWABLE WEAR AND REPAIR DATA

C/
4

6~b
x

Detail A
M31-8151A

EFFECTIVITY:

Flap Preselect Assembly Allowable Wear and Repair


Figure 1 (Sheet 1 of 3)
31-001 AND

SUBSEQUENT;

36-054 AND SUBSEQUENT


SRM-4

35-509 AND

SUBSEQUENT;

Data

51-71-28

Page

Jun 6/98

Learjet
~1
STRUCTURAL REPAIR MANUAL
WEAR ALLOWANCES

ITEM I

I
EFF.

DESCRIPTION

NO.

Handle-2615269-5

I
HOLE I

MFD

MFD

HOLE

SHAFT

ID

OD

0.3750

0.1250

0.1 890

MFD

WEAR

ALLOWANCE

ID

OD

ID

ALLOWANCE
OD

1 +0.00201
-0.0000
1 +0.00201
-0.0000

Frame- 2615269-16

Screw- NAS1203-110

0.1895

Bushing-261526&3

0.3735

Link- 261 5269-32

0.1250

1
1

0.1250

1 +0.0000/
-0.0010

1 +0.0020/
-0.0000

1 +0.00201
-0.0000

Pin- MS20392-1C13

0.1240

1 +0.00001

Pin-MS20392-1 C7

0.1240

1 +0.00001

-0.0020
7

-0.0020

Flap Preselect Assembly Allowable Wear and Repair Data


Figure 1 (Sheet 2 of 3)

EFFECTIVITY:

31-001

ANDSUBSEQUENT; 35-509ANDSUBSEQ~TENT;
SUBSEQUENT

36-054 AND
SRM-I

51-n-28

Page 2
Jun 6/98

Leariet
~Learjet

STRUCTURAL REPAIR MANUAL


REPAIR DATA

ITEM

DESCRIPTION

NO.

EFF.

Handle 2615269-5
Frame 2615269-16
Screw NAS1203-110
Bushing 261526&3
Link 2615269-32
Pin MS20392-1C13
Pin MS20392-1C7

1
2

3
4

6
7

CODES
1

REPAIR

IHOLE

A, B

C
D

E,

Replace worn part.


Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.
Replace worn part.

EFFECTIVITIES
31-001 and

Subsequent;

35509 and

Flap Preselect Assembly

Subsequent;

36-054 and

Allowable Wear and

Subsequent

Repair Data

Figure 1 (Sheet 3 of 3)
EFFECTIVITY:

SRM-4

31-001 AND

SUBSEQUENT; 35-509 AND SUBSEQUENT;

36-054 AND

SUBSEQUENT

51-71-28

Page 3
Jun 6/98

CHAPTER

DOORS

Learjet
Leariet

STRUCTURAL REPAIR MANUAL


Chapter
Section

Subject

Subject
DOORS-STRUCTURAL IDENTIFICATION

Description

Page

....52-00-00
1

......................,.....................................................................................................52-00-00

PASSENGER/CREW UPPER DOOR (24-Inch Door)


STRUCTURAL IDENTImCATION..............................................................................52-10-00

Description
Passenger/Crew Upper (24-Inch) Door Structure Repair Index

.52-10-00

1
1

....................................52-10-00

PASSENGER/CREW UPPER DOOR (36-Inch Door)STRUCTURAL IDENTIFICATION..............................................................................52-10-00

Description
Passenger/Crew Upper (36-Inch) Door Structure Repair Index

............................................................................................................................52-10-00

....................................52-10-00

PASSENGER/CREW UPPER DOOR ALLOWABLE DAMAGE.....................................52-10-00


Allowable

Damage Limits

101

....................................................................................................52-10-00

PASSENGER/CREW UPPER DOOR REPAIR

52-10-00
52-10-00

Approved Repairs

201

PASSENGER/CREW LOWER DOOR (24-Inch Door)STRUCTURAL IDENTIFICATION

52-10-10

Description
Passenger/Crew Lower (24-Inch) Door Structure Repair Index

........................................................................,...................................................52-10-10

....................................52-10-10

PASSENGER/CREW LOWER DOOR (36-Inch Door)STRUCTURAL IDENTJFICATION..............................................................................52-10-10


5

Description
Passenger/Crew Lower (36-Inch)
............................................................................................................................52-10-10

Door Structure Repair Index


PASSENGER/CREW LOWER DOOR ALLOWABLE DAMAGE
Allowable Damage Limits
PASSENGER/CREW LOWER DOOR REPAIR..................................................................52-10-10

....................................52-10-00

...................................52-10-10

101

....................................................................................................52-10-10

Approved Repairs

201

..................................................................................................................52-10-10

EMERGENCY EXIT DOOR

STRUCTURAL IDENTImCATION.....................................

52-20-00
1

Description
Emergency Exit Door Structure Repair Index.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52-20-0O
....................................................................................................52-20-00

EMERGENCY EXIT DOOR ALLOWABLE DAMAGE


Allowable Damage Limits

1
.....................................................52-20-0O

101

....................................................................................................52-20-00

EMERGENCY EXIT DOOR

REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52-20-00
52-20-00

Approved Repairs
SERVICE DOORS -STRUCTURAL IDENTIFICATION

Description

............................................................................................................................52-40-00

STRUCTURAL IDENTlmCATION...................................
TaiIcone Access Door Structure Repair Index..
TAILCONE ACCESS DOOR ALLOWABLE DAMAGE
TAJLCONE ACCESS DOOR

Allowable

Damage Limits

TAILCONE ACCESS DOOR

201

.....................................................52-40-0O

52-40-01

52-40-01

.52-40-01
101

....................................................................................................52-40-01

REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5240-01

Approved Repairs

................................................................52-40-01

NOSE COMPARTMENT ACCESS DOORS STRUCTURAL IDENTIFICATION .........52-40-05


Nose Compartment Access Doors Structure Repair Zndex..............................................52-40-05

NOSE COMPARTMENT ACCESS DOORS


Allowable Damage Limits
....................................................................................................52-40-05

201
1

ALLOWABLE DAMAGE..........................52-40-05
101

52- Contents

SRMI

Page 1
May 15/92

~3 Learjet
STRUCTURAL REPAIR MANUAL
Chapter
Section

Subject

Subject
REPAIR

NOSE COMPARTMENT ACCESS DOORS

Approved Repairs

.................;......................................52-40-05

201

.......................................................................................................~..........52-40-05

STRUCTURAL IDENTIFICATION

OIL FILLER ACCESS DOOR

..................................52-40-10

Repair Index.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52-40-10


ALLOWABLE DAMAGE

Oil Filler Access Door Structure


OIL FILLER ACCESS DOOR

Allowable

Damage Limits

52-40-10
101

....................................................................................................52-40-10

REPAIR

OIL FILLER ACCESS DOOR

.................................................................................52-40-10

52-40-10

Approved Repairs
OXYGEN BOTTLE ACCESS DOOR

STRUCTURAL IDENTIFICATION

Oxygen Bottle (Nose Compartment) Access Door Structure Repair Index.


Oxygen Bottle (Dorsal Fin) Access Door Structure Repair Index
Damage Limits

201

52-40-15

52-40-15

1
2

...................................52-40-15

OXYGEN BOTTLE ACCESS DOOR

Allowable

Page

ALLOWABLE DAMAGE.......................................52-40-15
101

....................................................................................................52-40-15

OXYGEN BOTTLE ACCESS DOOR

REPAIR

.....................................................................52-40-15

......52-40-15

Approved Repairs.........

201

SINGLE-POINT PRESSURE REFUELING DOOR


STRUCTURAL IDENTIFICATION..............................................................................52-40-20

Single-Point Pressure Refueling Door Structure Repair Index........................................52-40-20


SINGLE-POINT PRESSURE REFUELING DOOR

ALLOWABLE DAMAGE

Allowable Damage Limits


SINGLE-POINT PRESSURE REFUELING DOOR

REPAIR..............................................52-40-20

52-40-20
101

....................................................................................................52-40-20

Approved Repairs
Description

201

..............................................~...................................................................52-40-20

MAIN LANDING GEAR DOORS

STRUCTURAL IDENTIFICATZON..........................

52-80-00
1

..........~.................................................................................................................52-80-00

MAIN LANDING GEAR INBOARD DOOR

STRUCTURAL IDENTIFICATION .......52-80-10


Main Landing Gear Inboard Door Structure Repair Index..............................................52-80-10
MAIN LANDING GEAR INBOARD DOOR ALLOWABLE DAMAGE
52-80-10
Allowable

Damage Limits

101

....................................................................................................52-80-10

MAIN LANDING GEAR INBOARD DOOR

REPAIR.......................................................52-80-10

52-80-10
STRUCTURAL IDENTIFICATION ...52-80-20
Main Landing Gear Outboard Door Structure Repair Index
.52-80-20
MAIN LANDING GEAR OUTBOARD DOOR ALLOWABLE DAMAGE

Approved Repairs.......

201

MAIN LANDING GEAR OUTBOARD DOOR

..........................................52-80-20

Allowable

Damage

Limits

101

....................................................................................................52-80-20

MAIN LANDING GEAR OUTBOARD DOOR

Approved Repairs

REPAIR...................................................52-80-20

201

..................................................................................................................52-80-20

NOSE LANDING GEAR DOOR STRUCTURAL IDENTIFICATION


Nose Landing Gear Door Structure Repair Index.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52-81-00
NOSE LANDING GEAR DOOR ALLOWABLE DAMAGE.............................................52-81-00
Allowable Damage Limits
NOSE LANDING GEAR DOOR

Approved Repairs............

REPAIR

............................52-81-00

52-81-00

101

.52-81-00

201

...........................................................................52-81-00

52- Contents

Page 2
SRM-d

May 15/92

Leariet

STRUCTURAL REPAIR MANUAL


Chapter

Chapter

Section

Section
Date

Subject

Page
101

Jun 1/95

52-40-00

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52-TITLE
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portion of the

text affected

or

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Date

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101

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102

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52-81-00
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Deleted

deleted

Pages.
by current revision.

by the current revision is indicated by a

vertical line in the outer

margin of the

page.
52

Pages
Pagel

List of Effective

Jun 1/95
SRM-4

e~ Learjet
STRUCTURAL REPAIR MANUAL
DOORS- STRUCTURAL IDENTIFICATION
i.

DESCRIPTION
NOTE:

The
the

following structural data covers the basic non-modified aircraft. When applicable, refer to
appropriate kit drawing for additions, modifications and changes to the structural compo-

nents and assemblies.

A.

This

Chapter

covers

structural components, allowable

damage limits,

skin gap tolerances, and

repair

of aircraft doors.
B.

C.
D.

repair index (Figure 1) is incorporated to aid in location of specific component repair


indexes throughout this chapter.
Allowable damage limits for each door are given in each respective section.
Skin gap tolerances for each door are given in each respective section.
A door master

Chapter
Section

Description

Item

Passenger/Crew Upper Door


Passenger/Crew Lower Door

52-10-00

2
3

Emergency Exit Door

52-20-00

Tailcone Access Door

52-40-00

Nose

Oil Filler Access Door

52-40-10

Oxygen Bottle Access Door


(Nose Cylinder Oxygen System)
Oxygen Bottle Access Door
(Dorsal Cylinder Oxygen System)
Single-Point Pressure
Refueling Door
Main Landing Gear Doors
Nose Landing Gear Doors

52-40-15

9
10
11

Compartment Access Doors

Master Door

Figure

EFFECTIVITY:
SRM~

ALL

Subject

52-10-10

52-40-05

52-40-15

52-40-20
52-80-00

52-81-00

Repair Index

1 (Sheet 1 of 4)

52-00-00

Pagel
May 15/92

Learjet
Learie~l
STRUCTURAL REPAIR MANUAL
DOORS- STRUCTURAL IDENTIFICATION

\O

(MODEL 23 SERIES

It

TYPICAL)

(3

QOO

is
(MODEL 24 SERIES
Master Door

Figure
EFFECTIVITY:
SRM-4

NOTED

TYPICAL)

Repair Index

(Sheet 2 of 4)

52-00-00

Page 2
May 15/92

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


DOORS- STRUCTURAL IDENTTFICATION

000

(MODEL 25 SERIES

TYPICAL)

0000

(MODEL28/29 SERIES-TYPICAL)
Master Door

Figure
EFFECTIVITY:
srzM-4

NOTED

Repair Index

1 (Sheet 3 of 4)

52-00-00

Page 3
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
DOORS- STRUCTURAL IDENTIFICATION

6) (8) (8
1)

(3

00000

2)

~10)

(MODEL 31 SERIES

(4

TYPICAL)

6)
7)

(8

(3

0000

116

(MODEL 35/36 SERIES


Master Door

Figure
EFFECTIVITY:
SRM4

NOTED

TYPICAL)

Repair Index

1 (Sheet 4 of 4)

52-00-00

Page 4
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


PASSENGER/CREW UPPER DOOR

i.

STRUCTURAL IDENTIFICATION

DESCRIPTION
A.

passenger/crew door is located on the left side of the fuselage in the forward passenger compartment. The passenger/crew door can be either a 24-inch executive door or a 36-inch cargo door. The
door consists of an upper door assembly that forms a canopy when open, and a lower door assembly
with integral entrance steps.

The

a~

(5)

(1

8cz
o~be

6dd

2-2cne

Em~CTTVITY:
SRM4

FWD)

Passenger/Crew Upper (24 Inch) Door Structure Repair Index


Figure 1 (Sheet 1 of 6)
AIRCRAFT EQUIPPED WITH 24
PASSENGER/CREW DOOR

INCH

52-10-00

Page 1
May 15/92

~Learieil
STRUCTURAL REPAIR MANUAL
PASSENGER/CREW UPPER DOOR

STRUCTURAL IDENTIFICATION

C777>

44

Is

C>
o

~BG;I

I_

FWDI)

2-202C

EFFECTNITY:

Passenger/Crew Upper (24 Inch) Door Structure Repair Index


Figure 1 (Sheet 2 of 6)
AIRCRAFT EQUIPPED WITH 24

PASSENGER/CREW DOOR
SRM~

INCH

52-10-00

Page 2
May 15/92

Learjet

STRUCTURAL REPAIR WIANUAL


ITEM

NO.

DWG. I
NO.
I

I
DESCRIPTION

Passenger/Crew Upper
(24 Inch) Door Assembly

2411495

EFF.I

MATERIAL

IFINISH

REPAIR

I GAGE I CODE

FIG. NO.

2411496

Channel

2024-T42 Clad

0.050

2411496

2024-T42 Clad

0.050

2411496

Angle
Angle

2411496 1

Plate

2024-T42 Clad
2024-T3 Clad

0.050

4
5

2411496 1

Plate

2024-T3 Clad

0.100

1
1
1
1
1

2411496 1

Plate

2024-T3 Clad

0.100

Replace
Replace
Replace
Replace
Replace
Replace

2411496 1

Skin

2024-T3 Clad

0.040

51-70-02

2411496 1
241 1496 1

Door Jamb, Aft


Door Jamb, Fwd

S-552

S-552

10

2411496

Spacer

2024-T3 Clad

0.050

Replace

11

2411496

Frame

Assy.

0.063

I
I
I
I
I

2411496

Frame

2024-T42 Clad

0.050

51-70-03

2411496

Doubler

4130

SteelI~

0.050

51-70-03

2024-T42Clad

0.050

2024-T42 Clad

0.050

Replace
Replace

2411496

Clip

2411496

Stiffener

12

2411496

Channel

2024-T42 Clad

0.050

51-70-03

13

2411496

Channel

2024-T42 Clad

0.050

51-70-03

14

2411496

ChannelAssy.

2411496

Stiffener

2024-T42 Clad

0.040

51-70-03

2411496

Channel

2024-T42 Clad

0.050

51-70-03

15

2411496

Channel

2024-T42 Clad

0.050

51-70-03

16

2411496 1

Frame

2024-T42 Clad

0.050

51-70-03

17

2411496 1

Frame

2024-T42 Clad

0.050

51-70-03

18

2411496 1

Frame

2024-T42 Clad

0.050

19

2411496 1

Frame

2024-T42 Clad

0.050

20

2411496

ChannelAssy.

2024-T42 Clad

0.050

2024-T42 Clad

0.071

Channel

2411496
21

2411496

2411496
22

2411496

Support Assy.
Bracket(2ea.)
Support Assy.

51-70-03

51-70-03

Replace

1
1

Replace

2411496 1

Bracket

2024-T42 Clad

0.050

2411496 1

Plate

2024-T3 Clad

0.190

1
1

I
I

I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace

Replace

23

2411496

24

2311495

25

2311495

Angle
Angle
Angle

2411496

Angle
Angle

2411496

2411496

27

2411496 1

2024-T42 Clad

0.050

2024-T42 Clad

0.050

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

0.050
0.050

1
1
1

2024-T3 Clad

0.063

3
4

IShim, Laminated

26

2
3

Plate

0.050

4
4

Passenger/Crew Upper (24 Inch) Door Structure Repair Index


Figure 1 (Sheet 3 of 6)
EFFECTIVITY:

AIRCRAFT

EQUIPPED WITH 24 INCH

PASSENGER/CREW DOOR
SRM~

52-10-00

Page 3
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

NO.
28
29

DWG.
NO.

I
I

I
DESCRIPTION

EFF.

MATERIAL

I
IFINISH
CODE
I GAGE

REPAIR

FIG. NO.

2311495 1

Striker Plate

4130 Steel

0.080

2411496 1

Striker Plate

4130 Steel

0.180

1
1

I
I

Replace
Replace

2411496

Support Assy.
Bracket(2 ea.)

2024-T42 Clad

0.071

2024-T42 Clad

0.050

2024-T42 Clad

0.050

1
1

I
I

Replace
Replace
Replace

2024-T3 Clad

0.190

2024-142 Clad

0.080

1
1

I
I

Replace
Replace

Replace
Replace
51-70-03

2411496

30

2411496 1

31

2411496 1

Plate

32

2411496

CoverAssy.
Bearing

2411496
2411496 1
2411496

Plate

Cover

CoverAssy.
Bearing

2411496

AL Bronze

L~

2411496

Cover

2024-T42 Clad

0.080

33

2411496

Channel

2024-T42 Clad

0.050

34

2411496

Channel

2024-T42 Clad

0.050

51-70-03

35

2411496 1

Channel

2024-T42 Clad

0.050

51-70-03

36

2411496 1

Channel

2024-T42 Clad

0.050

51-70-03

37

2411498

Frame

Stiffener

2024-T42 Clad

0.040

Replace

Doubler

4130 Steel~

0.050

51-70-04

6
6

2024-T42 Clad

0.050

2411496 1
2411496

Doubler

4130 Steel~

0.050

51-70-04

2024-T42 Clad

0.050

Replace

2024-T3511

0.250

Replace

1
1

Replace
Replace

Support Assy.
Bracket

Support Assy.
Plate

Replace

5
5

Support Assy.

2411496

2411496

Bracket

2024-T42 Clad

0.050

2411496

Plate

2024-T3 Clad

0.080

2024-T42 Clad

0.071

2024-T3 Clad

0.100

I
I

Replace
Replace

2024-T42 Clad
2024-T3 Clad

0.071

Replace

0.100

Replace

2024-T42 Clad

0.071

Replace

2024-T42 Clad
2024-T3 Clad

0.071

2411496

2411496
2411496 1

1 2411496
2411496

42

2411496

43

2411496

Plate

Plate

2411496
2411496

Plate

Bracket

1
1

Support Assy.
Bracket(2ea.)
Support Assy.
Bracket(2ea.)

2411496

2411496

Support Assy.
Bracket(2ea.)

SupportAssy.
Bracket(2ea.)

2411496

44

Assy.

Frame

2411496

41

Frame

2411496

2411496

40

2411496

2411496 1

39

2411496 1
2411496

38

Assy.

1
1

1
1
1

Assy.

0.100

1
1

I
I

Replace
Replace
Replace
Replace

2411496

Zee

4130 Steel

0.050

2411496

Plate

4130 Steel~

0.050

Passenger/Crew Upper (24 Inch) DoorStructure Repair Index


Figure 1 (Sheet 4 of 6)
EFFECTTVITY:
sRM-a

AIRCRAFT EQUIPPED WITH 24


PASSENGER/CREW DOOR

INCH

52-10-00

Page 4
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

NO.
45

DWG.
NO.

2411496

I
DESCRIPTION
Bracket

EFF.I

Assy.

MATERIAL

IFINISH
GAGE

REPAIR
FIG. NO.

CODE

2411496

Zee

4130 Steel~

0.050

2411496

Plate

4130 Steel~

0. 050

1
1
1
1

I
I
I
I

46

2411491

Center Pin Guide

4139 Steel

0.100

47

2411494 1

Pin Guide

4139 Steel

0.100

48

2411494 1

Pin Guide

4139 Steel

0.100

49

2311502 1

Clevis

2024-T3 Clad

0.040

50

2311502

Guide

2024-T3 Clad

0.040

51

2311502

2024-T3 Clad

0.040

52

2311495

2024-T42 Clad

0. 050

53

2311495

Phenolic

0.312

54

2311278

Clip
Splice Plate
Spacer
Hinge Arm

4130 Steel~

0.250

55

2411497

Guide

4130

Steell~

0.880

56

2411497

Guide

4130 Steel~

0.880

57

2411496

Doubler

Assy.

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2411496

Bracket(2ea.)

2024-T42 Clad

0.050

2411496 1

Doubler

2024-T42 Clad

0.050

Spacer

2024-T3 Clad

0.063

58

2411493

Guide

4130 Steel~

0.190

59

2411493

Guide

4130

Steel~

0.190

Replace
Replace
Replace
Replace
Replace

60

2411496

2024-T42 Clad

0.080

Replace

2024-T42 Clad

0.080

2024-T42 Clad

0.080

Replace

2024-T42 Clad

0.080

Replace

2024-T42 Clad

0.080

Replace

2024-T42 Clad

0.080

Replace

2024-T42 Clad

0.080

Replace

2411472

Support Assy.
Bracket(2ea.)
Support Assy.
Bracket(2 ea.)
Support Assy.
Bracket(eea.)
Support Assy.
Bracket(2ea.)
Support Assy.
Bracket(2 ea.)
Support Assy.
Bracket(2ea.)
Support Assy.
Bracket(2ea.)
Support Assy.
Bracket(2ea.)

2024-T42 Clad

0.080

Replace

2411499 1

Inner Skin

2024-T3 Clad

0.032

51-70-02

2411496

2411496
2411472
2411472
61

1 2411496 1
2411496
2411472
2411472

62

2411496

2411496
2411472

1
1
1

2411472
63

2411496
2411496

2411472
64

Passenger/Crew Upper (24


Figure
EFFECTIVITY:
SRM~

5
6
6

Replace

5
5

6
6
5
5

6
6
5
5

Inch) Door Structure Repair Index


1 (Sheet 5 of 6)

AIRCRAFT EQUIPPED WITH 24


PASSENGER/CREW DOOR

INCH

52-10-00

Page

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
EFFECTIVITIES

CODES

24-272, 24-295 THRU 24-357; 25-134, 25-168 THRU 25-373; 28-003 THRU 28-005; 29-001 THRU
29-004; 35-002 AND SUBSEQUENT; 36-001 AND SUBSEQUENT
24-304 THRU 24-357; 25-187 THRU 25-373; 28-003 THRU 28-005; 29-001 THRU 29-004; 35-017
AND SUBSEQUENT; 36-007, 36-009 AND SUBSEQUENT
24-272, 24-295 THRU 24-303; 24-309 THRU 24-314; 25-134, 25-168 THRU 25-186; 35-002 THRU
35-016; 36-001 THRU 36-006 AND 36-008
24-304 THRU 24357; 25-187 THRU 25-373; 28-003 THRU 28-005; 29-001 THRU 29-004; 35-017
AND SUBSEQUENT; 36-007, 36-009 AND SUBSEQUENT
24-272, 24-295 THRU 24-334; 25-134, 25-168 THRU 25-208; 35-002 THRU 35-084; 36-001 THRU

1
2
3
4
5

36-021
24-335 THRU

AND

24-357; 25-209 THRU 25-373; 28-003 THRU 28-005;


SUBSEQUENT; 36-022 AND SUBSEQUENT

29-001 THRU 29-004; 35-085

NOTES
Shims may be used between stiffeners and door skin and between bracket flanges and door skin,
improve door skin contour. Refer to Approved Repairs for fabrication and usage of shims.

as

required,

to

Laminated shim stock, 0.002


num sheet.

or

0.003 lamination per MlL-S-22499

Heat Treat to 125,000

140,000 psi.

Heat Treat to 125,000

145,000 psi.

Heat Treat to 180,000

200,000

Type

1 Class 1

or

Class 2 1145-H19 alumi-

psi.

Aluminum bronze per AMS4640.

Condition Annealed

Type

FBG per MIL-P-15035.

Passenger/Crew Upper (24


Figure

EFFECTIVITY:
SRM-4

Inch) Door Structure


1

AIRCRAFT EQUIPPED WITH 24


PASSENGER/CREW DOOR

Repair Index

(Sheet 6of 6)

INCH

52-10-00

Page 6
May 15/92

Learjet 1

STRUCTU RAL REPAIR MANUAL


PASSENGER/CREW UPPER DOOR

STRUCTURAL IDENTIFICATION

33~

13

22)

(10

n)

2-141B2

EFFECTIVITY:
SRMII

~2

Passenger/Crew Upper (36 Inch) Door Structure Repair Index


Figure 2 (Sheet 1 of 5)
AIRCRAFT EQUIPPED WITH 36
PASSENGER/CREW DOOR

INCH

52-10-00

Page 7
May 15/92

STRUCTURAL REPAIR MANUAL


PASSENGER/CREW UPPER DOOR

00

STRUCTURAL IDENTIFICATION

00

oO
00

OO

(3~
O

oC)o

oo

FWDI)

2-141B1

Passenger/Crew Upper (36

Inch) Door Structure

Repair Index

Figure 2 (Sheet 2 of 5)
EFFECTIVITY:
SRM4

AIRCRAFT EQUIPPED WITH 36 INCH


PASSENGER/CREW DOOR

52-10-00

Page 8
May 15/92

Leariet
Learjet

STRUCTURAL REPAIR MANUAL


ITEM

NO.

DWG.
NO.

EFF.

Passenger/Crew Upper
(36 Inch) Door Assy.

2311495
1

I
DESCRIPTION

IFINISH

I GAGE

MATERIAL

REPAIR
FIG. NO.

CODE

2311495 1

Skin

2024-T42 Clad

0.040

51-70-02

2311495

Skin

2024-T42 Clad

0.040

2311495 1

Frame

2024-T42 Clad

0.050

1
1

1
1

51-70-03

2311495 1

Frame

2024 Clad

0.050

51-70-03

2311495

4130

0.050

Replace

2311495

1
1

I
I

2311495

Plate

Splice
Splice Plate Assy.
SplicePlate
Angle
Splice Plate

Steell~

51-70-02

5
5

4130 Steel

4130

Steell~

0.050

0.050

2311495

2024-T42 Clad

2311495 IStiffener

S-554

Replace
Replace
Replace
Replace

2311495 1

Channel

2024-T3 Clad

0.040

51-70-03

2311495 1

Stiffener

2024-T42 Clad

0.050

51-70-03

2311495 IStiffener

S-554

2311495 IStiffener

S-554

10

2311495

S-554

1
1
1

51-70-04

I
I
I

11

2311495

2311495

Stiffener

2311495

Bracket

Assy.
Bracket(2ea.)

0.050

1
1
1

1
1

2024-T42 Clad

0.050

Replace

2024-T42 Clad

0.050

51-70-03

51-70-04

I
I
I
I

Replace
Replace
Replace
Replace
Replace

12

2311495 1

13

2311495 IStiffener

3-554

14

2311495

Channel

S-554

2311495

Channel

2024-T3 Clad

0.040

Gusset

2024-T3 Clad
2024-T3 Clad

0.050

Rocker Arm

2024-T3 Clad

0.080

1
1
1

2024-T3 Clad
2024-T42 Clad

0.100

0.050

Phenolic

0.375

15

2311495

16

2311495
2311495

17

2311495

1
1
1

Support
Rocker Arm Support
Support Assy.

2311495

Disc
Bracket

2311495
18

Frame

2311495

BearingPlate
CoverAssy.

1 2311495

51-70-04
51-70-04

0.050

1
1

Replace
Replace
Replace

2311495

Cover

2024-T42 Clad

0.080

2311495

Disc

2024-T3 Clad

0.190

1
1

I
I

Clip

2024-T3 Clad

0.050

Replace
Replace
Replace

Exterior Handle Instl.

1
1
1
1

I
I
I

Replace
Replace
Replace
Replace

19

2311495

20

2311678 1

2311678 IPan

2311678
2311678 1

6061-T6

0.050

End Pan (2 ea.)


Doubler

6061-T6

0.050

2024-T3 Clad

0.063

2024-T3 Clad

0.050

0.050

0.050

1
1

1
1

51-70-03

2024-T42 Clad
2024-T42 Clad

2024-T42 Clad

0.050

51-70-03

21

2311495

22

2311495 1

23

2311495

Rocker Arm Support


Frame
Channel

24

2311495 1

Frame

51-70-03

Passenger/Crew Upper (36 Inch) Door Structure Repair Index


Figure 2 (Sheet 3 of 5)
EFFECTIVITY:
srzh~-a

AIRCRAFT EQUIPPED WITH 3~ INCH


PASSENGER/CREW DOOR

52-10-00

Page 9
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ITEM
NO.

DWG.
NO.

25

2311495

Splice Plate
SpliceAngle Assy.
SpliceAngle
Angle
Guide Pin Assy.

2311495
2311495
2311495
26

27

I
DESCRIPTION

2311271

EFF.

MATERIAL

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

Steell~

0.050

4130 Steel~

0.050

4130 Steel~

0.050

1
1

4130

Replace

2311271

Cover

2024-T42 Clad

0.080

2311271

Disc

2024-T3 Clad

0.190

2311495 1

Bracket

2024-T3 Clad

0.050

2311495

Stiffener

2024-T3 Clad

0.050

2311271

Plate, Fwd 6 Aft Upper

4130 Steel~

0.100

1
1
1
1
1

I
I
I
I

2311495 1

Bracket

2024-T3 Clad

0.050

28

2311495 1

Frame

2024-T3 Clad

0.050

29

2311495 1

Lower Channel

2024-T42 Clad

0.050

1
1

I
I

I
I
I
I

30

2311495 1

Forward Door Jamb

S-552

2311495

Aft DoorJamb

S-552

Lower

2024-T3 Clad
2024-T3 Clad

0.100

Edge

31

2311495

32

2311495

Bracket

33

2311495 1

Bracket

2024-Tr12 Clad

0.050

1
1

34

2311495 1

Doubler

301 Stainless

0.040

35

2311502

ClevisPin BracketAssy.

10

2024-T3 Clad

0.063

Clip

10

0.040

I
I

2311502

Clevis

10

Guide

10

I
I

2311502

2024-T3 Clad
4130 Steel
4130 Steel

1
1

2311502

Plate

Replace
Replace

0.063

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

36

2311499 1

Inner Skin

2024-T42 Clad

0.032

51-70-02

37

2311499

Stiffener

2024-T42 Clad

0.040

38

2311499

Cover

2024-T3 Clad

0.032

Replace
Replace

Passenger/Crew Upper (36 Inch) Door Structure Repair Index


Figure 2 (Sheet 4 of 5)
EFFECTIVITY:
sRM-a

AIRCRAFT EQUIPPED WITH 36


PASSENGER/CREW DOOR

INCH

52-10-00

Page 10
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
EFFECTIVITIES

CODES

23-002 THRU 23-099; 24-100 THRU

24-357; 25-002 THRU 25-373; 35-002 AND SUBSEQUENT;

36-001 AND SUBSEQUENT

23-003 THRU 23-008


23-009 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-373; 35-002 AND SUBSEQUENT;
36-001 AND SUBSEQUENT
23-002 THRU 23-090; 24-100 THRU 24-169; 25-002 THRU 25-010
24-170 THRU 24-357; 25-011 THRU 25-061, 25-067 THRU 25-373; 35-002 AND SUBSEQUENT;

3
4
5

36-001 AND SUBSEQUENT

24-344 THRU 24-357; 25-219 THRU 25373; 35-101 AND

SUBSEQUENT;

36-030 AND SUBSE-

SUBSEQUENT;

36-018 AND SUBSE-

QUENT
24-327 THRU 24-357; 25-002 THRU 25-373; 35-059 AND

QUENT
23-014 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25373; 35-002 AND SUBSEQUENT;
36-001 AND SUBSEQUENT
23-060 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-373; 35-002 AND SUBSEQUENT;
36-001 AND SUBSEQUENT
24-100 THRU 24-357; 25-002 THRU 25-373; 35-002 AND SUBSEQUENT; 36-001 AND SUBSE-

8
9

10

QUENT

NOTES:
Condition Annealed.

I~

Heat Treat to 125,000

Type

145,000 psi.

FBG per MIL-P-15035.

Condition 1/2 Hard.

Passenger/Crew Upper (36 Inch) Door Structure Repair Index


Figure 2 (Sheet 5 of 5)
EFFECTIVITY:

AIRCRA~ EQUIPPED WITH 36


PASSENGER/CREW DOOR

INCH

52-10-00

Page 11
May 15/92

Learjet
~Learjet
STRUCTURAL REPAIR MANUAL
PASSENGERICREW UPPER DOOR
i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS

All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose

or

failed rivets

are

not allowed. A loose or failed rivet can cause increased stress concentra-

progressive joint failure. A careful inspection must be


performed to ensure that joint failure has not spread from the area of the loose or failed rivet. (Refer to Chapter 51 for definition of rivet failure.)
tions

the

on

(2) Loose

or

remaining

failed

rivets and lead to

screws are

not allowed. A loose or failed screw can cause increased stress concen-

surrounding screws and lead to progressive joint failure. A careful inspection must be
performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
trations

B.

on

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired, and refinished in accordance


C.
D.

re-

Chapter 51.

Deformation

(1) Deformation of the primary door assembly structure or door hinges is not allowed.
Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

with

more

than

specified.

Dents

(1) Dents

are

permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
depth, do not exceed 10% of total surface area in one (1) square foot, and are not

(2.54 mm) in

closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component reF.

G.

H.

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(See Figure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
Structural
(2)
components must be replaced or repaired if nicks reduce the original material thickthan
ness more
specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTIVITY:
SRM-4

ALL

52-10-00

Page 101
May 15/92

STRUCTURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0,100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFFECTIVITY:
SRM4

ALL

101

52-10-00

Page 102
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


PASSENGER/CREW UPPER DOOR
i.

APPROVED REPAIRS

NOTE:

All dimensions

Refer to

B.

Refer to the basic


for door

C.

are

in inches unless otherwise

specified.

Chapter 51 for typical repairs for the passenger/crew upper door structure.
Learjet Maintenance Manual, Chapter 52, for repairs and maintenance procedures

A.

bar

components

such

as

door seals, door latch mechanism, door hook

mechanism, and

torsion

assembly.

Skin gap tolerance between the passenger/crew door skin and fuselage skin is 0.030-inch (0.762 mm)
minimum to 0.0B0-inch (1.524 mm) maximum around perimeter of door (see Figure 201).

(TWICAL FOR 24

EFFECTIVIIY:

INCH OR 36

0.030

Inch Minimum

0.060

Inch Maximum

INCH DOOR)

Door Skin

Gap Tolerances
Figure 201

2-146A

SRM~I

REPAIR

ALL

52-10-00

Page 201
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


CONDITION

Out-of-Contour condition

1.

can

exists when door skin is secured in

place and

door is dented.

LIMITATIONS
1.

Out-of-Contour

2.

Maximum thickness of shim may not exceed 0.063 inch (1.6 mm).
Dents may or may not cause deformation of the door substructure which affects the structural

area

may not exceed 12.0 inches (304 mm) in

length by 0.080

inch (2.03 mm) in

depth.
integri-

ty of the door.
REPAIR

6.

length and depth of area to be shimed.


a shim of proper length, thickness and taper, from 2024-T3 aluminum sheet.
Apply one (1) coat epoxy primer to shim.
Apply faying surface seal to both sides of shim. (Refer to Chapter 51.)
Slid~ shim into place.
Drill proper size holes from skin side through shim.

7.

InstallMS20426AD fasteners.

8.

Paintaffected

i.

Determine

2.

Fabricate

3.
4.

5.

areas.

Door Stiffeners

(Ref)

Door Frame

(Ref)

Door Skin

(Ref)

,i,

Outside
Door Skin
Contour
Door Frame

(Normal)

(ReO

Detail A
2-153A

EFFECTTVITY:
SRM-4

Upper Door Skin Repair


Figure 202

Out-of-Contour

ALL

52-10-00

Page 202
May 15/92

Learjet
~LBarjet
STRUCTURAL REPAIR MANUAL
PASSENGER/CREW LOWER DOOR

1.

STRUCTURAL IDENTIFICATION

DESCRIPTION
A.

passenger/crew door is located on the left side of the fuselage in the forward passenger compartment. The passenger/crew door can be either a 24-inch executive door or a 36-inch cargo door. The
door consists of an upper assembly that forms a canopy when open, and a lower door assembly with
integral entrance steps.
The

1
o

20r

-1)
~!II

I"

ol~d

32r

2-2000

EFFECTIVITY:
SRM-4

Passenger/Crew Lower (24 Inch) Door Structure Repair Index


Figure 1 (Sheet 1 of 4)
AIRCRAFT EQUIPPED WITH 24
PASSENGER/CREW MX)R

INCH

52-10-10

Page 1
Jun 1/95

Inarpt
~Learjetl
STRUCTURAL REPAIR MANUAL
PASS~ENGER/CREW LOWER DOOR

STRUCTURAL IDENTIFICATION

~7 cl
II

0/

(25

(AF]T E~D

LOOKING AFT)

(FWD END

~s

Detail A

LOOKING FWD)

DetailB

,o

,e

21

(VIEW LOOKING AFT)

(VIEW LOOKING FWD)

DetailC

DetailD

2aOOC

Passenger/Crew Lower (24

Inch) Door Structure

Repair Index

Figure 1 (Sheet 2 of 4)
EFFECTIVITY:
SRM~

AIRCRAFT EQUIPPED WITH 24


PASSENGER/CREW DOOR

INCH

52-10-10

Page 2
May 15/92

Lsarjet i
~I Leariet

STRUCTURAL REPAIR MANUAL


ITEMI
NO.

DWG.

NO.

Passenger/Crew Lower
(24 Inch) Door Assy.

2411250

I
MATERIAL

EFF.

DESCRIPTION

GAGE

IFINISHI REPAIR
CODE
FIG. NO.

1
1

2024-T42 Clad

0.040

2024-T3 Clad

0.080

F4-6

2511271

Skin, Outer
Skin, Inner
Shim, Laminated (Max. 0.032)
Angle(3 ea.)

2024-T42 Clad

0.050

F4-6

F4-6

2411250

2411250

2411250

51-70-02

2511271

Clip

2024-T42 Clad

0.050

2511271

2024-T3 Clad

0.063

2511271

Cover (2 ea.)
Bracket

4130 Steel

0.063

2511271

Doubler

12024-T3Clad

0.050

2511271

Cover

2024-13 Clad

0.032

2511271

CoverAssy.

2511271

Cover

2024-T3 Clad

2511271

Stiffener

S654

2511271

Stiffener

10

2511271

Stiffener

11

2511271

12

13

F4-6

F4-6

0.032

I
F4-6

F4-6

S-554

F4-6

S-554

F4-6

Stiffener

5654

F4-6

2511271

Stiffener

S-554

F4-6

2511271

Strap

2024-T42 Clad

0.063

F4-6

14

2511271

2024-T42 Clad

2311216

0.050
0.063

F4-6

15

Seal Retainer
Doubler

o.loo

F4a

0.050

F4-6

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.050

F4-6

51-70-04

2311216

ISpacer

2024-T3 Clad
12024-T3Clad

16

2311216

Bracket

2024-T3 Clad

0.032

17

2311273

Latch Arm

4130 Steel

0.125

18

2311666

2024-T42 Clad

0.063

F4-6

19

2411276

Angle(2ea.)
Angle(2ea.)
Clip(2 ea.)
Spring
Hinge
Fitting

2024-T42 Clad

0.050

F4-6

2024-T42 Clad

0.050

F4-6

Music wire

0.042

2411276
20

2411276

21

2511297

22

2511297

23

2411276

MS35821-2A

4130 Steel

Plate

4130 Steel

Cover

2024-T3 Clad

24

2511271

Frame

2024-T42 Clad

25

2511271

Stiffener

S-554

26

2511271

Frame

2024-T42 Clad

2411232

Frame

2511271

2411230

Support
Support

27
28
29

Replace
Replace
Replace
Replace
Replace
Replace
Replace

Replace
Replace
Replace

F4-6

2411276

51-70-02

F4-6
F4-6

I
F4-6

Replace

0.050

F4-6

51-70-04

2024-T42 Clad

0.050

F4-6

51-70-04

2024-T42 Clad

0.050

F4-6

2024-T42 Clad

0.050

F4-6

Replace
Replace

2511271

Frame

2024-T42 Clad

0.050

F4-6

51-70-04

2411231

Frame

2024-T42 Clad

0.050

F4-6

51-70-04

2511271

Support
Support
Angle (2ea.)

2024-T42 Clad

0.050

F4-6

2024-T42 Clad

0.050

F4-6

2024-T3 Clad

0.063

F4-6

Replace
Replace
Replace

2411230

2411233

Passenger/Crew Lower (24 Inch) Door Structure Repair Index


Figure 1 (Sheet 3 of 4)
EFFECTIVITY:
SRM-I

AIRCRAFT EQUIPPED WITH 24


PASSENGER/CREW DOOR

INCH

52-10-10

Page 3
Jun 1/95

Learjet
~Learjetl

STRUCTURAL REPAIR MANLIAL


ITEM
NO.

FINISH

DWG.
NO.

DESCRIPTION

EFF.

MATERIAL

30

2511271

Doubler

2024-T3 Clad

31

2511271

DoorJamb

S-552

2511271

Bracket Assy.
Bracket

2511271

32

Plate

2511211
33
34

0.050

CODE
F4-6

F4-6

REPAIR
FIG. NO.

Replace
Replace

2024-T42 Clad

0.063

F4-6

2024-T3 Clad

0.100

F4-6

Replace
Replace

2511271

Frame

2024-T42 Clad

0.050

F4-6

51-70-04

2511271

Frame

2024-T42 Clad

0.050

F4-6

51-70-04

2511271

DoorJamb

S-552

F4-6

2511271

Filler

2024-T42 Clad

0.100

F4-6

Filler

2024T3 Clad

0.160

F4-6

Replace
Replace
Replace
Replace
Replace
Replace

2511271

2511282

35

GAGE

25~1282
2511282

CODES

HingeAssy., LowerDoor
Hinge(2 ea.)
Hinge Pin

1
1

F176

EFFECTIVITIES
24-272, 24-295 THRU 24-357; 25-134, 25-168 THRU 25-373; 35-002 AND SUBSEQUENT; 36-001
AND SUBSEQUENT
24-272, 24-295 THRU 24-314; 25-134, 25-168 THRU 25-189; 35-002 THRU 35-020; 36-001 THRU

36-013
3

24-272, 24-295 THRU 24-357; 25-134, 25-168 THRU 25336; 35002 THRU 35-392; 36-001 THRU

25-337 AND

24-350 THRU 24-357; 25-227 THRU 25-373; 35-1 17 AND SUBSEQU ENT; 36-033 AND SUBSE-

36-047

SUBSEQUENT; 35-393 AND SUBSEQUENT; 36-048 AND SUBSEQUENT

QUENT

NOTES:

F4-Glnterior, F4Exterior.
Laminated shim stock, 0.902
sheet.

or

0.003 lamination per MlL-S-22499

Type

1 Class 1 or Class 2 1145-H19 alumi-

num

Condition Annealed.
HeatTreatto 150,000 -180,000

psi.

HeatTreatto 125,000 -150,000

psi.

HeatTreatto125,000- 145,000psi.
MadefromA151321 or347.

Madefrom

MS202536pin.

Passenger/Crew Lower (24 Inch) Door Structure Repair Index


Figure 1 (Sheet 4 of 4)
EFFECTIVITY:
SRM-4

AIRCRAFT EQUIPPED WITH 24


PASSENGER/CREW DOOR

INCH

52-10-10

Page 4
Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


PASSENGER/CREW LOWER DOOR

1.

STRUCTURAL IDENTIFICATION

DESCRIPTION
A.

passenger/crew door is located on the left side of the fuselage in the forward passenger compartpassenger/crew door can be either a 2Pinch executive door or a 36-inch cargo door. The
door consists of an upper assembly that forms a canopy when open, and a lower door assembly with
integral entrance steps.
The

ment. The

~dS:

A:

2-198C

Passenger/Crew Lower (36 Inch) Door Structure Repair Index


Figure 2 (Sheet 1 of 8)

EFFECTIVITY:

AIRCRAE~ 23-002 THRU 23-099; 24-100 THRU 24-229; 25-002 THRU


INCH PASSENGER/CREW DOOR

25-060 EQUIPPED WITH 36


SRM-4

52-10-10

Page 5
Tun 1/95

Learjet
STRUCTURAL REPAIR MANUAL
PASSENGER/CREW LOWER DOOR

5)

I1

STRUCTURAL IDENTIFICATION

~19

oS

~i
o~
(AFT END

P~ d

LOOKING FWD)

Detail B
(FWD END

LOOKING APT)

Detail A
~Y

r;
9)

@i\

o/

uy

0)

(VIEW LOOKING EUID)

(VIEW LOOKING APT)

(VIEW LOOKING AFT)

DetailC

DetailD

DetailE

2-19ec

EFFECTnrITY:

Passenger/Crew Lower (36 Inch) Door Structure Repair Index


Figure 2 (Sheet 2 of 8)
AIRCRAFT 23-002 THRU 23-099; 24-100 THRU 24-229; 25-002 THRU
25-060 EQUIPPED WITH 36

SRM-4

(10

INCH PASSENGER/CREW DOOR

52-10-10

Page 6
Jun 1/95

Leariet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

Passenger/Crew Lower
(36 Inch) Door Assy

2311270

I
EFF.

DESCRIPTION

I
MATERIAL

IFINISH

1
1

2024-T42 Clad

S-552

S-552

2311275

Skin, Outer
DoorJamb, Fwd
DoorJamb, Aft
Filler (2 ea.)

2024-T3 Clad

0.100

2311275

Filler

2024-T3 Clad

0.160

2311275

Stiffener(2 ea.)

S-554

2311275

Stiffener

S654

2311271

Guide,

4130 Steel

2311271

Plate

4130 Steel

0.100

1
1

2311275

2311275

2311275

REPAIR
FIG. NO.

CODE

I GAGE

Pin

0.040

1
1

1~

51-70-02

I
I

I
I

1
1

I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

I
0.100

2311275

2024-T42 Clad

0.050

51-70-04

2311275

Support, Fwd
Support, Aft

10

2024-T42 Clad

0.050

51-70-04

11

2311275

End Frame, Fwd

2024-T42 Clad

0.050

51-7004

12

2311275

Frame(2 ea.)

2024-T42 Clad

0.050

2311275

Plate

2024-T3 Clad

0.050

1
1

/2024-T3Clad

0.050

IClip

231 1275

13

2311275

Stiffener

S-554

14

2311275

Cover

2024-T3 Clad

0.032

2311275

Plate

2024-T3 Clad

0.125

15

2311275

Skin, Inner

2024-T3 Clad

0.080

1
1

I
I

16

2311275

Doubler

2024-T3 Clad

0.050

2311275 1

Plate

2024-T3 Clad

0.025

1
1

I
I

2024-T42 Clad

0.080

0.032

2311275
17

18

19

20

Pan, SeatRail

1 2311275

Cover

2311275

Angle

2311275

Frame

2024-T3 Clad
2024-T42 Clad
2024-T42 Clad

2311275

Seat Rail

S-537

2311275

Switch Bracket

2311275

Gusset (2ea.)

2311275

2311275

Clip
Clip

2311275

2311275
2311275
2311275

I
i

0.050

0.050

1
I

I
I

2024-T42 Clad

0.050

2024-T3 Clad

0.063

2024-T42 Clad

0.050

2024-T42 Clad

0.050

Cover

2024-T3 Clad

0.063

1
1

CoverAssy.

2024-T3 Clad

0.032

Cover

Shim, Laminated (Max. 0.032)

4~

2311275

Plate

2024-T3 Clad

21

2311275

Stiffener(2 ea.)

S-554

22

2311275

Channel

2024-T3 Clad

0.080

1
0.080

1
I
1

I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Passenger/Crew Lower (36 Inch) Door Structure Repair Index


Figure 2 (Sheet 3 of 8)
EFFECTIVITY:

AIRCRAFT 23-002 THRU 23-099; 24-100 THRU 24-229; 25-002 THRU

25-060
SRM-I

EQUIPPED

WITH 36

INCH PASSENGER/CREW DOOR

52-10-10

Page 7
Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


FINISH
CODE

REPAIR
FIG. NO.

ITEM

DWG.

NO.

NO.

23

2311661

Bracket

2024-T42 Clad

0.063

Replace

2311663

Pulley Support

2024-T42 Clad

0.050

2311664

2024-T42 Clad

0.063

2311666

Clip
Angle(4ea.)

2024-T3 Clad

0.063

2311673

Doubler

2024-T3 Clad

0.063

2311663

Pulley Support

2024-T42 Clad

0.050

2311275

Frame

2024-T42 Clad

0.050

2311275

Plate

2024-T3 Clad

0.063

2311275

Angle(2ea.)

2024-T42 Clad

0.050

2311501

End Frame, Aft

2024-T42 Clad

0.050

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2311275

Hinge

MS35821-2A

2311275

Spring

Music Wire

0.042

Cover

2024-T3 Clad

0.063

24
25

26

DESCRIPTION

27

2311275

28

2411282

2411282
2411282

CODES

HingeAssy., LowerDoor
Hinge(2 ea.)
Hinge Pin

EFF.

MATERIAL

F17-6

F176

23-002 THRU 23-008

23-009 THRU 23-099; 24-100 THRU 24-229; 25-002 THRU 25-060


23-003 THRU 23-099; 24-100 THRU 24-229; 25-002 THRU 25-060
24-140 THRU 24-229; 25-002 THRU 25-060

Replace
Replace

EFFECTIVITIES
23-002 THRU 23-099; 24-100 THRU 24-229; 25-002 THRU 25-060
23035 THRU 231)39

Replace
Replace
Replace
Replace

GAGE

NOTES:

Laminated shim stock, 0.002


sheet.

or

0.003 lamination per MlL-S-22499

Type

1 Class 1

or

Class 2 1145-H19 alumi-

num

Heat Treat to 125,000

I~

145,000 psi.

MadefromA151321 or347.
Madefrom

MS20253-5pin.

Passenger/Crew Lower (36 Inch) Door Structure Repair Index


Figure 2 (Sheet 4 of 8)
EFFECTIVITY:

AIRCRAFT 23-002 THRU 23-099; 24-100 THRU 24-229; 25-002 THRU


INCH PASSENGER/CREW DOOR

25-060 EQUIPPED WITH 36


SRM-4

52-10-10

Page 8
Jun 1/95

Learjet
~jLearjet
STRUCTURAL REPAIR MANUAL
PASSENGER/CREW LOWER DOOR

STRUCTURAL IDENTIFICATION

~an\
26

g*~B
(Airmaft 24-320 thru 24-357: 25-261 th~u 25373; 28-002 thru 28-005: 29-001 thru 29-004: 31-002 and Subseauent: 35-002 and Subseauent: 36-001 and Subseauent. eaainned with 36 Inch PassenperlCrew Door)

2-197C

EFFECTIVITY:

Passenger/Crew Lower (36 Inch) Door Structure Repair Index


Figure 2 (Sheet 5 of 8)
NOTED

52-10-10

Page9
SRM-I

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


PASSENGER/CREW LOWER DOOR

STRUCTURAL IDENTIFICATION

~B

1"1

"o

6)

j/

O 1,
LI

(FWD END

(3

LOOKING AFT)

(AFT END

Detail A

LOOKING FWD)

DetailB

(VIEW LOOKING FWD)

Detail C
(Aircrafl 24320 thru 24-357: 25-261 thru 25-373: 2&001 thvu 28-005: 29-002 thru 29-004.: 31-002 and Subseauent: 35-002 and Subseauent: 36-001 and Subseauent. eauirttled wifh 36 Inch PassenaerlCrew Door)
2-197(3

Passenger/Crew Lower (36

Inch) Door Structure Repair Index

Figure 2 (Sheet 6 of 8)

EFFECTIVITY:

NOTED

52-10-10

Page
SRM-4

10

Jun 1/95

~j Learjet
STRUCTURAL REPAIR NIANUAL
ITEM( DWG.
NO.

I
EFF.

DESCRIPTION

NO,

PassengerlCrew

2411234

MATERIAL

(FINISH( REPAIR

Lower

2411234

2411234

(36 Inch) Door Assy.


Skin, Outer
Skin, Inner

2311216

2311216

1
1

2024-T42 Clad

0.040

51-70-02

2024-T3 Clad

0.080

51-70-02

Doubler

2024-T3 Clad

0.063

Bracket

4130 Stainless

2024-T3 Clad
2024-T3 Clad

0.032

I
I

Replace
Replace
Replace
Replace

I
I
I

Replace
Replace
Replace

51-70-04

2311216

Spacer

2311216

Bracket

2311661

BracketAssy.

0.100

Bracket

2024-T42 Clad

0.063

2024-T3 Clad

0.063

2311666

Angle (2ea.)
Angle(2ea.)

1
1

2024-T3 Clad

0.063

1
1
1

2411273

Frame, Aft

2024-T42 Clad

0.050

2411274

Actuator

2024-T3 Clad
2024-T42 Clad

0.063

2311661

2311666

10

Support Assy.

Gusset(2ea.)

11

2411274

12

2411277

1
1

13

2411276

Frame, Fwd
Stiffener(2 ea.)

S-554

14

2411276

Stiffener

S-554

15

2411276

Stiffener(2 ea.)

2411276

0.050

1
1

16

2411276

Seal Retainer
Filler

S-554
2024-T42 Clad
2024-T42 Clad

17

2411276

Angle(2 ea.)

2024-T42 Clad

0.050

18

2411276

Filler(2 ea.)

0.100

19

2411276

Doubler

2024-T3 Clad
2024-T3 Clad

20

2411276

Cover

2024-T3 Clad

21

2411276

Cover

2411276

Cover

2411276

CoverAssy.

22

2411276

2411276
2411276
2411276
2411276

I
1
1

I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace

2024-T3 Clad

0.063

Replace

2024-T3 Clad

0.032

Replace

0.032

I
I
I
I

Replace
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.050

2024-T3 Clad
6061-T6

Clip, Fwd
Clipi Aft
Hinge Assy.
Hinge
Spring

2024-T42 Clad

0.050

2024-T42 Clad

0.050

0.042

I
1
1

I
I
I
I

1
1

I
I

MS35821-2A

Music Wire

Plate

2024-T3 Clad

Angle
Clip (2 ea.)

S-606

Support
Clip(2 ea.)

Replace
Replace

2411276

2411276

0.063

2411276

I
I
I

24

2411276

51-70-04

1
1
1

23

2411276

0.050

Replace

RecessHandle

2411276

0.050

I
1

Cover

2411276

25

CODE I FIG. NO.

I GAGE

I
0.063

2024-T3 Clad

0.050

2024-T42 Clad

0.080

2024-T3 Clad

0.050

(Aircraft 24-320 thru 24357: 25-261 thru 25-373: 28-001 thre 28-005: 29-001 thru 29-004.: 31-002 and Subsewith 36 Inch PassenperlCrao Door)
auent: 35-002 and Subseauent: 36-001 and Subseauent.

Passenger/Crew Lower (36 Inch)

Door Structure

Repair Index

Figure 2 (Sheet 7 of 8)
EFFECTIVITY:

NOTED

52-10-10

Page 11
SRM-4

Jun 1/95

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

26

2411276

Frame

2024-T3 Clad

0.050

27

2411276

Cover

2024-T3 Clad

0.050

28

2411276

Stiffener

S-554

29

2411276

S-552

30

2411276

Door Jamb, Fwd


Door Jamb, Aft

S-552

31

2411276

Frame

2024-T42 Clad

0.050

32

2411276

Frame

2024-T42 Clad

0.050

33

2411276

Support(2 ea.)

2024-T42 Clad

0.050

34

2411276

Cover

2024-T3 Clad

0.050

35

2411276

Filler(2ea.)

2024-T3 Clad

0.160

36

2411282
2411282
2411282

CODES

EFF.

DESCRIPTION

HingeAssy., LowerDoor
Hinge Half (2 ea.)
Hinge Pin

MATERIAL

GAGE

FINISH
CODE

F17-6

F176

REPAIR
FIG. NO.

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

EFFECTIVITIES
24-230 THRU 24-357; 25-061 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004; 31-002
AND SUBSEQUENT; 35-002 AND SUBSEQUENT; 36-001 AND SUBSEQUENT
31-030 AND SUBSEQUENT; 35-664 AND SUBSEQUENT; 36-064 AND SUBSEQUENT

1
2

NOTES:

Condition Annealed.

MadefromA151321 or347.
Madefrom

MS20253-5pin.

(Airmaft 24-320 thre 24357: 25-261 thru 25-373: 28-001 thru 28-005: 29-001 thtrr 29-004: 31-002 and Subseauettt: 35-002 and Subseauent: 36-001 and Subseauent, eauitlt~ed with 36 Inch PassenaerlCrew Door)

Passenger/Crew Lower (36 Inch)


Figure

EFFECTIVITY:

sRM-a

NOTED

Door Structure

Repair Index

(Sheet 8 of 8)

52-10-10

Page 12
Tun1/95

Learjet

STRUCTURAL REPAIR MANUAL


ALLOWABLE DAMAGE

PASSENGER/CREW LOWER DOOR

i.

ALLOWABLE DAMAGELIMITS

All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose or failed rivets

are

not allowed. A loose

or

failed rivet

can cause

increased stress concentra-

progressive joint failure. A careful inspection must be


remaining
has
failure
not
that
to
ensure
spread from the area of the loose or failed rivet. (Rejoint
performed
fer to Chapter 51 for definition of rivet failure.)

tions

(2) Loose

rivets and lead to

the

on

or

failed

screws are

not allowed. A loose

or

failed

screw can cause

increased stress

concen-

progressive joint failure. A careful inspection must be


failure
has
the
not spread from the area of the loose or failed screw.
that
to
ensure
joint
performed
trations
B.

on

surrounding

screws

and lead to

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired,

and refinished in accordance with

re-

Chapter 51.

C.

Deformation

D.

(1) Deformation of the primary door assembly structure or door hinges is not allowed.
Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness more than specified.

E.

Dents

(1) Dents

are

permissible,

(2.54 mm) in

depth,

if smooth and without

abrupt changes in contour, do

do not exceed 10% of total surface

area

in

one

not exceed 0.100 inch

(1) square foot, and

are

not

closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to

rivet

or

structural

area.

Such dents shall be

repaired

or

the

component

re-

placed.
F.

Scratches(See Figure 101.)


(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to

Chapter 51

must be

than

specified.

thickness by
G.

procedures.)
replaced or repaired

for protective treatment

(2) Structural components


more

if scratches reduce the

original

material

Nicks (See Figure 101.)


(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to

protective treatment procedures.)


must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings andForgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.
Chapter 51

for

(2) Structural components


H.

EFFECTIVITY:
SRM~

ALL

52-10-10

page 101
May 15/92

Learjet

STRU%TURAL REPAIR MANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135
0.0175

0.020
0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure

EFFECTIVITY:
SRM~

ALL

101

52-10-10

Page 102
May 15/92

Learjet
Learjetl
STRUCTURAL REPAIR MANUAL
PASSENGER/CREW LOWER DOOR
i.

APPROVED REPAIRS

NOTE:

All dimensions

are

in inches unless otherwise

Refer to

B.

Refer to the basic

for door components such


C.

specified.

Chapter 51 for typical repairs for the passenger/crew lower door structure.
Leajet Maintenance Manual, Chapter 52, for repairs and maintenance procedures

A.

bar

as

door seals, door latch mechanism, door hook mechanism, and torsion

assembly.

Skin gap tolerance between the passenger/crew door skin and fuselage skin is 0.030-inch (0.762 mm)
minimum to 0.060-inch (1.524 mm) maximum around perimeter of door (see Figure 201).

(TYPICAL FOR 24

EFFECTIVITY:

INCH OR 36

0.030

Inch Minimum

0.060

Inch Maximum

INCH DOOR)

Door Skin

Gap Tolerance
Figure 201

2-146A

SRM~

REPAIR

ALL

52-10-10

Page 201
May 15/92

Learjet
Learjefl
STRUCTURAL REPAIR MANUAL
CONDITION

Out-of-Contour condition

1.

can

exists when door skin is secured in

place and

door is dented.

LIMITATIONS
area may not exceed 12.0 inches (304 mm) in length
Maximum thickness of shim may not exceed 0.063 inch (1.6 mm).

1.

Out-of-Contour

2.

Dents may or may not


ty of the door.

cause

by 0.080

depth.

inch (2.03 mm) in

deformation of the door substructure which affects the structural

integri-

REPAIR

6.

length and depth of area to be shimmed.


shim of proper length, thickness and taper, from 2024-T3 aluminum sheet.
Apply one (1) coat epoxy primer to shim.
Apply faying surface seal to both sides of shim. (Refer to Chapter 51.)
Slide shim into place.
Drill proper size holes from skin side through shim.

7.

InstallMS20426AD fasteners.

8.

Paint affected

1.

Determine

2.

Fabricate

3.
4.

5.

areas.

Door Stiffeners

(Ref)

Door Frame

(Ref)

Door Skin

Ref)

Shim

Outside
Door Skin

Contour
DoorFrame--Y

(Normal)

(ReO

Detail A
2-153A

EFFECTTVITY:
SRMII

Upper Door Skin Repair


Figure 202

Out-of-Contour

ALL

52-10-10

Page 202
May 15/92

Learjet
~Learjet
STRUCTU RAL REPAIR MANUAL
STRUCTURAL IDENTIFICATION

EMERGENCY EXIT DOOR


i.

DESCRIPTION

B.

The emergency exit door is located on the fuselage left side in the the aft passenger compartment. The
door contains an acrylic window and can be opened from inside or outside of the aircraft.
Refer to the basic Learjet Maintenance Manual, Chapter 52, for repairs and maintenance procedures

C.

Refer to the basic

A.

for door

components such as door seals and door latch mechanism.


Learjet Maintenance Manual, Chapter 56, for repairs and

maintenance

procedures

for the emergency exit door window.


FS 194.09

205.51

(Ref)

(Ref)

J,FS 182.65

~FS171.26

(Ref)

(Ref)

FS 157.28

(Ref)
1

ii

~I

i:t

~I

lo

j ii

FWD~
i:
(VIEWED FROM RIGHT SIDE LOOKING INBOARD)

O
(VIEW LOOKING FWD)

(VIEW LOOKING AFT)

Detail A

DetailB

2-203(3

EFFECTIVITY:
SRM~

Emergency Exit Door Structure Repair Index


Figure 1 (Sheet 1 of 6)
23-002 THRU 23-099; 24-100 THRU 24-229, EXCEPT 24-218

52-20-00

Page 1
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

I
DESCRIPTION

I
EFF.

MATERIAL

2388195

Emergency
Emergency

2311320

Gusset

2024-T4 Clad

0.040

2311320 1

Bulkhead

2024-T4 Clad

0.040

2311320 1

Retainer

2024-T3 Clad

0.190

2311320

Catch, Lower

2014-T6

0.375

2311320

Doubler

2024-T3 Clad

0.080

2311320

Retainer

2024-T3 Clad

0.050
0.040

2311320

3
4

Exit

DoorAssy.
DoorAssy.

REPAIR

CODE

FIG. NO.

1
1

I
I

Replace
Replace

I
I
I
I
I
I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Gusset

2024-T42 Clad

2311320

Retainer

2024-T4 Clad

0.250

2311320 1

Plate

2024-T3 Clad

0.080

2311320

2024-T42 Clad

0.250

2388195

Spacer
Spacer

1
1
1
1
1
1
1
1

2024-T42 Clad

0.250

2311320

1
2311320 1

Frame, Window Outer


Retainer, Window Inner

2024-T3 Clad

0.090

2024-T3 Clad

0.090

I
I
I

2311320

2024-T42 Clad

0.040

2024-T42 Clad

0.040

1
1

I
I

2024-T42 Clad

0.040

2311320

Channel(2ea.)
Channel(2ea.)
Channel(2ea.)
Gang Channel

2311320

Retainer

1 2311320

2311320

2311320

Exit

IFINISH
GAGE

2311320 IRetainer
10

2311320

Frame

11

2311320

12

2311320

Ring,
Ring,

2014-T6

0.375

10

2014-T6

0.250

Replace
Replace
Replace
Replace
Replace
Replace

6061-T6

0.040

51-70-04

Aft

2024-T3 Clad

0.080

Fwd

2024-T3 Clad

0.080

2024-T3 Clad

0.125

Replace
Replace
Replace
Replace

321 Stainless
2024T4 Clad

0.125

0.830

1
1

I
I

5-578

2311320

Shim, Laminated (Max. 0.125)

10

2311320

Retainer

10

Pin

2388195
2388195
2388195
2311321

Assy.

Link

Pin

Angle (2 ea.)

Replace
Replace
Replace

Emergency Exit Door Structure Repair Index


Figure 1 (Sheet 2 of 6)
EFFECTIVITY:
SRM-4

23-002 THRU 23-099; 24-100 THRU 24-229 EXCEPT 24-218

52-20-00

Page 2
May 15/92

Learjet
Learjet

STRUCTURAL REPAIR MANUAL


CODES

EFFECTIVITIES

23-002 THRU 23-099

24-100 THRU 24-229

23-002 THRU

23-002 THRU 23-012

23-005 THRU

23-004 THRU 23-099; 24-100 THRU 24-229


23-012 AND 23-013

23-099; 24-100 THRU

24-229

23-099; 24-100 THRU 24-229

23-022 THRU 23-099; 24-100 THRU 24-229


23-022 THRU 23-099; 24-100 THRU 24-140

8
9

24-141 THRU 24-229

10

NOTES:

Made from G1000-3-10-5,

Kaynar Mfg.

Laminated shim stock, 0.002


num sheet.

or

0.003 lamination per MIL-S-22499

Type

1 Class 1

or

Class 2 1145-H19 alumi-

Emergency Exit Door Structure Repair Index


Figure 1 (Sheet 3 of 6)
EFFECTIVITY:
SRM-4

23-002 THRU 23-099; 24-100 THRU 24-229 EXCEPT 24-218

52-20-00

Page 3
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


EMERGENCY EMT DOOR

91

STRUCTURAL IDENTIFICATION

~s

~jj

ii
I

Nli :I %I"
B

I\

1)

(4
a

~u"d
(TYPICAL)
2-48

EFFECTIVITY:
SRM~

Emergency Exit Door Structure Repair Index


Figure 1 (Sheet 4 of 6)
24-218, 24-230 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005; 29-001
THRU 29-004; 31-002 AND SUBSEQUENT; 35-002 AND SUBSEQUENT;
36-001 AND SUBSEQUENT

52-20-00

Page 4
May 15/92

Learjet
~Hrietl
STRUCTURAL REPAIR MANUAL
ITEM
NO.

DWG.
NO.

2511320

2411320

FIG. NO.

1
2

2024-T42 Clad

0.040

0.040

0.063

1
1
1
1

I
I
I
I

1
1

I
I
I

I
I
I

2511323
2511323

Spacer,
Spacer,

2511324

lSpacer,

Internal

2024-T42 Clad
2024-T3 Clad

Internal

2024-T3 Clad

0.063

Pan

2024-T42 Clad

0.063

Filler

2024-T3 Clad

0.063

Inner

2024-T42 Clad

0.125

Outer

2024-T42 Clad

0.125

Outer

2024-T351 Clad

0.250

2411322

Catch

2024-T351 Clad

2411320

Catch, Lower

2014-T6 Clad

2411322

Spacer
Support

2024-T3 Clad

0.063

2024-T351

1.600

1
1

2411322

Tee

Arm, Fwd
Arm, Aft

2411322

2411322

Strap
Clip Support

0.375

2024-T351

2.000

2024-T351

0.438

0.250

2024-T3 Clad
2024-T3 Clad

0.040

2411322 IPin

2024-T4

0.438

24113211 Pin

2024-T4

0.438

2024-T4 Clad

0.375

1
1

I
I

2014-T6 Clad

0.250

2411322

2411323

2411320

2411320

IShim, Laminated (Max. 0.125)


1
Fairing
Pin Assy.

2388195

2388195
2388195

10

REPAIR

CODE

2511327 1

IFINISH

I GAGE

2511322 1

2411322

I
MATERIAL

External

2411325

I
EFF.

External

Skin,
Skin,
Skin,
Skin,

1
2511325 1
2511320

DESCRIPTION

Emergency Exit DoorAssy.


Emergency Exit DoorAssy.

2411320
1

2388195

Retainer(2 ea.)
Retainer(2 ea.)

Link

Pin

2411323 1

Retainer

2311320

Gang

Channel

2~
2

2024T3 Clad

0.750

321 Stainless

0.125

2024T4 Clad

0.830

2024-T4 Clad

0.375

0.080

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Replace
Replace
Replace

2311320 1

Plate

2024-T3 Clad

2311321

Angle (2 ea.)

S-578

Replace
Replace

Emergency Exi~ Door Structure Repair Index


Figure 1 (Sheet 5 of 6)
EFFECTIVITY:
SRM-4

24-218, 24-230 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005; 29-001
THRU 29-004; 31-002 AND SUBSEQUENT; 35-002 AND SUBSEQUENT;
36-001 AND SUBSEQUENT

52-20-00

Page 5
May 15/92

Learjet
Learjet

STRUCTURAL REPAIR NIANUAL


CODES

EFFECTIVITIES

24-218, 24-230 THRU 24- 357; 25-061, 25-070 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU

2
3

29-004; 31-002 AND SUBSEQUENT; 35-002 AND SUBSEQUENT;

36-001 AND SUBSEQUENT

25-002 THRU 25-066, EXCEPT 25-061


24-218, 24-230 THRU 24-357; 25-002 THRU

28-005; 29-001 THRU 29-004;

31-002 AND

SUBSEQUENT;

35-002 AND

25-373;

28-001 THRU

SUBSEQUENT;

36-001 AND SUBSEQUENT

NOTES:

Made from

G1000-3-10-5, Kaynar Mfg.

Laminated shim stock, 0.002


num sheet.

or

0.003 lamination per MIL-S-22499

Type

1 Class 1

or

Class 2 1145-H19 alumi-

Emergency Exit Door Structure Repair Index


Figure 1 (Sheet 6 of 6)
EFFECTIVITY:
SRM-4

24-218, 24-230 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005; 29-001
THRU 29-004; 31-002 AND SUBSEQUENT; 35-002 AND
36-001 AND SUBSEQUENT

SUBSEQUENT;

52-20-00

Page 6
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


EMERGENCY EXIT DOOR
i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGE LIMITS


All dimensions

NOTE:
A.

specified.

Fasteners

(1) Loose
tions

or

failed rivets
the

on

performed
fer to Chapter 51
(2) Loose

or

trations

ensure

failed

on

performed

not allowed. A loose

are

remaining

to

B.

in inches unless otherwise

are

rivets and lead to

that

joint

or

failed rivet

can cause

increased stress concentra-

inspection must be
progressive joint
of
the
loose
from
the
or failed rivet. (Rearea
spread
failure. A careful

failure has not

for definition of rivet failure.)

screws are not

surrounding

allowed. A loose

to ensure that the

or

failed

screw can cause

increased stress

failure. A careful

and lead to

progressive joint
joint failure has not spread from the area

screws

concen-

inspection must be

of the loose

or

failed

screw.

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired,
C.
D.

and refinished in accordance with

Deformation

(1) Deformation of the emergency exit door assembly or structure is not allowed.
Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

Chapter

re-

51.

more

than

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to
F.

G.

H.

rivet

or

structural

area.

Such dents shall be

repaired

or

the

component

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(See Figure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTIVITY:

ALL

52-20-00

Page
sRM-a

re-

101

May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016
0.020

0.0135

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0;063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFFECTIVITY:
SRMI

ALL

101

52-20-00

Page 102
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
EMERGENCY EXIT DOOR
i.

REPAIR

APPROVED REPAIRS

NOTE:

All dimensions

are

in inches unless otherwise

specified.

Chapter 51 for typical repairs for the emergency exit door structure.
Learjet Maintenance Manual, Chapter 52, for repairs and

A.

Refer to

B.

Refer to the basic

C.

for emergency exit door components such as door seals and door latch mechanism.
Skin gap tolerance between the emergency exit door skin and fuselage skin is 0.040-inch (1.016 mm)
minimum to 0.080-inch (2.032 mm) maximum around

maintenance

procedures

perimeter of door (see Figure 201).

0.040

Inch Minimum

0.080

Inch Maximum

(TYPICAL)

Emergency Exit Door Skin Gap Tolerance


Figure 201

2-145A

EFFECTIVITY:
SRM~

ALL

52-20-00

Page 201
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
STRUCTURAL IDENTIFICATION

SERVICE DOORS
1.

DESCRIPTION
A.

Service doors covered in this section

the tailcone

are

access

door,

nose

compartment

access

doors, oil

filler doors, oxygen bottle access door and single-point pressure refueling door.
(1) The tailcone access door is located on the bottom side of the fuselage, in the aft section of the aircraft. Refer to Tailcone Access Door Structure Repair Index (52-40-01) for structural components.

applicable kit and/or kit drawing for


additions, modifications and changes to structural components and assemblies.

On Aircraft eauim7ed with drag chute, refer to the

NOTE:

(2) The

nose

compartment

access

windshield. Refer to Nose

doors

are

Compartment

located

on

the

top side

Access Door Structure

of the

Repair

fuselage

forward of the

Index (52-40-05) for struc-

tural components.

(3) The oil filler

access

doors

are

located

(4) On Aircraft eaui~med with


hand side of the

inder.
cess

an access

nose

nose

Door Structure

the upper cowl

assembly of each engine

nacelle. Refer to

Repair Index (52-40-10)

compartment

door is located

on

for structural components.


comt7artment oxwaen~culinder, an access door is located

Oil Filler Access Doors Structure

on

aft of frame 2. On Aircraft eauitwed with

the

right

on

dorsal fin

hand side of the dorsal fin. Refer to

the

right

oxvaerr

Oxygen

clA~-

Bottle Ac-

Repair Index (52-40-15) for structural components.

(5) On Aircraft eauim?ed with sinale-~oint

tlressure

refue2ina, an

access

door is located

on

the

right

hand

fuselage just above and aft of the wing trailing edge. Refer to Single-Point Pressure ReAccess Door Structure Repair Index (52-40-20) for structural components.

side of the

fueling
B.

for service door

EFFECTIVITY:
SRM-4

Learjet Maintenance Manual, Chapter 52, for repairs


components such as seals, and door latch mechanism.

Refer to the basic

ALL

and maintenance

procedures

52-40-00

Page 1
May 15/92

Leariet
I~jti
STRUCTURAL REPAIR MANUAL
TAILCONE ACCESS DOOR

STRUCTURAL IDENTIFICATION

(23-002 thru 23-099: 24-100 thru 24-357)

(25-002 thru 25-357. 28-001 thtle 28-005; 29-001 thtu 29-004: 31-002 thnr 31-089: 35-002 th~ 35-676:
36-001 thfic 36-063)

(31-089 and Subseauent: 35-677 and Subseauent: 36-064 and Subseauent)


3-68

Tailcone Access Door Structure Repair Index

3-5C

3-528

EFFECTIVITY:

Figure 1 (Sheet 1 of 2)
NOTED

52-40-01

Page
sRM-a

Jun 1/95

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.
2312015

2024-T3 Clad

S-557

2312015

Stringer
Spacer(2ea.)

1
1

2024-T3 Clad

0.040

2312015

Doubler

2024-T3 Clad

0.040

2024-T3 Clad

0.040

2512049

TailconeAccess Door Instl.

2512049

TailconeAccess Door Instl.

2512051

I Replace

j Replace

Replace

Replace

51-70-02

Inner Pan

2024-T42 Clad

0.032

F4-1

Doubler

2024-T3 Clad

0.040

F4-1

Shim, Laminated (Max. 0.040)


TailconeAccess DoorAssy.

2
3

2024-T42 Clad

0.040

2588061

Skin, Inner
Skin, Gutter

2024-T3 Clad

0.050

2588061

Doubler

2024-T3 Clad

0.071

2024-T3 Bar

0.500

2588061
4

2488716

2512042
2512042

2512042
2512015
2512015
2512015
2488715
2488700

3
2

8 RH

Angle, LH 8 RH
Hinge Arm, LW RH
HingeAssy.(2ea.)

S-608

2024-T351 Clad

i
0.250

3
3

Channel

0.500

4130 Steel Bar

2024-T42 Clad

0.040

2588061

Shim, Laminated (Max. 0.094)

2512047

Clip,LH&RH
CIIp,LH&RH
CIIRLH&RH
Clip,LH&RH
HingeSpacer(2ea.)

2024-T42 Clad

0.100

2024-T42 Clad

0.100

2024-T42 Clad

0.100

2024-T42 Clad

0.100

2024-T351 Clad

0.050

2024-T42 Clad

0.063

2512046
2512045
2512044
2512043

Intercostal, LH 8 RH (3 ea.j

2512015
2512015

2512015

Angle(2ea.)
Stiffener(2ea.)

51-70-02

0.063

4
4

S-681

2512049

Doubler

2024-T42 Clad

0.090

2512049

Filler(Gea.)

2024-T3 Clad

0.032

Replace
Replace
Replace
I Replace
Replace

F4-1

HingeHalf(L~ea.)
Hinge Pin (2 ea.)
Hinge, LH 8 RH
ChannelAssy.

2488700

F4-1

Shim, Laminated (Max. 0.040)

Hinge, LH 8 RH
Hinge Assy., LH

51-70-02

2312051
3112052

FIG. NO.

Tailcone Access Door Assy.


Skin

2588061

F4-1

0.040

2312051
251 2051

CODE

DoorAssy

2312051

TailconeAccess

(FINISHI REPAIR
GAGE

MATERIAL

EFF.

Door

2312015
2312015

I
DESCRIPTION

Replace
Replace
F-l
Replace
I Replace
F4-6
Replace
F4-6
Replace
Replace
F4-1
Replace
F4-1
Replace
F8
Replace
I Replace
F4-1
Replace
Replace
F4-1
Replace
F4-1
Replace
F4-1
Replace
F4-1
Replace
F4-1
Replace
F4-1
Replace
F8-1
Replace
F4-1
Replace
F4-4
Replace
F4-1
Replace

Repair Index
Figure 1 (Sheet 2 of 2)

Tailcone Access Door Structure

EFFECTIVITY:

ALL

52-40-01

Page 2
SRM-4

Jun 1/95

Learjet
~tl

STRUCTURAL REPAIR MANUAL


CODES

EFFECTIVITIES
23-002 THRU 23-099; 24-100 THRU 24-357
25-002 THRU 25-373; 28-001 THRU 2&005; 24001 THRU 29-004; 31-002 THRU 31-088; 35-002
THRU 35676; 36-001 THRU 36-063
31-089 AND SUBSEQUENT; 35-677 AND SUBSEQUENT; 36-064 AND SUBSEQUENT
25-002 THRU 25-373; 28-001 THRU 28005; 29-001 THRU 29-004; 31-002 AND SUBSEQUENT;
35-002 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

1
2

3
4

NOTES:
Finish F14-1 interior, F-l exterior.

L~

Laminated shim stock, 0.002


sheet.

or

0.003 lamination per MlL-S-22499

Type 1, Class

or

Class 2, 1145H19 alumi-

num

I~

Madefrom MS20001-4.

Madefrom MS20252P2.

4130 Steel, Condition Normalized.

EFFECTIVITY:

ALL

52-40-01

Page 3
SRM-4

Jun 1/95

Learjet
STRUCTURAL REPAIR MANUAL
TAILCONE ACCESS DOOR
i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGE LIMITS

All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose

or

failed rivets

are

not allowed. A loose

or

failed rivet

can cause

increased stress concentrainspection must be

failure. A careful

tions on
progressive joint
remaining
performed to ensure that joint failure has not spread from the area of the loose or failed rivet.
fer to Chapter 51 for definition of rivet failure.)
rivets and lead to

the

(2) Loose

or

trations

failed

on

performed
B.

screws are

surrounding
to

ensure

not allowed. A loose

failed

screw can cause

increased stress

concen-

must be

failure. A careful

inspection
progressive joint
joint failure has not spread from the area of the loose or failed screw.

screws

that the

or

(Re-

and lead to

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired,
C.

and refinished in accordance with

Chapter

re-

51.

Deformation

(1) Deformation of the tailcone access door, structure assembly or door hinges is not allowed.
D. Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
Structural
(2)
components must be repaired or replaced if corrosion repair reduces the original material thickness
E.

more

than

specified.

Dents

(1) Dents

are

permissible,

~2.54 mm) in

depth,

if smooth and without

abrupt changes in

do not exceed 10% of total surface

area

in

contour, do not exceed 0.100 inch


one (1) square foot, and are not

closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to

rivet

or

structural

area.

Such dents shall be

repaired

or

the

component

re-

placed.
F.

Scratches(See Figure 101.)


(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Re-

protective treatment procedures,)


must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 301.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.
fer to

Chapter 51

for

(2) Structural components

G.

H.

EFFECTTVITY:

ALL

52-40-01

Page
SRM~

101

May 15/92

Leariet
~tl
STRUCTURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040
0.050

0.037

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFFECTIVITY:

ALL

101

52-40-01

Page
SI~M-4

May

102

15/92

Learjet I

STRUCTURAL REPAIR MANUAL


TAILCONE ACCESS DOOR
i.

REPAIR

APPROVED REPAIRS

NOTE:
A.
B.

C.

All dimensions

are

in inches unless othenuise

specified.

Chapter 51 for typical repairs for the tailcone access door structure.
See Figure 201 for tailcone access door skin gap tolerances.
Refer to the basic Learjet Maintenance Manual, Chapter 52, for repairs and
Refer to

for tailcone

access

door

components

such

as

maintenance

procedures

seals, and door latch mechanism.

Tailcone Access Door

CFWD

a.050

Inch Maximum

(VIEW LOOKING UP)

Tailcone Access Door Skin

2-146C

Figure
EFFECTIVITY:
SRM4

ALL

Gap Tolerance

201

52-40-01

Page 201
May 15/92

Learjet
~rjrl
STRUCTURAL REPAIR MANUAL
NOSE COMPARTMENT ACCESS DOORS

STRUCTURAL IDENTIFICATION

~FWO
(VIEW LOOKING DOWN)
(LH SHOWN, RH TYPICAL)

ITEM
NO.

DWG.
NO.

I
DESCRIPTION

2311450

NoseCompartmentAccess
Assy, LH RH

I
EFF.

I
MATERIAL

IFINISH
GAGE

REPAIR
FIG. NO.

CODE

Door
1

2311450

Door

2024-T42 Clad

0.032

51-70-02

2311450

Pan

2024-T42 Clad

0.025

51-70-02

CODES
1

EFFECTIVITIES
23-002 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005; 29-001
THRU 29-004; 31-001 AND SUBSEQUENT; 35-002 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

Nose

1-188

Compartment

Access Doors Structure

Figure
EFFECTIVITY:

ALL

Repair Index

52-40-05

Page
SRM~

May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


NOSE COMPARTMENT ACCESS DOORS
i.

ALLOWABLE DAMAGE

ALLOWABLE DAMACELIMITS

All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose

or

failed rivets

are

not allowed. A loose or failed rivet

can cause

increased stress concentrainspection must be

failure. A careful

tions on the remaining rivets and lead to progressive joint


performed to ensure that joint failure has not spread from the area of the loose or failed
fer to Chapter 51 for definition of rivet failure.)

(2) Loose

or

failed

screws are

not allowed. A loose

or

failed

screw can cause

rivet. (Re-

increased stress

concen-

failure. A careful

inspection must be
progressive joint
of
the
loose
from
the
or failed screw.
area
performed to ensure that the joint failure has not spread
trations
B.

on

surrounding

screws

and lead to

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired, and
C.
D.

refinished in accordance with

Deformation

(1) Deformation of the nose compartment access doors or structure assembly is not allowed.
Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

re-

Chapter 51.

more

than

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component reF.

G.

I-I.

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(See Figure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings andForgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTIVITY:
SRM-4

ALL

52-40-05

Page 101
May 15/92

STRUCTURAL REPAIR MANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.073

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure

EFFECTIVITY:
SRM4

ALL

101

52-40-05

Page 102
May 15/92

Learjet
LBarjet
STRUCTURAL REPAIR MANUAL
NOSE COMPARTMENT ACCESS DOORS
i.

REPAIR

APPROVED REPAIRS

NOTE:

All dimensions

in inches unless otherwise

specified.

Chapter 51 for typical repairs for the nose compartment access door structure.
Learjet Maintenance Manual, Chapter 52, for repairs and maintenance procedures
for door components such as door seals and door latch mechanism.
See Figure 201 for nose compartment access door skin gap tolerances.

A.

Refer to

B.

Refer to the basic

C.

are

CFWO

Nose

2-146(3

EFFECTIVITY:
SRM~

ALL

0.050

Inch Minimum

0.070

Inch Maximum

Compartment Access Doors Skin Gap Tolerances


Figure 201
52-40-05

Page 201
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


STRUCTURAL IDENTIFICATION

OIL FILLER ACCESS DOOR

r I
I

jI
I

iI I

Ii
i I

_I I

I:

i I
I
I

ii

I I

Z--

(5)

(3)

(TYPICAL)

ITEM

DWO.

NO.

NO.

2452004
2652023

OilFillerDoorAssy., LH&RH

LH B RH

Oil Filler Door

2452004
2652023

126520231

2652023/

12652023/

I
EFF.

DESCRIPTION

Assy.,

Skin, Outer
Skin, Outer
Pan,lnner
Filler

2024-T42 Clad

0.063

51-70-02

0.025
0.025

51-70-02
51-70-02

2024-T42 Clad
i 2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

2
i

GAGE

2
2

Filler

IFINISHI REPAIR
CODE
FIG. NO.

I
MATERIAL

Replace

0.080
0.080

Replace

MSeOO~i

1P4-700

I Hinge Assy.

~4085-4 jHingePin

CODES
1

I
I

Replace
Replace

EFFECTIVITIES
23-002 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 2&005; 29-001
THRU 29-004

31-002 AND

1C195A

SUBSEQUENT; 35-002 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

Oil Filler Access Door Structure

Figure
EFFECTIVITY:

SRLI-I

ALL

Repair Index

52-40-10

Page 1
Jun1/95

Learjet

STRUCTURAL REPAIR MANUAL


OIL FILLER ACCESS DOOR
i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS

All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose

or

failed rivets

are

not allowed. A loose or

failed rivet

can cause

increased stress concentra-

progressive joint failure. A careful inspection must be


remaining
has
that
failure
not
to
ensure
spread from the area of the loose or failed rivet. (Rejoint
performed
fer to Chapter 51 for definition of rivet failure.)
tions

(2) Loose

rivets and lead to

the

on

or

failed

screws are

not allowed. A loose

or

failed

screw can cause

increased stress

concen-

progressive joint failure. A careful inspection must be


performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
trations
B.

on

surrounding

screws

and lead to

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

re-

paired, and refinished in accordance with Chapter 51.


C.
D.

Deformation

(1) Deformation of the oil filler access door, structure assembly or door hinges is not allowed.
Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

more

than

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component reF.

G.

H.

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTIVITY:

ALL

52-40-10

Page 101
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFFECTTVITY:
SRM-4

ALL

201

52-40-10

Page 102
May 15/92

Leariet

STRUCTURAL REPAIR MANUAL


OIL FILLER ACCESS DOOR
i.

REPAIR

APPROVED REPAIRS

NOTE:
A.
B.

C.

All dimensions

are

in inches unless otherwise

specified

Chapter 51 for typical repairs for the oil filler access door structure.
Refer to the basic Leajet Maintenance Manual, Chapter 52, for repairs and
for door components such as door seals and door latch mechanism.
See Figure 201 for oil filler access door skin gap tolerances.
Refer to

0.020

maintenance

procedures

Inch Maximum

010

0.050 (f0.020)- Inch Maximum

(TYPICAL)
Oil Filler Access Door Skin

2-146C

Gap Tolerances

Figure 201
EFFECTIVITY:

ALL

52-40-10

Page 201
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


OXYGEN BOTTLE ACCESS DOOR

STRUCTURAL IDENTIFICATION

li.-_

FWOI)

ii

(VIEW FROM RIGHT SIDE, LOOKING INBOARD)

DWG.

ITEM

DESCRIPTION

NO.

NO.

Oxygen Bottle Nose Compartment


Access Door Assy.

2319055
1

Door

2024-T42 Clad

0.040

Spacer
Hinge

2024-T42 Clad

0.032

MS35821-5A

2-2048

REPAIR

CODE

FIG. NO.

2319055

CODES

IFINISH
GAGE

MATERIAL

2319055 1

2319055

I
EFF.

1
1

I
I

Replace
Replace
Replace

EFFECTIVITIES
24-110 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004; 31-002
AND SUBSEQUENT; 35-002 AND SUBSEQUENT 36-001 AND SUBSEQUENT

Oxygen Bottle (Nose Compartment) Access Door Stntcture Repair Index


Figure 1

EFFECTIVITY:

AIRCRAFT 24-110 THRU 24-357; 25-002 THRU 25-373; 28-001

SRM-4

THRU 28-005; 29-001 THRU 29-004; 31-002 AND SUBSEQUENT;


35-002 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

52-40-15

Page 1
May 15/92

Learjet
~Learietl
STRUCTURAL REPAIR MANUAL
OXYGEN BOTTLE ACCESS DOOR

STRUCTURAL IDENTIFICATION

1!

tiia

-7

i 17~

FWDI)

ITEM

DWG.

NO.

NO.

DESCRIPTION

2512021
2512052

Oxygen Battle Access Door Assy.


Oxygen Bottle Access DoorAssy.

EFF.

2512021

Door

1
2

Door
Stiffener

2512052

Stiffener

Spacer
Spacer
Hinge
Hinge

2512052

2512021
2512052

CODES

FINISH

REPAIR

CODE

FIG. NO.

2512052
2512021

1 2512021

GAGE

MATERIAL

1
2

2024-T42 Clad
2024-T3 Clad
2024-T42 Clad
2024-T3 Clad

2024-T3 Clad
2024-T3 Clad
MS35821-5A
MS35821-10A

0.040
0.040

0.025
0.025

0.032
0.032

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

EFFECTIVITIES

25-002 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004; 35-002 THRU 35-491;36-001
THRU 36-034

31-002 AND

SUBSEQUENT; 35-492 AND SUBSEQUENT; 36-035 AND SUBSEQUENT

Oxygen Bottle (Dorsal Fin) Access Door Structure Repair Index


Figure 2
EFFECTIVITY:

ALL

52-40-15

Page 2
SRM-4

May 15/92

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


OXYGEN BOTTLE ACCESS DOOR

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS

i.

All dimensions

NOTE:
A.

in inches unless otherwise

are

Fasteners

(1) Loose
tions

failed rivets

or

the

on

are

remaining

performed
fer to Chapter 51
(2) Loose

or

trations

failed

on

performed

not allowed. A loose or failed rivet can

rivets and lead to

to ensure that

B.

specified.

joint

cause

increased stress concentra-

failure. A careful

progressive joint
inspection must be
from
of
the
the
loose
area
or failed rivet. (Respread

failure has not

for definition of rivet failure.)

screws are

surrounding

not

allowed. A loose

to ensure that the

or

failed

screw can cause

increased stress

failure. A careful

and lead to

concen-

must be

progressive joint
inspection
joint failure has not spread from the area of the loose or failed

screws

screw.

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired,

and refinished in accordance with

C.

Deformation

D.

Corrosion

(1) Deformation of the oxygen bottle

access

Chapter

door,

re-

51.

structure

assembly or door hinges is not allowed.

(SeeFigurelOl.)
damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
Structural components must be repaired or replaced if corrosion repair reduces the original material thickness more than specified.

(1) Corrosion

(2)
E.

Dents

(1) Dents

are

permissible,

(2.54 mm) in

depth,

if smooth and without

abrupt changes in contour, do

do not exceed 10% of total surface

area

in

one

not exceed 0.100 inch

(1) square foot, and

are

not

closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to
F.

G.

H.

rivet

or

structural

area.

Such dents shall be

repaired

or

the

component

re-

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(See Figure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFlFECTIVITY:
SRM-4

ALL

52-40-15

Page 101
May 15/92

Learjet
E~ Learietl
STRUCTURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure 101
EFFECTIVITY:

ALL

52-40-15

Page 102
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


OXYGEN BO~LE ACCESS DOOR
i.

REPAIR

APPROVED REPAIRS

All dimensions

NOTE:

Refer to

Refer to the basic

C.

See

in inches unless otherwise

specified.

Chapter 51 for typical repairs for the oxygen bottle access door structure.
Learjet Maintenance Manual for repairs and maintenance procedures

A.
B.

bottle

are

door

access

Figure 201

for oxygen bottle

access

door skin gap tolerances.

0.030

for oxygen

components such as door seals and door latch mechanism.

Inch Minimum

-_J

FWDI)
i~------

I
I

0.120

Inch

Maximum1

(Aircraft eauitl~ed with Nose Com27artmen~ Oxvaen Bottle A_ccess Door)

(VIEW FROM RIGHT SIDE, LOOKING INBOARD)

Oxygen Bottle Access Door Skin Gap Tolerances


Figure 201 (Sheet 1 of 2)

2-2048

EFFECTIVITY:
SRM-4

NOTED

52-40-15

Page 201
May 15/92

Learjet I
STRUCTURAL REPAIR MANUAL
OXYGEN BOTTLE ACCESS DOOR

_C0.050
jr

REPAIR

Inch Minimum

FWD

I)

Ir;--T---tt

111

I
I

:-------_1I~LL
0.060

Inch

MaximumJ

(Airmaft eauitltled wifh Dorsal Fin OxuPen Bottle Access Doorl

(VIEW FROM RIGHT SIDE, LOOKING INBOARD)


2-2048

Oxygen

Bottle Access Door Skin

Figure
EFFECTIVITY:
SRM-4

NOTED

Gap Tolerances

201 (Sheet 2 of 2)

52-40-15

Page 202
May 15/92

STRUCTURAL REPAIR MANUAL


SINGLE-POINT PRESSURE REFUELING DOOR

STRUCTURAL IDENTIFICATION

;f:

slp~b
ITEM

DWG.

NO.

NO.

I
DESCRIPTION

3112015

Single-Point

Pressure

Refueling

EFF.

IFINISH
GAGE

MATERIAL

REPAIR
FIG. NO.

CODE

Door
1

3112015

Door

2024-T42

3112015

Bracket

j2024-T42

HingeAssy.

13112013

CODES

0.050

0.050

Replace
Replace
Replace

EFFECTIVITIES
31-001 AND SUBSEQUENT

NOTES:
Made from MS35822-10C Butt

12-818

EFFECTIVITY:

Hinge.

Single-Point Pressure Re~fueling Door Structure Repair Index


Figure 1
AIRCRAFT

EQUIPPED WTTH SINGLE-POINT

PRESSURE REFUELING
5RM-4

52-40-20

Page

Jun1/95

Learjet
Learjet

STRUCTURAL REPAIR WIANUAL


SINGLE-POINT PRESSURE REFUELING DOOR
i.

ALLOWABLE DAMAGE

ALLOWABLE
All dimensions

NOTE:

A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose

or

failed rivets

are

not allowed. A loose or failed rivet

can cause

increased stress concentra-

progressive joint failure. A careful inspection must be


remaining
failure
has
that
not
to
ensure
spread from the area of the loose or failed rivet. (Rejoint
performed
fer to Chapter 51 for definition of rivet failure.)
tions

(2) Loose

or

trations

failed

on

performed
B.

rivets and lead to

the

on

screws are

surrounding

not allowed. A loose

screws

to ensure that the

and lead to

joint

increased stress

failure. A careful

concen-

progressive joint
inspection
spread from the area of the loose or failed

must

be

screw.

not allowed. Cracked

forgings
with Chapter 51.

fittings

in accordance

and

fittings or forgings must be replaced.


considered allowable if properly

are

re-

Deformation

(1) Deformation of single-point pressure refueling door, structure or door hinges is not allowed.
Corrosion(SeeFigure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

screw can cause

Cracks

paired, and refinished

D.

failed

failure has not

(1) Cracks in any fitting or forging are


(2) Cracks in components other than
C.

or

more

than

specified.

Dents
are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50

(1) Dents

inch (12.7 mm) to

rivet

or

structural

area.

Such dents shall be

repaired

or

the

component

re-

placed.
F.

Scratches(See Figure 101.)


(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Re-

protective treatment procedures.)


must be replaced or repaired
thickness by more than specified.
fer to

Chapter 51

for

(2) Structural components


G.

H.

original

material

Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTIVITY:

AIRCRAFT WITH SINGLE-POINT PRESSURE


REFUELING

SRM-4

if scratches reduce the

52-40-20

Page 101
May 15/92

Learjet
~tl
STRUCIURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(Inch)

fInch)
0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.030

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure 101

EFFECTIVITY:

AIRCRAFT WITH SINGLE-POINT PRESSURE


REFUELING

SRM-4

52-40-20

Page 102
May 15/92

Learjet
Leari~t

STRUCTURAL REPAIR MANUAL


SINGLE-POINT PRESSURE REFUELING DOOR
i.

REPAIR

APPROVED REPAIRS

All dimensions

NOTE:

in inches unless otherwise

specified.

Chapter 51 for typical repairs for the single-point pressure refueling door structure.
Learjet Maintenance Manual, Chapter 28, for repairs and maintenance procedures
single-point pressure refueling door components such as door seals and door latch mecha-

A.

Refer to

B.

Refer to the basic


for the

are

nism.

C.

See

Figure 201

for

single-point pressure refueling door skin gap tolerances.

0.020

Inch Maximum

Fwn~
0.020

Inch Maximum

f
(VIEW FROM RIGHT SIDE, LOOKING INBOARD)

2-201B

EFFECTIVITY:

Single-Point Pressure Refueling Door Skin Gap Tolerances


Figure 201
AIRCRAFT EQUIPPED WITH SINGLE-POINT
PRESSURE REFUELING

52-40-20

Page 201
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


MAIN LANDING GEAR DOORS

i.

STRUCTURAL IDENTIFICATION

DESCRIPTION
A.
B.

C.

landing gear doors and outboard landing gear doors are covered in this
See Figure 1, 52-80-10, for main landing gear inboard door structure repair index.
See Figure 1, 52-80-20, for main landing gear outboard door structure repair index.
Both inboard

EFFECTIVITY:

ALL

section.

52-80-00

Page
SRM-4

May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


MAIN LANDING GEAR INBOARD DOOR

STRUCTURAL IDENTIFICATION

$$t~

$LI

6-6C

EFFECTIVITY:

Main

ALL

(6

Landing Gear Inboard Door Structure Repair Index


Figure 1 (Sheet 1 of 2)
52-80-10

Page
SRM-4

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
DWG.
NO.

ITEM

NO.

DESCRIPTION
Main Landing Gear Inboard Instl.
Main Landing Gear Inboard

2311620
2496200
2311620

8 RH

Door

Assy., LH

Main

Landing Gear Inboard


Assy., LH 8 RH

Door

EFF.

MATERIAL

GAGE

Door

2024-T42 Clad

0.040

2311620

DoorPan

2024-T42 Clad

0.050

2024-T42 Clad

0.050

4130 Steel~

0.071

S-627

2311620

2327020

DoorPanSupport
SupportAngle
Fitting
Fitting

2024-T351

Doubler

2024-T3 Clad

0.032

2311620

Stopper

Nylon

0.189

2311620

Filler

2024-T3

0.100

2311628

Lever

2311628

Plate

321 Stainless

0.080

2311628

Lug
StopPlate

321 Stainless

0.080

321 Stainless

0.080

3127010
2311620

2311628

Hook

2348040

4130

Steel~

0.125

2348040

Hook

4130 Steel~

0.250

231 i 630

Bracket

2311630

Tee

S-592

2311630

Bracket

2024-T42 Clad

0.100

Gusset

2024-T42 Clad
S-646

0.063

2311630
2311630

Assy.

Channel

Replace
Replace
Replace
Replace
Replace

2327021

Plate

2024-T3 Clad

0.120

2311628

Bushing

4130 Steel

0.250

CODES

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Assy.
MountingPlate

2348040

Assy.

FIG. NO.

2311620
2311620

REPAIR

CODE

FINISH

Replace
Replace
Replace
Replace
Replace
Replace

EFFECTIVITIES
23-002 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005; 29-001
THRU 29-004; 31-002 AND SUBSEQUENT; 35-002 AND SUBSEQUENT; 36-001 AND SUBSE-

QUENT
23-002 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005; 29-001
THRU 29-004; 35-002 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

31-002 AND SUBSEQUENT

NOTES:
Condition Normalized.
Condition Annealed.

Main

EFFECTIVITY:
SRM4

ALL

Landing Gear Inboard Door Structure Repair Index


Figure 1 (Sheet 2 of 2)
52-80-10

Page 2
May 15/92

Learjet
Learjet
STRUCTURAL REPAIR MANUAL
MAIN LANDING GEAR INBOARD DOOR
1.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS
All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose

or

failed rivets

are

not allowed. A loose

or

failed rivet

can cause

increased stress concentra-

progressive joint failure. A careful inspection must be


performed to ensure that joint failure has not spread from the area of the loose or failed rivet. (Refer to Chapter 51 for definition of rivet failure.)
tions

the

on

(2) Loose

or

remaining

failed

rivets and lead to

screws are not

allowed. A loose

or

failed

screw can cause

increased stress

concen-

progressive joint failure. A careful inspection must be


performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
trations
B.

on

surrounding

screws

and lead to

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired, and refinished


C.

in accordance with

re-

Chapter 51.

Deformation

(1) Deformation of the main landing gear inboard door,

structure

assembly

or

door

hinges

is not al-

lowed.
D.

Corrosion(See Figure 101.)


(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original mate-

E.

Dents

rial thickness

more

than

specified.

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to
F.

G.

H.

rivet

or

structural

area.

Such dents shall be

repaired

or

the

component

re-

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(See Figure 301.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)

EFFECTIVITY:
SRM-4

ALL

52-80-10

Page 101
May 15/92

STRUCTURAL REPAIR MANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.0~6

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure

EFFECTIVITY:
SRMII

ALL

101

52-80-10

Page 102
May 15/92

Learjet
Learjet

STRUCTURAL REPAIR MANUAL


MAIN LANDING GEAR INBOARD DOOR
i.

REPAIR

APPROVED REPAIRS
NOTE:

All dimensions

in inches unless otherwise

specified.

Chapter 51 for typical repairs for the main landing gear inboard door structure.
Learjet Maintenance Manual, Chapter 32, for repairs and maintenance procedures
for main landing gear inboard door components such as door seals and door latch mechanism.
See Figure 201 for main landing gear inboard door skin gap tolerances.

A.

Refer to

B.

Refer to the basic

C.

are

Main

Landing Gear

Outboard Door
0.040 (f0.020)- Inch Maximum

0.020-Inch
h~aximum

FWD

Main

Landing Gear

Inboard Door

~t

(VIEW LOOKING UP)


(RH SHOWN, LH TYPICAL)
Main

EFFECTIVITY:
SRM-4

ALL

Landing Gear Inboard Door Skin Gap Tolerances


Figure 201
52-80-10

Page 201
May 15/92

STRUCTURAL REPAIR MANUAL


MAIN LANDING GEAR OUTBOARD DOOR

STRUCTURAL IDENTIFICATION

,P

66C

EFFECTNITY:
SRM-4

Main

ALL

Landing Gear Outboard Door Structure Repair Index


Figure 1 (Sheet 1 of 2)
52-80-20

Page Z
May 15/92

~Learjetl
STRUCTURAL REPAIR MANUAL
DWG.

ITEM
NO.

EFF.

DESCRIPTION

NO.
2422520

Landing Gear Outboard


Assy., LH 8 RH

Main

MATERIAL

GAGE

2024-T42 Clad

0.040

2024-0 Clad

0.050

Fitting
Support Angle

2522521

Doubler

2522521

Filler

2522521

2522521

2522521

Support
Hinge Assy.
Hinge Half (2 ea.)
Hinge Pin

3
4

2522521

CODES
1

FIG. NO.

Door Pan

2422520
2422520
2322522
2522521

REPAIR

CODE

Door

Panel

FINISH

495
2024-T42 Clad
2024-T3 Clad

0.100

2024-T3 Clad
S520

0.190

0.040

1
1

MS35823-4C

MS20253P-1092

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

EFFECTIVITIES
23-002 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005; 29-001
THRU 29-004; 31-001 AND SUBSEQUENT; 35-002 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

~e

EFFECTIVITY:

Main

ALL

Landing Gear Outboard Door Structure Repair Index


Figure 1 (Sheet 2 of 2)
52-80-20

Rage 2
SRM-4

Jun 1/95

~j Learjet
STRUCTURAL REPAIR MANUAL
MAIN LANDING GEAR OUTBOARD DOOR
i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGE LIMITS


All dimensions

NOTE:
A.

are

in inches unless otherwise

Fasteners

(1) Loose
tions

failed rivets

or

the

on

are

remaining

performed
fer to Chapter 51
(2) Loose

or

trations

failed

on

performed

not allowed. A loose

rivets and lead to

to ensure that

B.

specified.

joint

or

failed rivet

can cause

increased stress concentra-

failure. A careful

progressive joint
inspection must be
the
from
of
loose
the
area
or failed rivet. (Respread

failure has not

for definition of rivet failure.)

screws are not

surrounding

allowed. A loose

screws

to ensure that the

increased stress concenA


careful
failure.
progressive joint
inspection must be
failure has not spread from the area of the loose or failed screw.
or

failed

screw can cause

and lead to

joint

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired,
C.

and refinished in accordance with

Chapter

re-

51.

Deformation

(1) Deformation of the main landing gear outboard door,

structure

assembly or door hinges is

not al-

lowed.
D.

Corrosion(See FigurelOl.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original mate-

E.

Dents

rial thickness

more

than

specified.

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to
F.

rivet

or

structural

area.

Such dents shall be

repaired

or

the

component

re-

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to

Chapter 51

for

protective

procedures.)
replaced or repaired

treatment

if scratches reduce the original material


by more than specified.
Nicks(See Figure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings andForgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)

(2) Structural components

must be

thickness

G.

H.

EFFECTIVITY:
SRM-4

ALL

52-80-20

Page 101
May 15/92

STRUCTURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020
0.025

0.0175

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFFECTIVITY:
SRM~

ALL

101

52-80-20

Page 102
May 15/92

Learjet
~g Learjet]

STRUCTURAL REPAIR MANUAL


MAIN LANDING GEAR OUTBOARD DOOR
i.

REPAIR

APPROVED REPAIRS
NOTE:

All dimensions

A.

Refer to

B.

Refer to the basic

C.

are

in inches unless otherwise

specified.

Chapter 51 for typical repairs for the main landing gear outboard door structure.
Learjet Maintenance Manual, Chapter 32, for repairs and maintenance procedures
for main landing gear outboard door components such as door seals and door latch mechanism.
See Figure 201 for main landing gear outboard door skin gap tolerances.

Main

Landing Gear

Outbcard Door

0.040 (fO.0U0)- Inch Maximum

0.020-Inch

Maximum

Main

FWD

Landing Gear

Inboard Door

(VIEW LOOKING UP)

(RH SHOWN, LH TMJICAL)


4-57B

Main

Landing Gear

Outboard Door Skin

Figure
EFFECTIVITY:

ALL

Gap Tolerances

201

52-80-20

Page 201
May 15/92

Leariet
Learlet

STRUCTU RAL REPAIR MANUAL


NOSE LANDING GEAR DOORS

STRUCTURAL IDENTIFICATION

i/

IdD

EFFECTIVITY:
sRM-4

Nose

ALL

Landing Gear Door Structure Repair Index


Figure 1 (Sheet 1 of 2)
52-81-00

Page 1
May 15/92

Learjet
Learjet/
STRUCTURAL REPAIR MANUAL
DWG.
NO.

ITEM

NO.

DESCRIPTION

2391062

EFF.

MATERIAL

GAGE

LH

RH

Door

2024-T42 Clad

0. 040

2310620

Door Pan

2024-T42 Clad

0.050

2310620

Door Actuator

2024-T42 Clad

0.080

2310620

Door Panel

2024-T42 Clad

0.040

2310620
2310620

Support
Support

Hinge Assy.
Hinge
Pin

1
1

MS20001Y4-4000

MS20001 Y4-3900

2310620

Retainer

2024-T42 Clad

0.032

2310620

Deflector

2024-T42 Clad

0.032

CODES
1

FIG. NO.

2310620

1 2310620

REPAIR

CODE

Noseianding GearDoorAssy,

FINISH

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

EFFECTIVITIES
23-002 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005; 29-001
THRU 29-004; 31-001 AND SUBSEQUENT; 35-002 AND SUBSEQUENT; 36-001 AND SUBSE-

QUENT

Nose

EFFECTIVITY:

ALL

Landing Gear Door Structure Repair Index


Figure 1 (Sheet 2 of 2)
52-81-00

Page
SRM~

May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ALLOWABLE DAMAGE

NOSE LANDING GEAR DOOR


i.

ALLOWABLE DAMAGELIMITS

All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

failed rivets

or

on

the

are

not allowed. A loose

or

failed rivet

can cause

increased stress concentra-

rivets and lead to

progressive joint failure. A careful inspection must be


that joint failure has not spread from the area of the loose or failed rivet. (Re-

remaining

performed to ensure
fer to Chapter 51 for definition of rivet failure.)
(2) Loose

or

failed

screws are not

allowed. A loose

or

failed

screw can cause

increased stress

concen-

trations on surrounding screws and lead to progressive joint failure. A careful inspection must be
performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
B.

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired, and refinished


C.
D.

re-

Chapter 51.

Deformation

(1) Deformation of the nose landing gear door, structure assembly or door hinges is not allowed.
Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

in accordance with

more

than

specified.

Dents

(1) Dents

are

permissible, if smooth and without abrupt changes in contour, do not exceed

(2.54 mm) in

depth,

do not exceed 10% of total surface

area

in

one

0.100 inch

(1) square foot, and

are

not

closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to
F.

G.

H.

rivet

or

structural

area.

Such dents shall be

repaired

or

the

component

re-

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(See Figure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTIVITY:
sras~

ALL

52-81-00

Page 101
May 15/92

STRUCTURAL REPAIR WIANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)
0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFFECTIVITY:

ALL

101

52-81-00

Page
sRM-4

102

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
NOSE LANDING GEAR
i.

DOR

REPAIR

APPROVED REPAIRS

NOTE:

All dimensions

in inches unless otherwise

specified.

Chapter 51 for typical repairs for the nose landing gear door structure.
Leajet Maintenance Manual, Chapter 32, for repairs and maintenance procedures
for nose landing gear door components such as door seals and door latch mechanism.
See Figure 201 for nose landing gear door skin gap tolerances.

A.

Refer to

B.

Refer to the basic

C.

are

0.030

0.030

Inch Maximum

Inch Maximum

0.040

Inch Minimum

0.060

Inch Maximum

(VIEW LOOKING DOWN)


M6B

EFFECTIVITY:
SRM-4

Nose

ALL

Landing Gear Door Skin Gap Tolerances


Figure 201
52-81-00

Page 201
May 15/92

CHAPTER

F USE LAG E

STRUCTURAL REPAIR MANUAL


Chapter
Section

Subject

Subject
FUSELAGE- STRUCTURAL IDENTIFICATION

Description
RepairIndex

................................................................53-00-00

............................................................................................................................53-00-00

...........................................................................................................................53-00-00

NOSE ASSEMBLY

STRUCTURAL IDENTIFICATION

....................................................53-10-00

Description
Nose Assembly Repair Index
............................................................................................................................53-10-00

(Model 23 Aircraft and Earlu Model 24 Series Aircraft)


Nose

Page

..................................................53-10-00

Assembly Repair Index

(Late Model 24 Aircraft and Model 25/28/29/31/35/36 Series Aircraft)


NOSE ASSEMBLY ALLOWABLE DAMAGE
Allowable

Damage Limits

NOSE ASSEMBLY

101

...................................................................................................53-10-00

Approved Repairs
STRUCTURAL IDENTIFICATION
ALLOWABLE DAMAGE

Allowable Damage Limits


FUSELAGE ASSEMBLY REPAIR

53-10-00

201

53-20-00

..........................................53-20-00

Description
FUSELAGE ASSEMBLY

53-10-00

....................................................................................................53-10-00

REPAIR

FUSELAGE ASSEMBLY

..........................53-10-00

...........53-20-00
101

....................................................................................................53-20-00

Approved Repairs

201

..................................................................................................................53-20-00

FUSELAGE FRAMES

Description

.........................................................................................53-20-00

STRUCTURAL IDENTIFICATION

...............................................53-21-00

............................................................................................................................53-21-00

FUSELAGE FRAMES ALLOWABLE DAMAGE...


Allowable Damage Limits

...............................................53-21-00

53-21-00

FUSELAGE FRAMES- REPAIR

53-21-00

Approved Repairs
FUSELAGE STRINGERS -STRUCTURAL IDENTIFICATION

Description

ALLOWABLE DAMAGE..........................................................53-22-05

Allowable Damage Limits


FUSELAGE STRINGERS -REPAIR

101

....................................................................................................53-22-05

........................................................................................53-22-05

53-22-05

Approved Repairs
WINDSHIELD STRUCTURE

Description

Repair

Damage Limits

201

53-24-00
1

WINDSHIELD STRUCTURE
Allowable

STRUCTURAL IDENTIFICATION....

............................................................................................................................53-24-00

Windshield Structure

201

.........................................53-22-05

............................................................................................................................53-22-05

FUSELAGE STRINGERS

101

53-21-00

Index

.....................................................................................53-24-00

ALLOWABLE DAMAGE

53-24-00
101

....................................................................................................53-24-00

WINDSHIELD STRUCTURE

REPAIR

.................................................................................53-24-00

Approved Repairs

53-24-00

201

FUSELAGE INSTRUMENT PANEL SUPPORT STRUCTURE


STRUCTURAL IDENTIFICATION...,.,........................................................................53-25-00

Description

............................................................................................................................53-25-00

53-Contents

Pagel
sRM-4

Jan 15/93

~-jtl
STRU~TURAL REPAIR MANUAL
Chapter
Section

Subject

Subject

Page

FUSELAGE INSTRUMENT PANEL SUPPORT STRUCTURE


ALLOWABLE DAMAGE

Allowable

Damage Limits

..............................................................................................53-25-00

101

....................................................................................................53-25-00

FUSELAGE INSTRUMENT PANEL SUPPORT STRUCTURE

REPAIR

........................53-25-00

Approved Repairs....

.........53-25-00

201

FUSELAGE CIRCUIT BREAKER PANEL SUPPORT STRUCTURE


STRUCTURAL IDENTIFICATION
.....................................................................................53-26-00

Description

............................................................................................................................53-26-00

FUSELAGE CIRCUIT BREAKER PANEL SUPPORT STRUCTURE


ALLOWABLE DAMAGE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53-26-00
Allowable Damage Limits
FUSELAGE CIRCUIT BREAKER PANEL SUPPORT STRUCTURE

101

....................................................................................................53-26-00

REPAIR ...............53-26-00

Approved Repairs
FUSELAGE SKINS

.........53-26-00

201

STRUCTURAL IDENTIFICATION....................................................53-28-00

Fuselage Skins Repair Index


(Model 23/24 Series Aircraft)

Fuselage

Skins

Repair

(Model 25/28/29 Series Aircraft with 24-1nch PassenaerlCrao Door).

Fuselage

Skins

Repair

53-28-00

.53-28-00

Index
Index

(Model 25128/29 Series Aircraft with 36-inch PassenaerlCrao Door).............................53-28-00

Fuselage Skins Repair Index


(Model 31/35/36 Series Aircraft)
FUSELAGE SKINS
Allowable

Damage

FUSELAGE SKINS

Approved Repairs

.......................................................................................53-28-00

ALLOWABLE DAMAGE

....................................................................53-28-00

Limits

53-28-00

REPAIR....

101

53-28-00
201

..................................................................................................................53-28-00

FUSELAGE SEAT AND BAGGAGE FLOOR STRUCTURE

STRUCTURAL IDENTIFICATION...,,.........................................................................53-29-00

Description

............................................................................................................................53-29-00

FUSELAGE SEAT AND BAGGAGE FLOOR STRUCTURE


ALLOWABLE DAMAGE
..............................................................................................53-29-00

Allowable

Damage

Limits

FUSELAGE SEAT AND BAGGAGE FLOOR STRUCTURE

Approved Repairs

Damage

.........,53-30-00
1

ALLOWABLE DAMAGE...........................................................53-30-00

Limits

....................................................................................................53-30-00

TAILCONE ASSEMBLY- REPAIR

Approved Repairs

53-29-00
201

STRUCTURAL IDENTIFICATION

............................................................................................................................53-30-00

TAILCONE ASSEMBLY

Allowable

REPAIR

..................................................................................................................53-29-00

TAILCONE ASSEMBLY

Description

101

....................................................................................................53-29-00

..................................................................................................................53-30-00

101

.........................................................................................53-30-00

201

53-Contents

Page
snM-4

Tan 15/93

STRUCTURAL REPAIR MANUAL


Chapter
Section

Subject

Subject

TAILCONE BULKHEAD (FRAME)- STRUCTURAL IDENTIFICATION


Tailcone Bulkhead (Frame) Repair Index

......................53-31-00

...........................................................................53-31-00

TAILCONE BULKHEAD (FRAME)- ALLOWABLE DAMAGE


Allowable Damage Limits

.......................................53-31-00

.........53-31-00

TAILCONE BULKHEAD (FRAME)- REPAIR

Tailcone

53-31-00

STRUCTURAL IDENTIFICATION

Allowable

ALLOWABLE DAMAGE..........................................................53-32-00

Damage Limits

101

....................................................................................................53-32-00

TAILCONE STRINGERS- REPAIR

Approved Repairs

201

53-32-00

Stringer Repair Index.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .,.,. . 53-32-00

TAILCONE STRINGERS

101

53-31-00

Approved Repairs............
TAILCONE STRINGERS

Page

........................................................................................53-32-00

201

..................................................................................................................53-32-00

TAILCONE VENTRAL FIN AND STRINGER

STRUCTURAL IDENTIFICATION ....53-33-00


Tailcone Ventral Fin and Stinger Repair Index (Model 35/3 6 Series Aircraft)
53-33-00
53-33-00
Stinger Repair Index -(Model 31 Series Aircraft). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TAILCONE VENTRAL FIN AND STRINGER ALLOWABLE DAMAGE
Allowable Damage Limits
TAILCONE VENTRAL FIN AND STRINGER REPAIR
53-33-00

.....................53-33-00

....................................................................................................53-33-00

Approved Repairs
Tailcone Dorsal

STRUCTURAL IDENTIFICATION

....53-34-00

Assembly Repair Index.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53-34-00

TAILCONE DORSAL ASSEMBLY


Allowable

201

..................................................................................................................53-33-00

TAILCONE DORSAL ASSEMBLY

Damage Limits

Approved Repairs

ALLOWABLE DAMAGE

.........................................53-34-00

101

....................................................................................................53-34-00

TAILCONE DORSAL ASSEMBLY

101

REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53-34-00
201

..................................................................................................................53-34-00

TAILCONE SKINS

STRUCTURAL IDENTIFICATION
Tailcone Skins Repair Index
TAILCONE SKINS ALLOWABLE DAMAGE

...................................................53-35-00

..................53-35-00

....................................................................53-35-00

Allowable

Damage Limits

TAILCONE SKINS

101

....................................................................................................53-35-00

REPAIR

..................................................................................................53-35-00

Approved Repairs

.........53-35-00

DELTA FINS

STRUCTURAL IDENTIFICATION..........
Delta Fins Repair Index
DELTA FINS ALLOWABLE DAMAGE
Allowable Damage Limits
DELTA FINS REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53-36-00

.........................................................................................................53-36-00

.........53-36-00
101

....................................................................................................53-36-00

Approved Repairs

201

..................................................................................................................53-36-00

FUSELAGE FUEL CELL

STRUCTURAL IDENTIFICATION

..........................................53-40-00

Description

53-40-00

FUSELAGE FUEL CELL ALLOWABLE DAMAGE


Allowable Damage Limits
....................................................................................................53-40-00

201

.........,53-36-00

..........................................................53-40-00

101

53-Contents

Page3
SRM-4

Tan 15/93

STRUCTURAL REPAIR MANUAL


Chapter
Section

Subject

Subject
FUSELAGE FUEL CELL

Approved Repairs

REPAIR

.........................................................................................53-40-00

201

..................................................................................................................53-40-00

FUSELAGE FUEL CELL STRUCTURE STRUCTURAL IDENTIFICATION .................53-40-05


53-40-05
Fuselage Fuel Cell Structure Repair Index
FUSELAGE FUEL CELL STRUCTURE ALLOWABLE DAMAGE..................................53-40-05
Allowable Damage Limits
FUSELAGE FUEL CELL STRUCTURE

Approved Repairs
Description

REPAIR

................................................................53-40-05

201

..................................................................................................................53-40-05

STRUCTURAL IDENTIFICATION

......................................53-50-00

............................................................................................................................53-50-00

ALLOWABLE DAMAGE

KEELBEAM ASSEMBLIES
Allowable

Damage

Limits

....................................................,.53-50-00

101

....................................................................................................53-50-00

REPAIR

KEELBEAM ASSEMBLIES

Approved Repairs

.....................................................................................53-50-00

201

..................................................................................................................53-50-00

FORWARD KEELBEAM

STRUCTURAL IDENTIFICATION

......53-51-00
53-51-00

Forward Keelbeam Repair Index


FORWARD KEELBEAM ALLOWABLE DAMAGE
Allowable Damage Limits

FORWARD KEELBEAM

53-51-00
53-51-00

1
....................................................53-53-00

101

Allowable Damage Limits


UNDERWING KEELBEAM REPAIR

....................................................................................................53-53-00

Aft

Allowable

201

..................................................................................................................53-53-00

Limits

REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Approved Repairs

......................................................53-55-00

..................................................................................53-55-00

ALLOWABLE DAMAGE

Damage

AFT KEELBEAM

53-53-00

STRUCTURAL IDENTIFICATION

Fuselage Keelbeam Repair Index

AFT KEELBEAM

201

STRUCTURAL IDENTIFICATION....................................53-53-00

Underwing Keelbeam Repair Index.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53-53-00


UNDERWING KEELBEAM ALLOWABLE DAMAGE

Approved Repairs

101

53-51-00

REPAIR

UNDERWING KEELBEAM

53-51-00

Approved Repairs

AFT KEELBEAM

101

....................................................................................................53-40-05

KEELBEAM ASSEMBLIES

Page

.......................................................................53-55-00

53-55-00

101

53-55-00
53-55-00

201

53-Contents

Page 4
SRM-I

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Learjet
Learjet/

STRUCTURAt REPAIR MANUAL


Chapter

Chapter
I

Section

Subject
53-TJTLE
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5S-Contents
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Page

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1*53-21-00

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1
1
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1*53-21-00
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53-21-00
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19
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27
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6
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102

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1
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7
8
9
10
12

Pages; Destroy Superseded or Deleted Pages.


Asterisk indicates pages revised, deleted, or added by current revision.
The portion of the text affected by the current revision is indicated by a vertical lii~e in the outer
Insert Latest Revised

margin of the

page.
53

sRM4

List of Effective

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Page 1

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Learjet
~Learjet
STRUCTURAL REPAIR MANUAL
Chapter

Chapter
I

Section

Subject

Page

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15

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1
1
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1
1
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1
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1
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3
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101

53-29-00

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53-29-00

201

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53

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Tun 1/95
Jun 1/95
May 15/92
May 15/92
May 15/92

List of Effective

Pages
Page 2

Jun 1/95

Learjet
Learjet 1

STRUCTURAL REPAIR MANUAL


Chapter

Chapter

Section

Section

Subject

Page

53-35-00
53-36-00
53-36-00
53-36-00
53-36-00
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53-40-00
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201
1

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5331-00
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5351-00
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*53-53-00
~53-53-00
*53-53-00
*5333-00
*53-53-00

102
201

*53-53-00

*53-53-00
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53-53-00
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1

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3
4

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53

List of Effective

Pages
Page 3

Jun 1/95
SRM~

Learjet
STRUCTURAL REPAIR MANUAL
FUSELAGE- STRUCTURAL IDENTIFICATION
i.

DESCRTPTION
NOTE:

The
the

following structural data covers the basic non-modified aircraft. When applicable, refer to
appropriate kit drawing for additions, modifications and changes to the structural compo-

nents and assemblies.

A.
B.

main frame is constructed of frames, stringers, keelbeams, longerons, a forward and aft
and frames around openings.
bulkhead
pressure
Located between frame 1 and frame 34 are transverse frames spaced approximately 3.5 to 17 inches
apart. The tailcone contains canted frames for attachment of the vertical stabilizer. Cutouts are located around the perimeter of the frames for stringer clearance. Frames 2 and 4 terminate where they
The

fuselage

wheel well. Frame 3 terminates where it meets the nose compartment access door
nose wheel well. Frames 6 through 8 terminate where they meet the windshield.
opening
Frame 11, and frame 12 ton aircraft eauirtt?ed with 36" Ilassenaerlcrau door), terminate where they meet
the passenger/crew door. Frames 16 through 21 terminate when the lower end meets a longeron
meet the

nose

and the

wing passes through the fuselage.


Longitudinal stringers are located around the perimeter of the frames, and are spaced approximately
5 inches apart. The stringers are aluminum extrusions cut to various lengths.
The forward, underwing and aft keelbeam assemblies, located along the bottom side of the aircraft,
provide a major structural component used to complete the fuselage structure when the wing assembly is installed. The keelbeams also provide housings for fuel and hydraulic lines and control cables.
Fuselage frames are interrupted at the keel and are continued through the keel by webs. The floorboards are secured on top of the forward keelbeam and become a part of the aircraft structure. Access covers, located along the bottom side of the keelbeams, form a smooth aerodynamic surface on
the bottom side of the aircraft. Refer to Chapter 51 for forward, underwing and aft keelbeam station
locations. Refer to 53-50-00 for keelbeam Master Repair Indexes.
A longeron extends longitudinally down each side of the fuselage at the point where the fuselage and
wing intersect.
where the

C.
D.

E.

F.

an ah pressure bulkhead are installed in the aircraft. The forward pressure bulkhead
is located at frame 5, the aft pressure bulkhead location will vary depending upon aircraft model and
fuel system configuration. Refer to Chapter 51 for forward and aft pressure bulkhead locations.

A forward and

EEFECTIVITY:
SRM-4

ALL

53-00-00

Page 1
May 15/91

Learjet
Learjetl

STRUCTURAL REPAIR MANUAL

Chapter/
Section/
Item
1

Nose

53-10-00

Assembly
Fuselage Assembly
Tailcone Assembly
Fuselage Fuel Tank Assembly

Keelbeam Assemblies

53-50-00

53-20-00
53-30-00

53-40-00

(TYPICAL)

Fuselage

Structure Master

Figure
EFFECTNITY:

ALL

Repair Index

53-00-00

Page
SRM~

May 15/91

Learjet I
Learjet
STRUCTURAL REPAIR MANUAL
NOSE AS SEMBLY

i.

STRUCTURAL IDENTIFICATION

DESCRIPTION
A.

The

nose

assembly

consists of the structure

structure consists of five

assembly

from frame

one

to and

including

frame 5. The

(5) major bulkhead assemblies, stringers, minor structural subassemblies,

and skins.
B.

assembly provides mounting provisions for various avionics and radio equipment, various
nose landing gear when retracted. Two nose access doors are inthe
to
aerodynamic configuration and protection of the equipment installed withcorporated provide
in the nose assembly. Two nose wheel doors complete the aerodynamic configuration on the lower
side of the nose assembly and also provides protection for the nose gear. (Refer to Chapter 52 for additional information pertaining to nose doors.)

The

nose

aircraft systems, and storage for the

EFFECTIVITY:

ALL

53-10-00

Page
sRM-a

May 15/92

STRUCTURAL REPAIR MANUAL


NOSE ASSEMBLY

STRUCTURAL IDENTIFICATION

(TYPICAL)
14-194C

EFFECTIVITY:
SRM-b

Assembly Repair Index


Figure 1 (Sheet 1 of 7)

Nose

23-002 THRU 23-099; 24-100 THRU

24-229, EXCEPT 24-218

53-10-00

Page 2
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

Nose

2311000
1

2311010

2311010
2311010
2311010

2311010
2311010

2311010
2311010
2311010
2311020

S151-1
3

2311030

I
1

2311030 1
2311030

2311030
2311030

1
1
1

2311030
4

2311030

2311040

2024T42 Clad

0.040

F4-1

2024T42 Clad

0.080

F4-1

Bracket

2024T42 Clad

S-549

2024T42 Clad

0.040

F4-1

0.040

F4-1

Bulkhead Instl., Frame No. 2

2024T42 Clad

S-633

S-633

S-591

0.040

1
1
1
1

I
I
I
I

Replace
Replace
Replace
Replace

0.040

51-70-04

2024-T42 Clad

0.040

Replace

2024-T3 Clad

0.040

2024-T3 Clad

0.040

Replace
Replace

2024-T42 Clad

0.032

51-70-04

2024-T3 Clad

0.032

2024-T3 Clad

0.032

2024-T3 Clad

0.040

1
1

I
I

Replace
Replace
Replace

2024-T3 Clad

0.040

2024-T3 Clad

0.040

Gusset

2024-T42 Clad

0.040

Bracket(2ea.)
FrameWeb(eea.)
Clip(4ea.)

2024-T42 Clad

2024-T42 Clad

Gusset(2 ea.)
Frame Web (2 ea.)
Clip
Connecting Plate
Angle
Bulkhead Instl., Frame No. 4
Frame Web (2 ea.)

1
1

Bulkhead Instl., Frame No. 3


Gusset

F4-1

0.050

Replace
Replace
Replace
Replace
Replace
Replace

1
1

2024-T42 Clad

0.040

51-70-04

Connecting Angle

2024-T42 Clad

0.063

2024-T3 Clad

0.032

I
I

Replace

Bracket

1
1

Angle

2024-T42 Clad

0.040

2311030 1

Filler

2024-T3 Clad

0.040

2311030 1

Gusset

2024-T3 Clad

0.040

I
I
I

2311030

Gusset(2ea.)

2024-T3 Clad

0.040

1
1
1
1

2311040

SpliceAngle

2024-T42 Clad

0.040

Channel(2ea.)

2024-T42 Clad

0.040

Replace
Replace
Replace
Replace
Replace
Replace

0.050

1
I

I
I

2311040
231 1 040

2311040 1

2311030

2311040
5

1
2

2311020
2311020

REPAIR
FIG. NO.

CODE

FlangeRing(eea.)
ZeeClip

ReinforcementAngle (2ea.)
Stiffener(2ea.)

2311020

IFINISH

I GAGE

Assembly, Fuselage

2311020

2311020

I
MATERIAL

Bulkhead Instl., Frame No. 1

Brace

I
EFF.

SupportAngle(2ea.)
1
Angle
Channel (2 ea.)
1
Support (2 ea.)
1
ISupport

2311010
2

I
DESCRIPTION

2311050
2411050

1
1

2310525
2310525
2310525
2310526

2310526

Bulkhead Instl., Frame No. 5

11

Doubler(2 ea.)
Supportlnstl.,LH&RH
SupportWeb
Angle
Support Instl., LH 8 RH
Support

1
1

2024-T3 Clad

2024-T42 Clad

0.032

2024-T42 Clad

0.032

1
1

2024-T42 Clad

0.032

Replace

Replace
Replace
Replace
Replace

1
1

Replace

Assembly Repair Index


Figure 1 (Sheet 2 of 7)

Nose

EFFECTIVITY:
SRM~

23-002 THRU 23-099; 24-100 THRU 24-229, EXCEPT 24-218

53-10-00

Page 3
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

I
DESCRIPTION

2311574

Supportlnstl.,LH&RH
Support(2ea.)
Supportlnstl.,LH&RH
Support
1
Support Instl., LH 8 RH
SupportWebb
Support Instl., LH 8 RH
1
SupportWeb
ISegmentlnstl.
Support
Support
Anglelnstl.,LH&RH
Supportlnstl.,LH&RH
Support
Supportlnstl.,LH&RH
Support
Suppartlnstl.,LH&RH
Support(8 ea.)
SafetyBand
SupportAngle

2311581

Frame Piece Instl.

2310527
2310527
2310533
2310533
2310531
2310531
2310538
2310538

2311267
2311267
2511229
2310533
2311575
2311575
2311577
2311577

2311583
2311583
2311050

2311581
2311580

2310521
2310521
2310521
2310522
2310522
2310522

2310523

2310537
2310532

2310537

IFINISH
MATERIAL

GAGE

REPAIR
FIG. NO.

CODE

2024-T42 Clad

0.032

2024-T42 Clad

0.040

2024-T42 Clad

0.040

2024-T42 Clad

0.040

2024-T42 Clad

0.063

2024-T42 Clad

0.063

Replace
Replace

2024-T42 Clad

0.040

Replace

2024-142 Clad

0.080

Replace

2024-T42 Clad

0.032

2024-T3 Clad

0.063

2024-T42 Clad

0.040

Replace
Replace
Replace

0.040

Replace

Replace
Replace
Replace

Replace

Replace

Replace

1
1
9
9

4
4

F4-1

Replace

1
1
1
1
1
1

F4-1

1
F4-1

Frame

2311584

I
EFF.

2024-T42 Clad

Stiffener, LH RH
Bearing Assy., LH 8 RH
Support Instl., LH 8 RH

Casting

2024-T42

0.040

Support
Angle
Supportlnstl.,LH&RH
Support
Angle
Washer(2 ea.)
Support Instl., Nose Gear
Support Instl., Nose Gear
SupportAngle(3 ea.)
SupportAngle(2 ea.)

2024-T42 Clad

0.071

2024-T42 Clad

0.063

I
I

1
1

2024-T42 Clad

0.071

2024-T42 Clad

0.063

2024-T3 Clad

0.100

1
1
1

2024-T24 Clad

0.080

2024-T24 Clad

0.063

I
I

Replace
Replace
Replace

4
9

2310532

Channel

2024-T24 Clad

0.063

2310532

Angle(2 ea.)

2024-T24 Clad

0.080

Web

2024-T24 Clad

0.080

Replace
Replace
Replace
Replace
Replace

Casting

51-71-00

2310532

2310537

2311579
2310509
2310509
2310510

Fitting, NoseWheelActuator
Channellnstl.,LH&RH
Channel

1
1

Channellnstl.,LH&RH

2024-T42 Clad

0.032

Replace

1
1

I
I

Replace
Replace

2310510

Channel

2024-T42 Clad

0.071

2310510

Angle

2024-T42 Clad

0.071

Assembly Repair Index


Figure 1 (Sheet 3 of 7)

Nose

EEFECTIVITY:
SRM-4

23-002 THRU 23-099; 24-100 THRU 24-229, EXCEPT 24-218

53-10-00

Page 4
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

I
DESCRIPTION

I
EFF.

I
MATERIAL

2310513 IHorizontalBeam Instl.

11

"I"Beam

11

S-642

11

2024-T42 Clad

0.071

11

2024-T42

0.063

2310513

Plate

2310513
231 0511

Clip

2310514

Doubler

Assy.,

LH 8 RH

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

F4-1
F4-1

13

2310514

Doubler

13

2024-T42 Clad

0.063

F4-1

2310514

Filler

13

2024-T3 Clad

0.050

F4-1

2310514

Channel

13

2024-T3 Clad

0.063

F4-1

2311583 IBeamlnstl.

2311583

4130 Steel

0.080

F8-1

4130 Steel

0.080

F8-1

4130 Steel

0.080

F8-1

S-566

Channel, Upper(2ea.)
Channel, Lower (2 ea.)

2311583
2311583

Splice Plate
SupportTee(2ea.)

2311583

Bulkhead Beam Instl., LH 8 RH


Beam Assy.

2311667

2311667
2311667
2311667

2311668
2311668
2311669

2311669
2310505 1
2310505

2310505
2310505
2310505

2310506 1
2310506
2310506

2310507

2310508

15

15

Bulkhead Beam Instl.


Beam Assy., LH 8 RH

Bulkhead Beam Instl.

14

LH 8 RH

Replace

S-630

F4-1

Replace

2024-T42 Clad

0.080

F4-1

2024-T3 Clad

0.032

F4-1

2024-T42 Clad

0.040

F4-1

14

Assy., LH 8
(2 ea.)
Splice Plate

I
I
I

I
2024-T42 Clad

0.032

F4-1

14

2024-T3 Clad

0.032

F4-1

RH

14

14

2024-T42 Clad

0.032

F4-1

14

2024-T3 Clad

0.032

F4-1

RH

14

14

2024-T42 Clad

0.032

F4-1

2024-T3 Clad

0.032

F4-1

6061-T6 Clad

0.063

F4-1

2311050

Web

2024-T3 Clad

0.032

F4-1

2024-T42 Clad

0.040

F4-1

2024-T3 Clad

0.125

F4-1

2311050

Plate

Replace
Replace
Replace

Replace
Replace
Replace

Replace
Replace
Replace
Replace

14

14

Splice

Replace
Replace
Replace
Replace

14

FramePiece

14

2311059
2311050

Replace
Replace
Replace

Channel(2ea.)
SplicePlate
Clip

Channel

2310508

F4-1

15

Beam

2310508

Bulkhead Beam Instl., LH 8 RH


Beam

BulkheadBeamlnstl.

2310508

15

Beam Assy., LH 8
Channel(2ea.)
Splice Plate

2310507

S-630

15

Bulkhead Beam Instl., LH 8 RH


Beam

BulkheadBeamlnstl.

2310507

S-571

I
I
I

Clip

Assy.,

Replace
Replace
Replace

I
I
I

S-630

SplicePlate

2310507

15
15

Channel

Replace
Replace
Replace

15

Bsam

Beam

2310506 1

Replace
Replace
Replace

(2 ea.)

Doubler

Replace
Replace
Replace

Nose

Assembly Repair Index


Figure 1 (Sheet 4 of 7)

EFFECTIVITY:

23-002 THRU

23-099; 24-100 THRU 24-229, EXCEPT 24-218

53-10-00

Page 5
SRM-4

Tan 15/93

Learjet
~Learjefl
STRU~TURAL REPAIR MANUAL
ITEM
NO.

DWG.
NO.

I
EFF.

2311050

DoublerAssy.

2311050

Doubler

MATERIAL

I
IFINISH
I GAGE
CODE

2024-T42 Clad

0.050

F4-1

2024-T3 Clad

0.080

F4-1

20

2024-T3 Clad

0.050

F4-1

2311050

Angle
SpliceAngle(2ea.)
Angle(4ea.)

10

S-545

2311050

Reinforcement

16

2024-T3 Clad

0.071

F4-1

2311050

Reinforcement

17

2024-T3 Clad

0.100

F4-1

2311050

Filler(2ea.)
Filler(2ea.)

14

2024-T3 Clad

0.032

F4-1

2311050

15

2024-T3 Clad

0.050

F4-1

2311050 1

Plate

19

2024-T3 Clad

0.063

2311050
2311050

Shim,Laminated

2311050
6

I
DESCRIPTION

2311250 1

18

Nose Wheel Box Instl.

2311250

Channel(2ea.)
Angle(Gea.)
Angle(2ea.)
BulkheadSegment

2311250

SupportAngle(eea.)

2311250
2311250

2311250

REPAIR
FIG. NO.

Replace
Replace
Replace

F4-1

0.062

1
1
1
1

I
I
I
I

1
1

2024-T42 Clad

0.040

2024-T3 Clad

0.040

2024-T42 Clad

0.080

2024-T42 Clad

0.040

S-549

2024-T42 Clad

S-306

2024-T42 Clad

0.040

2024-T3 Clad

0.032

2024-T3 Clad

0.032

2024-T42 Clad

0.040

Reinforcement Plate

2024-T3 Clad

0.050

2311250

EndPlate

2024-T42 Clad

0.050

2311250

AftSidePlate,LH&RH

2024-T42 Clad

0.050

2024-T42 Clad

0.050

2024-T42 Clad

0.050

1
1
1
i

I
I
I
i

2024-T42 Clad

0.063

2024-T3 Clad

0.040

2024-T42 Clad

0.050

S-512

S-571

SealAngle
2311250
Seal(Fwd)
2311250
ReinforcementAngle
2311250
TopPlate(Fwd)
2311250 1
Top Plate (Aft)
2311250
Pan,LH&RH(Bea.)

2311250

2311250 1

2311250

Support(2ea.)
Clip
BracketAssy.
Bracket(2ea.)
Gusset(4ea.)
Support
Angle(2ea.)
Angle(Sea.)

2311250

2311250
2311250
2311250

2311250
2311250
2311250

I
0.032

I
I

I
I

I
I

I
I

I
I

Filler

2024-T3 Clad

0.040

2311250

SupportChannel(2ea.)
Pan(eea.)
Cover(Gea.)
Clip

2024-T42 Clad

0.050

2024-T3 Clad

0.040

1
1

I
I

2024-T42 Clad

0.032

2024-T42 Clad

0.050

Doubler

2024-T42 Clad

1
1

I
I

MS20001 V4

2024-T42 Clad

0.040

2024-T42 Clad

0.032

1
1

I
I

2311250
2311250
2311250

HingeHalf

2311250
2311250

2311250

Channel, LH 6 RH
Aft Top Plate, RH

Nose

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.062

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Assembly Repair Index

Figure
EFFECTIVITY:

Replace
Replace

2311250
2311250

Replace
Replace
Replace
Replace
Replace
Replace

1 (Sheet 5 of 7)

23-002 THRU 23-099; 24-100 THRU 24-229, EXCEPT 24-218

53-10-00

Page
SRM-4

Jan 15/93

Learjet
STRUCTURAL REPAIR MANUAL
ITEM
NO.

DWG.

2311250
2311250
2311250

2311250

2311250 1

2317031 1
2317031
2310612

2310612
2411001
2310720
2311450
2311450
2311450
2311450

2311450

FIG. NO.

2024-T42 Clad

0.032

2024-T42 Clad

0.032

1
I

Doubler

2024-T3 Clad

0.050

Angle

0.040

Shim

2024-T3 Clad
2024-T3 Clad

2024-T42 Clad

0.050

2024-T42 Clad

0.050

2024-T42 Clad

0.050

Angle
Clip
Doubler(2 ea.)
Bracket Assy.

F4-1

Replace
Replace

2024-T42 Clad

0.032

51-70-02

8 RH

12

2024-T42 Clad

0.032

51-70-02

2024-T42 Clad

0.040

Replace

0.050

Replace
Replace

I
I

Replace
Replace
Replace

1
1

Access Door Instl.

SplicePlate
Lip, Lower (2 ea.)

IDoorAssy.
(Refer to Chapter 52)

I
F4-1

Equip.
Splice, Plate (2 ea.)

Channel

1
1

11

Nose

2311000 1

0.040

Replace
Replace
Replace
Replace
Replace
Replace

8 RH

HatSection

2311450

REPAIR

CODE

Stiffener

2311450

IFINISH

I GAGE

Bracket

1
1

I
MATERIAL

SidePlate,LH

IBradtetlnstl., RH

2310720

I
EFF.

Side Plate (2 ea.)

Skin, LH
Skin, LH

2311500

1
1

2024-T3 Clad

S-522

2024-T3 Clad

0.050

2024-T42 Clad

0.040

2024-T42 Clad

0.050

I
1
1

0.050

1
4

2024-T42 Clad

No. 19 LH 8 RH

S-554

No. 17 LH 8 RH

S-554

No. 16 LH 8 RH

S-554

No. 14 LH 8 RH

S-554

Replace

51-70-04

51-70-04

1
1

1
I

i
1

51-70-04

I
I
I
I

1
1
1
1

51-70-04

2311000

Stringer,
Stringer,
Stringer,
Stringer,

2311000

Stringer,

No. 13 LH 8 RH

S-522

Stringer,
Stringer,
Stringer,
Stringer,

No. 12 LH 8 RH

S-554

No. 18 LH 8 RH

5-554

No. 11 LH 8 RH

S-566

1
1
1
1

No. 10 LH 8 RH

S-554

51-70-04

15 LH 8 RH

14

S-566

15

S-554

I
I

1
1

51-70-04

15 LH 8 RH

1
1

2311000

2311000
2311000

I
DESCRIPTION

NO.

2311000
2311000
10

2311000

11

2311000
2311000
2311000

Stringer, No.
Stringer, No.

51-70-04
51-70-04
51-70-04
51-70-04

51-70-04

Assembly Repair Index


Figure 1 (Sheet 6 of 7)

Nose

EFFECTIVITY:

23-002 THRU 23-099; 24-100 TKRU 24-229, EXCEPT 24-218

53-20-00

Page
SRM~

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
CODES

EFFECTIVITIES

23-002 THRU

23-002 THRU

23-099; 24-100 THRU 24-229, EXCEPT 24-218


23-099; 24-146 THRU 24-229, EXECPT 24-218

23-002 THRU 23-014

24-100 THRU

23-002 THRU

24-229, EXCEPT 24-218


23-099; 24-100 THRU 24-145
24-146 THRU 24-229, EXCEPT 24-218
23-015 THRU 23-099; 24-100 THRU 24-124
24-122, 24-123, 24-140 THRU 24-229, EXCEPT 24-218

23-002 THRU 23-099

11

23-015 THRU 23-099; 24-100 THRU 24-229, EXCEPT 24-218


23-002 THRU 23-099; 24-100 THRU 24-119

12

24-120 THRU

13

24-150 THRU

10

24-229, EXCEPT 24-218


24-229, EXCEPT 24-218

14

23-002 THRU 23-029

15
16

23-030 THRU 23-099; 24-100 THRU 24-229, EXCEPT 24-218


23-002 THRU 23-009

17

23-01 0 TH RU

18

23-002 THRU 23-069

23-099; 24-1 00 TH RU 24-229, EXCEPT 24-21 8

19

23-070 THRU

20

24-100 THRU 24-129

23-099; 24-100 THRU 24-229, EXCEPT 24-218

NOTES:

Laminated shim stock, 0.002


sheet.

or

0.003 lamination per MIL-S-22499

Type

1 Class 1

or

Class 2 1145-H19 aiumi-

num

Nose

Assembly Repair Index


Figure 1 (Sheet 7 of 7)

EFFECTIVITY:

23-002 THRU 23-099; 24-100 THRU 24-229, EXCEPT 24-218

53-10-00

Page 8
May 15/92

STRUCTURAL REPAIR MANUAL


NOSE ASSEMBLY

STRUCTURAL IDENTIFICATION

(TYPICAL)
14-194C

EFFECTIVITY:
srud~

Nose

Assembly Repair Index


Figure 2 (Sheet 1 of 7)

24-218, 24-230 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005;

53-10-00

29-001 THRU 29-004; 31-002 AND SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

Page 9
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

2311010

FIG. NO.

Bulkhead Instl., Frame No. 1

FlangeRing(2ea.)

2024T42 Clad

0.040

F4-1

2024T42 Clad

0.080

F4-1
F4-1

2418119

Zee

2024T42 Clad

0.080

2311010

Bracket

2024T42 Clad

0.050

2418119

Support

2024T42 Clad

0.063

2311010

DoublerPlate

2024T3 Clad

0.050

2418119

Zee

2024T42 Clad

0.063

2311010

S-549

2311010

SupportAngle(2ea.)
Angle(2ea.)

2024T42 Clad

0.040

F4-1

2311010

Channel

2024T42 Clad

0.040

F4-1

2311010 1

Frame

2024T42 Clad

0.040

F4-1

2311010

Flange Door

2024T42 Clad

0.040

F4-1

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2311010

Support Angle

S-633

2311010

SupportAngle
SupportAngle

S-633

S691
0.063

F4-1

Replace

2311020

Seal

(2 ea.)

ChannelAssy.(2ea.)
ChannelAssy.(2ea.)
1

Bulkhead Instl., Frame No. 2

2311020

ReinforcementAngle (2 ea.)

2311020

Stiffener

S-556

2024T42 Clad

F4-1

F4-1

F4-1
F4-1

2024-T3 Clad

0.040

2024-T3 Clad

0.040

1
1
1
1

I
I
I

Replace
Replace
Replace
Replace

2311020 1

Stiffener

2024-T42 Clad

0.040

2311020

Gusset

2024-T42 Clad

0.040

2311020

FrameWeb(2ea.)
Clip(G ea.)

2024-T42 Clad
2024-T42 Clad

0.040

51-70-04

0.040

Replace

S151-1

2311030
2311040

Bulkhead Instl., FrameNo. 3


Gusset

1 2311030
2311030

FrameWeb

1
1

Bulkhead Instl., Frame No. 4

2024-T3 Clad
2024-T42 Clad

0.040

Replace

0.032

51-70-04

1
1

2024-T42 Clad

0.040

51-70-04

2311040

FrameWeb(2ea.)
ConnectingAngle

2024-T42 Clad

0.063

Bracket

2024-T3 Clad

0.032

2311030

Gusset

10

1
1
1

2311040 1

I
I

Replace
Replace
Replace
Replace
Replace

2311040

REPAIR

CODE

Zee

2418120

IFINISH
GAGE

2311010

2418120

I
MATERIAL

2311010

2311010

I
EFF.I

NoseAssembly, Fuselage

2511500
1

I
DESCRIPTION

2311040

2311040

2311050

1
1

2411050
2411050
2310525

2310525
2310525

Splice Angle (2 ea.)


Channel(2 ea.)
Bulkhead Instl., Frame No. 5
Bulkhead Instl., Frame No. 5

Doubler(2ea.)
Supportlnstl.,LH&RH
SupportWeb
Angle

2024-T3 Clad

0.040

2024-T42 Clad

0.040

2024-T42 Clad

0.040

1
1

0.040

I
1
1

I
i

11

12

2024-T3 Clad

1
1

2024-T42 Clad

0.032

2024-T42 Clad

0.032

Replace
Replace
Replace
Replace

Assembly Repair Index


Figure 2 (Sheet 2 of 7)

Nose

EFFECTIVITY:
SRM~

24-218, 24-230 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005;
29-001 THRU 29-004; 31-002 AND SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

53-10-00

Page 10
May 15/92

Learjet
~Learjetl
STRUCTWRAL REPAIR MANUAL
ITEM
NO.

DWG.
NO.

I
DESCRIPTION

2310526
2310526
2310527
2310527

I
EFF.

Supportlnstl.,LH&RH
Support
Supportlnstl.,LH&RH
Support(3 ea.)

1
1

MATERIAL

0.032

2024-T42 Clad

0.032

2024-T42 Clad

0.040

2024-T42 Clad

0.032

2024-T42 Clad
2024-T42 Clad

0.063

2024-T42 Clad

0.040

2024-T42 Clad

0.080

RH

2310533

2311575

Support
Supportlnstl.,LH&RH
SupportWeb
ISegmentlnstl.
Support
Support
Supportlnstl.,LH&RH
Support

2411577

Supportlnstl.,LH&RH

2411577

Support
Support Instl., LH 8 RH
Support(8 ea.)
Support Plate (2 ea.)
Angle (2 ea.)
SafetyBand
Support Angle

2024-T42 Clad

0.032

2024-T3 Clad

0.040

2024-T42 Clad

0.050

2024-T3 Clad

0.063

2024-T42 Clad

Frame Center Piece Instl.

2310538
2311267
2311267
2511229
2311575

2411583
2311583

2411052
2411052
2411058

2411574
2411581
2411584
2311580

2488296

1
13
14

2310522

Replace

Replace

Replace
Replace

Replace

Replace

0.063

F4-1

0.040

1
1

I
I

Replace
Replace
Replace
Replace
Replace

0.040

Replace

2024-T42 Clad

Casting

Bearing Assy.

2024-T42 Clad

0.040

2024-T42 Clad

0.040

1
1

Doubler

Replace
Replace

2024-T42 Clad

0.063

2024-T42 Clad

0.080

Replace
Replace

2024-T42 Clad

0.071

2024-T42 Clad

0.063

1
1

I
I

Replace
Replace

2024-T42 Clad

0.071

2024-T42 Clad

0.063

1
1

I
I

2024-T3 Clad

0.100

Replace
Replace
Replace

2024-T24 Clad

0.080

2024-T24 Clad

0.063

1
1

I
I

12

2310522

11

2310521

Bulkhead

2310521

Replace

Bulkhead

2310521

2411050
2411050

Replace

2311050

1
1
2411050 1

Stiffener, LH 8 RH

Frame

2411521

FIG. NO.

2024-T42 Clad

2310538

REPAIR

CODE

2310533

Support Instl., LH

IFINISH
GAGE

Assy, Frame 5
Assy, Frame 5
Bulkhead Frame Support
SupportAngle
Support Instl., LH 8 RH
Support
Angle

Supportinstl.,LH&RH
Support

Angle
2310523 1
Washer(2 ea.)
2310537 Supportlnstl., NoseGear
2310537
SupportAngle(Sea.)
2310532
SupportAngle(2 ea.)
2310522

2310532

Channel

2024-T24 Clad

0.063

2310537

Web

2024-T24 Clad

0.080

Replace
Replace
Replace
Replace

Assembly Repair Index


Figure 2 (Sheet 3 of 7)

Nose

EFFECTIVITY:
SRMII

24-218, 24-230 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005;
29-001 THRU 29-004; 31-002 AND SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

53-10-00

Page 11
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

I
DESCRIPTION

EFF.

Fitting, NoseWheelActuator
ChannelSupport

2410514
2410509

Channellnstl.,LH&RH

2411243

2410509
2410510

Channel

Channellnstl.,LH&RH

I
MATERIAL

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

0.063

I
1

1
I

51-71-00

2024-T42 Clad

2024-T42 Clad

0.032

Replace

Replace

2410510

Channel

2024-T42 Clad

0.071

2410510

Angle

2024-T42 Clad

0.071

Replace
Replace

Replace
Replace
Replace
Replace

2410513

HorizontalBeamlnstl.

2410513 I."I"Beam

S-642

2410513

Plate

241 0511

Clip
SupportPan
Doubler Assy.,

2024-T42 Clad
2024-T42

0.063

2024-T42 Clad

0.063

2024-T42 Clad
2024-T3 Clad
2024-T3 Clad

0.050

0.050

0.100

Replace
Replace
Replace

2024-T3 Clad

0.040

Replace

2410514
2411051

LH 8 RH

Doubler

2411051

Filler

Doubler

2411054
2411054
2411055
2411055

F4-1
F4-1

2411051
2411053

0.071

ChannelAssy.

Channel

Bulkhead Beam Instl., LH 8 RH


Beam

1
1

S-630

2024-T42 Clad

0.063

2411056

SupportAngle(2 ea.)
SupportAngle(2 ea.)

2024-T3 Clad

0.040

2411057

Filler

2024-T3 Clad

0.050

Filler

2024-T3 Clad

0.050

2411059 1

Filler

2024-T3 Clad

0.050

I
I
I

2411059 1

Doubler

2024-T3 Clad

0.040

1
1
1
1

2411055

2411057

Doubler

2024-T3 Clad

2411061

2411059 1

Washer

S-610

2411582

SupportTee

S-566

2411583
2411583

Horizontal Beam Instl., LH 8

RHJ

Channel, Upper (2 ea.)


Channel, Lower (2 ea.)

2411583
2411583

Splice

Plate

0.125

I
1

F4-1

1
I
I

F4-1
F4-1

1
1

4130 Steel

0.080

F8-1

4130 Steel

0.080

F8-1

4130 Steel

0.080

F8-1

Replace
Replace
Replace

2411667

Bulkhead Beam Instl., LH 8 RH1


8eam

S-630

2411667

Clip

S-571

S-630

F4-1
F4-1

2411667

2411668

Bulkhead Beam Instl., LH 8 RH


Beam

2411669

Bulkhead Beam Instl., LH 8 RH


Beam

1
1

S-630

2614023 IBracket

S-642

2614023

2024-T3 Clad

Spacer

Replace
Replace

2411668
2411669

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.040

Replace

Replace
Replace
Replace

Nose

Assembly Repair Index


Figure 2 (Sheet 4 of 7)

EFFECTIVITY:

24-218, 24-230 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005;

53-10-00

29-004; 31-002 AND SUBSEQUENT; 35-003 AND SUBSEAND SUBSEQUENT


36-001
QUENT;

Page 32
May 15/92

29-001 THRU

SRMI

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

2311250

1
1

2311250

2311250
2311250
2311250

2311250
2311250
2311250

2311250
2311250

1
1

IFINISH
GAGE

0.050

Replace

2024-T42 Clad

0.040

2024-T3 Clad

0.040

1
1

I
I

2024-T42 Clad

0.080

2024-T42 Clad

0.040

S-549

2024-T42 Clad

S-306

2024-T42 Clad

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

(2 ea.)
Angle(Gea.)
Angle(2 ea.)
Bulkhead Segment
SupportAngle(2ea.)
Seal Angle
Seal(Fwd)
ReinforcementAngle
TopPlate(Fwd)
Top Plate (Aft)
Pan, LH 6 RH (2 ea.)

0.040

2024-T3 Clad

0.032

2024-T3 Clad

0.032

1
1
1
1

I
I
I
I

1
1

I
I

Replace
Replace

1
1
1

I
I
I

Replace
Replace
Replace
Replace
Replace

0.032

2024-T42 Clad

0.040

2024-T3 Clad

0.050

2311250

EndPlate

Aft Side Plate, LH 6 RH

2024-T42 Clad
2024-T42 Clad

0.050

2311250

2024-T42 Clad

0.050

2024-T42 Clad

0.050

2024-T42 Clad

0.063

2024-T3 Clad

0.040
0.050

2311250

Support (2 ea.)
2311250
Clip
2311250
BracketAssy.
2311250
Bracket(~ea.)
2311250
Gusset(4ea.)
2311250
Support
2311250 1
Angle (2 ea.)
2311250 1
Angle(5 ea.)

0.050

2024-T42 Clad

S-512

S-571

Filler

2024-T3 Clad

0.040

2311250

2024-T42 Clad

0.050

2311250

SupportChannel(eea.)
Pan(2ea.)

2024-T3 Clad

0.040

2311250

Cover

2024-T42 Clad

0.032

2311250

Clip

2024-T42 Clad

0.050

2311250 1

Doubler

2024-T42 Clad

0.062

2311250

Hinge
Angle

Half

MS20001V4

2024-T42 Clad

0.040

1
1
1
1

I
I
I
I

Replace
Replace
Replace
Replace

1
1

I
I

I
i

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2311250

Channel LH 6 RH

2024-T42 Clad

0.040

1
1

2311250

2024-T42 Clad

0.032

2311250

AftTopPlate,RH
SidePlate(2ea.)

2024-T42 Clad

0.032

2311250

SidePlate,LH

2024-T42 Clad

0.032

1
1

2311250 1

Doubler

2024-T3 Clad

0.050

2311250

Angle

2024-T3 Clad

0.040

2311250 1

Shim

2024-T3 Clad

0.040

2317031

Angle
Clip

2024-T42 Clad

0.050

F4-1

2024-T42 Clad

0.050

F4-1

2317031

Replace

2311250 1

2311250

Reinforcement Plate

2311250 1

REPAIR
FIG. NO.

CODE

2024-T42 Clad

Nose Wheel Box Instl.


Channel

2311250

I
MATERIAL

Gusset

2311250 1

I
EFF.

GussetAssy.

2618138
2618138

I
DESCRIPTION

Replace
Replace
Replace
Replace
Replace

Assembly Repair Index


Figure 2 (Sheet 5 of 7)

Nose

EFFECTIVITY:

SRM-4

24-218, 24-230 THRU 24-357; 25-001 THRU 25-373; 28-001 THRU 28-005;
29-001 THRU 29-004; 31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

53-10-00

Page

13

Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

NO.

DWG.
NO.

NoseGearSafetyCam Instl.
Angle(2 ea.)
Clip(2 ea.)

2317085

2317085
2317085

REPAIR
FIG. NO.

CODE

S-512

2024-T42 Clad

0.050

F4-1
F4-1

2024-T3 Clad

0.125

2024-T42 Clad

0.063

2411471

Bracket

2024-T42 Clad

0.040

Cam

MountingBracket

Instl.

Replace
Replace
Replace
Replace
Replace

2488676

Pan

2024-T3 Clad

0.040

2488676

Zee

2024-T3 Clad

0.040

2024-T42 Clad

0.050

Replace
Replace
Replace

19

2024-T42 Clad

0.050

20

2024-T42 Clad

0.050

1
1

I
I

Replace
Replace

11

2024-T42 Clad

0.032

51-70-02

12

2024-T42 Clad

0.032

51-70-02

2024-T42 Clad

0.040

Replace

2024-T3 Clad

0.050

Replace

S-522

2024-T3 Clad

0.050

2311450

SplicePlate
Lip,Lower(2ea.)

2024-T42 Clad

0.040

2311450

HatSection

2024-T42 Clad

0.050

1
1

I
I

Replace
Replace
Replace
Replace

I
I

Replace
Replace

2310612

Doubler(2 ea.)

19

2388366 IDoublerlnstl.

Doubler

2388366
2688149 1

Doubler

2610612

Bracket

2610612

Bracket

17

Assy.
Assy.

18

Skin, LH 8 RH
2411001
Skin, LH 8 RH
2310720 IBradtetlnstl., RH
2311500

2311450

Bracket

2310720

Nose

Equip.:

1
Access Door Instl.

Splice,Plate(eea.)

2311450

2311450 IStiffener
2311450

DoorAssy.
(Refer to Chapter 52)

2311450

1
1

2311000

Channel

2024-T42 Clad

0.050

2511500

Channel

2024-T42 Clad

0.050

No. 19 LH 6 RH

12

S-554

51-70-04

No. 19 LH 8 RH

11

S-554

51-70-04

No. 18 LH 8 RH

12

S-554

51-70-04

17 LH 8 RH

12

S-554

51-70-04

17 LH

RH

11

S-554

51-70-04

16 LH

RH

12

S-554

51-70-04

16 LH 8 RH

11

S-554

51-70-04

14 LH 8 RH

12

S-554

51-70-04

14 LH 6 RH

11

S-554

51-70-04

13 LH 8 RH

12

S-554

51-70-04

13 LH 8 RH

11

S-522

51-70-04

12 LH 8 RH

12

S-554

51-70-04

12 LH

RH

11

S-554

51-70-04

18 LH 8 RH

12

S-554

51-70-04

No. 18 LH 8 RH

11

S-554

51-70-04

2511500
2311000

2511500

Stringer,
Stringer,
Stringer,

2511500

Stringer, No.
Stringer, No.
Stringer, No.
Stringer, No.
Stringer, No.
Stringer, No.
Stringer, No.
Stringer, No.
Stringer, No.
Stringer, No.
Stringer, No.

2311000

Stringer,

2511500
2311000
2511500
231 1 000

IFINISH
GAGE

Pan

2488676

I
MATERIAL

2411471

2317093

I
EFF.

DESCRIPTION

2511500
2311000
2511500
2311000
2511500
2311000

1
1

Assembly Repair Index


Figure 2 (Sheet 6 of 7)

Nose

EFFECTIVITY:

s~M-a

24-218, 24-230 THRU 24-357; 25-001 THRU 25-373; 28-001 THRU 28-005;
29-001 THRU 29-004; 31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

53-10-00

Page

14

Jan 15/93

~j Learjet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

10

2511500
2511500

2311000
11

2511500
2311000

2311000
2611130
2311000

CODES
1

EFF.

DESCRIPTION

Stringer,
Stringer,
Stringer,
Stringer,
Stringer,
Stringer,
Stringer,
Stringer,

MATERIAL

GAGE

FINISH
CODE

REPAIR
FIG. NO.

No. 11LH

12

S-566

51-70-04

No. 11RH

12

S-544

51-70-04

No. 11 LH 8 RH

11

S-566

51-70-04

No. 10 LH 8 RH

12

S-554

51-70-04

No. 10 LH 8 RH

11

S-554

51-70-04

No. 15 LH 8 RH

15

S-566

51-70-04

No. 15 LH 8 RH

16

S-554

51-70-04

No. 15 LH 8 RH

11

S-554

51-70-04

EFFECTIVITIES
24-218, 24-230 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004;

SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT


24-218, 24-230 THRU 24-248; 25-002 THRU 25-087
24-249 THRU 24-357; 25-088 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004;
AND SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT
31-002 AND

2
3

25-002 THRU 25-066, EXCEPT 25-061


24-218, 24-230 THRU 24-357; 25-061, 25-067 THRU

25-002 THRU 25-087

24-252 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU

25-373; 28-001 THRU 28-005; 29-001 THRU


29-004; 31-002 AND SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

AND

SUBSEQUENT;

35-001 AND

29-004; 31-002

SUBSEQUENT; 36-001 AND SUBSEQUENT

25-002 THRU 25-066, EXCEPT 25-061

24-350 THRU 24-357; 25-227 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU
AND SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

10

31-002

29-004;

31-002

24-357; 25-227 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004;
SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT
24-218, 24-230 THRU 24-246; 25-061, 25-067 THRU 25-077

31-002

24-146 THRU
AND

11

13

24-247 THRU 24-357; 25-061, 25-078 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004;
31-002 AND SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT
24-218, 24-230 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004;

14

35-625 AND

12

35-001 THRU 35-624; 36-001 THRU 36-055


15

16
17
18
19
20

SUBSEQUENT; 36-056 AND SUBSEQUENT


24-218, 24-230 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004;
35-001 THRU 35-504; 36-001 THRU 36-052
31-002 AND SUBSEQUENT; 35-505 AND SUBSEQUENT; 36-053 AND SUBSEQUENT
24-218, 24-230 THRU 24357; 25-002 THRU 25-289; 28-001 THRU 28-005; 29-001 THRU 29-004;
35-001 THRU 35-278; 36-001 THRU 36-044
25-290 THRU 25-373; 35-279 AND SUBSEQUENT; 36-045 AND SUBSEQUENT
24-273 THRU 24-350; 25-061, 25-135 THRU 25-226; 35-001 THRU 35-124; 36-001 THRU 36-032
24-351 THRU 24-357; 25-227 THRU 25-373; 35-125 AND SUBSEQUENT; 36-033 AND SUBSEQUENT

Nose

Assembly Repair Index


Figure 2 (Sheet 7 of 7)

EFFECTIVITY:
SRM-4

24-218, 24-230 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005;
29-001 THRU 29-004; 31-002 AND SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

53-10-00

Page 15
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
NOSE AS SEMBLY

i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS

All dimensions

NOTE:
A.

in inches unless otherwise

are

specified.

Fasteners

(1) Loose

or

failed rivets

are

not allowed. A loose

or

failed rivet

can cause

increased stress concentrainspection must be

failure. A careful

tions on the remaining rivets and lead to progressive joint


performed to ensure that joint failure has not spread from the area of the loose or failed rivet. (Refer to Chapter 51 for definition of rivet failure.)

(2) Loose

or

trations

failed

on

performed
B.

screws are

surrounding

not allowed. A loose

failed

screw can cause

increased stress

concen-

must be

failure. A careful

inspection
progressive joint
joint failure has not spread from the area of the loose or failed

screws

to ensure that the

or

and lead to

screw.

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired, and refinished


C.
D.

re-

Chapter 51.

Deformation

(1) Deformation of the nose assembly structure is not allowed.


Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
Structural
(2)
components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

in accordance with

more

than

specified.

Dents

permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not

(1) Dents
(2.54

are

closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to
F.

rivet

or

structural

area.

Such dents shall be

repaired

or

the

component

re-

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to

Chapter 51

for

protective treatment procedures.)


replaced or repaired

(2) Structural components must be


thickness by more than specified.
G.

if scratches reduce the

original

material

Nicks(See Figure 101.)


(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to

protective treatment procedures.)


components must be replaced or repaired if nicks reduce the original material thickthan
ness more
specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.
Chapter 51

for

(2) Structural

Fl.

EFFECTIVITY:
SRM-4

ALL

53-10-00

Page 101
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFFECTIVITY:
SRM-4

ALL

101

53-20-00

Page 102
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
NOSE ASSEMBLY
i.

REPAIR

APPROVED REPAIRS
A.

RefertoChapterlil fortypicalrepairs.

Em7ECTTVITY:
SRM-4

ALL

53-10-00

Page 201
May 15/92

Learjet I
STRUCTURAL REPAIR MANUAL
FUSELAGE ASSEMBLY
1.

STRUCTURAL IDENTIFICATION

DESCRIPTION
A.

The

fuselage assembly

consists of the structural assemblies from frame 5 to frame 22. A forward and

aft pressure bulkhead are installed in the aircraft. The forward pressure bulkhead is located at
frame 5, the aft pressure bulkhead location will vary depending upon aircraft model and fuel system

an

configuration.

EFFECTIVITY:

Refer to

31-001 AND

Chapter 51

for forward and aft pressure bulkhead locations.

SUBSEQUENT; 35-001 AND SUBSEQUENT;

36-001 AND SUBSEQUENT


SRM-4

53-20-00

Page

Jan 15/93

E~Learjef
STRUCTURAL REPAIR MANUAL
STRUCTURAL IDENTIFICATION

FUSELAGE ASSEMBLY

Frame 17A

Frame 20

Frame 22

Frame 5

Frame 7

Frame 9

Frame 11

Frame 13

Frame 13D

Frame 13B

Frame 14

Frame 16

FS 378.05

FS 402.42

FS 421.42

FS 160.77

FS 184.78

FS 209.19

FS 234.19

FS 258.01

FS 283.99

FS 308.49

FS 332.66

FS 355.49

(Ref)

(Ref)

(ReO

(Ref)

(Ref)

(Ref)

(Ref)

(Ref)

(Ref)

(Ref)

Frame 18

(Ref)

(Ref)
Frame 13A
I

Frame 4

Frame 6

Frame 8

Frame 20

Frame 12

Frame 13E

FS 151.12

FS 172.19

FS 196.99

FS 221.59

FS 246.09

FS 271.99

FS 296.49

FS 321.24

FS 346.63

FS 368.68

(Ref)

(Ref)

(Ref)

(Ref)

(Ref)

(Ref)

(ReO

cRef,

cRef,

(Ref)

Frame 13C

Frame 15

FS381.79

Framel7

(Ref)

FramelB

Frame 21

FS 392.50

(Ref)

9)

(6)

(5)

(I

1911

I18

I_;

;;i;

I~

1;1 i~

7~P"

I:

i~il
s-~-4

I--re

f~_-f-;

~lr I!I

--1i
1!1

;-----Ti

r;I
;=--;L1

.:jj

i
t

i----~

i_--J-~

O
_~-

I---,--

(VIEW LH SIDE LOOKING INBOARD)


(TYPICAL)

2-150D

EFFECTn/TITY:

Fuselage Assembly Repair Index


Figure 1(Sheet 1 of 15)
SUBSEQUENT; 35-001 AND SUBSEQUENT;
SUBSEQUENT, EQUIPPED WITH 24-INCH
PASSENGER/CREW DOOR
31-001 AND

36-001 AND
SRM-4

53-20-00

Page 2
Jan 15/93

FS411.95

(Ref)

Learjet
STRUCTURAL REPAIR MANUAL
FUSELAGE ASSEMBLY

STRUCTURAL IDENTIFICATION

Frame 17A
FS 378.05

(Ref)

FrameZO

Frame22

(Ref)

(ReO

Frame 13D

Frame 13

Frame 1~

Frame 9

Fmme 7

Frame 5

FSZ58.01

88 23419

FS u)9.19

FS1~.78

F5160.77

(ReO

(Refi

(Ren

(ReO

(Refl

FS35j.49

FSJ~2.66

FS308.49

(Ref)

(Refi

(ReO

(ReD

Frame 15

Frame 17

Frame 18

Frame 1JB

FS 283.99

FS 402.42

F5421.42

Frame ~4

Frame 16

Fmme6

Frame 4

FS2n.99

FS 246.09

FS 221.59

FS 196.99

FS~72.19

FS 151.12

[Ref)

(ReO

(Ref)

(Refl

~Ref)

FS 368.68

FS 346.63

FS 321.24

(ReO

(ReD

(Ref)

(Ref)

(Refi

(Ref)

Frame 19

FS 392.50

(Ref)

(Ref)

~(17)1

/I(

I,

III

II

C-

i.

L~

jl

1~

1.

I--------

t--

II

-r-

FmmeB

Frame 13C

FS381.79

Frame 21

FramelO

Frame 13A

FS 296.49

FS411.95

Frame 12

Frame 13E

_I

r_______~

i-

I,

4--

ic~

I
;Lr~i

(i
I

i-

ir,jI

i
I

ii

rl

;f~;-;
f

iii

II

,t

!II:

II

II

II

I~
,I

~Tjl-

1,7

1(1

I I
,I

;I
I

i,.

1~1

1,,

/i

I i

,\__,__

=-7

ii

II

II!:

I,

i --

i
r

1,

r----

nl~

I,

II
i

II

bt~-tr

r;;;-----r-r--

ii

I
I

II

I,

71"

II);

,______

Iri

--C----4

Lf----

I
~,-----___

c------i.

r-

(VIEW RH SIDE LOOKING INBOARD)


(TWICAL)

nao

EFFECT~VITY:

Fuselage Assembly Repair Tndex


Figure 1 (Sheel 2 of 15)
31-001 AND
36-001 AND

SRM-4

SUBSEQUENT; 35-001 AND SUBSEQUENT;


SUBSEQUENT, EQUIPPED WITH 2I-INCH

PASSENGER/CREW DOOR

53-20-00

Page 3
Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

DWG,

NO.

NO.

I
DESCRIPTION

2611003

I
EFF.

Fuselage Structure Assembly


Fuselage Frames Instl.
(Refer to 53-21-00)
Fuselage Stringers Instl.
(Refer to 53-22-00)
Fuselage Windshield Instl.
(Refer to 53-24-00)
Fuselage Instrument Panel

MATERIAL

IFINISH

REPAIR

CODE

FIG. NO.

I GAGE

Structure Instl.

(Refer to 53-25-00)
Fuselage Circuit Breaker

Panel

Structure Instl.

(Refer to 53-26-00)
Fuselage Skins Instl.
(Refer to 53-28-00)
Fuselage Keelbeam Assemblies
(Refer to 53-50-00)
1

2311150

IBulkheadlnsti. (Frame 15)

1
1

2311150

Stiffener, Center
Stiffener, LH 8 RH (5 ea.)

2311150

Angle,Support

2311150

2311150

S-554
S-554

1
1

S-565
2024-T42 Clad
2024-T42 Clad
2024-T3 Clad

I
I

I
I

0.050

0.063

1
1

I
I

FrameWeb
Stiffener

1
1

2024-T3 Clad
4130 Steel

0.120

2311154

Strap(4 ea.)
Strap(2 ea.)
Strap,Outer

2311155

Strap,Outer

4130 Steel

0.063

2311153

IFitting, Longeron
SafetyBand(2ea.)

2311150

2311150
2311153

2311150

1
1

2311150

Shim

2311150

Plate

2311150

Stiffener, LH

2311150

SafetyBand

(2ea.)
8 RH

2024-T3 Clad

0.032

2024-T42 Clad
2024-T3 Clad

0.080

0.063

2024-T3 Clad

0.040

Replace

2024-T3 Clad

0.040

2024-T42 Clad
2024-T42 Clad
2024-T3 Clad
2024-T42 Clad

0.080

2311150

WebAssy.

2311150
2311151
2

2618326

2511321

0.025

Web

2311150

Replace

IWebAssy.

F8-1

Replace
Replace
Replace
Replace
Replace
Replace

Shim, Laminated (Max. 0.032)

2311150

F8-1

0. 025

Web

0.080

2024-T42
2024-T3 Clad

2311150
2311150

0.063

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Stiffener(2ea.)
Fitting

Doubler, RH Side Only


Skin Doubler, Escape Hatch

4
1

1.250
0.025
0.080

Replace
Replace
Replace
Replace
Replace

Fuselage Assembly Repair Index


Figure 1 (Sheet 3 of 15)
EFFECTIVITY:

31-001 AND

SUBSEQUENT; 35-001 AND SUBSEQUENT;

53-20-00

Page 4

SRM~

36-001 AND SUBSEQUENT, EQUIPPED WITH 24-INCH


PASSENGER/CREW DOOR

Jan 15/93

Learjetl
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

2511330

2611330

2611330

2611330

I
DESCRIPTION

2511000

2511295

2311479

1
1
1

Window Doubler, RH Aft


Window Doubler, RH Fwd
Window Doubler, LH Fwd
Window Doubler, LH Aft

Splice

Band

(4 ea.)
Inner Skin Instl., Door Frame

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

2024-T42 Clad

0.063

2024-T42 Clad

0.063

2024-T42 Clad

0.063

1
1

I
I

2024-T42 Clad

0.063

2024-T42 Clad

0.063

1
1

I
I

1
1

I
I

1
1

I
I

Replace
Replace
Replace
Replace
Replace

1
1

2024-T42 Clad

0.040

0.050

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

2024-T42 Clad

0.050

2311479 1

Flex Conduit

1
1
1

Flex Conduit

(2 ea.)
Rigid Conduit
Clip(2 ea.)

1
1

5052-0 Tube

0.035

2024-T42 Clad

0.032

Channel
Intercoastal

0.040

Skin

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

1
1

0.040

Skin

2024-T3 Clad

0.040

1
1
1

I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2024-T42 Clad

0.020

Replace

2024-T42 Clad

0.020

2024-T3 Clad

0.050

2024-T42 Clad

0.080

1
1
1

I
I
I

Replace

2024-T3 Clad
2024-T42 Clad

0.063

0.032

I
I

Replace
Replace
Replace
Replace
Replace

2511314

2311479
2311479
2311479
2311479
2511295

1
1

2511295 1
2511295 1
2511295 1
2511295 1
2611092

2611092

2511002 1
2311560
2311560

Track

Support)

Filler

ILongeron Instl.,
Top Centerline Fwd
1
Safety Band (2 ea.)

2311560

Web, LH
Web, LH
Web, LH

2311560

Angle(2 ea.)

2311560
2311560

0.040

Replace

Replace

RH Center
RH Fwd
8 RH Aft

Torsion Bar Instl., Lower Door

2311272
2311272

0.040

Frame, LH 8 RH

(Curtain
Strap

2511000

0.040

Frame, LH 8 RH

(Curtain Track Support)

10

I
MATERIAL

Stiffener(8)
Clip(2 ea.)
Stiffener(7 ea.)
Clip(4 ea.)
Clip(3 ea.)

2511314

I
EFF.I

2024-T42 Clad

0.032

2024-T42 Clad

0.032

2024-T42 Clad

0.040

1
1

FittingAssy.

2311272

Plate

4130 Steel

0.100

2311272

Fitting

4130 Steel

3/8 Dia

Replace
Replace

2311272

(Bearing

6061-T6

0.090

Replace

6061-T6

I Replace

Bracket

2024-T42 Clad

Spacer
EndFitting

Phenolic

4130 Steel

Plate

2311272
2311272 1
2311272 1
2311272
2311272
2311272

Sleeve

Torsion Bar

Assy.

0.040

I
1.5 Dia

Replace
Replace
Replace

Replace
Replace
Replace

F8-1

2311272

Torsion Bar

2311272

Link

A151 17-4 P.H. SS


A151 17-4 P.H. SS

2311272

Link

A151 301 SS

5/16 Dia
0.125
0.125

F-21

1
F-21

Fuselage Assembly Repair Index


Figure 1 (Sheet 4 of 15)
EFFECTIVITY:

31-001 AND

36-001 AND
SRM-4

SUBSEQUENT; 35-001 AND SUBSEQUENT;


SUBSEQUENT, EQUIPPED WITH 24-INCH

PASSENGER/CREW DOOR

53-20-00

Page 5
Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

11

2311623 1

Shim

ISupport

2311623

12

2311623 IAnale
Plate
2311623
Stiffener
2511674
2511674
Angle
2511674

2511664

I
0.100

2024-T3 Clad

0.050

I
I

S-591

2024-T3 Clad

0.190

2024-T42 Clad
2024-T42 Clad

0.050

I
I

I
I

1
I
I
1
1

I
I
I
I
I

Replace

1
1
I
I

I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace

2024-T3 Clad

10

1
1

I
I

0.250

I
I
6061-0

0.190

6061-0

0.100

2315122
2315122 1
2315122
2315122

2315122
2315122

2615123
3315123
2615289
2615123

3315123
2615289
2615123
3315123
2615289

2615123
2615123
2315122

2615181
2411002

I
2024-T42 Clad

0.050

2024-T42 Clad
S-554
S-520

0.040

1
1

IAngle
Sector Support Instl.
1
Sector Support Instl.
1
Bearing Plate
Bracket Assy., Upper
1
Bracket Assy., Upper
1
Bracket Assy., Upper
1
1
SectorSupport
1
SectorSupport
1
SectorSupport
1
Spacer
Spacer
Spacer
Bracket Assy., Upper (2 ea.)
1
Sector Support
1
1
Bearing Plate
Clamp Support (2 ea.)
Clip(2 ea.)
1

1
1

Bracket

Replace

I
I

2315122

Replace

1
1

0.050

2315122

I
I
I
I

Replace
Replace
Replace
Replace

2024-T42 Clad

2311684 IChannel
Bellcrank Support Instl.,
2315122 1

Angle
Angle
Angle
SupportAssy.

I
I
I
I
I

0.050

2311684 IPlate

2315122

I
1
I
I
1

8
9

RH

I Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Bracket

1
1
1
I

10

Rudder LH

REPAIR
FIG. NO.

CODE

IFitting
1
Spacer
JackPadSupport Instl.
Bracket Assy.

2311677

IFINISH
GAGE

IFitting

2315122 1

15

S-578

2511666

2311677

14

2511666

2511666
13

2024-T3 Clad

Stiffener(2ea.)
Clip
Fitting

2511674

S-551

Fitting Instl. (2 ea.)

Bracket(2ea.)
AngleAssy.(2ea.)

2311623

I
MATERIAL

Tee

2311623

I
EFF.

Support Instl.

2311623

2311623

I
DESCRIPTION

1
I
I

2024-T42 Clad

S-738

0.050

1
I

I
I

0.050

1
I

I
I

I
I
1
1
1

I
I
I
I

1
1

I
I

0.050

1
I

I
I

1
1

I
I

1
1

I
I

10
11

2024-T42 Clad

1
11

12

1
1

I
I

13

11

2024-T42 Clad

0.050

12

0.050

13

2024-T42 Clad
2024-T42 Clad

11

2024-T42 Clad

0.050

12

2024-T42 Clad

0.050

2024-T42 Clad

13

12

0.050

12

2024-T42 Clad

0.050

12

2024-T42 Clad

0.100

11

2024-T42 Clad
2024-T42 Clad

0.050

0.050

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Fuselage Assembly Repair Index


Figure 1 (Sheet 5 of 15)
EFFECTIVITY:

snM-4

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT, EQUIPPED WITH 24-INCH

PASSENGER/CREW DOOR

53-20-00

Page

Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

NO.

DWG.
NO.

2411002
2411002

1
1

2411002

I
DESCRIPTION

Splice Angle (6 ea.)


Splice Angle (6 ea.)
Splice Angle

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

MATERIAL

15

S-544
S-748

1
1

I
I

16

S-544

16

S-544

I
I
I

14

2411002 IDoubler

I
I

2411321 1

Channel

2024-T42 Clad

0.040

2411321

Gusset(2 ea.)
Gusset(2ea.)

2024-T42 Clad
2024-T42 Clad

0.040
0.040

I
1
1
1

2024-13 Clad

0.050

2024-T3 Clad

0.050

I
1

10

2024-T42 Clad

0.040

10

2024-T42 Clad

0.040

10

2024-T3 Clad

0.040

10

2024-T3 Clad

0.050

10

2024-T42 Clad
2024-T42 Clad
4130 Steel

0.040
0.125

1
1
1
1
1

18

2024-T42 Clad

0.063

19

2024-T42 Clad

0.063

1
I

I
I

0.063

I
1
1
I

I
I
I
I

2511333

2514303

Doubler Instl., LH 8 RH
Doubler

26183811

Doubler Instl.

17

DoublerAssy.

17

2514303

2618382

2513315
2513315
2513315

2513193

2513193

2513193
2511340

2511340
3111097 i
2388162

2388162

1
1

2388162

2388162

2388162
2388162
3111098

3111098
3111098
2615101
2615101
2315123

2315123
2315123
2315123
2315123

10
10

Replace
Replace

0.040

j
i
i
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace

18
19
20

Clip(4 ea.)
Clip(2 ea.)
Support Assy., LH 8 RH
Support
SupportAssy.,LH&RH
Support
Support, LH 8 RH
Support Assy., LH 8 RH (2 ea.)
Support
Angle(2ea.)
Pedestal 8 Controls Support

20

2024-T42 Clad

0.063

20

2024-T42 Clad

0.040

1
1

I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

18

19

I
2024-T42 Clad
2024-T42 Clad

19
19
20

I
2024-T42 Clad

18

0.063
0.063

RH

BearingSupport,LH&RH
Bearing Support, LH RH

Angle(2ea.)
SupportFrame
Bearing Support,

Replace

10

Bracket
Shoulder Harness Instl.
Shoulder Harness Instl.
Shoulder Harness instl.

Structure Instl.
Intercostal, LH

17

Support,LowerFwd
Support,UpperFwd
Doubler(3ea.)
Spacer
Support, Lower Aft
Support, Upper Aft

2513315

2388162

Seat Belt Instl.

2513315

Replace
Replace
Replace
Replace
Replace
Replace
Replace

Doubler

2618382

16

I
EFF.

2024-T42 Clad

0.063

Replace

Fwd

21

2024-T42 Clad

0.050

Fwd

22

0.050

I
I

2024-T42 Clad
2024-T42 Clad

1
1

0.040

2024-T42 Clad

0.063

2024-T42 Clad

0.050

1
1
1

Replace
Replace
Replace

Replace
Replace

LH 8 RH Aft

Fuselage Assembly Repair Index


Figure 1 (Sheet 6 of 15)
SUBSEQUENT; 35-001 AND SUBSEQUENT;

EFFECTIVITY:

31-001 AND

SRM-4

36-001 AND SUBSEQUENT, EQUIPPED WITH 24-INCH


PASSENCERJCREW DOOR

53-20-00

Page

Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


ITEM
NO.

DWG.
NO.

2511370

2511370

2511370 1
2411371

2511370
2511370

2411371

2411280 1

Longeron Instl., LH 8 RH
AttachAngle(2ea.)

2411280

2411280
2411280

2411281
2411281

2411281
2411281

1
1

2411281

2411281

1
2411281 1
2411281
2411281

241 1281

2024-T42 Clad

0.063

2024-T3 Clad

0.063

Drag Block
Longeron

S-517

2024-T42 Clad

0.100

I
1

I
I

Filler

2024-T3 Clad

0.100

Drag Block, Fwd

S-5017

S-308

I
I

I
I

I
I

S-308

S-308

S-308

S-308
S-308

I
I
I

I
I
I

I
I
I

Aft

Door Frame Instl.

Seal,FwdUppar
Seal,AftLower
Seal, Aft Upper
Plug(eea.)
RainSealDiaphragm
Switch Support (8 ea.)
Guide Plate (8 ea.)
Tube Assy.
Seal Plate (2 ea.)
Garner

Splice,
Corner Splice,

1
i
1

Mat. No. 4554

0.013

2024-T42 Clad

0.080

4130 Steel

0.080

2024-T3 Clad

0.040

2024-T42 Clad

0.040

2024-T42 Clad
2024-T42 Clad

0.040

1
1
1

I
I
I

1
1

I
I

Aft
Fwd

Fwd

2024-T42 Clad
2024-T42 Clad

0.032

Corner Seal Retainer,


Corner Seal Retainer,

Aft

2024-T42 Clad

0.032

2024-T3 Clad

0.063

2024-T42 Clad

0.040

Doubler

2411281

Seal Retainer,
Tube Assy.

Upr
Upr

Upper

Tube

321

2411281

Tube

Stainless~

MS20001PX4

2411283

Hinge Pin
Hinge Half
1
Hinge Assy., Upper
HingeHalf
HingePin
HingeHalf

321 Stainless~MS20253-2-140

2411284

SealRetainer,Fwd

2411281
2411283

2411283
2411283

2411284
2411282
2411282
2411282
2411281

0.032
0.032

Replace
Replace
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

I
I

I
I

I
I

I
I

I
I
I

0.050

j
I
I

I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.050

Replace

2411281

2411281

Corner Seal Retainer, Lwr Fwd


Corner Seal Retainer, Lwr Aft

2411281
2411281

REPAIR
FIG. NO.

CODE

Seal,Bottom
2411280 1
Seal, Fwd Lower
2411280

IFINISH
GAGE

Doubler

2411280
2411280

I
MATERIAL

Seal,Top

2411280

I
EFF.

DESCRIPTION

1
1

ISealRetainer, Aft
1
Hinge Assy., Lower
HingeHalf(2ea.)
HingePin
Plate (3 ea.)

1
I
I

MS20253-5

~P

S-553
S-553

0.050

I
1
1

1
1

~P

1
1

0.050

301 Stainless

0.063

F18

Replace
Replace

Fuselage Assembly Repair Index


Figure 1 (Sheet 7 of 15)
EFFECTIVITY:

SRM-4

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT, EQUIPPED WITH 24-INCH

PASSENGER/CREW DOOR

53-20-00

Page

Jan 15/93

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.
2318763

2318763
2688038

2688038
2688038

26183971
2618398 1
2511416

RH

Angle(2ea.)
Doubler Instl. (2 ea.)
Angle(2ea.)
Angle(2 ea.)

2411323 1

2411323

2411323
2411323

2411323
2411323

2411323

2411323
2411328

2411325
2411328
2611127 1

Replace

2024-T42 Clad
2024-T42 Clad

0.050
0.050

1
1

I
I

Replace
Replace

2024-T42 Clad

0.020

2024-T3 Clad
2024-T3 Clad

0.090

0.032

Replace
Replace
Replace

23

27

(18 ea.)

Spacer

2024-T4 Rod

0.250

Bellcrank Drive

2024-T351 Plate

0.375

I
I

I
I

Bellcrankldler
Pin (2 ea.)
Pin

(2 ea.)
GuidePin(2ea.)
FlushLatch HandleAssy.
Spring Retainer
Spring
Connector Box Instl.

0.375

2024-T4 Plate

0.375

2024-T3

0.125

2024-T351 Plate

0.500

1
1
1

I
I
I

28

2024-T4 Al Rod
2024-T4 Al Rod

0.438

29
1

2024-T351 Plate

0.500

30

2611125
2611125

Support

2611126

Rib, LH

8 RH

LH

RH

Cover

2611128

Support(3ea.)
Filler(Gea.)

2611128

MS24585-C414

1
1
1

I
I
I

0.050

30

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

30

2024-T42 Clad

0.040

30

2024-T42 Clad

0.040

30

2024-T42 Clad

0.071

0.050

0.050

I
1

I
I

1
1

I
I

0.050

0.050

30

2024-T42 Clad

30

0.100
0.063

1
1

I
I

2024-T3 Clad

0.080

Replace

2024-T3 Clad

0.050

Replace

30

ABS Therm Plastic

0.063

Support
Support, LH

30

2024-T42 Clad

0.040

2611125

1
1

30

2611125

2611125

RH
Gusset, LH
Filler(2 ea.)
Bracket, LH 8 RH

30

S-626
2024-T42 Clad
2024-T3 Clad

30

2024-T42 Clad

IDoubler(FS196, between
Stringers 10 11)
Doubler(FS 196, between
26185511

31

Stringers

32

2511216

8 RH

(2 ea.)

Replace
Replace
Replace
Replace
Replace
Replace

0.040

30

2611125

Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Seal

2511183

Replace
Replace

30
S-522
2024-T42 Clad

2611128

F3

Replace
Replace
Replace

30
30

Assy.,

F3

0.438

Replace
Replace
Replace
Replace
Replace
Replace

1
1

End,LH&RH
End, LH 6 RH
Bracket,LH&RH

Cover

I
I

2611123

I
S-580
6061-T6

Cover

2611128

FIG. NO.

0.050

2611118
2611124

REPAIR

CODE

2024-T42 Clad

26

Angle Assy.
Angle
ISpacer
Linkage
1
ILinkage

2411323

IFINISH
GAGE

25

2411323

MATERIAL

Doubler Instl.
Doubler
Shim

I
EFF.

24

2411325 IExternalRelease Instl.


2411323

18

Doubler Instl., LH

Filler

2688151

17

I
DESCRIPTION

30

2618314

10

11)

Fuselage Assembly Repair Index


Figure 1 (Sheet 8 of 15)
EFFECTIVITY:

SRM-4

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT, EQUIPPED WITH 24-JNCH

PASSENGER/CREW DOOR

53-20-00

Page

Jan 15/93

STRUCTURAL REPAIR MANUAL


ITEM

NO.

DWG.
NO.

Stiffener(3ea.)
Filler

0.032

2024-T42 Clad

0.507

I
I

3111118

Support

33

3111118

Filler

3111119

Angle
Angle
Angle
Seal (4 ea.)

2511332

2511215

2511216

2511216 1
2511216

2619042 1

2411321
2311258

1
1

0.071

0.040

33

2024-T42 Clad
2024-T42 Clad

1
1
1

I
I
I

33

S-5001

0.010

33

S-5001

0.012

33

S-5001

0.015

I
I
I
I

34

Skin Doubler, LH Aft


Blower Evaporator Support

I
I
I
I
I

0.063

Channel

37

2024-T42 Clad

0.040

Clip(2 ea.)

37

2024-T42 Clad

0.040

2024-T3 Clad

0.050

1
1
1
1
1

2024-T42 Clad

0.040

2024-T42 Clad
2024-T42 Clad

0.050

0.050

2024-T3 Clad
2024-T3 Clad

0.050

1
1
1

Replace
Replace
Replace
Replace

2024-T3 Clad

0.250

2024-T351

1.600

1
1

I
I

Replace
Replace

0.040

1
I

I
I

0.063

Replace
Replace
Replace

2024-T42 Clad
2024-T42 Clad
2024-T3 Clad

0.050

1
1
1

I
I
I

0.050

Bracket

Channel(Above Escape Hatch)


Inner Skin Instl. (FS 160
to 209, RH
LH)

Filler

40

40

Escape Hatch Instl.


Escape Hatch Assy.
(Refer to Chapter 52)
Strap
1
Tee Support
1
IClipAssy.
ClipSupport
Clip
Doubler, Aft Fuselage Window
1
Stiffener

Plate Instl., LH

RH

0.063

0.160

1
1

1
1

2024-T3 Clad
NAS1464-038-05C
2024-T42 Clad

1
1

2511674

Clip(2 ea.)
Angle
Plate(LHOnly)
Plate(RHOnly)
Stiffener(3ea.)

2024-T3 Clad
2024-T42 Clad

2511674

Filler

2024-T3 Clad

0.063

j
1

2511674 1

Stiffener

2024-T42 Clad

0.063

2511674
2511674
2511674

Replace
Replace
Replace
Replace
Replace
Replace

2311258 1

2511674 1
2511674

2024-T42 Clad
2024-T42 Clad

2311258

2411322

36

39

2411322

0.063

Skin,LH&RH
Strap

2411322

2024-T3 Clad

35

2311258

2411322

0.010

1
1
1
1

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Bracket,LH&RH
RH
Bracket, LH

38

2411322

0.040

33

Skin,LH&RH

2411322

I
0.050

2311258

2411320

1
2024-T42 Clad
2024-T42 Clad

33

Structure Instl.
2511216

20

S-522

33

33

3111119

I
I

33

33

8 RH

I
1

0.507

Rib

3111119

FIG. NO.

2024-T42 Clad

3111118

3111119

REPAIR

CODE

33

3111118

Rib

IFINISH
GAGE

33

Cover

Assy., LH
Rib(2ea.)

3111118

I
MATERIAL

33

CoverAssy.,LH&RH

3111119

I
EFF.

Pressurized Connector Box Instl.

3111116 1
3111117
3111119
3111119

19

I
DESCRIPTION

1
1
1

0.050
0.080
0.050

Replace
Replace
Replace
Replace
Replace
Replace
Replace

Fuselage Assembly Repair Index


Figure 1 (Sheet 9 of 15)
EFFECTIVITY:

SRM-4

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT, EQUIPPED WITH 24-INCH

PASSENGER/CREW DOOR

53-20-00

Page

10

Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

NO.

DWG,
NO.

DESCRIPTION

I
MATERIAL

EFF.

GAGE

2511674 1

Plate

2024-T3 Clad

0.050

2511674

Stiffener

2024-T42 Clad

0.063

2511644

IFitting

2411324

IFINISH
CODE

REPAIR

FIG. NO.

1
1

I
I

Replace
Replace
Replace

1
1
I

I
I
I

Replace
Replace
Replace

I
1
1
1

I
I
I
I

Replace
Replace
Replace
Replace

Inner Doubler

Assy.,
(Escape Hatch)

2411324 IDoubler

41

6061-T6

0.040

2411324 IDoubler

42

0.040

41
42

2024-T42 Clad

41

2411323

Plate

41

2024-T42 Clad
2024-T42 Clad
2024-T3 Clad

0.040

2411326

Spacer(4 ea.)
Spacer(4 ea.)
NutRetainer(4ea.)
NutRetainer(4ea.)

6061-T6
2024-T42 Clad

2411323

Plate

42

2024-T3 Clad

0.090

1
1

2024-T42 Clad

0.040

1
1

I
I

Replace
Replace

2024-T42 Clad

0.050

2024-T3 Clad

0.125

1
1

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2411324
2411324

1
1

2411326

42

2411321 1
Frame(FS 350, RH Side
2489168 IDoublerlnstl.
2489168 1
2489168

Doubler
Radius Filler

2489168

Doubler

2489168 1

Wedae

2489168

2489168

2489168 1
2489168

Fwd

(2ea.)
I

Filler

2489168
2489168

(4 ea.)

DoublerAssy.,

2489168

Only)

Filler(2ea.)
Angle Assy.
Angle
Wedae
Doubler Instl.

0.090

I
2024-T3 Clad

0.040

2024-T3 Clad

0.190

2024-T3 Clad

0.050

2024-T3 Clad

0.025

(ADF Antenna)

0.040

A/R
A/R

I
I

2024-T42 Clad
2024-T3 Clad

0.050

0.190

2489168 1

Doubler

2024-T42 Clad

0.050

2489168

RadiusFiller(4ea.)
Doubler Assy., Aft (2 ea.)

2024-T3 Clad

0.125

1
1

I
I

0.160

I
1

I
I

2024-T3 Clad
2024-T3 Clad

2024-T3 Clad

0.160

1
1

I
I

2024-T3 Clad

0.025

2489168

2489168 1
2489168

Filler

Wedge
Filler(2ea.)
AngleAssy.
Angle

2489168
2489168
2489168
2489168
2489168 1
3118916

Wedae

1
1

Wedae

IDoublerlnstl. (ADFAntenna)

3118919 IDoubler

0.050

Replace
Replace
Replace

Replace
Replace
Replace

2024-T42 Clad
2024-T3 Clad

0.050

0.190

2024-T351 Clad

0.313

Filler

2024-T3 Clad

0.063

2511580

EndPlate

Clip

2024-T42 Clad
2024-T3 Clad

0.040

2511580

0.063

Filler

2024-T3 Clad

0.100

I
I

Clip

2024-T3 Clad

0.050

Shim, Laminated (Max. 0.032)

2511580
2511580 1

2511580 1
2511581

Replace
Replace
Replace
Replace

Crew Seat Rails Instl., LH 8 RH

21 1 2411473

Replace
Replace
Replace

Replace
Replace
Replace
Replace

Fuselage Assembly Repair Index


Figure 1 (Sheet 10 of 15)
EFFECTIVITY:

SRM-4

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT, EQUIPPED WITH 24-INCH

PASSENGER/CREW DOOR

53-20-00

Page

11

ran 15/93

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

DESCRIPTION

2511581 1

MATERIAL

Intercostal

2024-T3 Clad

0.040

0.040

2511581 1

Plate

2511581

Floor Board

Support

43

2511581

Floor Board Support


Zee, Rail Support
Zee, Rail Support

44

2024-T3 Clad
2024-T3 Clad
2024-T42 Clad
2024-T42 Clad

43

2024-T3 Clad

44

2024-T3 Clad

Channel, Rail Support


Channel, Rail Support
Seat Rail (3 ea.)
Seat Rail (3 ea.)

43

2024-T42 Clad

0.040
0.040
0.040

44

2024-T42 Clad

43

SS37

44

S-537

End Plate

45

2511581

2511581
2511581
2511581

2511582

2511582

1
1

2511580

Assy.

EndPlate

2511580

2511580
2511580
2511581
2511581
2511581
2511581

ClipAssy.(2ea.)
Clip(2ea.)
Intercostal Assy. (2 ea.)

45
45

Intercostal

Rail

Support

Assy. (2 ea.)

45

I Replace

0.040

I Replace

0.080

1
1
1
1

I Replace
I Replace
I Replace
I Replace
Replace
I Replace

0.040

0.040

I
2024-T3 Clad

0.063

I
2024-T42 Clad

0.040

1
2024-T3 Clad

0.040

2511581

Plate

45

2024-T3 Clad

0.040

2614063

Glareshieldlnstl.

46

2614063

Glareshield Instl.

47

2614063

Glareshield Instl.

48
46

2024-T42 Clad

0.050

49

6061-T6

0.050

46

2024-T42 Clad
2024-T42 Clad

0.050

49
49

3003-H14 Al

Doubler,LH&RH

49

Doubler,Center

49

2024-T3 Clad
2024-T3 Clad
2024-T3 Clad

2614063 IGlareshield
2614063

2614063

2614063

2614063
2614063
2611116
2611116

2611122

Angle
Angle
Screen

(3 ea.)

Pressurized ConnectorBox Instl.

1
1

Plate(2 ea.)
Cover Assy.,

I
I
I

0.050

Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.050

Replace

I Replace

I
I
1

I
I
I

I
I

I
I
1

I
I
I

0.050

I
0.050

50
50

LH

RH

51

Assy., LH

RH

52

Cover

53

2611122 IChannel

53

5-707
S-325

53

2024-T3 Clad

0.050

54

2024-T3 Clad

0.050

Filler(8 ea.)

26111161 Cover

Seal(8 ea.)

1
1

Rib Assy., LH
Rib Assy., LH
Rib Assy., LH
Rib

2611117 1

I
1

50

RH

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

1
1

lSupport

2511183
2611 117
2611117
2611117

I
I
I
I
I
I
i
I

2611122

I Replace

I
1
I
1
I
1
1
1

2611122

2611122

45

Glareshield

Zee

2614063 1

Replace

I Replace

45

Zee

FIG. NO.

2024-T42 Clad

45

REPAIR

CODE

0.080

45

(FINISH
GAGE

Angle Tie

2511581

22

EFF.

51

RH

55

RH

56
50

1
1
2024-T3 Clad

0.063

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Fuselage Assembly Repair Index


Figure 1(Sheet 11 of 15)
EFFECTIVITY:

SRM4

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT, EQUIPPED WITH 24-INCH

PASSENGER/CREW DOOR

53-20-00

Page

12

Tan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.
2611118

2611118

1
1

2611118 1
2611119

2611119

I
DESCRIPTION

1
1

2611119 1

End

I
EFF.

Assy., LH 8 RH
End Assy., LH 8 RH
End

51

57

End
End

Assy.,
Assy.,

RH

51

LH

RH

57

End

FIG. NO.

Replace

I Replace

1
I
I
1
I
I

I
I
I
I
I
I

0.063

1
1

I
I

0.063

I
I
I
I

0.063

I
I
2024-T3 Clad

50

REPAIR

CODE

1
1

IFINISH
GAGE

2024-T3 Clad

50

LH

I
MATERIAL

0.063

2611120

Angle Assy.
Angle Assy.
Angle
Angle

2611122

Gusset

50

2024-T3 Clad
2024-T3 Clad
2024-T24 Clad

2611122

Angle, LH RH
Support, LH RH
Support, LH RH
Cover(2 ea.)

50

S-522

60

2024-T3 Clad

0.032

56

2024-T3 Clad
2024-T42 Clad

0.032

1
1

0.050

2611120
2611120
2611120

2611122
2611122
2611122

58
59
58

59

50

1
1

I
I
0.063

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Fuselage Assembly Repair Index


Figure 1 (Sheet 12 of 15)
EFFECTIVITY:

SUBSEQUENT; 35-001 AND SUBSEQUENT;


SUBSEQUENT, EQUIPPED WITH 24-INCH
PASSENGER/CREW DOOR
31-001 AND
36-001 AND

SRM4

53-20-00

Page

13

Jan 15/93

Learjet
STRUCTURAL REPAIR MANUAL
CODES

EFFECTIVITIES

SUBSEQUENT;

SUBSEQUENT; 36-001 AND SUBSEQUENT


SUBSEQUENT; 36-001 AND SUBSEQUENT

35-001 AND

31-001 AND

2
3

31-001 THRU 31-034; 35-001 AND


31-035 AND SUBSEQUENT

31-001 AND

35-001 THRU 35-264; 36-001 AND SUBSEQUENT


35-001 THRU 35-477; 36-001 THRU 36-050
35-478 AND SUBSEQUENT; 36-051 AND SUBSEQUENT

6
7
8
9

10

SUBSEQUENT; 35-492 AND SUBSEQUENT;

36-051 AND SUBSEQUENT

31-001 THRU 31-027; 35-001 THRU 35-658, 35-660 THRU 35-662; 36-001 THRU 36-063
31-028 THRU 31-041, 31-043 THRU 31-051; 35-659, 35-663 THRU 35-666
31-042, 31-052 AND SUBSEQUENT; 35-676 AND SUBSEQUENT 36-064 AND SUBSEQUENT

12

35-001 THRU 35-519; 36-001 THRU 36-053


35-520 THRU 35-623; 36-054, 36-055

13

35-624 AND

14
15

35-001 THRU 35-534, 35-589, 35-590; 36-001 THRU 36-053


35-535 THRU 35-588, 35-591 AND SUBSEQUENT; 36-054 AND SUBSEQUENT

16

35-001 THRU

17

31-001 AND

18

31-001 THRU 31-022, 31-035 THRU 31-038; 35-478 THRU 35-668; 36-051 THRU 36-036
31-023 THRU 31-034; 35-662 THRU 35-666
31-039 AND SUBSEQUENT; 35-669 AND SUBSEQUENT; 36-064 AND SUBSEQUENT

11

19
20

SUBSEQUENT; 36-056 AND SUBSEQUENT

35-505; 36-001 THRU 36-053

SUBSEQUENT;

35-456 AND

SUBSEQUENT;

36-051 AND SUBSEQUENT

22

35-001 THRU 35-130; 36-001 THRU 36-033


35-131 AND SUBSEQUENT; 36-034 AND SUBSEQUENT

23

36-051 AND SUBSEQUENT

24

35-281 AND

25

26

35-001 THRU 35-281; 36-001 THRU 36-044


35-282 AND SUBSEQUENT; 36-045 AND SUBSEQUENT

27

31-011 AND

28
29

35-001 THRU 35-264; 36-001 THRU 36-044


35-265 AND SUBSEQUENT; 36-045 AND SUBSEQUENT

30

36-001 AND SUBSEQUENT

31
32

31-001 THRU 31-060; 35-390, 35-394 THRU 35-673; 36-048 THRU 36-063
31-061 AND SUBSEQUENT; 35-674 AND SUBSEQUENT; 36-064 AND SUBSEQUENT

33

31 SERIES AIRCRAFT EQUIPPED FOR EXTENDED RANGE

34

31-001 AND

35
36

35-001 THRU 35-091; 36-001 THRU 36-024


35-092 AND SUBSEQUENT; 36-025 AND SUBSEQUENT

37

36-001 THRU 36-059

38
39

35-001 THRU 35-122, 35-149 AND SUBSEQUENT; 36-001 THRU 36-032, 36-037 AND SUBSEQUENT
35-123 THRU 35-148; 36-033 THRU 36-036

40

35-123 AND

41

35-001 THRU 35-130; 36-001 THRU 35-034


35-131 AND SUBSEQUENT; 36-035 AND SUBSEQUENT

21

42

SUBSEQUENT; 36-045 AND SUBSEQUENT

SUBSEQUENT;

35-647 AND

SUBSEQUENT;

36-058 AND SUBSEQUENT

SUBSEQUENT; 35-265, 35-369, 35-371 AND SUBSEQU ENT

SUBSEQUENT; 36-042 AND SUBSEQUENT

Fuselage Assembly Repair Index


Figure 1 (Sheet 13 of 15)

SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT, EQUIPPED WITH 24-INCH

EFFECTIVITY:

31-001 AND

SRM-4

PASSENGER/CREW DOOR

53-20-00

Page

14

Jan 15/93

STRUCTURAL REPAIR MANUAL


43

35-001 THRU

44

35-630 AND

45

31-063

46

35-001

35-629; 36-001 THRU 36-055


SUBSEQUENT; 36-056 AND SUBSEQUENT
AND SUBSEQUENT; 35-675 AND SUBSEQUENT; 36-064 AND SUBSEQUENT
THRU 35-039; 36-001 THRU 36-016
THRU 35-642; 36-017 AND SUBSEQUENT
AND SUBSEQUENT; 35-643 AND SUBSEQUENT
AND SUBSEQUENT; 35-040 AND SUBSEQUENT; 36-017 AND SUBSEQUENT
AND SUBSEQUENT; 35-370, 35-390 AND SUBSEQUENT

47

35-040

48

31-001

49

31-001

50

31-001

51
53

35-370, 35-390 THRU 35-508


31-001 THRU 31-030; 35-509 THRU 35-664
31-001 THRU 31-030; 35-370, 35-390 THRU 35-664

54

31-031 AND

52

55

56
57
58
59
60

SUBSEQUENT; 35-665 AND SUBSEQUENT


31-072; 35-509 THRU 35-676
31-073 AND SUBSEQUENT; 35-677 AND SUBSEQUENT
31-001 AND SUBSEQUENT; 35-509 AND SUBSEQUENT
31-001 THRU 31-063; 35-001 THRU 35-674
31-064 AND SUBSEQUENT; 35-675 AND SUBSEQUENT
31-001 THRU 31-072; 35-370, 35-390 THRU 35-676
31-001 THRU

Fuselage Assembly Repair Index


Figure 1 (Sheet 14 of 15)
EFFECTIVITY:

SUBSEQUENT; 35-001 AND SUBSEQUENT;


SUBSEQUENT, EQUIPPED WITH 24-INCH
PASSENGER/CREW DOOR
31-001 AND

36-001 AND
SRM-4

53-20-00

Page

15

Jan 15/93

Learjet
STRUCTURAL REPAIR MANUAL
NOTES:

Laminated shim stock, 0.002

or

0.003 lamination per MIL-S-22499

Type

1 Class 1

or

Class 2 1145-H19 aluminum

sheet.

1/4 OD

3/16 ID Teflon

1/2 OD

3/8 ID Teflon

3/8 OD

0.065 Wall

Type

I~

FBG

or

Tubing

Tubing

Tubing

FBM per MIL-P-15035

Heat Treat to 180,000 PSI


Condition 1/2 Hard

Commercial Grade, Low

~g

Density Silicon Sponge Rubber

Tubing

0.650 OD

0.065 Wall 4130 Steel

0.187 OD

0.035 Wall 321 Stainless Steel

0.250 OD

0.035 Wall 321 Stainless Steel

321

or

347 Stainless Steel

Condition 1/4 Hard

~9

Make from NAS1169DD1OL

Screens 3/16. 0.032, 1/4- inch Centers

ABS Thermo Plastic 0.063,

Optional

to make from 0.060 Thermo Formidable Plastic

Fuselage Assembly Repair Index


Figure 1 (Sheet 15 of 15)

EFFECTIVITY:

SRM-1

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT, EQUIPPED WITH 24-INCH

PASSENGER/CREW DOOR

53-20-00

Page

16

Tan 15/93

Learietl
STRUCTURAL REPAIR MANUAL
FUSELAGEASSEMBLY-STRUCTURALIDENTIFTCATION
Frame 17A
FS 378.05

(ReD
Frame 18
Frame 5

Frame 7

Frame 9

FS 160.77

FS 184.78

FS 209.19

FS 234.19

(Ref)

(Ref)

(Ref)

(Ref)

Frame 6

Frame 8

Frame 10

FS 151.12

FS 172.19

FS 196.99

FS 22159

(Ref)

(Ref)

(Ref)

(Ref)

Frame 4

9)

FS 381.79

Frame 11

Frame 13

Frame 13D

Frame 138

Frame 14

Frame 16

FS 258.01

FS 283.99

FS 308.49

FS 332.66

FS 355.49

1
1

(Ref)

(Ref)

(Ref)

Frame 13E

Frame 13C

FS 245.59

FS 271.99

FS 296.49

FS 321.24

(Ref)

(ReO

(ReO

(Ref)

------~L;

ii

litiTr~

~it

II I

_J~;i;

FS 346.63

FS 368.68

FS 392.50

(Ref)

(Ref)

(Ref)

(ReO

(7)

Cj

In I

I ,I

Il

II

ii\
il ii

(19

ii

IiI

(Ref)
Frame 21
FS 411.95

j/l

;Sil

(ReD
Frame 19

at,I:ii 1cIi -ii ilipI ia


ti

_Ji
i,

(6)

Frame 22
FS 421,42

Frame 17

Frame 15

Frame 13A

Fame 20
FS 402.42

(Ref)

(Ref)

Frame 12

(Ref)

ii[i
I

L___~

!_____.

iit I

ii ii
i Il~i

ii ii
ii ii __1__

-----,,,r---I

;I

;i

iic--~

ii

iblU

~uf

---------if---

~CiFC;

r,

-bll
i,if

i1

i II

13)

(16~

(11)

(15)

(n)

(le)

(12

(VIEW LH SIDE LOOKING TNBOARD)

(TYPICAL)

2-15JD

Fuselage Assembly Repair Index


Figure 2 (Sheet 1 of 15)

EFFECTIVITY:

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;

SRM-4

36-001 AND SUBSEQUENT, EQUIPPED WITH 36-INCH


PASSENGER/CREW DOOR

iii

;I

53-20-00

Page

17

Jan 15/93

I ii

~L

STRUCTURAL REPAIR NIANUAL


FUSELAGE ASSEMBLY

STRUCTURAL IDENTIFICATION

Frame 17A

Frame 22

Frame 20

FS 421.42

FS 402.42

(ReR

(ReO

FS 378.05

Frame 16

Frame 14

Frame 13B

Frame 13D

Frame 13

Frame 11

Frame 9

Frame 7

Frame 5

(Rff)

FS 355.49

FS 332.66

FS 308.49

FS 283.99

FS 258.01

FS 234.19

FS 209.19

FS1&1.78

FS 160.77

(ReD

(Ref)

(Ref)

(Ref)

(Ref)

(Ref)

(Ref)

(Ref)

(Ref)

Frame 13C

Frame 13E

Frame 18

Frame 17

FramelS

Frame I3A

FS 381.79 1

FS 368.68

FS 346.63

FS 321.24

FS 296.49

FS 271.99

IRef)

(Ref)

(Ref)

(ReR

(ReR

(Ref)
Frame 21

Frame 19

FS 411.95

FS 392.50

(Ref)

(Ref)

Frame #12
FS 245.59

(Ref)

Frame lO

FS 221.59

(Ref)

Frame 6
FS 172.19

FS 151.12

(Ref)

(Ref)

(Ref)

I;I

i
s

f"

;i

i!lli;:---~II-lf
I

I&

-----~lliZ---- --F
L------

-----r

i:----.~____

L----4

r
I
,~I, ,=,,i~Z----------h

(VIEW RH SIDE LOOKING ZNBOARD)


(TYPICAL)

2-1491)

EFFECTZ?VITY:

Fuselage Assembly Repair Index


Figure 2 (Sheet 2 of 15)
SUBSEQUENT; 35-001 AND SUBSEQUENT;
SUBSEQUENT, EQUIPPED WITI-l 36-~CH
PASSENGER/CREW DOOR
31-001 AND

36-001 AND

SRM-4

53-20-00

Page

18

Jan 15/93

Frame 8
FS 196.99

Frame 4

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

NO.

DWG.
NO.

I
DESCRIPTION

Fuselage StructureAssembly
Fuselage Frames Instl.
(Refer to 53-21-00)
Fuselage Stringers Instl.
(Refer to 53-22-00)
Fuselage Windshield Instl.
(Refer to 53-24-00)
Fuselage Instrument Panel

2611000

I
EFF.I

I
MATERIAL

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

Structure Instl.

(Refer to 53-25-00)
Fuselage Circuit Breaker

Panel

Structure Instl.

2311150

(Refer to 53-26-00)
Fuselage Skins Instl.
(Refer to 53-28-00)
Fuselage Seat 8 Baggage Flr.
(Refer to 53-29-00)
Fuselage t<eelbeam Assemblies
(Refer to 53-50-00)
IBulkheadlnstl. (Frame 15)

2311150
2311150

Stiffener, Center
Stiffener, LH 8 RH (5 ea.)

2311150

Angle, Support

1
1

S-554

S-554

1
1
1

2024-T3 Clad

0.025

2024-T3 Clad

0.032

Stiffener, LH 8 RH

2024-T42 Clad

0.080

SafetyBand

2024-T3 Clad

0.063

1
1

I
I

2024-T3 Clad

0.040

Replace

2024-T3 Clad

0.040

2024-T42 Clad

0.080

1
1
1
1
1

I
I
I
I
I

Replace
Replace
Replace
Replace

2024-T42 Clad

0.050

2311150

Stiffener

2024-T42 Clad

0.063

2024-T3 Clad
2024-T3 Clad
4130 Steel

0.063

2311155
2311153
2311150

Strap(4ea.)
Strap(eea.)
Strap,Outer
Strap,Outer
IFitting, Longeron
SafetyBand(2ea.)

2311150

Shim
Plate

2311150
2311150

2311150

2311150

2311150

1
1

(2 ea.)

Web

Stiffener(2 ea.)

2311151

Fitting

2618326

Doubler

2511321

(RH

0.063

2024-T42

0.025

I
F8-1
F8-1

0.080

I
1

I
I

1
1

I
I

1
2
3

Web

2311150
2311150

WebAssy.

2311150

0.120

4130 Steel

IShim, Laminated (Max. 0.032)


IWebAssy.

2311150

I
I
I

S-565

2311154

1
1

FrameWeb

2311153

I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2311150
2311150

I
I
I

Side

Skin Doubler,

Only)

Escape

Hatch

2024-T42 Clad

1.250

2024-T3 Clad

0.025

2024-T42 Clad

0.080

Replace

Fuselage Assembly Repair Index


Figure 2 (Sheet 3 of 15)
EFFECTIVITY:

31-001 AND SUBSEQUENT; 35-001 AND

36-001 AND
SRM-I

SUBSEQUENT,

PASSENGER/CREW DOOR

SUBSEQUENT;

EQUIPPED WITH 36-INCH

53-20-00

Page

19

Jan 15/93

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

2511000

Splice Band (4ea.)

Inner Skin Instl., Door Frame

2611330

2611330

2311479

2024-T42 Clad

0.063

2024-T42 Clad

0.063

2024-T42 Clad

0.063

2024-T42 Clad
2024-T42 Clad

0.063

2024-T42 Clad
2024-T42 Clad

2311479 1

Flex Conduit

REPAIR

CODE

FIG. NO.

1
1
1

I
I
I

0.063

1
1

I
I

Replace
Replace
Replace
Replace
Replace

0.040

Replace

0.040

I Replace

I Replace
I

0.032

1
1
1
1

0.040

Replace

FlexConduit(2ea.)
RigidConduit
Splice(3ea.)
Clip(2ea.)
1
Clip(2 ea.)

IFINISH
GAGE

Stiffener(8)
Clip(2ea.)

2311479
2311479

I
MATERIAL

2311479

2311479

5052-0 Tube

0.035

0.040

0.040

Replace
Replace
Replace
Replace
Replace
Replace

2311479

Skin

2311479

Skin

2024-T3 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T3 Clad

Support)

2024-T42 Clad

0.020

Replace

(Curtain Track Support)


Strap

0.020

0.050

Filler

2024-T42 Clad
2024-T3 Clad
2024-T42 Clad

0.080

Replace
Replace
Replace

I
I

2311479
2311479
2511295

2611092

Frame, LH 6 RH

(Curtain

Track

2611092

Frame, LH

6 RH

2511000
2511002
2311560

1
1

0.040

j
I

ILangeron Instl.,
Top Centerline Fwd
SafetyBand(2ea.)

1
1

2024-T3 Clad

0.063

2024-T42 Clad

0.032

2311560

Web,LH&RHCenter
RH Fwd
Web, LH

2024-T42 Clad

0.032

2311560

Web, LH 6 RH Aft

0.032

2311560

Angle(eea.)

2024-T42 Clad
2024-T42 Clad

0.040

Replace
Replace
Replace
Replace
Replace
Replace
Replace

2311560
2311560

10

I
EFF.I

2611330

2511330

I
DESCRIPTION
Window Doubler, RH Aft
Window Doubler, RH Fwd
Window Doubler, LH Fwd
Window Doubler, LH Aft

2311272
2311272

Torsion Bar Instl., Lower Door

FittingAssy.

1
1
1

4130 Steel

0.100

4130 Steel

3/8 Dia

2311272

Fitting
Bearing

2311272

Plate

6061-T6

0.090

2311272
2311272

Plate

6061-T6
2024-T42 Clad

Phenolic I~

2311272

Spacer
EndFitting

4130 Steel

2311272

TorsionBarAssy.

2311272
2311272

2311272

Sleeve
Bracket

2311272

Torsion Bar
Link

A151 17-4 P.H. SS


A151 17-4 P.H. SS

2311272

Link

A151 301 SS

2311272

Replace
Replace
Replace
Replace
Replace

0.040

I
1.5 Dia
5/16 Dia
0.125
0.125

I
F8-1
F-21

I
F-21

Replace
Replace
Replace

Fuselage Assembly Repair Index


Figure 2 (Sheet 4
EFFECTIVITY:

of 15)

SUBSEQUENT; 35-001 AND SUBSEQUENT;


SUBSEQUENT, EQUIPPED WITH 36-INCH
PASSENGER/CREW DOOR
31-001 AND
36-001 AND

53-20-00

Page 20
~an 15/93

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

11

Shim

ISupport
Bracket(2ea.)
AngleAssy.(2sa.)
Angle

2311623

2311623
2311623
2311623

2311623 1

2311674

1
1

2311674

Instl.

Plate
Channel

2315122
2315122 1

2315122

2315122
2315122
2315122
2615123
2615289

2615123

3315123

1
1

2615289

2615123
3315123
2615289
2615123

1
1
1

2615123

2315122
2615181
2411002

I Replace
I Replace

2024-T42 Clad

0.050

2024-T42 Clad

0.050

1
I
I

I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

I
I

I
2024-T3 Clad

0.250

I
I

6061-0

0.190

I
1

I
I

6061-0

0.100

Support Instl.,

Rudder LH
Bracket

RH

Angle
Angle
Angle
SupportAssy.

2024-T42 Clad

2024-T42 Clad

S-554

S-520

Bracket

IAngle
Sector Support Instl.
Sector Support Instl.
1
Bearing Plate
BracketAssy.,Upper

3315123

Replace

I
I

10

Jack Pad Support Instl.


Bracket Assy.

2315122

Replace

Replace

10

2315122

I Replace

IFitting
1
Spacer

2315122

0.190

2511666

2315122 i

0.050

I
I

I Replace

1
1

Bellcrank

S-591

0.100

2024-T3 Clad

2315122

IFitting

2311684

REPAIR
FIG. NO.

CODE

IFitting

2311677

IFINISH
GAGE

2024-T3 Clad

2511662

2311684

15

2024-T3 Clad
S-578

Angle
Stiffener(2 ea.)

2311677

14

S-551

2511666
2511666

13

Fitting

1
1

Plate
Stiffener&

2311674

I
MATERIAL

Tee

2311623

I
EFF.

ISupportlnstl.

2311623
2311623

12

I
DESCRIPTION

2024-T42 Clad

S-738

I
I

0.050

0.040

1
I
I
0.050

I
I
I

I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

10
11

2024-T42 Clad

1
11

BracketAssy,Upper
Bracket Assy., Upper
Sector Support
SectorSupport
Sector Support
Spacer

12
13

I
1
1

0.050

I
I
I

11

2024-T42 Clad

0.050

12

2024-T42 Clad

0.050

13

2024-T42 Clad

0.050

11

2024-T42 Clad

0.050

Spacer
Spacer

12

2024-T42 Clad

0.050

Bracket

12

2024-T42 Clad

13

Assy., Upper (2 ea.)


SectorSupport
Bearing Plate
Clamp Support (2 ea.)
Clip(2 ea.)

1
I
I
I
1

I
I
I
I
I

1
1

I
I

1
1
I

I
I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

12

2024-T42 Clad

0.050

12

2024-T42 Clad

0.100

Replace
Replace
Replace
Replace

11

2024-T42 Clad

0.050

2024-T42 Clad

0.050

1
1

I
I

Replace
Replace

0.050

Fuselage Assembly Repair Index


Figure 2 (Sheet 5 of 15)
EFFECTIVITY:

srzM-4

35-001 AND

SUBSEQUENT;

31-001 AND

SUBSEQUENT;

36-001 AND

SUBSEQUENT, EQUIPPED WITH 36-INCH

PASSENGER/CREW DOOR

53-20-00

Page

21

Tan 15/93

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

2411002

I
DESCRIPTION

Splice Angle (6 ea.)


SpliceAngle (6ea.)
Splice Angle

2411002

2411002

2411002 IDoubler

2411321

Channel

2411321

Gusset

(2 ea.)
Gusset(2ea.)

2511333

REPAIR

CODE

FIG. NO.

14

S-544
S-748

1
1

15

I
I

16

S-544

16

S-544

I
1
1
1

I
I
I
I

2024-T42 Clad

0.040

2024-T42 Clad
2024-T42 Clad

0.040

2024-T3 Clad

0.050

0.040

2024-T3 Clad

0.050

10

2024-T42 Clad

0.040

10

2024-T42 Clad

0.040

10

2024-T3 Clad

0.040

1
1
1

I
I
I

10

2024-T3 Clad

0.050

10

0.040

1
1

I
I

I
I

17

17

2513193

Support,UpperAft

10

2513193

Bracket

10

4130 Steel

0.125

18

2024-T42 Clad

0.063

19

2024-T42 Clad

0.063

1
1

2024-T42 Clad

0.063

19

2024-T42 Clad

0.063

19

2024-T42 Clad

0.063

2513315

2511340 1

3111097
2388162
2388162

2388162
2388162
2388162
2388162
2388162
31 1 1 098

1
1

3111098

3111098
2615101

1
1

2615101
2315123

1
1

2315123

2315123

2315123

2315123

ShoulderHarness instl.
Shoulder Harness Instl.
Shoulder Harness Instl.

2511340

0.040

Replace
Replace
Replace
Replace
Replace
Replace
Replace

18
19
20

Clip(4ea.)
Clip(2ea.)
1
Support Assy., LH RH
Support
SupportAssy,LH&RH
Support
Support, LH RH
Support Assy., LH 8 RH (2 ea.)
Support
Angle (2 ea.)
Pedestal
Controls Support

18
19

20

1
1

I
0.063

20

2024-T42 Clad

0.040

2024-T42 Clad
2024-T42 Clad

0.063

2024-T42 Clad
2024-T42 Clad

0.050

2024-T42 Clad
2024-T42 Clad

0.063

1
21

22
1
1
1

I
I

2024-T42 Clad

8 RH Aft

20

Intercostal, LH 8 RH
Bearing Support, LH& RH Fwd
8 RH Fwd

18

Structure Instl.

Bearing Support, LH
Angle(2 ea.)
Support Frame
Bearing Support, LH

Replace
Replace

10

2024-T42 Clad
2024-T42 Clad

2513315

Replace
Replace
Replace

2513193

2513315

Replace
Replace
Replace
Replace
Replace

17

Support,LowerFwd
Support,UpperFwd
Doubler(Bea.)
Spacer
Support, LowerAft

2513315

IFINISH

I GAGE

2514303

16

I
MATERIAL

Doubler Instl., LH 8 RH
Doubler
26183811 Doubler Instl.
2618382
DoublerAssy.
Doubler
2618382
Seat Belt Instl.
2513315
2514303

I
EFF.

0.050

0.040
0.050

1
1

I
I

I
I
i

1
1
1

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace

Fuselage Assembly Repair Index


Figure 2 (Sheet 6 of 15)
EFFECTIVITY:

31-001 AND
36-001 AND

SRM-4

SUBSEQUENT; 35-001 AND SUBSEQUENT;


SUBSEQUENT, EQUIPPED WITH 36-TNCH

PASSENGER/CREW DOOR

53-20-00

Page

22

Jan 15/93

Ledrietl
STRUCTURAL REPAIR MANUAL
ITEMI
NO.

DWG.

NO.
2511370
2511370

2511370 1
2411371 1
2411280 1

Doubler
Aft Drag Block

I
EFF.

Longeron Instl., LH 8 RH
Attach Angle (2 ea.)

1
1

2511370 1
2411371 1
2511370

I
DESCRIPTION

I
MATERIAL

2024-T42 Clad

0.063

2024-T3 Clad

0.063

1
1
1

I
I

I
I
I

I
I

I
I

S-517

2024-T42 Clad

0.100

Filler

0.100

Drag Block, Fwd

2024-T3 Clad
S-5017

Door Frame Instl.

I
S-308

2411280

2411280

JSeal, Bottom
1
Seal, Fwd Lower

S-308
S-308

2411280

Ssal,FwdUpper

S-308

2411280

Seal, Aft Lower

S-308

2411280

Seal,AftUpper
Plug (2 ea.)
RainSealDiaphragm
Switch Support (8 ea.)
Guide Plate (8 ea.)
1
Tube Assy.

S-308

2411281
2411281
2411281

Seal Plate (2 ea.)


Corner Splice, Aft
Corner Splice, Fwd
Corner Seal Retainer, Lwr Fwd
Corner Seal Retainer, Lwr Aft

2411281

2411281
2411281

2411281
2411281
2411281
2411281

2411281

I
I

Mat. No. 4554


2024-T42 Clad
4130 Steel

1
1

1
1
1

1
1

Doubler

Upper

0.013

0.080

0.080

Corner Seal Retainer, Upr Fwd


Corner Seal Retainer, Upr Aft
Seal Retainer,
Tube Assy.

2411281

Longeron

2411280

FIG. NO.

ISeal, Top

2411281

REPAIR

CODE

2411280

2411280

IFINISH
GAGE

2024-T3 Clad
2024-T42 Clad

0.040

0.040

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

0.040

1
1

I
I

0.032

0.032

1
1
1

I
I
I

1
1

I
I

0.032

2024-T42 Clad
2024-T42 Clad

2024-73 Clad

0.063

2024-T42 Clad

0.040

0.032

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2411281

Tube

321 Stainless

2411281
2411281

Tube

321 Stainless

MS20253-2-140
MS20001PX4

SealRetainer,Fwd
2411284 ISealRetainer, Aft

S-553

S-553

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2411282

HingeAssy.,Lower

2411282

Hinge Half (2 ea.)


HingePin
Plate (3 ea.)

Replace
Replace

2411281
2411283

2411283
2411283
2411283

Hinge Pin
Hinge Half
HingeAssy.,Upper
HingeHalf
HingePin
Hinge Half

2411281

0.050

0.050

i MS20253-5

2411284

2411282

0.050

[13>

0.050

301 Stainless

0.063

F18

Replace

Fuselage Assembly Repair Index


Figure 2 (Sheet 7 of 15)
EFFECTIVITY:

SRM-4

31-001 AND

SUBSEQUENT; 35-001 AND SUBSEQUENT;

36-001 AND

SUBSEQUENT, EQUIPPED WITH 36-INCH

PASSENGER/CREW DOOR

53-20-00

Page

23

Tan 15/93

Lear
~Learjefl

STRUCTURAL REPAIR MANUAL


ITEM
NO.

JF~NISH

DWG.
NO.

DESCRIPTION

2318763

Doubler Instl., LH 8 RH

2318763

Angle(2ea.)
Doubler Instl. (2 ea.)
Angle(2ea.)
Angle(2ea.)

2688038
2688038
2688038

EFF.

REPAIR
FIG. NO.

CODE

2
24

2024-T42 Clad

0.050

25

2024-T42 Clad
2024-T42 Clad

0.050

0.050

26

Replace

Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

23

2618398

Doubler

2024-T42 Clad

0.020

2688151

Filler

2024-T3 Clad

0.090

27

2024-T3 Clad

0.032

I
I
I

Shim

2511416

(18 ea.)

2411325 IExternalRelease Instl.

2411323
2411323

2024-T4 Rod

0.250

2024-T351 Plate

0.375

I
I

I
I

2411323
2411323
2411323
2411323
2411323

2411323
2411323
2411323

Spacer
BellcrankDrive

Angle Assy.
Angle
ISpacer
Linkage
1
ILinkage

1
1

1
1

Bellcrankldler
Pin (2 ea.)
Pin

(2 ea.)

2411328

2411325

Spring
Spring

2411328
2611127 1

6061-T6

0.375

0.375

2024-T3

0.125

2024-T351 Plate
2024-T4 Al Rod

0.500

2024-T4 Al Rod
2024-T351 Plate

0.438

Ij9

MS24585-C414

30
30

2611125

End,LH&RH
End,LH&RH
Bracket,LH&RH

2611125

Support

30

2611124

2611126
2611128

Rib, LH

2611128

Cover

8 RH

8 RH

Cover

2611128

Support(3ea.)
Filler(Gea.)

2611128

30

IDoubler(FS196, between
Stringers 10 8 11)
Doubler (FS 196, between
Stringers 10 8 11)

261 8551

0.050

1
1

I
I

0.071

30

2024-T42 Clad

0.050

30

S-522

30

2024-T42 Clad
ABS Therm Plastic
2024-T42 Clad
S-626
2024-T42 Clad

0.050

1
1

I
I
I

Replace
Replace
Replace
Replace
Replace
Replace

30

30

2618314

Replace
Replace

Filler(2ea.)
RH

0.040

2611125

Bracket, LH

2611125

Replace
Replace

0.040

30

2511216

0.050

30

Support
Support, LH 8 RH (2 ea.)
Gusset,LH&RH

2611125

F3

Replace
Replace
Replace
Replace

0.500

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

30

30

2611125

I
F3

0.050

Seal

2511183

0.438

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

30

Assy., LH

Connector Box Instl.


Cover

2611118 1
2611123

2024-T4 Plate

Assy.

S-580

29

Retainer

28

Guide Pin (2 ea.)


Flush Latch Handle

2411323

18

I GAGE

2618397 IDoublerlnstl.

17

MATERIAL

30
30
30

2024-T3 Clad
2024-T42 Clad

0.040

0.100
0.063

1
1

I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.063
0.040

31

12024-T3 Clad

0.080

Replace

32

2024-T3 Clad

0.050

Replace

Fuselage Assembly Repair Index


Figure 2 (Sheet 8 of 15)
EFFECTIVITY:

31-001 AND

SUBSEQUENT; 35-001 AND SUBSEQUENT;


SUBSEQUENT, EQUIPPED WITH 36-INCH
PASSENGER/CREW DOOR
36-001 AND

aad~

53-20-00

Page 24
Jan 15/93

Learjet

SIRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

3111116 1

RibAssy., LH
Rib(2ea.)

3111118
3111118

8 RH

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

2024-T42 Clad

0.507

33

S-522

0.032

33

2024-T42 Clad

0.507

1
1
I

I
I
I

1
1

I
I

1
1
1
1

I
I
I
I

33

33

I
2024-T42 Clad
2024-T42 Clad

0.050

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

3111118

Rib

33

3111118

Support

33

2024-T42 Clad

0.040

3111118

Filler

33

2024-T42 Clad

0.040

Angle
Angle

33

S-5001

0.010

33

S-5001

0.012

Angle
Seal (4 ea.)

33

S-5001

0.015

33

[i~

0.010

34

2024-T3 Clad

0.063

2024-T42
2024-T42
2024-T42
2024-T42

Clad
Clad
Clad

0.063

0.063

0.040

Clad

0.040

2024-T3 Clad
2024-T42 Clad

0.050

1
1
1

I
I
I

I
I
I

Replace
Replace
Replace
Replace

Replace
Replace

3111119

3111119
3111119
3111119
2511332

2511215

Skin Doubler, LH Aft


Blower Evaporator Support
Structure instl.

2511216
2511216 1
2511216

2619042 1

2411321

2311258

2311258

35
36

Channel

37

Clip(2 ea.)

37

Bracket

Channel(Above Escape Hatch)


Inner Skin Instl. (FS 160
to 209, RH 8 LH)
Skin, LH

0.071

Bracket,LH&RH
Bracket,LH&RH

2511216

20

33

Filler

3111119

I
MATERIAL

33
33

Stiffener(3ea.)

3111119

Pressurized Connector Box Instl.


Cover

3111119

I
EFF.

CoverAssy.,LH&RH

3111117

19

I
DESCRIPTION

0.040

8 RH

38

2024-T42 Clad

0.050

2311258

Skin, LH 6 RH

39

2024-T42 Clad

0.050

2311258

Strap

40

2024-T3 Clad

0.050

1
1
1

2311258 1

Filler

40

2024-T3 Clad

0.160

2024-T3 Clad

0.250

2024-T351

1.600

0.040

2411320

2411322

Escape Hatch Instl.


Escape Hatch Assy.
(Refer to Chapter 52)

2411322

IClipAssy.

2411322

ClipSupport

2024-T3 Clad

NAS1464-038-05C

Doubler, Aft Fuselage Window

2024-T42 Clad

0.063

Stiffener 8 Plate Instl., LH

1
1

2024-T42 Clad

0.050

0.050

2024-T42 Clad
2024-T3 Clad
2024-T3 Clad
2024-T42 Clad

I
I
I
I
I

Clip

2411322
2411322

Strap
Tee Support

2411322

2511674

1
1
1
1

RH

2511674

Clip(2 ea.)
Angle
Plate (LH Only)
Plate (RH Only)
Stiffener(3 ea.)

0.050

1
1
1
1
1

2511674

Filler

2024-T3 Clad

0.063

2511674 i

Stiffener

2024-T42 Clad

0.063

2511674

2511674
2511674

251 1 674

Replace
Replace
Replace
Replace
Replace
Replace

1
1

0.080
0.050

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Fuselage Assembly Repair Index


Figure 2 (Sheet 9 of 15)
SUBSEQUENT;

35-001 AND

SUBSEQUENT;

EFFECTIVITY:

31-001 AND

SRM-4

36-001 AND SUBSEQUENT, EQUIPPED WITH 36-INCH


PASSENGER/CREW DOOR

53-20-00

Page

25

Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

NO.

DWG.
NO.

2511674
2511644

IFitting

2411324

I
EFF.

IFINISH
GAGE

2024-T3 Clad
2024-T42 Clad

1
1

I
MATERIAL

Plate
Stiffener

2511674

0.050

0.063

REPAIR
FIG. NO.

CODE

1
1

I
I

Replace
Replace
Replace

Inner Doubler

Assy.,
(Escape Hatch)

2411324 IDoubler

41

6061-T6

0.040

2411324 IDoubler

42
41

A/R

1
I

2411324
2411326
2411326

Spacer(4ea.)
Spacer(4ea.)
NutRetainer(4ea.)
NutRetainer(4ea.)

6061-T6
2024-T42 Clad

0.040

I
I

42

2024-T42 Clad

A/R

41

2024-T42 Clad

0.040

I
I

42

2024-T42 Clad

0.040

2411323 1

Plate

41

2024-T3 Clad

0.090

42

2024-T3 Clad

0.090

2024-T42 Clad

0.040

1
1
1
1

I
I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

1
I
1
1
1

I
I
I
I
I
I

Replace
Replace
Replace
Replace
Replace
Replace

1
I
1
1

I
I
I
I

Replace
Replace
Replace
Replace

1
1

I
I

I
I

0.050

2411324

Plate

2411323 1

2411321

Frame (FS 350, RH Side


Doubler Instl.

2489168

Only)

1
1

2489168

Doubler

2024-T42 Clad

0.050

2489168

RadiusFiller(4ea.)
DoublerAssy., Fwd (2 ea.)

2024-T3 Clad

0.125

2489168
2489168

Doubler

2489168 1

Wedae

2489168

Filler

2489168
2489168

2489168 1
2489168

2489168
2489168

Filler(eea.)
AngleAssy.
Angle

2489168

2489168 1

Aft

2489168 1

Wedne

3118916

Wedae

Doubler
Crew Seat Rails

2411473

2024-T3 Clad

0.050

2024-T3 Clad

0.025

2024-T42 Clad
2024-T3 Clad

0.050

2024-T42 Clad

0.050

2024-T3 Clad

0.125

0.160

2024-T3 Clad
2024-T3 Clad
2024-T3 Clad

0.160

2024-T3 Clad

0.025

I
I
I
I
I

Replace

2024-TJ2 Clad

0.050

2024-T3 Clad

0.190

1
I
1
1

2024-T351 Clad

0.313

Instl., LH 8 RH

0.190

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

IDoublerlnstl. (ADFAntenna)

3118919

0.190

Filler(2ea.)
AngleAssy.
Angle

2489168 1

2024-T3 Clad

(2ea.)

2489168

2489168

0.040

2489168

I
2024-T3 Clad

Wedae
Filler

2489168

Wedae
Doubler Instl. (ADF Antenna)
Doubler
Radius Filler (4 ea.)

DaublerAssy.,

2489168

21

I
DESCRIPTION

I Replace

2511580 1

Filler

2024-T3 Clad

0.063

2511580 1

End Plate

2024-T42 Clad

0.040

Clip

2024-T3 Clad

0.063

Filler

2024-T3 Clad

0.100

1
j

I
I

Replace
Replace
Replace
Replace

Clip

2024-T3 Clad

0.050

Replace

Shim, Laminated (Max. 0.032)

2511580

2511580

2511580 1

2511581

Fuselage Assembly Repair Index


Figure 2 (Sheet 10 of 15)

EFFECTIVITY:

SUBSEQUENT; 35-001 AND SUBSEQUENT;


SUBSEQUENT, EQUIPPED WITH 36-INCH
PASSENGER/CREW DOOR
31-001 AND
36-001 AND

SRM-4

53-20-00

Page

26

Jan 15/93

Learjet j

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

2511581 1
2511581

I
DESCRIPTION

Intercostal
Tie

End Plate

2511580
2511580

2511581

Intercostal

2511581
2511581

22

0.040
0.080

1
1
1

I
I

44

2024-T3 Clad
2024-T42 Clad
2024-T42 Clad
2024-T3 Clad
2024-T3 Clad

43

2024-T42 Clad

0.040

1
1

I
I

44

2024-T42 Clad

0.040

43

S-537

1
I

I
I

44

S-537

Replace
Replace
Replace
Replace

I
1

I
I

Replace
Replace

I
I
I
I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace

43
44
43

45

45

Assy. (2 ea.)

0.040

0.040

2024-T3 Clad
2024-T3 Clad

0.040
0.040

46

2024-T42 Clad

0.050

49

0.050

1
1

I
I

0.050

0.050

I
1
1

1
I
I
I
I

I
I
I
I
I

45

45

0.063

I
2024-T42 Clad

0.040

46

47
48

Angle

46

6061-T6
2024-T42 Clad

2614063

Angle

49

2024-T42 Clad

2614063

Screen

49

3003-H14 Al

49

2024-T3 Clad

0.050

49

2024-T3 Clad

0.050

2614063

Glareshield

2614063

Pressurized ConnectorBox Instl.

2611116

2611116
2611122
2611122
2611122
2611122

Plate(2 ea.)
Assy.,
Cover Assy.,
1
Support
Cover

2611122

2611116 1
2511183
2611117

(3 ea.)
RH
Doubler, LH

Doubler, Center

2614063

1
1
1

2611117
2611117 1
26111171

Replace
Replace
Replace
Replace

Replace
Replace
Replace

50

2024-T3 Clad

50

LH 8 RH

51

RH

52

LH

Replace
Replace

I
1
I
1
I
1

45

2614063

2614063

Replace
Replace
Replace
Replace
Replace

0.040

2024-T3 Clad

45

45

Glareshieldlnstl.
Glareshield Instl.
2614063
Glareshield Instl.
2614063
Glareshield
2614063 1

0.080

2024-T42 Clad

45

Rail Support Zee


Zee
Plate

2511581
2511581

45

ClipAssy.(2ea.)
Clip(2ea.)
Intercostal Assy. (2 ea.)

2511580

CODE

0.040

Support
Floor Board Support
2511581
2511581
Zee, Rail Support
2511581 1
Zee, Rail Support
2511581 1
Channel, Rail Support
2511581 1
Channel, Rail Support
2511582
SeatRail(3ea.)
2511582
SeatRail(Sea.)
2511580
EndPlateAssy.

REPAIR
FIG. NO.

IFINISH
GAGE
0.040

Floor Board

2511581

I
MATERIAL
2024-T3 Clad
2024-T3 Clad

Angle
Plate

2511581

I
EFF.I

1
1

53

S-707

Channel

53

S-325

FiBer(8ea.)

0.050

I
I
I
1

53

\2024-T3Clad

Cover

54

2024-T3 Clad

Seal (8 ea.)
Rib Assy., LH 8 RH

50

51

Rib Assy., LH 6 RH
RH
Rib Assy., LH
Rib

55

56

I
1

I
j

0.050
0.050

50

2024-T3 Clad

0.063

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Fuselage Assembly Repair Index


Figure 2 (Sheet 11 of 15)
EFFECTIVITY:

31-001 AND

36-001 AND

SUBSEQUENT; 35-001 AND SUBSEQUENT;

SUBSEQUENT, EQUIPPED

PASSENGER/CREW DOOR

WITH 36-INCH

53-20-00

Page

27

jan 15/93

~itl
STRUCTURAL REPAIR MANUAL
ITEM
NO.

DWG.
NO.

2611118

1
1

2611118

2611118 1

2611119

2611119
2611119

I
DESCRIPTION

1
1

End Assy., LH 8 RH
End Assy., LH 8 RH
End
End
End

Assy.,
Assy.,

LH 8 RH
LH 8 RH

End

I
EFF.
51
57

MATERIAL

1
i

51
57

I
I
2024-T3 Clad

50

1
1

0.063

I
I
2024-T3 Clad

50

IFINISH
GAGE

58

2024-T3 Clad

0.063

2611120

59

0.063

2611122

Gusset

50

2024-T3 Clad
2024-T24 Clad

2611122

Angle, LH 8 RH
Support, LH 8 RH
Support, LH 8 RH
Cover (2 ea.)

50

S-522

60

2024-T3 Clad

0.032

55

2024-T3 Clad
2024-T42 Clad

0.032

2611120
2611120

2611122
2611122
2611122

58
59

50

1
1

I
I

I Replace
I Replace

I
I

I Replace
I Replace

I
I

I Replace
I Replace

0.063

Angle Assy.
Angle Assy.
Angle
Angle

2611120

REPAIR
FIG. NO.

CODE

I
0.063

1
0.050

Replace

Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace

Fuselage Assembly Repair Index


Figure 2 (Sheet 12 of 15)
EFFECTIVITY:

31-001 AND
36-001 AND

SRM-I

SUBSEQUENT; 35-001 AND SUBSEQUENT;


SUBSEQUENT, EQUIPPED WITH 36-INCH

PASSENGER/CREW DOOR

53-20-00

Page

28

Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


CODES

EFFECTIVIT\ES

SUBSEQUENT;

SUBSEQUENT; 36-001 AND SUBSEQUENT


SUBSEQUENT; 36-001 AND SUBSEQUENT

35-001 AND

31-001 AND

2
3

31-001 THRU 31-034; 35-001 AND


31-035 AND SUBSEQU ENT

31-001 AND SUBSEQU ENT; 35-492 AND

35-001 THRU

6
7
8

9
10
11
12
13
14
15
16

SUBSEQUENT;

36-051 AND SUBSEQUENT

35-264; 36-001 AND SUBSEQUENT


35-001 THRU 35-477; 36-001 THRU 36-050
35-478 AND SUBSEQUENT; 36-051 AND SUBSEQUENT
31-001 THRU 31-027; 35-001 THRU 35-658, 35-660 THRU 35-662; 36-001 THRU 36-063
31-028 THRU 31-041, 31-043 THRU 31-051;35-659, 35-663 THRU 35-666
31-042, 31-052 AND SUBSEQUENT; 35-676 AND SUBSEQUENT; 36-064 AND SUBSEQUENT
35-001 THRU 35-519; 36-001 THRU 36-053
35-520 THRU 35-623; 36-054, 36-055
35-624 AND SUBSEQUENT; 36-056 AND SUBSEQUENT
35-001 THRU 35-534, 35-589, 35-590; 36-001 THRU 36-053
35-535 THRU 35-588, 35-591 AND SUBSEQUENT; 36-054 AND SUBSEQUENT
35-001 THRU 35-505; 36-001 THRU 36-053

17

31-001 AND

18

SUBSEQUENT;

35-456 AND

SUBSEQUENT;

36-051 AND SUBSEQUENT

19

31-001 THRU 31-022, 31-035 THRU 31-038; 35-478 THRU 35-668; 36-051 THRU 36-036
31-023 THRU 31-034; 35-662 THRU 35-666

20

31-039 AND

21

35-001 THRU

22

35-131

23

36-051 AND SUBSEQUENT

24

35-281 AND

25

SUBSEQUENT; 35-669 AND SUBSEQUENT; 36-064 AND SUBSEQUENT


35-130; 36-001 THRU 36-033
AND SUBSEQUENT; 36-034 AND SUBSEQUENT
SUBSEQUENT; 36-045 AND SUBSEQUENT

26

35-001 THRU 35-281; 36-001 THRU 36-044


35-282 AND SUBSEQUENT; 36-045 AND SUBSEQUENT

27

31-011 AND

28

35-001 THRU

29

35-265 AND

30

36-001 AND SUBSEQUENT

SUBSEQUENT; 35-647 AND SUBSEQUENT;


35-264; 36-001 THRU 36-044

SUBSEQUENT;

31

31-001 THRU

32

31-061 AND

36-058 AND SUBSEQUENT

36-045 AND SUBSEQUENT

31-060; 35-390, 35-394 THRU 35-673; 36-048 THRU 36-063


SUBSEQUENT; 35-674 AND SUBSEQUENT 36-064 AND SUBSEQUENT

33

31 SERIES AIRCRAFT EQUIPPED FOR EXTENDED RANGE

34

31-001 AND

35

35-001 THRU

36

35-092

37

36-001 THRU 36-059

38
39

35-001 THRU 35-122, 35-1 49 AND SUBSEQUENT; 36-001 THRU 36-032, 36-037 AND SUBSEQUENT
35-123 THRU 35-148; 36-033 THRU 36-036

40

35-123 AND

41

35-001 THRU

42

SUBSEQUENT; 35-265, 35-369, 35-371 AND SUBSEQUENT


35-091; 36-001 THRU 36-024
AND SUBSEQUENT; 36-025 AND SUBSEQUENT

SUBSEQUENT; 36-042 AND SUBSEQUENT


35-130; 36-001 THRU 35-034
35-131 AND SUBSEQUENT; 36-035 AND SUBSEQUENT

Fuselage Assembly Repair Index


Figure 2 (Sheet 13 of 15)
EFFECTIVITY:

31-001 AND

SUBSEQUENT; 35-001 AND SUBSEQUENT;

53-20-00

SRM-4

36-001 AND SUBSEQUENT, EQUIPPED WITH 36-INCH


PASSENGER/CREW DOOR

j8n 15/93

Page 29

Learjet

STRUCTURAL REPAIR MANUAL

47

35-629; 36-001 THRU 36-055


SUBSEQUENT; 36-056 AND SUBSEQUENT
31-063 AND SUBSEQUENT; 35-675 AND SUBSEQUENT; 36-064 AND SUBSEQUENT
35-001 THRU 35-039; 36-001 THRU 36-016
35-040 THRU 35-642; 36-017 AND SUBSEQUENT

48

31-001 AND

49

31-001 AND

50

31-001

51
53

35-370, 35-390 THRU 35-508


31-001 THRU 31-030; 35-509 THRU 35-664
31-001 THRU 31-030; 35-370, 35-390 THRU 35-664

54

31-031 AND

55

56

31-001 THRU 31-072; 35-509 THRU 35-676


31-073 AND SUBSEQUENT; 35-677 AND SUBSEQUENT

57

31-001 AND

58

31-001 THRU 31-063; 35-001 THRU 35-674


31-064 AND SUBSEQUENT; 35-675 AND SUBSEQUENT
31-001 THRU 31-072; 35-370, 35-390 THRU 35-676

43
44
45
46

52

59
60

35-001 THRU
35-630 AND

SUBSEQUENT; 35-643 AND SUBSEQUENT


SUBSEQUENT; 35-040 AND SUBSEQUENT; 36-017 AND SUBSEQUENT
AND SUBSEQUENT; 35-370, 35-390 AND SUBSEQUENT

SUBSEQUENT;

35-665 AND SUBSEQUENT

SUBSEQUENT; 35-509 AND SUBSEQUENT

Fuselage Assembly Repair Index


Figure 2 (Sheet 14 of 15)

EFFECTIVITY:

31-001 AND
36-001 AND

SRM-4

SUBSEQUENT; 35-001 AND SUBSEQUENT;


SUBSEQUENT, EQUIPPED WITH 36-INCH

PASSENGER/CREW DOOR

53-20-00

Page

30

lan 15/93

~Le,Learijet
STRUCTURAL REPAIR MANUAL
NOTES

Laminated shim stock, 0.002

or

0.003 lamination per MIL-S-22499

Type

1 Class 1

or

Class 2 1145-H19 aluminum

sheet.
1/4 OD

3/16 ID Teflon

1/2 OD

3/8 ID Teilon

3/8 OD

0.065 Wall

Type

FBG

or

Tubing

Tubing

Tubing

FBM per MIL-P-15035

Heat Treat to 180,000 PSI

Condition 1/2 Hard

Commercial Grade, Low Density Silicon Sponge Rubber

Tubing

0.650 OD

0.065 Wall 4130 Steel

0.187 OD

0.035 Wall 321 Stainless Steel

0.250 OD

0.035 Wall 321 Stainless Steel

321

or

347 Stainless Steel

Condition 1/4 Hard


Make from NAS1169DD1OL
Screens 3/16. 0.032, 1/4- inch Centers
ABS Thermo Plastic 0.063,

Optional

to make from 0.060 Thermo Formidable Plastic

Fuselage Assembly Repair Index


Figure 2 (Sheet 15 of 15)

EFFECTIVITY:

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT, EQUIPPED WITH 36-INCH

PASSENGER/CREW DOOR

53-20-00

Page

31

Tan 15/93

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


FUSELAGE ASSEMBLY
1.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGE LIMITS

All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

failed rivets

or

the

on

are

not allowed. A loose

or

failed rivet

can cause

increased stress concentra-

rivets and lead to

progressive joint failure. A careful inspection must be


that joint failure has not spread from the area of the loose or failed rivet. (Re-

remaining

performed to ensure
fer to Chapter 51 for definition of rivet failure.)
(2) Loose

or

trations

failed

screws are

surrounding

not allowed. A loose

or

failed

screw can cause

increased stress

concen-

and lead to

progressive joint failure. A careful inspection must be


performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
B.

on

screws

Cracks

(1) Cracks in any fitting or forging are


(2) Cracks in components other than

not allowed. Cracked

fittings

and

forgings
paired, and refinished in accordance with Chapter 51.

C.
D.

fittings or forgings must be replaced.


considered allowable if properly

are

Deformation

(1) Deformation of the fuselage assembly structure is not allowed.


Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original
rial thickness

E.

re-

more

than

mate-

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component re-

placed.
F.

Scratches(See Figure 101.)


(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to

Chapter 51

for

protective treatment procedures.)


replaced or repaired

(2) Structural components must be


thickness by more than specified.
G.

H.

original

material

Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings andForgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTIVITY:
SRM~

if scratches reduce the

ALL

53-20-00

Page 101
May 35~92

C~ Learjet
STRU~IURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.025

0.0175

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFFECTTVITY:
sRM-a

ALL

101

53-20-00

Page 102
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


FUSELAGE ASSEMBLY
i.

REPAIR

APPROVED REPAIRS

A.

RefertoChapter51 fortypicalrepairs.

EFFECTIVITY:

ALL

53-20-00

Page 201
SRM~

May 15/92

Learjet
Lsarjet

STRUCTURAL REPAIR MANUAL


FUSELAGE FRAMES
i.

STRUCTURAL IDENTIFICATION

DESCRIEr~ION
A. The fuselage frame installation consists of frame assemblies, doublers, web assemblies and minor
structural subassemblies. The fuselage frames begin at frame 6 and continue through frame 21 and
the aft pressure bulkhead.
B. The fuselage frame installation provides overall structural continuity and aerodynamics of the aircraft.

FS 234.19

FS411.95

FS 245.88

FS 246.09

FS 221.59

FS 368.68
FS 283.99
FS 296.49

258.01

FS 196.99

FS 381.79

FS 346.62

FS

FS 355.49

FS 321.24

FS 271.99

FS209.19

F540222

FS 378.05

FS 308.49

FS 172.19

FS184.78

FS 332.66

FS 151.12

11

I)

1)

IS

1(

II

1)

NOTES

Fuselage Stations for 24-inch Passenger/Crew Door Configuration.

(TYPICAL)

REPRO

EFFECTIVITY:

SRM-4

Fuselage Frames Repair index


Figure 1 (Sheet 1 of 9)
31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;
36-001 AND SUBSEQUENT

53-21-00

Page

Jan 15/93

Learjet
STRUCTURAL REPAIR MANUAL
ITEM
NO.

DWG.
NO.
2611000
2611003

2411060
2411060
2411060

I
EfF.

DESCRIPTION

Fuselage Frameslnstl.
Fuselage Frames instl.

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

MATERIAL

Frame Instl., FrameG

FrameWeb,Bottom
Stiffener(eea.)

3
3

2411060

Filler(2ea.)

2411060

Filler

2411060

Clip(2ea.)

2411060
2411060

Frame Web, LH 8 RH
Frame Web, LH 8 RH

1 2411070

Gusset

26

(2 ea.)

Framelnstl.,Frame7

27

2024-T42 Clad
Sd22
2024-T42 Clad
2024-T42 Clad
2024-T42
2024-T42
2024-T42
2024-T42

0.050

I
0.080
0.100

51-70-03

I
I

Replace
Replace
Replace
Replace
Replace

0.063

I
I

0.050

1
1

1
1

51-70-03

51-70-03

Clad
Clad
Clad
Clad

0.050

0.050

51-70-03

2411070

WebAssy.,UpperCenter

2411070
2411070

FrameWeb, LH
FrameWeb, LowerCenter

2024-T42 Clad

0.050

2024-T42 Clad

0.050

1
1

1
i

2411070

2411070
2411070
2411070

2411080
2411080
2411080
2411080
2411080
2411080
2411080
2411080
2411080
2411080
2411080
2411080

2411060

2411070
2411070

2615124
2411090
2411090
2411090
2411090
2411090
2411090

2411090
2411090
2411090

FrameAssy.,LH&RH
Angle

2024-142 Clad

0.025

Replace

FrameWeb

26

2024-T42 Clad

0.050

27

2024-T3 Clad

0.080

1
1

51-70-03

FrameWeb(2ea.)

1
1

2024-T42 Clad

0.050

Replace

2024-T42 Clad
2024-T42 Clad

0.050
0.050

51-70-03

2024-T42 Clad

0.040

1
1

I
I

Replace
Replace

0.050

51-70-03

0.050
0.050

1
1

I
I

0.050

Replace
Replace
Replace

2024-T42 Clad
2024-T42 Clad
2024-T3 Clad
2024-T42 Clad
2024-T42 Clad

0.050

51-70-03

2024-T42 Clad

0.063

2024-T42 Clad

0.050

1
1

I
I

Replace
Replace

2024-T42 Clad
2024-T42 Clad

0.050
0.050

1
1

1
1

51-70-03
51-70-03

2024-T42 Clad

0.050

Replace

2024-T42 Clad
.1 2024-T42 Clad
2024-T42 Clad
2024-T3 Clad

0.050

AngleAssy.,LH&RH

Angle
Frame Instl., Frame8

51-70-03

3
3
3

WebAssy.,Top
Web,Top

Frame Doubler, LH 8 RH
Clip, LH 8 RH

FrameWebAssy.,LH&RH

3
3

Frame

FrameDoubler
Filler
WebAssy., Bottom
Frame

Angle
Clip(2 ea.)

3
3

Framelnstl., FrameS

WebAssy.,Top
WebAssy.,Top
FrameWeb,Top
FrameWeb,Top
Doubler(2ea.)
WebAssy.,LH&RH
WebAssy.,LH&RH

5
4

6
7

FrameDoubler

3
6

2411090

FrameWeb,LH
FrameWeb, LH

2411090

Clip

2411090

51-70-03

Replace

1
1

51-70-03

0.050

1
1

0.050

Replace

0.050

51-70-03

Fuselage Frames Repair Index


Figure 1 (Sheet 2 of 9)
EFFECTIVITY:

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT

SRM-4

53-21-00

Page 2
Jun 1/95

I Learjet
Learjet(
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

I
DESCRIPTION

SpliceBand(2ea.)
SpliceAngle(eea.)

2411090
2411090
5

IFramelnstl., Frame 10

2411100

2411100

2411100
2411100

2411100
2411100

2411100

2411100

0.050

F4-6

51-70-03

4130 Steel
301 Stainless

0.040

F9
F17-6

Replace
Replace

SpliceBand

2411100

Filler

2024-T42 Clad

0.050

2024-T42 Clad

0.050

2024-T42 Clad

0.050

Replace

2024-T42 Clad
2024-T42 Clad

0.050

I
I

Replace
Replace

51-70-03

1
I

Replace
Replace

)2024-T42Clad

0.050

2024-T42 Clad
2024-T42 Clad

0.063
0.050

2024-T42 Clad
2024-T42 Clad
2024-T3 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

0.050

0.063
0.040

2024-T42 Clad

3
3

2411100

FrameWeb,RH

SpliceAngle
Angle

Frame

Instl., Frame 11

2411110
2411110

FrameWebAssy.,RH

2411110

FrameWeb

2411110

Clip Assy.

2411110

1
1

2411110

2411110

Replace
Replace

0.050

51-70-03

51-70-03

Frame Web (2 ea.)

2024-T42 Clad

51-70-03

Splice Angle (4 ea.)


Cap

2024-T42 Clad

0.063

2024-T3 Clad

0.040

Replace
Replace

2024-T42 Clad

0.050

51-70-03

2024-T42 Clad

0.050

51-70-03

2024-T42 Clad

0.050

2024-T42 Clad
2024-T42 Clad

0.063

1
1
1

I
I
I

Replace
Replace
Replace

2513193

0.050

2411120

FrameWebAssy.
FrameWeb, RH

DoublerAssy.
DoublerAssy.

1
1

51-70-03

0.050
0.050

2411110

j2024-T42Clad

2511121 1

2024-T42 Clad

IFramelnstl., Frame 12
FrameWebAssy.
2411120
FrameWeb(Bea.)

2411120

Replace
Replace

2411120

2411120

51-70-03

11

2411120

2411120

0.025
0.050
0.050

Frame Web Assy.


FrameWeb

51-70-03
51-70-03

0.050

2411110

24111101

0.020

10

2411100

2411110

2024-0 Clad

FrameWeb, Bottom

2513193
6

51-70-03

WebAssy.,Bottom

2411100

Replace

Clip

2411100

Doubler
Doubler
Web Assy., LH Lower
Frame Web, Lower
Doubler

2411100
2411100

0.050

IDoublerAssy.

2411100
2411090

0.025

2024-T42 Clad

Doubler

2411100

FIG. NO.

2024-T42 Clad

Assy., Upper
FrameWeb,Upper
FrameWeb, Upper
Doubler Assy., LH

2411100

REPAIR

CODE

Web

2411100

IFINISH
GAGE

3
3

FrameWeb
FrameDoubler
Plate Doubler

2411100

I
MATERIAL

WebAssy.,LH

2411100

I
EFF.

Replace

12

13

Doubler

Angle(2 ea.)
Splice Angle

0.080

Fuselage Frames Repair Index


Figure 1 (Sheet 3 of 9)
EFFECTIVITY:

31-002 AND

SUBSEQUENT; 35-001

36-001 AND SUBSEQUENT


SRM-I

AND

SUBSEQUENT;

53-21-00

Page 3
Jun1/95

Learjet

STRUCTURAL REPAIR MANIIAL


ITEM
NO.

DWG.

NO.
2511121

2511121(

I
EFF.

Frame Instl., Frame 12

FrameWebAssy.

Frame Web, Bottom

2024-T42 Clad

2513193

SpliceAngle(2ea.)
DoublerAssy.
DoublerAssy.

2024-T42 Clad

0.050
0.080

2411120

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

MATERIAL

2511121
2511121

51-70-03

Replace

14
15

2511121 1

Doubler

14

2024-T42 Clad

0.050

Replace

2411090 1

Doubler

15

0.050

2411130

0.050

2411130

Filler(2ea.)
SplicePlate

2411130

Doubler

2411130

FrameWeb,Bottom

2024-T42 Clad
2024-T3 Clad
2024-T3 Clad
1 301 Stainless
2024-T3 Clad

0.050

j
1

i
I

Replace
Replace
Replace
Replace
Replace

2411120

FrameWebAssy.,

RH

Upper

0.050
0.020

51-70-03

2024-T42 Clad
2024-T3 Clad

0.050

SplicePlate
SpliceAngle (3 ea.)

0.050

2024-T42 Clad

0.063

2511121 1

Doubler

0.036

2511121

Frame Web, LH

4130 Steel
2024-T42 Clad

Replace
Replace
Replace

0.050

51-70-03

2511121(

FrameWeb,Tap

(2024-T42Clad

0.050

2511121

Frame Web, RH Bottom

2024-T42 Clad

FrameWeb

2411120
2411130
2411110

I
DESCRIPTION

2411130

IFramelnstl., Frame 13

2411130

FrameAssy.
FrameWeb,RHUpper

51-70-03

0.050

1
1
i
i

51-70-03

1
1

51-70-03

2024-T42 Clad

0.050

FrameWeb,LH
FrameWeb,Bottom

1 2024-T42 Clad

i 2024-T42 Clad

0.050
0.050

FrameWeb,Top

2024-T42 Clad

0.050

Frame Web, RH Bottom

2024-T42 Clad

0.050

Filler(2 ea.)
Splice Plate (3 ea.)

0.050

2411130

Doubler

2411130

Splice

2411130

Doubler

2024-T3 Clad
2024-T3 Clad
301 Stainless
2024-T42 Bare
4130 Steel
2024-T42 Clad

2024-T42 Clad

0.063

16

2024-T42 Clad

0.050

17

2024-T42 Clad

51-70-03

2024-T42 Clad

0.050
0.050

51-70-03

FrameWeb, LH Upper
FrameWeb, Bottom
FrameWeb, RH Bottom

0.050
0.050

1
1
1

1
1
1

51-70-03

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

SpliceAngle
SplicePlate
Splice Plate (3 ea.)

2024-T42 Clad

0.063

2024-T3 Clad

0.050

2024-T3 Clad

1
0.050 j

j
I

Replace
Replace
Replace

2411130
2411130
2411130

2411130
2411130
2411130
2411130

Band

(3 ea.)

2411130
2411130
2411110
2411130

2511130

1
1
1

Doubler(eea.)
SpliceAngle
2511130 IFramelnstl., Frame 13
Frame Web Assy.
2411130
2411130
FrameWeb(2ea.)
2511130
FrameWeb(2ea.)
2411130
FrameWeb, RH Upper
2411090
2411110

2411130

0.050
0.040
0.025

1
1

0.040
0.050

i
1
i
1

51-70-03

I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace

51-70-03
51-70-03

51-70-03

I
I
1

2
2

0.050

51-70-03

51-70-03
51-70-03

Fuselage Frames Repair Index


Figure 1 (Sheet 4 of 9)

EFFECTIVITY:

31-002 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT

SRM-I

53-21-00

Page 4
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.
NO.

NO.
9

I
DESCRIPTION

2511137

IFrame(Bulkhead) Instl.,

2511137

Frame 13E
2511137

2511137
2511135

RH

2024-T42 Clad

0.040

2024-T42 Clad

0.040

Frame,RH(2ea.)
FrameWebAssy.

2024-T42 Clad

1
1
1

51-70-03

0.040

1
1
1

51-70-03
51-70-03

2024-T42 Clad

0.040

51-70-03

2511110

SpliceAngle(Gea.)

0.063

2411110

Cap(eea.)

2024-T42 Clad
2024-T3 Clad

1
1

I
I

Replace
Replace

2511137

IFrame(Bulkhead) Instl.,

2511137

0.040

3
3

2511137

Frame Assy., LH 6 RH
Frame

2024-T42 Clad

0.040

Frame,Upper

2024-T42 Clad

0.040

1
1

1
1

51-70-03

2511137

Frame, LH 6 RH

2024-T42 Clad

0.040

51-70-03

2024-T42 Clad
2024-T42 Clad

0.040

51-70-03

0.063

Replace

0.040

1
1
1

51-70-03

0.040

1
1
I

51-70-03

51-70-03

Replace
Replace

2511137

2511135

IFrameWebAssy.
FrameWeb

2511110

2511137

1
Splice Angle (4 ea.)
IFrame(Bulkhead) Instl.,

2511137

2511137 1

Frame Assy., LH
Frame

2511137

Frame,Upper

2511137

Frame,LH&RH

2511110

RH

2511135
2511137

IFrame(Bulkhead) Instl.,

2511137

Frame 138
2511137

2511135

0.040

2024-T42 Bare

0.025

2024-T42 Clad

0.040

2024-T42 Clad
2024-142 Clad

0.040

1
1

1
1

0.040

51-70-03
51-70-03

0.063

51-70-03

FrameWeb

2024-T42 Clad
2024-T42 Clad

FrameWebAssy.

2511135
2511135

RH

Frame, Upper
Frame,LH&RH

2511137

51-70-03

3
LH

Frame

2511137

2511110

Assy.,

0.040

Splice Angle (4 ea.)


Splice Band

Frame

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

FrameWeb

3
3

FrameWebAssy.

2511135

51-70-03

2511135

2511135

FIG. NO.

Frame 13C

12

REPAIR

CODE

3
3

Frame 13D

11

IFINISH

I GAGE

Frame, Upper

FrameWeb

2511135

I
MATERIAL

3
LH

Assy.,

Frame

2511137

10

Frame

I
EFF.I

Splice Angle (4 ea.)


SpliceBand

2024-T42 Clad

0.040

51-70-03

2024-T42 Clad

0.063

2024-T42 Bare

0.025

1
1

I
I

Replace
Replace

Fuselage Frames Repair Index


Figure 1 (Sheet 5 of 9)
EFFECTIVITY:

31-002 AND

SUBSEQUENT; 35-001 AND SUBSEQUENT;

36-001 AND SUBSEQUENT


SRM-4

53-21-00

Page 5
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
DWG.
NO.

ITEM

NO.
13

2411135

IFrame(Bulkhead) Instl.,

2411135

2411135

REPAIR

CODE

FIG. NO.

8 RH

2024-T42 Clad

0.040

51-70-03

2024-T42 Clad

0.040

51-70-03

2411135

FrameWeb

2024-T42 Clad

0.040

51-70-03

2411135

FrameWeb,Top

2024-T42 Clad

0.040

51-70-03

2411135

2024-T42 Clad
2024-T42 Clad

0.040

0.040

Replace
Replace

2411140

SpliceAngle(eea.)
Clip(4ea.)
IFramelnstl., Frame 14
Frame Assy., LH 6 RH
1

2411140

FrameWeb

2024-T42 Clad

0.040

51-70-03

2024-T42 Clad
2024-T42 Clad

0.040

51-70-03

0.040

51-70-03

2024-T42 Clad

0.040

51-70-03

2024-T42 Clad

0.040

2024-T42 Clad

0.050

I
I

2024-T42 Clad

0.040

2024-T42 Clad

0.063

1
1
1
1

Replace
Replace
Replace
Replace

2024-T42 Clad

0.050

51-70-03

2024-T42 Clad

0.050

51-70-03

1
1

I
I

Replace
Replace

51-70-04

I
I
I
I

Replace
Replace
Replace
Replace

2411135
2411140

2411140
2411135
2411140

2511150
2511150

3
3

FrameWeb

2411140

2411110

Lower

FrameWeb,Top
FrameWebAssy.

2411140

2411140

FrameWeb,LowerLH&RH

2411140

1
1

Clip(4ea.)
Clip(2ea.)
Splice Angle (2 ea.)
Splice Angle

IFramelnstl., Frame 15
FrameWeb,LH&RH
FrameWeb

2511150

2511150

Strap

2024-T3

0.100

2511150

Filler

2024-T3

0.063

2311152
2311150
2511150
2511150
16

IFINISH
GAGE

WebAssy.,LH&RHBottom

2411135

15

Web, LH

I
MATERIAL

Frame 13A
Web Assy., LH 8 RH
Frame

I
EFF.I

FrameWeb

2411135

14

I
DESCRIPTION

LongeronFitting(2ea.)
Strap
SpliceBand(eea.)
Clip
Splice Angle

2411110

2411160

IFramelnstl., Frame

16

FrameAssy.

2411160

S-578

2024-T3 Clad

0.100

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

0.025
0.063

1
1
1
1

3
3

0.050

Frame, LH 8 RH Aft
Frame, LH 8 RH Fwd

2024-T42 Clad

0.063

2024-T42 Clad

0.063

2024-T42 Clad

0.063

I
I

2024-T42 Clad

0.063

0.063

1
1

I
I

2024-T42 Clad
2024-T42 Clad

2024-T3 Clad

0.063

1
1

I
I

0.063

1
1

I
I

2411161

Bracket, LH

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

0.063

2411161

Frame,TopAft
Frame,TopFwd
InnerCap,LH&RH
SpiiceAngle, (4ea.)
Splice Plate
Support, LH 8 RH Aft
Support, LH 8 RH Fwd

1
1

0.040

2411161

Doubler

19

2024-T3 Clad

0.063

Splice Plate
Fitting Assy.

18

2024-T3 Clad

0.040

1
1

I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

51-71-00

Doubler

19

Replace

2411160

2411160
2411160
2411160
2411160
2411160
2411160
2411161

2411161

2311161

2811161

6 RH

0.063

2024-T3 Clad

0.063

Fuselage Frames Repair Index


Figure 1 (Sheet 6 of 9)
EFFECTIVITY:

31-002 AND
36-001 AND

SRM~

SUBSEQUENT; 35-001 AND SUBSEQUENT;


SUBSEQUENT

53-21-00

Page

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.
17

DWG.
NO.

24111701 Framelnstl., Frame

17

2411170

Channel, LH 8 RH
Gusset, LH 8 RH

3
3

Splice Angle
Frame (Bulkhead) Instl.,

2511175
2511175

2511175
2511175

0.040

0.063

2024-T42 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad

0.063

3
20

21
22

0.160

22
23

2024-T3 Clad

0.050

2024-T42 Clad
2024-T42 Clad

0.063

3
3

0.100
0. 050

0.050

Assy.

2511180
2511180
2511180

InnerCap

25

Filler

25

25

2511180

Frame,TopFwd
Channel,TopAft

2511180

Frame, Fwd LH

6 RH

25

2511180

Channel, LH

RH Aft

25

2311181

Fitting, LH 8
SpliceAngle
Angle

25
8 RH

25

25

RH

25
25

2024-T3 Clad
2024-T42 Clad
2024-T42 Clad
2024-T3 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
S-613

0.071
0. 032
0.071
0.071
0.063
0.063

0.063
0.063

25

2511181

Doubler, LH 8 RH Fwd
RH Aft
Doubler, LH

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

25

2024-T42 Clad

0.050

2511182

Gusset, LH

8 RH

25

0.050

2411180

Gusset, LH 8 RH

25

2611181

Reinforcement Doubler
Pressure Bulkhead Instl.

25

2024-T42 Clad
2024-T42 Clad
2024-T3 Clad

0.050

25

2024-T3 Clad
2024-T3 Clad

0.125

25

2024-T3 Clad

0.063

ABS Therm Plastic


ABS Therm Plastic
2024-T3 Clad

0.063

2511184
2511184
251 1 1 83
2511183
2611181

51-70-03

25

Closeout, LH

2511184 1
2511184

25

2511180

2511184

Replace
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.160

0.100

23

Doubler

2511181

0.050

2024-T3 Clad
2024-T3 Clad
2024-T3 Clad

2511180

2411180

0.063

2024-T42 Clad

Bulkhead

REPAIR
FIG. NO.

CODE

(2 ea.)
2311175
Filler(2 ea.)
2511175
Filler (2 ea.)
2511175
Skin, LH 8 RH
2511175
Frame, LH RH
25111801 Framelnstl.,Framel8

2411180

2024-T42 Clad
2024-T42 Clad

Washer

0.160
0.063

Doubler,LH&RHAft

2511175

2511180

2024-T3 Clad
2024-T42 Clad

2311175

2511228

IFINISH
GAGE

Frame 17A, LH 8 RH
Doubler, LH 8 RH Fwd

Angle
Splice Plate (2 ea.)
Splice Plate (2 ea.)
Washer(2 ea.)

2311175

I
MATERIAL

Filler

2411110

19

I
EFF.

2411170 1

2411171
18

I
DESCRIPTION

25

Mounting Plate
Doubler
Panel
Seal, LH 8 RH

0.080

0.040
0.050

0.032

Replace
Replace
Replace
Replace
Replace
Replace
Replace

25

Doubler

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

25

0. 063

Replace
Replace

25
25

Seal, Tee Stringer

25

Seal Plate

25

0.063
0.050

Replace
Replace
Replace
Replace
Replace

Fuselage Frames Repair Index


Figure 1 (Sheet 7 of 9)
EFFECTIVITY:

31-002 AND

36-001 AND
SRM-4

SUBSEQUENT;
SUBSEQUENT

35-001 AND

SUBSEQUENT;

53-21-00

Page

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEIMI
NO. I

DWG.

NO.

I
DESCRIPTION

IFramelnstl., Frame 18
Frame Assy.
1
2511180
Channel,TopAft
2411180
Channel,TopFwd
2311181
Fitting, LH 8 RH
2411180
Gusset(Sea.)
2411180
Inner Cap, LH 8 RH
2411180

24

2411180

24

2411180

2411~180
2411180
2411180
2411180
2511180
2511180
2411180
2411180
20

2024-T42 Clad
2024-T42 Clad

24

I
I
I
I
I
I
I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Replace

Replace
Replace
Replace

1
1

I
I
I
I
I

Replace
Replace
Replace
Replace
Replace

51-71-00

1
1
1

Replace
Replace
Replace
Replace

24

S-613

24

2024-T42 Clad

0.032

24

2024-T42 Clad

0.063

Channel, LH 8 RHAft
Channel, LH 8 RH Fwd

24

2024-T42 Clad

0.063

24

0.063

Sleeve

24

Angle, LH 8 RH
SpliceAngle(2ea.)
Channel,TopAft

24

2024-T42 Clad
5052-0 Tube
2024-T42 Clad

24

2024-T42 Clad

0.080

24

Clad

0.063

Frame, Fwd LH 8 RH

24

Clad

0.063

SpliceAngle
SplicePlate

24

2024-T42
2024-T42
2024-T42
2024-T42

Clad

0.080

1
1
i
1
1
1
1
1
1
1

Clad

0.063

1
j
1
1

24

0.035
0.040

2024-T42 Clad

0.063

2024-T42 Clad

0.025

2024-T42 Clad

0.063

Frame Instl., FrameeO

FrameAssy.

Frame Web,

Upper Aft
FrameWeb, UpperFwd

2024-T42 Clad

0.050

2024-T42 Clad

0.050

FrameWeb, LH 8 RH Aft
FrameWeb, LH 8 RH Fwd

2024-T42 Clad

0.050

2024-T42 Clad

0.050

2024-T42 Clad

0.080

2511200

SpliceAngle(Qea.)
Fitting, LH 8 RH (2 ea.)
InnerCapStrip(2ea.)

2311200
2311210

Reinf. Channel, LH 8 RH
Seal Bracket, LH 8 RH

2511200
2511200
2511200
2411180
2311201

2511210

2511210
2511210

SpliceAngle

25112101 Framelnstl.,Frame21
2511210

FrameAssy.
Frame,TopAft
Frame,TopFwd

2024-T3 Clad

0.050

2024-T42 Clad

0.080

2024-T42 Clad

0.032

301 Stainless

0.020

2024-T42 Clad
2024-T42 Clad

0.050

Replace
Replace

0.050

0.050

I
I

Replace
Replace
Replace
Replace

I
I

Replace
Replace
Replace

0.050

Frame, Lower LH

2024-T42 Clad

Frame, Fwd Lower RH


Frame,AftLowerLH
Aft Frame, Lower RH

3
3

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

301 Stainless

0.020

2024-T3 Clad

0.050

2024-T3 Clad

0.050

2511210
2511210

lnnerSplicePlate
InnerCapStrip
InnerCapStrip

I
F1 7-6

2511210

2511210

1
1

2511210

2511210
2511210

Replace
Replace

FrameWeb,LH&RH

FIG. NO.

0.063

SafetyBand(3ea.)
SpliceAngle

2511200

REPAIR

CODE

0.063

2511190

2511200

IFINISH
GAGE

2511190

2511200

22

I
MATERIAL

24

25111901 Framelnstl.,FramelS

2311190
21

I
EFF.

0.050
0.050

F1 7-6

1
1

Fuselage Frames Repair Index


Figure 1 (Sheet 8 of 9)
EFFECTIVITY:

31-002 AND
36-001 AND

SRM-4

SUBSEQUENT; 35-001 AND SUBSEQUENT;


SUBSEQUENT

53-21-00

Page

May 15/92

Learjet

STRUCTURAL;REPAIR MANUAL
DWG.

ITEM
NO.

NO.
2311210
2311210
2311211
2311212
2411180
2411180

CODES
1

3
4

5
6

7
8
9

10
11

12
13
14

15
16
17

18
19

20
21
22

23
24
25
26
27

FINISH
DESCRIPTION

EFF.

MATERIAL

GAGE

Seal Bracket, LH 8 RH
Reinf. Channel, LH 8 RH
Fitting, LH 8 RH (2 ea.)
Fitting, LH 6 RH

2024-T42 Clad

0.032

2024-T42 Clad

0.050

SpliceAngle(2ea.)
SpliceAngle

3
3

CODE

REPAIR
FIG. NO.

Replace
Replace
51-71-00

51-71-00

2024-T42 Clad
2024-T42 Clad

0.080

0.080

Replace
Replace

EFFECTIVITIES
31-002 AND

SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT, ALL WITH

36-INCH PASSENGERICREW DOOR


31-002 AND SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT, ALL WITH
24-INCH PASSENGER/CREW DOOR
31-002 AND SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT
31-002 THRU 31-047; 35-001 THRU 35-672; 36-001 THRU 36-063
31-048 AND SUBSEQUENT; 35-673 AND SUBSEQUENT; 36-064 AND SUBSEQUENT
31-002 THRU 31-062; 35001 THRU 35-674; 36-001 THRU 36-063
31-064 AND SUBSEQUENT; 35-675 AND SUBSEQUENT; 36-064 AND SUBSEQUENT

35-001 THRU 35-626; 36-001 THRU 36-055


31-002 THRU 31-038; 35001 THRU 35-668; 36-001 THRU 36-063
31-039 AND SUBSEQU,ENT; 35-669 AND SUBSEQUENT; 36-064 AND SUBSEQUENT
35-001 THRU 35-618; 36-001 THRU 36-055
31-002 THRU 31-034; 35001 THRU 35-669; 36-001 THRU 36-063, ALL WITH 36-INCH PASSENGER/CREW DOOR
31-035 AND SUBSEQUENT; 35-670 AND SUBSEQUENT; 36-064 AND SUBSEQUENT, ALL WITH
36-INCH PASSENGER/CREW DOOR
35-001 THRU 35-317; 36-001 THRU 36-045
31-002 AND SUBSEQUENT; 35-318 AND SUBSEQUENT; 36-046 AND SUBSEQUENT
35-001 THRU 35-034, EXCEPT 35-028; 36-001 THRU 36-017, 36-019
31-002 AND SUBSEQUENT; 35-028, 35-035 AND SUBSEQUENT; 36-018, 36-020 AND SUBSEQUENT
35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT
31-002 AND SUBSEQUENT
35-001 THRU 35-182; 36-001 THRU 36-038
31-002 AND SUBSEQUENT; 35-183 AND SUBSEQUENT; 36-039 AND SUBSEQUENT
35-001 THRU 35-280; 36-001 THRU 36-0442
31-002 AND SUBSEQUENT; 35-281 AND SUBSEQUENT; 36-045 AND SUBSEQUENT
35-001 AND SUBSEQUENT; 31-002 AND SUBSEQUENT
36-001 AND SUBSEQUENT
31-002 THRU 31-088; 35-001 THRU 35-676; 36-001 THRU 36-063
31-089 AND SUBSEQUENT; 35-677 AND SUBSEQUENT; 36-064 AND SUBSEQUENT

Fuselage Frames Repair Index


Figure 1 (Sheet 9 of 9)
EFFECTIVITY:

SRM-4

31-002 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT

53-21-00

Page 9
Jun 1/95

Learjet
~Learjetl

STRUCTURAL REPAIR MANUAL


FUSELAGE FRAMES
i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGE LIMITS


All dimensions

NOTE:
A.

in inches unless otherwise

are

specified.

Fasteners

(1) Loose
tions

or

failed rivets
the

on

are

remaining

not allowed. A loose

rivets and lead to

or

failed rivet

progressive joint

performed to ensure that joint failure has not spread


fer to Chapter 51 for definition of rivet failure.)
(2) Loose

or

trations

failed

on

performed
B.

screws are

ensure

loose

or

from the

failed

increased stress concentra-

area

of the loose

screw can cause

inspection
or

must be

failed rivet. (Re-

increased stress

concen-

and lead to progressive joint failure. A careful inspection must be


that the joint failure has not spread from the area of the loose or failed screw.

surrounding
to

not allowed. A

can cause

failure. A careful

screws

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired, and refinished


C.
D.

Chapter

re-

51.

Deformation

(1) Deformation of the fuselage frames is not allowed.


Corrosion(SeeFigure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

in accordance with

more

than

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component reF.

G.

H.

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(See Figure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittingsand Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTIVITY:
SRM-4

ALL

53-21-00

Page 101
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225
0.0295

0.032
0.040

0.059

0.063
0.071

0.037
0.046

0.050

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure 101
EFFECTNITY:
SRM~

ALL

53-21-00

Page 102
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
FUSELAGE FRAMES
1.

APPROVED REPAIRS
A.

RefertoChapter51 fortypicalrepairs.

EFFECTIVITY:
SRM~I

REPAIR

ALL

53-21-00

Page 201
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


FUSELAGE STRINGERS
1.

STRUCTURAL IDENTIFICATION

DESCRIPTION
A.

B.

fuselage stringers provide longitudinal support to the overall composition of the fuselage. The
stringers are located around the perimeter of the frames. A total of 41 stringers, spaced approximately 5-inches apart are made of aluminum extrusion and cut to various lengths.
The fuselage stringers installation provides overall structural continuity and aerodynamics of the airThe

craft.

C.

The

fuselage stringer repair index figures are separated

into 24" and 36"

passenger/crew door config-

urations.

EFFECTIVITY:

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT

53-22-05

Page

Jan 15/93

tearjetJ
STRUCTURAL REPAIR MANUAL
I;USELAGE STRINGERS

STRUCTURAL IDENTIFICATION

Frame 17A
FS 378.05

Frame 5

Frame 7

Frame 9

Frame 11

Frame 13

FS 160.77

Frame 13D

FS 184.78

FS 209.19

Frame 13B

FS 234.19

FS 258.01

Frame 14

Frame 16

FS 283.99

FS 308.49

(Refl

(Rcf)

FS 332.66

(Ref)

FS 355.49

(Ref)

(Ref)

(Refl

(ReD

(ReD

(Ref)
Frame 18

(ReD

Frame 6

Frame 8

Frame 10

Frame 12

Frame 13E

Frame 13C

FS 157.12

FS 172.19

Frame 13A

FS 196.99

FS 221.59

FS 246.09

Frame 15

Frame 17

FS 271.99

FS 296.49

FS 321.24

FS 346.63

FS 368.68

(Ref)

(Ref)

(Ref)

(Ren

(Ref)

(ReD

(Ref)

(ReD

Frame 22

(Ref)

(ReD

FS 381.79

Frame 4

(ReD

Frame 20
FS 402.42

(ReO

FS 421.42

Frame 21
FS411.95

(ReD

Framel9

(ReD

FS 392.50

i~l

(Ref)

1L,r I

_I

i.

I I

ol

JI~

--li.
1~;-

1~7

21

111

_i-

-i
:i

I;/

3-

II

II

1=r--

r_----=--~i
I

11---

iZ

II F
!I

16

II I

rj\

Y2i

;il

1.

28

T~-\--1TI

sc~i

t-----

_i

Ijr,

C~

-r

i--

ii

C---=;;=

ii
~r-

I---,--~t---

40)

~5)

(VIEW LH SIDE LOOKING INBOARD)


(TWICAL)

2-150D

Fuselage Stringers Repair Index


Figure 1 (Sheet 1 of 7)

EFFECTIVITY:

31-001 AND

SUBSEQUENT; 35-001 AND SUBSEQUENT;

53-22-05

SRM~

36-001 AND SUBSEQUENT, EQUIPPED WITH 24-INCH


PASSENGER/CREW DOOR

Ian 15/93

Page 2

(42)

(36)

(33

17

Learjet
STRUCTURAL REPAIR MANUAL
FUSELAGE STRINGERS

STRUCTURAL IDENTIFICATION

Frame 17A
FS 378.05
Frame 22

Frame 20

FS421.42

FS 402.42

(Ref~

(Ref)

(Ref)

Frame 16

Frame 14

Frame 13

Frame II

Frame 9

Frame 7

Frame 5

ES 355.49

Frame 1311
FS 308.49

Frame 13D

FS 332.66

FS 283.99

FS 258.01

FS 234.19

F5 209.19

FS 184.78

FS 160.77

(ReD

(Ref)

(Refi

(Ref)

(Ref)

(ReD

(Ref)

(Ref)

(Ref)

FS 381.79

FS 368.68

FS 346.63

Frame 13A
FS 321.24

(Ref)

(ReO

(ReO

(ReO

Frame Is

Frame 21

Frame 19

FS 41795

FS 392.50

(Ref)

(Ref)

Frame 15

Frame 17

Frame 13C
FS 296.49

Frame 13E

(Ret)

(Ref)

Frame 10

Frame 8

Frame 6

Frame 4

FS 246.09

FS 221.59

FS 1%.99

FS 172.19

FS 151.12

(ReO

(Ref)

(Ref)

(Ref)

(Ref)

Frame 12

FS 271.99

I
12)

Pii iiiil

jlli

iiil

ii

liliI:

ii;liZ
I,:

j ij

II,:

II;;rl 1
I

II

(23

~1

ii;

(18)1

i
__iL__

---------~!___________1:_________I:__

I;

____It
ii

)i

7T--""

II~
_____

30)

(3()

(37)

(41)

_itl__________l:.~_l__ITIIJI.___

111 1

31

1._______~

5~)

(56)

(531

(VZEW RH SIDE LOOKING INBOARD)


(TYPICAL)

n51D

EFFECTIVITY:

SRM~

Fuselage Stringers Repair Index


Figure I (Sheet 2 of 7)
SUBSEQUENT; 35-001 AND SUBSEQUENT;
SUBSEQUENT, EQUIPPED WITH 24-INCH
PASSENGER/CREW DOOR
31-001 AND

53-22-05

36-001 AND

Page 3
Tan 15/93

(49

Learjet

STRUCTURAL REPAIR MANUAL


FUSELAGE STRINGERS

STRUCTURAL IDENTIFICATION

23

1B

12

Frame 4
FS 151.12

(Ref)

CFWO

21

15

(VIEW LOOKING DOWN, FWD SECTION)

Frame 13D

(TYFICAL)

(Ref)

FS 283.99

Detail A
1

1)

13

19

24

Frame

SFBJI

308.49

~O

(ReD

(16)
(11)

(22)

(VIEW LOOKING DOWN, AFT SECTION)

I~ Frame 22
FS 421.42

(Ref)

(TYPICAL)

Detail B
2-~J"LD

EFFECTIVITY:
SRM4

Fuselage Stringers Repair Index


Figure 1 (Sheet 3 of 7)
31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;
36-001 AND SUBSEQUENT, EQUIPPED WITH 24-TNCH

PASSENGER/CREW DOOR

53-22-05

Page 4
Jan 15/93

STRUCTURAL REPAIR MANUAL


ITEM

NO.

DWG.
NO.

FuselageStringer Instl.
Stringer(C/L)
(FS 216.62 to 420.92)
Stringer No. 2 LH 8 RH
(FS 216.62 to 420.92)
1
Stringer No. 2 LH 8 RH
(FS 216.62 to 420.92)
Stringer No. 2 LH 8 RH
(FS 183.03 to 207.73)
StringerNo.3LH&RH
(FS 216.62 to 420.92)
1
Stringer No. 3 LH 8 RH

2611003
1

2611007

2611007

2611007
3

2411000

1 2611007
2611007

2411000

2411000
6

2611007

2611007
7

2611007
2611007

2611007

I
DESCRIPTION

(FS 216.62 to 420.92)


Stringer No. 3 LH 8 RH
(FS 186.03 to 217.73)
StringerNo.3LH& RH
(FS 194.87 to 217. 13)
Stringer No. 4 LH
(FS 206.62 to 420.92)

Stringer No. 4 RH
(FS 206.62 to 420.92)
Stringer No. 5 LH
(FS 206.62 to 420.92)
Stringer No. 5 LH
(FS 206.62 to 420.92)
Stringer No. 6 LH
(FS

2611007
9

2611007

10

2411000

11

2411000

2611000
12

2411000

13

2611000

14

2611000

210.06 to

I
EFF.

MATERIAL

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

1
1

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-681

51-70-04

S-681

51-70-04

S-681

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

420.92)

Stringer No. 6 LH
(FS 210.06 to 420.92)
Stringer No. 6 RH
(FS 210.06 to 420.92)
Stringer No. 7 LH
(FS 206.95 to 219.64)
StringerNo. 7LH
(FS 368.90 to 420.92)
StringerNo. 7LH
(FS 368.90 to 420.92)
StringerNo. 7RH
(FS 210.06 to 219.64)
Stringer No. 7 RH
(FS 368.90 to 420.92)
Stringer No. 7 RH
(FS 351.96 to 357.40)

Fuselage Stringers Repair Index


Figure 1 (Sheet 4 of 7)
EFFECTIVITY:

SRM-4

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT, EQUIPPED WITH 24-INCH

PASSENGER/CREW DOOR

53-22-05

Page 5
~an 15/93

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

15

2411000

16

2411000

17

2511000

18

19

2411000

2611000

2511000
20

2611000

21

2411000

2411000
22

2411000

2511000
23

I
DESCRIPTION

2411000
2411000

24

2611000

25

2611000

26

2411000

27

2411000

28

2411000

29

2411000

30

2611000

31

2611000

2411000

2611000

StringerNo. 8 LH
(FS 206.95 to 219.64)
Stringer No. 8 LH
(FS 399.77 to 420.92)
Stringer No. 8 LH
(FS 348.68 to 420.92)
Stringer No. 8 RH
(FS 210.06 to 221.32)
Stringer No. 8 RH
(FS 368.86 to 420.92)
StringerNo. 8 RH
(FS 368,86 to 420.92)
Stringer Na. 8 RH
(FS 351.46 to 357.40)
Stringer No. 9 LH
(FS 199.17 to 219.64)
StringerNo. 9LH
(FS 160.87 to 187.53)
StringerNo. 9LH
(FS 368.90 to 420.92)
Stringer No. 9 LH
(FS 368.90 to 420.92)
Stringer No. 9 RH
(FS 199.73 to 221.40)
Stringer No. 9 RH
(FS 161.27 to 187.53)
Stringer No. 9 RH
(FS 368.90 to 420.92)
Stringer No. 9 RH
(FS 351.96 to 357.40)
Stringer No. 9 RH
(FS 368.90 to 420.92)
Stringer No. 10 LH
(FS 160.83 to 219.64)
Stringer No. 10 LH
(FS 346.73 to 420.92)
Stringer No. 10 RH
(FS 1 61 .27 to 22 1.47)
Stringer No. 10 RH
(FS 415.48 to 420.92)
Stringer No. 10 RH
(FS 351.96 to 420.92)
Stringer No. 10 RH
(FS 368.90 to 420.92)
Stringer No. 10 RH
(FS 351.96 to 357.40)

I
EFF.

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

MATERIAL

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

18-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

1S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

Fuselage Stringers Repair Index


Figure 1 (Sheet 5 of 7)
EFFECTIVITY:

SRM-4

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT, EQUIPPED WITH 24-INCH
PASSENGER/CREW DOOR

53-22-05

Page 6
Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


ITEM
NO.
32

DWG.
NO.

1
DESCRIPTION

Stringer

2411000

(FS
33

2611007

34

2611007

35

2411000
2411000

36

2611007

37

2611007

38

2411000

39

2611007

40

2411000

41

2611007

42

2511000

43

2411000

44

2611007

45

2611007

46

2611007

2611007

47

2411000

48

2611007

49

2611007

50

2411000

51

2611007

No. 11 LH

160.83 to

(FS

I
MATERIAL

IFINISH
GAGE

REPAIR
FIG. NO.

CODE

S-566

51-70-04

S-566

51-70-04

S-566

51-70-04

S-566

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

5-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-681

S-sal

I~

51-70-04

s-salD

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

219.64)

Stringer No. 11 LH
(FS 247.60 to 420.92)
Stringer No. 11 RH
(FS 369.90 to 420.92)
Stringer No. 12 LH
(FS 160.83 to 219.64)
Stringer No. 12 LH
(FS 160.83 to 219.64)
Stringer No. 12 LH
(FS 247.60 to 378.00)
Stringer No. 12 RH
(FS 159.23 to 377.83)
Stringer No. 13 LH
(FS 180.63 to 219.64)
Stringer No. 13 LH
(FS 247.60 to 354. 10)
Stringer No. 13 LH 8 RH
(FS 356.80 to 377.93)
Stringer No. 13 RH
(FS 159.28 to 354.98)
Stringer No. 12A LH 8 RH
(FS 382.70 to 399.61)
Stringer No. 14 LH
(FS 160.83 to 219.64)
Stringer No. 14 LH
(FS 247.60 to 313.60)
StringerNo. 14RH
(FS 159.24 to 311.54)
Stringer No. 15 LH
(FS 247.60 to 346.60)
Stringer No. 15 RH
(FS 159.13 to 346.60)
StringerNo. 16LH
(FS 160.83 to 219.64)
Stringer No. 16 LH
(FS 247.60 to 346.60)
Stringer No. 16 RH
(FS 244.30 to 345.30)
StringerNo. 17LH
(FS 160.83 to 219.64)
Stringer No. 17 LH
259.52 to

I
EFF.

51-70-04

346.60)

Fuselage Stringers Repair Index


Figure 1 (Sheet 6 of 7)
EFFECTIVITY:

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;

53-22-05

Page

sRM-4

36-001 AND SUBSEQUENT, EQUIPPED WITH 24-INCH


PASSENGER/CREW DOOR

Jan 15/93

Learjet
STRUCTURAL REPAIR MANUAL
DWG.
NO.

ITEM

NO.

EFF.

DESCRI PTIO N

52

2411000

53

2611007

54

2411000

55

2611007

56

2611007

57

2411000

58

2611007

59

2611007

60

2411000

61

1 2611007

StringerNo. 17RH
(FS 161.27 to 220.08)
StringerNo. 17RH
(FS 213.63 to 346.53)
Stringer No. 18 LH
(FS 160.83 to 219.64)
Stringer No. 18 LH
(FS 247.60 to 346.60)
Stringer No. 18 RH
(FS 159.13 to 346.53)
Stringer No. 19 LH
(FS 160.83 to 219.64)
Stringer No. 19 LH
(FS 247.60 to 346.53)
Stringer No. 19 RH
(FS 159.13 to 346.53)
Stringer No. 21 LH 8 RH
(FS 160.83 to 172.09)
StringerNo.21LH&RH
(FS 170.83 to 346.53)

MATERIAL

.GAGE

FINISH

REPAIR

CODE

FIG. NO.

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

5-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

EFFECTIVITIES

CODES
1

31-001 AND

2
3

35-001 THRU 35-369, 35-371 THRU 35-389; 36-001 THRU 36-047


35-370, 35-390 AND SUBSEQUENT; 36-048 AND SUBSEQUENT

31-001 AND

36-001 AND SUBSEQUENT

SUBSEQUENT;

SUBSEQUENT;

35-001 AND

SUBSEQUENT;

36-001 AND SUBSEQUENT

35-001 AND SUBSEQUENT

NOTES

Optional

to manufacture from S-5093.

Fuselage Stringers Repair Index


Figure 1 (Sheet 7 of 7)

EFFECTIVITY:

SRM-4

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT, EQUIPPED WITH 24-INCH

PASSENGER/CREW DOOR

53-22-05

Page 8
Tan 15/93

Learjet
STRUCTURAL REPAIR MANUAL

Frame 17A
FS 378.05

FUSELAGE STRINGERS

STRUCTURAL IDENTIFICATION

(Ref)
Frame 18
FS381.79

Frame 5

Frame 7

Frame 9

Frame 11

Frame 13

Frame 13D

FS 160.77

FS 184.78

FS 209.19

FS 234.19

FS 258.01

(Ref)

(Ref)

(Ref)

(Re~

(Ref)

Frame 4
FS 151.12

(Ref)

Frame 14

Frame 16

FS 283.99

Frame 13B
FS 308.49

FS 332.66

FS 355.49

(Ref)

(Ref)

(Ref)

(ReO

Frame 6

Frame 8

Frame 10

Frame 12

Frame 13E

Frame 13C

Frame 13A

Frame 15

FS 172.19

FS 196.99

FS 22159

FS 245.59

FS 271.99

FS 296.49

FS 321.24

FS 346.63

(Ref)

(Ref)

(Ref)

(Ref)

(Ref)

(Ref)

(Ref)

(Ref)

Al
io~

19

I?

\I

1
1

(Ref)

Frame 20

Frame 22

FS 402.42

FS 421.42

(Ref)

(Ref)

Frame 17

Frame 19

FS 368.68

FS 392.50

FS 411.95

(Ref)

(Ref)

(Ref)

I I

Frame 21

IB

-U
i-------

ii

. . .I% ~fP-3

ii

\ii:;II
i

II))I

ii
___,,

ii;

-i

pi-i

:n:

li ii

I!

,II! 1!

i iiI
Ii
iii

ill i

ill i

!jI

ii

41;--i

illr;1

I~

ij

jj

ji

ii

i.

~f--

ii

;il!i/i
i
Ia i
n+~---

:i

mn

ii II
ii

fj

Ii
r:

-m-----

--~-I

ii

II

i
:___TS---lf

:-Ftr=

00

0~

(VIEW LH SIDE LOOKING INBOARD)

(TYPICAL)

2-153D

EFFECTIVITY:

Fuselage Stringers Repair Index


Figure 2 fSheet 1 of 7)
31-001 AND SUBSEQUENT; 35-001 AND
36-001 AND

SRMII

SUBSEQUENT, EQUIPPED
PASSENGER/CREW DOOR

SUBSEQUENT;

WITH 36-INCH

53-22-05

Page

Jan 15/93

50)

Learjet
STRUCTURAL REPAIR MANUAL
FUSELAGE STRINGERS

STRUCTURAL IDENTIFICATION

Frame 17A
FS 378.05
Frame22

Fmme u)

FS 421.42

FS 402.42

(Ref)

(Ref)

~eO

Frame 16

Frame 14

Frame 13B

Frame 13D

Frame 13

Frame 11

Frame 9

Frame 7

Frame 5

FS 355.49

FS 332.66

FS 308.49

FS 283.99

FS 258.01

FS 231.19

FS 209.19

FS 184.78

FS 160.77

(ReD

cRen

(Ref)

(Ref)

Ref)

(Ref)

(Ref)

(ReD

(ReD
Frame 4

Frame 15

Frame 13A

Frame 1X

Frame 13E

Frame 12

Frame 10

FS 381.79

FS 368.68

FS 346.63

FS 321.24

FS 2%.49

FS 271.99

FS 246.09

FS 221.59

FS 196.99

FS 172.19

FS 151.12

(Ref)

(Ref)

(Ref)

(Ref)

(Ref)

(Ref)

(Ref)

(Ref)

(Ref)

(Ref)

(Ref)

Frame 18

Frame 21

Frame 19

FS 411.95

FS 392.50

(Ref)

(Ref)

28)

Frame 6

117) (12
n)
I

13

~r

1~

1IL

Frame 17

Frame 8

crc--

II

Il

I;

~I

I:

~1611

(23

II(;
I i!

.ii4!

,I
I

t
im~cui.

,___

ii~

TffE;;~1

ii:

II
II

II

I:

ii

i:

II

I~

~I

I
C7--

ill
t.

;II

J------

1!

Ii IY

r--

"1:

*-,-----i~

i/

I~n

3lr-----r5r

1.~_

ii

I
1

iii
t

-,c~

i,:

7ii

I;

,i

II
I

Il

ii
Il
_

7\UI

ii:

ii;

-I

I
-I--------

-C-

------~1---------

1!

(36)

(35)

I;

JI

\1 111

1561

(53)

(TYPICAL)

Fuselage Shingers Repair Index

Figure 2 (Sheet 2
31-001 AND
3M~1 AND

of 7)

SUBSEQUENT; 35-001 AND SUBSEQUENT


SUBSEQUENT, EQUIPPED WITH 36-INCH

PASSENGER/CREW DOOR

53-22-05

Page

~-4P----

(a

(VIEW RH SIDE LOOKING INBOARD)

sah4

-------I~--

ssl

EFFEC~TVrTY:

_r_

(42)

29)

2-l~o

_,--------

(32)

-i-----

%I____

I~
L

27)

:111

10

Tan 15/93

Ir_------f~_

i~H

Learjet
~Learjetl

STRUCTURAL REPAIR MANUAL


FUSELAGE STRINGERS

STRUCTURAL IDENTIFICATION

23

16

17

246

Frame 4
FS 151.12

(Ref)
2

10

20

1~

Frame 13D

(VIEW LOOKING DOWN, FWD SECTION)

~FWO

FS 283.99

(TYPICAL)

(Ref)

Detail A
8

14

16

16

24

27

Frame 13B
FS 308.49

(Ref)

13

21

26

Frame 22
FS421.42

(VIEW LOOKING DOWN, AFT SECTION)

(Ref)

(TYPICAL)

Detail B
2-152D

EFFECTIVITY:
SRM-4

Fuselage Stringers Repair Index


Figure 2 (Sheet 3 of 7)
31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;
36-001 AND SUBSEQUENT, EQUIPPED WITH 36-INCH

PASSENGER/CREW DOOR

53-22-05

Page

11

Jan 15/93

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.
2611000

2611000

2411000

2611000

2411000

2611000

2411000

2611000

2611000

2611000
2611000

FuselageStringer Instl.
Stringer(C/L)
(FS 218.59 to 420.92)
Stringer No. 2 LH 8 RH
(FS 183.73 to 215.43)
Stringer No. 2 LH 8 RH
(FS 215.43 to 420.92)
Stringer No. 3 LH 8 RH
(FS 183.73 to 215.43)
Stringer No. 3 LH 8 RH
(FS 215.43 to 420.92)
Stringer No. 4 LH 8 RH
(FS 196.14 to 215.43)
Stringer No. 4 LH 8 RH
1
(FS 215.43 to 420.92)
Stringer No. 5 LH 8 RH
(FS 209.87 to 420.92)
Stringer No. 6 LH
(FS 208.51 to 420.92)
Stringer No. 6 RH
(FS 208.51 to 420.92)
StringerNo.

2611000

10

1 2411000
2611000
2611000

2411000

12

2611000

13

2611000

11

2611000
14

2411000

15

2411000

2511000

I
DESCRIPTION

6 LH

(FS 208.51 to 420.92)


StringerNo.7LH
(FS 208.47 to 221.16)
Stringer No. 7 LH
(FS 368.90 to 420.92)
Stringer No. 7 LH
(FS 346.78 to 420.92)
Stringer Na. 7 RH
(FS 208.47 to 222.73)
Stringer No. 7 RH
(FS 351.96 to 357.40)
Stringer No. 7 RH
(FS 368.90 to 420.92)
Stringer No. 7 RH
(FS 351.96 to 420.92)
Stringer No. 8 LH
(FS 208.47 to 221.16)
Stringer No. 8 LH
(FS 399.77 to 420.92)
Stringer No. 8 LH
(FS 346.73 to 420.92)

I
EFF.

I
MATERIAL

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-681

51-70-04

S-681

51-70-04

18-5093

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

18654

51-70-04

5-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

Fuselage Stringers Repair Index


Figure 2 (Sheet 4 of 7)
EFFECTIVITY:

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT, EQUIPPED WITH 36-INCH

PASSENGER/CREW DOOR

53-22-05

Page

12

Tan 15/93

Learjet

STRUCTU RAL REPAIR MAN UAL


ITEM

NO.

DWG.
NO.

16

2411000

17

2611000

I
I

18 1 2611000

2411000
19 1 2411000
20

2411000

21

2411000

2511000

22

2411000

23

2411000

24

2611000
2611000

2411000
25

2411000

26

2411000

2511000
27

2611000
2411000

28

2611000

29

2411000

30

2411000

31

2611000

I
DESCRIPTION

Stringer No. 8 RH
(FS 208.47 to 222.73)
Stringer No. 8 RH
(FS 351.96 to 357.40)
Stringer No. 8 RH
(FS 368.90 to 420.92)
Stringer No. 8 RH
(FS 368.90 to 420.92)
Stringer No. 9 LH
(FS 160.77 to 186.43)
Stringer No. 9 LH
(FS 200.99 to 221.16)
Stringer No. 9 LH
(FS 368.90 to 420.92)
Stringer No. 9 LH
(FS 346.73 to 420.92)
Stringer No. 9 RH
(FS 160.77 to 187.03)
Stringer No. 9 RH
(FS 199.44 to 221.16)
Stringer No. 9 RH
(FS 368.90 to 420.92)
Stringer No. 9 RH
(FS 351.96 to 357.40)
StringerNo. 9RH
(FS 368.90 to 420.92)
Stringer No. 10 LH
(FS 160.77 to 221.16)
Stringer No. 10 LH
(FS 368.90 to 420.92)
Stringer No. 10 LH
(FS 346.73 to 420.92)
Stringer No. 10 RH
(FS 351.96 to 357.40)
Stringer No. 10 RH
(FS 321.24 to 378.05)
Stringer No. 10 RH
(FS 351.96 to 357.40)
Stringer No. 10 RH
(FS 368.90 to 420.92)
Stringer Na. 11 LH
(FS 162.65 to 221.16)
Stringer No. 11 LH
(FS 259.32 to 420.92)

I
EFF.

I
MATERIAL

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-566

51-70-04

S-566

51-70-04

Fuselage Stringers Repair Index


Figure 2 (Sheet 5 of 7)
SUBSEQUENT; 35-001 AND SUBSEQUENT;

EFFECTIVITY:

31-001 AND

SRM-4

36-001 AND SUBSEQUENT, EQUIPPED WITH 36-INCH


PASSENGER/CREW DOOR

53-22-05

Page

13

Jan 15/93

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

32

2611000

33

2411000

34

2611000

35

2611000

36

2511000

37

2411000

38

2611000

39

2411000

40

2511000

41

2611000

42

2411000

43

2411000

44

2611000

45

2611000

46

2411000

47

2611000

48

2611000

49

2411000

50

2611000

51

2611000

52

2411000
2611000

Stringer No. 11 RH
(FS 161.27 to 420.92)
StringerNo. 12 LH
(FS 162.65 to 221.16)
Stringer No. 12 LH
(FS 239.52 to 377.89)
Stringer Na. 12 RH
(FS 161.27 to 377.89)
Stringer No. 12A RH
(FS 382.76 to 399.61)
Stringer No. 13 LH
(FS 162.65 to 221.16)
Stringer No. 13 LH
(FS 259.52 to 354.58)
Stringer No. 13 LH
(FS 355.49 to 378.05)
StringerNo. 13LH
(FS 382.70 to 399.61)
Stringer No. 13 RH
(FS 161.27 to 354.98)
Stringer No. 13 RH
(FS 356.92 to 378.05)
StringerNo. 14LH
(FS i 60.77 to 221.16)
StringerNo. 14LH
(FS 259.52 to 311.54)
StringerNo. 14RH
(FS 161.27 to 311.54)
StringerNo. 15 LH
(FS 160.77 to 221.1 6)
Stringer No. 15 LH
(FS 259.32 to 346.45)
Stringer No. 15 RH
(FS 161.27 to 346.45)
Stringer No. 16 LH
(FS 160.77 to 221.16)
Stringer No. 16 LH
(FS 259.32 to 346.45)
Stringer No. 16 RH
(FS 161.27 to 346.45)
Stringer No. 17 LH RH
(FS 160.77 to 221.16)
StringerNo. 17LH
(FS 259.52 to 346.45)

I
EFF.

DESCRIPTION

I
MATERIAL

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

S-566

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-5093

51-70-04

S-5093

51-70-04

S-5093

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

5-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

Fuselage Stringers Repair Index


Figure 2 (Sheet 6 of 7)
EFFECTIVITY:

SUBSEQUENT; 35-001 AND SUBSEQUENT;


SUBSEQUENT, EQUIPPED WITH 36-INCH
PASSENGER/CREW DOOR
31-001 AND
36-001 AND

SRM-4

53-22-05

Page

14

Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

DESCRIPTION

53

2611000

54

2411000

55

2611000

56

2611000

57

2411000

58

2611000

59

2611000

2411000
2611000

CODES

StringerNo. 17RH
(FS 215.59 to 346.45)
Stringer No. 18 LH
(FS 160.77 to 221.16)
Stringer No. 18 LH
(FS 259.52 to 346.45)
StringerNo. 18RH
(FS 162.27 to 346.45)
StringerNo. 19LH
(FS 160.77 to 221.16)
StringerNo. 19LH
(FS 172.29 to 346.45)
Stringer No. 19 RH
(FS 161.27 to 346.45)
Stringer No. 21 LH RH
(FS 160.77 to 172.01)
Stringer No. 21 LH RH
(FS 172.29 to 346.45)

EFF.

MATERIAL

GAGE

FINISH

REPAIR

CODE

FIG. NO.

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

S-554

51-70-04

EFFECTIVITIES

31-001 AND

31-001 AND

36-001 AND SUBSEQUENT

SUBSEQUENT; 35-001 AND SUBSEQUENT;


SUBSEQUENT; 35-001 AND SUBSEQUENT

36-001 AND SUBSEQUENT

Fuselage Stringers Repair Index


Figure 2 (Sheet 7 of 7)
EFFECTIVITY:

SRM-4

SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT, EQUIPPED WITH 36-INCH
PASSENGER/CREW DOOR
31-001 AND

53-22-05

Page

15

Tan 15/93

Learjet
STRUCTU RAL REPAIR MANUAL
ALLOWABLE DAMAGE

FUSELAGE STRINGERS
i.

ALLOWABLE DAMAGELIMITS

All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose

or

failed rivets

are

not allowed. A loose

or

failed rivet

can cause

increased stress concentra-

rivets and lead to

progressive joint failure. A careful inspection must be


performed to ensure that joint failure has not spread from the area of the loose or failed rivet. (Refer to Chapter 51 for definition of rivet failure.)
tions

the

on

(2) Loose

or

remaining

failed

screws are

not allowed. A loose

surrounding screws and lead


performed to ensure that the joint failure
trations

B.

on

or

failed

increased stress

screw can cause

concen-

progressive joint failure. A careful inspection must be


has not spread from the area of the loose or failed screw.
to

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired, and
C.
D.

refinished in accordance with

Deformation

(1) Deformation of the fuselage stringers is not allowed.


Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

re-

Chapter 51.

more

than

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 100/o of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component re-

placed.
F.

Scratches(See Figure 101.)


(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to

Chapter 51

for

protective treatment procedures.)


replaced or repaired

(2) Structural components must be


thickness by more than specified.
G.

Nicks(See Figure 101.)


(1) Nicks are permissible if the affected

area

if scratches reduce the

H.

must be

specified.
Fittings and Forgings
(1) Fittings or forgings must
ness more

material

is sanded smooth, refinished in accordance with

51, and the repairs do not reduce the original material thickness
Chapter 51 for protective treatment procedures.)
(2) Structural components

original

replaced

or

repaired

more

than

if nicks reduce the

Chapter
specified. (Refer to

original

material thick-

than

replaced if cracked or
Chapter 51.)
with
(2) Fittings or forgings
bushing shall be repaired.
be

if

fitting

hole (non-bushed) tolerance exceeds

the allowable limits. (Refer to

EFFECTIVITY:

ALL

53-22-05

Page
SRM-4

101

Jan 15/93

STRUCTURAL REPAIR MANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure

EFFECTIVITY:

ALL

101

53-22-05

Page
SRM-4

102

~an 15/93

Leariet

STRUCTURAL REPAIR MANUAL


FUSELAGE STRINGERS -RE
i.

APPROVED REPAIRS
A.

RefertoChapterS1 fortypicalrepairs.

EFFECTIVITY:

ALL

53-22-05

Page 201
SRM-4

jan 15/93

hhPNOPL

~R

~drapilolg

i~spact

supu"

A
B

n\e

yide V31

The Wr-~
4

s~

/e

ey/

~o

d~

/O

~-9A.e

BLB

s~
e~

/o

so
a

9-

tv\

PF

(\1

nx7~-I_

I,

OOo

r"
D

Og

~P,

Oso.eo
OoP

eePs

OSySPOBB

as

eee_o_pes

~F
o

""B

\Q

P~;ss_Meeee

11

IZ

(T)[PI

~de*

kpr,i

hnay

35-670;
2-loC-3

,,aoz 71nn~ jba63


36-001
sluda

53-1

~itl
Learjet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

2311268

2311268

2311269

1
1

2311269

IFINISH
CODE

GAGE

S-604

Inner

S-604

Top Fitting
Top Fitting
OuterGasket(2ea.)
inner Gasket (2 ea.)

I
I

I
I

i
i
i

1
1

2024-T42 Clad

0.090

2024-T42 Clad

0.063

2024-13 Clad

0.040

1
1
1

2024-T3 Clad

0.063

2024-T3 Clad

0.090

S-680

Splice
Angle, LH 8 RH
Splice(2 ea.)

2024-T42 Clad

0.063

Retainer, LH 8 RH Inner

2024-T42 Clad

0.063

Seal Plate

2024-T3 Clad

0.025

Doubler, Inner Fwd


Spacer(2 ea.)

2024-T42 Clad

0.040

2024-T3 Clad

0.032

2311260

2311260

2311260

1
1

2311260

2311260

2311260

2311257

10

2311260

11

2311260
2311260

REPAIR

FIG. NO.

Outer

Retainer, LH 8 RH
Retainer, Inner Fwd
Doubler, Top Fwd
Filler(2 ea.)

1 2311260

Center Post

1
1
1

I
I
I
I
I
I

2024-T42 Clad

0.063

2311260

Splice Angle
Channel, Upper LH

1
1
1

8 RH

2024-T42 Clad

0.050

2311260

Channel, Lower LH

RH

2024-T42 Clad

0.050

2311260

Splice
Splice,

2024-T42 Clad

0.090

LH 8 RH Lower

2024-T42 Clad

0.080

1
1
1

I
I
I

Retainer, LH 8 RH inner
Doubler, LH 8 RH Lower Fwd
Doubler, LH 8 RH

2024-T42 Clad

0.063

2024-T42 Clad

0.040

2024-T42 Clad

0.063

2024-T42 Clad

0.080

S-604

Clip(4ea.)
Filler(2 ea.)

2024-T42 Clad

0.050

2024-T3 Clad

0.040

Filler(2 ea.)
Filler(2 ea.)
Clip(4 ea.)

2024-T3 Clad

0.063

1
1
1
1
I
1
1
1

I
I
I
I
I
I
I
I

2024-T3 Clad

0.093

2024-T42 Clad

0.040

1
1

I
I

2311260
2311260

12

2311260

13

2311260
2311260

1
1

2311260

14

2311260

15

2311259

16

2311260
2311260
2311260

2311260
17

I
MATERIAL

D
D

2311260

CenterPost,
Center Post,
Center Post,
Center Post,

I
EFF.

Windshield Installation

2311260
1

I
DESCRIPTION

2311260

CODES

Splice,

1
1
1
1

LH 8 RH

Upper
Center Post, Lower Fitting

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

EFFECTIVITIES

31-002 THRU 31-029; 35-001 THRU 35-670; 36-001 THRU 36-063


35-001 THRU 35-542. 35-589 THRU 35-596; 36-001 THRU 36-053

31-002 THRU 31-029; 35-543 THRU 35-588, 35-597 THRU 35-670; 36-054 THRU 36-063

NOTES:
Dacron 2000 reinforced Silastic 55U

Windshield Structure

Figure
EFFECTIVITY:
SRM-4

Repair Index

1 (Sheet 2 of 2)

31-002 THRU 31-029; 35-001 THRU 35-670;


36-001 THRU 36-063

53-24-00

Page 2
May 15/92

CATIDPJ
S~ITPU

S~t;aE;r;O

ST~J57J

I~

C~

ts

/4~

8.

I
~a30
u
-~p4a

O/p9C /8/iC

~b

/b~-

"BB

Bg

o~pOO

i~cfi

-X~"
o

P48PB

as

dd
Sa

8L~

-t~8

P
~Tucrure d
,1~t11 cr;sleet 1

Wt~eZ

2-~oC4;3SQz

32-D30A~D
~n-o

ra&e
Nltsy

3
L.

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

2311268

2311268

2311269

2311260

2311260

2611260

2311260

2311260

S-604

S-604

I
I
I

1~

OuterGasket(2ea.)
Inner Gasket (2 ea.)

I~

Retainer, LH RH
Retainer, Inner Fwd
Filler(2 ea.)

2024-T42 Clad

0.090

2024-T42 Clad

0.063

2024-T3 Clad

0.063

1
1
1

2024-T3 Clad

0.090

7075-0

0.080

2611260

2611260

1
2311260 1

Retainer, LH 8 RH Inner
Doubler, Fwd

2611260

1 2024-T42 Clad
1 2024-T42 Clad

0.080

1
1

2024-T42 Clad

0.040

301 Stainless

0.032

2024-T42 Clad

0.063

0.090

2024-T42 Clad

0.050

2311260

Channel, Lower LH

8 RH

2024-T42 Clad

0.050

2611137

Support Assy.,

2024-T42 Clad

0.063

Doubler, LH 8 RH

2024-T3 Clad

0.063

Filler

2024-T3 Clad

0.040

Filler(G ea.)

Silicons Sheet

0.125

2024-T3 Clad

0.063

F4-6

301 Stainless

0.032

F17-6

2024-T42 Clad

0.090

2024-T42 Clad

0.080
0.100

2024-T3 Clad
2024-T42 Clad
2024-T42 Clad

2024-T42 Clad

2024-T42 Clad

0.080

S-604

2024-T42 Clad

0.050

2611260 1
2611260

1
1
1

LH 8 RH

2311260

Splice Strap, LH
Ramp(l2 ea.)
Splice
Splice, LH 8 RH

2311260

Shim

231 i 260

1
2311260 1
2311260 1

Retainer, LH 8 RH Inner
Doubler, LH 8 RH Lower Fwd
Doubler, LH 8 RM

14

2311260

Splice,

15

2311259

16

2311260

Upper
CenterPost, LowerFitting
Clip(4ea.)

2311260

Filler

2024-T3 Clad

0.040

Filler(4 ea.)
Filler(2 ea.)
Clip(8 ea.)
Clip(8 ea.)

2024-T3 Clad

0.063

2024-T3 Clad

0.093

2024-T42 Clad

0.040

2024-T42 Clad

0.040

2611260
2611260
2311260

2311260
2311260

17

I
I
I
I
I
I
I

8 RH

2611260

13

F4-6

1
1
1
1
1
1
1

2311260

2311260

12

I
F4-6-1

IDoubler, Fwd
Splice Angle
Channel, Upper LH

2611260

1
1

2311260
2413270

CODES

8 RH

Lower

LH 8 RH

F4-6
F4-6

1
1

I
I

0.063

1
1

I
I

0.040

0.063

1
1

I
I

1
1
1

I
I
I
I
I
I

1
1

Replace
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

EFFECTIVITIES
31-030 AND

REPAIR

FIG. NO.

11

IFINISH
CODE

GAGE

CenterPost, Inner
CenterPost, TopFitting

10

2311260

I
MATERIAL

Center Post, Outer

Splice
Support, LH 8 RH
Splice(2 ea.)

I
EFF.

Windshield Installation

2611260
1

I
DESCRIPTION

SUBSEQUENT; 35-671 AND SUBSEQUENT;

36-064 AND SUBSEQUENT

NOTES:
Dacron 2000 reinforced Silastic 55U

Windshield Structure

Repair Index
Figure 2 (Sheet 2 of 2)

EFFECTIVITY:

31-030 AND

SUBSEQUENT; 35-671 AND SUBSEQUENT;

36-064 AND SUBSEQUENT


SRM~

53-24-00

Page 4
May 15/92

Learjet
LBarjet
STRUCTURAL REPAIR MANUAL
WINDSMELD STRUCTURE
i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS

All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

or

failed rivets
the

on

not allowed. A loose or

are

remaining

rivets and lead to

that

failed rivet

can cause

increased stress concentra-

failure. A careful

inspection must be
progressive joint
of
the
loose
from
the
or failed rivet. (Rearea
spread

failure has not

joint
performed to ensure
fer to Chapter 51 for definition of rivet failure.)
(2) Loose

or

trations

failed

B.

not allowed. A loose or failed screw

and lead to

on

performed

screws are

can cause

increased stress

failure. A careful

progressive joint
surrounding screws
ensure that the joint failure has not spread from the area of the

to

inspection

loose

or

concen-

must be

failed

screw.

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired, and
C.
D.

refinished in accordance with

Deformation

(1) Deformation of the windshield assembly structure is not allowed.


Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

re-

Chapter 51.

more

than

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component reF.

G.

H.

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Stntctural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFlFCCTNITY:
SRM-Q

ALL

53-24-00

Page 101
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

o.o251

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFlFCTIVITY:
SRM4

ALL

101

53-24-00

Page 102
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

A.

RefertoChapterEil fortypicalrepairs.

Page 201
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


FUSELAGE INSTRUMENT PANEL SUPPORT STRUCTURE
i.

DESCRIPTION
A.

The

fuselage

panel support structure is located at Frame 6 in the forward cockpit area.


provides structural support and mounting provisions for various avionic, comsupport
and associated equipment.
instrumentation
munications,
The

EFFECTIVITY:

instrument

structure

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND

SRM-4

STRUCTURAL IDENTIFICATION

SUBSEQUENT

53-25-00

Pagel
Tan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


FUSELAGE INSTRUMENT PANEL SUPPORT STRUCTURE

STRUCTURAL IDENTIFICATION

oooo

IA

19)

I))

El

II

Is)

ii

~I

[13

ih
O

(VIEW LOOKING FORWARD)


(TYPICAL)

Detail A
1674C

EFFECTTVITY:

Fuselage Instrument Panel Support Structure Repair Index


Figure 1 (Sheet 1 of 4)
35-001 THRU 35-508; 36-001 THRU 36-053

53-25-00

Page
s~M-l

Tan 15/93

Learje
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

I
DESCRIPTION

2614017

StructuralSupport Instl.,

2614017

StructureAssy., Instrument
SupportAssy.
Support
Support
SupportAssy.
Support
TrayAssy.
TrayAssy.
Tray
Tray
StrapAssy.

Instrument Panel
2614017
2614017
1

2614017

2614017

2614017
2614017
2614059
2614017
2

2614059
2614060
2614060 1

I
EFF.

MATERIAL

I
IFINISH
I GAGE CODE

Panel

1
1

1
1

StraD

26142711 Hinae
2614060 IHinae

I
2024-T42 Clad

I~

4~

1
1

1
1
1
1
1
1
1

I
I
I
I
I
I
I

Replace

1
1

I
I

Replace
Replace

1
I
I

I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.050

2024-T42 Clad

0.050

2024-T42 Clad

0.040

2024-T3 Clad

0.050

2614017

Clip(3ea.)
Support(2ea.)

2024-T42 Clad

0.032

2614017

SupportLH&RH

2024-T42 Clad

0.050

2614017

Bracket,LH&RH

2024-T42 Clad

0.032

2614017

2024-T42 Clad

0.050

2024-T42 Clad

0.040

2614017

Angle, LH 6 RH
Angle, LH 6 RH
Angle(3ea.)

2024-T42 Clad

0.050

2614017

Channel

2024-T42 Clad

0.090

2614017

2024-T42 Clad

0.050

2614017

2614017

Support
BowAssy.
Channel(3ea.)
Angle(Gea.)
Angle(4ea.)
Support

2614017

Doubler

2614017

2614017

2614017
2614017
2614017
9

2614017
2614017
10

1 2614017
2614017

11

2614017
2614017
2614059
2614017

12

1 2614059
2614017

I
I
I

0.032

2614017

2024-T42 Clad

S-571

S-705

S-636

S-636

Support(2ea.)
Spacer

2024-T42 Clad

0.050

2024-T3 Clad

0.020

I
1
1

I
I
I

Extender

2024-T3 Clad

0.063

Shim

2024-T42 Clad

0.050

1
1

I
I

ReceptacleStrip(2ea.)
Angle(Sea.)
Angle(5ea.)
Clip
Clip
Angle

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.050

2614017

Replace
Replace
Replace
Replace

I
I

1
I
I
1
1

I
I
2024-T42 Clad

I
1
1
I

0.050

2024-T42 Clad

4
1

0.063

I
2024-T42 Clad

1
4

0.050

2024-T42 Clad

I
2024-T42 Clad

Clip(3ea.)
Clip(2ea.)

REPAIR

FIG. NO.

0.063

PR 3 1/2~

S-705

S-705

I
I

I
I

I
I

2024-T42 Clad

0.050

2024-T42 Glad

0.050

2024-T42 Clad

0.050

1
1
1

I
I
I

Replace
Replace
Replace
Replace
Replace
Replace

Fuselage Instrument Panel Support Structure Repair Index


Figure 1 (Sheet 2 of 4)
EFFECTNITY:

35-001 THRU 35-508; 36-001 THRU 36-053

53-25-00

Page 3
SRM-4

Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


I

ITEM

DWG.

NO.

NO.

13

2614059

Angle

2024-T42 Clad

0.050

26140171

Pan

2024-T42 Clad

0.032

2614059

Pan

2024-T42 Clad

0.032

S-571

2024-T42 Clad

0.050

2024-T42 Clad

0.050

2024-T42 Clad

0.190

2024-T42 Clad

0.190

2024-T42 Clad

0.160

2024-T3 Clad

2024-T42 Clad

S-606

S-636

1
1

14

2614090
2614017
15

2614059

EFF.I

DESCRIPTION

IAngle
Support
Support

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

MATERIAL

1
1
1
I
1
1
1
1

I
I
I
I
I
I
I
I

0.032

1
1

I
I

0.071

I
I

I
I

16

2614059

Spacer(2ea.)
Spacer
Spacer
Spacer
Spacer
TrimAngle(2ea.)
TrimAngle(2ea.)

17

2614059

Stiffener, LH& RH

S-636

2614017

Spacer
Spacer
BowSupport,LH&RH
Strap,LH&RH
Strap, LH 8 RH
Shim(2ea.)

2024-T3 Clad

0.312

2024-T42 Clad

0.032

2024-T42 Clad

0.032

1
1

-17-4PH Stainless

0.250

-17-4PH Stainless

0.250

2024-T42 Clad

0.063

1
1

2614017
2614059
2614059
2614017
2614059

2614017

2614059
18

2614059

2614059
19

2614059

2614059

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Fuselage Instrument Panel Support Structure Repair Index


Figure 1 (Sheet 3 of 4)
EFFECTIVITY:

35-001 THRU 35-508; 36-001 THRU 36-053

53-25-00

Page
SRM-4

Jan 15/93

STRUCTURAL REPAIR MANUAL


CODES

EFFECTIVITIES

35-001 THRU 35-508; 36-001 THRU 36-053


35-001 THRU 35-015; 36-001 THRU 36-008

35-016 THRU

35-001 THRU

35-094 THRU 35-508; 36-025 THRU 36-053


35-123 THRU 35-508; 36-033 THRU 36-053

35-508; 36-009 THRU 36-053


35-093; 36-001 THRU 36-024

35-123 THRU 35-184; 36-033 THRU 36-038


35-185 THRU 35-508; 36-039 THRU 36-053

35-500 THRU 35-508

NOTES:

Made from MS2000P4-138

hinge.

Made from MS2000PH9-140

I~

Product of Dzus

hinge.

Fastener, Westslip, NY

Fuselage Instrument Panel Support Structure Repair Index


Figure 1 (Sheet 4 of 4)
EFFECTIVITY:

35-001 THRU 35-508; 36-001 THRU 36-053

53-25-00

Page 5
SRM-4

Jan 15/93

Learjet
STR.UCTURAL REPAIR MANUAL
STRUCTURAL IDENTIFICATION

FUSELAGE INSTRUMENT PANEL SUPPORT STRUCTURE

ao

o o

a~ P~

13

ii

to

!5)

,I

(19

sl

(12

r .i-~/
.6

(TYPICAL)
(VIEW LOOKING FORWARD)

Detail A
lc74C

EFFECTIVITY:

Fuselage Instrument Panel Support Structure Repair Index


Figure 2 (Sheet 1 of 4)
31-001 AND

SUBSEQUENT; 35-509 AND SUBSEQUENT;

36-054 AND SUBSEQUENT


SRM-4

53-25-00

Page

Jan 15/93

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

I
DESCRIPTION

2614074

StructuralSupport Instl.,

3114036

StructuralSupport Instl.,

Instrument Panel

2614074

3114036
1
2

0.090

2024-T42 Clad

0.050

2024-T42 Clad

2024-T42 Clad

2614017

2024-T3 Clad

2614017

Channel

2024-T42 Clad

0.063

2614017

ReceptacleStrip(2ea.)
Clip
Spacer

PR 3 1/2

2024-T3 Clad

0.050

2024-T3 Clad

0.020

Extender

2024-T3 Clad

2614017

Doubler

S-636

2614017

Angle(4ea.)
Clip(eea.)
Angle, LH 8 RH
Bracket(~ea.)
Support
Angle(Qea.)
Support
Support
Angle
BowSupport,LH&RH
BowSupport,LH&RH
Strap,LH&RH

S-571

2614017

2614017

2614017

2614017
2614017
2614017
2614017

2614017
2614017

1 2614017
2614017
2614017

11

2614017

12

2614017
2614017
2614017

2614017
2614059
2614059
2614059
15

2614059

16

2614059

Shim

Channel(2ea.)
Channel(2ea.)
Support(2ea.)
Support
Shim(2ea.)
Angle(2ea.)
Tray
Angle
Angle
Angle(3ea.)
Clip

REPAIR

FIG. NO.

2024-T42 Clad

2614017

14

13

2614017

10

Instrument Panel

StructureAssy., InstrumentPanel
StructureAssy., InstrumentPanel
Angle
Angle(Sea.)
Clip(3ea.)
Clip

2614017

IFINISH
CODE

Channel

2614017

GAGE

2614017

2614017

I
MATERIAL

2614017

2614017

I
EFF.

0.050

1
1
1

I
I
I

0.050

0.050

1
1
1

I
I

I
I

I
I
I
I
I
I

0.063

1
1

I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.050

I
I

Replace
Replace

0.063

1
1
1
I

I
I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.063

1
I

2024-T42 Clad

0.040

2024-T42 Clad

0.040

2024-T42 Clad

0.032

1
1
1

2024-T42 Clad

0.050

S-705

2024-T42 Clad

2024-T42 Clad

S-571

2024-T42 Clad

0.063

2024-T42 Clad

0.063

-17-4PH Stainless

0.250

2024-T42 Clad

0.050

2024-T42 Clad

0.063

2024-T42 Clad

2024-T42 Clad

S-636

2024-T3 Clad

S-705

2024-T42 Clad

0.050

2024-T42 Clad

0.050

2024-T42 Clad

S-705

2024-T42 Clad

I
0.050
0.050

1
1
I
1
1
1

I
I

1
I

0.050

I
0.050

I
I
I

Fuselage Instrument Panel Support Structure Repair Index


Figure 2 (Sheet 2 of 4)
EFEECTNITY:

31-001 AND SUBSEQUENT; 35-509 AND SUBSEQUENT;

36-054 AND SUBSEQUENT


SRM-4

53-25-00

Page 7
Jan 15/93

Leariet
STRUCTURAL REPAIR MANUAL

NO.

DWG.
NO.

17

2614059

ITEM

2614059
2614059
18

2614059

19

2614059
2614059

2614059
2614059
2614059
2614059
2614059
2614059
2614059
20

2614073
2614073
2614073
2614073
2614073
2614059

2614059
2614074
2614074
2614059
2614059
2614059
2614059

2614059
2614059
2614059

I
I

I
DESCRIPTION

Angle
Angle
Angle
Pan

Stiffener(eea.)
PanAssy.

I
EFF.

MATERIAL

S-603

S-705

S-705

2024-T42 Clad

S-636

Stiffener(2ea.)
Support
Spacer
Spacer
Spacer
Spacer
SupportAssy.
AngleAssy.
Angle (2 ea.)
AngleAssy.
Angle
Bracket Assy. (2 ea.)
Bracket

BracketAssy.(2ea.)
Angle
BracketAssy.(2ea.)
Bracket

PlateAssy.

PlateAssy.
Plate
Shim

REPAIR
FIG. NO.

I
I
I
1

I
I
I
I

I
1

I
I

0.032

0.032

S-636

2024-T42 Clad

0.050

2024-T42 Clad

0.190

2024-T42 Clad

0.071

2024-T42 Clad

0.032

I
I

1
1
1
I
I

I
I
I
I
I

I
I
I

1
1

3
3

S-636

0.160

2024-T42 Clad

2024-T42 Clad

0.050

I
2024-T42 Clad

I
0.050

11

2024-T3 Clad

0.050

11

2024-T3 Clad

0.020

S-637

10
11

I
2024-T42 Clad

11
11

11

I
1
I

I
I
I
1
I
1
I
1

10

0.050

I
2024-T3 Clad

11

Plate

I
I
I

2024-T42 Clad

Pan

I
IFINISH
CODE
I GAGE

0.063

I
I
I
I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Fuselage Instrument Panel Support Structure Repair Index


Figure 2 (Sheet 3 of 4)
EFFECTIVITY:

31-001 AND

SUBSEQUENT; 35-509 AND SUBSEQUENT;

36-054 AND SUBSEQUENT


SRM-4

53-25-00

Page

Jan 15/93

Learjet
STRUCTURAL REPAIR MANUAL
CODES

EFFECTIVITIES

31-001 THRU

31-035 AND SUBSEQUENT

31-034; 35-509 AND SUBSEQUENT; 36-054 AND SUBSEQUENT

31-001 AND

31-001 THRU 31-032, 31-035 AND

SUBSEQUENT;

35-509 AND

SUBSEQUENT; 36-054 AND SUBSEQUENT


SUBSEQUENT; 35-509 AND SUBSEQUENT; 36-054

AND

SUBSEQUENT
31-001 THRU 31-032, 31-035 THRU 31-066; 35-509 AND SUBSEQUENT; 36-054 AND SUBSEQUENT
31-001 THRU 31-032; 35-509 AND SUBSEQUENT; 36-054 AND SUBSEQUENT
35-509 THRU 35-616; 36-054 AND 36-055
31-035 AND SUBSEQUENT; 35-617 AND SUBSEQUENT; 36-056 AND SUBSEQUENT

31-035 THRU 31-066

6
7

10

31-033 AND 31-034

11

31-067 AND SUBSEQUENT

NOTES:

Product of Dzus Fastener,

Westslip,

NY

Fuselage Instrument Panel Support Structure Repair Index


Figure 2 (Sheet 4 of 4)
EFFECTNITY:

SRM~

31-001 AND SUBSEQUENT; 35-509 AND


36-054 AND SUBSEQUENT

SUBSEQUENT;

53-25-00

Page 9
Tan 15/93

Learje
STRUCTURAL REPAIR MANUAL
FUSELAGE INSTRUMENT PANEL SUPPORT STRUCTURE
1.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGE LIMITS


All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose

or

failed rivets

are

not allowed. A loose

or

failed rivet

can cause

increased stress concentra-

progressive joint failure. A careful inspection must be


remaining
failure
has
that
to
not
ensure
spread from the area of the loose or failed rivet. (Rejoint
performed
fer to Chapter 51 for definition of rivet failure.)
tions

the

on

(2) Loose

or

failed

rivets and lead to

screws are

not allowed. A loose

or

failed

screw can cause

increased stress

concen-

progressive joint failure. A careful inspection must be


the
failure
that
has
to
not spread from the area of the loose or failed screw.
ensure
joint
performed
trations
B.

on

surrounding

screws

and lead to

Cracks

(1) Cracks in any fitting or forging are


(2) Cracks in components other than

paired,

and

not allowed. Cracked

fittings or forgings must be replaced.


considered allowable if properly
fittings
forgings
refinished in accordance with Chapter 51.
and

are

re-

C.

Deformation

D.

(1) Deformation of the fuselage instrument panel support structure is not allowed.
Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance

Chapter 51, and these repairs do not reduce the original material thickness more than speciChapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness more than specified.
with

fied. (Refer to

E.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component reF.

G.

H.

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTIVITY:

ALL

53-25-00

Page

101

Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFFECTIVITY:

ALL

101

53-25-00

Page
sRM-a

102

Jan 15/93

LRar

STRUCTURAL REPAIR MANUAL


FUSELAGE INSTRUMENT PANEL SUPPORT STRUCTURE
1.

REPAIR

APPROVED REPAIRS
A.

RefertoChapter51 fortypicalrepairs.

EFFECTNITY:

ALL

53-25-00

Page 201
SRM-4

Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


FUSELAGE CIRCUIT BREAKER PANEL STRUCTURE
1.

STRUCTURAL IDENTIFICATION

DESCRIPTION
A.

The
on

fuselage

ing provisions for

EFFECTIVITY:

SRM4

structure is located in the

cockpit, at frame 7 and frame 8,


provides structural support and mountthe circuit breaker panels, electrical components and wiring connections.

circuit breaker

panel support

the LH and RH sides of the aircraft. The

support

structure

31-001 AND

SUBSEQUENT; 35-001 AND SUBSEQUENT;

36-001 AND

SUBSEQUENT

53-26-00

Page

Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


FUSELAGE CIRCUIT BREAKER PANEL STRUCTURE

STRUCTURAL IDENTIFICATION

,f
O

OOO00
O

00
O

_n0

Frame 87

.O

(Ref)
O

oo

O0

OOOOO

Stringer 13L
(Ref)

00

OO

00

000

000
00

9\
Frame7

(Ref)

(LH SHOWN, RH OPPOSITE)


(TYPICAL)

Detail A
9-11828

EFFECTIVITY:

Fuselage Circuit Breaker Panel Structure Repair Index


Figure 1 (Sheet 1 of 3)
31-001 AND SUBSEQUENT

53-26-00

Page
SRM~

Jan 15/93

Learje
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

Support Instl., Circuit


Bracket Assy.

3118213

2614071

2314035

1
1

2614025

LowerPanel
Panel Assy., Lower LH

2614025
2614025
2614026
2614026

2614026
2614026

2614026
2614025

2614025
4

2614025

2614025
311 8214

3118214
5

3118214

3118214
3118214

3118214 1
6

3118214

3118214 1
7

3118215
3118215
2614025

1
1
1

3118215

3118215 1

RH

0.032

1
I

I
I

0.032

0.032

0.032

I
I

2024-T42 Clad
2024-T42 Clad

2024-T42 Clad

0.050

I
I

0.032

I
I

0.040

1
I
1
I
1

0.040

I
1

I
I

0.040

I
1

I
I

0.040

I
1

I
I

I
1
1

I
I
I
I
I

0.040

2024-T3 Clad

0.050

2
3
2
3

Phenolic Sht

1
2024-T42 Clad

2024-T42 Clad

Bracket
LH

RH

Bracket

Support Assy.,
Support
Support Angle
Spacer

LH

Filler

RH

I
2024-T42 Clad

0.032

I
2024-T3 Clad

I
2024-T3 Clad

I
2024-T3 Clad

I
2024-T3 Clad

Panel

0.050

2024-T42 Clad

Assy.,

I
2024-T42 Clad

4
5

Assy. (2 ea.)
KickPanel,Upper
Bracket Assy., LH
RH
KickPanel,Upper
Bracket Assy., LH
RH

Panel

I
I

2024-T3 Clad

Bracket

Bracket

1
1

RH

FIG. NO.

I
I

Support Angle
Support Angle
Kick Panel Assy., LH
KickPanel,Upper
Kick Panel Assy., LH
KickPanel,Upper

REPAIR

CODE

I
1

0.040

2
RH

I
2024-T42 Clad

3
RH

LowerPanel

2614026

RH

IFINISH
GAGE

RH

I
MATERIAL

2614025
1

Breaker Panel

Plate(3 ea.)
Placard (2 ea.)
Insulator (2 ea.)
Support Angle Assy., LH
SupportAngle
Support Angle Assy., LH
SupportAngle
Panel Assy., Lower LH

2614025

I
EFF.I

Bracket

2618099
2614071

I
DESCRIPTION

I
0.040

2024-T42 Clad
2024-T42 Clad

7075T651

0.750

2024-T3 Clad

0.032

0.040

I
I

Replace
Replace
Replace
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Fuselage Circuit Breaker Panel Structure Repair Index


Figure 1 (Sheet 2 of 3)

EFFECTIVITY:

31-001 AND

SUBSEQUENT

53-26-00

Page
SRM-4

~an 15/93

Learjet
STRUCTURAL REPAIR MANUAL
EFFECTIVITIES

CODES
1

31-001 AND SUBSEQUENT

31-001 TH RU 31 -034

31-035 AND SUBSEQUENT

31-001 THRU 31-046

31-047 AND SUBSEQUENT

31-001 THRU 31-006

31-007 AND SUBSEQUENT

31-057 AND SUBSEQUENT

NOTES:

Type

FBG per MIL-P-15035

Fuselage Circuit Breaker Panel Structure Repair Index


Figure 1 (Sheet 3 of 3)
EFFECTIVITY:

31-001 AND

SUBSEQUENT

53-26-00

Page 4
SRM-4

Jan 15/93

Learjet
STRUCTURAL REPAIR MANUAL
FUSELAGE CIRCUIT BREAKER PANEL STRUCTURE

STRUCTURAL IDENTIFICATION

:r

ts

I/ii
O

Frame 8

(Ref)

ii

\ii

Frame 7

(Ref)

~40"
(1,11 SHOWN, RH OPPOSITE)

(TYPICAL)

Detail A
9-60C

EFFECTIVITY:

Fuselage Circuit Breaker Panel Structure Repair Index


Figure 2 (Sheet 1 of 3)
35-001 AND

SUBSEQUENT; 36-001 AND SUBSEQUENT

53-26-00

Page5
SRM-4

Jan 15/93

Learjet

SIRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

2614025

2614072
1

2614025
2614025

1
1

2614025

2614025

2614025
2614025
3

2614025
2614025

1
1
1

2614071
2614025
2614025
2614025

2614025
2614025
2614025

1
1

2614025

2614025

2614025

2614025

2614025 1
7

2614025

2614025 1

2614025

2614025 1
2614071

2614071 1
2614071

Support Instl., Circuit Breaker Panel


Support Instl., Circuit Breaker Panel
Insulator (2 ea.)
Panel Support Assy., LH 8 RH
Support Angle (2 LH 8 1 RH)
Panel Support Assy., LH 8 RH
Support Angle (2 LH 8 i RH)
Panel Support Assy., LH
Support Angle (2 ea.)
Panel Support Assy., RH

2618099 1
2614071 1

4
5

Assy. (2 ea.)

RH

Bracket

Bracket
Plate

0.040

1
I

I
I

0.032

0.032

1
1
I
1
1

I
I
I
I
I

0.032

I
1

I
I

0.032

1
I

I
I

0.040

0.040

I
1

I
I

1
I
1
I
1
1

I
I
I
I
I
I

0.040
0.040

I
2024-T42 Clad
2024-T42 Clad

0.040

0.032

I
2024-T42 Clad

2024-T42 Clad

I
2024-T42 Clad

I
2024-T42 Clad

11

12
2

I
I
I
I
I

2024-T42 Clad
2024-T42 Clad

12

1
I
1
I
1

0.040

2024-T42 Clad

11

I
I

2024-T42 Clad

10

0.040

2024-T42 Clad

10

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.040

2024-T42 Clad

9
6

i Replace

I
1
I

2
3

Bracket
Bracket Assy., LH 8 RH
Bracket
Bracket Assy. (2 ea.)
Bracket
Bracket Assy. (2 ea.)
Bracket

Assy.

FIG. NO.

2024-T42 Clad

Kick Panel, Upper


Kick Panel, Lower
Bracket

LH

REPAIR

CODE

2024-T42 Clad

Assy.,

SupportAngle
Support Angle Assy.,
Support Angle
Splice Plate
Kick Panel Assy., LH
Kick Panel, Upper
Kid< Panel

Phenolic Sht

8 RH

IFINISH
GAGE

LH 8 RH

I
MATERIAL

Panel Support Assy., RH


Panel Support

KickPanel,Lower

2614025

I
EFF.

SupportAngle,RH

2614025
2614071

I
DESCRIPTION

I
2024-T42 Clad

0.040

I
2024-T42 Clad

0.040

2024-T3 Clad

0.040

13

2024-T42 Clad

0.040

Fuselage Circuit Breaker Panel Structure Repair Index


Figure 2 (Sheet 2 of 3)
EFFECTIVITY:

35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

53-26-00

Page
SRM-4

3an 15/93

Learjet

STRUCTU RAL REPAIR MANUAL


EFFECTIVITIES

CODES

35-001 THRU 35-508, 35-589 THRU 35-623, 35-626, 35-627, 35-630 AND
AND SUBSEQUENT
35-509 THRU 35-588, 35-624, 35-625, 35-628 AND 35-629
35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

1
2
3

SUBSEQUENT;

36-001

35-001 THRU 35-201, 35-205; 36-001 THRU 36-041


35-202 THRU 35-204, 35-206 THRU 35-462, 35-470; 36-042 THRU 36-050
35-463 THRU 35-469, 35-471 AND SUBSEQUENT; 36-051 AND SUBSEQUENT

35-463 THRU 35-469, 35-471 THRU 35-508, 35-589 THRU 35-623, 35-626, 35-627, 35-630 AND

35-001 THRU

35-001 THRU 35-462, 35-470; 36-001 THRU 35-050


35-001 THRU 35-123; 36-001 THRU 36-032

4
5

SUBSEQUENT

10

35-015; 36-001 THRU 36-008

11

35-124 THRU 35-508, 35-589 THRU 35-623, 35-626, 35-627, 35-630 THRU 35-663; 36-032 THRU
35-058

12

35-664 AND

13

35-509 THRU 35-588, 35-624,

SUBSEQUENT;

36-059 AND SUBSEQUENT

35-625, 35-628, 35-629 AND SUBSEQUENT

NOTES:

Type

FBG per MIL-P-15035

Fuselage Circuit Breaker Panel Structure Repair Index


Figure 2 (Sheet 3 of 3)
EFFECTIVITY:

35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

53-26-00

Page
SRM~I

Jan 15/93

~Leariefl
STRUCTURAL REPAIR MANUAL
FUSELAGE CIRCUIT BREAKER PANEL STRUCTURE
1.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS
All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

failed rivets

or

the

on

are

remaining

not allowed. A loose or failed rivet

can cause

increased stress concentra-

rivets and lead to

progressive joint failure. A careful inspection must be


has not spread from the area of the loose or failed rivet. (Re-

performed to ensure that joint failure


fer to Chapter 51 for definition of rivet failure.)
(2) Loose

or

trations

failed

screws are

surrounding

not allowed. A loose

or

failed

screw can cause

increased stress

concen-

and lead to

progressive joint failure. A careful inspection must be


performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
B.

on

screws

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired, and
C.
D.

refinished in accordance with

Deformation

(1) Deformation of the fuselage circuit breaker panel structure is not allowed.
Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

re-

Chapter 51.

more

than

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component reF.

C.

H.

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTIVITY:

ALL

53-26-00

Page
SRM~

101

Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure

EFFECTTVITY:

ALL

101

53-26-00

Page

102

Jan 15/93

~Learpt
STRUCTURAL REPAIR MANUAL
FUSELAGE CIRCUIT BREAKER PANEL STRUCTURE
1.

REPAIR

APPROVED REPAIRS

A.

RefertoChapter51 fortypicalrepairs.

EFFECTIVITY:

ALL

53-26-00

Page 201
Jan 15/93

Learjet I
STRUCTURAL REPAIR MANUAL
STRUCTURAL IDENTIFICATION

FUSELAGE SKINS

FS

FS 6.65

(Ref)

(Ref)

FS51,/I

FS

(Ref)

(Ref)

FS 272.1

FS

120.86I

(Ref)

(Ref)

(Ref)

13

109.20I /I

02)

FS 145.36

FS 242.52

(Ref)

(Ref)

(24 Series Airmaft W/24-Inch PassenperlCrew Door)

FS 6.65

(neO

(ReD

FS 51.05

(Ref)

(ReO

FS 120.86

FS 196.

(Ref)

(Ref)

cl" -I
s

9)

*pl~

(12)

FS 272.1

(ReD
15

(II

-I

FS 158.

FS 242.52

(Ref)

(Ref)

16

(23 and 24 Series Airmaft W/36-Inch PassenPeulCrew Door)

(FUSELAGE SHOWN WITHOUT WINDOW CUTOUTS)

2-209A

EFFECTIVITY:
SRM~

Fuselage Skins Repair Index


Figure 1 (Sheet 1 of 3)

23-002 THRU 23-099; 24-100 THRU 24-357

53-28-00

Page 1
May 15/92

Learjet
STRUCTURAL REPAIR MAMUAL
ITEM

NO.

DWG.
NO.

Fuselage StructureAssy
Fuselage StructureAssy
Fuselage StructureAssy

2311000
2411000
2411003
1

I
DESCRIPTION

2311500

(FS
(FS
2

2311500

51.05)

2024-T42 Clad

0.040

51-70-02

6.65 to

51.05)

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

RH Side

51.05 to

84.80)

2024-T42 Clad

0.040

51-70-02

(FS51.05

RH Side

109.20)

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

2311500

Skin, Fwd Bottom


(FS51.05 to 109.20)
Skin, LH 8 RH Upper

(FS

2024-T42 Clad

0.040

51-70-02

2411001

Skin, LH

2024-T42 Clad

0.040

51-70-02

158.00)

2024-T42 Clad

0.040

51-70-02

158.00)

2024-T42 Clad

0.040

51-70-02

158.00)

2024-T42 Clad

0.040

51-70-02

109.20 to

2024-T42
2024-T42
2024-T42
2024-T42

Clad
Clad

0.040

51-70-02

0.040

51-70-02

0.040

51-70-02

0.040

51-70-02

Clad
Clad
2024-T42 Clad

0.a40

51-70-02

196.65)

2024-T42 Clad

0.040

51-70-02

196.65)

2024-T42 Clad

o.a4o

51-70-02

196.65)

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad

0.040

2024-T42 Clad

0.040

2024-T42 Clad

0.040

1
1
1

1
1
1

51-70-02

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

1 2311500

to

84.80 to

120.86)
Upper
120.86)

RH

84.80 to

Skin,Bottom
109.20 to

24110011

Skin, Bottom

2411006

Skin, Bottom

2311500

(FS

109.20 to
109.20 to

2311500

2411001

Skin, LH Side

10

2411006

Skin, LHSide

2511001
2411006
2311500

1
1
1

2411001

(FS

(FS

(FS

Top
Top
Top
Top
Top

(FS
(FS
(FS
(FS
(FS

158.00)
109.20 to 158.00)
109.20 to 158.00)
84.80 to 109.20)
84.80 to 109.20)

2
3
1

LH 8 RH Side

158.00 to

158.00 to

158.00 to

2411001

Skin, RH Side

2311500

1
1

(FS 158.00 to 196.65)


Skin,Top (FS 158.00 to 196.65)
Skin,Top(FS 145.36 to 196.65)

2411001
12

RH Nose

Skin,
Skin,
Skin,
Skin,
Skin,
Skin,

11

1
2

(FS 51.05 to 84.80)


Skin, Fwd Bottom

(FS

FIG. NO.

2311500

(FS

REPAIR

CODE

Skin, LH

(FS
5

IFINISH

I GAGE

2411001

2411001
4

6.65 to

Skin, LH

(FS

I
MATERIAL

Skin, LH 8 RH Nose

Skin, LH

2411001

I
EFF.

Skin, Bottom
(FS 158.00 to 196.65)
2411001
Skin, Bottom
(FS 158.00 to 196.65)
2411006 ISkin, Bottom
(FS 158.00 to i 96.65)

51-70-02
51-70-02

2311500

Fuselage Skins Repair Index


Figure 1 (Sheet 2 of 3)
EFFECTIVITY:

23-002 THRU23-099; 24-100THRU24-357

53-28-00

Page
SRM-4

May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


DWG.
NO.

ITEM

NO.
13

DESCRIPTION

2311500

Skin, Top (FS 196.65


Skin, Top (FS 196.65
Skin,LH&RHSide

2511001

Skin, LH

2311500
2511001

14 1

(FS

to

242.52)
242.52)

196.65 to 242.52)
RH Side

(FS 196.65

MATERIAL

GAGE

FINISH
CODE

REPAIR
FIG. NO.

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

2024-T42 Ciad

0.040

51-70-02

4
1

2024-T42 Clad
2024-T42 Clad

0.040
0.040

51-70-02
51-70-02

2024-T42 Clad

0.040

51-70-02

2311500

Skin, Top (FS 242.52 to 272.19)


Skin, Tap (FS 242.52 to 272.19)
RH Side
Skin, LH

(FS

242.52 to 272.19)
RH Side

2024-T42 Clad

0.040

51-70-02

2411001

Skin, LH

242.52 to

2024-T42 Clad

0.040

51-70-02

15 1 2311500

2411001
16

to

EFF.

(FS

CODES
1

2
3
4

to

242.52)

272.19)

EFFECTIVITIES
23-002 THRU

23-099; 24-100 THRU 24-229 EXCEPT 24-218


24-218, 24-230 THRU 24-357 WITH 36-INCH PASSENGER/CREW DOOR
24-272, 24-295 THRU 24-357 WITH 24-INCH PASSENGER/CREW DOOR
24-218, 24-230 THRU 24-357

Fuselage Skins Repair Index


Figure 1 (Sheet 3 of 3)
EFFECTTVITY:
sRM-4

23-002 THRU 23-099; 24-100 THRU 24-357

53-28-00

Page 3
May 15/92

Learjet
Learj~tj

STRUCTURAL REPAIR MANUAL


FUSELAGE SKINS

FS 164.37

(Ref)

FS 198.03

FS 234.81

(Ref)

(Ref)

FS 222.44

(Ref)

STRUCTURAL IDENTIFICATION

FS 273.32

I(Ref)

FS 346.62

(ReO

FS

422.11

(Ref)
to

FS 259.34296.49
(Ref)
(ReO

1,

FS 392.50

(ReO

(FUSELAGE SHOWN WITHOUT WINDOW CUTOUTS)


2-210A

EFFECTIVITY:

Fuselage Skins Repair Index


Figure 2 (Sheet 1 of 2)
25-061, 25-071 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004
WITH 24-INCH PASSENGER/CREW DOOR

SRM-4

53-28-00

Page 4

May 15/92

Learjet
~lit I
STRUCTURAL REPAIR MANUAL
DWG.
NO.

ITEM
NO.

2511000
1

2511002
2411001

2411001

2411001

2511006

2511006

2411001

2511006

2511006

2511006

10

2511001

11

2511001

12

2411001

13

2411001

14

2511006

FINISH

REPAIR

CODE

FIG. NO.

GAGE

Skin, LH 8 RH Side

(FS 164.37 to 198.03)


Skin, Fwd Bottom
(FS 164.37 to 222.44)
Skin, LH 8 RH Upper
(FS 198.03 to 234.84)

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad
2024-T42 Clad

0.040

51-70-02

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad
2024-T42 Clad

0.040

51-70-02

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

Skin,Bottom
222.44 to

273.32)

Skin, Top(FS222.441o 273.32)


Skin, Top (FS 198.03 to 222.44)

Skin,LH&RHSide
(FS 259.34 to 346.62)
Skin,Top(FS 273.32t0346.62)
Skin,Bottom

(FS

273.32 to

296.49)

Skin, Top (FS 346.62


Skin, LH 8 RH Side

(FS

MATERIAL

Fuselage StructureAssy
Fuselage StructureAssy

(FS

CODES

EFF.

DESCRIPTION

346.62 to

to

392.50)

392.50)

Skin, Top (FS 392.50 to 422.17)


Skin, LH 8 RH Side
(FS 392.50 to 422.17)
Skin,Bottom
(FS 296.49 to 346.62)

EFFECTIVITIES
MODELS 258 8 250 SERIALS 25-061, 25-071 THRU 25-373 WITH 24-INCH PASSENGER/CREW
DOOR

2
3

MODELS 25C 8 25F SERIALS 25-061, 25-071 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU
29-004; WITH 24-INCH PASSENGER/CREW DOOR
25-061,25-071 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004; WITH 24-INCH PASSENGER/CREW DOOR

Fuselage Skins Repair Index


Figure 2 (Sheet 2 of 2)
EFFECTIVITY:
SRM-4

25-061, 25-071 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004
WITH 24-INCH PASSENGER/CREW DOOR

53-28-00

Page

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
FUSELAGE SKINS

STRUCTURAL IDENTIFICATION

FS 164.37FS 198.03

(ReO

FS 271.26

r(ReO

(Ref)

FS 210.2FS 234.84

(Ref)

(Ref)

FS 346.62

(Ref)

FS

FS 422.1

(Ref)

(ReO

308.49

(ReD

(FUSELAGE SHOWN WITHOUT WINDOW CUTOUTS)

2-210A

EFFECTIVITY:
SRM-4

Skins Repair Index


Figure 3 (Sheet 1 of 3)

Fuselage

25-002 THRU 25-373; 28-001 THRU 28-005; 29W1 THRU 29-004


WITH 36-INCH PASSENGER DOOR

53-28-00

Page 6
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


DWG.
NO.

ITEM
NO.

2511004

REPAIR

CODE

FIG. NO.

RH Side

Skin, LH

2024-T42 Clad

0.040

51-70-02

2411001

164.37 to 198.03)
Skin, LH 8 RH Side

198.03)

2024-T42 Clad

0.040

51-70-02

2311500

Skin, Fwd Bottom


3

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

0.040

1
1

51-70-02

0.040

1
1

0.040

51-70-02

2024-T42 Clad
2024-T42 Clad

0.040

51-70-02

0.040

51-70-02

2024-T42 Clad
2024-T42 Clad

0.040

51-70-02

0.040

51-70-02

(FS

164.37 to
164.37 to

210.24)

2411001

Skin, Fwd Bottom

2311500

Skin, LH

2411001

210.24)
Upper
(FS i 98.03 to 234.84)
Skin, LH 8 RH Upper
(FS 198.03 to 234.84)

(FS

IFINISH
GAGE

2311500

(FS

I
MATERIAL

(FS

I
EFF.

Fuselage Structure Assy


Fuselage StructureAssy

2511003
1

I
DESCRIPTION

164.37 to

6 RH

2311500

Skin, Bottom

2411001

Skin, Bottom

(FS

(FS
5

251 i 001

2311500

210.24 to

210.24 to

Skin,
Skin,
Skin,
Skin,

Top (FS
Top (FS
Top (FS

2411001

2511001

2511001

(FS
Skin,Top(FS

2511001)

Skin, Bottom

271.26)
271.26)
210.24 to
198.03 to
198.03 to

271.26)
210.24)
210.24)

LH 8 RH Side
271.26 to 346.62)

(FS

271.26 to

3
4
5

271.26 to

346.62)

308.49)

51-70-02

10

2511001

11

2511001

Skin, Top (FS 346.50


Skin, LH 8 RH Side

(FS 346.62 to 392.50)

2024-T42 Clad

0.040

51-70-02

12

2311500

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

2311500

1
1

Skin, Top(FS 392.50to 422.17)


Skin, Top (FS 392.50 to 422.17)
Skin, LH 8 RH Side

2024-T42 Clad

0.040

51-70-02

2411001

422.17)

2024-T42 Clad

0.040

51-70-02

346.62)

2024-T42 Clad

0.040

51-70-02

346.62)

2024-T42 Clad

0.040

51-70-02

2411001
13

(FS
(FS
14

392.50 to

Skin, LH

to

422.17)

392.50)

8 RH Side

392.50 to

25110011 Skin,Bottom

(FS
26110011

308.49 to

Skin, Bottom

(FS

308.49 to

Fuselage Skins Repair Index


Figure 3 (Sheet 2 of 3)
EFFECTIVITY:
sahcll

25-002 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004


WITH 36-INCH PASSENGER/CREW DOOR

53-28-00

Page 7
May 75/92

Learjet
STRUCTURAL REPAIR MANUAL
CODES

EFFECTIVITIES

24-002 THRU 25-065, EXCEPT 25-061; AND MODELS 258 8 25D SERIALS 25-061,25-071 THRU
25-373; WITH 36-INCH PASSENGER/CREW DOOR

MODELS 25C 8 25F SERIALS 25-061, 25-071 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU
29-004; WITH 36-INCH PASSENGER/CREW DOOR
25-002 THRU 25-064, EXCEPT 25-061
25-061,25-071 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004
25-002 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004

3
4
5

Fuselage Skins Repair Index


Figure 3 (Sheet 3 of 3)
EFFECTIVITY:

25-002 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004


WITH 36-INCH PASSENGER/CREW DOOR

SRM4

53-28-00

Page 8
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


STRUCTURAL IDENTIFICATION

FUSELAGE SKINS
FS 221.59

(Ref)

151.12

(Ref)

.1(Ref)

rFS

FS 246.09

FS 209.3

(ReO

,I

lo

258.01I"

FS1

FS

(ReO

(Ref)

392.50

(Ref)

FS

:-I

(ReD

1J

FS 422.17

(Ref)

130 Series Airmaft W/24-Inch PassenPerlCrew Door)

FS

FS 221.59

151.12(Ref)

(Ref)

(Ref)

FS 209

FS 1

-1

(ReO

FS 258.01

/i(Ref)

FS 392.50

(Ref)

FS 2%.49

FS 346.62

FS 422.17

(Ref)

(Ref)

(Ref)

(30 Series Aircraft W/361nch PassenaevlCrew Door)

(FUSELAGE SHOWN WITHOUT WINDOW CUTOUTS)


2-210A

EFFECTNITY:
SRML

Fuselage Skins Repair Index


Figure 4 (Sheet 1 of 2)
31-002 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;
36-001 AND SUBSEQUENT

53-28-00

Page 9
May 15/92

E~ Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

I
I

I
DESCRIPTION

2611003

Fuselage StructureAssy
Fuselage StructureAssy

2411001

Skin, LH 8 RH Side

2411001

Skin, Fwd Bottom

2411001

Skin, LH 8 RH Upper

2511006

Skin, Bottom

2411001

Skin, Bottom

2511001

2611000

(FS
(FS

(FS
(FS
(FS
5 1

151.12 to
151.12 to

184.78 to
209.19 to
209.19 to

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

221.59)

2024-T42 Clad

0.040

51-70-02

258.01)

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad

0.040

0.040

2024-T42 Clad
2024-T42 Clad

2024-T42 Clad

0.040

1
1
1
1

1
1
1
1

51-70-02

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

2024-T42 Clad

0.040

51-70-02

209.19)

258.01)

2611006
2611001

Skin, LH 8 RH Side

2611001

(FS 258.01 to 346.62)


Skin,Top (FS 258.01 to 346.62)

2611006

Skin, Bottom

2611001

Skin, Bottom

10

2511001

11

(FS
(FS

FIG. NO.

2024-T42 Clad

(FS

REPAIR

CODE

184.78)

2411001

IFINISH

I GAGE

2511001

I
MATERIAL

Skin,
Skin,
Skin,
Skin,

Top (FS
Top (FS
Top (FS

I
EFF.

209.19 to
209.19 to
184.78 to

246.09)
258.01)
209.19)

0.040

51-70-02
51-70-02

51-70-02

LH 6 RH Side

258.01 to

258.01 to
258.01 to

346.62)

296.49)

2024-T42 Clad

0.040

51-70-02

392.50)

2024-T42 Clad

0.040

51-70-02

2511001

Skin, Top (FS 346.50


Skin, LH 8 RH Side

2024-T42 Clad

0.040

2024-T42 Clad

0.040

1
1

1
1

51-70-02

2411001

(FS 346.62 to 392.50)


Skin, Top (FS 392.50 to 422.17)

12
13

2411001

Skin, LH 8 RH Side

422.17)

2024-T42 Clad

0.040

51-70-02

14

2611001

Skin,Bottom

346.62)

2024-T42 Clad

0.040

51-70-02

15

2611001

258.01)

2024-T42 Clad

0.040

51-70-02

258.01)

2024-T42 Clad

0.040

51-70-02

(FS
(FS
1

51-70-02

246.09 to

Skin, RH Side

(FS

CODES

296.49 to

to

Skin, LH Side

(FS
2611001

392.50 to

296.49)

221.59 to

EFFECTIVITIES

31-001 AND

SUBSEQUENT; 36-001 AND SUBSEQUENT; WITH 36INCH PASSENGER/CREW DOOR


31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

SUBSEQUENT; 35-001 AND


INCH PASSENGEWCREW DOOR
31-001 AND SUBSEQUENT; 35-001 AND

SUBSEQUENT;

36-001 AND

SUBSEQUENT; WITH 24-

Fuselage Skins Repair Index


Figure 4 (Sheet 2 of 2)
EFFECTIVITY:

31-002 AND
36-001 AND

srzM~

SUBSEQUENT; 35-001 AND SUBSEQUENT;


SUBSEQUENT

53-28-00

Page 10
May 15/92

LEARJET 20/30 SERIES

STRUCTURAL REPAIR MANUAL

TEMPORARY REVISION NO. 53-1


Learjet Model 20/30 Series Structural Repair Manual.

MANUAL AFFECTED:

adjacent to 53-28-00, page 101,

FILING INSTRUCTIONS: Insert

REASON: To

provide

allowable

damage

dated

limits for contour deviations

May 15/92

on

and retain until further notice.

Aircraft certified for Reduced Vertical

Separation Minimum Ooerations.

INSTRUCTIONS: Revise paragraph 1. Allowable Damage Limits and add Figure 102
1.

as

follows:

AllowableDamage Limits
All dimensions

NOTE:

A.

are

in inches unless otherwise

specified.

Fasteners

(1)

Loose

or

failed rivets

are

not allowed. A loose

or

failed rivet

can cause

increased stress concentra-

remaining rivets and lead to progressive joint failure. A careful inspection must be performed to ensure that joint failure has not spread from the area of the loose or failed rivet. (Refer to
Chapter 51 for definition of rivet failure.)

tions

(2)

on

Loose

the

or

failed

centrations
be

on

performed

screws are

surrounding

not allowed. A loose


screws

to ensure that the

or

failed

screw can cause

increased stress

con-

progressive joint failure. A careful inspection must


has not spread from the area of the loose or failed

and lead to

joint

failure

screw.

B.

Cracks

(1)

Cracks in any

(2)

Cracks in

repaired
C.

fitting

and refinished in

allowed. Cracked

fittings

fittings and forgings


accordance with Chapter 51.
than

are

or

forgings

must be

replaced.

considered allowable if

properly

the forward

fuselage

skins is not allowed.

Corrosion(See Figure 101.)


(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original matemore

than

specified.

Dents

(1)

permissible if smooth and without abrupt changes in contour, do not exceed 0.100 inch
[2.54 mm] in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch [12.7 mm] to any rivet or structural area.
Dents

are

TEMPORARY REVISION NO. 53-1

sR~n-4

are not

Deformation

rial thickness
E.

forging

components other

(1) Deformation of
D.

or

53-28-00

Page

1 of 4

Jun 15/01

LEARJET 20/30 SERIES


STRUCTURAL REPAIR MANUAL

(2)

Dents

not allowed if

are

[2.54 mm]
0.50 inch

depth,
[12.7 mm]
in

sharp,

~t0.045 inch

[1.143 mm].

NOTE:

For limits and

one

are

greater than 0.100 inch

(1) square foot, and are closer than


repaired or the component

area

beneath the

primary pitot-static probes (see Figure 102)

procedures to determine skin contour and deviation


Learjet Model 31/31A Maintenance Manual.

of the basic

(1)

area

in

for Reduced Vertical Seoaration Minimum Ooerations, the maximum allowed

skin contour deviation in the

Scratches

fracture of the skin has occurred,

to a rivet or structural area. Such dents shall be

replaced.
(3) On Aircraft certified

F.

exceeds 10% of total surface

refer to

Chapter

is

53

(See Figure 101.)

Scratches

permissible if the affected area is sanded smooth, refinished in accordance with


Chapter 51, and the repairs do not reduce the original material thickness more than specified.
(Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material thickness by more than specified.
G.

are

Nicks(See Figure 101.)


(1) Nicks are permissible

if the affected

51, and the repairs do

Chapter
(2)

protective

treatment

Structural components must be


more

H.

51 for

than

area

is sanded smooth, refinished in accordance with

original
procedures.)

not reduce the

replaced

material thickness

or

repaired

if nicks reduce the

than

Chapter
specified. (Refer to

original

material thickness

specified.

Fittings and Forgings


(1) Fittings or forgings

replaced if cracked or
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.
must be

TEMPORARY REVISION NO. 53-1

SRM-4

more

if

fitting

hole

(non-bushed)

tolerance exceeds

53-28-00

Page

2 of 4

Jun 15/01

LEARJET 20/30 SERIES


STRUCTURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(inch Imml)

(inch Imml)

0.016

~0.406]

o.oi 35

~0.3429]

8.020

[0.508]

o.oi 75

[0.4445]

0.025

[0.635]

0.0225

[0.5715)

0.032

[0.8131

0.0295

[0.7493]

0.040

[1 .016]

0.037

[0.940]

0.050

[1.270]

0.046

[1.168]

0.063

[1.600]

0.059

[1.499]

0.071

[1.803]

0.067

E1.702]

0.080

~2.032]

0.076

[1.930]

0.100

[2.5401

0.095

[2.413]

0.125

[3.175]

0.120

[3.048]

0.190

E4.826]

0.180

[4.572]

0.250

[6.350]

0.237

16.020]

Allowable MaterialThickness

Figure

TEMPORARY REVISION NO. 53-1

SRMd

101

53-28-00

Page

3 of 4

Jun 15/01

LEARJET 20/30 SERIES

STRUCTURAL REPAIR MANUAL

oS

0.96
g.0 in

in

mmlA160.n

[228.6 mml

INSPECTION ZONE

PROBE

PROJECTED
ON TO SKIN

a.s\in [63.6 mml

t\n 163.5 mm~

2.5R.!n\

II

ji~ii
LH PITOT-STATIC PROBE

STA 151.12

PROBE

MID

STA 138.11

VIEW LOOKING INBOARD AT LH SIDE


RH SIDE OPPOSITE

f~etail A
S31-532800-1P2-01

Pitot/Static Probe Zone Skin Contour

Figure

TEMPORARY REVISION NO. 53-1

SRM-4

Inspection

102

53-28-00

Page

4 of 4

Jun 15/01

Learjet
STRUCTURAL REPAIR MANUAL
FUSELAGE SKINS
1.

ALLOWABLE DAMAGE

ALLOWABLE DAMACELIMITS

NOTE:
A.

All dimensions

in inches unless otherwise

are

specified.

Fasteners

(1) Loose
tions

or

on

failed rivets
the

are

remaining

not allowed. A loose or failed rivet can cause increased stress concentra-

rivets and lead to

progressive joint failure. A careful inspection must be


spread from the area of the loose or failed rivet. (Re-

failure has not

performed to ensure that joint


Chapter 51 for definition of rivet failure.)

fer to

(2) Loose

or

failed

screws are

not allowed. A loose

or

failed

screw can cause

increased stress

concen-

progressive joint failure. A careful inspection must be


performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
trations
B.

on

surrounding

screws

and lead to

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

re-

paired, and refinished in accordance with Chapter 51.


C.

Deformation

D.

(1) Deformation of the fuselage skins is not allowed.


Corrosion(See Figure 101.)
(3) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with

Chapter 51, and

these

repairs do not

reduce the

original material thickness more

fied. (Refer to Chapter 51 for protective treatment procedures.)


(2) Structural components must be repaired or replaced if corrosion
rial thickness more than specified.
E.

repair reduces

the

than

speci-

original

mate-

Dents

permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not

(1) Dents
(2.54

are

closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to
F.

G.

i-I.

rivet

structural

or

area.

Such dents shall be

or

the

component

re-

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings andForgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTIVITY:

ALL

1.

NOTE: Please

see

the

TEMPORARY
slaril

repaired

ICllii~"

REVISION

that revises this page.

53-28-00

Page 101
May 15/92

Leariet
STRUCTURAL REPAIR MANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

NOTE: Please

see

the

TEMPORARY
REVSON

II

that revises this page.

Allowable Material Thickness

Figure 101

EFFECTNITY:
SRMI

ALL

53-28-00

Page 102
May 15/92

Learjet
Learjetl

STRUCTURAL REPAIR MANUAL


FUSELAGE SKINS
i.

APPROVED REPAIRS
A.

RefertoChapterS1 fortypicalrepairs.

EFFECTIVITY:
SRM~

REPAIR

ALL

53-28-00

Page 201
May 15/92

STRUCTURAL REPAIR MANUAL


FUSELAGE SEAT AND BAGGAGE FLOOR STRUCTURE
i.

STRUCTURAL IDENTIFICATION

DESCRIPTION
A.

The

fuselage

seat and

baggage

floor structures

are

located within the

fuselage between

frame 15 and

frame 22.
B.

The floor structure

provides

structural

continuity,

and

support for cabin

and

baggage compartment

The floor structure consist of beam assemblies, webs, channels and minor floor assemblies,
with different configurations of components required depending upon aircraft model and fuel sysareas.

tems

incorporated.

EFFECTNITY:

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT

53-29-00

Page

Jan 15/93

Learjet

STRUCTU RAL REPAIR MANUAL


FUSELAGE SEAT AND BAGGAGE FLOOR STRUCTURE
Frame 15
FS

34f~ fs~

STRUCTURAL IDEN~FICATION

Frame 16

Frame 17

ES ~55 49..

FS 7~8 C,R

Frame 17A

Frame 18

Frame 19

Frame 20

Frame 21

Frame 22

FS 392.50

ES 40242

FS 411.95

FS 421.42

1)

(3)

(3)

(3)

(3)

If(
O

~i

;e

st

i!ll
Q

~I

el

it

!III

ii:

,5

i
e
l
~
I
a
1
I;.
IIi
i
i i

13

I,

gl

Q1

.i

~I

ii i

i i:

111

)B

!II

iv.

j,

~I

atI~
toI~

II

~I

ii

Ii
i-

;li

lie

ii

10 ~i8

__ii

i:B: Yli

II
9o

nl
22

12)

(io)

(Is) (a)lsl

~VIEW FROM LH SIDE, LOOKING INBOARD)

~FWD

(TYPICAL)

Detail A
Fuselage Seat and Baggage Floor Structure Repair Index
Figure 1 (Sheet 1 of 4)
31-001 AND

36-001 AND
SRM~

SUBSEQUENT; 35-001
SUBSEQUENT

AND

SUBSEQUENT;

1L.

53-29-00

Page 2
~an 15/93

ill-I---

i,i

EFFECTIVITY:

20

!!I

2-151R

cl

i;

Is

10

(9)

~10)

(23

Learjet
~Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

Seat& BaggageFloorlnstl.
Seat& BaggageFloorlnstl.
Beam Instl.

2411390
2511390
2411391
2411391

Radius Filler

2411391

Stiffener(3 ea.)

2411391
2411391

Attachment Web, LH 8 RH
Attachment Web, LH 8 RH

2411391

Clip
Clip(Pea.)
Filler(2 ea.)

5
3
3

Stiffener

Beam Instl.

3
3

2411392
2411392
2411392

Stiffener
Stiffener

3
3

2411392

LowerCap
Filler(eea.)
Bushing(aea.)
Support Assy. (2 ea.)

2411392
2411392 1
2411392
2411393
2411393

2411393
2411393
2411393
1 2411394
2411394
2411394
2411394

SUpport
Web
Beam Instl.

BeamAssy.
UpperCap
LowerCap
Web
Beamlnstl.

BeamAssy.
UpperCap
LowerCap

3
7

REPAIR

FIG. NO.

I
0.063

0.080

I
0.050
0.050

1
1

0.050

0.250

1
I

S-566
S-566
2024-T3 Clad

3
3

2411395

Seat Floor

2411395

2411395

10

2411395

Attach Angle, LH 8 RH (4 ea.)


Attach Angle, LH 8 RH
Channel, LH 8 RH (2 ea.)

1
1

I
I

1
I

I
I

I
I

I
1
I

0.160
0.080

0.160

8
9

0.063

1
I
1
1
0.063

I
1

1
I
I
I
1
I

I
I
I
I

I
I
1

I
I

1
1
1

I
I

0.050

I
I

3
3

0.063

I
S-568
S-568
2024-T3 Clad

3
3

1
1

3
3
3

I
I

0.050

2024-T3 Clad
2024-T3 Clad

3
3

F25

2311391
2311391

2311391
5

Web
Gusset Instl.
Gusset Assy.
Gusset (4 ea.)

2411394

IFINISH
CODE

I
S-551
2024-T3 Clad
2024-T3 Clad
S-554
S-551
3-554
3-565
2024-T3 Clad

3
3

0.125

Filler(Pea.)
Stiffener(Sea.)

2411392

GAGE

I
2024-T42 Clad
3-578
2024-T3 Clad
2024-T3 Clad
S-554
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T351 Clad
S-569

BeamAssy.
UpperCap
Fitting(4 ea.)

2411392

Web

2411392
2411392
2411392

3
3
3

2411391
2411391
2411391

2411392
2411392

I
MATERIAL

Assy.
UpperCap
Lower Cap

2411391
2411391
2411391

I
EFF.I

Beam

2411391

I
DESCRIPTION

2024-T42 Clad

0.125

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

0.080

I
0.020
0.050

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

FuselageSeat and Baggage Floor Structure Repair Index


Figure 1 (Sheet 2 of 4)
EFFECTNITY:

31-001 AND SUBSEQUENT; 35-001 AND

36-001 AND SUBSEQUENT


SRM-4

SUBSEQUENT;

53-29-00

Page 3
Jun 1/95

Learjet
~trl
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

ii

2411395

12

2411395

13

2411395
2411395

14

DESCRIPTION

SealAngle(3ea.)
Attach Angle, LH 6
Attach Angle
Filler(P ea.)

I
EFF.

(2 ea.)

3
3
3

Fuel Cell Floor, Aft


Angle, LH 6 RH

10

2511411

Seal

10

2511393

10

2511411

Drain Pan, Fuel Cell (2 ea.)


Attach Angle, LH 6 RH

2511391

Splice(2 ea.)

2511391

Channel

2511392

FuelCell Floor

2511411

Angle
Seal Angle, LH
Nutplate Assy.

2511391

2411395
2411396

0.090

2024-T42 Clad
2024-T3 Clad

0.032

I 2024-T42Clad
2024-T42 Clad
2024-T3 Clad
2024-T3 Clad

0.032
0.020
0.032

1
13

2024-T3 Clad
2024-T3 Clad

0.050

14

2024-T3 Clad

0.050

17

2411395

Splice

18

Seal Angle (12 ea.)


Seal Angle (2 ea.)
Tube
Seal Angle, LH 6 RH
Seal Angle, LH 6 RH
Seal Angle
Baggage Floor
Baggage Floor

3
3

2411395
241 i 395

22

2411395

2411395
23 1 2411395
2411395

1
0.080

0.032

12

2411395

21

1~

2024-T42 Clad

16

19

0.050

2411395

20

0.050

0.032

15

2411395
2411395

0.080

2024-T3 Clad
2024-T3 Clad
2024-T3 Clad

10

REPAIR
FIG. NO.

CODE

0.080

0.032

11

6 RH

IFINISH

I GAGE

2024-T42 Clad

Plate (2 ea.)
Attach Bracket
Seal Channel, LH 6 RH

2411396

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

RH

I
MATERIAL

12
1

0.050
0.080

3
3
1
0.020

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Fuselage Seat and Baggage moor Structure Repair Index


Figure 1 (Sheet 3 of 4)
EFFECI~IVITY:
srau

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT

53-29-00

Page 4
Jun1/95

STRUCTURAL REPAIR MANUAL


CODES

EFFECTIVITIES
31-001 AND SUBSEQUENT; 35001 AND SUBSEQUENT
36-001 AND SUBSEQUENT
31-001 AND SUBSEQUENT, INCLUDING 31 SERIES AIRCRAFT EQUIPPED FOR EXTENDED
RANGE; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT
31-001 THRU 31-037; 35-001 THRU 35-667; 36-001 THRU 36-063
31-038 AND SUBSEQUENT; 35668 AND SUBSEQUENT; 36-064 AND SUBSEQUENT
31-001 AND SUBSEQUENT; 35087 AND SUBSEQUENT; 36-022 AND SUBSEQUENT
31-001 AND SUBSEQUENT; 35-345 AND SUBSEQUENT; 36-046 AND SUBSEQUENT
35-001 THRU 35-240; 36-001 THRU 36-044
31-001 AND SUBSEQUENT; 35241 AND SUBSEQUENT; 36-045 AND SUBSEQUENT
31-001 AND SUBSEQUENT EQUIPPED FOR EXTENDED RANGE; 36-001 AND SUBSEQUENT
31-001 AND SUBSEQUENT EQUIPPED FOR EXTENDED RANGE

1
2

3
4

5
6
7

8
9
10
11

31-001 AND SUBSEQUENT; 35094 AND SUBSEQUENT


31-001 THRU 31-032, 31-035 AND SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND
SUBSEQUENT
31-033AND31-034

12
13
14

NOTES:
Core 1/8 Cell, 5056 AL,
2024T3

0015 Foil,
Clad, overall thickness 1.050.

No. 181 Glass Cloth Per

6.1~FT3

Normal

Density, CR

III Treated. Skin both sides with 0.050

MILF-9084, Polyester per MlL-R-7575, Type II.

0.187 Q.D. X 0.035 I.D., 5052-0 AL

Tubing

0.625 OD X 0.125 W, 4130N Steel Tube.

Fuselage Seat and Baggage Floor Structure Repair Index


Figure 1 (Sheet 4 of 4)
EFFECTIVITY:

31-001 AND
36-001 AND

SRM-4

SUBSEQUENT; 35-001
SUBSEQUENT

AND

SUBSEQUENT;

53-29-00

Page 5
Jun 1/95

~F-I
STRUCTURAL REPAIR MANUAL
FUSELAGE SEAT AND BAGGAGE FLOOR SUPPORT STRUCTURE
1.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS
All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

or

failed rivets

the

on

remaining

performed
fer to Chapter 51
to

(2) Loose

or

trations

are not

ensure

failed

allowed. A loose

rivets and lead to

that

joint

or

failed rivet

can cause

increased stress concentra-

failure. A careful

inspection must be
progressive joint
from
the
of
the
loose
area
or failed rivet. (Respread

failure has not

for definition of rivet failure.)

screws are

surrounding

not allowed. A loose or

failed

screw can cause

increased stress

concen-

failure. A careful

and lead to

progressive joint
inspection must be
has
of
the
failure
from
the
the
that
not
loose
to
area
or failed screw.
spread
joint
performed ensure
B.

on

screws

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired,
C.
D.

and refinished in accordance with

Deformation

(1) Deformation of the fuselage seat and baggage floor support structure is not allowed.
Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

Chapter

re-

51.

more

than

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.

(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component reF.

G.

H.

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(See Figure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTIVITY:

ALL

53-29-00

Page
sRM-4

101

Jan 15/93

Learjet
STRUCTURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFFECTIVITY:

ALL

101

53-29-00

Page
SRM-4

102

Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


FUSELAGE SEAT AND BAGGAGE FLOOR STRUCTURE
1.

REPAIR

APPROVED REPAIRS
A.

RefertoChapter51 fortypicalrepairs.

B.

Fabricate

glass cloth

seal

angles using

two

piles No.

181

glass cloth

per MIL-F-9084 and

polyester per

MIL-R-7575, Type II.

EFFECTIVITY:

ALL

53-29-00

Page 201
SRM4

Tan 15/93

STRUCTURAL REPAIR MANUAL


TAILCONE ASSEMBLY
i.

STRUCTURAL IDENTIFICATION

DESCRIPTION
A.

The tailcone
The

major

assembly begins

at FS 421

assemblies consist of frames,

(frame 22) and

runs

to the aft

edge

of the tailcone

stringer.

stringers, skins, dorsal assembly, ventral fin assembly

Model 31 Series), delta fins (Model 31 Series onlu),and tailcone stinger assembly.

EFFECIWITY:

ALL

53-30-00

PageZ
May 15/92

Leariet
STRUCTURAL REPAIR MANUAL
TAILCONE ASSEMBLY
i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS
All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

or

failed rivets
the

on

are

not

allowed. A loose

or

failed rivet

can cause

increased stress concentra-

progressive joint failure. A careful inspection must be


that joint failure has not spread from the area of the loose or failed rivet. (Re-

remaining

rivets and lead to

performed to ensure
fer to Chapter 51 for definition of rivet failure.)
(2) Loose

or

failed

screws are

not allowed. A loose

or

failed

screw can cause

increased stress

c~ncen-

surrounding screws and lead to progressive joint failure. A careful inspection must be
performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
trations

B.

C.
D.

on

Cracks
(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly
paired, and refinished in accordance with Chapter 51.
Deformation

(1) Deformation of the tailcone assembly structure is not allowed.


Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

re-

more

than

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component reF.

G.

H.

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. fRefer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTJVITY:
SRM-4

ALL

53-30-00

Page 101
May 15/92

Learjet i
Learjet
STRUCTURAL REPAIR MANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095
0.120

0.125

0.190

0.180
0.237

0.250

Allowable Material Thickness

Figure

EFFECTIVITY:
SRM4

ALL

101

53-30-00

Page 102
May 15/92

LEARJET 20/30 SERIES

STRUCTURAL REPAIR MANUAL.

TEMPORARY REVISION NO. 53-4


MANUALS AFFECTED:

Learjet 20/30

FILING INSTRUCTIONS:

insert

Series Structural

prior to 53-30-00,

Repair

Manual

page 201, dated

May 15,

1992 and retain until further

notice.

REASON:

To add

INSTRUCTIONS:

Revise manual

repair procedure.
as

follows:

TAILCONE ASSEMBLY
1.

REPAIR

APPROVED REPAIRS
A.

RefertoChapter51 fortypical repairs.

B.

Aft

Wing-to-Fuselage Fairing, LH and RH Cracked or Oversized Fastener Holes Repair


(1) Stop-drill cracks. (Refer to 51-70-02.)
(2) Fabricate external repair doubler. (See Figure 201.)
(a) Make doubler from 0.040 inch thick 2024-T3 clad aluminum, finish F4-6 (refer to 51-30-04)
that is sized to extend a minimum of two (2) fastener rows beyond the forward fastener row.
(b) Radius corners of doubler 0.025 inch.
(c) Chamfer the edge of the doubler.
(3) Position doubler and secure with fasteners (CR3214-4 or CR3242-4) that have been wetted with
Pro-Seal 890.

(4)

Restore

original

surface finish.

TEMPORARY REVISION NO. 53-4


SRM-4

53-30-00

Page

1 of 2

Jan 18/02

LEARJET 20130 SERIES


STRUCTURAL REPAIR MANUAL

00D00

DOUBLER

BUUVIEAD
ASSEMBLY

(REF)

r\

+I

+I

NUTPVITE(REF)

nl
t-

i-

+I

Detail A

Aft

Wing-to-Fuselage Fairing fastener


Figure 201

TEMPBRARY REVISION NO. 53-4


SRM-4

Holes

Repair

53-30-00

Page

2 of 2

Jan 18/02

Learjet
Lsarjet
STRUCTURAL REPAIR MANUAL
TAILCONE ASSEMBLY
i.

REPAIR

APPROVED REPAIRS
A.

RefertoChapter51 fortypicalrepairs.

NOTE: Please

see

the

TEMPORARY

REVISION
EFFECTNITY:
SRM4

ALL

that revises this page.

53-30-00

Page 201
May 15/92

Learjet
STRUCTU RAL REPAIR MAN UL
TAILCONE BULKHEAD (FRAME)- STRUCTURAL IDENTIFICATION

(s)

MID

(TYPICAL)

31BD

Tailcone Bulkhead(Frame) Repair Index


Figure 1 (Sheet 1 of 7)

31-002 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT

53-31-00

Page 1
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

Tailcone

2612000
1

2512225
2512220

I
DESCRIPTION

1
1

2512225
2512220
2511411
2412220
2512225

2512220

Assembly

I
EFF.I

Bulkhead Instl., Frame 22


Bulkhead Member, LH 8 RH

3
2

2024-T42 Clad

0.050

Bulkhead Member, LH 8 RH
CellDivider

2024-T42 Clad

0.050

S-555

SkinSplice
BulkheadAssy.
BulkheadAssy.
AttachAngle

2024-T3 Clad

0.063

1
1
I
1

I
I
I
I

Replace
Replace
Replace
Replace

1
1
1
1
I
I
1
1

I
I
I
I
I
I
I
I

1
1

I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2024-T42 Clad

0.032

2024-T42 Clad

0.050

2512220

2024-T42 Clad

0.050

2512225

SupportAngle

2024-T42 Clad
S-555

2512225

REPAIR

FIG. NO.

Bulkhead Instl., Frame 22

Bulkhead Member, Lwr


Bulkhead Member, Lwr

2512225

IFINISH
CODE

GAGE

MATERIAL

2512225

Cell Divider

2512220

Cell Divider

0.050

1
1

S-555

2511413

Fitting(2ea.)

2024-T4 Rod

2511411

Filler

2024-T3 Clad

2412221

Tee, LH 8 RH

S-558

2412221

RH

2024-T42 Clad

0.063

2412221

Clip Assy., LH
Clip Assy., LH

8 RH

2024-T42 Clad

0.050

2412221

Attachment, LH 8 RH

Seal

1
2

I 2024-T42Clad
2024-T42 Clad
2024-T42 Clad

0.063

2412221

1
1

S-568

S-557

2024-T3 Clad

S-558

S-558

2024-T3 Clad

2.750
0.050

Replace

0.063

1
1

I
I

2024-T42 Clad

0.063

2024-T3 Clad

0.090

I
1

I
I

I
1
1
1

I
I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2412220

Angle
Clip Assy. (4 ea.)
Clip Assy. (6 ea.)
Angle(4 ea.)
Angle (4 ea.)
Angle, LH RM (3 ea.)
Web(3 ea.)
Tee(2 ea.)
RH (2 ea.)
Tee, LH
Web, Lwr (2 ea.)
Web, Lwr (2 ea.)

2024-T3 Clad

0.032

2412220

Filler

2024-T3 Clad

0.050

2412220

Bulkhead Joint, LH 8 RH

S-556

2412220

Filler(4ea.)

2024-T3 Clad

0.032

2512225

Doubler

2024-T3 Clad

0.050

2512220

Doubler

2024-T3 Clad

0.050

2512225

Web,
Web,
Web,
Web,

Fwd

2024-T3 Clad

0.050

Fwd

2024-T3 Clad

0.050

Aft LH 8 RH

2024-T3 Clad

Aft LH 8 RH

2024-T3 Clad

2412221
2412221

2412221
2412221
2412221
2412221

2412221
2412221
2412221

2512220
2512225
2512220

0.025

0.050

0.032

0.032

1
1

I
I

0.032

Replace

Replace
Replace
Replace
Replace
Replace

Tailcone Bulkhead(Frame) Repair Index


Figure 1 (Sheet 2 of 7)

EFFECTIVITY:

31-002 AND

SUBSEQUENT; 35-001 AND SUBSEQUENT;

36-001 AND SUBSEQUENT


srzM-4

53-31-00

Page 2
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM
NO.
2

DWG.
NO.

IEFF.I

Frame Instl., Frame 23

2512230
2512230

I
DESCRIPTION

MATERIAL

IFINISH
GAGE

FrameAssy.

2512230

Frame

2024-T42 Clad

0.050

2512230

Doubler(2 ea.)

2024-T42 Clad

0.050

Frame Instl., Frame 24


Doubler, Lwr Fwd LH

2612240 1
2612241

Member, LH

REPAIR
FIG. NO.

CODE

6 RH

1
1

I
I

Replace
Replace

Replace
Replace
Replace

2024-T3 Clad

0.071

2024-T3 Clad

0.071

2024-T42 Clad

0.071

2024-T3 Clad

0.071

0.071

2024-T3 Clad
2024-T42 Clad

2024-T42 Clad

0.071

2024-T42 Clad

2024-T42 Clad

2024-T42 Clad

S-571

2612041

Clip, LH 6 RH (4 ea.)
Stlfener(4 ea.)
Filler(4 ea.)

2024-T3 Clad

0.020

2612041

Attach

2024-T42 Clad

0.050

2024-T42 Clad

0.050

2024-T42 Clad

0.050

I
I
I

2024-T42 Clad
S-555

1
1
1

2024-T3 Clad

0.040

2024-T42 Clad

0.025

2024-T42 Clad

0.025

1
1
1

I
I
I

2024-T3 Clad

0.025

2024-T3 Clad

0.025

I
I
I

I Replace
I Replace
I Replace

I Replace

2612241
2612241

2612241
2612241
2612241
2612241
2612241

2612241
2612241
2612241

Doubler, Lwr Aft LH


Plate, LH 6 RH Aft
Doubler, RH Fwd
Doubler, RH Aft
Frame, LH 6 RH (2 ea.)
Plate, LH 6 RH Fwd
Plate, LH 6 RH Aft
Frame, LH 6 RH Aft

2612241

Angle, LH 8 RH (2 ea.)
Clip (4 ea.)
Attach Angle (4 ea.)
Clip(l8 ea.)
Divider(2 ea.)

2612240

Strap,LH&RH

2612041
2612041

2612241

2612240

Cap, LH 6 RH Side
2612240
Cap, LH 6 RH
2612240
Cap, Lower
2612240
Cap,Upper
2612040 1
Beam Assy.
2612041
Channel, Upper

S-729

Channel, Lower

S-729

2612042

Fitting(2ea.)
Doubler(4 ea.)
Web Assy., Fwd

2612041
2612041

I
I
I

0.071

1
1
1

I
I
I

0.050

I Replace

0.050

I Replace

0.050

1
I

0.050

Replace
Replace

Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2612041
2612041

1
1
1

1
1

1
1
I

2024-T3 Clad

0.071

Replace

2612041

Web
Web Assy., Aft
Web

2024-T42 Clad

0.050

2612041

Filler (4 ea.)

2024-T3 Clad

0.050

1
1

I
I

2612041

Stiffener(4 ea.)
Stiffener(G ea.)
Zee (3 ea.)

S-571

S-636

2024-T3 Clad

0.032

I
I
1

I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace

RH Fwd
Stiffener, LH
Stiffener, Aft (2 ea.)

2024-T42 Clad

0.040

Replace

2024-T42 Clad

0.040

I Replace

2612041

2612041

2612041
2612041

2612041

2024-T42 Clad

1
1

Tailcone Buikhead(Frame)

Figure
EFFECTIVITY:

0.050

I
1

Repair Index

1 (Sheet 3 of 7)

31-002 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT

53-31-00

Page 3
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM
NO.

DWG.
NO.

Doubler, Aft (2 ea.)


Doubler, Fwd (2 ea.)

2612041
2612041

2024-T3 Clad

0.050

2024-T3 Clad

0.050

\2024-T42Clad

0.050

2024-T3 Clad

0.032

2612041

Shim (4 ea.)
Plate (2 ea.)

2024-T3 Clad

0.093

2024-T42 Clad

2612250

2612250

2024-T3 Clad

0.160

2024-T42 Clad

0.050

Filler(2 ea.)

2024-T3 Clad

0.025

Cell Divider

S-555

S-644

1
1
1

Frame

2612250

2612250 IStiffener
2612250

Strap
AttachAngle(2ea.)

2024-T3 Clad

0.080

0.050

1
1
1

I
I
I
I
I
I
I
I

2612250

Filler

2024-T42 Clad
2024-T3 Clad

2612251

Web(2 ea.)

2024-T3 Clad

0.125

Instl., Frame 25A


Bulkhead,Fwd
Bulkhead,Aft

1
1

2024-T42 Clad

0.040

2024-T42 Clad

0.040

0.050

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

2024-T42 Clad

0.025

1
1
1
1
1
1

2024-T3 Clad

0.040

2024-T42 Clad

0.032

2024-T3 Clad

0.040

2024-T42 Clad

0.050

2024-T42 Clad

0.050

2024-T3 Clad

0.100

2024-T3 Clad

0.032

I
I
I
I
I

2024-T3 Clad

0.050

1
1
1
1
I
1
1

S-733

2024-T42 Clad

0.050

2612250

2612255
2612255

2612255

Frame

0.025

2612256

BulkheadSupport,Fwd
BulkheadSuppolt,Aft
Cap,LH&RH
Cap,Upper
Filler(4ea.)
SupportChannel,LH&RH
SupportChannel,LH&RH
Bracket,LH&RH(2ea.)
Angle(8ea.)
Shim(4ea.)
Filler(4ea.)
Filler(Gea.)

2612256

Tee, LH

2612256

2612256

Angle(8ea.)
Angle(2ea.)

2024-T42 Clad

0.032

2612256

Intercostal

2024-T42 Clad

0.032

2612256

5-733

I
I

2612256

Tee, LH 8 RH
Intercostal, LH 6 RH (2 ea.)

1
I

2024-T42 Clad

0.050

2612055

AftSupportBeamAssy.

2612255
2612255
2612255
2612255
2612058

2612256
2612256
2612256

2612256
2612256
2612256

2612055

2612055

6 RH

(2 ea.)

SupportChannel, Upper
SupportChannel, Lower

Figure

EFFECTIVITY:

0.050

0.025

S-728

S-728

Tailcone Bulkhead(Frame)

SRM~

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.050

FrameAssy.

2612250

I
I

Frame Instl., Frame25

2612250

1
1

I
I
I

Strap(3 ea.)

2612041

CODE

1
1
1

Shim, Laminated (Max. 0.032)

2612041

REPAIR
FIG. NO.

IFINISH
GAGE

Baffle

Stiffsner(4ea.)

2612041

I
MATERIAL

2612041

2612041

I
EFF.

DESCRIPTION

I
i

Replace
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Repair Index

(Sheet 4 of 7)

31-002 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT

53-31-00

Page 4
May 15/92

Learjet

STRUCTU RAL REPAIR MANUAL


ITEMI DWG. I
NO.

Web,Aft

2612055

Web, Fwd
Shim, Laminated (Max. 0.032)

2612055
2612055

2024-T3 Clad

0.040

Replace

2024-T3 Clad

0.040

I Replace
I Replace

1
1
1

Replace
I Replace
I Replace

0.063

2612058

2024-T3 Clad

0.160

2612059

Bracket

2024-T3 Clad

0.040

2612058

2024-T3 Clad

0.160

2024-T3 Clad

0.032

2024-T42 Clad

0.063

2612059

Filler(2ea.)
Baffle (2 ea.)
Support Bracket
Bracket(3 ea.)

2024-T42 Clad

0.063

1
1

2612256

SupportAngle(4ea.)

2024-T3 Clad

0.040

Fitting,

2512260
2412251

2512260
2512260

2512260 1

2512265 1
2512265

LH 8 RH

2024-T42 Clad

0.040

Replace
I Replace
I Replace
I Replace
I Replace
I Replace
I Replace
I Replace

2024-T3 Clad

0.100

2024-T3 Clad

0.025

I
I
I
I

Former, LH 8 RH
Bulkhead Instl., Frame 26

2512260

2512260

Stop(2 ea.)
SpliceBand
ClipAssy.
Splice Band (3 ea.)

2024-T3 Clad

0.050

2024-T3 Clad

0.025

1
1
1
1

Doubler, LH 8 RH

2024-T42 Clad

0.032

Frame

2024-T42 Clad

0.032

Bulkhead Instl., Frame 26A

(FrameAssy.

2024-T42 Clad

0.040

2512265

Washer

Copper

0.050

2512706

Support

2024-T42 Clad

0.050

S-557

2512270

2512270 1

1 2512280 1
2512280

2512290

2512290 1
2512290

Bulkhead Instl., Frame 27

2512295 1

1 2512300
2512300

2512300

F4-1

Replace
I Replace
I Replace
Replace

2024-T42 Clad

0.050

Frame Web

2024-T42 Clad

0.040

I Replace

2024-T42 Clad

0.040

2024-T42 Clad

0.025

I Replace
I Replace

0.040

Bulkhead Instl., Frame 28

Splice

Band

(3 ea.)
Bulkhead instl., Frame

29

Frame Web

1
1

2024-T42 Clad

S-607

Bulkhead Instl., Frame30

Splice
Splice

Replace

Bulkhead Instl., Frame 29A


Frame Web

I Replace
I Replace

2024-T42 Clad

0.050

F4-1

Replace
Replace
Replace
Replace

2024-T42 Clad

0.040

F4-1

Band

2024-T42 Clad

0.025

F4-1

Band

2024-T3 Clad

0.025

F4-1

Frame

2512300

F4-1

IAngle

2512295 1

Sheet

Support

Bulkhead

2512280

Replace
Replace
Replace
I Replace
I Replace

Frame

2512270

Replace

2512265

2317079 I.Mount

12

2024-T42 Clad

2652096

11

FIG. NO.

2612056

10

REPAIR

CODE

0.063

2612059

IFINISH
GAGE

2024-T42 Clad

2612055

I
MATERIAL

2612057

I
EFF.

Support, Aft (2 ea.)


Beam Support, Fwd (2 ea.)
Filler(2 ea.)
Beam

2612057

I
DESCRIPTION

NO.

Tailcone Bulkhead(Frame) Repair Index


Figure 1 (Sheet 5 of 7)

EFFECTIVITY:

31-002 AND

SUBSEQUENT; 35-001

36-001 AND SUBSEQUENT


SRM~

AND

SUBSEQUENT;

53-31-00

Page 5
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

NO.
13

DWG.
NO.

23120311 Bulkhead Instl., Frame

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

2312031 1

Bulkhead

2024-T42 Clad

0.050

Bulkhead

2024-T42 Clad

0.050

2312031

Cover(2 ea.)

2024-T4 Clad

0.032

2312031

Doubler

2024-T3 Clad

0.080

2312031

Doubler

2024-T3 Clad

0.080

2312031

Doubler

2024-T3 Clad

0.080

2312032 1
2312032 1
2312032
2312031
2312033

2312033

1 2312034 1
2312034

Web, LH 6 RH

2024-T3 Clad

0.032

Filler(2 ea.)

2024-T3 Clad

0.063

Bulkhead Instl., Frame 32


Bulkhead

2024-T42 Clad

0.050

2024-T3 Clad

0.080

Doubler

2024-T3 Clad

0.080

2024-T42 Clad

0.050

2024-T3 Clad

0.080

2024-T42 Clad

0.071

2024-T3 Clad

0.025

2024-T42 Clad

0.025

Bulkhead Instl., Frame 33


Bulkhead
Bulkhead Instl., Frame 34
Bulkhead

2312034

Filler

2312034

Doubler, LH

6 RH

I
I
I
I
I
I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Replace
Replace
Replace

DoublarQea.)

Doubler(3ea.)

2312033
16

MATERIAL

2312031 1

2312031

15

31

I
EFF.I

1
1
1
1
1
1
1
1

2312031

14

I
DESCRIPTION

F4-1

Replace
Replace

Replace
Replace
Replace

F4-1

1
1
1

Tailcone Bulkhead(Frame) Repair Index


Figure 1 (Sheet 6 of 7)

EFFECTIVITY:-

31-002 AND

SUBSEQUENT; 35-001 AND SUBSEQUENT;

36-001 AND SUBSEQUENT


SRM-4

53-31-00

Page 6
May 15/92

STRUCTURAL REPAIR MANUAL


CODES

EFFECTIVITIES

31-002 AND SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

36-001 AND SUBSEQUENT


31-002 AND SUBSEQUENT; 35-001 AND SUBSEQUENT

35-001 THRU 35-646; 36-001 THRU


31-002 AND SUBSEQUENT; 35-647
31-002 THRU 31-029; 35-001 THRU
31-030 AND SUBSEQUENT; 35-649

4
5

6
7

36-059
AND

SUBSEQUENT;

36-059 AND SUBSEQUENT

35-648; 36-001 THRU 36-057


AND SUBSEQUENT; 36-058 AND SUBSEQUENT

NOTES:
Laminated shim stock, 0.002
num sheet.

or

0.003 lamination per MIL-S-22499

Type

1 Class 1

or

Class 2 1145-H19 alumi-

Annealed per QQ-C-576

Tailcone Bulkhead(Frame) Repair Index


Figure 1 (Sheet 7 of 7)

EFFECTNITY:

31-002 AND
36-001 AND

SRM4

SUBSEQUENT; 35-001 AND SUBSEQUENT;


SUBSEQUENT

53-31-00

Page 7
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ALLOWABLE DAMAGE

TAILCONE BULKHEAD (FRAME)


ALLOWABLE DAMAGE LIMITS

1.

All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

or

failed rivets

the

on

remaining

performed
Chapter 51
to

fer to

(2) Loose

or

ensure

not allowed. A loose or failed rivet can cause

are

rivets and lead to

that

joint

increased stress concen~a-

failure. A careful

inspection must be
progressive joint
spread from the area of the loose or failed rivet. (Re-

failure has not

for definition of rivet failure.)


failed screws are not allowed. A loose

or

failed

screw can cause

increased stress

failure. A careful

and lead to

concen-

must be

inspection
progressive joint
surrounding
performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
trations

B.

on

screws

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired,

and refinished in accordance with

Chapter

re-

51.

C.

Deformation

D.

(1) Deformation of the tailcone bulkhead (frame) structure is not allowed.


Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished

in accordance

Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness more than specified.
with

E.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component re-

placed.
F.

G.

H.

Scratches(See Figure 101.)


(1) Scratches are permissible if the affected

EFFECTIVITY:
SRM~

area

is sanded smooth, refinished in accordance with

Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(See Figure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings andForgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.
ALL

53-31-00

Fage 101
May 15/92

STRUCTURAL REPAIR MANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175
0.0225

0.025
0.040

0.0295
0.037

0.050

0.046

0.032

0.059

0.063
0.071

0.067

0.080

0.076

0.100

0.095
0.120

0.125
0.190

0.180

0.237

0.250

Allowable Material Thickness

Figure
EFFECTIVITY:

ALL

101

53-31-00

Page 102
May 15/92

LAarjet i
STRUCTURAL REPAIR MANUAL
TAILCONE BULKHEAD (FRAME)- REPAIR
i.

APPROVED REPAIRS
A.

RefertoChapter51 fortypicalrepairs.

EFFErrrvlTy:
SHM4

ALL

53-31-00

Page 201
May 15/92

Learjet
STRU~TURAL REPAIR MANUAL
TAILCONE STRINGERS

STRUCTURAL IDENTIFICATION

O
I

CFWD

(TYPICAL)
518D

EFFECTIVITY:

Stringer Repair Tndex


Figure 3 (Sheet 1 of 2)

Tailcone

31-002 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND

SRM~

SUBSEQUENT

53-32-00

Page 1
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.
2612000

2612000

2612000

3
4

2612000
2612000

2612000

2612000

2612000

2612000

10

2612000
2612000

11

2612000

12

2612000

13

2612000

14

2612000

15

2612000
2612000
2612000
2512000

16
17
18

2612000
19

2512000

20

2512000
2512000

2512000
2612000

CODES

DESCRIPTION

EFF.

Tailcone Assy.
Stringer No. 2, LM RH
Stringer No. 3, LH 8 RH
Stringer No. 4, LH 8 RH
Stringer No. 5, LH 8 RH
Stringer Na. 6, LH 8 RH
Stringer No. 7 LH 8 RH
Stringer No. 8, LH 8 RH
Stringer No. 9, LH 8 RH
Stringer No. 10, LH 8 RH
Stringer No. 11, LH 8 RH
Stnnger No. 12, LH 8 RH
Stringer No. 13, LH 8 RH
Stringer No. 13A, LH 8 RH
Stringer No. 14, LH 8 RH
Stringer No. 15, LH 8 RH
Stringer No. 16, LH RH

Stringer No.
Stringer No.
Stringer Na.
Stringer No.
Stringer No.
Stringer No.
Stringer No.
Stringer No.

MATERIAL

GAGE

FINISH
CODE

REPAIR
FIG. NO.

1
1

S-554
S-554
S-554
S-554
S-554
5-554
S-554
S-554
S-554
S-554
S-554
S-554
S-554
S-556
S-554
S-554
S-554
S-554
S-554
S-554
S-554
S-554
S-554
S-554

1
1
1

1
1
1
1

1
1

1
1
1

1
1
f

17, LH 8 RH
18, LH 8 RH
18, LH 8 RH
16, LH 8 RH
17 LH 8 RH
17, LH 8 RH
2, RH
18A, LH 8 RH

1
2
3
1

2
3
1
3

51-70-04

51-70-04
51-70-04
51-70-04
51-70-04
51-70-04
51-70-04

51-70-04
51-70-04

51-70-04
51-70-04
51-70-04
51-70-04

51-70-04
51-70-04
51-70-04
51-70-04
51-70-04

51-70-04
51-70-04

51-70-04
51-70-04
51-70-04
51-70-04

EFFECTIVITIES

31-002 AND

35-001 THRU

31-002 AND

SUBSEQUENT;

35-001 AND

SUBSEQUENT

36-001 AND SUBSEQUENT

35-646; 36-001 THRU 36-058

SUBSEQUENT;

35-647 AND

SUBSEQUENT;

36-05 AND SUBSEQUENT

Tailcone

Stringer Repair Index


Figure 1 (Sheet 2 of 2)

EFFECTNITY:

31-002 AND

SUBSEQUENT; 35-002

36-001 AND SUBSEQUENT


SRMI

AND

SUBSEQUENT;

53-32-00

Page 2
1Llay 15/92

Learjet
Learjet

STRUCTURAL REPAIR MANUAL


TAILCONE STRINGERS
i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS
All dimensions

NOTE:

A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

or

failed rivets
the

on

are

not allowed. A loose

or

failed rivet

can cause

increased stress concentra-

progressive joint failure. A care~ul inspection must be


that joint failure has not spread from the area of the loose or failed rivet. (Re-

remaining

rivets and lead to

performed to ensure
Chapter 51 for definition of rivet failure.)

fer to

(2) Loose

or

failed

screws are

not allowed. A loose or failed screw can cause increased stress concen-

surrounding screws and lead to progressive joint failure. A careful inspection must be
performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
trations

B.

on

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

re-

paired, and refinished in accordance with Chapter 51.


C.

Deformation

D.

(1) Deformation of the tailcone stringers is not allowed.


Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance

Chapter 51, and these repairs do not reduce the original material thickness more than speciChapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness more than specified.
with

fied. (Refer to

E.

Dents

(1) Dents

are

permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
depth, do not exceed 10% of total surface area in one (1) square foot, and are not

(2.54 mm) in

closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component re-

placed.
F.

Scratches(See Figure 101.)


(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Re-

protective treatment procedures.)


components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittingsand Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.
fer to

Chapter 51

for

(2) Structural

G.

H.

EFFECI~IVITY:
SIZM4

ALL

53-32-00

Page 101
May 15/92

~iqlearjeil
STRUCTURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125
0.190

0.120

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFFECTIVITY:

ALL

101

53-32-00

Page
SRM-4

102

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
TAILCONE STRINGERS
i.

APPROVED REPAIRS
A.

RefertoChapterS1 fortypicalrepairs.

EFFECTIVITY:
SRM~

REPAIR

ALL

53-32-00

Page 201
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
TAILCONE VENTRAL mN AND STINGER

STRUCTURAL IDENTIFICATION

g~
A

(TYPICAL)

Detai IA
Tailcone Ventral Fin and

Figure

EFFECTIVITY:
SRM-4

Stinger Repair Index

(Sheet 1 of 4)

35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

53-33-00

Page 1
May 15/92

LAarjet
Learjet

STRUCTURAL REPAIR MANUAL


TAILCONE VENTRAL FIN AND STINGER

STRUCTURAL IDENTIFICATION

~JB

0000

\S

a~

II

Is

(TYPICAL)

Detail B
Tailcone Ventral Fin and

3-208

Figure

EFFECTIVITY:
SRM~

35-001 AND

Stinger Repair Index

(Sheet 2 of 4)

SUBSEQUENT; 36-001 AND SUBSEQUENT

53-33-00

Page 2
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM
NO.

DWG.
NO.

I
DESCRIPTION
VentralFinlnstl.

2512005

IFINISH

I GAGE

MATERIAL

REPAIR
FIG. NO.

CODE

Ventral FinAssy.

2512005

EFF.

2512005

0.020

Replace

2512005

Skin

2024-T42 Clad

0.032

2312005

Skin,LH&RH

2024-T42 Clad

0.032

1
1

51-70-02

1
1

2312005

Bracket

2024-T42 Clad

0.050

2312005

HoneycombCore,LH&RH

2312005 1

Bracket

2024-T42 Clad

0.080

2312005

Bracket,LH&RH

2024-T42 Clad

0.071

Doubler

2024-T3 Clad

0.032

2024-T42 Clad

0.025

2024-T3 Clad

0.040

6061-0

0.040

SplicePlate

2312005 1

2312010
8

Instl.

CoverPlate

2312010

AngleAssy.
Angle
CoverAssy.

2312012
2312012
2312010
2312010

10

2312010

11

2312010

12

2312010

Replace

Replace

Replace

51-70-02

2024-T42 Clad

0.032

Replace
Replace

Skin, LH 8 RH Lwr
Angle (2 ea.)

2024-T42 Clad

0.025

51-70-02

2024-T42 Clad

0.063

2024-T42 Clad

0.040

1
1

I
I

2024-142 Clad

0.032

2024-T42 Clad

0.032

S-512

S-512

S-5101

I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace

51-70-02

Honeycomb Core,
UpperRib(2ea.)

16

2312010

2312010

LowerRib

1
LH 8

RHJ

StiffenerAngle (6 ea.)
StiffenerAngle (2 ea.)
StiffenerAngle, LH 8 RH
Skin, Upper

I
I
I

I
I
I

6061 -T6

0.025

2024-T42 Clad

0.050

F4-6

2024-T42 Clad

0.050

F4-6

3112012

Channel

3112012

Bracket

3112012

Clip,

2024-T3 Clad

0.050

F4-6

3112012

Doubler

2024-T3 Clad

0.050

F4-6

3112012

Angle
CoverAssy.,Antenna

2024-T42 Clad

0.032

F4-6

(2 ea.)

LH 8 RH

Tailcone Ventral Fin and

Figure
EFFECTIVITY:

Replace

Mounting Ring
SplicePlate

3112012

0.032

2312010

2312010

Replace
Replace
Replace

2024-T42 Clad

15

2312010

1
1

2312010

18

Skin

2312010

2312010

Skin, LH 8 RH

14

2312010

Replace

StingerAssy.
Skin Assy.

13

17

51-70-02

2312010
2312010

Stinger

.301 Stainless

35M)1 AND

SUBSEQUENT;

Replace
Replace
Replace

Replace
Replace
I

Replace

Stinger Repair Index

Z (Sheet 3 of

4)

36-001 AND SUBSEQUENT

53-33-00

Fage 3

May 15/92

STRUCTURAL REPAIR MANUAL


CODES

EFFECTIVITIES

35-001 AND

35-001 THRU 35-676; 36-001 THRU 36-062


35-677 AND SUBSEQUENT; 36-063 AND SUBSEQUENT

SUBSEQUENT;

36-001 AND SUBSEQUENT

NOTES:
Hexcel HRH10-1/8-3.0

(2)-

.25

Honeyconb

core

Tailcone Ventral Fin and

Figure
EFFECTNITY:
SRM-4

35-001 AND

Stinger Repair Index

1 (Sheet 4 of 4)

SUBSEQUENT; 36-001 AND SUBSEQUENT

53-33-00

Page 4
May 15/92

Learjet
~Learietl
STRUCTURAL REPAIR MANUAL
TAILCONE STINGER

STRUCTURAL IDENTIFICATION

00000

~eaa

(TYPICAL)

Detail A
Stinger Repair Index
Figure 2 (Sheet 1 of 2)
EFFECITVITY:
SRM-4

31-001 AND SUBSEQUENT

53-33-00

Page 5
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.
3112010

3112010
1

2312010

3112010

3112011
3112010

2312010
3112012

3112010
3112010

3112010

EFF.

DESCRIPTION

MATERIAL

2024-T42 Clad

0.025

2024-T42 Clad

0.032

F4-6

51-70-02

Rib, Fwd

RibAssy.,Aft

Replace

Rib, Aft

2024-T42 Clad

0.032

F4-6

51-70-02

Doubler

2024-T3 Clad

0.050

F4-6

51-70-02

StiffenerAssy.,LH&RH
Stiffener
Skin Assy.

1
1

S-733

3112010

Skin,Lwr

2024-T42 Clad
2024-T42 Clad

3112010

Stiffener

S-733

3112010

Stiffener,LH&RH

S-5101

2024-T42 Clad

Replace
Replace

RibAssy.,Fwd

Skin

CODES

REPAIR

FIG. NO,

CoverPlate

3112010

3118455

FINISH
CODE

Stingerlnstl.
Stinger Assy.

3112010

GAGE

Mounting Ring
Cover Assy., Antenna

0.050
0.050

F4-6
0.050

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

EFFECTIVITIES
31-001 AND SUBSEQUENT

Stinger Repair Index


Figure 2 (Sheet 2 of 2)
EFFECTIVITY:
SRM-4

31-001 AND SUBSEQUENT

53-33-00

Page 6
May 15/92

Learjet i
STRUCTURAL REPAIR MANUAL
TAILCONE VENTRAL FIN AND STINGER
i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS
All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

or

failed rivets
the

on

remaining

performed
fer to Chapter
to

(2) Loose

or

not allowed. A loose

are

rivets and lead to

or

failed rivet

progressive joint

can cause

joint failure has not spread from the


51 for definition of rivet failure.)

ensure

failed

that

screws are

not

allowed. A loose

or

failed

increased stress concentra-

failure. A careful
area

of the loose

screw can cause

or

failed rivet. (Re-

increased stress

failure. A careful

and lead to

must be

inspection

concen-

must be

surrounding
progressive joint
inspection
performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
trations

B.

screws

on

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired,
C.
D.

and refinished in accordance with

Deformation

(1) Deformation of the tailcone ventral fin and stinger assembly structure is not allowed.
Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

Chapter

re-

51.

more

than

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (2) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component reF.

G.

Fl.

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings andForgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTIVITY:
SRM-4

ALL

53-33-00

Page 101
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure

EFFECTIVITY:
SRM-4

ALL

101

53-33-00

Page 102
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
TAILCONE VENTRAL, FIN AND STINGER
i.

APPROVED REPAIRS
A.

RefertoChapter51 fortypicalrepairs.

EFFECTIVITY:
SRM-4

REPAIR

ALL

53-33-00

Page 201
May ~5/92

~j Learjet
STRUCTURAL REPAIR MANUAL
TAILCONE DORSAL ASSEMBLY

STRUCTURAL IDENTIFICATION

A
00000

~P
Detail A
Tailcone Dorsal

Assembly Repair Index


Figure 1 (Sheet 1 of 3)

EFFECTIVITY:
sRM-a

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT

53-34-00

Page 1
Jun 1/95

Learjet
~LearjetJ

STRUCTURAL REPAIR MANUAL


ITEM
NO.

DWG.
NO.

I
DESCRIPTION

2612020

TailconeDorsal Instl.

2512020

TailconeDorsal Instl.

2612020

Tailcone Dorsal
Tailcone Dorsal

2512020

Assy.
Assy.

MATERIAL

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

Replace
Replace

2612020

DorsalMember

2512020

DorsalMember

51-70-05

2312020

Gusset(eea.)

51-70-05

2312020

Tube

2312020

Duct

2312020

RubBlock(2ea.)
RetainerAssy.

2312020

2312020 IPlate
5

2512020

2512022
2512022
2512022

2512022
2512022
6

2512021

0.050

Phenolic

0.060

14130Steel

Cradle

Support, Fwd
Support,Aft
Support
Support, LH 8 RH
SupportAngle
Angle, LH 3 RH
Door Assy., Dorsal Access

0.090

Replace
Replace
Replace
51-70-05

2024-T42 Clad

0.040

F4-1

2024-T42 Clad

0.040

F4-1

2024-T42 Clad

0.040

F4-1

2024-T42 Clad

0.040

F4-1

2024-T42 Clad

0.040

F4-1

2024-T3 Clad

0.040

F4-1

2024-T42 Clad

0.040

F4-1

2024-T42 Clad

0.025

51-70-05

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2512021

Skin

2024-T3 Clad

0.040

F4-1

51-70-02

2512021

Stiffener

2024-T3 Clad

0.025

F4-1

251 2021

Hinge
Spacer
Stiffener(2 ea.)

MS35821-1 OA

2024-T3 Clad

S-554
2024-T3 Clad

2512021

2512021
7

5052-0

51-70-05

CradleAssy.

2512022 1

51-70-05

Bracket

2512022
2512022

Stiffener

2512022

2512021

Pad

2519215

DorsalAssy.

2519215

DuctExtension

2519215

Attach

12024-T3Clad

Replace
Replace
Replace
Replace
Replace

51-70-05

I
I

I F4-6
0.063

F4-6

I
0.063

Strap

0.040

F4-6

6608066

Duct

2512023

BulkheadAssy.

Replace
Replace
Replace

2512023

Bulkhead

51-70-05

Tailcone Dorsal

Figure
EFFECTIVITY:

31-001 AND

Assembly Repair Index


1

(Sheet 2 of 3)

SUBSEQUENT; 35-001

36-001 AND SUBSEQUENT


SRM-4

I
EFF.

AND

SUBSEQUENT;

53-34-00

Page 2
Jun 1/95

Learjet
STRUCTURAL REPAIR MANUAL
EFFECTIVITIES

CODES

35-001 THRU 35391; 36-001 THRU


35392 AND SUBSEQUENT; 36-051
31-001 AND SUBSEQUENT; 35-001
31-001 THRU 31-101; 35001 THRU
31-102 AND SUBSEQUENT; 35-677
31-102 AND SUBSEQUENT

2
3
4

36-050

AND SUBSEQUENT
AND SUBSEQUENT; 36-001 AND SUBSEQUENT
35-676; 36-001 THRU 36063
AND SUBSEQUENT; 36-064 AND SUBSEQUENT

NOTES:
5

Ply No. 181 Glass Cloth Per Mil-F-9084; Polyester Resin Mil-R-7575, Type I, Fabricate per Chapter 51

Tube 0.050 O.D. X 0.035 l.D.

Per Mil-P-15035

MadehOm8M1416Sp~ngeFOam

Tailcone Dorsal

Figure
EFFECTIVIPI:
SRM-4

Assembly Repair Index


1

(Sheet 3 of 3)

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT

53-34-00

Page 3
Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


TAILCONE DORSAL ASSEMBLY
i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS

All dimensions

NOTE:
A.

in inches unless otherwise

are

Fasteners

(1) Loose
tions

or

on

failed rivets
the

not

are

remaining

performed
Chapter 51

fer to

(2) Loose

or

trations

allowed. A loose

rivets and lead to

to ensure that

joint

on

surrounding
to ensure

from the

failed

area

of the loose

screw can cause

must be

inspection
or

failed rivet. (Re-

increased stress

failure. A careful

and lead to

allowed. Cracked
fittings and forgings
not

and refinished in accordance with

concen-

must be

Chapter

fittings or forgings must be replaced.


considered allowable if properly

are

re-

51.

Deformation

(1) Deformation of the tailcone dorsal assembly structure is not allowed.


Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

or

increased stress concentra-

Cracks

paired,

D.

spread

can cause

failure. A careful

progressive joint
inspection
joint failure has not spread from the area of the loose or failed screw.

screws

that the

failed rivet

progressive joint

failure has not

(1) Cracks in any fitting or forging are


(2) Cracks in components other than
C.

or

for definition of rivet failure.)


failed screws are not allowed. A loose

performed
B.

specified.

more

than

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt


(2.54 mm) in

depth,

changes in contour,

do not exceed 10% of total surface

area

in

one

do not exceed 0.100 inch

(1) square foot, and

are

not

closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to

rivet

or

structural

area.

Such dents shall be

repaired

or

the

component

re-

placed.
F.

Scratches(See Figure 101.)


(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Re-

protective treatment procedures.)


must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings andForgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.
fer to

Chapter 51

for

(2) Structural components

G.

H.

EFFECTIVITY:

ALL

53-34-00

Page
SRM-4

101

May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076
0.095

0.100
0.125

0.120

0.190

.0.180
0.237

0.250

Allowable Material Thickness

Figure
EFFECTIVITY:

ALL

101

53-34-00

Page 102
May 15/92

Learjet
STRUCTURAL REPAIR WIANUAL
TAILCONE DORSAL ASSEMBLY

i.

REPAIR

APPROVED REPAIRS

A.

RefertoChapterlil fortypicalrepairs.

EFFECTTVITY:
SRM~L

ALL

53-34-00

Page 201
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
TAILCONE SKINS

STRUCTURAL IDENTIFICATION

~FWD

(TYPICAL)
~18D

Tailcone Skins

Figure
EFFECTIVITY:

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


3MX)1 AND SUBSEQUENT

SI~M-4

Repair Index

1 (Sheet 1 of 2)

53-35-00

Page 1
May 15/92

STRUCTURAL REPAIR MANUAL


DWG.
NO.

ITEM

NO.

2612000
1

2612000

2612000

2612000

2612000

2612000

2612000
6

2512000

2512000

2512000

2512000

2612000

2612000
10

12512000
2612000

11

2512000
2612000

12

2512000

CODES

Assembly
Top

Bottom

LH 8 RH

Top

Top

Top

Bottom

Bottom

RH
LH
LH 8 RH
LH 8 RH
LH
RH

Bottom

Bottom

Tailcone

Skin,
Skin,
Skin,
Skin,
Skin,
Skin,
Skin,
Skin,
Skin,
Skin,
Skin,
Skin,
Skin,
Skin,
Skin,
Skin,
Skin,

LH
LH

2
3

4
5

Tailcone Skins

Figure
31-001 AND

36-001 AND
SRM4

GAGE

FINISH

REPAIR

CODE

FIG. NO.

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

0.040

51-70-02

0.040

51-70-02

0.040

51-70-02

2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42

Clad
Clad

0.040

51-70-02

0.040

51-70-02

Clad

0.040

51-70-02

Clad

0.040

51-70-02

Clad

0.040

51-70-02

Clad
Clad

0.040

51-70-02
51-70-02

Clad

0.040

51-70-02

Clad

0.040

51-70-02

Clad

0.050

51-70-02

Clad

0.050

51-70-02

Clad
Clad

0.050

51-70-02

0.050

51-70-02

Clad

0.050

51-70-02

0.040

SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT


31-013; 35-001 THRU 35-657; 36-001 THRU 36-058
31-014 AND SUBSEQUENT; 35-658 AND SUBSEQUENT; 36-059 AND SUBSEQUENT
35-001 THRU 35-646; 36-001 THRU 36-058
31-001 AND SUBSEQUENT; 35-647 AND SUBSEQUENT; 36-059 AND SUBSEQUENT
31-001 THRU

EFFECTIVITY:

MATERIAL

EFFECTIVITIES
31-001 AND

Top

RH
RH

2
3

EFF.

DESCRIPTION

Repair Index

1 (Sheet 2 of 2)

SUBSEQUENT; 35-001 AND SUBSEQUENT;


SUBSEQUENT

53-35-00

Page 2
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
TAILCONE SKINS

ALLOWABLE DAMAGE

ALLOWABLE DAIMAGELIMITS

i.

All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

or

on

failed rivets
the

not allowed. A loose or failed rivet can cause increased stress concentra-

are

remaining

rivets and lead to

progressive joint

failure. A careful

inspection

must be

joint failure has not spread from the area of the loose or failed rivet. (Reperformed
fer to Chapter 51 for definition of rivet failure.)
(2) Loose or failed screws are not allowed. A loose or failed screw can cause increased stress concentrations on surrounding screws and lead to progressive joint failure. A careful inspection must be
to ensure that

performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
B.

Cracks

paired,
C~
D.

and refinished

and

are

re-

Deformation

(1) Deformation of the tailcone structure is not allowed.


Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

not allowed. Cracked

fittings or forgings must be replaced.


considered allowable if properly
fittings
forgings
in accordance with Chapter 51.

(1) Cracks in any fitting or forging are


(2) Cracks in components other than

more

than

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component reF.

G.

i-I.

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(See Figure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings andForgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTIVITY:

ALL

53-35-00

Page
SRM-II

101

May 15/92

STRUCTURAL REPAIR MANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

~0.180

0.250

0.237

Allowable Material Thickness

Figure

EFFECTIVITY:
srzM-4

ALL

101

5335-00

Page 102
May 15/92

Learjet I
STRUCTURAL REPAIR MANUAL
TAILCONE SKINS -REPAIR
i.

APPROVED REPAIRS
A.

RefertoChapter51 fortypicalrepairs.

EFFECTIVITY:
SRM~

ALL

53-35-00

rage 201
May ~5/92

Learjet
STRUCTURAL REPAIR MANUAL
DELTA FINS
i.

STRUCTURAL IDENTIFICATION

DESCRIPTION
A.

The delta fins provide aerodynamic support to the flight system. The delta fin installation consists of
delta fin assemblies and fairing installations, and are located behveen FS 540.00 and FS 642.89 on the
aft

fuselage.

2-211A

Delta Fins

Figure
EFFECTIVITY:

31-001 ANDSUBSEQUENT

Repair Index

(Sheet 1 of 2)

53-36-00

Page 1
May 15/92

STRUCTURAL REPAIR MANUAL


I

DWG.
NO.

ITEM

NO.

3112100
3112101

3112101
3112101
3112101

1
1
1

1
3112102 1
3112101

CODES
1

REPAIR
FIG. NO.

IFINISH
GAGE

CODE

Angle, Upper (2 ea.)


Angle, Lower (2 ea.)
Angle, Upper (2 ea.)
Angle, Lower (2 ea.)
Delta Fin Assy., LH 6 RH

2024-T42 Clad

0.063

F4-6

2024-T42 Clad

0.063

F4-6

2024-T42 Clad

0.032

F4-6

2024-T42 Clad

0.032

F4-6

Replace
Replace
Replace
Replace
Replace

EFFECTIVITIES
31-001 AND SUBSEQUENT

Figure

SRM4

I
MATERIAL

DeltaFin Installation
Fairing Instl., LH RH

Delta Fins

EFFECTIVITY:

I
EFF.

DESCRIPTION

31-001

ANDSUBSEQUENT

Repair Index

1 (Sheet 2 of 2)

53-36-00

Page 2
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
DELTA FINS

1.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGE LIMITS

NOTE:

Maintenance to the delta fins is limited to

lowing information pertains to

A.

the

replacement only, except as noted below. The folfairingq and attachment points of the delta fins.

All dimensions

are

in inches unless otherwise

failed rivets

are

not allowed. A loose

specified.

Fasteners

(1) Loose
tions

or

on

the

remaining

or

failed rivet

can cause

increased stress concentra-

rivets and lead to

progressive joint failure. A careful inspection must be


that joint failure has not spread from the area of the loose or failed rivet. (Re-

performed to ensure
Chapter 51 for definition of rivet failure.)

fer to

(2) Loose

or

failed

screws are

not allowed. A loose

or

failed

screw can cause

increased stress

concen-

surrounding screws and lead to progressive joint failure. A careful inspection must be
performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
trations
B.

on

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired, and

refinished in accordance with

re-

Chapter 51.

C.

Deformation

D.

(1) Deformation of the delta fins is not allowed.


Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected

area is properly repaired, refinished in accordance


Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
Structural
(2)
components must be repaired or replaced if corrosion repair reduces the original material thickness more than specified.

with

E.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component re-

placed.
F.

Scratches(See Figure 101.)


(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to

Chapter 51

for

protective treatment procedures.)


must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks (See Figure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 5? for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
(2) Structural components

G.

EFFECTNITY:
SRM~

31-001ANDSUBSEQUENT

53-36-00

Page 101
May 15/92

LEARJET 20/30 SERIES


STRUCTURAL REPAIR MANUAL

TEMPORARY REVISION NO. 53-2


MANUAL AFFECTED: Learjet Model 20/30 Series Structural Repair Manual.

NOTE:

Temporary Revision
Temporary Revision

53-2 supersedes

Temporary Revision 53-1 Dated Jul 1/99. The reason for


duplication of temporary revision numbers. Temporary
15/01, located in 53-28-00, is still good. Remove Temporary Revi-

53-2 is to eliminate

Revision 53-1, dated Jun

sion 53-1 Dated Jul 1/99 from the manual.

FILING INSTRUCTIONS: Insert adjacent to 53-38-00, page 102, dated May 15/92, and retain until further

no-

tice.

REASON: To add

procedures for

INSTRUCTIONS: Added item B.

loose rivets and

Repair

Foreign Object Removal procedures.

of Loose Rivets, and item C.


DELTA FINS

i.

Foreign Object

Removal

as

follows:

REPAIR

APPROVED REPAIRS

Chapter 51

for

A.

Refer to

B.

Repair of loose rivets.


(1) Around delta fin periphery where three (3) rivets or less are loose, replace rivets installing replacement rivets (MS2042883) using wet epoxy primer.
Around
delta fin periphery where more than three (3) rivets in a row are loose, remove rivets, clean
(2)
faying surfaces and treat with Dow Chemical Treatment No. 19, epoxy primer and fay seal joint
with Proseal 890. Reinstall rivets (MS2,3426B3) and allow to room temperature cure.

C.

Foreign object

(1)

To

typical repairs

for the delta fins.

removal.

foreign objects trapped in lower outboard edge, when internal access is not available, it
permissible to remove existing rivet common to skin and substructure joint near foreign object
and spray with a light coat of HI-STRENGTH 90 (3M) spray adhesive. Allow to cure and reinstall
remove

is

rivet.

TEMPORARY REVISIQN NO. 53-2

SRM-4

53-36-00

Page

1 of 1

Jul i/ai

IL~il
STRUCTURAL REPAIR MANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076
0.095

0.100
0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure
EEFECTIVITY:
SRM-I

101

53-36-00

31-001ANDSUBSEQUENT
NOTE: Please

see

the

TEMPORARY
REVISION
that revises this page.

Page 102
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
DELTA FINS
i.

APPROVED REPAIRS

NOTE:

A.

Approved repairs to the delta fins is limited


in Allowable Damage Limits (53-36-00).

to

replacement only, except

those

repairs

as

noted

RefertoChapter51 fortypicalrepairs.

EFFECTIVITY:
SRM~

REPAIR

31-001

ANDSUBSEQUENT

53-36-00

Page 201
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
FUSELAGE FUEL CELL
i.

STRUCTURAL IDENTIFICATION

DESCRIPTION
A.

fuselage fuel cell structure is located between frames 22 and 25 on Model 31 Series Aircraft not
eaui~aed with extended rang fuel cells, and between frames 20 and 25 on Model 31 Series Aircraft eauit?tled
zoith extended rang fuel cells. On Model 35/35A Aircraft the fuselage fuel cell structure is located between frames 22 and 25, and on Model 36/36A Aircraft between frames 18 and 25.

B.

The

The

fuselage

fuel cell structure is used to

secure

and house,

multiple,

rubber-bladder type cells for

fuel storage. The fuel cell is a sealed structure made up of ribs, stringers, stiffeners, skins, cavity
drains and cell dividers. Receptacles are installed in the upper portion of the fuel cell area to mate

hangers on the rubber bladders. The cavity drains are installed as an aid to eliminate any moisbuildup which may occur between the fuel cells and surrounding structure.
For additional information pertaining to the fuselage fuel cell, refer to the basic Learjet Maintenance
Manual, Chapter 28.
with
ture

C.

EFFEC~TVITY:

31-001 AND
36-001 AND

SRM~

SUBSEQUENT; 35-001 AND SUBSEQUENT;


SUBSEQUENT

53-40-00

Page 1
May 15/92

~Learjet
STRUCTURAL REPAIR MANUAL
FUSELAGE FUEL CELL
1.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGE LIMITS

NOTE:
A.

All dimensions

are

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

or

failed rivets
the

are

not allowed. A loose or failed rivet can cause increased stress concentra-

rivets and lead to

progressive joint failure. A careful inspection must be


performed to ensure that joint failure has not spread from the area of the loose or failed rivet. (Refer to Chapter 51 for definition of rivet failure.)
on

(2) Loose

or

trations

failed

screws are

surrounding

on

performed
B.

remaining

not allowed. A loose or failed screw can cause increased stress concen-

and lead to progressive joint failure. A careful inspection must be


joint failure has not spread from the area of the loose or failed screw.

screws

to ensure that the

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired, and
C.
D.

refinished in accordance with

Deformation

(1) Deformation of the fuselage fuel cell structure is not allowed.


Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original
rial thickness

E.

re-

Chapter 51.

more

than

mate-

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component reF.

G.

H.

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings andForgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTIVITY:
srua~

ALL

53-40-00

Fage 101
May 15/92

STRUCTURAL REPAIR MANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Znch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0,046

0.063

0.059

0.071

0.067

1
1

0.076

0.100
0.125

0.120

0.190

0.080

0.250

0.095
0.180
0.237

Allowable Material Thickness

Figure 101
EFFECTIVITY:
SRM-4

ALL

53-40-00

Page 102
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


FUSELAGE FUEL CELL
i.

REPAIR

APPROVED REPAIRS

A.

RefertoChapterEil fortypicalrepairs.

EFFECTIVITY:

ALL

53-40-00

Page 201
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
FUSELAGE FUEL CELL STRUCTURE
i.

STRUCTURAL IDENTIFICATION

DESCRIPTION
A.

On Model 31/31A Series Aircraft not eauitmed with extended

range.

the

fuselage fuel cell

structure is locat-

ed in between frame 22 and frame 25.

On Model 31/31A Series Aircraft

eauia2~ed with

extended

range,

the

fuselage

fuel cell structure is located

between frame 22 and frame 25, and the forward fuel cell structure is located between frame 20 and
frame 22.
On Model 35/35A Series Aircraft the fuselage fuel cell structure is located between frame 22 and frame
25.

B.

On Model 36/36A Series Aircraft the fuselage fuel cell structure is located between frame 22 and frame
25, and the forward fuel cell structure is located between frame 18 and frame 22.
The fuel cell and forward fuel cell structure consist of intercostals, support assemblies, webs, stiffen-

center, lower and upper cell dividers, with different


upon aircraft model and fuel systems incorporated.
ers,

EFFECTIVITY:

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;

36-001 AND SUBSEQUENT


SRM~

configurations

of components

depending

53-40-05

Page

Jan 15/93

Learjet(
STRUCTURAL REPAIR MANUAL
FUSELAGE FUEL CELL STRUCTURE

STRUCTURAL IDENTIFICATION

B
oo o

o\~

Stringer #4

Stringer #6
Stringer #8

30

Stringer #1

Stringer #12

stringer #14~ 1

II1_________ CI __-------~

Detai IC
[I IC!

Detail A

1~"""

(VIEW LEFT SIDE LOOKING INBOARD)

(TYPICAL)
2149C-1

EFFECTNITY:

Fuselage Fuel Cell Structure Repair Index


Figure 1 (Sheet 1 of 4)
31-001 AND

SUBSEQUENT; 35-001 AND SUBSEQUENT;

36-001 AND SUBSEQUENT


SRM-4

Aft Fuel Cell

53-40-05

Page 2
Jan 15/93

Learjet
Learjetl
STRUCTURAL REfPAIR MANUAL
FUSELAGE FUEL CELL STRUCTURE

STRUCTURAL IDENTIFICATION

125

28~

22)

~Z

-\I

i/

FS 458

(VIEW LEFT SIDE LOOKING INBOARD)


(FUEL CELL DIVIDER, BL 0.00)
(TYPICAL)

Detai IB
Fuselage Fuel Cell Structure Repair Index
Figure 1 (Sheet 2 of 4)
EFFECTIVITY:

SRM4

31-001 AND

SUBSEQUENT;

36-001 AND

SUBSEQUENT

35-001 AND

Aft Fuel Cell

SUBSEQUENT;

53-40-05

Page 3
Jan 35/93

Learjet(
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

2612410
1

2612410

2612410

I
EFF.

DESCRIPTION

Fuselage Fuel Cell Structure Instl.


Skin, Fwd (2 ea.j
Skin, Aft (2 ea.)

REPAIR

CODE

FIG. NO.

0.032

51-70-02

0.032

51-70-02

0.032

51-70-02

2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad

0.032

51-70-02

2024-T3 Clad

0.032
0.063

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

1
2
3

2612410
2312037
2412411

Skin, LH Aft
Skin, RH Aft
Skin, Splice (2 ea.)
Support Bracket, Fuel Probe

Angle (2 ea.)

6061-0
2024-T3 Clad

2412411

Stiffener, LH

2024-T42 Clad

0.050

2412411

Seal

2024-T3 Clad

0.032

2412411

2412411
2412411

2024-T42 Clad
2024-T42 Clad
2024-T3 Clad

0.050

10

0.063

11

2412411

2024-T42 Clad

0.050

12

2412411
2412411
2412411

Stiffener, LH 8 RH
Stiffener, LH 8 RH
Doubler(S ea.)
Stiffener, LH 6 RH
Angle (2 ea.)
Angle (6 ea.)

1
1
1
1
1
1
1
1

0.050

0.050

Doubler
Plate
Angle, LH&RH

2024-T42 Clad
S-571
2024-T3 Clad

2612410
2612410
3

13

8 RH

Angle (2 ea.)

2024-T42 Clad
S-571

Angle (2ea.)
Angle (2ea.)

S-571

Stiffener, LH 8 RH

Angle
Stiffener(5 ea.)
Stiffener(S ea.)

S-571
2024-T42 Clad
2024-T42 Clad

14

2412415 1

15

2512426

16

2512426

17

2512426

18
19

2512427
2512427

20

2612412

21

2612412

22

2612412

Stiffener, LH 8 RH (10 ea.)

23

2612412

Angle(2ea.)
Angle (4ea.)
Angle, LH 8 RH

24

2612412

25

2612412

26

2612412
2612412

27

28
29
30

31

2612412
2612412
2612412
2612412
2612412
2612412

32

i
I

0.050

1
1

I
I

Clad

0.032

Clad

0.032

Clad

0.050

Clad

0.050

1
I

i
I
I

0.190

I
I
I
0.050

0.032

Cell Divider
Cell Divider
Angle, LH 8 RH

1
1

0.032

2024-T42 Clad
2024-T42 Clad
2024-T3 Clad

Angle (4ea.)
Angle, LH 8 RH (2 ea.)
Angle, LH 8 RH (2 ea.)
Angle, LH 6 RH
Angle, LH 8 RH
Angle, LH 8 RH

2024-T42 Clad

S-571
2024-T42 Clad

1
1
j
1
I
1

I
I
I
I
I
I

1
1

I
I
I

1
4
5

Skin, LH 8 RH Top Aft

2612412

Skin, RH CenterAft
Skin, RH CenterAft
Skin, Center Aft, LH

Intercostal, LH

8 RH

3
1

2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42

Fuselage Fuel Cell Structure Repair Index


Figure 1 (Sheet 3 of 4)
EFFECTTVITY:

0.125

S-571

2612412

2612412
2612412

2024-T3 Clad

34

35

0.050

I
I
I
I

2612412
2612412

2024-T42
2024-T42
2024-T42
2024-T42

0.032

33

31-001 AND
36-001 AND

SRM4

IFINISH
GAGE

MATERIAL

SUBSEQUENT;
SUBSEQUENT

35-001 AND

I
0.032

0.032
0.050

I
0.050

Clad
Clad

0.050

Clad
Clad

0.050
0.050

Clad
Clad

0.025

51-70-02

0.025
0.025

1
1

51-70-02

Clad
Clad

1
1

0.025

51-70-02

0.050

51-70-02

Aft Fuel Cell

SUBSEQUENT;

53-40-05

Page 4
Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

36

2612412
2612412
2612412

37

2612412

38

2612412

39

2612412
2412411
2612411

40

2612413

2612413
2612413
2612413
2612413
2612413
2612413

2612413
2612413

DESCRIPTION
Lower Aft, LH
Lower Aft, RH
LowerAft, RH

CODES

REPAIR

CODE

FIG. NO.
51-70-02
51-70-02

0.025

51-70-02

2024-T42 Clad

0.025

51-70-02

2024-T42 Clad

0.025

51-70-02

2024-T42 Clad
2024-T3 Clad

0.025

51-70-02

0.050

Replace

2024-T42 Clad

0.032

Shroud, LH 8 RH Fwd
Shroud, LH 8 RH

2024-T42 Clad

0.032

2024-T42 Clad

0.032

Strap(2ea.)
Angle, LH 8 RH Upper
Angle, LH 8 RH Lower
Angle,LH&RH

0.032

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

2024-T3 Clad

0.032

2024-T3 Clad

0.032

2024-T3 Clad

0.032

1
2

LH 8 RH Top Fwd
LH 8 RH Center Fwd

LH 8 RH Lower Fwd
Doubler (2 ea.)
Shroud Instl.

i
1

Shroud,LH&RHAftAssy.

Shroud

Fuel Drain Instl.

2316039

FINISH

0.025

2316039
2316039

GAGE
0.025

2612430
2316039

MATERIAL
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

Skin,
Skin,
Skin,
Skin,
Skin,
Skin,

Clip(4ea.)
Angle(2ea.)
Hanger Instl., Fuel Cell

2612413

EFF.

0.032
0.032

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

1
1

Drain

Fitting (2 ea.)
Tube Assy. (2 ea.)

Replace
Replace
Replace

1
1

1~

Tube

EFFECTIVITIES

SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT


SUBSEQUENT; 36-001 AND SUBSEQUENT AND 31-001 AND SUBSEQUENT NOT

31-001 AND

35-001 AND

31-010 AND SUBSEQUENT EQUIIPPED WITH SINGLE-POINT PRESSURE REFUELING


35-001 THRU 35-539, 35-589 THRU 35-595; 36-001 THRU 36-053

35-540 THRU 35-588, 35-596 AND

EQUIPPED WITH SINGLE-POINT PRESSURE REFUELING

SUBSEQUENT; 36-054 AND SUBSEQUENT

NOTES:
Fabricated from AN832-4D

fitting

Fabricated from 5052-0, 0.250 O.D. X 0.035 I.D. aluminum

tubing

Fuselage Fuel Cell Structure Repair Index


Figure 1 (Sheet 4 of 4)
EFFECTIVITY:

SRM-4

SUBSEQUENT; 35-001
36-001 AND SUBSEQUENT
31-001 AND

AND

Aft Fuel Cell

SUBSEQUENT;

53-40-05

Page 5
Jan 15/93

Learjet
~LearjetJ

STRUCTURAL REPAIR MANUAL


FUSELAGE FUEL CELL STRUCTURE

STRUCTURAL IDENTIFICATION

Frame 20

Frame 22

(Ref)

(Ref)

Stringer #1
(Ref)

B
I

(i

Stringer #41
(Ref)

(VIEW LOOKING DOWN)

Detail B

CFWO

Frame 20

Frame 21---L

Frame

(Ref)

(Ref)

(Ref)

22-I

(VIEW LOOKING INBOARD FROM LH SIDE)

Detail A
(TYPICAL)
Rcpro

EFFECTIVITY:

SRM-4

Fuselage

Fuel Cell Structure

Repair Index
Figure 2 (Sheet 1 of 3)

31-001 AND SUBSEQUENT, EQUIPPED WITH


EXTENDED RANGE FUEL SYSTEM

Fwd Fuel Cell

53-40-05

Page 6
Tan 15/93

Learjet
STRUCTURAL REPAIR MANUAL
FUSELAGE FUEL CELL STRUCTURE

STRUCTURAL IDENTIFICATION

C
Frame

Frame 21

Frame 22

(Ref)

(Ref)

(Ref)

D
R

5i

aI

lo

Fuel

Baggage

Floor (Ref)

(VIEW LOOKING FWD, RH SIDE FRAME 20)

(VIEW LEFT SIDE LOOKING INBOARD)


(FUEL CELL DIVIDER, BL 0.00)

Detail C

Detail D

(TYPICAL)
Repro

Fuselage

Fuel Cell Structure

Figure

EFFECTIVITY:

SRM-4

Repair Index

Fwd Fuel Cell

(Sheet 2 of 3)

31-001 AND SUBSEQUENT, EQUIPPED WITH


EXTENDED RANGE FUEL SYSTEM

53-40-05

Page

Jan 15/93

Learjet
STRUCTURAL REPAIR MANUAL
ITEM
NO.

DWG.
NO.

DESCRIPTION

EFF.

3111410

Fuselage Fuel Cell Structure Instl.,

2511411

Fwd Fuel Cell


Intercostal, LH 8 RH

2511411
2511411

Angle (10 ea.)


Filler(G ea.)

2511411
2511411

Intercostal, LH 8 RH (14 ea.)


Stiffener(4 ea.)

(2 ea.)

MATERIAL

GAGE

2024-T42 Clad

0.032

0.032

FINISH
CODE

REPAIR
FIG. NO.

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2511411

Web(2 ea.)

2511411

Cell Divider

2511411
2511411
2511411

Cell Divider, Upper


Cell Divider, Lower
Angle, LH RH (4 ea.)
Intercostal (6 ea.)
Angle, LH 8 RH (2 ea.)

Angle (8 ea.)
Angle, LH 8 RH (2 ea.)

Filler (2 ea.)
Inner Skin, LH 8 RH

2024-T42 Clad
2024-T3 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
S-555
2024-T42 Clad
S-555
2024-T42 Clad
2024-T42 Clad
2024-T3 Clad
2024-T3 Clad
2024-T42 Clad
2024-T3 Clad

I~

Fitting (4 ea.)
Support Assy., LH
SupportPan

2024-T4 Clad

2.750

2024-T42 Clad

0.040

2024-T3 Clad

0.025

Replace
Replace
Replace
Replace
Replace

2024-T3 Clad

0.025

Replace

2
3

2511411

2511411
2511411
2511411
2511411
8

2511412

2511413

10

2511414

2511414
2511414
2511415
2511415

2511415
2511415

CODES

i
1
1
1

8 RH

0.080
0.032
0.032
0.032
0.032
0.032
0.032

0.032
0.032
0.032
0.032

RubStick

Shroud Instl., LH 8 RH
Shroud,LH
Shroud,Center
Shroud,RH

1
1

EFFECTIVITIES
31-001 AND SUBSEQUENT EQUIPPED WITH EXTENDED RANGE FUEL SYSTEM

NOTES:
No. 181 Glass Cloth Per MIL-F-9084,
Fabricated from 0.062

Neoprene,

Polyester per MlL-R-7575, Type

40-50 Duro

Fuselage Fuel Cell Structure Repair Index


Figure 2 (Sheet 3 of 3)

EFFECTIVITY:

31-001 AND

II.

SUBSEQUENT, EQUIPPED WITH

Fwd Fuel Cell

53-40-05

EXTENDED RANGE FUEL SYSTEM


sIzM-a

Jan

15/93Page

STRUCTURAL REPAIR MANUAL


FUSELAGE FUEL CELL STRUCTURE

STRUCTURAL IDENTIFICATION
Frame

)feR(2

Frame 18

/t
o

(ReO
3)

(12

Stringer #1
(Ref)

Stringer #4
(Ref)

(VIEW LOOKING DOWN)


Frame 18

Stringer #1

Frame 20

(Ref)

(Ref)

(Refl

B\

Detail B
Frame 22

(Ref)

Stringer

#4

(Ref)

~FWD

Fuel
Floor (Ref)

(VIEW LEFT SIDE LOOKING INBOARD)

Detail A
Repro

EFFECTIVITY:

Fuselage Fuel Cell Structure Repair Index


Figure 3 (Sheet 1 of 3)
36-001 AND SUBSEQUENT

Fwd Fuel Cell

53-40-05

Page 9
SRM-4

Jan 15/93

Learjet
~Learietl

STRUCTURAL REPAIR MANUAL


FUSELAGE FUEL CELL, STRUCTURE

STRUCTURAL IDENTIFICATION

Frame 18

Frame 19

Frame

Frame 21

(Ref)

(ReO

(ReO

(Ren

"~7

Frame 22

(Ref)

D"s

Baggage and Fuel

12

Cell moor

(Ren

15

(FUEL CELL DIVIDER, BL 0.00)

Detail D

(VIEW LOOKING FWD, LH SIDE, FRAME 18)

Detail C
Repro

EFFECTIVITY:

Fuselage Fuel Cell Structure Repair Index


Figure 3 (Sheet 2 of 3)
36-001 AND

SUBSEQUENT

Fwd Fuel Cell

53-40-05

Page
SRM-1

10

Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

DESCRIPTION

EFF.

2511410

Fuselage Fuel Cell Structure Instl.,

2511411

Fwd Fuel Cell


Intercostal, LH 6 RH

(6 ea.)

MATERIAL

GAGE

2024-T42 Clad

0.032

Replace

0.032

2024-T42 Clad
2024-T42 Clad

Replace
Replace
Replace
Replace
Replace

2511411

S-549

2511411

Intercostal

2511411

Angle (23 ea.)

2511411

Cell Divider

2024-T42 Clad
2024-T3 Clad
S-555

0.032

4
6

2511411

Cell

2511411

2511411

2024-T42 Clad
S-555
2024-T42 Clad

0.032

2511411

Divider, Upper
Cell Divider, Lower
Stiffener(4 ea.)
Filler (12 ea.)

2024-T3 Clad

0.032

2511411
2511411

Web(2 ea.)
Angle, LH 8 RH

0.032

10

2511411

11

2511411

12
13

2511411
2511411

Intercostal, LH 8 RH (9 ea.)
Angle, LH 8 RH (4 ea.)
Intercostal, LH 8 RH (4 ea.)

14

2511411
2511411

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T3 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

15

2511412

16

2511413

2024-T4 Clad

2.750

17

2511414

2024-T42 Clad

0.040

2511414

1
i

Angle (4 ea.)
Angle, LH 8 RH

Intercostal, LH
Inner Skin, LH
Fitting (4 ea.)

8 RH

Support Assy.,
SupportPan

LH 6 RH

(3 ea.)

RH

RubStick

2511415

Shroud Instl., LH 6 RH
Shroud,LH
Shroud,Center
Shroud, RH

2511415
2511415

CODES

0.032

0.032

0.032

0.032

0.032
0.032

0.032
0.032
0.032
0.032

2511414
2511415

FIG. NO.

2511411

REPAIR

CODE

Angle, LH 8 RH
Angle (2 ea.)
Angle

251 1411

FINISH

Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

I~

2024-T3 Clad

0.025

2024-T3 Clad

0.025

Replace
Replace

EFFECTIVITIES
36-001 AND SUBSEQUENT

NOTES
No. 181 Glass Cloth Per MIL-F-9084,

I~

Polyester

per MIL-R-7575,

Type II.

Fabricated from 0.062 Neoprene, 40-50 Duro

Fuselage Fuel

Cell Structure

Figure
EFFECTIVITY:

36-001 AND SUBSEQUENT

Repair Index

Fwd Fuel Cell

3 (Sheet 3 of 3)

53-40-05

Page
SRM4

11

~an 15/93

Learjet

STRUCTURAL REPAIR MANUAL


FUSELAGE FUEL CELL STRUCTURE
1.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS

All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

or

failed rivets

the

on

are

not allowed. A loose or

failed rivet

can cause

increased stress concentra-

rivets and lead to

remaining

progressive joint failure. A careful inspection must be


that joint failure has not spread from the area of the loose or failed rivet. (Re-

performed to ensure
Chapter 51 for definition of rivet failure.)

fer to

(2) Loose

or

trations

failed

screws are

surrounding

not allowed. A loose

or

failed

screw can cause

increased stress

concen-

and lead to

progressive joint failure. A careful inspection must be


performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
B.

on

screws

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly
paired, and refinished in accordance with Chapter 51.
C.
D.

Deformation

(1) Deformation of the fuselage fuel cell structure is not allowed.


Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedurea)
(2) Structural components
rial thickness

E.

re-

more

must be

than

repaired

or

replaced

if corrosion

repair reduces

the

original

mate-

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or stntctural area. Such dents shall be repaired or the component reF.

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to

Chapter 51

for

protective treatment procedures.)


must be replaced or repaired

(2) Structural components

if scratches reduce the original material


by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings andForgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

thickness

G.

H.

EFFECTIVITY:
SRM~

ALL

53-40-05

Page 101
May 15/92

Leariea~tlt
STRUCTURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(Inch)

(Znch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080
0.100

0.076
0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure

EFFECTTVITY:
SRM~

ALL

101

53-40-05

Page 102
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
FUSELAGE FUEL CELL STRUCTURE
i.

APPROVED REPAIRS
A.

Refer to

EFFECTIVITY:
SI~M-4

REPAIR

Chapter51

ALL

for

typical repairs.

53-40-05

Page 201
May 15/92

STRUCTURAL REPAIR MANUAL


KEELBEAM ASSEMBLIES

1,

STRUCTURAL IDENTIFICATION

DESCRIPTION
A.

underving and ah keelbeam assemblies, located along the bottom side of the aircraft,
provide a major structural component used to complete the fuselage structure when the wing assembly is installed. The keelbeams also provide housings for fuel lines, hydraulic lines and control cables.
Fuselage frames are interrupted at the keel and are continued through the keel by webs. The floorboards are secured on top of the forward keelbeam and become a part of the aircraft structure. Access covers, located along the bottom side of the keelbeams, form a smooth aerodynamic surface on
the bottom side of the aircraft. Refer to Chapter 51 for forward, underwing and aft keelbeam station
The forward,

locations.

EFFECTIVITY:

SRM~

ALL

53-50-00

Page I
May 15/92

STRUCTURAL REPAIR MANUAL


ALLOWABLE DAMAGE

KEELBEAM ASSEMBLIES
i.

ALLOWABLE DAMAGELIMITS

All dimensions

NOTE:
A.

in inches unless otherwise

are

specified.

Fasteners

(1) Loose
tions

or

on

failed rivets
the

are

not allowed. A loose or failed rivet can cause increased stress concentra-

rivets and lead to

remaining

progressive joint failure. A careful inspection must be


spread from the area of the loose or failed rivet. (Re-

failure has not

performed to ensure that joint


fer to Chapter 51 for definition of rivet failure.)
(2) Loose

or

failed

screws are not

allowed. A loose

or

failed

screw can cause

increased stress

concen-

failure. A careful

and lead to

inspection must be
progressive joint
failure
from
of
the
has
the
the
that
not
loose
or failed screw.
area
joint
spread
performed to ensure
trations

B.

on

surrounding

screws

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired,

and refinished in accordance with

(3) Cracks in the keelbeam


C.

structure

are

Chapter

re-

51.

not allowed.

Deformation

(1) Deformation of any kind to the keelbeam structure is not allowed.


(2) Slight deformation of outboard bulkheads is permissible if such deformation does

adjacent

ference with

structure

or

plumbing

and does not

prohibit

not

cause

the installation of the

interaccess

covers.

D.

Corrosion(See Figure 101.)


(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original mate-

E.

Dents

rial thickness

more

than

specified.

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to

rivet

or

structural

area.

Such dents shall be

repaired

or

the

component

re-

placed.
F.

Scratches(See Figure 101.)


(1) Scratches are permissible if the affected area is sanded smooth, an epoxy primer and/or exterior
paint is applied, and the repairs do not reduce the original material thickness more than specified.

(Refer to Chapter 51 for protective treatment procedures.)


(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by
G.

more

than

specified.

Nicks(See Figure 101.)


(1) Nicks are permissible if the affected

area

is sanded smooth,

an

epoxy

primer and/or

exterior

original material thickness more than specified.


repairs
paint applied,
(Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
is

EFFECTIVITY:

ALL

and the

do not reduce the

53-50-00

Page 101
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
H.

Fittings

and

Forgings
replaced
Chapter 51.)

(1) Fittings
fer to
I.

must be

if cracked

or

if

fitting

hole tolerance exceeds the allowable limits. (Re-

Bolts
must be replaced if fatigue cracks are evident, bolt is bent or there is thread
damage, or if the minimum allowable diameter is exceeded. (Refer to Chapter 51.)

(1) Keelbeam attach bolts

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure

EFFECTIVITY:

ALL

101

53-50-00

Page 102
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


KEELBEAM ASSEMBLIES
1.

REPAIR

APPROVED REPAIRS

C.

RefertoChapterFil fortypicalrepairs.
Repairs provided in this section shall be used in lieu of the typical repairs in Chapter 51,
fied in the repair Figure Number Column of the Repair Indexes.
Refer to Chapter 51 for allowable wear and repair data for keelbeam assembly fittings.

D.

Condition

A.

B.

(1) Damage
ner

F.

speci-

upper and lower

corner

angles extends from fastener location outward

upper and lower

corner

angle extends from fastener location inward to bend radius of

to

edge of cor-

angle.

(2) Damage
E.

to

when

to

angle.
Repair(Conditionl, Detail A)
(1) If damage is in the form of a crack, between fastener locations, stop drill crack with a No. 30 hole.
(2) Clean out crack and smooth edges.
(3) Apply protective treatment to angle.
(4) Fabricate repair angle from same gage and type material. Length of repair angle to be 5 fasteners
either side of damaged area.
(5) Drill out existing fasteners. If necessary, drill out to next oversize.
(6) Apply protective treatment to area and repair angle. Install repair angle.
Repair(ConditionZ Detail B)
(1) Cutout damaged area from corner angle. Cutout must be Ihree to five fasteners either side of
damaged area.
CAUTION:

IF CUTOUT EXPENDS INTO AREA WHERE A GUSSET IS INSTALLED

AND THREE TO FIVE FASTENERS CANNOT BE PICKED

MUST EXTEND TO WHERE

UP, CUTOUT
ADEQUATE FASTENERS CAN BE PICKED

UP TO COMPLETE THE REPAIRS.

WHERE AN ANGLE IS

ENCOUNTERED, IT IS PERMISSIBLE TO LOWER

THE ANGLE BY THE MATERIAL THICKNESS OF THE REPAIR ANGLE

AND INSTALL A SPACER BETWEEN THE ANGLE AND THE TOP CAP.

(2) Fabricate filler, same length as cutout, from same gage and type material of corner angle.
(3) Fabricate two repair angles from same gage and type material as corner angle. Length of repair

angles shall be three to five fasteners either side of end of cutout.


(4) Drill out existing fasteners. If necessary, drill out to next oversize.
(5) Apply protective treatment and install filler and repair angle.

EFFECTIVITY:

SRM-4

ALL

53-50-00

Page 201
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
KEELBEAM ASSEMBLIES

REPAIR

Top Cap
Gusset and/or

Ref)

Angle 7

(Ref)
Corner

Angle

(Ref)

Web

(Ren

bOutboard

Corner

Angle
(ReD

Inboard Corner

Angle
(Ref)

(TYPICAL CROSS SECTION)

Repair Angle
I

Chamfer Corner
450 x O.~ inch

(Same material and gage


Bend radius 0.12 inch.)

asoriginal.

Repair Angle
(Same material and gage
Bend radius 0.19 inch.)

as

original.

Repair Angle
(Make from SS68

angle)

V,Pickup existing fastener location.

Pickup existing fastener location.


Drill

out next

oversize, if necessary.

Drill

DetailB

(TMPLCAL)
Keelbeam Assemblies

2-155A

oversize, if necessary.

(LOWER CORNER OF KEELBEAM)

(UPPER CORNER OF KEELBEAM)

Detail A

out next

Repair

Figure 201
EFFECTIVITY:

SRM-4

ALL

53-50-00

Page 202
May 15/92

Leariet
STRUCTURAL REPAIR MANUAL
FORWARD KEELBEAM

STRUCTURAL IDENTIFICATION

FS160.77

JFS172.19

FS 184.78

Frame #5

Frame #6

(Ref)

(Ref)

Frame#7
(Ref)

16)

(n)

(3) 1

FS 196.99

/FS 209.19

Frame#8

Frame #9

Frame #10

(Ref)

(Ref)

(Ref)

Cls) I (Is) (11)

(a)

(3a)

(13)

(w)

FS 221.59

(It)

IICjli I

(2~ (25)

FS 258.01

Frame #13

Frame #13E

8 6

(Ti

,FS 346.63

Frame #14

(Ref)

Frame #15

(Rcf)

(1

illi ~O .O O O

8 O

to

(ij)

,FS 332.66

I/

Frame #13D

(Ref)

(Ref)

e~

(n~

,FS 283.99

/FS 271.99

(Ref)

g~

Oil

(n)

1)

(6)

(5)

CFWO

2-150R

Forward Keelbeam

Figure
EFFECTNITY:
SRM-4

Repair Index

1 (Sheet 1 of 3)

31-001 AND SUBSEQUENT; 35-001 AND


36-001 AND SUBSEQUENT

SUBSEQUENT;

53-51-00

Page 1
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM
NO.

DWG.
NO.

DESCRIPTION

2611240

1
2
3

4
5

6
7
8

9
10

11
12
13

2611240
2611250

2611250

2611250

RH
LH

LH

REPAIR
FIG. NO.

CODE

RH

2
3

S-537

S-537
S-551
S-55 t
5-551

3
4
5

2024-T4 Clad
2024-T3 Clad
2024-T42 Clad

0.310

0.032

2024-T42 Clad
2024-T3 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

0.063

1
1
1

0.040
0.063

Replace
Replace
I Replace
Replace
I Replace
Replace
I Replace
I Replace
I Replace
I Replace
I Replace
Replace

0.032

Replace

0.063

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

5
5
5
5

5
5
5

0.040

2024-T3 Clad

0.063

2024-T3 Clad

0.032

2611241

Doubler

0.032

Spacer(2 ea.)
Spacer (2 ea.)

2024-T42 Clad
2024-T3 Clad

0.080

Spacer(LH only)

2024-T3 Clad
2024-T3 Clad

Spacer(RH only)
Angle
Angle, Outer
Angle, Inner
Spacer
Angle, Outer
Angle, Inner
Spacer
Ang[e(3 ea.)
Spacer(3 ea.)

2024-T3 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

0.040

1
1

I
I

0.125

2611241
16

2611241

17

2611241

18

2611241
2611241
1 2611241

1
1

2611241
2611241
2611241 1
2611241
2611241 1
2311240
2311240
2311240 1
2311240 1

5
5
5
5

5
5

5
5

Doubler
Doubler
Doubler

5
8
9

Angle(G ea.)
Stiffener(RH only)

Figure
EFFECTIVITY:

31-001 AND
36-001 AND

0.100

0.020

0.063
0.063

2024-T3 Clad
2024-T42 Clad
2024-T42 Clad
2024-T3 Clad
2024-T42 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad

S-549

2024-T42 Clad

Forward Keelbeam

SRM-4

JFINISH

I GAGE

Doubler

15

21

LH

I
MATERIAL

2611241 1

2611241
2611241

22

2611512
2311240
2311512
Tee (2 ea.)
1 2311240
2311241
Fitting
2311240
Spacer
Web
2511240
2611241 1
Stringer
2611241
Angle,
2511240
Splice
Doubler
2311240
Web
2611241
Doubler
2311240
2611241
Angle

2611241

20

LH

SeatRail
SeatRail
SeatRail
SeatRail

2611242

14

19

Assy, Forward,
(W/24-lnch Door)
Keerbeam Assy, Forward,
(W/36-lnch Door)
Keelbeam Assy, Forward,
Keelbeam Assy, Forward,
(W/24-lnch Door)
Keelbeam Assy, Forward,
(W/36-lnch Door)
Keelbeam Assy, Forward,
Keslbeam

2611240

EFF.I

0.080
0.063

0.063
0.040
0.063

0.040
0.063
0.080

I
1

1
1

I
j

1
1

0.080

1
1

Replace
Replace

I Replace

0.032

Replace

Repair Index

Z (Sheet 2 of 3)

SUBSEQUENT; 35-001
SUBSEQUENT

AND

SUBSEQUENT;

53-51-00

Page 2
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ITEM
NO.

DWG.
NO.

23

2311240

24

2311240

25

2311240

26

2311240

Doubler

2311240

Filler

27

2611241

28

2611241
261 i 241

Splice Angle
Spacer (RH only)
Spacer
Spacer
Spacer(LH only)
Angle

29

2611241

2611241
2611241

30

CODES
1

2
3

DESCRIPTION

EFF.

Stiffener(3ea.)
DoubleSplice
Angle(Pea.)

5
5

5
5

5
5
5

10

MATERIAL
S-522
2024-T3 Clad
2024-T42 Clad
2024-T42 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
2024-T42 Clad

GAGE

FINISH
CODE

REPAIR
FlG. NO.

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.040
0.040

0.080
0.080
0.040
0.032

0.100
0.080

0.020
0.063

EFFECTIVITIES
35-001 THRU 35-011; 36-001 THRU 36-006
31-001 AND SUBSEQUENT; 35-012 AND SUBSEQUENT; 36-007 AND SUBSEQUENT

31-001 AND

SUBSEQUENT;

35-012 AND

SUBSEQUENT;

36-007 AND SUBSEQUENT WITH 24-

INCH PASSENGER/CREW DOOR


4
5

6
7
8

10

SUBSEQUENT; 35-012 AND SUBSEQUENT; 36-006 AND SUBSEQUENT WITH 36INCH PASSENGEWCREW DOOR
31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT
35-001 THRU 35-404; 36-001 THRU 36-047
35-405 AND SUBSEQUENT; 36-048 AND SUBSEQUENT
35-001 THRU 35-347; 36-001 THRU 36-045
35-348 AND SUBSEQUENT; 36-046 AND SUBSEQUENT
35-506 AND SUBSEQUENT; 36-054 AND SUBSEQUENT
31-001 AND

Forward Keelbeam

Figure
EFFECTIVITY:
SRM4

Repair Index

(Sheet 3 of 3)

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT

53-51-00

Page 3
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
DAMAGE

FOBWARD KEELBEAM
i.

ALLOWABLE DAMAGE LIMITS


All dimensions

NOTE:
A.

are

in inches unless otheMrise

specified.

Fasteners

(1) Loose
tions

or

on

failed rivets
the

are

remaining

not allowed. A loose or

rivets and lead to

failed rivet

can cause

increased stress concentra-

failure. A careful

progressive joint
inspection must be
from
the
of
the
loose
or failed rivet. (Rearea
spread

that joint failure has not

performed to ensure
fer to Chapter 51 for definition of rivet failure.)
(2) Loose

or

failed

screws are not

allowed. A loose

or

failed

screw can cause

increased stress

concen-

trations on surrounding screws and lead to progressive joint failure. A careful inspection must be
performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
B.

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

re-

paired, and refinished in accordance with Chapter 51.


(3) Cracks in the keelbeam structure
C.

are

not allowed.

Deformation

(1) Deformation of any kind to the keelbeam structure is not allowed.


(2) Slight deformation of outboard bulkheads is permissible if such deformation does
ference with

adjacent

structure

or

plumbing

and does not

prohibit

not cause inter-

the installation of the

access

covers.

D.

Corrosion(See Figure 101.)


(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired
rial thickness more than specified.

E.

or

replaced

if corrosion

repair reduces

the

original

mate-

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component reF.

G.

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, an epoxy primer and/or exterior
paint is applied, and the repairs do not reduce the original material thickness more than specified.
(Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, an epoxy primer and/or exterior
paint is applied, and the repairs do not reduce the original material thickness more than specified.
(Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.

EFFECTIVITY:

ALL

53-51-00

Page
SRM~

101

May 15/92

STRUCTURAL REPAIR MANUAL


H.

I.

Fittings andForgings
(1) FitHngs must be replaced
fer to Chapter 51.)

if cracked

or

if

fitting hole

tolerance exceeds the allowable limits. (Re-

Bolts

(1) Keelbeam attach bolts

damage,

or

must be

replaced if fatigue cracks are evident, bolt is bent or there


Chapter 51.)

is thread

if the minimum allowable diameter is exceeded. (Refer to

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFFECTIVITY:
sI~M-1

ALL

101

53-51-00

Page 102
May 15/92

STRUCTURAL REPAIR MANUAL


FORWARD KEELBEAM -REPAIR
i.

APPROVED REPAIRS
A.
B.

RefertoChapter51 fortypicalrepairs.
Refer to 51-50-00 for keelbeam specific repairs.

EPPECTIVII"Y:
SRM4

ALL

53-51-00

Page 201
May 15/92

L~arjet
Learjet

STRUCTURAL REPAIR MANUAL


UNDERWING KEELBEAM

STRUCTURAL IDENTIFICATION

BL 0.00

1?(ReD

of

(MEW LOOKING AFD


(TYPICAL)

FS

271.4 (Model

23

Detail B

24)

(Model 25, 35

36)

Sta 421.22

(Ref)
(Model 23

SF89.4&3

(Model 25, 35

36)

(Ref)

36)

FS 411.95

(Ref)
(Model 23

24)

FS 261.97

235.00

(Model 25, 35
FS

(Model 23

24)

1
n

24)

FS 227.35

(Model 25, 35

,o

36)

FS 377.53

(Ref)
(Model 23

24)

FS 205.51

(Mode125,
FS

\I

35

355.49/

(Ref)
i,
2

i/

-(1

15

-i~
blOC

EFFECTIVITY:

Detail A
Underring Keelbeam Repair Index
Figure 1 (Sheet 1 of 7)

23-002 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-373;


SUBSEQUENT; 36-001 AND SUBSEQUENT

35-001 AND
sRM-a

oz~JB
53-53-00

Page

Tun 1/95

Learjet
STRUCTURAL REPAIR MANUAL
UNDERWING KEELBEAM

STRUCTURAL IDENTIFICATION
BL 0.00

(ReD

12

25

(VIEW LOOKING AFT)

(TYPICAL)

DetailB

FS 421.22

(Ref)
FS 411.95

33

3a

(Ref)

34

19

FS 384.98

(Ref)
30

FS 377.53

(Ref)

~s

I"

~29

FS 355.49

(Ref)

(I

~y

1~

PP~

(5

15)

(?3

1
31)

22

it

4-10C-1

EFFECTIVITY:

Underwing Keelbeam Repair Index


Figure 1 (Sheet 2 of 7)
28-001 THRU 28-005; 29-001 THRU 29-004;
31-002 AND

SRM-8

Detail A

SUBSEQUENT

53-53-00

Page 2
jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


UNDERW~NG KEELBEAM

STRUCTURAL IDENTIFICATION

FS431.48

(Ref)

FS

4d3.26

(Ref)

~pP

FS 369.54

(Ref)
FS 3~6.63

(Ref)
4-81C

EFFECTIVITY:

Detail A
Underwing Keelbeam Repair Index
Figure 1 (Sheet 3 of 7)
31-105 AND SUBSEQUENT

53-53-00

Page 3
SRM-I

Jun 1/95

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

2311600
2

3
4

5
6

UndeMling
(2 ea.)
(2 ea.)
Access Cover (RH only)
Access Cover, (2 ea.)
Access Cover (LH only)

2311600
2311600

2311600

10

2311600
2311600

11

12

13

2327014
2311610

12225-0032
2311610

12225-0032
2311610

15

12225-0032
2311610
2311610

16

2311610

17

2311610
2311610
2311 610
2311610
2311610
2311610
2311610
2311610
2311610
2311610

14

18

19
20

2024-T3
2024-T3
2024-T3
2024-T3
2024-T3

2024-T42 Clad

2024-T42 Clad
2024-T42 Clad
6061-T6

2
3
4

Seal

Angle (2 ea.)

Bulkhead
Gusset Assy. (4
Gusset
Filler
Bulkhead Assy.,
Bulkhead
Slice Plate
Bulkhead Assy.,
Bulkhead
Doubler
Bulkhead Assy.,
Bulkhead

LH 8 RH

ea.)

2311610

REPAIR

CODE

FIG. NO.

Clad
Clad
Clad
Clad
Clad

0.032

F4-6

51-70-02

0.032

F4-6

51-70-02

0.063
0.063
0.063
0.032
0.050 1
0.050 1

F4-6
F4-6
F4-6
F4-6

0.040

F4-1

51-70-02
51-70-02
51-70-02
51-70-02

1
1

51-70-02
51-70-02
51-70-02

I
I
LH 8 RH

1
1

LH 8 RH

F4-6

51-70-03

2024-T42 Clad

0.050

F4-6

51-70-02

2024-T42 Clad
2024-T3 Clad

0.050

F4-6

51-70-03

0.063

F4-6

51-70-02

2024-T42 Clad
2024-T42 Clad

0.0251
0.032

F4-6
F4-6

51-70-03
51-70-02

2024-T42 Clad
2024-T3 Clad

0.025

F4-6
F4-6

51-70-03
51-70-02

F4-6
F4-6

51-70-02

F4-6
F4-6

1
1

LH 8 RH

0.032

1
1

Support Angle
UnderwingKeelbeamAssy.
Underwing Keelbeam Assy.
Top Cap
Top Cap
Top Angle LH 8 RH
Top Angle LH 8 RH
Angle(2 ea.)
Angle(4 ea.)

Angle(lO ea.)
Angle(8 ea.)
Angle(5 ea.)
HingeAssy.
Hinge Half (2 ea.)
Hinge Pin

0.025

1
1

Bracket

2024-T42 Clad

2024-T3 Clad
S-571

0.050

51-70-03

8
9

22 Bondolite

2024-T3 Clad
S-568

8
9
11
1

Angle, LH 8 RH
Angle LH 8 RH (3 ea.)
Angle LH 8 RH (2 ea.)
Filler(4ea.)
BracketAssy.

2311610

IFINISH

GAGE

Access Cover (4 ea.)


Seal Angle (6 ea.)

Clip (4 ea.)
Bulkhead Assy.,

MATERIAL

Fuel Vent Cover


Keel Beam Assy.

2311600
8

EFF.

Keelbeam Instl.,
Access Cover
Access Cover

2311600
2311600
2311600
2388366
2688149
2311600
2311600
2311600
2323018
2311600
2311600
2311600
2311600
2311600
2311600
2311600
2311600
2311600

I
DESCRIPTION

8
8
9
1

0.091
0.050

S-568
2024-T42 Clad
2024-T42 Clad
2024-T3 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

0.063
0.063

Replace
Replace
Replace
Replace
Replace
Replace

F4-6
F4-6

0.032

F4-6
F4-6

0.080

F4-6

0.063

F4-6

0.063
0.032

F4-6

Replace
Replace
Replace
Replace
Replace

F4-6

2024-T42 Clad

0.071

F4-6

8
14

2024-0 Clad
2024-0 Clad

0.063
0.063

F4-6
F4-6

15

2024-0 Clad

0.063

F4-6

Replace
Replace
Replace
Replace

1
1

D
D

I
3/16

Replace
Replace

Underwing Keelbeam Repair Index


Figure 1 (Sheet 4 of 7)
EFFECTIVrTY:

SRM-4

ALL

53-53-00

Page 4
Jun1/95

Leariet

STRUCTURAL REPAIR MANUAL

21

22

23

DWG.
NO.

ITEM
NO.

DESCRIPTION

24

25
26

27

28

29

14
12

19

8
14

8
9
8

Gusset(3ea.)
Gusset(3 ea.)
Angle, LH 5 RH

17

Stiffener

10

Stiffener
Bracket

16

Fillers(S ea.)
Fillers(2ea.)

19

Fillers(2 ea.)
Strap(8 ea.)
Doubler(2 ea.)
Angle LH 8 RH
Angle LH 8 RH
Angle (2 ea.)
Angle LH 8 RH (2 ea.)
Angle LH 8 RH (3 ea.)

12225-0032
12225-0032
122250032
12225-0032
12225-0032
12225-0032

1
1

2516055
2516055
2516055
2516055
5404010
5404010
5404010
3111954
3111955
3111955
3111955
3111955
3111955

Bracket, LH RH
Bracket, LH RH

Spacer

17

9
14
14
9
9

14
16

14

Fitting, Fwd (2 ea.)


Fitting, Aft (2 ea.)
BracketAssy., LH RH

2311611

Fillers (2 ea.)

2311611

33
34
35
36
37
38
39
40

F4-6

Fwd Cover
Fwd Cover
CenterCover

12225-0032\

32

F4-6

0.090
0.100

2311610

12225-0032

0.090

14

12225-0032
12225-0032

31

2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
6061-0
6061-0
2024-0 Clad
2024-T3 Clad
2024-T3 Clad

Fillers(3 ea.)

12225-0032(

30

Fillers (2 ea.)

CenterCover
AftCover
AftCover
Web LH 8 RH
Web LH 8 RH

Angle
ARgle

8
8
8

Filler (2 ea.J
Doubler, LH 8 RH (2 ea.)
Stiffener, LH 8 RH
Stiffener, LH 8 RH (2 ea.)

15

15
15
15
15

15

2024-T3 Clad
2024-T3Clad
2024-T3 Clad
2024-T3Clad
2024-T3Clad
2024-T3 Clad
2024-0 Clad
S-571
2024-0 Clad
2024-0 Clad
5-571
S-571

0.040

F4-6

F4-6
F4-6
F4-6
F4-6
F4-6
F4-6
F4-6

F4-6

0.090

F4-6

1 0.090)

F4-6

0.032
0.100

F4-6
F4-6
F4-6
F4-6
F4-6
F4-6
F4-6
F4-6

0.040

0.040
0.080

I
0.063
0.063

Replace

0.050
0.032

F4-1

0.090

F4-1

1
I

I
0.080
0.080
0.063
0.080

0.050
0.063
0.080

Replace
Replace
Replace
Replace
51-70-00

1
F4-1
F4-1

Replace
Replace
Replace
Replace
Replace
Replace

I
I
I

2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
S-678
S-501
2024-T3 Clad
2024-0 Clad
2024-0 Clad
2024-73 Clad
2024-T3 Clad
2024-0 Clad
2024-0 Clad

F4-6
F4-6
F4-6

F4-6

0.040

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

F4-6

0.100
0.050
0.100
0.1001
0.100
0.080
0.080
0.080
0.080
0.063

D
D

Doubler

Angle, LH 8 RH
Angle(S ea.)

FIO. NO.

GAGE

12225-0032

12225-0032
2311610
2311610
2311610
12225-0032
2311610
12225-0032
2311610
12225-0032
2311610
2311610
12225-0032
S-151
12225-0032

REPAIR

CODE

MATERIAL

2311610

JFINISH
EFF.

F4-6

F4-6
F4-6
F4-6
F4-6
F4-6
F4-6

51-70-00

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Underwing Keelbeam Repair Index


Figure 1 (Sheet 5 of 7)
EFFECT~VITY:

ALL

53-53-00

Page5
SRM-4

Jun 1/95

Learjet
~tJ

STRUCTURAL REPAIR MANUAL


ITEM
NO.

DWG.
NO.

41

2111955

42

2111955

DESCRIPTION
Filler

21 1 1 955
31 1 t 950
43
44
45

(4 ea.)

Filler (2 ea.)
Filler (2 ea.)
Skit Plate Instl.
Skid Plate, Fwd
Skid Plate, Center
Skid Plate, Aft

3111951
3111952
3111953

CODE

MATERIAL

GAGE

15

2024-T3 Clad
2024-T3 Clad
2024-T3 Clad

0.063

F4-6

0.100

F4-6

0.032

F4-6

7075T7351 AL
7075T7351 AL
7075T7351AL

2.000
2.000

F4-6

2.000)

F4-6

15
15

REPAIR
FIG. NO.

(FINISH

EFF.

Replace
Replace
Replace

15
15
15
15

F4-6

Replace
Replace
Replace

Underwing Keelbeam Repair Index


Figure 1 (Sheet 6 of 7)
EFFECTIVITY:

ALL

53-53-00

Page 6
sRM-a

Jun 1/95

Learjet
~1

STRUCTURAL REPAIR MANUAL


CODES

EFFECTIVITIES
23-002 THRU 23-099; 24-100 THRU 24357; 25-002 THRU 25373; 28-001 THRU 28005; 29-001
THRU 29-004; 31-002 AND SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSE-

QUENT
23-003 THRU 23-099; 24-100 THRU 24-197; 25-002 THRU 25033
24-240 THRU 24-357; 25-034 THRU 25-357; 35-001 AND SUBSEQUENT; 36-001 AND SUBSE-

QUENT
24-240 THRU 24-350; 25-034 THRU
24-251 THRU 24-357; 25-227 THRU

25-226; 35-001 THRU 35124; 36-001 THRU 36-032


25373; 35-125 AND SUBSEQUENT; 36-033 AND SUBSE-

QUENT
24-100 THRU 24-357; 25-002 fHRU

25-373; 35-001 AND SUBSEQUENT; 36-001 AND SUBSE-

QUENT
23-002 THRU 23639
23-002 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25373; 35-001 AND SUBSEQUENT;
36-001 AND SUBSEQUENT
28001 THRU 28-005; 29-001 THRU 29-004; 31-002 AND SUBSEQUENT
25002 THRU 25-373; 28-001 THRU 28005; 24001 THRU 29-004; 35-001 AND SUBSEQUENT;
36-001 AND SUBSEQUENT
2&001 THRU 28-005; 29-001 AND 24002; 31-002 AND SUBSEQUENT
23-002 THRU 23-099
23-090 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-373; 35-001 AND SUBSEQUENT;
36-001 AND SUBSEQUENT
2&001 THRU 28-005; 29-001 THRU 29004; 31-002 THRU 31-104
31-105 AND SUBSEQUENT
31-002 AND SUBSEQUENT
31-019 AND SUBSEQUENT
24-308, 24-323 THRU 24-357; 25-002 THRU 25-373; 2&001 THRU 2&005; 29-001 THRU 24004;
31-002 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;.36-001 AND SUBSEQUENT
24-100 THRU 24-357; 25-002 THRU 25373; 28-001 THRU 2&005; 29~01; 31-002 THRU 31-105;
35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

8
9

10
11
12

13
14

15
16
17
18
19

NOTES:

Madefrom MS20257XC5.
302B Stainless Steel Rod, Heat Treat per Mll-S-7720A.

Aluminum 2014T6

forging.

Underwing Keelbeam Repair Index


Figure 1 (Sheet 7 of 7)
EFFECTIVITY:

ALL

53-53-00

Page7
SRM-4

Jun 1/95

Learjet
LBarjet

STRUCTURAL REPAIR WIANUAL


ALLOWABLE DAMAGE

UNDERWING KEELBEAM
i.

ALLOWABLE DAMAGELIMITS
All dimensions

NOTE:
A.

in inches unless otherwise

are

specified.

Fasteners

(1) Loose

or

failed rivets

are not

allowed. A loose

or

failed rivet

can cause

increased stress concentra-

progressive joint failure. A careful inspection must be


performed to ensure that joint failure has not spread from the area of the loose or failed rivet. (Refer to Chapter 51 for definition of rivet failure.)
tions

the

on

(2) Loose

or

trations

remaining

failed

on

rivets and lead to

screws are not

surrounding

allowed. A loose

screws

and lead to

or

failed

screw can cause

progressive joint

increased stress

failure. A careful

concen-

inspection must be

performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
B.

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked


(2) Cracks in components other than fittings and forgings

paired, and refinished in accordance


(3) Cracks in the keelbeam
C.

with

fittings or forgings must be replaced.


considered allowable if properly

are

re-

Chapter 51.

structure are not allowed.

Deformation

(1) Deformation of any kind to the keelbeam structure is not allowed.


(2) Slight deformation of outboard bulkheads is permissible if such deformation does
ference with

adjacent

structure or

plumbing

and does not

prohibit

not cause inter-

the installation of the

access

covers.

D.

Corrosion(SeeFigure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired
rial thickness more than specified.

E.

or

replaced

if corrosion

repair reduces

the

original

mate-

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 100/o of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to
F.

G.

rivet

or

structural

area.

Such dents shall be

repaired

or

the

component

re-

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, an epoxy primer and/or exterior
paint is applied, and the repairs do not reduce the original material thickness more than specified.
(Refer to Chapter 51 for protective treatment procedures.)
Structural
(2)
components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(See Figure 101.)
(1) Nicks are permissible if the affected

paint

is

(Refer

ness more

EFFECTIVITY:

and the

ALL

area

is sanded smooth, an epoxy primer and/or exterior


original material thickness more than specified.

do not reduce the

repairs
protective treatment procedures.)
components must be replaced or repaired if nicks
than specified.

applied,
Chapter 51

to

(2) Structural

SRM~

for

reduce the

original

material thick-

53-53-00

Page 101
May 15/92

STRUCTURAL REPAIR MANUAL


H.

andForgings
must be replaced
fer to Chapter 51.)

Fittin~s

(1) Fittings
I.

if cracked

or

if

fitting

hole tolerance exceeds the allowable limits. (Re-

Bolts
must be replaced if fatigue cracks are evident, bolt is bent or there is thread
damage, or if the minimum allowable diameter is exceeded. (Refer to Chapter 51.)

(1) Keelbeam attach bolts

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFFECTNITY:
SRM-4

ALL

101

53-53-00

Page 102
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
UNDERWING KEELBEAM
i.

REPAIR

APPROVED REPAIRS

A.
B.

RefertoChapterS1 fortypicalrepairs.
specific repairs.

Refer to 51-50-00 for keelbeam

EFFECTIVITY:
SRM~

ALL

53-53-00

Page 201
May 15/91

Learjet
~ti
STRUCTURAL REPAIR MANUAL
AFT FUSELAGE KEELBEAM

STRUCTURAL IDENTIFICATION

00000

3)

(10)(1

L/

A
O

j
1 ~50 m

_~

(VIEW LOOKING AFT)

Detail B

B,

CFWD
(TYPICAL)
(VIEW LEFT SIDE LOOKING INBOARD)

Detail A
Aft

EFFECTIVITY:

Fuselage Keelbeam Repair Index


Figure 1 (Sheet 1 of 2)

31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT

SRM-4

53-55-00

Page 1
May 15/92

Learjet

STRUCTURAL:REPAIR MANUAL
ITEM

DWG.

NO.

NO.

FINISH
CODE

REPAIR
FIG. NO.

0.090

F4-1

51-70-02

2312017
2312017

Plate

6061-T6

2312017

Tube

2312017

Cover

2024-T3 Clad

0.050

2512017

Splice Plate

2024-T42 Clad

0.063

S-571
2024-T3 Clad
2024-T3 Clad

0.032
0.100
0.063

2312017

2512017
1 2512017
2312017
2312017

GAGE

2512017
2312017
2312017

MATERIAL

EFF.

AftFuselageKeelbeam Instl.
Cap Plate
Angle, LH 8 RH
Angle (2 ea.)
Tee(2 ea.)
Drain Assy.

2512017
1

DESCRIPTION

2312017
6

2312018

Keelbeam Assy., LH
Angle(4ea.)

6 RH Aft

2024-T3 Clad
S-571
2024-T3 Clad

S-596

1
1

1
i

Shim

Fitting

0.050

2024-T3 Clad

I~

F4-1

2312017

Doubler

2024-T3 Clad

0.050

2312017

SupportAngle

0.032

Webb

2024-T3 Clad
2024-T42 Clad
S-568
2024-T42 Clad
2024-T42 Clad

2512017

10

2512017

11

2512017

12

2512017

CODES

0.040

F4-1
F4-1

0.068

F4-1

0.080

F4-1

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

EFFECTIVITIES
31-001 AND

Angle, Upper
Angle,Lower
Angle, Lower

Replace
Replace
Replace
Replace

F4-1

1
1

Shim
Shim

Replace
Replace
Replace
Replace
Replace
Replace

0.063

SUBSEQUENT; 35-001 AND SUBSEQUENT;

36-001 AND SUBSEQUENT

NOTES:
Fabricated from 6061T6 0.375 O.D. X 0.035 I.D. Seamless

I~

Forging-2014T6

Aft

EFFECTNITY:
SRM-4

tubing

Fuselage Keelbeam Repair Index


Figure 1 (Sheet 2 of 2)

SUBSEQUENT; 35-001 AND SUBSEQUENT;


36-001 AND SUBSEQUENT

31-001 AND

53-55-00

Page 2
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
AFT FUSELAGE KEELBEAM

i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGE LIMITS


All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose

or

failed rivets

are

not allowed. A loose

or

failed rivet

can cause

increased stress concentrainspection must be

failure. A careful

rivets and lead to

on
progressive joint
remaining
performed to ensure that joint failure has not spread from the area of the loose or failed
fer to Chapter 51 for definition of rivet failure.)

the

tions

(2) Loose

or

trations

failed

on

performed
B.

screws are not

surrounding

to ensure that the

or

failed

screw can cause

increased stress

failure. A careful

and lead to

progressive joint
joint failure has not spread from the area

inspection

of the loose

or

concen-

must be

failed

screw.

Cracks
(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly
paired, and refinished in accordance with Chapter 51.

(3) Cracks in the keelbeam


C.

allowed. A loose

screws

rivet. (Re-

structure

are

not

re-

allowed.

Deformation

(1) Deformation of any kind to the keelbeam structure is not allowed.


(2) Slight deformation of outboard bulkheads is permissible if such deformation does
ference with

adjacent

structure

or

plumbing

and does not

prohibit

not cause inter-

the installation of the

access

covers.

D.

Corrosion(See Figure 101.)


(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired
rial thickness more than specified.

E.

or

replaced

if corrosion

repair reduces

the

original

mate-

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.300 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component reF.

G.

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, an epoxy primer and/or exterior
paint is applied, and the repairs do not reduce the original material thickness more than specified.
(Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, an epoxy primer and/or exterior
paint is applied, and the repairs do not reduce the original material thickness more than specified.
(Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.

EFFECTIVITY:
SRM-4

ALL

53-55-00

Page 101
May 15/92

Learjet
STRU~TURAL REPAIR MANUAL
H.

I.

Fittingsand Forgings
(1) Fittings must be replaced
fer to Chapter 51.)

if cracked

or

if

fitting

hole tolerance exceeds the allowable limits. (Re-

Bolts
must be replaced if fatigue cracks are evident, bolt is bent or there is thread
damage, or if the minimum allowable diameter is exceeded. (Refer to Chapter 51.)

(1) Keelbeam attach bolts

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063
0.071

0.059

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.250

0.180

0.237

Allowable Material Thickness

Figure
EFFECTIVITY:
SRM~

ALL

101

53-55-00

Page 102
May 15/92

STRUCTURAL REPAIR MANUAL


AFT FUSELAGE KEELBEAM
1.

REPAIR

APPROVED REPAIRS
A.
B.

RefertoChapter51 fortypicalrepairs.
specific repairs.

Refer to 51-50-00 for keelbeam

EFFECTIVITY:
SRM-4

ALL

53-55-00

Page 201
May 15/92

CHAPTER

NACELLES
PYLONS

Learjet
STRUCTURAL REPAIR MANUAL
Chapter
Section

Subject

Subject
STRUCTURAL IDENTIFICATION

NACELLES AND PYLONS

....................................54-00-00

Description
RepairIndex
Allowable Damage.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,. . . . . . . . . . .54-00-00
Skin Gap Tolerances

............................................................................................................................54-00-00

NACELLE FIREWALL

Description

54-00-00

STRUCTURAL IDENTIFICATION

1
2
.............................................................54-10-10

101

....................................................................................................54-10-10

Approved Repairs

201

..........................54-10-10

STRUCTURAL IDENTImCATION.....................................54-20-10

UPPER COWL ASSEMBLY

Upper Cowl Assembly Repair Index


UPPER COWL ASSEMBLY

54-20-10

ALLOWABLE DAMAGE

101

REPAIR. . . .,. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54-20-10

Approved Repairs

....54-20-10

LOWER COWL ASSEMBLY STRUCTURAL IDENTIFICATION


Lower cowl Assembly Repair Index
LOWER COWL ASSEMBLY ALLOWABLE DAMAGE....................................................54-20-20
Allowable Damage Limits..........
LOWER COWL ASSEMBLY REPAIR

54-20-20

101

..................................................................................54-20-20

Approved Repairs. . . . . . . . . . . . . . . . . . . . . . . . ,. . . . . . . . . . . . . . 54-20-20

201

STRUCTURAL IDENTIFICATION

Description
Engine Inlet Assembly Repair Index

..................................54-30-10

............................................................................................................................54-30-10

Allowable Damage Limits


ENGINE INLET ASSEMBLY

201

...................................54-20-20

...................................................................................54-20-20

ENGINE INLET ASSEMBLY

.....................................................54-20-10

....................................................................................................54-20-10

UPPER COWL ASSEMBLY

ENGINE INLET ASSEMBLY

............................................54-10-10

............................................................................................................................54-10-10

Damage Limits

54-00-00

Nacelle Firewall Assembly Repair Index.. . . . . . . . . . . . . . . . . . . . . . . . . . .,. . . . . . . . . . .54-10-10


NACELLE FIREWALL ALLOWABLE DAMAGE
Allowable Damage Limits
NACELLE FIREWALL REFAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54-10-10

Allowable

Page

..........................................54-30-10

ALLOWABLE DAMAGE

54-30-10
101

....................................................................................................54-30-10

REPAIR

.................................................................................54-30-10

...........54-30-10

Approved Repairs............

201

DUCT ASSEMBLY, FAN, EXHAUST AND INNER WALL


STRUCTURAL IDENTIFICATION..............................................................................5430-20
Duct Assembly, Fan, Exhaust and Inner Wail Repair Index
DUCT ASSEMBLY, FAN, EXHAUST AND INNER WALL
ALLOWABLE DAMAGE
Allowable Damage Limits
DUCT ASSEMBLY, FAN, EXHAUST AND INNER WALL

...........................................54-30-20

....54-30-20
101

....................................................................................................54-30-20

REPAIR

.............................54-30-20

Approved Repairs

.........54-30-20

ENGINE NACELLE AFTERBODY STRUCTURAL IDENTIFICATION


Engine Nacelle Afterbody Repair Index
(Earlv Mode135/36 Series Aircraft)
......................................~...........................................54-30-30

Engine

Nacelle

Afterbody Repair

201

.54-30-30
1

Index

(Latc: Model 35/36 Series Aircraft and 31 Series Aircraff)................................................54-30-30

54-Contents

SRM-d

Page 1
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


Chapter
Section

Subject

Subject
ENGWE NACELLE AF~ERBODY
Allowable Damage Limits
ENGINE NACELLE AF~ERBODY

ALLOWABLE DAMAGE.........................................54-30-30
101

....................................................................................................54-30-30

REPAIR

Approved Repairs.......
ENGINE EXHAUST NOZZLE ASSEMBLY

Engine

Exhaust Nozzle

Damage Limits

....54-30-30
STRUCTURAL IDENTIFICATION .........54-30-40

........................................................54-30-QO

201
.......................................................................54-50-00

Pylon Repair Index.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54-50-00


ALLOWABLE DAMAGE

Allowable

Damage

Limits

Approved Repairs

1
........................................................................................54-50M)

101

....................................................................................................54-50-00

PYLON-REPAIR

54-30-40
101

REPAIR

..................................................................................................................54-30-40

PYLON- STRUCTURAL IDENTIFICATION


PYLON

201
1

...............................................................54-30-40

ALLOWABLE DAMAGE

.............,,..............,......................................................................54-30-40

ENGINE EXHAUST NOZZLE ASSEMBLY

Approved Repairs

.......................................................................54-30-30

Assembly Repair Index

ENGINE EXHAUST NOZZLE ASSEMBLY

Allowable

Page

........................................54-50-00

..,...............................................................................................................54-50-00

201

54-Contents

Page 2
SRM-4

May 15/92

STRUCTURAL REPAIR MANUAL


Chapter

Chapter

Section

Section

Page

Subject
54-TTTLE
54-List of Eff.
54-Contents
54-Contents
54-00-00
54-00-00
54-00-00
54-00-00
54-10-10
54-10-10
54-10-10
54-10-10

Pgs.

1
1
2
1

2
3
4
1

2
3

101

54-10-10
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102

54-20-10
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54-30-30

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May 15/92
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May 15/92
May 15/92
May 15/92

Subject
54-30-30
54-30-30
54-30-30
54-30-30
54-30-30
54-30-30
54-30-30
54-3030
54-30-40
54-30-40
5430-40
54-3040
54-30-40

54-50-00
54-50-00
54-50-00
54-50-00
54-50-00
54-50-00
54-50~0
54-50-00

Page
4

5
6
7
8

101
102

20t
1
2

101
102
201
1

2
3
4

5
101
102

201

54

sffM~

Date

May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 15/92

Pages
Pagel
May 15/92

List of Effective

Learjet
STRUCTURAL REPAIR MANUAL
NACELLES AND PYLONS
1.

STRUCTURAL IDENTIFICATION

DESCRIPTION

The

NOTE:

the

following structural data covers the basic non-modified aircraft. When applicable, refer to
appropriate kit drawing for additions, modifications and changes to the structural compo-

nents and assemblies.

A.

chapter covers structural components, allowable damage limits,


plicable), and repair procedures for nacelles and pylons.

This

skin gap tolerances (where ap-

REPAIRINDEX
A.

An

engine nacelle and pylon master repair index is provided


pylon assemblies throughout this Chapter. (See Figure 1.)

to aid in the location of

specific

nacelle

and
3.

ALLOWABLE DAMAGE
A.

Allowable damage limits for nacelle and pylon components are provided in each
Refer to nacelle and pylon master repair index (Figure 2) for specific sections.

respective

section.

SKIN GAPTOLERANCES

4.

A.

Skin gap tolerances for nacelle and

EFFECTNITY:

ALL

pylon are given in Figure 2.

54-00-00

Page
SRM-P

May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

a~
Chapter
Section

Description

Item
1
2

3
4

6
7

Firewall

Assembly
Upper Cowl Assembly
Lower Cowl Assembly
Engine Inlet Assembly
Duct/Fan/Exhaust Assembly
Engine Nacelle Afterbody
Nozzle Assembly, Engine Exhaust
Pylon Assembly

Subject
54-10-10
54-20-10

54-20-20
54-30-10
54-30-20

54-30-30
54-30-40
54-50-00

(TYPICAL)
Nacelle and

EFFECTIVITY:
SRM4

ALL

Pylon Master Repair Index


Figure 1
54-00-00

Page 2
May 15/92

STRUCTURAL REPAIR NIANUAL

0.060 in.

max.

0.000 in. min.

0.060 in.

max.

0.000 in. min.

0.090 in.

max.

0.030 in. min.

0.060(+0.060)in.

Inlet Skin

(VZEW LOOKING FORWARD AT AIR INTAKE TUBE)

Detail A

757A
754A

EFFECTNITY:
SRM4

Engine Nacelle Installation Skin Gap Tolerances


Figure 2 (Sheet 1 of 2)
MODEL 23/24/25/28/29 SERIES AIRCRA~

54-00-00

Page 3
May 15/92

Learjet

0.040 (+0.000/-0.020) in.

0.030 in.

max.

i
0.030 in.

max.

-~c)Je

i)

11

0.040 in.

max.

0.040 in.

max.

0.020(+0.000/-0,020)in.

Refer to 52-40-00 for Oil Filler

Access Door Skin

Gap

Inlet Skin

0.060(+0.060)in.

ENGINE INLET ASSEMBLY

NOTES

Dn Aircraft 32-002 thru 31-022: 35-002 thuu 35-659: 361002 fhru 36-959. 36-062 and 36-963:

0.120 in.

max./0.030 in. min.


On Aircraft 31-022 and Subsenuent: 35-660 and Swbsc~uent; 36-060, 36-061. 36-064 and Subseauent
0.090 in max./0.030 in min.

I~

Maximum allowable variance of 0.030 inches

7-57A
754A

EFFECTIVITY:
srzM-4

over

any 18 inch section.

Engine Nacelle Installation Skin Gap Tolerances


Figure 2 (Sheet 2 of 2)
MODEL 31/35/36SERIES AIRCRAFZ~

54-00-00

Fage 4
May 15/92

Leariet
STRUCTURAL R:EPAIR MANUAL
NACELLE FIREWALL
1.

STRUCTURAL IDENTIFICATION

DESCRIPTION
A.

The nacelle firewall

assembly is constructed basically of stainless steel

and

provides for

attachment of

hydraulic lines, electrical wiring feedthruq engine controls, and other systems. The firewall
assembly is installed to prevent the spread of heat or fire into the pylon and fuselage area.
fuel and

B.

cating

and

EFFECTIVITY:
SRM-4

assembly repair index (Figure 1)


identifying structural components.

The nacelle firewall

ALL

is

provided

to aid maintenance

personnel

in lo-

54-10-10

Page 1
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
NACELLE FIREWALL

STRUCTURAL IDENTIFICATION

.,o

Ba

oOO

D1B
(LH SHOWN, RH TYPZCAL)

Detail A
A7-30C

Nacelle Firewall

Figure
EFFECTIVITY:
sRM-a

Assembly Repair Index

(Sheet 1 of 2)

MODEL 31/35/36 SERIES AZRCRAF~

54-10-10

Page 2
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

NO.

DWG.
NO.

2652030

Stiffener

2024-T42 Clad

0.040

2652030

Stiffener

2024-T42 Clad

0.032

2652030

Stiffener

2024-T42 Clad

0.032

2652030

Stiffener

2024-T42 Clad

0.032

ITEM

EFF.

DESCRIPTION

2652030

Firewall

Assembly, LH and

RH

MATERIAL

GAGE

2652030

Stiffener

2024-T42 Clad

0.040

2652030

2024-T42 Clad

0.040

2652030

Angle
Spacer

2024-T3 Clad

0.020

2652030

Channel

S-735

2652030

Skin

321 Stainless

0.025

2652030

Filler

321 Stainless

0.025

2652030

Doubler

321 Stainless

0.032

2652055

Fire Seal

301 Stainless

0.020

10

2652030

Stiffener

2024-T42 Clad

0.032

11

2652030

Channel

S-735

12

2652030

Channel

S-735

13

2652030

Longeron

2024-T42 Clad

2652030

Guide Retainer

2652030

Guide Retainer

CODES

ea.)
ea.)

0.040

0.032

1~

0.032

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

EFFECTIVITIES
31-001 AND

(LH,
(RH,

REPAIR
FIG. NO.

FINISH
CODE

SUBSEQUENT; 35-002 AND SUBSEQUENT; 36-002 AND SUBSEQUENT

NOTES:

I~

finish

F14-1 inside after

assembly,

301 Stainless Full

Hard, optional

no

to

on

use

outside.

301 Stainless 3/4 Hard.

Condition annealed.

Nacelle Firewall

Figure
EFFECTIVITY:

Assembly Repair Index


1

(Sheet 2 of 2)

MODEL 31/35/36SERIES AIRCRAFT

54-10-10

Page 3
SRM~

May 35/92

Learjet
~Learjet/
STRUCTURAL REPAIR MANUAL
NACELLE FIREWALL
i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS
All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

or

failed rivets
the

on

are

not allowed. A loose

or

failed rivet

can cause

increased stress concentra-

progressive joint failure. A careful inspection must be


that joint failure has not spread from the area of the loose or failed rivet. (Re-

remaining

rivets and lead to

performed to ensure
fer to Chapter 51 for definition of rivet failure.)
(2) Loose

or

failed

screws are not

allowed. A loose

or

failed

screw can cause

increased stress

concen-

and lead to

progressive joint failure. A careful inspection must be


performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
trations
B.

on

surrounding

screws

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly
paired, and refinished in accordance with Chapter 51.
C.

Deformation

D.

(2) Deformation of the nacelle firewall structure is not allowed.


Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly

re-

repaired, refinished in accordance


Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness more than specified.
with

E.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component reF.

G.

H.

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings andForgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
or forgings with bushing shall be repaired.

(2) Fittings

EFFECT?VITY:
SRM~L

ALL

54-10-10

Page 101
May 15/92

STRUCTURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0,037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125
0.190

0.120

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFFECTIVITY:
sru~

ALL

101

54-1820

Page 102
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
NACELLE FIREWALL
i.

APPROVED REPAIRS
A.

Refer to

EFFECTIVITY:
SRM4

REPAIR

Chapter 51

ALL

for

typical repairs for the nacelle firewall assembly.

54-10-10

Page 201
May 15/92

STRUCTURAL REPAIR MANUAL


UPPER COWL ASSEMBLY

(II

STRUCTURAL IDENTIFICATION

A]
1)

PP

(8

~FWD

dd~

~3)

(5)

(10

(TYPICAL)

Detail A
?-54e

EFFECTIVITY:
SRM-4

Upper Cowl Assembly Repair Index


Figure 1 (Sheet 1 of 3)
MODEL 31/35/36SERIES AIRCRAFT

54-20-10

Page 1
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

NO.

DWG.
NO.

DESCRIPTION

2652023

I
I
IEFF.

LH and RH

2652023

Skin

2652023

Stiffener

2652023

Doubler, Fwd

2652023

Channel

(2

Plate

2652023

Splice

Shim, Laminated

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

IFINISH
CODE

0.025

2652023 IChannel

0.040

0.032

S-735

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

2652023
5

2652023

Stiffener

2024-T42 Clad

0.025

2652023

Clad

0.025

2024-T42
2024-T42
2024-T42
2024-T42

Clad

0.040

Clad

0.025

2652023

1
1

2652023

2652023

Stiffener

2652023

Stiffener

2652023

Doubler, Aft

2652023

Doubler

2652023
2652023

Doubler(e ea.)
Filler(2 ea.)

2652023 1

Shim

2652023
2652023

Channel(2ea.)
Splice Plate

2652023

2652023

10

11

0.080
0.050

1
1

1
1

0.025
0.040

2024-T42 Clad
2024-T42 Clad

2024-T42 Clad

0.032

2024-T42 Clad

0.032

1
1
1
I
1

2024-T42 Clad

0.072

2024-T42 Clad

0.025

2024-T42 Clad

0.032

1
1

I
I

2024-T42 Clad
i~

0.032

Shim, Laminated
Channel

S-735

2652023

Filler

2024-T3 Clad

0.160

1
I
1

2652023
2652023

Filler

0.190

2652023

Doubler, (Inbd.)

2024-T42 Clad
2024-T42 Clad

0.020

2652023

Filler(4 ea.)

2024-T42 Clad

0.020

0.032

Replace

I Replace

Clad

Replace
Replace

0.032

0.040

51-70-02

Replace
I

0.040

I~

1~

Stiffener
Stiffener
Stiffener

0.032
0.032

Doubler,Side(2ea.)
Filler(4 ea.)
Longeron
Bearing Plates

REPAIR
FIG. NO.

I Replace

0.025

2024-T42 Clad
1
2024-T42 Clad
1~

ea.

2652023

1 2652023
2652023

GAGE

EngineCowlAssembly, Upper,

I
MATERIAL

I
I
I

I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Upper Cowl Assembly Repair Index


Figure 1 (Sheet 2 of 3)
EFFECTIVITY:
SRM~L

MODEL 31/35/36 SERIESAIRCRAFT

54-20-10

Page 2
May 15/92

Learjet
~litl

STRUCTURAL REPAIR MANUAL


CODES

EFFECTIVITIES
31-002 AND SUBSEQUENT; 35-002 AND SUBSEQUENT; 36-002 AND SUBSEQUENT
35-002 THRU 35-263; 36-002 THRU 36-044
31-001 AND SUBSEQUENT 35-264 AND SUBSEQUENT; 36-045 AND SUBSEQUENT

2
3

NOTES:

Laminated shim stook, 2024-T3, 0.002

Optional

to

use

or

0.003 lamination.

2024-T3 laminated shim stock with 0.002

301 Stainless Full Hard,

optional

or

0.003 laminations.

to use 301 Stainless 3/4 Hard.

Upper Cowl Assembly Repair Index


Figure I (Sheet 3 of 3)
EFFECTNITY:

MODEL 31/35/36SERIES AIRCRAFT

54-20-10

Page 3
SRM-4

May 15/92

STRUCTURAL REPAIR MANUAL


UPPER COWL ASSEMBLY
i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIM~TS
All dimensions

NOTE:
A.

in inches unless otherwise

are

specified.

Fasteners

(1) Loose
tions

or

failed rivets
the

on

are

not allowed. A loose

or

failed rivet

can cause

increased stress concentra-

progressive joint failure. A careful inspection must be


that joint failure has not spread from the area of the loose or failed rivet. (Re-

remaining

rivets and lead to

performed to ensure
fer to Chapter 51 for definition of rivet failure.)
(2) Loose

or

failed

screws are

not allowed. A loose or

failed

screw can cause

increased stress

concen-

progressive joint failure. A careful inspection must be


performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
trations

B.

on

surrounding

screws

and lead to

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired, and
C.
D.

refinished in accordance with

Deformation

(1) Deformation of the upper cowl assembly structure is not allowed.


Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

re-

Chapter 51.

more

than

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component re-

placed.
F.

Scratches(See Figure 101.)


(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to

Chapter 51

for protective treatment

(2) Structural components must be


thickness by more than specified.
G.

H.

if scratches reduce the

original

material

Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTNITY:
SRM-4

procedures.)
replaced or repaired

ALL

54-20-10

Page 101
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure 101
EFFECTIVITY:
sed4

ALL

54-20-10

Page 102
May 15/92

STRUCTURAL REPAIR MANUAL


UPPER COWL. ASSEMBLY
i.

APPROVED REPAIRS
A.

Refer to

EFFECTIVIIT"Y:
SRM-4

REPAIR

Chapter 51

ALL

for

typical repairs for the upper cowl assembly.

54-20-10

Page 201
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


LOWER COWL ASSEMBLY- STRUCTURAL IDENTIFICATION

(a

Ibal

II

1I1
6)

(10~

51

(n

pBPD
(Model 35/36 Series Airmaft)

n
B

17

Detail 8

(2~odel 31 Series Aivcrclft)

(TYPICAL)

Detail A
Assembly Repair Index
Figure I (Sheet 1 of 3)

Lower Cowl

EFFECTTVITY:
SRM~

MODEL 31/35/36SERIES AIRCRAFT

54-20-20

Page 1
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM
NO.

DWG.
NO.

Engine

2652028
1
2

Cowl

EFF.

Assy, Lower, LH/RH

MATERIAL

IFINISH
GAGE

Skin

2024-T42 Clad

0.025

51-70-02

2652028 1

Skin

2024-T42 Clad

0.032

51-70-02

2652028 1

Stiffener
i

2024-T42 Clad
2024-T42 Clad

0.025

Doubler, Fwd
Latch Channel

2024-T42 Clad

1
1

I
I
I

S-654

Replace
Replace
Replace
Replace

S-568

I Replace

2024-T3 Clad

2652028 1

Clip Angle
2652025
Clip Angle
2652025
Bearing Plate
2652025 IShim, Laminated

1~

1
1
1

2652025

0.040

0.032

0.032

2652028 1

Stiffener

2024-T42 Clad

0.025

2652028 1

Stiffener

2024-T42 Clad

0.025

2652028 1

Stiffener

2024-T42 Clad

0.025

2652028 1

Doubler

2024-T3 Clad

0.020

2652028 1

Latch Channel

2024-T42 Clad

0.032

IShim, Laminated

2652025

Clip Angle
Clip Angle
Bearing Plate

S-654

S-568

2024-T3 Clad

0.032

Stiffener

2024-T42 Clad

0.025

0.040

2652025

2652025

2652028 1

2652025

Longeron

2024-T42 Clad

2652025

Doubler, Side

2024-T3 Clad

0.040

2652028

Doubler(Outbd.)

304 Stainless

0.018

10

(Inbd.)~

2652028

Doubler

304 Stainless

0.018

2652028 1

Latch Channel

2024-T42 Clad

0.032

2652025

S-654

S-568

2652025

Clip Angle
Clip Angle
Beari:ng Plate

2652025

2652025

Shim, Laminated

2024-T3 Clad

I~

1
1

Stiffener

2024-T42 Clad

0.025

2652025

Doubler, Aft

1 2024-T42 Clad

0.040

11

2652028

Doubler

12

2652025

Scupper Assy

2652025

Funnel

2652025 1
13

2652112

14

2652111
2652113

Vent Tube

304 Stainless

1
I

I
I

1
1

I
F17-6
F17-6

I
I

I
I

I
F17-6

0.018

6061-T6 Al

0.040

6061-16 Al

0.040

Air Vent, Generator Exhaust

2024-T42 Clad

0.032

2024-T42 Clad

0.032

2024-T42 Clad

0.032

Door(2 ea.)
Plug (2 ea.)
Mount(2 ea.)

2024-T42 Clad

0.050

2652111

0.032

2652028 1

1
1

1~

2652025

REPAIR
FIG. NO.

CODE

2652028 1

2652025
3

I
DESCRIPTION

1
1
1
1
1
1

I
I
I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Lower Cowl

Assembly Repair Index


Figure 1 (Sheet 2 of 3)

EFFECTIVITY:
SRM-L

MODEL 31/35/36SERIES AIRCRAFT

54-20-20

Page 2
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

15

3152001

3152000

3152000
3152000

17

Exit Inst.,
Plate
Wall

IEFF.

DESCRIPTION
Air Exit Instl., Lower
Air Vent

3152001
16

Engine

Nac.

IFINISH
GAGE

2024-T42 Clad

6061-T6

0.063

6061-T6

0.040

1
1

Replace
Replace
I Replace
I Replace
Replace
Replace

0.032

0.032

Ramp

6061-0

0.030

3152000

Skin

6061-T6

0.050

3152000

Doubler

6061-T6

0.040

3152000

Doubler

321 Stainless

0.016

Airlnletlnstl., LowerEngineNac.

3152002

Duct

6061-0

Lip

S639

2024-T3 Clad

CODES

Filler

1
1

3152002
3152002

I Replace

0.032

3152000

1 3152002

REPAIR
FIG. NO.

CODE

6
6

GeneratorCooling

I
MATERIAL

Replace
Replace
Replace

EFFECTIVITIES

31-001 AND

SUBSEQUENT; 35-002 AND SUBSEQUENT; 36-002 AND SUBSEQUENT


35-002 THRU 35-005; 36-002 6 36-003
35-006 AND SUBSEQUENT; 36-004 AND SUBSEQUENT
35-354 AND SUBSEQUENT; 36-046 AND SUBSEQUENT
35-002 AND SUBSEQUENT; 36-002 AND SUBSEQUENT
31-001 AND SUBSEQUENT

35-026, 35-031 AND SUBSEQUENT; 36-014, 36-017 AND SUBSEQUENT; 31-001 AND SUBSE-

2
3

4
5

QUENT

NOTES:

Laminated shim stock, per MIL-S-22499, 2024 aluminum, 0.002

Fay

surface seal per

or

0.003 lamination,

Comp 1, Type 1,

Class 2.

Chapter 51.

321 Stainless Condition A.

Lower Cowl

Assembly Repair Index


Figure 1 (Sheet 3 of 3)

EFFECTIVITY:

MODEL 31/35/36 SERIES AIRCRAFT

54-20-20

Page 3
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


LOWER COWL ASSEMBLY
i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS

All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

failed rivets

or

the

on

are

remaining

to ensure that

performed
fer to Chapter 51
(2) Loose

or

failed

not allowed. A loose or failed rivet can cause increased stress concentra-

progressive joint failure. A careful inspection must be


joint failure has not spread from the area of the loose or failed rivet. (Re-

rivets and lead to

for definition of rivet failure.)

screws are not

allowed. A loose

or

failed

screw can cause

increased stress

concen-

surrounding screws and lead to progressive joint failure. A careful inspection must be
performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
trations

B.

on

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired, and

refinished in accordance with

re-

Chapter 51.

C.

Deformation

D.

Corrosion (See Figure 101.)


(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than speci-

(1) Deformation of the lower cowl assembly structure is

not allowed.

fied. (Refer to Chapter 51 for protective treatment procedures.)


(2) Structural components must be repaired or replaced if corrosion repair reduces the original
rial thickness
E.

more

than

mate-

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component re-

placed.
F.

Scratches(See Figure 101.)


(1) Scratches ate permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Re-

protective treatment procedures.)


must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(See Figure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.
fer to

Chapter 51

for

(2) Structural components

G.

H.

EFFECTNITY:
SRM4

ALL

54-20-20

Page 101
May 15/92

STRUCTURAL REPAIR MANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.067

0.071
0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness


Figure 101

EFFECTTVITY:
SRM-4

ALL

54-20-20

Page 102
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


LOWER COWL ASSEMBLY
i.

REPAIR

APPROVED REPAIRS
A.

Refer to

EFFECTIVITY:
SRM~

Chapter 51

ALL

for

typical repairs for the lower cowl assembly.

54-20-20

Page 201
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ENGINE INLET ASSEMBLY
1.

STRUCTURAL IDENTIFICATION

DESCRIPTION
consists of

stainless steel inlet, and inlet duct bond

The

B.

head assemblies, and an outside skin covering.


The engine inlet assembly repair index (Figure 1) is
ing and identifying structural components.

engine

EFFECTIVITY:

inlet

assembly

A.

ALL

provided

assembly,

to aid maintenance

two bulk-

personnel

in locat-

54-30-10

Pagel
SI~M4

May 75/92

Learjet
STRUCTURAL REPAIR MANUAL
ENGINE INLET ASSEMBLY

STRUCTURAL IDENTIFICATION

~::::t

DetailA

r-

Detail B
750;
A7-51A

Engine

Inlet

Assembly Repair Index

Figure
EFFECTIVITY:

1 (Sheet 1 of 3)

MODEL31/35/36SERIES AIRCRAF~

54-30-10

Page 2
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


I

ITEM
NO.

DWG.
NO.

2652010

Skin, Nose~

301

2652010

Doubler

301 Stainless

2652010

301

EnginelnletAssy.,

2652010

REPAIR

CODE

FIG. NO.

LH/RH

StainlessI~

0.032

54-30-10

Replace
Replace
Replace
Replace
51-70-03

0.032

Stainlessl~

0.032

2652010

SpliceDoubler, Upper
Splice Doubler, Lower

2652010

Inlet Duct Bond

2652012

Bulkhead Instl.

2652012

Bulkhead

321 Stainless

0.032

2652012

321 Stainless

0.032

I Replace

2652012

Ring
Spray Tube (1.25
Wall)

321 Stainless

I Replace

2652012

Boss

321 Stainless

0.750

2652012

Tube,Transition (2ea.)

321 Stainless

0.032

2652012

Tube

321 Stainless

Assy.

OD

OD

0.032

0.032

0.035

Wall)

I Replace

0.032

1
1

I
I

321 Stainless

0.025

Replace
Replace
Replace

2652015

Bulkhead,Upper

2024-T42 Clad

0.032

51-70-03

2652015

Bulkhead,Lower

2024-T42 Clad

0.032

51-70-03

2652015

SpliceDoubler(2ea.)

2024-T42 Clad

0.040

2652015

Door

2024-T3 Clad

0.063

I Replace
I Replace

Angle

2024-T42 Clad

0.032

StainlessI~

0.040

2652015

Shim

321

2652015

RubStrip
RubStrip
BracketClip(A/R)
Receptacle(A/R)
Shim(2ea.)

321 Stainless

0.032

2024-T42 Clad

0.032

AN743-13

244-1 6SD

2024-T42 Clad

0.020

2024-T42 Clad

0.040

2024-T42 Clad

0.040

S-633

212-12N

321 Stainless

2652015
2652015
2652015
2652015

Shim

2652015

2652015

Shim(2ea.)
ClipAssy.

2652015

Receptacle(A/R)

2652015

Bulkhead Instl.

1 2652015

2652015

(1.00

301 Stainless

Adapter

2652012
4

0.035

Wall)

1
1

Tube

2652017

Plate

321 Stainless

2652017

Plate

321 Stainless

2652017

Tube

(1.000Dx0.035Wall)

321 Stainless

2652016

Air

Inlet, Gen. Cooling, LH/RH

3MAF-114FR

2652016

Strip
Strip
Strip
Scoop Inst.,

2024-T3 Clad

0.032

2024-T3 Clad

0.032

2024-T3 Clad

0.032

2652016
3152003

(1.00

OD

2652017

2652016

Gen.

Cooling Inlet

I
I

I
i
I

0.032

0.032

I
I

I
1

I Replace

InletDuct

10

3MAF-114FR

3152003

Door

10

2024-T42 Clad

0.032

3152003

Doubler

10

2024-T42 Clad

0.040

3152003

FlangeDoubler

10

2024-T42 Clad

0.040

EFFECTIVITY:

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

10

3152003

Engine

SRM-4

(FINISH
GAGE

MATERIAL

EFF.

DESCRIPTION

Replace
Replace
Replace

Inlet Assembly Repair Index


Figure 1 (Sheet 2 of 3)

MODEL 31/35/36SERIES AIRCRAFT

54-30-10

Fage 3
May 15/92

Learjet I

TEMPORARY REVISION NO. 54-1


Leajet 20/30 Series Aircraft Structural Repair Manual (SRM-4).

MANUAL AFFECTED:

Insert

FILING INSTRUCTIONS:

adjacent

to

51-30-10, page 4, dated May 15/92, and retain until further

notice.

Revised Allowable

REASON:

INSTRUCTIONS:

Damage

Limits for dents in

Add revised item E., Dents, and

ENGINE INLET ASSEMBLY


1.

Figure

Engine Inlet Assembly


102

as

and added

Figure 102.

follows:

ALLOWABLE DAMAGE

ALLOWABLE DAMAGE LIMITS


E.

Dents(SeeFigure 102.)
(1) Dents located
of

on

the inlet

leading edge

may

adversely

affect

engine performance

and

fatigue

life

engine fan blades.

(2) Dent allowables in the inlet leading edge is divided into

two sections as defined by the tangent, or


very leading edge point. All dents must be smooth and free creases.
(3) Contact Leajet Field Service if engine performance discrepancies are noted with any dent present
in the inlet leading edge.

TEMPORARY REVISION NO. 51-1

SRM~

54-30-10

Page 1 of 2
Aug13/99

STRUCTURAL REPAIR MANUAL

Tangent~ntLine

Extelioi Dents

0.060 Inch Maximum

Depth

Tangent Point

Interior Dents
0.020 Inch Maximum

Depth

A-A
VIEW ~LOOKING AFT

Acceptable

Acceptable

Dent Location

as

is

with

Restrictions

Contact Learjet
Field Service

Representative
if dent is:

Inside

Tangent

Outside

Tangent

Less than 0.020 Inch

0.020 to 0.060 Inch

Greater than 0.060 Inch

Less than 0.060 Inch

0.060 to 0.100 Inch

Greater than 0.100 Inch

DENT ALLOWABLE CRITERIA

C~

All dents must be smooth with no cracks

Affected

engine

must be

making

or creases.

rated power for the day without any surges,


or other engine discrepancies.

imbalances, compressor stalls


Dents must be

repaired

within 300

Dents must be

repaired

at next

Engine

TEMPORARY REVISION NO. 5(1-1

SRM-I

Inlet

Flight

engine

Hours.

MPI.

Lip Skin Dent Criteria


Figure 102

54-30-10

Page 2 of 2
Aug 13/99

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

DESCRIPTION

MATERIAL

GAGE

2652010

Skin, Outer, RH~


Skin,Outer, LHI~
Skin,Outer, RHL~
Skin,Outer, LH~
Skin, Outer(Lower)
Skin, Outer(Lower)
Skin, Outer(Upper)
Skin, Outer (Upper)
Splice Doubler, RH

2652010

CiipAngle, (2ea.)

2024-T42 Clad

0.032

2652010

Doubler

2024-T42 Clad

0.050

2652010

EFF.

2652010
2652010

2652010
2652010
2652010
2652010

2652010

FINISH
CODE

REPAIR

FIG. NO.

301 Stainless

0.025

301 Stainless

0.025

51-70-02

11

301 Stainless

0.032

51-70-02

11

301 Stainless

0.032

51-70-02

2024-T42 Clad

0.025

51-70-02

11

2024-T42 Clad

0.032

51-70-02

2024-T42 Clad

0.025

51-70-02

11

2024-T42 Clad

0.032

51-70-02

2024-T42 Clad

0.032

Replace
Replace
Replace

L~

51-70-02

EFFECTIVITIES

CODES

31-001 AND

SUBSEQUENT; 35-002 AND SUBSEQUENT; 36-002 AND SUBSEQUENT


SUBSEQUENT; 36-045 AND SUBSEQUENT
35-021, 35-023 THRU 35-026, 35-028 AND SUBSEQUENT; 36-007, 36-014 AND SUBSEQUENT
35-051 AND SUBSEQUENT; 36-017 AND SUBSEQUENT
35-002 THRU 35-005; 36-002 THRU 36-003
35-006 AND SUBSEQUENT; 36-004 AND SUBSEQUENT
35-088 AND SUBSEQUENT; 36-023 AND SUBSEQUENT
35-186 AND SUBSEQUENT; 36-039 AND SUBSEQUENT
35-002 AND SUBSEQUENT; 36-002 AND SUBSEQUENT

35-225 AND

2
3
4

6
7
8
9

10

31-001 AND SUBSEQUENT

11

31-001 AND

SUBSEQUENT; 35-006 AND SUBSEQUENT;

36-004 AND SUBSEQUENT

NOTES:

Optional

to use 321 Stainless Annealed.

Condition Annealed.
Condition Full Hard.

I~

Condition 1/4 Hard.

Apply dissimilar metal protection

to stainless steel surfaces

contacting

dissimilar metal per

Chapter

51.

layers of pre-pregnated adhesive fabric, 3MAF-114FR or equivalent; Narmco 550-181 CType C), Narmco
Div., Whittaker Corp.; 9702-181 (Type C) Shell Chemical Co.; HHM2.1 (Type 2) 181 weight epoxy glass, H 8 H
Parts Co., Wichita, KS.

Three

Finish F14-1 interior

only

Engine

EFFECTIVTTY:

Inlet Assembly Repair Index


Figure 3 (Sheet 3 of 3)

MODEL31/35/36 SERIES AIRCRAFT

NOTE: Please

see

the

TEMPORARY

REVISION
that revises this page.

5P30-10

Page 4
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ENGINE INLET ASSEMBLY

i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS

All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

or

failed rivets
the

on

are

not allowed. A loose

or

failed rivet

can cause

increased stress concentra-

progressive joint failure. A careful inspection must be


that joint failure has not spread from the area of the loose or failed rivet. (Re-

remaining

rivets and lead to

performed to ensure
fer to Chapter 51 for definition of rivet failure.)
(2) Loose

or

trations

failed

on

performed
B.

screws are not

surrounding

allowed. A loose

to ensure that

or

failed

screw can cause

increased stress

concen-

progressive joint failure. A careful inspection must be


the joint failure has not spread from the area of the loose or failed screw.

screws

and lead to

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

re-

paired, and refinished in accordance with Chapter 51.


C.
D.

Deformation

(1) Deformation of the engine inlet assembly strucure is not allowed.


Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

more

than

specified.

Dents

permissible, if smooth and without abrupt changes in contour, do not


depth (0.002 inch/inch maximum rate of change).
remaining structure are permissible, if smooth and without abrupt changes in conexceed 0.06 inch (1.52 mm) in depth, exceeds 10% of total surface area in one (1)

(1) Dents in the inlet

nose are

exceed 0.010 inch (0.254 mm) in

(2) Dents in the

tour, do not
square foot, and

are

closer than 0.050 inch (12.7 mm) to

rivet

or

structural

area.

(3) Dents are


sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
of total surface area in one (1) square foot, and are closer than 0.50
10%
mm) in depth, exceeds
rivet
or structural area. Such dents shall be repaired or the component reinch (12.7 mm) to a
not allowed if

placed.
(4) Repairs

square inches in the


F.

G.

an

"as

completed" repair

area

of three (3)

Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
Structural
(2)
components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(See Figure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.

EFFECTIVZTY:
SRM-4

assembly shall not exceed


perforated inner skin and core.

to the inlet duct bond

ALL

54-30-10

Page 101
May 15/92

STRUCTURAL REPAIR MANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0,0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.030

0.076

0.100

0.095

0.125

0.120

0.190

.0.180

0.237

0.250

Allowable Material Thickness

Figure

EFFECTIVITY:
SRM-4

ALL

101

54-30-10

Page 102
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ENGINE INLET ASSEMBLY

REPAIR

APPROVED REPAIRS

1.

A.

If

replacement of the engine inlet nose

skin is

required, refer

to

SSK-992, "Replacement of Engine Inlet

Nose Skin".
B.

Repair of Nacelle Inlet Duct Band Assembly. (See Figure 201.)


CAUTION:

THIS REPAIR PROCEDURE IS EXTREMELY CRITICAL. POOR WORKMANSHIP


CANNOT BE TOLERATED AS IT COULD ADVERSELY AFFECT ENGINE PERFORMANCE.

(1) Tools and equipment


NOTE:

Equivalent substitutes may be used in lieu

NAME

PART NUMBER

Methyl Ethyl Ketone

(MEK)

Clean cotton cloth


or

of the

following:

MANUFACTURER

USE

Commercially available

Cleaning

Commercially available

Cleaning

cheesecloth

Ultrasonic

Sandicator 52B

Air motor

Dotco 10L1200B

inspection
equipment

Inspecting dam
aged area

Commercially available

Routing and
surface machin-

ing
Vacuum cleaner

Commercially available

Masking tape

Commercially available

Masking

Commercially available

Masking

Brown

wrapping paper

Adhesive

Abrasive

Hysol EA9330.3

nylon pad

Abrasive paper

I-lysol

Division of

Filling repair

the Dexter

Corp.
Pittsburgh, CA

area

Scotchbrite

3M

Polishing

220

Commercially available

Sanding

grit aluminum

oxide

Filter, compressed air

EFFECTIVITY:
SRM-4

ALL

Drive air motor

54-30-10

Page 201
May 15/92

STRUCTURAL REPAIR MANUAL


PARTNUMBER

NAME

MANUFACTURER

950

Extrusion gun,
cartridge, nozzle
Permanent ink marker

Pyles Ind., Inc.


Detroit, Michigan

Applying adhe-

Magic Marker

Mark

(2) Using visual inspection, ultrasonic equipment, coin tap test,

ing method,

examine

area

for skin fracture

or

USE

deformation,

or

sive

other

core

damage

suitable non-destructive test-

fracture, crippling,

or

bond frac-

ture, and de-bond of skin and core.


(3) Outline damage area with permanent ink marker.

(4) Determine whether damage

area is 3 square inches or less. If damage area is greater than 3


square
inches, replace bonded inlet nacelle. If damage area is within tolerance, proceed as follows:
(5) Mask off engine inlet opening and entire perforated inner skin except for 1/4 inch around out-

lined

damage area.

(6) Using air motor, machine out damage area.


(7) Ensure that ail fracture and/or de-bonded core and perforated skin material is removed.
NOTE:

The

core

does not have to be cut out

Crippled

core

completely down to

does not have to be removed

providing

the

opposite skin.

the adhesive bond is still

se-

cure.

(8) Use vacuum to remove all cuttings and debris.


(9) Using clean, cotton cloth or cheesecloth dampened

in

MEK, thoroughly scrub remaining

un-

masked skin around

damage area.
nylon pad or abrasive

(10) Using abrasive


area

with

(11) Reclean around

oughly

paper, abrade cleaned skin around

damage

area.

Reclean

vacuum.

remove

damage

area

with clean cotton cloth

MEK from surface

by wiping

or cheesecloth dampened with MEK. Thorwith cotton material. Do not allow MEK to air dry as

residue will remain which will prevent proper bonding of adhesive.


(12) Add 33 parts by weight of EA9330.3 Part B (light yellow) into 100 parts by weight of EA9330.3
Part A (gray) and thoroughly mix until components blend into a uniform, gray paste.
a

NOTE:

Mix

no more

Cease

material than

can

be used within 20 minutes.

mixing as soon as paste color is uniform; overmixing will


application time.

accelerate

cure

and

reduce

(13) Transfer mixed material


sion gun.
(14) Using nozzle

to

an

extrusion gun

polycthylene cartridge

and install

cartridge

in extru-

required, inject adhesive into routed damage area. Start at center of cutout and
expanding circle until entire bottom skin surface and any remaining core in cutout are
completely coated with adhesive. (See Figure 201, Detail B.)
(15) Apply masking tape to cover complete work area, overlapping previously applied masking matework in

as

an

rial.

(16) Make

EFFECTIVITY:
SRM~

hole in center of

ALL

tape large enough

to

accept nozzle.

54-30-10

Page 202
May 15/92

Learjet
~I
STRUCTWRAL R:EPAIR MANUAL
(17) Insert nozzle thru hole and continue
Figure 201, Detail B.)
CAUTION:

extruding

adhesive until machined

area

is overfilled. (See

DO NOT EXCEED 1750F (790C) CURE TEMPERATURE LIMIT. TEMPERATURES IN EXCESS OF 175" F (79"C) CAN DAMAGE BONDED ASSEMBLY.

NOTE:

If there is insufficient material to be machined to contour


cess must

be

(18) Allow adhesive to cure at room temperature (77"F [25"C]) for


to 175aF (650 to 790C) for 4 hours.
CAUTION:

following cure.

the entire pro-

repeated.
24 hours

or

accelerate

cure

at 1500

REMOVING TOO MUCH ADHESIVE WILL NECESSITATE REPEATING ENTIRE REPAIR PROCESS.

(19) Using air motor, abrasive nylon pad, and abrasive paper, machine cured adhesive
rect contour blended

to

achieve

cor-

adjacent structure. Surface of repair areas shall be within a


tolerance of 0.006 inch (.152 mm) below design contour. No further finish is required.
(20) If proper contour has not been achieved, rout all adhesive from repaired area and repeat entire
procedure.

EFFECTIVITY:
SRM-4

ALL

smoothly

into

54-30-10

Page 203
May 15/92

Leariet

STRUCTURAL REPAIR MANUAL

Dented

Inner

Skin

Crippled

Core

Skin

Ma sking

Out Area

Skin Dent and

Crippled

Core

Fractured Skin

and/or

Core

Crippled

Inner

Core

Skin

Masking
Machined Out Area

Skin Ptacture and

Crippled

Core

Fractured Skin

and/or Core

Inner

De-Sonded Core

Skin

Maski ng

Machined Out Area

Crippled

Core

SKIN FRACTURE AND FRACTURED, CRIPPLED, AND/OR DE-BONDED CORE

Engine Inlet Repair


Figure 201 (Sheet 1 of 2)

EFFECTIVITY:

ALL

54-30-10

Page 204
May 25/92

Learjet

STRU~TURAL REPAIR NIANUAL

~njected Adhesive
Nozzle

inner Skin

Masking

Detail A

Injected Adhesive

r_

Nozzle

Masking Tape

Inner

Skin

Masking

Detail B

Engine Inlet Repair


Figure 201 (Shect 2 of 2)
EFFECTIVITY:
SRM~L

ALL

54-30-10

Page 205
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


DUCT

ASSEMBLY, FAN, EMI[AUST

AND INNER WALL

STRUCTURAL IDENTIFICATION

I"

Detail B

lo

(TYPICAL)

Detail A
Duct

EFFECTIVITY:
SRM~

Assembly, Fan, Exhaust and Inner Wall Repair Index


Figure 1 (Sheet 1 of 3)

MODEL 31/35/36SERIES AIRCRAF~

54-30-20

Page 1
May 15/92

Learjet
Leariet

STRUCTURAL REPAIR MANUAL


ITEM
NO.

DWG.
NO.
2652035
2652037

CODE

1
2
1

StainlessI~

321

321 Stainless

0.025
0.025

1
1
1

321 Stainless

0.025

Doubler, Lower(LH Duct)

321 Stainless

0.020

2652035

321 Stainless

0.025

321 Stainless

2652035

Doubler,Lower(RHDuct)
Doubler,Fwd.
Strap,Upper/Lower

321 Stainless

1
1
0.025 1
0.025 1

2652035 1

Duct Half

321 Stainless

0.025

2652035

2652035

Assy., Outbd.
DuctRetainer, UpperRower
Doubler,Aft
Doubler, Lower(LH Duct)
Doubler, Lower(RHDuct)
Doubler,Fwd.

REPAIR
FIG. NO.

IFIN1SH
GAGE

Doubler

2652035

Replace

I Replace
I Replace
I
I

Replace
Replace
Replace
Replace
Replace

I Replace
I Replace
I Replace

Duct Half Weld

321 Stainless

0.025

321 Stainless

0.025

321

321 Stainless

0.025

321 Stainless

0.025

321

321 Stainless

0.025

321 Stainless

0.025

Stainlessl~

0.020

2652035

Doubler

321 Stainless

0.032

2652035 1

Door

321 Stainless

0.025

1
1

Replace
Replace
I Replace
Replace
I Replace
Replace
1 Replace

2652037

Duct Half Weld

2652035

2652035

Strap,Upper/Lower

2652035

DuctHalf

2652035

2652035

Doubler

Assy.,

Lower

StainlessI~

0.025

1
1

2652037

Doubler,Lower(Sea.)

321 Stainless

0.025

2652037

Doubler, Fwd., Lower (2 ea.)

321 Stainless~

0.025

2652037

DuctHalf

321 Stainless

0.025

2652035

Doubler,Aft

321 Stainless

0.025

1 2652037

DuctHalf WeldAssy., Upper


DuctRetainer

321 Stainless

0.025

2652037

Doubler

321 Stainless

0.025

321

321 Stainless

0.025

2652037

Doubler,Upper
Doubler,Fwd.Upper
Strap(3ea.)

StainlessI~

0.025

321 Stainless

0.025

2652037

DuctHalf

321 Stainless

0.025

2652035

Doubler,Aft

321 Stainless

0.025

321 Stainless

0.025
0.025

2652037

2652035

Door

2652035

Door

321 Stainless

2652074

Nosecap

321 Stainless

0.040

2652074

Channel(2ea.)
Fairing

321 Stainless

0.040

321 Stainless

0.040

2652074

Duct

EFFECTTVITY:

Replace
Replace
Replace
I Replace

2652037

2652037

I
MATERIAL

2652035

2652035

Inbd.

I
EFF.

2652035

2652035

WeldAssy.,

DuctRetainer, Upper/Lower
Doubler,Aft

2652035

Fan Exhaust Duct Assy., LH/RH


FanExhaustDuctAssy., LH/RH
DuctHalf

2652035
2652035

I
DESCRIPTION

1
1

I Replace
i Replace
Replace
I Replace
I Replace
I Replace
Replace
Replace
I Replace
I Replace
Replace
I Replace

Assembly, Fan, Exhaust and Inner Wall Repair Index


Figure 1 (Sheet 2 of 3)

MODEL 31/35/36SERIES AIRCRAFT

54-30-20

Page 2
sRM-a

May 15/92

Learjet I

STRUCTURAL REPAIR MANUAL


ITEM
NO.

DWG.
NO.

DESCRIPTION
Shroud Assy., LH/RH
Pan

2652036

2652036
2652036

2652036
2652036

2652036
2652021

2652021

CODES

SafetylockSupport
SupportAnglegea.)
NutplateSpacer
SafetylockChannel
Support Channel (2 ea.)
Support Angle (2 ea.)
Clip

IEFF.I

IFINISH
GAGE

MATERIAL

CODE

REPAIR
flG. NO.

5
5

301 Stainless

0.025

301 Stainless

0.025

301 Stainless

301 Stainless

301 Stainless

0.025

301 Stainless

0.025

301 Stainless

AN743C13

0.025

1~

0.050

L~

0.040

1
I

Replace
Replace
Replace
Replace
I Replace
Replace
Replace
I Replace

EFFECTIVITIES
35-002 THRU 35-035, EXCEPT 35-028, 35-033 AND 35-034; 36-002 THRU 36-016, EXCEPT 36-014
31-001 AND SUBSEQUENT; 35-028, 35-033, 35-034, 35-036 AND SUBSEQUENT; 36-01 4, 36-017

1
2

AND SUBSEQUENT
3
4
5
6

35-028, 35-033, 35-034, 35-036 THRU 35-048; 36-014


31-001 AND SUBSEQUENT; 35-049 AND SUBSEQUENT; 36-017 AND SUBSEQUENT
31-001 AND SUBSEQUENT; 35-002 AND SUBSEQUENT; 36-002 AND SUBSEQUENT
31-001 AND SUBSEQUENT; 35-245 AND SUBSEQUENT; 36-045 AND SUBSEQUENT

NOTES

Optional to

I~

use

321 stainless annealed.

Condition annealed.
Condition 1/4 hard.
Condition 1/2 Hard.

Duct

EFFECTIVITY:

Assembly, Fan, Exhaust and Inner Wall Repair Index


Figure 1 (Sheet 3 of 3)

MODEL 31/35/36SERIES AIRCRAFT

54-30-20

Page 3
SRM-P

May 15/92

Learjet
~Learjet

STRUf=TURAL REPAIR MANUAL


DUCT
i.

ASSEMBLY, FAN, EXHAUST AND

INNER WALL

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS

NOTE:
A.

All dimensions

are

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

or

failed rivets
the

are

remaining

not allowed. A loose

or

failed rivet

can cause

increased stress concentra-

rivets and lead to

progressive joint failure. A careful inspection must be


that
failure
to
has
not
ensure
performed
joint
spread from the area of the loose or failed rivet. (nefer to Chapter 51 for definition of rivet failure.)
on

(2) Loose

or

trations

failed

on

performed
B.

screws are

surrounding

not allowed. A loose

to ensure that

or

failed

and lead to

screw can cause

increased stress

concen-

failure. A careful

progressive joint
inspection must be
the joint failure has not spread from the area of the loose or failed screw.

screws

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked


(2) Cracks in components other than fittings and forgings

paired, and

refinished in accordance with

fittings or forgings must be replaced.


are considered allowable if properly

re-

Chapter 51.

C.

Deformation

D.

(1) Deformation of the duct assembly, fan, exhaust and inner wall is not allowed.
Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance

Chapter 51, and these repairs do not reduce the original material thickness more than speciChapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness more than specified.
with

fied. (Refer to

E.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component re-

placed.
F.

Scratches(See Figure 101.)


(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to

Chapter 51

for

protective treatment procedures.)


must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(See Figure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.
(2) Structural components

G.

H.

EFFECTTVITY:
SRM4

ALL

54-30-20

Page 101
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025
0.032

0.0225
0.0295

0.040
0.050
0.063
0.071
0.080
0.100

0.037
0.046
0.059
0.067
0.076
0.095

0.125
0.190
0.250

EFFECTIVITY:

ALL

0.120

0.180
0.237

54-30-20

Page
srud-a

102

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
DUCT ASSEMBLY, FAN, EXHAUST AND INNER WALL
i.

APPROVED REPAIRS
A.

Refer to

EFFECTIVITY:
smVI~

REPAIR

Chapter 51

ALL

for

typical repairs for the duct assembly.

54-30-20

Page 201
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ENGINE NACELLE AFTERBODY

STRUCTURAL IDENTIFICATION

8)

~3

i-

II;

I,

i i

__,jd-

I I

-I-L~_-------tYt---\-

-~i;l--I; i"-

-C --4

-;-tt--------TT~I!,i

9)

i.;i

,I

60~

jjj
I,
~1

I-;-~iZ

ir---

:I

i i

13

i i

i;l

--~if--III

rt;l

6
I I

--II

IBF~-,_

(35-002 thtu 35-035 excent 35-928. 35-033 and


35-034: 36-002 thru 36-016. excet~t36-034)

Detail A
7-36C-1

EFFECTIVITY:
SRM~

Engine Nacelle Afterbody Repair Index


Figure (Sheet 1 of 4)
NOTED

54-30-30

Pagel
May 15/92

Learjet
~arjet I

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.
2652040

2652040

2652040
2652040
2652040
2652040

2652040
2652040
2652040

2652040
2652040
2

2652040

1
DESCRIPTION

Engine Nacelle
Afterbody Assy.,

2024-T42 Clad

0.025

2024-T42 Clad

0.025

Lower Outer Aft

2024-T42 Clad

0.025

Center

321 Stainless

0.020

Doubler Door

1 I~

2024-T42 Clad
2024-T42 Clad

0.032

Bracket(G ea.)
Splice Doubler (3 ea.)
Doubler Door (2 ea.)
Former Door (2 ea.)
Afterbody Frame Assy.

0.040

2042-T42 Clad

0.032

2024-T42 Clad
2024-T42 Clad

0.032

1
1
1
1
I
1

1
1

Skin, Inner Aft


Skin, inner Fwd. (2 ea.)

0.032

I
2024-T42 Clad
2024-T42 Clad

0.025
0.025

Bulkhead Inst.
Frame

2024-T42 Clad

0.032

2024-T42 Clad

0.032

2652046

Splice Plate
Splice Plate

32 i Stainless

0.032

2652046

Shim

2024-T42 Clad

0.040

2652046

Shim

321 Stainless

2652047

Flange Assy.
Flange(2 ea.)
Splice Plate (2 ea.)
Splice Plate (2 ea.)

12652046
2652046
2652046

2652042

Bulkheadlnst.
Frame

2652018
2652043

Shim (3 ea.)
Bulkheadlnst.

2652042

0.040

REPAIR

FIG. NO.

I Replace
Replace

Upper Outer Fwd.


Upper Outer Aft

2652046

I
0.025

2652046

IFINISH
CODE

2024-T42 Clad

2652047

GAGE

2852040

RH

I
MATERIAL

Lower Outer Fwd.

Skin,
Skin,
Skin,
Skin,
Skin,

2652040
3

LH

I
EFF.

1
1
1
1
i

I
I
I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

I Replace
I Replace
I Replace
Replace
I Replace
I Replace
I Replace
I Replace
I Replace

2024-T42 Clad

0.040

2024-T42 Clad
2024-T42 Clad

0.032
0.050

1
1

2024-T42 Clad

0.032

2024-T42 Clad

0.032

I Replace
I Replace

2652043

Frame

2024-T42 Clad

0.032

2652018
2652044
2652044
2652018

Shim

(3 ea.)

2024-T42 Clad

0.032

1
1

I Replace
Replace

Bulkheadlnst.
Frame

2024-T42 Clad
2024-T42 Clad

0.032

Shim (3 ea.)
Bulkhead Inst.

0.032

I Replace
I Replace

Frame
Shim (3 ea.)

2652050

2652044
2652018
2652046

i
1
1

Receptacle (4 ea.)

2024-T42 Clad
2024-T42 Clad
244-16SD

0.032
0.032

Replace
Replace
I Replace

Engine Nacelle Afterbody Repair Index

Figure
EFFECTIVITY:
SRM~

NOTED

1 (Sheet 2 of 4)

54-30-30

Page 2
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM I
NO.
8

DWG.
NO.
2652040
2652040
2652040

I
DESCRIPTION

2652040

2652040
2652040

Assy.
Clip(2 ea.)
Stiffener Angle
Stiffener Angle

Inner Door
Outer Door
Drain Tube

Door

2652040
2652040
2652040

I
EFF.

2024-T42 Clad

\2024-T42C\ad
6061-T6 I~
2024-T42 Clad
2024-T42 Clad
6061 Tube 1/4 O.D.

2
2
2

REPAIR

CODE

FIG. NO.

0.063
0.032

0.032
0.025

1
1

I
I

0.025

I
I

Door Assy.
Door Pan

IFINISH
GAGE

MATERIAL

2024-T42

0.025

2024-T42

0.040

F14-1extl

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Flint
Door Skin
Tube Assy.

301 Stainless

0.020

Fi 7

2652051

Door, Upper
Rub Plate, Upper

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

301Stainless

0.020

F17

Replace

2652051

Spacer, Upper

301Std~nless

0.025

F17

2652051
2652051

Seal Retainer,
Doubler Assy.

1
i

301Stainless

1~

0.020

F17

301 Stainless~

0.025

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2652040
2652040

0.025
0.032

1
I
1
1
1

I
I
I
I
I

Tube

5052-0

0.035

Plate

5052-0

0.032

Angle (4 ea.)
Fairing Assy.
Fairing, Upper
Fairing, Lower
Closure Ring
Door Assy.

2024-T42

0.040

2652045

2652056
2652040
2652040
2652040

I
321Stainless

321Stainless

12042-T42Clad

Door

2042-T3

0.025

Doubler

2042-T3 Clad

0.032
0.062

Seal

I~

2652053
2652051

Spacer
Door Assy., Upper

Phenolic

2652051
2652051

0.025

Upper

Plate

Door

Assy.,

Lower

2652040

265205 i

1~

I
1
1

2652040
2652040

2652045

12
13

2652040

2652045
10
11

0.625

Door, Lower
Rub Plate, Lower

301Stainless

0.020

F17

2652051

301Stainless

0.020

F17

2652051

Spacer, Lower

301Stainless

0.025

F17

2652051

Seal Retainer, Lower


Doubler Assy.

301Stainless

0.020

Fi7

2652051

2652051

Plate

2652051

2652051

Seal

301 Stainless

0.025

301 Stainless

0.020

1
1

I
I

Engine Nacelle Afterbody Repair Index


Figure 1 (Sheet 3 of 4)
EFFECTIVITY:
S~M-4

NOTED

54-30-30

Fage3
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
EFFECTIVITIES

CODES

35-002 THRU 35-035 EXCEPT 35-028, 35-033, AND 35-034; 36-002 MRU 36-016, EXCEPT 36-014
35-002 THRU 35-025, 35-027, 35-029 AND 35-030; 36-002 THRU 36-016, EXCEPT 36-014

35-026, 35-031 THRU 35-035 EXCEPT 35-033 AND 35-034

NOTES

Optional

to heat treat before

welding.

Condition Annealed.
Phenolic sheet, MIL-P-15035, Grade FBG.

Optional

to

use

Apply dissimilar

Neoprene,

2024-T3, 0.032.
metal

protection

Class I, Duro 40-60,

to stainless steel

surfaces contacting dissimilar metal per Chapter 51.

MIL-S-6855; Rubber Supply Ca., Wichita, KS.

Finish interior surface F14-1, outer surface to be Fi.


Condition 1/4 Hard.

Engine Nacelle Afterbody Repair Index


Figure 1 (Sheet 4 of 4)

EEFECTIVITY:
SRM-4

NOTED

54-30-30

Page 4
May 15/92

Learjet
STRUCTU RAL REPAIR MANUAL
ENGINE NACELLE AFTERBODY

STRUCTURAL IDENTIFICATION

22)

(7)

~2)

~23)

(24

21

19

~i--------:::
iiii

II

;I!

1111

ill

I i

ill
-~i!---

~--------,J1----------r
o

--_-

II

--n-li

,(19

m__~_

-----r;i---------

Inf~-------_

--1~1

YT
0

lot

llr

i~i 17-I I

Llr

11

15

i"! 11

~6

-B--~--

oca

-Lt_t______

fpf-Lrii----9)

-I-C*;--

rC I
I;

--II
rl
11

:I

c;

Y~

/35-028. 35-033. 35-031. 35-036 and Subseauent;


36-014. 36-027 and Subseauent: 31-002 and Subseauent)

Detail A
Engine Nacelle Afterbody Repair Index
Figure 2 (Sheet 1 of 4)
EFFECTIVITY:

NOTED

54-30-30

Page 5
SRM-4,

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

I
DESCRIPTION

I
EFF.

I
MATERIAL

GAGE

IFINISH

REPAIR

CODE

FIG. NO.

Engine Nacelle Afterbody Assy.,

2652100

LH and RH
1

2652040
2

2652040

2652040
3
4

2652040
2652040
2652040

2652040
5

2652100

2652100

2652100

2652040

2652100
2652100

10

2652100

11

2652100

Lower Outer Fwd

2024-T42 Clad

0.020

Lower Outer Fwd


Upper Outer Fwd

0.032

2024-T42 Clad
2024-T42 Clad

0.020

Upper Outer Fwd


Upper Outer Aft
Upper Outer Aft

2024-T42 Clad

0.032

2024-T42 Clad

0.020

2024-T42 Clad

0.032

Lower Outer Aft

2024-T42 Clad

0.020

Lower Outer Aft

2024-T42 Clad

Center

Inner Lower Fwd

Inner Upper Fwd


Inner Aft
Longeron, Lower

Skin,
Skin,
Skin,
Skin,
Skin,
Skin,
Skin,
Skin,
Skin,
Skin,
Skin,
Skin,

2652040

2652100
2652100
2652100

2652040

2652040

1
1

1
2
3

51-70-02

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2025-T42 Clad
2024-T42 Glad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

0.025 1
0.025 1

51-70-02

51-70-02

0.025

51-70-02

0.032

0.032

0.032

1
1
1
1
1
1
1

2024-T3 Clad
2024-T3 Clad
1 2024-T42 Clad

Door Pan
Door Skin

2652010
2652040

Angle (4 ea.)

Doubler

Tube

14

2652100

2652101

0.040

1
1

I Replace
I Replace
I Replace

I Replace

0.040

0.025

5052-0

0.375 OD

Plate

5052-0 Sht Al

0.032

I Replace

2024-T42

0.040

I Replace
Replace
Replace
I Replace
I Replace
Replace

Tubing

Angle(3 ea.)
Door Assy., Aft Engine
Flange

I
I

I
I

I Replace

Mount
1

2024-T42 Clad

0.040

Shim

321 Stainless

0.040

2652101
2652101

Splice

321 Stai n less

0.032

2024-T42 Clad
1 2024-T42 Clad

0.025

0.032

Plate
Inner Skin
Frame

2652101

I Replace

2652101

2652101

51-70-02

Assy.
Tube (0.25 OD x 0.035 Wall)
Tube(TyGon Tubing)

0.062 wall

2652040

0.025

I
0.025

Clad
Clad
Clad
Clad

51-70-02

2024-T42
2024-T42
2024-T42
2024-T42

51-70-02

0.032

0.032

0.062

51-70-02

1
1

0.032
0.032

51-70-02

0.032

0.032

0.032

51-70-02
51-70-02

I Replace
I Replace
I Replace
I Replace
I Replace
I Replace
I Replace
Replace
I Replace
Replace
I Replace
Replace
I Replace
I Replace
Replace

0.025

2652040

2652040

2024-T3

2652040

0.020

2024-T3 Clad

2652040

321 Stainless

DoorAssy.

2652040

0.032

Doubler

12652040

51-70-02

1
1
1
1
1
1

Door

2652100

2652100

51-70-02

1
1
1
i
1
1
1

Doubler

2652100

2652100

Seal
Door Assy.
Door
1
Doubler

2652040

13

Splice Doubler
Longeron, Upper
Splice Doubler
Longeron, Center
Longeron, Center
Splice Doubler
Door Assy.

2652040
12

Engine Nacelle Afterbody Repair Index


Figlre 2 (Sheet 2 of 4)

EFFECTIVITY:

NOTED

54-30-30

Page 6
SRM~

May 15/92

f~ Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

I
I

15

2652101

16

2652101

1
1

2652101

2652101

I
DESCRIPTION

17
18

Center Fwd
Lower Fwd

Lower Aft

I
GAGE

MATERIAL
Clad

0.032

Clad

0.032

Clad

0.032

Fwd

2024-T42
2024-T42
2024-T42
2024-T42

Clad

0.032

Aft

2024-T42 Clad

0.032

Door, LowerOuter
Door, Upper Outer

321 Stainless

0.020

321 Stainless

0.020

Longeron,
Longeron,
Longeron,
Longeron,
Longeron,

2652101

I
EFF.

Upper
Upper

2652101

2652101

2652105

Fire Seal Mount

301 Stainless

0.032

2652106

Outlet Box

321

0.032

2652101

ISealRetainer

Stainlessl~
321 Stainlessl~

2652101

Spacer

321 Stainless

0.032

2652101

Filler

321 Stainless

2652045

IFairingAssy
Fairing, Lower Fwd (2 ea.)
Fairing, Upper Fwd (2 ea.)
Fairing, Lower Aft (2 ea.)
Doubler, Upper Fwd

2652045
2652045

0.032

321 Stainless

0.025

321 Stainless

0.025

321 Stainless

0.025

321 Stainless

0.025

1
1
1

I
I
I

1
1
1
1
1
1
1

I
I

I
I
I
I

2652045

Doubler, Lower Fwd

321 Stainless~

0.025

1
1
1

2652045

End Retainer

321

Stainlessl~

0.025

Fwd

Aft

0.032

1
1
1

2024-T42
2024--r42
2024-T42
2024-T42

321 Stainless~

0.032

Filler, Center
Doubler, Lower Fwd
Doubler, Upper Fwd

2024-T42 Clad

0.032

0.040

2024-T42 Clad
2024-f42 Clad

0.040

I
I
I
I
I
j
I
I

2652045
2652045

2652101

2652101

Angle,
Attach Angle,

2652101

1
1

Doubler, Lower Aft


Filler, Fwd

2652101

Attach

2652101
2652101

IRetainer

2652101

2652101

0.032

REPAIR
FIG. NO.

IFINISH
CODE

Clad
Clad
Clad
Clad

0.040
0.040
0.040

2652101

Bulkhead

2024-~42 Clad

0.032

2652101

Shim

Clad

0.032

Skin Inner
Filler, Aft

Clad
Clad

0.025

19

2652101
2652101
2652056

Ring

2652042

Clad
Clad

0.032

20

2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42

Clad
Clad

0.032

1
1
1
1
1
1
1

0.032

Clad
Clad
Clad
Clad

0.032

0.032

0.032

0.032

Clad

0.040

22

23

Closure
Frame

1
1

1 2652044
2652018

Shim
Frame
Shim

2652104

Frame

2652104

2652103

Doubler
Frame

2652107

Tension

2652018
21

1
1

Angle

0.032

0.032

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Engine Nacelle Afterbody Repair Index


Figure 2 (Sheet 3 of 4)
EFFECI~IVITY:
SI~M-4

NOTED

54-30-30

Page 7
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

NO.
24

DWG.
NO.

I
DESCRIPTION

2652102

Frame

2652102

Splice

IEFF.
1

Plate

Shim

2652108
2652 1 08

Flange, Upper
Flange, Lower

2652047
2652047

Splice
Splice

2652102

Plate
Plate

1
1
1

I
MATERIAL

GAGE

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T3 Clad
2024-T42 Clad

0.032

IFINISH

REPAIR

CODE

FIG. NO.

0.040

1
1
1
1

I
I
I
I

0.040

0.032

1
1

0.032
0.040

0.050

Replace
Replace
Replace
Replace
Replace
Replace
Replace

EFFECTIVITIES

CODES

35-028, 35-033, 35-034, 35-036 AND SUBSEQUENT; 36-014, 36-017 AND SUBSEQUENT; 31-001

AND SUBSEQUENT

35-028, 35-033, 35-034, 35-036 THRU 35-103; 36-014, 36-017 THRU 36-029
SUBSEQUENT; 36-030 AND SUBSEQUENT; 31-001 AND SUBSEQUENT
35-028, 35-033, 35-034, 35-036 THRU 35-042; 36-014
35-043 AND SUBSEQUENT 36-017 AND SUBSEQUENT; 31-001 AND SUBSEQUENT
35-589 AND SUBSEQUENT 36-054 AND SUBSEQUENT; 31-001 AND SUBSEQUENT
35-028, 35-033, 35-034, 35-036 THRU 35-353; 36-014, 36-017 THRU 36-045
35-354 AND SUBSEQUENT; 36-046 AND SUBSEQUENT; 31-001 AND SUBSEQUENT

35-104 AND

3
4
5
6

NOTES
Condition Annealed.

Optional

to

Neoprene,

use

2024-T3, 0.032.

Class I, Duro 40-60, MIL-S-6855; Rubber

Supply Co., Wichita,

KS.

1/4 Hard Condition

Engine Nacelle Afterbody Repair Index


Figure 2 (Sheet 4 of 4)
EFFECTIVITY:
SRM4

NOTED

54-30-30

Page 8
May 15/92

STRUCTURAL REPAIR MANUAL


ENGINE NACELLE AFTERBODY
i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS
All dimensions

NOTE:
A.

are

specified.

Fasteners

(1) Loose
tions

or

failed rivets
the

on

performed
fer to Chapter 51
(2) Loose

or

trations

are

remaining

to

ensure

not allowed. A loose or failed rivet can cause increased stress concentra-

rivets and lead to

that

joint

progressive joint failure. A careful inspection must be


spread from the area of the loose or failed rivet. (Re-

failure has not

for definition of rivet failure.)


failed screws are not allowed. A loose

on

performed
B.

in inches unless otherwise

surrounding
to

ensure

screws

that the

and lead to

joint

or

failed

screw can cause

increased stress

failure. A careful

concen-

progressive joint
spread from the area of the loose or failed

failure has not

inspection must

be

screw.

Cracks

paired,

and refinished

not allowed. Cracked

fittings or forgings must be replaced.


considered allowable if properly
forgings
in accordance with Chapter 51.

(1) Cracks in any fitting or forging are


(2) Cracks in components other than

fittings

and

C.

Deformation

D.

(1) Deformation of the engine nacelle afterbody structure is


Corrosion(See Figure 101.)

are

not

re-

allowed.

damage is permissible if the affected area is properly repaired, refinished in accordance


Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness more than specified.

(1) Corrosion
with

E.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
are not allowed if sharp, a fracture of the skin has occurred,

greater than 0.100 inch (2.54


mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component re-

(2) Dents

F.

G.

H.

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(See Figure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Rcfer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTIVITY:
sRM-a

ALL

54-30-30

Fage 101
May 15/92

STRUCTURAL REPAIR MANUAL

Nominal Thickness

EFFECTIVITY:
SRM-4

ALL

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

54-30-30

Page 102
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ENGINE NACELLE AFTERBODY
1.

APPROVED REPAIRS

A.

Refer to

EFFECTIVITY:
SRM~

REPAIR

Chapter 51

ALL

for

typical repairs for the nacelle afterbody.

54-30-30

Page 201
May 15/92

Learjet

MANUAL
REPAIR
RAL
SfRUCTU
ASSEMBZ~LY
EXHAUST NOZZZ~E

ENGINE

STRUCTURAI~ IDENTIEICATION

zI

)i

i? \:5
s.~

P~

~fiI

I;

u:
i?

~5

~5"-r
i

fs

;c~,,x

Nozzle AssemblY Repair


Engine Exhaust
1 of 2)
Figure 1(Sheet

Index

54-30-40

EFFECTIVITY:
SRM-4

ALL

Page 1
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
I

DWG.
NO.

ITEM

NO.

I
EFF.

I
MATERIAL

LH and RH

2652065

Cone

Hastelloy per
AM5 5536

2652065

Ring

Hastelloy

per
AM5 5536

2652065

Support Flange

Hastelloy

CODES
1

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

EngineExhaust NozzleAssy,

2652065
1

I
DESCRIPTION

per
AM5 5536

0.025

I Replace

0.032
0.094

I Replace

I Replace

EFFECTIVITIES
31-001 AND

SUBSEQUENT; 35-002 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

Engine Exhaust Nozzle Assembly Repair Index


Figure 1 (Sheet 2 of 2)
EFFECTIVITY:
SRM~

ALL

54-30-40

Fage 2
May 15/92

Learjet
11~t1

STRUCTURAL REPAIR MANWAL


ENGINE EMIAUST NOZZLE ASSEMBLY
i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS

All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

failed rivets

or

the

are

not allowed. A

loose

or

failed rivet

can cause

increased stress concentra-

rivets and lead to

progressive joint failure. A careful inspection must be


performed to ensure that joint failure has not spread from the area of the loose or failed rivet. (Refer to Chapter 51 for definition of rivet failure.)
on

(2) Loose

or

remaining

failed

screws are

not allowed. A loose or

failed

screw can cause

increased stress

concen-

surrounding screws and lead to progressive joint failure. A careful inspection must be
performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
trations

B.

on

Cracks

(1) Cracks in any fitting or forging are


(2) Cracks in components other than

not allowed. Cracked

fittings and forgings


paired, and refinished in accordance with Chapter 51.

C.
D.

re-

Deformation

(1) Deformation of the engine exhaust nozzle assembly structure is not allowed.
Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

fittings or forgings must be replaced.


considered allowable if properly

are

more

than

specified.

Dents

(1) Dents

permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not

(2.54

are

closer than 0.50 inch (12.7 mm) to any rivet or structural area.
are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
in
mm)
depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component re-

(2) Dents

placed.
F.

Scratches(See FigurelOl.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to

Chapter 51

protective treatment procedures.)


must be

than

specified.

thickness

G.

for

(2) Structural components

by

more

replaced

or

repaired

if scratches reduce the

original

material

Nicks(See Figure 101.)


(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to

Chapter 51

for

protective treatment procedures.)


must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.
(2) Structural components

I-I.

EFFECTIVITY:
SRM-L

ALL

54-30-40

rage 101
May 15/92

STRUCTURAL REPAIR MANUAL

Nominal Thickness

EFFECTIVITY:
SRM-4

ALL

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

54-30-40

Page 102
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ENGINE EXHAUST NOZZLE ASSEMBLY
i.

APPROVED REPAIRS
A.

Refer to

EFFECTNITY:
SRM~

REPAIR

Chapter 51

ALL

for

typical repairs for the exhaust nozz)e assembly.

54-30-40

Page 201
May 15/92

STRUCTURAL REPAIR MANUAL


PnON

STRUCTURAL LDENTIFICATION

a
00

(LH SHOWN, RH TY~PICAL)

Detail A
(31-002 and Subseaue~t: 35-092 and Subseauent: 36-902 anbSubseauent)

Pylon Repair Index


Figrtre 3 (Sheet 1 0~5)
EFFECIIVITY:
SRM~

NOTEI~

54-50-00

Page 1
May 15/92

STRUCTURAL REPAIR MANUAL


PYLON- STRUCTURAL IDENTIFICATION

(35-002 Thru 35-153 Qnlu:36-002 Thuu 36-038 Onlvl

Detail B
B

~I

81-002 and Subseauent; 35-002 and Subseauent;


36-002 and Subseauent)

Detail A
Pylon Repair Index
Figure 1 (Sheet 2 of 5)
EFFECTIVITY:
SRM4

NOTED

54-50-00

Page 2
May 15/92

Learjet

STRUC~TURAL REPAIR MANUAL


ITEM
NO.

DVVG.
NO.

LH 6 RH

I
EFF.

Pylon Instl.,
Nose Rib
Former

Doubler, Upper
Doubler, Lower

Stiffener
Rib

2652090
2612412
2652070
2652070

Support Angle

Intercostal

Drag Angle, Upper


Drag Angle, Lower

1
1

2652072

Former

2652072

Support Angle

2652070
2652070

Support,

1
1

2652072

2652070
2652070
2652072
2652072
2652072

12652072
2652090
2652090

2652072
2652090
2652072
2652072

2652072
2652090
2652090

2652090
4

DESCRIPTION

2652072

2652072
2652072
2652072

2652090
2652072

12652072
2652072

Support,
Support, Upper
Support, Upper
Bracket(2 ea.)
Clip Angle
Clip Angle
Splice
Support Assy, Lower
Support, Lower
Clip Angle
Spacer, Upper
Clip Angle
Bracket Assy
Bracket

Spacer, Lower
Support Assy, Upper
Support, Upper
FormerAssy

GAGE

REPAIR
FIG. NO.

CODE

2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
6061-T6
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42

301Stainless

0.020

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

0.063

2024-T42 Clad

0.040

2024-T42 Clad

0.063

2024-T42 Clad

0.063
0.040

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-142 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

2024-T42 Clad

0.040

2024-T42 Clad

0.063

1
1

Lower
Lower

IFINISH
MATERIAL

1
1

1
1

Clad
Clad
Clad
Clad
Clad
Clad

0.032 1
0.040

0.040
0.040

0.040

1
I
I
I

0.032
0.040

Clad
Clad
Clad

Clad
Clad
Clad
Clad
Clad
Clad
Clad
Clad
Clad

0.050

I
I

0.040
0.040
0.040
0.040

0.080
0.080

0.080

0.080

0.040

I
I

0.040
0.040

51-70-03

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Replace
Replace
Replace
Replace

1
1
1
1

0.063

Replace
Replace
Replace
Replace

I
I

Replace
Replace

Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.040

0.040

1
1

Former

2652072
2652072

Angle
Angle

2652072
2652072
2652090
2652090

Doubler

Stiffener

Drag Angle, Upper


Spacer, Upper

2652072

Doubler

2652090
2652090

Support Assy
Spacer, Upper

6
6

0.032

1
I

0.032
0.040

0.040

1
I

0.040

0.063

I
I

Replace

Pylon Repair Index


Figure 1 (Shect 3 of 5)
EFFECTIVITY:
SRM-4

NOTED

54-50-00

Page 3
May 15/92

STRUCTURAL REPAIR MANUAL


ITEM

NO.

2652090
2652090
2652090
2652090
2652090
2652090
2652090
2652090
2652090
2652090
2652090
5

DWG.
NO.

2652090
2652090
2652072
2652072
2652072
2652090

Support, Upper
Support Assy
Spacer, Lower
Support, Lower
1
Splice Assy
Splice
Drag Angle, Lower
Support Assy, Lower
Support, Lower
Support Assy, Upper
Support, Upper
Splice Assy
Splice Plate
FormerAssy

1 Former

FIG. NO.

1 2024-T42 Clad

0.063

I Replace

6
6

2024-T42 Clad

0.063

Replace

2024-T42 Clad

0.063

1
1

12024-T3Clad
2024-T42 Clad

0.080
0.040

I Replace
1 Replace
I Replace
Replace

2024-T42 Clad

0.063

I Replace

1 2024-T42 Clad

0.063

2024-T42 Clad

0.080

Clad

0.040

I Replace

Clad
Clad
Clad
Clad
Clad

0.040

Replace
Replace
I Replace
Replace
I Replace
Replace
Replace
I Replace
Replace
Replace
Replace

2
2
1
1
1
1

I Replace

1
1

Replace

2024-T42
2024-T42
2024-T42
1 2024-T42
2024-T42
2024-T42

2652072

Doubler, Lower

2652072

321 Stainless

0.032

2652072
2652090

Rib
Doubler

321Stainless
321 Stainless
32 i Stainless
2024-T42 Clad
2024-T3 Clad

0.032

2652072

Angle, Upper
Angle, Lower
Angle, Upper (2 ea.)
Angle, Lower (2 ea.)

2652072
2652072

FormerAssy

Former

2024-T42 Clad

0.040

2652072
2652072

Angle

2024-T42 Clad
2024-T42 Clad

0.040

I Replace
I Replace

0.032

Replace

2652072
2652072

1
1
1

8
1

1 Rib
Former Assy
1 Former

Angle

10

2652072

Rib

11

2652072

Former Assy
Former

2652072

2652072
2652072

0.050

0.050
0.040

0.040

0.032
0.032

1
1
1

0.032
0.040

2652072

12

REPAIR

CODE

2652072

2652072

IFINISH
GAGE

2652072

I
MATERIAL

Angle
Drag Angle
Drag Angle, Lower
Doubler, Upper

2652090

EFF.

DESCRIPTION

0.040 1

51-70-03

51-70-03

0.040 1

51-70-03

Replace

I Replace

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

0.040

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

0.040

0.032

Replace

0.032 1

1
1

Angle

Rib

Pylon Repair Index


Figure 1 (Sheet 4 of 5)
EFFECTIVITY:
SRMI

ALL

54-50-00

Page 4
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
DWG.
NO.

ITEM
NO.

DESCRIPTION

EFF.

MATERIAL

GAGE

13

2652072

Former

2024-T42 Clad

0.040

Angle, Lower
Angle, Upper
Support Angle

Rib

Filler

2652072

Spacer
Spacer

Skin

321 SS Annealed
321 SS Annealed
2024-T42 Clad
2024-T42 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T3 Clad
2024-T3 Clad

0.032
0.032

14

2652072
2652072
2652072
2652072
2652072

16

2652072
1 2652070
2652090
2652090

17

2652090

18
19

2652090

20

2652090

21

2652090

22

2652090

23

2652090
2652090

24

15

Skin

Skin,
Skin,
Skin,
Skin,

Upper

Lower

Upper
Upper,
Skin, Upper,

2652090

Inboard

FINISH
CODE

REPAIR
FIG. NO.

Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.032
0.040
0.500
0.125
1.000

Replace

0.032

51-70-02

0.040

51-70-02

0.032

51-70-02

0.032

51-70-02

0.032

51-70-02

0.032

51-70-02

Outboard

321 Stainless

0.032

51-70-02

321Stainless

0.032

51-70-02

0.032

51-70-02
51-70-02

0.032

51-70-02

26

321Stainless
32 1 Stainless I~
2024-T3 Clad
2024-T3 Clad
2024-T42 Clad
2024-T42 Clad

0.032

2652090
2652090
2652090

Closeout, Aft
Firewall, Forward
Skin, Lower, Outboard
Skin, Lower, Inboard
Skin, Lower
Skin, Upper, Forward
Skin, Upper, Aft

27
28

2612042
2612056

Engine Support Fitting, Fwd


Engine Support Fitting, Aft

25

1
1
1

6
6

51-70-02

0.032
0.032

51-70-02
51-70-02

0.040

Replace
Replace
Replace

0.032

51-70-02

0.032

51-70-02

1
1

2652056

Former

29

2652090

30

2652090

Skin, Lower, Aft


Skin, Lower, Forward

CODES

0.032

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

EFFECTIVITIES
31-002 AND

SUBSEQUENT; 35-002 AND SUBSEQUENT; 36-002 AND SUBSEQUENT


35-529; 36-002 THRU 36-053

35-002 THRU

2
3

35-002 THRU 35-022; 36-002 THRU 36-038


35-023 AND SUBSEQUENT; 36-014 AND SUBSEQUENT
35-028, 35-033, 35-034, 35-036 AND SUBSEQUENT; 35-014, 36-017 AND SUBSEQUENT
35-530 AND SUBSEQUENT; 36-054 AND SUBSEQUENT; 31-002 AND SUBSEQUENT
35-002 THRU 35-153; 36-002 THRU 36-038

35-154 AND

4
5

SUBSEQUENT; 36-039 AND SUBSEQUENT

NOTES

Condition Annealed

1/2 Condition Hard

Pylon Repair Index


Figure 1 (Sheet 5 of 5)
EFFEC~TVITY:
SRM-P

ALL

54-50-00

Page 5
May 15/92

Learjet
Learietl
STRUCTURAL REPAIR MANUAL
PnON
i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS
All dimensions

NOTE:

A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose

or

failed rivets

are

not allowed. A loose

or

failed rivet

can cause

increased stress concentra-

Progressive joint failure. A careful inspection must be


performed to ensure that joint failure has not spread from the area of the loose or failed rivet. (Refer to Chapter 51 for definition of rivet failure.)
tions

the

on

(2) Loose

or

remaining

failed

rivets and lead to

screws are

not allowed. A loose

or

failed

screw can cause

increased stress

concen-

surrounding screws and lead to progressive joint failure. A careful inspection must be
performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
trations

B.

on

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

re-

paired, and refinished in accordance with Chapter 51.


C.

Deformation

D.

Corrosion(See Figure 101.)


(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than speci-

(1) Deformation of the

pylon assembly

structure is not allowed.

fied. (Refer to Chapter 51 for protective treatment procedures.)


(2) Structural components must be repaired or replaced if corrosion repair reduces the
rial thickness
E.

more

than

original

mate-

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component reF.

G.

Fl.

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refjnished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings andForgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTIVITY:
SRM-4

ALL

54-50-00

Page 101
May 25/92

Leariet
STRUCTURAL REPAIR MANUAL

Nominal Thickness

(Inch)

Minimum Thickness

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness


Figure 101

EFFECTIVITY:

ALL

54-50-00

Page
SRMII

102

May 15/92

Learjet

STRUCTURAL REPAIR I~ANUAL


PYLON- REPAIR
1.

APPROVED REPAIRS
TEMPORARY (NON-FLUSH) REPAIR TO THE UPPER AND LOWER SURFACES
OF THE PYLON MAY AFFECT FLIGHT CHARACTERISTICS OF THE AIR-

WARNING:

CRAFT. A FLIGHT CHECK MUST BE MADE. (REFER TO 51-10-00.)


ALL TEMPORARY (NON-FLUSH) REPAIRS MUST BE CHANGED TO PERMA-

NENT TYPE REPAIRS AT THE EARLIEST POSSIBLE TIME.


A.

Chapter 52 for typical repairs, and for allowable


attaching parts located within the pylon assembly.

Refer to

and

EFFECTIVITY:
SRM4

ALL

wear

and

repair

data for

fittings, forgings

54-50-00

Page 201
May 15/92

CHAPTER

STABILIZERS

Learjet
~Learjetl

STRUCTURAL REPAIR MANUAL


Chapter
Section

Subject

Subject

STABILIZERS- STRUCTURAL IDENTIFICATION

Description

Repair Index

HORIZONTAL STABILIZER

Description

.........,55-00-00

............................................................................................................................55-00-00

Stabilizers Master

...........................................................................................55-00-00

STRUCTURAL IDENTIFJCATION..................................55-10-00
1

............................................................................................................................55-10-00

Horizontal Stabilizer
Horizontal Stabilizer

Repair Index
Repair Index

HORIZONTAL STABILIZER
Allowable Damage Limits
HORIZONTAL STABILIZER

(ModeE 23124/25/28/29131 Series Aircraft)..............55-10-00


(Model 35/36 Series Aircraft)
ALLOWABLE DAMAGE

..................................55-10-00

..................................................55-10-00

101

....................................................................................................55-10-00

General

REPAIR. . . .,. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55-10-00


201

...............................................................................................................,..................55-10-00

Limitations and

Inspections.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55-10-00

201

Materials and Processes


Repair Procedures

55-10-00

Spar Cap Repair

202

............................................................55-10-00

ELEVATOR- STRUCTURAL IDENTImCATION........................

....55-20-00
1

............................................................................................................................55-20-00

(Model 23124125 Series Aircraft)


(ModeI 28/29/31/35/36 Series Aircraft)

Damage

,..................................................55-20-00

ELEVATOR- ALLOWABLE DAMAGE


Allowable

201
202

..................................................................................................................55-10-00

Horizontal Stabilizer Rear

Description
Elevator Repair Index
Elevator Repair Index

Page

Limits

.........................................55-20-00

................................................................................55-20-00

101

....................................................................................................55-20-00

ELEVATOR- REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55-20-00

Approved Repairs
Description

201

..................................................................................................................55-20-00

VERTICAL STABILIZER

STRUCTURAL IDENTIFICATION

.........................................55-30-00

............................................................................................................................55-30-00

Vertical Stabilizer Repair Index

(Mode2 23/24/25 Series Aircraft)...................................55-30-00


Vertical Stabilizer Repair Index (Model 28/29/31 Series Aircraft)
Vertical Stabilizer Repair Index (ModeI 35/36 Series Aircraft)
VERTICAL STABILIZER ALLOWABLE DAMAGE..........................................................55-30M)
Allowable Damage Limits

55-30-00

55-30-00

14

101

....................................................................................................55-30-00

VERTICAL STABILIZER

Approved Repairs
FIN TIP
Fin
Fin

Tip
Tip

FIN TIP

REPAIR

201

..................................................................................................................55-30-00

STRUCTURAL IDENTIFICATION
Repair Index (Model 23/24/25/35/36 Series Aircraft)
Repair Index (Model 28/29131 Series Aircraft)
ALLOWABLE DAMAGE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,55-35-00
.......................................................................55-35-00

...........................................55-35-00

.....................................................55-35-0O

Allowable Damage Limits


REPAIR

FIN TIP

....55-30-00

101

....................................................................................................55-35-00

.....................................................................................................................55-35-00

Approved Repairs

55-35-00

201

55-Contents

Page
SRM-I

Jan 15/93

Learjet I

STRUCTURAL REPAIR MANUAL


Chapter
Section

Subj ect
RUDDER

Subject
TRIM TAB

Description
Rudder

STRUCTURAL IDENTlmCATION............................................55-40-00
1

............................................................................................................................55-40-00

Trim Tab

Page

Repair Index

(ModeI 23 Aircraft and Early Model 24/25 Series Aircraft)


Trim Tab Repair Index
(Late Model 24/25 Series Aircraft and Model 28/29131/35/36 Series Aircraft)................55-40-00
RUDDER
TRIM TAB ALLOWABLE DAMAGE
.............................................55-40-00

Rudder

............................................................55-40-00

Allowable
RUDDER

Damage Limits
TRIM TAB

Approved Repairs

I,,

REPAIR

.........,55-40-00

101

.........55-40-00
......55-40-00

201

Page

Learjet
STRUCTURAL REPAIR WIANUAL
Chapter

Chapter
Section

Subject
55-TITLE
55-List of Eff.

Page

Pgs.

55-Contents
55-Contents
55-00-00
55-10-00
55-10-00
55-10-00
*55-10-00
*55-10-00
55-10-00
Y
55-10-00
55-10-00
"55-10-00
55-10-00
"55-10-00
55-10-00
*55-10-00
55-10-00
55-1MX)
55-10-80
55-10-00
55-10-00
55-10-00
55-10-00
55-10-00
55-20-00
55-20-00
55-20-00
55-20-00
Y

55-20-00
55-20-00
55-20-00
55-20-00
55-20-00
55-20-00
55-30-00
55-30-00
55-30-00
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2
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3
4

5
6
7
8
9
10
11
12

13
24
101
102
201

202
203
204
205
1
2

3
4

5
6
7
101
102
201
1

3
4

5
6
7

Date

Jun 1/9s
Jan 15/93
Tan 35/93

May 15/92
May 15/92
May 15/92
Jun 1/95
Jun 1/95
Jun 1/95
Jun 1/95
Jun 1/95
Jun 2/95
Jun 1/95
Jun 2/95
Jun 1/95
Jun 2/95
Jun 1/95
Jun 1/95
May 15/92
May 15/92
Jan 15/93
lan 15/93
Jan 15/93
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May 15/92
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Section

Subject

1
I
1
1
1
1
1
1
1
1
1
1

f
1

1
1

55-30-00
55-30-00
55-30-00

55-30-00
5530-00
55-30-00
553000
5530-00
55-30-00
55-30-00
5530-00
5530-00
55-30-00
5530-00
5530-00
55-35-00
55-35-00
5535-00
55-35-00
55-35-00
55-35-00
55-35-00
55-35-00
5535-00

11

55-35-00

55-35-00

1
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Page

55-40-00
55-QOM)
55-40-00
55-40-00

55-40-00
55-40-00
55-40-00
55-40-00
55-40-00

Date

May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 35/92
May 15/92
May 15/92
May 15/92
May 35/92
May 15/92
May15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 25/92
May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
May 15/92
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9
10
12
13

14
IS
16
17

18
19
101

102
201
1

3
4

5
6
7
8

101

102
201
1

2
3

4
5
6

102
102
201

Pages; Destroy Superseded or Deleted Pages.

Asterisk indicates pages revised, deleted, or added by current revision.


The portion of the text affected by the current revision is indicated by a vertical line in the outer

of the

margin

page
55

SRM-4

List of Effective

Pages
Page 1

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


STABILIZERS- STRUCTURAL IDENTIFICATION
i.

DESCRIPTION
NOTE

The

the

following structural data covers the basic non-modified aircraft. When applicable, refer to
appropriate kit drawing for additions, modifications and changes to the structural compo-

nents and assemblies.

A.

This

chapter

covers

structural

components, allowable damage limits, skin gap tolerances and repair

of aircraft stabilizers.
B.

C.
D.

Stabilizers include the horizontal stabilizer, elevators, vertical stabilizer and rudder.
Repair indexes are incorporated in each respective section for the specific components.
Allowable damage limits for each component are given in each respective section.

Chapter
Section

Description

Item

Subject

Horizontal Stabilizer

Elevator

55-20-00

Vertical Stabilizer

55-30-00

Rudder and Trim Tab

55-40-00

55-1 0-00

bfi~

Stabilizers Master

14-193A

Figure
EFFECTIVITY:
snxn~

ALL

Repair Index
1

55-00-00

Page 1
May 15/92

Leariet
~Learjetl

STRUCTURAL REPAIR WIANUAL


HORIZONTAL STABILIZER
i.

STRUCTURAL IDENTIFICATION

DESCRIPTION
NOTE

The
the

following structural data covers the basic non-modified aircraft. When applicable, refer to
appropriate kit drawing for additions, modifications and changes to the structural compo-

nents and

A.

The

assemblies.

one-piece horizontal stabilizer is attached to the vertical stabilizer at two points.


serves as a pivot and consists of a large pin inserted through bearings

(I) The aft point

in the hori-

zontal and vertical stabilizers.

(2) The forward attach point attaches to the jack screw end of the horizontal stabilizer
(3) The base of the actuator is secured to the vertical stabilizer forward spar.
B.

C.

The horizontal stabilizer is constructed of spare and ribs covered with skin.
Access covers on the bottom skin of the horizontal stabilizer provide access to the

EFFECTIVITY:
SRM-4

ALL

actuator.

hinge points.

55-10-00

Page I
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


HORIZONTAL STABILIZER

STRUCTURAL IDENTIFICATION

C
D
t

E
51)(50) (49) (18)(47) (45)

(14)

(43)

(42

Detail A
A5-21C

Horizontal Stabilizer

Repair Index

Figure 1 (Sheet 1
EFFECTIVITY:

of 7)

MODEL 23/24/25/28/29/31 SERIES AIRCRAFT

55-10-00

Page
SIIM-4

May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


HORIZONTAL STABILIZER

STRUCTURAL IDENTIFICATION

~Y

Detail B

Detail C

21/BI
(31-078 and Subseauent)

(A2l 20 Series Aircraft and 31-001 Thru 31-077)

Detail D
814C

Horizontal Stabilizer

Figure

EFFECTIVITY:

Repair Index

1 (Sheet 2 of 7)

MODEL 23/24/25/28/29/31 SERIES AIRCRAFT

55-10-00

Page 3
SRM-4

Jun 1/95

Learjet
STRUCTORAL REPAIR MANUAL
STRUCTURAL IDENTIFICATION

HORIZONTAL STABILIZER

zsl

32)r(

//I

rso

(30

"n~8
Detail E
E5-20B1

Horizontal Stabilizer

Figure
EFFECTIVITY:

Repair

Index

(Sheet 3 o~ 7)

MODEL 28/29/31 SERIES AIRCRAFT

55-10-00

Page 4
SRM-I

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


ITENII
NO. I

DWG.
NO.

2332000

2332000
2332014

I
EFF.I

Assembly

I
MATERIAL

IFINISH
GAGE

REPAIR
FIG. NO.

CODE

Skin, Leading Edge LH and RH


Skin, LH 8 RH Upper
Skin, LH 8 RH Lower
Tip Cover, LH and RH

2332000
3

I
DESCRIPTION
Horizontal Stabilizer

2332000
t

2024-T42 Clad
2024-T42 Clad

2024-T42 Clad

6061-T42

0.040 1

51-70-02

0.050 1

51-70-02

0.050 1
1
0.040 F11)-)int

51-70-02
51-70-02

Flext

2332013

Hinge Assy., Outbd


Bracket, Outbd
Bracket, Inbd

2024-T42 Clad

0.080

F4-1

2024-T42 Clad

0.080

F4-1

Replace
Replace

Hinge Arm
Filler, Upper

2024-T42 Clad

0.250

F4-6

51-71-08

2024-T3 Clad

0.125

F4-1

2332013
2332013
2332013
2332013
2332013
2332018
2332018

10

2332018

11

12

2332018
2332018

13

2332018

5
6
7
8

2332018

15

8 Lower

Shim, Laminated (Max. 0.030)

Hinge Assy., Outbd LH

8 RH

Hinge Arm

Hinge Assy., Inbd LH

0.003

Hinge Arm

2332018

Bracket, Inbd

2024-T42 Clad

18

2332018

23

Shim, Laminated (Max. 0.030)


Center

0.071

1
1

I Replace
I Replace

0.160
0.071

0.003

51-71-08

Replace
Replace

51-71-08

14

Clip

Filler

Shim, Laminated (Max. 0.030)


Shim, Laminated (Max. 0.063)
Hinge Instl., LH 8 RH Center

3532000

0.250 1

Channel

2332019
2332019

0.003

2332018

22

Replace
Replace

0.071

16

21

51-71-08

2024-T42 Clad

17

20

IHingelnstl.,

0.250 1

2332018

2332019
2332019
2332019

Replace
Replace

0.160

6 RH

0.071

Bracket, Outbd
Filler, Upper 8 Lower

2332019

Replace
Replace

2024-T42 Clad
2024-T3 Clad
2024-T4 Clad

2024-T42 Clad
2024-T3 Clad
2024-T4 Clad

19

Bracket, Outbd
Filler, Upper 8 Lower
Bracket, Inbd
Shim, Laminated (Max. 0.030)

2332018
14

LH 8 RH

14

2024-T42 Clad

14

S-502

14

2024-T42

0.071

I Replace
0.080

Replace
Replace
Replace

0.003

142

0.003

15

Elevator
3532003
23a

3532001

23b

3532001
MS27641-4

23e

Hinge Assy. (2 ea.)


HingeArmAssy.
Hinge Arm
IBearing

15
2024-T3 Clad

15
15

Bracket, Elevator Center

3532002

I
I

15

15

0.250

I
I
1
I

I
I
I

301 Stainless

Replace
Replace
Replace
Replace
Replace

Hinge
MS21069L08
3532001

3532001
3532001

INutplate

15

2024T3 Clad

0.016

F4-6

Spacer

15

2024T3 Clad

0.080

F4-6

151~

Shim

Horizontal Stabilizer

Figure
EFFECTIVITY:

15

Filler(2 ea.)

Replace
Replace
Replace

Replace

Repair Index

1 (Sheet 4 of 7)

MODEL 23/24/25/28/29/31 SERIES AIRCRAFT

55-10-00

Page 5
SRM-4

Jun 1/95

Learjet

STRUCTURAL REPAIR AAANUAL


ITEM
NO.

DWO.

2332050
24

I
EFF.

DESCRIPTION
Bracket Instl.

I
GAGE

2024-T42 Clad

0.250

2024-T42 Clad

0.250

2332050

Doubler

2024~T42 Clad

0.080

2332050

Angle

2024-T3 Clad

0.040

2332050

Doubler, (LH Only)

4130 Steel

0.080

0.080

I
I

2024-T42 Clad

0.090 1

51-71-00

4130 Steel

1.300

Replace
Replace
Replace

51-71-08

Replace
Replace

Doubler

4130 Steel

2332050

Stiffener

S-551

2332050

Stop Plate
Filler, Laminated (Max. 0.070)
Doubler, LH Only
Angle
Rib, LH and RH

2024-T4 Clad

2332050

2332050
2631512

Retainer

2832052

27

2332050

28

2332050

29
30

11

S580

9
12
10

10

S-551

2332050
2332050

Doubler

10

2332050

Angle

31

2332050

Lower

32

2332050

Pointer

33

2332050

34

2332050
2332010
2332010

37

2332010

38

2332010

39

2332010

40

2332010

2332012
2332012

2332012
2332012
42

2332012

43

2332011

Cap

Stop Plate
Skin, Upper 8 Lower
Spar Assy., Rear
Spar Cap, Upper 8 Lower
Web, LH 8 RH
Angle, LH 8 RH
Angle, LH 8 RH
Web, LH 8 RH
Angle, LH 8 RH
Rib

Assy., LH

Rib (2

0.500

Stiffener
Filler, Laminated (Max. 0.063)

36

4130 Steel

12

Fitting
Upper Cap

2024-T42

35

0.003

10

2332010

I
0.250

4130 Steel

Stud, Dual

2631515
26

0.071

Assy.

12

Bracket, LH 8 RH

2631517

0.250

F8-1

0.003

10

2024-T42 Clad

0.080

2024-T~ Clad

0.063

10

2024-T42 Clad

0.250

2024-T3 Clad

0.050

2024-T4 Clad

0.250

2024-T42 Clad

0.063

1
I
1
1

S-740 (Alt S-584)

2024-T3 Clad

S-571

S-571

2024-T3 Clad

S-571

8 RH

I
1

51-70-02

51-70-04

51-70-04

0.040 1

51-70-02
51-70-04

1
1

2024-T42 Clad

0.032 1

51-70-03

2024-T42 Clad

0.040

2024-T3 Clad

0.040

2024-T42 Clad

1
0.032 1

Replace
Replace
Replace

51-70-03

Replace
Replace

ea.)

Clip
Clip
Rib Tip, LH 8 RH
Rib Assy., LH 8 RH

Rib

2024-T42 Glad

0.032 1

2332011

Rib

2024-T3 Clad

0.032

2024-T42 Clad

0.032

Clip
Clip(4 ea.)

Horizontal Stabilizer

Figure
EFFECTIVITY:

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.050 1

2332011

2332011

FIG. NO.

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2332050

2332050

CODE

1
9

2332050

41

IFINISHI REPAIR

MATERIAL

Cap, Upper
Cap, Lower

2332050
2332050

25

NO.

Repair Index

1 (Sheet 5 of 7)

MODEL 23/24/25/28/29/31 SERIES AIRCRAF~

55-10-00

Page 6
SRM-4

Jun 1/95

Learjet
Learjetl

.STRUCTURAL REPAIR MANUAL


ITEM(
NO.

DWG.
NO.

I
DESCRIPTION

EFF.

I FINISH( REPAIR
MATERIAL

44

2332011

Rib

45

2332000

2024-T42 Clad
S-554

46

2332000

S-554

47

2332011

Stringer, LH 8 RH Lower
Stringer, LH 8 RH Upper
Rib Assy., LH 8 RH
Rib

2332011

Rib

233201 i

Clip
Clip(4 ea.)

48

2332011

Rib, LH 8 RH

49

2332000
2332000
2332011
2332011
2332011

Stringer,

2332011

Rib

52

2332011

Rib, LH

53

2332000
2332000
2332011

Stringer, Upper LH
Stringer, Lower LH

51

54

2332011

Rib

2332011
55
56

57

2332011
2332010
2332010
2332010
2332010
2332010
2332010
2632010
2332012

2332012
2332012

2332012
2332012

2332012
2332012
2332012

51-70-03
51-70-04

51-70-04

51-70-03

0.032

0.032

Repalce

0.032 1

51-70-03

LH 8 RH

S-554

RH

I Replace

1
1

51-70-04

51-70-03

1
1

51-70-03

51-70-04

8 RH

2024-T3 Clad

0.050

2024-T3 Clad

0.032

2024-T42 Clad

0.032 1
0.032 1

8 RH

2024-T42 Clad
S-554

8 RH

S-554

51-70-04

51-70-04

Clip

Clip (4 ea.)
Rib, LH 8 RH
Spar Assy., Front

2024-T42 Clad

2024-T3 Clad

0.032 1

51-70-03

51-70-03

0.040 1

51-70-02

0.050 1

51-70-02

51-70-04

51-70-04

0.032

2024-T3 Clad

0.050

2024-T42 Clad

0.032 1

S-739 (Alt S-584)

Web, Outboard LH 8 RH
Web, Inboard LH 8 RH
Angle, LH 8 RH (3 ea.)

2024-T3 Clad

1
1

2024-T3 Clad
S-571

Filler, LH 8 RH
Filler, LH 8 RH (4 ea.)

2024-T3 Clad

0.080

6061-T6 Clad

0.080

Spar Cap, Upper 8

Rib Assy., LH 8 RH
Cap, Bottom LH 8

0.032 1

Lower LH 8 RH

Rib Assy., LH 8 RH
Rib

2332011

0.032 1

2024-T42 Clad
2024-T3 Clad

2024-T42 Clad
2024-T42 Clad
S-554

Stringer, Upper
Rib Assy., LH 8
Clip(G ea.)
Rib Clip

FIG. NO.

CODE

2332011

50

GAGE

Lower

51-70-04

RH

Cap, Top LH 8 Bottom RH


Filler, Top 8 Bottom

S-586
S-586

2024-T3 Clad

0.400

2024-T3 Clad

0.400

Top

Filler, Top 8 Bottom


Shim, Laminated (Max. 0.032)
Angle, Inboard Aft End

0.003

1
1

2024-T42 Clad

0.100

2024-T42 Clad

0.100

2332012

Angle, Inboard Aft End


Angle, Inboard Fwd End

2024-T42 Clad

0.100

2332012

Web

2024-T3 Clad

0.100 1

2332012

Doubler

13

2024-T3 Clad

0.025

2332015

Hinge Assy.

51-70-04

51-70-02

F4-1

I Replace

Horizontal Stabilizer Repair Index

Figure 1 (Sheet 6 of 7)
EFFECTIVITY:

MODEL 23/24/25/28/29/31 SERIES AIRCRAET

55-10-00

Page 7
SRM-I

Jun 1/95

Learjet
IL~riii
STRUCTURAL REPAIR MANUAL
ITEM

DWG.
NO.

NO.
58

DESCRIPTION

51-70-03
51-70-03

Gusset

2024-T42 Clad

0.100

Doubler

2024-T3 Clad

0.100

Angle

S-568

Gusset Instl.

Gusset

2024-T42 Clad

S-568

2832016

60

0.032

Gusset Instl.

2832051

2832016

CODES

Angle

FIG. NO.

2024-T42 Clad

Rib

2832016

REPAIR

CODE

GAGE

2332010

2832051

FINISH

MATERIAL

2832051

1 2832051

59

EFF.

0.100

51-70-03

EFFECTIVITIES
23-003 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005;
29-001 THRU 29-004; 31-001 AND SUBSEQUENT
23-003 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-272; 28-001 THRU 28-005;
29-001 THRU 29-002

1
2
3

25-373; 29-003 THRU 29-004; 31-001 AND SUBSEQUENT


23-018 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005;
29-001 THRU 29-004; 31-001 AND SUBSEQUENT
23-050 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25373; 28-001 THRU 28-005;
29-001 THRU 29-004; 31-001 AND SUBSEQUENT
24-156 THRU 24-357; 25-007 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004;
31-001 AND SUBSEQUENT
25-242 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004;
31-001 AND SUBSEQUENT

4
5

6
7

24-156 THRU 24-357; 25-002 THRU 25-241


23-003 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-373
28-001 THRU 28-005; 29-001 THRU 29-004; 31-001 AND SUBSEQUENT
23-002 THRU 23-017

9
10
11

25-301 AND SUBSEQUENT; 29-003 THRU 29-004


31-015 AND SUBSEQUENT

12
13
14

23-003 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005;
29-001 THRU 29-004; 31-001 THRU 31-077

15

31-078 AND SUBSEQUENT

NOTES

Laminated shim stock, 0.002

or

0.003 lamination per Mll-S-22499

Type

1 Class 1

or

Class 2 1145-H19 aluminum

sheet.

I~j)

Condition Normalized.

1~

301

StainlessSteel,l/4hard.

Madefrom M22499/1-017shim stock.

Horizontal Stabilizer

Figure
EFFECTIVITY:

Repair Index

(Sheet 7 of 7)

MODEL 23/24/25/28/29/31 SERIES AIRCRAET

55-10-00

Page 8
SRM-4

Jun1/95

Leariet

STRUCTURAL REPAIR MANUAL


HORIZONTAL STABILIZER

STRUCTURAL IDENTIFICATION

2o

C
D

ijr

Detail A
14-193A

A5-21C
8510C

EFFECTIVITY:

Horizontal Stabilizer

Figure

Repair Index

2 (Sheet 1 of 6)

MODEL 35/36 SERIESAIRCRAFT

55-10-00

Page 9
SRM-4

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


HORIZONTAL STABILIZER- STRUCTURAL IDENTIFICATION

Detail B
Detail C

(35-002 Thru 35-676: 36-001 Thru 36-063)

(35-677 and Subseauent: 36-064 and Subseauent)

Detail D
814C

Horizontal Stabilizer

Figure
EFFECTIVITY:

Repair Index

1 (Sheet 2 of 6)

MODEL35/36 SERIES AIRCRAFT

55-10-00

Page
SRM-4

10

Tun1/95

Leariet
STRUCTURAL REPAIR MANUAL
ITEM I
NO. I

DWO.

NO.
2632000

2632020
1

DESCRIPTION
Horizontal Stabilizer Assembly

Spar Instl., Front


Spar Assy.
Spar Cap, Upper

2632020
2632020

2632020
2632020

2632020
2632020

S-571

1
1

I
S-740

1 2024-T3 Clad

2024-T3 Clad

5-571

Rib Instl., BL 4.5, LH and RH


Rib Assy., LH and RH

2332012

2332012

Cap, Top and Bottom


Angle (3ea.)

S-586

2024-T42 Clad

HingeAssy.
Hinge

2332011
2332011

2332011
2332011

2332011
2332011
2332011

2332018

2332011

F4-1

F4-1

Replace

F4-1

51-70-02

F4-1

51-70-02

F4-1

Replace

0.050
0.040

1 2024-~3 Clad

0.100 1

0.025

Replace

51-71-00

2024-T3 Clad

0.400

F4-1

Replace

0.003

Replace

51-70-03

Replace
Replace

Replace
Replace
Replace
Replace

2024-T42 Clad

0.032 1

2024-T3 Clad

0.032

2024-T3 Clad

0.050

RH

Rib, 8L34.80

2024-T42 Clad

0.032

Clip
Glip(G ea.)
Angle

2024-T3 Clad

0.032

2024-T3 Clad

0.050

2024-T42

0.032

i
I

2024-T42 Clad

0.071

8 RH

Bracket(2 ea,)
I
Spacer
Shim, Laminated (Max. 0.032)

Rib

51-70-02

I Replace

0.100

Steel Forging

HingeArm
Assy., LH and

RH

1
1

1 2024-T3 Clad

0.080
0.003

2024-T3 Clad

0.160

2024-T4 Clad

0.250

Replace
Replace
Replace
Replace

51-71-00

Replace
Replace
Replace

Rib, BL 50.20

j 2024-T42 Clad

0.032

Rib

2024-T3 Clad

0.032

2024-T42 Clad

0.032

Clip
Clip(4 ea.)

Horizontal Stabilizer

Figure
EFFECTIVITY:

Clip
Rib Clip (6 ea.)
Rib Assy., LH and

Filler

Rib, BL 19.40

2332018

2332011

Replace

)2024-T3Clad

Rib

2332018

2332011

F4-1

Hinge Assy.

2332018

2332011

LH and AH

Hinge Instl., Inboard, LH

2332018

2332018

51-70-02

Rib

2332011

2332018

Assy.,

F4-1

Filler(2 ea.)
Shim, Laminated (Max. 0.032)
Rib

51-70-02

IDoubler

2332011

0.040

Replace

F4-1

Web

2332012

0.050

F4-1
F4-1

2332012

2332012

I
I

Angle(3 ea.)

2332015

I
1

2024-T3 Clad
1 2024-T3 Clad

Web

2332012

Web

2332012

S-739

2632020

2332015

2632020
2332012
3

8 Lower

Angle(3 ea.)
Sparlnstl., Rear
Spar Assy.
Spar Cap

2632020

(FINISH REPAIR
GAGE I CODE I NG. NO.

Web

2632020

I
MATERIAL

Web

2632020

I
EFF.I

MODEL 35/36 SERIESAIRCRAFT

Repair Index

(Sheet 3 of 6)

55-10-00

Page
SRM-(

11

Jun 1/95

STRUCTURAL REPAIR MANUAL


ITEM
NO.
8

DWG.

NO.

I
Rib

1 2332011

Rib, BL65.60

2332011

Rib

2332012
2332013

2332013

1 2332018

2332018
2332018

13

Retainer

1 2631512
2631515

0.032 1
i 0.040)

I
1

Replace
Replace
Replace

0.032

0.040

i
1

I
I

Replace
Replace

51-71-00

)2024-T42Clad

0.080

2024-T42 Clad

0.080

I
2024-T3 Clad

0.125

2024-T42 Clad
2024-T3 Clad

0.071

2024-T3 Clad
2024-T4 Clad
2024-T42 Clad

0.160

4130 Steel

1.300

Replace
Replace
Replace
Replace

0.250 1

51-71-00

0.032

Replace

0.003

3
3

Assy.

Replace

Stud, Dual

4130 Steel

0.500

0.250

Cap, Upper
Cap, Lower

2024-T42 Clad
2024-T42 Clad

0.250

Doubler

2024-T42 Clad

0.080

0.040

2332050

Doubler, LH

2024-T3 Clad
4130 Steel IZ

2332050

Doubler

0.071

2332050

Stiffener

4130 Steel 12_


S-551

2024-T4 Clad

2332050
2332051

1 2332051
2332051
2332051

Stop Plate
Filler, Laminated (Max. 0.070)

Doubler, LH
Rib, LH and RH
Gusset Instl.

I
I

0.250

0.080

2024-T42

0.100

2024-T3 Clad

0.100

S-568

ReplaceReplace

0.003

4130 Steel
2024-T42 Clad

F&l

0.080

0.090 1

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

51-71-00

I
I

Replace
Replace
Replace

Gusset
Doubler

Angle

Horizontal Stabilizer

Figure
EFFECTIVITY:

Bracket, LH 8 RH

Angle

2332050

2332050

2332050

0.080

2332050

2332050

Replace

Bracket Instl.

Replace
Replace
Replace

Tip

2332050

FIG. NO.

Rib

2332050

2024-T42 Clad
2024-T3 Clad

HingeArm

2332012

2332050

2024-T42 Clad

REPAIR

CODE

1
Spacer
Shim, Laminated (Max. 0.032)
Filler

2631517

14

Outboard LH 8 RH

Hinge Assy.
Bracket(2 ea,)

2332018

12

Hinge Instl.,

2332018

2332018

0.032

Filler

2332013

2332018

0.032

IFINISH

2332013

11

2024-T42 Clad
2024-T3 Clad
2024-T42 Clad

LH 8 RH

Bracket, Outboard
Bracket, Inboard

2332013

1
1

Hinge Assy.

2332013

GAGE

Clip
Clip
Hinge Instl., Outboard

2332012

10

Clip

Clip(4 ea.)

2332012

I
MATERIAL

Rib Instl., LH and RH


Rib

2332012

I
EFF.

Assy, LH and RH

2332011
2332011
9

I
DESCRIPTION

MODEL35/36 SERIESAIRCRAFT

1
I

Repair Index

(Sheet 4 of 6)

55-10-00

Fage 12
SRM-B

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


ITEM
NO. I

15

DWG.
NO.

I
I

Hingelnstl.,

2332019
1 2332019

I
I
IEFF.

DESCRIPTION

MATERIAL

Center

Channel

2024-T42 Clad

2332019

Clip

2332019

Filler

S-502
2024-T42

(Shim, Laminated(Max.O.OG~)
Shim, Laminated (Max. 0.032)
Hinge Instl., LH 8 RH Center

2332019

2332019
3532000

I
IFINISHI REPAIR
IGAOE I CODE I FIG. NO.

0.071 1

1
1

0.080 1

51-71-00
51-71-00

51-71-00

145H19

0.003 1

51-71-00

145H19

0.003 1

51-71-00

I
I

Replace
Replace
Replace
Replace

Elevator

Hinge Assy. (2 ea.)


Hinge Arm Assy.
Hinge Arm

3532003
15a

3532001

15b

3532001

MS27641-4
15e

2024-T3 Clad

(Bearing

Bracket, Elevator Center

3532002

0.250

1
301 Stainless

Replace

Hinge
MS21069L08
3532001
3532001
3532001
16

2332000

17

1 2332000

18

2332000

19

2632010

Replace
Replace
Replace
Replace

Replace

2024T3 Clad

0.016

F4-6

Spacer

2024T3 Clad

0.080

F4-6

I~

S-554

S-554

Replace

5-554

I Replace

Shim

Stringer, LH and RH,


Upper and Lower
Stringer, LH and RH,
Upper and Lower
Stringer, LH and RH,
Upper and Lower
Leading Edge Assy., LH

and RH

Skin

6061-T6

0.040 1

51-70-02

2632010

Baffle

6061-T6

0.032

6061-T6

0.063

I
I
I
I
I
I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Cover, LH Only
Clip(8 ea.)

6061-T6

0.032

2632011

Rib

6061-T6

0.032

2632012

Rib

6061-T6

0.032

2632010

2632013

Rib

6061-T6

0.032

2632014

Rib

6061-T6

0.032

2632015

Rib

6061-T6

0.032

2632016

Rib

6061-T6

0.032

6061-T6

0.040

6061-T6

0.080

6061-T6

1
1

263207 0
2632010
2632010

Door, (2 ea.)
Filler(G ea.)
Door, LH and RH

2332014

Tip Assy., LH and RH


Tip Half, Top
Tip Half, Bottom

2332000

Skin, LH and RH,

2332014
2332014

21

Filler(2 ea.)

2632010
2632010

20

INutplate

Upper and

1
1
1
1

0.040

6061-T4

0.040

6061-T4

0.040

1
1

2024-T42 Clad

0.050 1

Lower

Horizontal Stabilizer

Figure
EFFECTIVITY:

MODEL 35/36 SERIES AIRCRAFT

Replace
Replace
1

51-70-02

Repair Index

(Sheet 5 of 6)
55-10-00

Page
SRM-B

13

Jun 1/95

Learjet
~LBarjet]

STRUCTURAL REPAIR MANUAL


ITEM

DWG.
NO.

NO.

DESCRIPTION

EFF.

MATERIAL

GAGE

FINISH
CODE

REPAIR
FIG. NO.

2332000

Cover, LH and RH

2024-T42 Clad

0.050

2332000

Doubler

2024-T3 Clad

0.080

Replace
Replace

23

2632000

Skin

2024-T3 Clad

0.063

51-70-02

24

2331028

2431002

Hinge Pin
Stop

2024-T4 Clad

0.050

2431111

Sleeve

2332021

Fairing,

22

25

CODES

LH and RH

51-71-00

Replace
Replace
Replace

EFFECTIVITIES
35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT
35-001 THRU 35-240; 36-001 THRU 36-044
35-241 AND SUBSEQUENT; 36-045 AND SUBSEQUENT
35-649 AND SUBSEQUENT; 36-059 AND SUBSEQUENT
35-001 THRU 35-676; 36-001 THRU 36-063
35-677 AND SUBSEQUENT; 36-064 AND SUBSEQUENT

2
3
4

5
6

NOTES

Laminated shim stock, 0.002

or

0.003 lamination per MIL-S-22499

Type

1 Class 1

or

Class 2 1145-H19 aluminum

sheet.

Condition Normalized.

301StainlessSteel, 1/4hard.
Madefrom M22499/1-017shim stock.

Horizontal Stabilizer

Figure
EFFECTIVITY:

Repair Index

1 (Sheet 6 of 6)

MODEL35/36 SERIESAIRCRAFT

55-10-00

Page
SRM-4

14

Jun 1/95

STRUCTURAL REPAIR MANUAL


HORIZONTAL STABILIZER
i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS

All dimensions

NOTE:
A.

are

specified.

Fasteners

(1) Loose
tions

failed rivets

or

the

on

performed
fer to Chapter 51
(2) Loose

or

trations

ensure

not allowed. A loose or failed rivet can cause increased stress concentra-

are

remaining

to

rivets and lead to

that

joint

progressive joint failure. A careful inspection must be


spread from the area of the loose or failed rivet. (Re-

failure has not

for definition of rivet failure.)


failed screws are not allowed. A loose

on

performed
B.

in inches unless otherwise

surrounding

screws

to ensure that the

and lead to

joint failure

or

failed

screw can cause

increased stress

failure. A careful

progressive joint
spread from the area

has not

inspection

of the loose

or

concen-

must be

failed

screw.

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired,
C.
D.

and refinished in accordance with

Chapter

Deformation

(1) Deformation of the horizontal stabilizer structure is not allowed.


Corrosion (See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the

rial thickness
E.

re-

51.

more

than

original

mate-

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component reF.

G.

H.

placed.
Scratches(SeeFigure 101.)
~1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTNITY:
sed4

ALL

55-10-00

Page 101
May 15/92

Leariet

STRUCTURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063
0.071

0.059

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

0.067

Allowable Material Thickness

Figure 101
EFFECTIVITY:

ALL

55-10-00

Page
SRM~

102

May 15/92

STRUCTURAL REPAIR MANUAL


HORIZONTAL STABILIZER

1.

REPAIR

GENERAL
A.

responsibility of the aircraft ownerjmaintenance facility to determine qualifications of mainpersonnel performing repair procedures. As always, a clean environment and good general
shop practices shall be exercised any time repairs are performed on the aircraft.
Prior to, and after performing, any repairs on the horizontal stabilizer, ensure serviceability and reliabiIity of part. If serviceability and/or reliability of any part or repair remains in question or if guidIt is the

tenance

B.

making this determination, contact Leajet Field Service for additional information.
equal to, or greater in strength, than the original structure. Technique and material
variation is permissible only so far as to facilitate fabrication and ensure the original strength and usefulness of the affected component.
Repairs for structure not included in this section does not necessarily indicate that the structure involved is non-repairable, but that the application of a typical repair procedure to theoretical damage
has not yet been developed.
Refer to Chapter 52 for allowable wear and repair data, and for standard repair procedures not speciance

C.

D.

E.

is needed in

Repairs

must be

fied in this section.


F.

G.

H.

2.

Following any repair or maintenance procedures on the aircraft structure/components, update all aircraft log books as required.
Following any repair or maintenance procedures on the aircraft structure/components, ensure inspection records pertaining to any specific repair-related procedure are identified, properly documented and closely adhered too.
All parts fabricated by the repair facility shall be identified for future reference. Marking of parts shall
be accomplished in a manner which does not effect the serviceability and reliability of the part.

LIMITATIONS AND INSPECTIONS


A.

Limitations

(1) Learjet engineering approved repairs to the horizontal stabilizer are limited to those items/areas
outlined in step 4., REPAIR PROCEDURES.
(2) Limitations applied to repairs in this section must be followed unless Learjet engineering authori-

ty

to the

(3) Fittings

contrary is given.
or

forgings

must be

replaced if cracked or if fitting hole (non-bushed) tolerance exceeds


fitting or forging are not allowed. Fittings or forgings with

the allowable limits. Cracks in any


bushing shall be repaired.
3.

MATERIALSAND PROCESSES
A.

Materials

(1) Repair materials and required


terial

or

treatment variation is

treatments or

processes will be listed in the repair procedure. Maso far as to facilitate fabrication and ensure the

permissible only

original strength and usefulness of the affected component.


B.

Processes

(1) Refer

EFFECTIVITY:

to

Chapter 51

ALL

for chemical process and treatment

specifications.

55-10-00

Page 201
sr~M-l

Tan 15/93

Learjet I
~Learjet

STRUCTURAL REPAIR MANUAL


HORIZONTAL STABILIZER

REPAIR

REPAIR PROCEDURES

4.

All dimensions

NOTE:
A.

are

in inches unless otherwise

Horizontal Stabilizer Rear

Spar Cap Repair (See Figure 201.)

Repair procedures

NOTE:

for both upper and lower horizontal stabilizer

identical unless otherwise


Fasteners

specified.

spat caps

are

specified.

spar cap and ribs may require


flange during removal of cap.

common to

mation of rib

rear

special

attention to reduce defor-

(1) Tools and Equipment


NOTE:

Equivalent substitutes may be used

in lieu of the

following:

PART NUMBER

MANUFACTURER

Drill

#5

Commercially available

Drill holes for rivets

Drill

#11

Commercially available

Drill holes for rivets

Drill

#15

Commercially available

Drill holes for rivets

Drill

#26

Commercially available

Drill holes for rivets

Drill

1/8

Commercially available

Drill holes for rivets

Drill

13/64

Commercially available

Drill holes for rivets

NAME

USE

(2) Parts and Materials


NOTE:

Quantities listed below

are

per spar cap.

Equivalent substitutes may be used in lieu of the following:


NAME

Spar Cap

PARTNUMBER

MANUFACTURER

2332010-15

Learjet Inc.

USE

Replacement part.

Wichita, KS
Rivet (14 ea.)

MS20426AD4

Commercially available

Secure spar to structure

Rivet (70 ea.)

MS20426AD5

Commercially available

Secure spar to structure

12335-004

EFFECTIVITY:

ALL

55-10-00

Page 202
SRMII

lan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


HORIZONTAL STABILIZER

REPAIR

PARTNUMBER

MANUFACTURER

Rivet (5 ea.)

MS20426AD6

Commercially available

Secure spar to structure

Rivet (1 ea.)

CR32425-3

Commercially available

Secure spar to structure

Rivet (6 ea.)

CR32435-5

Commercially available

Secure spar to structure

Rivet (6 ea.)

CR32435-4

Commercially available

Secure spar to structure

Rivet (12 ea.)

CR32434-3

Commercially available

Secure spar to structure

Rivet (30 ea.)

CR32435-3

Commercially available

Secure spar to structure

Rivet (33 ea.)

CR324363

Commercially available

Secure spar to structure

Pin (2 ea.)

HL56-6-9

Commercially available

Secure spar

Pin (4 ea.)

HL20-64

Commercially available

Secure spar to structure

Pin (4 ea.)

HW7-6-4

Commercially available

Secure spar to structure

Collar (4 ea.)

HL87-6

Commercially available

Secure spar to structure

Collar (6 ea.)

HL83-6

Commercially available

Secure spar to structure

NAME

USE

to structure

(3) Repair Procedure: (See Figure 201.)


NOTE:

Ensure proper riveting procedures, as outlined in


adhered to while performing the following task.

(a) Remove applicable elevator


Manual.)
CAUTION:

assembly

chapter 51,

are

from aircraft. (Refer to the basic

closely

followed and

Learjet

Maintenance

USE EXTREME CARE NOT TO DEFORM FASTENER HOLES DURING


REMOVAL. REFER TO STANDARD PRACTICES, CHAPTER 51, FOR APPROPRIATE PROCEDURES.

03) Remove elevator hinge brackets from spar assembly.

EFFECTIVITY:

ALL

55-10-00

Page 203
SRM4

Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


HORIZONTAL STABILIZER

REPAIR

FASTENERS COMMON TO SPAR CAP AND RIBS REQUIRE ATTENTION TO PREVENT DEFORMATION OF RIB FLANGE DURING SPAR
CAP REMOVAL. REFER TO CHAPTER 51, STANDARD RIVETING PRO-

CAUTION:

CEDURES.

(c) Remove remaining fasteners from rear spar cap. Slide spar cap aft and remove from aircraft.
(d) Position new spar cap in alignment with existing fastener holes. Ensure edge distance is
maintained

as

noted in Table 201 of

Figure 201.

(e) Secure spar cap in place with clamps. Using existing

spaced

holes and install Clecos.

Verify edge

structure

as a

pattern, backdrill random

distance is maintained, and backdrill

remaining

holes.

(f)

Install Clecos

through upper

and lower bracket

flanges to

secure

spar cap and elevator

hinge

brackets to structure.

(g) Temporarily install

elevator.

Verify hinge alignment.

(h) Remove elevator. Install fasteners in spar cap and hinge brackets as noted in Figure 201.
(i) Touch up paint as required. (Refer to the basic Leajet Maintenance Manual.)
(j) Install elevator and perform adjustment/test. (Refer to the basic Leajet Maintenance Manual.)
(k) Update all aircraft log books to indicate that Horizontal Stabilizer Xear Saav Catl Field Xe~Iacement #12335-004 has been

(1)

EFFECTIVITY:

incorporated.

Restoreaircraft tonormal.

ALL

55-10-00

Page 204
SRM-4

lan 15/93

Learjet
STRUCTURAL REPAIR MANUAL
HORIZONTAL STABILIZER

REPAIR

A
BL 81.00

BL 65.60

(Ref)

(Ren

(VIEW LOOKING DOWN, LH UPPER)

i_

ii

BL 0.00
Elevator

Hinge
Assembly

Rib~

(Ref)

Rear

(Ref)

Spar Cap

Rib(Ref)
~I

D13i-I:30+

i-"-

; ; -;~9

it---6:I

Elevator

Elevator

Hinge --7

Lower

Spar Cap 7

Upper Spar Cap 7

Bracket, Outboard

Elevator

Hinge

Bracket (BLO.OO)

Hinge

(Ref)

Bracket, Center

(Ref)
I

++i

_i_.
t+,tt
-~_

i=:I

I-~-I

11.~1- 10-1

--l----t--~--t-
Horizontal Stabilizer Rear

Spar Cap

Fasteners

Table 201

(VIEW LOOKING FWD, LH SIDE)


Hole Dia.

Fastener

Edge
Distance

0.146/0.143

Number of fasteners

Fasteners

common

1~ 0.180/0.1 76
j~ 0.205/0.200
i~l 0.156
1
Do.lw
~1 0.190/0.187 1

equally spaced.

to

spar cap and ribs

require attention to prevent deformation


flange during spar removal.

0.203/0.200

through upper and lower


bracket flanges to secure hinge brackets
to structure during temporary elevator
alignment verification.

Install Clecos

Detail A
Horizontal Stabilizer Rear

Spar Cap

Repair

Figure 201
ALL

55-10-00

Page 205
S~M-4

CR32435

0.310

CR32436

Jan 15/93

0.310

MS20426AD5

10.300

MS20426AD4

0.300

HL20-6-4MN

I ~1

0.310

HL56-6-9 MN

HL83a COLLAR

MS20470AD6

10.310

0.205/0.200

CR32425

10.310

0.203/0.200

HL57-6-4 PIN

0.187

HL83dCOLLAR

Repro

EFFECTIVITY:

0.250

HL87-6COLLAR

of rib

(LH SHOWN, RH OPPOSITE)

CR32434

0.310

0.310

Learjet

STRU~TURAL REPAIR MANUAL


ELEVATOR- STRUCTURAL IDENTIFICATION
i.

DESCRIPTION
The

NOTE

the

following structural data covers the basic non-modified aircraft. When applicable, refer to
appropriate kit drawing for additions, modifications and changes to the structural compo-

nents and assemblies.

A.

Each elevator is connected to the horizontal stabilizer at three hinge points. The elevator structure
consists of ribs and spars covered with skin. Counterbalance weights are located in the leading edge
of the tip cover. An access cover located on the leading edge of the elevator provides access to the
center

hinge point.

17) (15

~(ii
It)~

J~7

18

16)
25

?4)~(li

5218-1

Elevator

Repair Index

(Sheet 3 of 4)

Figure

EFFECTIVITY:

MODEL

23/24/25SERIES AIRCRAFT

55-20-M)

Page
SRM~d

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

2334001
1

2334001

2334001
2334001

Rib

I
EFF.

Elevator Assy., LH and RH


Spar
Torque Tube Weld Assy.
Torque Tube

233400 i

I
MATERIAL

IFINISH

REPAIR

CODE

FIG. NO.

F4-1

51-70-03

F4-1

GAGE

2024-T42 Clad

0.063

1
1

4130 Steel

4130 Steel

I
I

I
I

10

2024-T42 Clad

0.032

F4-1

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Bracket

11

4130

Steell~

0.032

F-8

Replace

Bracket

10

2024-T42 Clad

0.032

F4-1

Bracket

11

4130 Steel

0.032

F-8

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

(2 ea.)

I~

F4-1

Rib

2024-T42 Clad

0.032

F4-1

Rib

2024-T42 Clad

0.032

F4-1

Rib

2024-T42 Clad

0.032

F4-1

Rib

2024-T42 Clad

0.032

F4-1

2334001

Rib

2024-T42 Clad

0.032

F4-1

2334001

Angle
Hinge
Hinge
Hinge
Hinge

2024- T42 Clad

0.032

F4-1

2334001

2334001

2334001

2334001

7
8

I
DESCRIPTION

2334001
2334001

2334001

2334001

Bracket

2334001

IAngle

S-608

2334001

Rib

2024-T42 Clad

0.032

F4-1

10

2334001

1
1

Rib

2024-T42 Clad

0.032

F4-1

11

2334001

Rib

2024-T42 Clad

0.032

F4-1

12

2334001

Rib

2024-T42 Clad

0.032

F4-1

13

2334001

Rib

2024-T42 Clad

0.032

F4-1

2334001

Channel

2024-T42 Clad

0.040

F4-1

14

2334001

Rib

2024-T42 Clad

0.032

F4-1

15

2334001

Rib

2024-142 Clad

0.032

F4-1

2334001

1
Angle
1
Hinge
Hinge
1
IAngle

16

2334001
2334001

2334001

2024-T42 Clad

0.032

F4-1

2024-T42 Clad

0.032

F4-1

Bracket

13

4130 Steel

0.032

1
16

Rib

Rib

2334001

Weight

5% Sb Lead

20

2334001

Rib

21

2334001

2024-T42 Clad
2024-T42 Clad

Rib

2334001

18

2334001

19

2334001

2334001
22

2334001

(2 ea.)

16

Skin, Leading Edge

1
1

(Inbd 8 Outbd)
Skin, Leading Edge
(Inbd 8 Outbd)
Skin, Trailing Edge,

EFFECTIVITY:
SRM-4

F4-1

2024-T42 Clad

0.032

F4-1

4130

0.080

Steel~

0.032

I
F4-1
F1 ext

0.032

IF14-1

51-70-02

int

F1 art

0.032

I
2024-T3 Clad

51-70-02

2024-T3 Clad

Elevator

Repair Index

Figure

(Sheet 2 of 4)

F4-6 art

F4-1 int

51-70-02

F4-6 ext
F4-1 int

51-70-02

0.025

I
1

MODEL 23/24/25 SERIESAIRCRAFT

F-8

Replace
Replace
Replace
Replace
Replace
Replace

F14-1int

Skin, Trailing Edge, RH Upper, I

F4-1
F4-1

2024-T3 Clad

LH Lower

F-8

I
0.040

I
9

LH

I
0.032

I
Upper, I

RH Lower
233400 i

F4-1

12

Clip

2334001

Bracket

S-608
2024-T42 Clad
2024-T3 Clad

17

0.025

55-20-00

Page 2
May 15/92

Learjet
Learjet
STRUCTURAL REPAIR MANUAL
ITEM
NO.

DWG.
NO.

I
EFF.

DESCRIPTION

17

S-649

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

MATERIAL

23

2334001

Extrusion, Trailing Edge

24

2334001

Door

2024-T3 Clad

0.032

2334001

Doubler

2024-T42 Clad

0.063

F4-1

6061-0

0.020

Fl art

14

2024-T3 Clad

0.050

F4-1

15

2024-T42 Clad

0.050

Fi

0.040

F-l ext

Replace
Replace

F1l-lint
2334001

Fairing

Replace
Replace

F16lint
25

2334001
2434001

26

2334001
2334001

27

2334001
2334001

28

2334001

29

2334001

30

2334001
2334001

Tab

Trailing
Trailing Tab
TipWeld Assy
Tip Half, Upper and
Weight
Weight
Angle
Stub Spar
Spoiler Tab, Lower
Spoiler Tab, Upper

Lower

SRM-L

6061-T6

Grade "8" Lead

5% Sb Lead

1
I
I

I
I
I

S626 BU-8

2024-T42

0.025

F4-1

2024-T42

0.050

F4-6

2024-T42

0.080

F4-6

Repair Index

(Sheet 3 of 4)

MODEL 23/24/25 SERIESATRCRAFT

I
I

Elevator

Figure
EFFECTIVITY:

Replace
Replace

F-l

Replace
Replace
Replace
Replace
Replace
Replace
Replace

5520-00

Page 3
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
CODES

EFFECTIVITIES

23-099; 24-101 THRU 24-357; 25-002 THRU 25-373

23-002 THRU

2
3

24-100 THRU 24-103, 24-105 THRU 24-119; 25-002 THRU 25-373


23-003 THRU 23-099; 24-100, 24-101, 24-103 THRU 24-105, 24-107 THRU 24-109

24-120 THRU

23-003 THRU 23-015

23-016 THRU

24-110 THRU 24-357; 25-002 THRU 25-373


23-003 THRU 23-099; 24-100 THRU 24-121

24-357; 25-002 THRU 25-373


23-357; 24-101 THRU 24-357; 25-002 THRU 25-373

24-122 THRU 24-357; 25-002 THRU 25-373

9
10

23-003 ONLY

11

23-004 THRU

12

23-003 THRU 23-017

13

23-018 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-373


24-122, 24-133, 24-140 THRU 24357; 25-002 THRU 25-373 AND PRIOR MODEL 23/24 SERIES AIR-

14

23-099; 24-002 THRU 24-357; 25-002 THRU 25-373

CRAFT MODIFIED FOR 45,000 FEET OPERATION


15

24-140 THRU 24-357; 25-002 THRU 25-373 MODIFIED PER SSK995; AND 23-003 THRU 23-099
AND 24-100 THRU 24-139 WHEN MODIFIED FOR 45,000 FEET OPERATION AND MODIFIED PER

16

24-122 THRU 24-357; 25-002 THRU 25-373


24-102, 24-106, 24-110 THRU 24-357; 25-002 THRU 25-373

SSK995
17

NOTES

23-029, F8-1
23-357; 24-101 THRU 24-357; 25-002 THRU 25-373, F8-6 External, F1-2 Internal
23-002 THRU 23-005, Refer to Service Bulletin 23-49
23-006 THRU

23-030 THRU

Condition Normalized at 95,000 psi minimum.


Condition Annealed at 95,000 psi minimum.
Condition Normalized.

Elevator

Figure
EFFECTIVITY:
SRM-4

Repair Index

1 (Sheet 4 of 4)

MODEL 23/24/25 SERIESAIRCRAF~

55-20-00

Page 4
May 15/92

STRUCTURAL REPAIR MANUAL


ELEVATOR- STRUCTURAL IDENTIFICATION
i.

DESCRIPTION
NOTE

The

the

following structural data covers the basic non-modified aircraft. When applicable, refer to
appropriate kit drawing for additions, modifications and changes to the structural compo-

nents and

A.

assemblies.

Each elevator is connected to the horizontal stabilizer at three hinge points. The elevator structure
consists of ribs and spars covered with skin. Counterbalance weights are located in the leading edge
of the
cover. An access cover located on the leading edge of the elevator provides access to the
center

tip
hinge point.

17) (15

13

12
7

11

8
19

2
C

18

16
25
v

24

23

22

QI

Repair Index
Figure 2 (Sheet 1 of 3)

5-2181

EFFECTIVITY:
sRM-a

Elevator

MODEL

28/29/31/35/36 SERIES AIRCRAFI~

55-20-00

Page 5
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

I
DESCRIPTION

2434000

Elevator

2434001

2434003

Spar
Torque

I
EFF.

Assy, LH and RH

IFINISH

REPAIR

CODE

FIG. NO.

F4-1

51-70-03

GAGE

1
1

Tube Weld

I
MATERIAL

Assy.

2024-T42 Clad

0.063

I F8-6 art

I
I

F15 int
2434003

Torque

2434003

Rib

Tube

(2 ea.)

4130 Steel

4130 Steel

2024-T42 Clad

S-706

I Replace
I Replace

2434001

2434001

IAngle

2434001

Rib

2024-T42 Clad

0.032

F4-1

2434001

Rib

2024-T42 Clad

0.032

F4-1

2434001

1
1

Rib

2024-T42 Clad

0.032

F4-1

2434001

Rib

2024-T42 Clad

0.032

F4-1

2434001

Angle
Hinge
IAngle

2024-T42 Clad

0.032

F4-1

4130 Steel~

S-608

2434001
2434001

Rib

Bracket

(2 ea.)

F4-1

0.032

0.032

F4-1

2434001

1
1

Rib

2024-T42 Clad

0.032

F4-1

2434001

Rib

2024-T42 Clad

0.032

F4-1

11

2434001

Rib

2024-T42 Clad

0.032

F4-1

12

2434001

Rib

2024-T42 Clad

0.032

F4-1

13

2434001

1
1

Rib

2024-T42 Clad

0.032

F4-1

2434001

Channel

2024-T42 Clad

0.040

F4-1

14

2434001

Rib

F4-1

2434001

Rib

2024-T42 Clad
2024-T42 Clad

0.032

15

1
1

0.032

F4-1

2024-T42 Clad

0.032

F4-1

4130 Steel

1~

0.032

S-608

2434001
2434001

17

2434001
2434001

F-8

F4-1

2024-T42 Clad

0.032

F4-1

Rib

2024-T42 Clad

0.032

F4-1

Angle

F-8

Rib

4130 Steel
4130 Steel

0.032

2434001

Weight

5% Sb Lead

2434001

Rib

2024-T42 Clad

18

2434001
2434001

19

2434001

20

Angle
Hinge Bracket (2 ea.)
IAngle
Rib (2 ea.)
1

1~

2434001

IAngle

S-608

21

2434000

2024-T42 Clad

22

2434000

Skin, Leading Edge


Skin, Trailing Edge, LH Upper,

RH Lower
2434000

2024-T3 Clad

S-649

F4-1

51-70-02

F-8

0.032

I
F4-1

I
0.032

2024-T3 Clad

Skin, Trailing Edge, RH Upper, I

F4-1

Replace
Replace
Replace
Replace
Replace
Replace
Replace

LH Lower

0.080

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

F-8

10

16

Replace

I Replace

F4-6 art
0.025

M-lint

I
0.025

51-70-02

F4-6 art
F4-1 int

51-70-02

23

2434001

Extrusion, Trailing Edge

24

2434001

Door

2024-T3 Clad

0.032

2434001

Doubler

2024-T3 Clad

0.032

F4-1

2434001

Doubler

2024-T42 Clad

0.071

F4-1

2434001

\Fairing

6061 -0

0.025) Flext)

I
F-l ext

Replace
Replace

F14-1int

Replace
Replace
Replace

F16lint

Elevator

Repair Index
Figure 2 (Sheet 2 of 3)

EFFEnIVIm:
SRM-4

MODEL 28/29/31/35/36 SERIES AIRCRAFT

55-20-00

Page 6
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

I
EFF.

0.050

F4-1

0.040

T6

6061-0

2434001

Weight

5% Sb Lead

CODES

Replace

Replace

I Replace

EFFECTIVITIES
28-001 THRU 28-005; 29-001 THRU 29-004; 31-001 AND
QUENT; 36-001 AND SUBSEQUENT

FIG. NO.

2024-T42 Clad

2434002

2434002

REPAIR

CODE

GAGE

2434001

26

IFINISH

MATERIAL

Trailing Tab
Tip Weld Assy.
Tip Half, Upper and Lower

25

27

I
DESCRIPTION

SUBSEQUENT;

35-001 AND SUBSE-

NOTES
Condition Normalized.

Condition Annealed.

Elevator

Repair Index

(Sheet 3 of 3)

Figure
EFFECTIVITY:
SRM~

MODEL 28/29/31/35/36SERIES AIRCRAFT

55-20-00

Page 7
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ELEVATOR -ALLOWABLE DAMAGE
i.

ALLOWABLE DAMAGELIMITS
All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

or

failed rivets
the

on

are

not allowed. A loose

or

failed rivet

can cause

increased stress concentra-

progressive joint failure. A careful inspection must be


that joint failure has not spread from the area of the loose or failed rivet. (Re-

remaining

rivets and lead to

performed to ensure
fer to Chapter 51 for definition of rivet failure.)
(2) Loose

or

failed

screws are

not allowed. A loose

or

failed

screw can cause

increased stress

concen-

progressive joint failure. A careful inspection must be


performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
trations

B.

on

surrounding

screws

and lead to

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired, and
C.
D.

refinished in accordance with

Deformation

(1) Deformation of the elevator structure is not allowed.


Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

re-

Chapter 51.

more

than

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component reF.

G.

H.

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
Structural
(2)
components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTIVITY:
SRM~

ALL

55-20-00

Page 101
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFFECTIVITY:
SRM~

ALL

101

55-20-00

Page 102
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ELEVATOR-REPAIR
1.

APPROVED REPAIRS
WARNING:

A CONTROL SURFACE BALANCE CHECK MUST BE PERFORMED FOLLOWING


REPAIR OF THE ELEVATOR. (REFER TO SECTION II OF THE BASIC

LEARJET

SERVICE MANUAL FOR MODEL 23, 24 AND 25 SERIES AIRCRAFT. REFER TO


CHAPTER 27 OF THE BASIC LEARJET MAINTENANCE MANUAL FOR MODEL 28,

29, 31, 35 AND 36 SERIES AIRCRAFT.)


A.

Refer to

blies

Chapter 51 for typical repairs,


fittings and attaching parts.

EFFECTnlTITY:
SRMI

ALL

and for allowable

wear

and

repair data

for the elevator

assem-

55-20-00

Page 201
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


VERTICAL STABILIZER- STRUCTURAL IDENTIFICATION
i.

DESCRIPTION
NOTE

The
the

Following structural data covers the basic non-modified aircraft. When applicable, refer to
appropriate kit drawing for additions, modifications and changes to the structural compo-

nents and assemblies.

A.

The vertical stabilizer structure consists of spars and ribs covered with skin. Access covers located on
the vertical stabilizer provide access for structural inspection and access to electrical wiring, horizontal stabilizer actuator, elevator controls, and rudder
zontal stabilizer are located on the vertical stabilizer.

hinges.

Attach

fittings

for the rudder and hori-

32)

32

0:

g~Qj
I)

ol

lo

d
5-6A

Vertical Stabilizer

521B2

Figure
EFFECTIVITY:
SRM4

a
Repair Index

(Sheet 1 of 7)

MODEL 23/24/25 SERIES AIRCRAFT

55-30-00

Page 1
May 15/92

Learjet
~Leariet(
STRUCTURAL REPAIR MANUAL
VERTICAL STABILIZER- STRUCTURAL IDENTIFICATION

r--

17

22

~3

0:

26

o/ p,

~r

8,

J~

5-14C-I

Vertical Stabilizer

Figure
EFFECTIVITY:
SRMI

Repair Index

1 (Sheet 2 of 7)

MODEL23/24/25 SERIESAIRCRAFT

55-30-00

Page 2
May 15/92

Learjet
Learjet

STRUCTURAL REPAIR MANUAL


ITEM
NO.

DWG.
NO.

2531012
2531012

2331 006
2331 006

REPAIR

CODE

FIG. NO.

4
1
1

2024-T42

0.063

F4-1

2024-T42

0.050

F4-1

2024-T42

0.063

F4-1

IAngle
ICap, LH
ICap, RH

S-568

S-588

S-588

2024-T3 Clad

0.100

F4-1

2331006

Doubler

F4-1

0.063

F4-1

2331006

Angle
Angle (2 ea.)

2024-T3 Clad
2024-T42 Clad

0.080

4130 Steel

I~

0.125

F4-1

2331006

Web

2024-T3 Clad

0.050

F4-1

2331007

Angle (2 ea.)
1
IClip
Spar Assy., No.

2331 006

IStiffener

2331006

Spacer

2331006

Doubler

233 i 006

Bracket

2331006

2331007

2331006
2331006

2024-T42 Clad

1
1
3

F4-1

0.080

S-575

0.190

F4-1

2024-T3 Clad
2024-T3 Clad

0.025

F4-1

S-591

0.125

Web

0.050

F4-1

0.080

F4-1

Angle(2 ea.)
Cap(2 ea.)

2024-T3 Clad
2024-T42 Clad

5-589

Web

2024-T4 Clad

(2 ea.)

Spar Assy., No. 4


Spar Cap (2 ea.)
Angle(2 ea.)

I
0.040

F4-1

2024-T42 Clad

0.080

F4-1

2024-T351 Clad

0.250

F4-1

2331007

IPlate
Filler
1

2024-T3 Clad

0.090

F4-1

2331 007

(Filler, LH

0.250

F4-1

2331 007

IFiller, RH

2024-T351 Clad
2024-T351 Clad

0.250

F4-1

2331007

2024-T3 Clad

0.120

F4-1

2531 539

IBracket, Downspring

2024-T4

1.100

F4-1

Doubler

2024-T3 Clad

0.050

F4-1

Web

2024-T3 Clad

0.040

F4-1

2024-T3 Clad

0.120

F4-1

2024-T42 Clad

0.063

F4-1

2331 007

2331007
2331007

2331007

Filler

2331007

Filler(2 ea.)
Spar, Rear

2531011

Rib Instl.

Vertical Stabilizer

Figure
EFFECTIVITY:

Replace
Replace
Replace
Replace

j Replace

S-590

2331007

Replace
Replace
Replace
I Replace

1
1

2331007

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

1
1

2331007

Replace

I Replace

2331006

2331006

Replace
Replace
Replace

Shim

S;151-1

suc4

IFINISH
GAGE

1
1

2331006

I
MATERIAL

10

Spar Assy., No. 2

2331006
2331 006

2
3

IDoubler

2531000

Vertical Fin

2531012

2531000

I
EFF.

Vertical Fin

2531012

2431000

I
DESCRIPTION

Assembly
Assembly
Vertical Fin Assembly
Vertical Fin Assembly
Spar Assy., No. 1
IAngle
Spar Web
1

2331001

I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Repair Index

1 (Sheet 3 of 7)

MODEL 23/24/25 SERIES AIRCRAFT

5530-00

Page 3
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

2431012

Rib

2431012

Rib

2431012

1
1

Rib

2431012

Rib Web

RH

S551

2024-T3 Clad

F4-1

0.032

0.050

F4-1

Doubler

2024-T42 Clad

0.032

F4-1

2024-T42 Clad

0.063

F4-1

2431012

2024-T3 Clad

0.080

F4-1

2431012

Doubler

2024-T3 Clad

0.125

F4-1

(4 ea.)

2024-T42 Clad

Stiffener(2 ea.)

S-549

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Rib Instl.
Rib

F4-1

0.032

2331016

2331016

Rib

2024-T42 Clad

0.050

F4-1

2331016

2024-T42 Clad

0.063

F4-1

2024-T42 Clad

0.040

F4-1

2024-T42 Clad

0.040

F4-1

Replace

I Replace

2331016

Angle
Angle
Angle

2331016

Doubler

2024-T3 Clad

0.040

F4-1

2331016

Attach

Angle

2024-T42 Clad

0.032

F4-1

Rib (5 ea.)
Angle (2 ea.)

2024-T42 Clad

0.032

F4-1

2024-T42 Clad

0.040

F4-1

Replace
Replace
Replace
Replace
Replace
Replace

Rib Instl.

2331015

Replace
Replace

Rib Instl.

2331014
2331014

Rib

2024-T42 Clad

0.032

F4-1

Replace

2331014

Rib

2024-T42 Clad

0.050

F4-1

Angle

Replace
Replace
Replace
Replace

2331014

(4 ea.)

2024-T42 Clad

0.050

F4-1

2331014

IGusset

2024-T3

0.063

F4-1

2331014

2024-T42 Clad

0.040

F4-1

Angle(3 ea.)
Rib Instl.

2331013

11

S551

Angle(2 ea.)
Filler(2 ea.)

2331015

2024-T42 Clad

REPAIR
FIG. NO.

CODE

2331015

10

LH

JFINISH
GAGE

2331016

I
MATERIAL

2431012

2331016

Cap,
Cap,

I
EFF.

2431012

2331016
7

I
DESCRIPTION

1
1

Rib(4 ea.)
Angle (3 ea.)

1 2024-T42 Clad

0.032

F4-1

2331013

2024-T42 Clad

0.040

F4-1

2331013

Rib

2024-T42 Clad

0.032

F4-1

2331013

2024-T42 Clad

0.040

F4-1

2331013

2331008

2331008
2331008

2331008
12

2331033

13

2331 040

Angle
Rib Assy.
Angle (3 ea.)
Rib (4 ea.)
Angle

2024-T42 Clad

0.040

F4-1

2024-T42 Clad

0.032

F4-1

2024-T42 Clad

0.040

F4-1

Rib

2024-T42 Clad

0.063

F4-1

Channel

Assy.,

Antenna

Channel

2024-T3 Clad

0.050

F4-1

2331040

Doubler

2024-T3 Clad

0.050

F4-1

Channel

Assy.,

Antenna

Channel

2024-T3 Clad

0.050

F4-1

2331040

Doubler

2024-T3 Clad

0.050

F4-1

Vertical Stabilizer

EFFECTIVITY:

Replace
Replace

2331040

Figure

Replace
Replace
Replace
Replace

2331040

2331 040

Replace
Replace
Replace
Replace

Replace
Replace

Repair Index

1 (Sheet 4 of 7)

MODEL 23/24/25 SERZESAIRCRAFT

55-30-00

Page 4
SRM~

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO. r
14

DWG.
NO.

Bracket

2024-T42 Clad

0.071

F4-1

2331030

Plate

2024-T3 Clad

0.100

F4-1

Replace
Replace

2024-T4 Clad
2024-T3 Clad

0.250

F4-1

51-71-00

0.100(

F4-1

Replace

Hinge Assy.
1

Bracket

2024-T42 Clad

0.071

F4-1

Bracket

2024-T42 Clad

0.071

F4-1

Replace
Replace

2024-T4 Clad

0.250

F4-1

51-71-00

2024-T3 Clad

0.040

F4-1

Hinge

2331031

Filler

2331 025
2331 025

Hinge,
Hinge,

2331 001

Plate

2431003

Plate

1 2431003

Arm

LH
RH

Replace
1

51-71-00

51-71-00

2024-T3

0.250

F4-1

Replace

10

2024-T42 Clad

0.250

F4-1

Replace

Assy.

Plate
Web

Assy.

Web

21

1 2024-T42 Clad

0.080(

F4-1

Replace

2331001

Shim

20

2024-T3 Clad

0.050

F4-1

Replace

2431003

Shim

10

2024-T3 Clad

0.050

F4-1

2331001

Filler

19

2024-T3 Clad

0.080

F4-1

2431003

Filler

17

2024-T3 Clad

0.080

F4-1

2331001

Skin Doubler

18

301 Stainless

0.020

F4-1

2431003

Skin Doubler

17

1301Stainless

0.0201

F4-1

2331001

2431005

Plate, LH
Plate, RH
Plate, LH
Plate, RH
Stiffener, Angle, LH 8 RH
Stiffener, Angle, LH 8 RH
Attach Angle (2 ea.)
Skin Support

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2331001

Stop

2331001

2024-T3 Clad

0.080

F4-1

2024-T3 Clad

0.080

F4-1

17

0.080

F4-1

17

2024-T3 Clad
2024-T3 Clad

22

S554

23

S554

24

2024-T42

0.040

F4-1

24

2024-T42

0.040

F4-1

2024-T4 Clad

0.500

F4-1

Replace
Replace
Replace
Replace
Replace

Skin, Leading Edge

2024-T42 Clad

0.040

F4-1

51-70-02

2388320

Antenna Cable

0.040

F4-1

2331001

Skin, LH
Skin, RH
Skin, LH

F4-1

2431003
243 i 003
2331001
2431003

2431005

2331001
21

2331031

2331001

20

Arm

2331031

2431003

19

Hinge
Filler

1 2331031

2431003
18

I
IFINIS~
REPAIR
IGAGE I CODE I FIG. NO.

Hinge Assy.

2331031

17

MATERIAL

2331030

2331030

16

I
EFF.I

2331030

2331030
15

DESCRIPTION

2331001

Support

F4-1

0.080

Replace

14

2024-T42 Clad

0.040

14

2024-T42 Clad

0.040

F4-1

Replace
Replace
Replace

15

2024-T42 Clad

0.040

Flext

Replace

F14-1 int

2331001

Skin, RH

15

1 2024-T42 Clad

0.040

Fi art

Replace

F16lint
22

2331001

Skin, LH

16

1 2024-T42 Clad

0.050

Flext

Replace

F14-lint
2331001

Skin, RH

16

1 2024-T42 Clad

0.050

Flext

Replace

F14-1 int
23

2331001

Skin, LH

13

Vertical Stabilizer

Figure
EFFECTIVITY:
SRM-4

1 2024-T42 Clad

0.063

F4-1

Replace

Repair Index

1 (Sheet 5 of 7)

MODEL 23/24/25 SERIESAIRCRAFT

55-30-00

Page 5
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

I
DESCRIPTION

I
EFF.

IFINISH

MATERIAL

GAGE

CODE

2331001

Skin, RH

2024-T42 Clad

0.063

F4-1

24

2331023

Door

2024-T3 Clad

0.040

F4-1

2331023

Doubler

2024-T3 Clad

0.063

F4-1

25

2331032

Door

2024-T3 Clad

0.040

F4-1

2331032

Doubler

2024-T3 Clad

0.063

F4-1

2331038

Door

0.040

F4-1

2331038

Doubler

2024-T3 Clad
2024-T3 Clad

0.071

F4-1

2331059

Door

2024-T3 Clad

0.040

F4-1

2331059

Doubler

F4-1

Door

2024-T3 Clad
2024-13 Clad
2024-T3 Clad
2024-T3 Clad

0.071

2331037

0.040

F4-1

26
27
28
29
30

31
32

13

0.071

F4-1

0.040

F4-1

0.071

F4-1

2024-T3 Clad
2024-T3 Clad

0.040

F4-1

Doubler

2024-T3 Clad

0.071

F4-1

2024-T3 Clad
2024-T3 Clad

0.040

F4-1

0.071

F4-1

2331037

Doubler

2331058

Door

2331058

Doubler

2331060

Door

2331060

Door

2331057

Doubler

2431105

Fin

1 2331057

Tip Instl.

See

Figure

Figure

SRM-4

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Vertical Stabilizer

EFFECTIVITY:

REPAIR
FIG. NO.

Repair Index

1 (Sheet 6 of 7)

MODEL23/24/25 SERIES AIRCRAFT

55-30-00

Page 6
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


CODES

EFFECTIVITIES

23-002 THRU

23-002 THRU

23-099; 24-100 THRU 24-357; 25-002 THRU 25-373


23-099; 24-100 THRU 24-229, EXCEPT 24-218; 25-002 THRU 25-066, EXCEPT 25-

061
3

24-218, 24-230 THRU 24-357 (D MODEL)

24-206 THRU 24-357

25-287 THRU 25-373

25-002 THRU 25-373

24-160; 25-011 THRU 25-373


25-373, 25-342 THRU 25373
23-090 THRU 23-099; 24-100 THRU 24357; 25-002 THRU 25-373
25-061, 25-067 THRU 25373

8
9
10

(F MODEL), 25-067 THRU

14

23-002 THRU 23-099; 24-100 THRU 24-357


25-002 THRU 25-373
23-002 THRU 23-093
23-094 THRU 23-099; 24-100 THRU 24-191

15

24-192 THRU 24-357

11
12
13

25-373

16

25-002 THRU 25-373

17

24-218, 24-230 THRU 24-357; 25-061, 25-067 THRU 25-373


23-030 THRU 23-099; 24-100 THRU 24-229, EXCEPT 24-218; 25-002 THRU 25-066, EXCEPT 25-

18

061

EXCEPT 24-218; 25-002 THRU 25-066 EXCEPT 25-061


24-100 THRU 24-357; 25-002 THRU 25-066, EXCEPT 25-061

22

24-192 THRU 24-229,


23-057 THRU 23-099;
24-218, 24-230 THRU
23-090 THRU 23-099;

23

25-061, 25-067 THRU 25-074

24

25-075 THRU 25-373

19
20
21

24-357
24-100 THRU 24-229, EXCEPT 24-218; 25-002 THRU 25-066, EXCEPT 25-

061

NOTES
Condition Normalized, heat treat to 125,000 -150,000 psi.
301 Stainless 1/2 Hard.

Vertical Stabilizer

Figure
EFFECTIVJTY:
SRM~

Repair Index

(Sheet 7 of 7)

MODEL 23/24/25 SERJES AIRCRAFT

5530-00

Page 7
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


VERTICAL STABILIZER

STRUCTURAL IDENTIFICATION

~14

0)

13
0

15

~3

~X
o

oi

a
~31

5-6A

5-218-2

EFFECTNITY:
SRM-4

Vertical Stabilizer

Repair Index
Figure 2 (Sheet 1 of 6)

MODEL28/29/31 SERIESAIRCRAF~

55-30-00

Page 8
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
VERTICAL STABILIZER

STRUCTURAL IDENTIFICATION

ti

r--

20

22

19

~3

23

2,

C3

5-14C-1

Vertical Stabilizer

V~-

Repair Index

Figure 2 (Sheet 2 of 6)
EFFECTIVITY:
SRM-4

MODEL28/29/31 SERIESAIRCRAE;T

5530-00

Page 9
May 15/92

Learjet
~tl
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

I
DESCRIPTION

2531000
1

Vertical Fin

2531012

2531012
2531012
2531012
2

Spar Assy., No.

IFINISH
GAGE

2024-T42

0.063

2024-T42

0.050

2024-T42

0.063

S-568

S-588

2331 006

S-588

Shim

2024-T3 Clad

0.100

2331006

Doubler

2024-T3 Clad

0.080

2331006

Angle
Angle (2 ea.)

2024-T42 Clad

0.063

2331006

4130 Steel

0.125

2331006

Web

2024-T3 Clad

0.050

2331007

Angle
Angle

2024-T42 Clad

0.080

2024-T42 Clad

0.080

Clip
Spar Assy.,

2331006
2331 006

No. 3

S-575

2024-T3 Clad

0.190
0.025

Replace

2331006

Doubler

2024-T3 Clad

2331006

Bracket(2 ea.)

S-591

0.125

2331006

Web

2024-T3 Clad

0.050

2331007

Angle (2 ea.)
Cap(2 ea.)

2024-T42 Clad

0.080

S-589

Web

2024-T4 Clad

0.040

0.080
0.090

2331006

2331007
2331007

Spar Assy., No. 4


Spar Cap (2 ea.)
Angle(2 ea.)

2331 007

Plate

2331007

Filler

2024-T3 Clad

2331 007

Filler, LH
Filler, RH

2024-T351

2331 007

2024-T351 Clad

0.250

2331007

Filler

0.120

2024-T3 Clad
2024-T4
2024-T3 Clad
2024-T3 Clad

0.040

2024-T3 Clad

0.120

2024-T42 Clad

0.063

1
1

2531 539

Bracket, Downspring

2331007

Doubler

2331007

Web

233 i 007

Filler

(2 ea.)

2331007

Spar, Rear
Rib Instl.

2431011
2431012
2431012

Rib

2431012

Rib Web

Rib

Cap,
Cap,

Clad

LH

S551

RH

S551

2024-T3 Clad

Vertical Stabilizer

Figure
EFFECTIVITY:

Replace
Replace
Replace
Replace
Replace
Replace

Replace

S-590
2024-T42 Clad
2024-T351 Clad

2331007

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Spacer

2331006

IStiffener

2331006

Replace
Replace
Replace

2331006

S-151-1

REPAIR
FIG. NO.

CODE

1
1

Cap, LH
Cap, RH

2331007

SRM-P

I
MATERIAL

/Angle

2331 006

Assembly
Spar Assy, No. 1
Angle
Spar Web
Doubler

2331006
2331 006

I
EFF.

0.250
0.250

1.100
0.050

0.050

F4-1

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Replace
Replace
Replace

Repair Index

2 (Sheet 3 of 6)

MODEL28/29/31 SERIESAIRCRAFT

55-30-00

Page 10
May 15/92

LAdriet
Learjet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.
NO.

NO.

2024-T42 Clad

0.032

F4-1

2024-T42 Clad

0.032

F4-1

Angle
Angle

2024-T42 Clad

0.063

F4-1

1 2024-T42 Clad

0.063

F4-1

Replace
Replace
Replace
Replace
Replace
Replace
Replace

Filler

2024-T3 Clad

0.080

F4-1

2431012

Filler

2024-T3 Clad

0.080

F4-1

2431012

Doubler

2024-T3 Clad

0.125

F4-1

Rib

2024-T42 Clad

0.032

F4-1

Stiffener(2 ea.)

S-549

2331016

Rib

2024-T42 Clad

0.050

F4-1

2331016

Angle
Angle (2 ea.)

2024-T42 Clad

0.063(

F4-1

2024-T42 Clad

0.040

F4-1

2331016

Rib (3 ea.)

2024-T42 Clad

0.032

2331016

Attach

Angle

2024-T42 Clad

0.032

2331015

Riblnstl.

Rib(5 ea.)
Angle (3 ea.)

2024-T42 Clad

0.032

F4-1

2024-T42 Clad

0.040

F4-1

Replace
Replace

Rib (4 ea.)
Rib

2024-T42 Clad

0.0321

F4-1

Replace

2024-T42 Clad

0.050

F4-1

Angle

2024-T42 Clad

0.050

F4-1

Replace
Replace
Replace
Replace

Riblnstl.
1

2331016

2331015

2331015

2331014

2331014

2331014

Gusset

2331014

Angle(3 ea.)

2024-T3

0.063

F4-1

2024-T42 Clad

0.040

F4-1

2024-T42 Clad

0.032

2024-T42 Clad

0.040

2024-T42 Clad

0.040

2024-T42 Clad

0.032

2024-T42 Clad

0.063

2024-T3 Clad

0.050

2024-T3 Clad

0.050

Rib Instl.

2331013

2331013

1
1

Rib(5 ea.)
Angle (4 ea.)
Rib Assy.
Angle (4 ea.)
Rib (4 ea.)

2331013
2331008

2331008
2331008
12

2331033

Rib

2331 040

Channel Assy., Antenna


Channel

2331040

Doubler

2331 040

Channel Assy., Antenna


Channel

2331040

Replace

Replace

I
I

Replace
Replace
Replace

I
I

Replace
Replace

I Replace

13

2331040

Replace
Replace
Replace
Replace
Replace
Replace
Replace

Rib Instl.

2331014

2331014

14

FIG. NO.

Doubler

2331016

11

REPAIR

CODE

Rib

2331016

IFINISH

2331016

10

GAGE

2431012

I
MATERIAL

2431012
2431012

I
EFF.

2431012

2431012

I
DESCRIPTION

1
1

2024-T3 Clad

0.050

2331040

Doubler

2024-T3 Clad

0.050

2331030

Hinge Assy.

2331030

Bracket

2024-T42 Clad

0.071

F4-1

2331030

Plate

2024-T3 Clad

0.100

F4-1

Replace
Replace

2024-T4 Clad

0.250

F4-1

51-71-00

2024-T3 Clad

0.100

F4-1

Replace

2331030

2331030

Hinge

Arm

Filler

Replace

Vertical Stabilizer

Repair Index
Figure 2 (Sheet 4 of 6)

EFFECTIVITY:
SRM-4

MODEL28/29/31 SERIESAIRCRAFT

55-30-00

Page 11
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.
15

DWG.
NO.
2331031
2331031

2331031

1
i

2331031
16

2331025

17

2431003

18

1 2431003

Filler

LH 8 RH

(1 ea.)
RH (1 ea.)

IFINISH

REPAIR

CODE

FIG. NO.

MATERIAL

GAGE

2024-T42 Clad

0.071

F4-1

Replace

0.250

F4-1

51-71-00

1 2024-T4 Clad

2024-T3 Clad
I

F4-1

0.040
I

7050-T7451

I
3.500

F4

51-71-00

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2024-T42 Clad

0.080

F4-1

2024-T3

0.250

F4-1

2024-T3 Clad

0.050

F4-1

2431003

2024-T3 Clad

0.080(

F4-1

2431003

Skin Doubler

301 Stainless

0.020

F4-1

2431003

Plate, LH
Plate, RH

2024-T3 Clad

0.080

F4-1

2431003

2024-T3 Clad

0.080

F4-1

2431005

Attach

2024-T42

0.040

F4-1

2024-T3 Clad

0.040

5-554

F4-1

S-554

F4-1

2024-T42 Clad

2431003

Web

2431005
2431 000

Shim, Laminated (Max. 0.040)

2531 000

Filler

StafoamAA604

Skin, Leading Edge

2024-T42 Clad

0.040

F4-1

51-70-02

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2431003

2431003

1 2431000

F4-1

F4-1

0.003

2388320

Antenna Cable

0.040

F4-1

2431000

Skin, LH
Skin, RH

2024-T42 Clad

0.050

F4-1

2024-T42 Clad

0.050

F4-1

21

1 2331023

Door

2024-T3 Clad

0.040

F4-1

2331023

Doubler

2024-T3 Clad

0.063

F4-1

2331032

Door

2024-T3 Clad

0.040

F4-1

2331032

Doubler

2024-T3 Clad

0.063

F4-1

2331038

Door

2024-T3 Clad

0.040

F4-1

2331038

Doubler

2024-T3 Clad

0.071

F4-1

24

2331059

Door

2024-T3 Clad

0.040

F4-1

2331059

Doubler

1 2024-T3 Clad

0.071

F4-1

25

2331037

Door

2024-T3 Clad

0.040

F4-1

2331037

Doubler

2024-T3 Clad

0.071

F4-1

2331058

Door

2024-T3 Clad

0.040

F4-1

2331058

Doubler

2024-T3 Clad

0.071

F4-1

2331038

Door

2024-T3 Clad

0.040

F4-1

2331038

Doubler

2024-T3 Clad

0.071

F4-1

2331057

Door

2024-T3 Clad

0.040

F4-1

2331057

Doubler

2024-T3 Clad

0.071

F4-1

2431105

Fin

2431000

26

27
28
29

Tip

Instl.

Support

See

Figure

Figure

SRM4

Replace

5.

Vertical Stabilizer

EFFECTIVITY:

Replace
Replace
Replace

F4-1

0.063

20

23

Angle
Skin Support
Angle LH
Angle RH
Attach Angle

2431005

22

Replace
51-71-00

Plate
Shim
Filler

2431003

19

Hinge Assy.
Bracket (2 ea.)
Hinge Arm

Hinge,
Hinge, LH
Web Assy

6031025

I
EFF.

DESCRIPTION

Repair Index

(Sheet 5 of 6)

MODEL28/29/31 SERTESAIRCRAFT

55-30-00

Page 12
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


CODES

EFFECTIV~TIES

28-005; 29-001 THRU 29-004; 31-001 AND SUBSEQUENT

28-001 THRU

29-003 THRU 29-004; 31-001 AND SUBSEQUENT


31-043 AND SUBSEQUENT

NOTES
Condition Normalized, heat treat

to

125,000 -150,000 psi.

301 Stainless 1/2 Hard.

Laminated shim stock, 0.002


sheet.

or

0.003 lamination per MIL-S-22499

Vertical Stabilizer

Figure
EFFECTIVITY:
SRM-4

Type

1 Class 1

or

Class 2 1145-H19 aluminum

Repair Index

2 (Sheet 6 of 6)

MODEL28/29/31 SERIESAIRCRAFT

55-30-00

Page 13
May 15/92

Learjet

STRU~TURAL REPAIR MANUAL


VERTICAL STABILIZER- STRUCTURAL IDENTIFICATION

28)

11~ I

~114

13

15

~X
c
o

4
o

0)

lo

5-6A

5-21B-2

Vertical Stabilizer

Figure
EFFECTNITY:
SRM4

Repair Index

3 (Sheet 1 of 6)

MODEL 35/36SERIESAIRCRAFI

55-30-00

Page 14
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
VERTICAL STABILIZER

STRUCTURAL IDENTIFICATION

0]
25

27

n)

cn

~3

22

23

24

~r

5-14C-1

Vertical Stabilizer

Figure
EFFECTIVITY:
SRM~

Repair Index

3 (Sheet 2 of 6)

MODEL 35/36 SERIESAIRCRAFT

55-30-00

Fage 15
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

Assembly
Spar Assy., No. 1

2531012

2024-T42

0.063

2024-T42

0.050

2531012

IDoubler

2024-T42

0.063

2331006

Spar Assy.,
Angle
ICap, LH
ICap, RH

2331 006
2331006
2331006

1
1

2024-T42 Clad

0.063

4130 Steel

0.125

2024-T3 Clad

0.050

2024-T42 Clad

0.080

1
1

1
1

S-575

Spacer

2024-T3 Clad

I
0.190

2024-T3 Clad

0.025

S-591

0.125

2331006

Web

0.050

2331006

Angle(2 ea.)
Cap(2 ea.)

2024-T3 Clad
2024-T42 Clad

S-589

2331006

Web

2024-T4 Clad

S-590

0.080

2024-T42 Clad
2024-T351 Clad

2024-T3 Clad

0.090

Spar Assy., No. 4


Spar Cap (2 ea.)
Angle (2 ea.)

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.250

0.250

2024-T3 Clad

0.120

2024-T4

1.100

Doubler

0.050

Web

2024-T3 Clad
2024-T3 Clad

0.040

2024-T42 Clad

0.063

I Replace
I Replace

Filler

Bracket, Downspring

2331007

Spar, Rear

2531011

Rib Instl.
Rib

Cap, LH
Cap, RH

0.250

I
I

S551

S551

Rib Web

2024-T3 Clad

0.050

Rib

2024-T42 Clad

0.032

2024-T42 Clad

0.030

2431012

Rib

2431012

1
1
1

Doubler

Vertical Stabilizer

MODEL 35/36SERIESAIRCRAF~

F4-1

I
I

Replace
Replace
Replace

Repair Index

Figure 3 (Sheet 3
EFFECTIVITY:

0.040

2024-T351 Clad

2431012

I
I
I
I

1
I

2024-T351 Clad

2331007

2431012

IFiller, LH
IFiller, RH

0.080

1
1

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

IPlate
Filler
1

2331007

Replace
Replace
Replace
Replace
Replace

I
I
I
I

2331 007

2431012

SRM-4

Bracket(2 ea.)

I
I
I

Doubler

2331007

2531 539

Replace

I Replace

0.100

0.080

2331 007

2024-T3 Clad
2024-T3 Clad

2331006

2331007

1
1

1
1

2331006

2331 007

Replace
Replace

Doubler

Stiffener

2331007

I
I

Shim

Angle(2 ea.)
IClip
Spar Assy., No.

2331907

I Replace

5-588

Web

2331007

Replace
Replace

2331007

I
I

S-568

2331006

2331006

S-588

2331007

2331 006

I Replace

Angle
Angle(2 ea.)

S-151-1

2331006

FIG. NO.

No. 2

2331006

2331006

REPAIR

CODE

1
1

2331 006

IFINISH
GAGE

IAngle
Spar Web
1

2331 006

I
MATERIAL

2531012

2531012

I
EFF.

Vertical Fin

2531000
1

I
DESCRIPTION

of 6)

5530-00

Page 26
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.
2431012

2431012
2431012
7

2331016
2331016
2331016

DESCRIPTION

IFINISH

MATERIAL

GAGE

CODE

Angle (2 ea.)
Filler(2 ea.)

2024-T42 Clad

0.063

F4-i

0.080

F4-1

Doubler

2024-~3 Clad
2024-T3 Clad

0.125

F4-1

2024-T42 Clad
S-549

0.032

F4-1

2331016

Rib

2024-T42 Clad

0.050

F4-1

2331016

Angle

2024-r42 Clad

0.063

F4-1

2331016

Angle(2 ea.)
Rib tea.)

2024-T42 Clad

0.040

F4-1

0.032

F4-1

Doubler

2024-T42 Clad
2024-T3 Clad

0.040

F4-1

2331016

Doubler

2024-T3 Clad

0.032

F4-1

2331016

Attach

2024-T42 Clad

0.032

F4-1

233101 5

Riblnstl.
1

2024-T42 Clad
2024-T42 Clad

0.032

F4-1

0.040

F4-1

Angle

2331015

Rib

2331015
2331014

Angle(3 ea.)

(2331014
2331014
2331014
2331014
2331014
2331013

10

1 2331013

11

2331013
1 2331008
2331008
2331008

(5 ea.)

Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Riblnstl.

Rib(2 ea.)

Rib

Angle

Gusset

Rib(2 ea.)
Angle(3 ea.)

2024-T42 Clad
2024-T42 Clad

0.0321

F4-1

0.050

F4-1

F4-1

2024-T42 Clad
2024-T3

0.050

0.063

F4-1

2024-T42 Clad

0.032

F4-1

2024-T42 Clad

0.040

F4-1
F4-1

Replace
Replace
Replace
Replace
Replace
Replace

Rib Instl.

Rib(S ea.)
Angle(4ea.)

2024-T42 Clad

0.032

2024-T42 Clad

0.040

2024-T42 Clad

0.040

2024-T42 Clad

0.032

F4-1
F4-1

2024-T42 Clad

0.040

F4-1

2024-T42 Clad

0.063

F4-1

Rib Assy.

2331008
2331033

Rib

13

2331 040

Channel

Assy., Antenna

Replace
Replace
Replace
Replace

2331040

Channel

2024-T3 Clad

0.050

F4-1

2331040

Doubler

2024-T3 Clad

0.050

F4-1

Channel

Replace

Replace
F4-1

Angle (3 ea.)
Rib (4 ea.)
Angle

12

2331 040

REPAIR
FIG. NO.

Rib Instl.
Rib

2331014

14

I
EFF.

Stiffener(2 ea.)

2331016
2331016

Replace
Replace

Assy., Antenna

2331040

Channel

2024-T3 Clad

0.050

F4-1

2331040

Doubler

2024-T3 Clad

0.050

F4-1

Replace
Replace

0.071

F4-1

Replace

0.100

F4-1

1 2331030

Hinge Assy.

2331030

Bracket

2331030

Plate

2331030

Hinge Arm

1 2024-T42 Clad
2024-T3 Clad
2024-T4 Clad

2024-T3 Clad

2331030

Filler

0.250 1
0.100

Replace
1

F4-1

51-71-00

Replace

Vertical Stabilizer Repair Index

Figure 3 (Sheet 4 of 6)
EFFECTIVITY:
sRM-a

MODEL 35/36SERIESAIRCRAFT

55-30-00

Page 17
May 15/92

Learjet

STRUCTURAL REPAIR rJ1ANUAL


ITEM
NO.
15

DWG.
NO.
1 2331031
2331031
2331031
2331031

16

i 2331025
603 t 025

17

21
22

Hinge

1
1

Filler

Hinge,
Hinge,

LH 8 RH (1 ea.)
LH 8 RH (1 ea.)

/7050-T7451

Plate

1
1

CODE

0.071

F4-1

Replace

0.250

F4-1

51-71-00

F4-1

0.040

I
3.500 1

51-71-00

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.250

F4-1
F4-i

2431003

Filler

2024T3 Clad

0.080

F4-1

2431003

Skin Doubler

301 Stainless

0.020

F4-1

2431003

Plate, LH
Plate, RH

2024-T3 Clad

0.080

F4-1

2024-T3 Clad

0.080

F4-1

2024-T42
2024-T3 Clad
2024-T42 Clad

0.040

F4-1

0.040

F4-1

2431005

Attach

2431 000

Shim, Laminated (Max. 0.040)

2531000

Filler

Stafoam AA604

2431000

Skin, Leading Edge


Antenna Cable Support
Skin, LH
Skin. RH

2331023

Door

2333 023

Doubler

1 2331 032

2331032

Door
Doubler

2331038

Door

2331038

Doubler

2331 059

1
1

1 2531000
2531000

0.063

F4-1

0.003

F4-1

2024-T42 Clad

0.0401

F4-1

0.040

F4-1

2024-T42 Clad

0.050

F4-1

2024-T42 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
1 2024-T3 Clad
2024-T3 Clad

0.050

F4-1

0.040\

F4-1

0.063

F4-1

0.040

F4-1

0.063

F4-1

0.040)

F4-1

Angle

2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad

0.071

F4-1

0.0401

F4-1

0.071

F4-1

0.0401

F4-1

2331059

Door
Doubler

24

2331037

Door

2331037

Doubler

25

2331058

Door

2331059

Doubler

26

\2331038

Door

2331038

Doubler

2024-T3 Clad

0.071

F4-1

27

2331057

Door

0.040

F4-1

2331057

Doubler

2024-T3 Clad
2024-T3 Clad

0.071

F4-1

2431105

Fin Tip Instl.

23

28

1
See

Figure

2024-T3 Clad
1 2024-T3 Clad
2024-T3 Clad

51-71-00

F4

0.050

Attach Angle
Skin Support

Replace
1

2024T3 Clad
2024-T3 Clad

2431005

REPAIR
FIG. NO.

IFINISH

IGAGE

2024T42 Clad
2024-T4 Clad
2024-T3 Clad

Arm

Shim

2388320

20

Hinge Assy.
Bracket(2 ea.)

2431003

2431005

19

I
MATERIA~

I EFF.

DESCRIPTION

1 2431003

2431003

18

0.071

F4-1

0.040

F4-1

0.071

F4-1

0.040)

F4-1

51-70-02

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Replace
I Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

4.

Repair Index
Figure 3 (Shee~ 5 of 6)

Vertical Stabilizer

EFFECTIVITY:
SRM-4

MODEL35/36SERIES AIRCRAFT

5530-00

Page 18
May 15/92

Ledliefl
STRUCTURAL REPAIR MANUAL
CODES

EFFECTIVITIES

35-001 AND

35-671 AND

SUBSEQUENT; 36-001 AND SUBSEQUENT


SUBSEQUENT; 36-064 AND SUBSEQUENT

NOTES
Condition Normalized, heat treat to 125,000 -150,000

psi.

301 Stainless 1/2 Hard.

Laminated shim stock, 0.002


sheet.

or

0.003 lamination per MIL-S-22499

Type

1 Class 1

or

Class 2 1145-H19 aluminum

Vertical Stabilizer

Repair Index
Figure 3 (Sheet 6 of 6)

EFFECTTVITY:
SRM-P

MODEL35/36 SERlESAIRCRAFT

55-30-00

Page 19
May 15/92

Learjet
~1
STRUCTURAL REPAIR MANUAL
VERTICAL STABILIZER
I.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS
All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

or

failed rivets
the

on

are

not allowed. A loose or failed rivet can

cause

increased stress concentra-

progressive joint failure. A careful inspection must be


that joint failure has not spread from the area of the loose or failed rivet. (Re-

remaining

rivets and lead to

performed to ensure
fer to Chapter 51 for definition of rivet failure.)
(2) Loose

or

failed

screws are

not allowed. A loose

or

failed

screw can cause

increased stress

concen-

progressive joint failure. A careful inspection must be


performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
trations
B.

on

surrounding

screws

and lead to

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

re-

paired, and refinished in accordance with Chapter 51.


C.
D.

Deformation

(1) Deformation of the vertical stabilizer is not allowed.


Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

more

than

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component re-

placed.
F.

Scratches(See Figure 101.)


(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to

Chapter 51

for

protective treatment procedures.)


replaced or repaired

(2) Structural components must be


thickness by more than specified.
G.

H.

original

material

Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTNITY:
SRM4

if scratches reduce the

ALL

55-30-00

Page 101
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFFECTIVITY:

ALL

101

55-30-00

Page
SRM~

102

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
VERTICAL STABILIZER -REPATR

i.

APPROVED REPAIRS

WARNIN~:

NO STRUCTURAL REPAIRS ARE ALLOWED TO THE SPARS IN TKE VERTICAL


STABILIZER.

A.

Chapter 51 for typical repairs, and


er assembly fittings and attaching parts.
Refer to

EFFECTIVITY:

ALL

for allowable

wear

and

repair data

for the vertical stabiliz-

55-30-00

Page
SRM~

201

May 15/92

LEARJET 20/30 SERIES


STRUCTURAL REPAIR MANUAL

TEMPORARY REVISION NO. 55-2


MANUAL AFFECTED:

Learjet

Model 20/30 Series Structural

FILING INSTRUCTIONS: Insert

adjacent

REASON: To correct material callouts


INSTRUCTIONS: Revise

as

on

to

Repair Manual.

55-35-00, page 1, dated May 15/92 and retain until further notice.

Fin

Tip Repair Index.

follows:

18

19

25

16

26

21

22

24
10

(23-003 THRU 23-099;

24-100 THRU 24-229 MCEPT 24-218;

25-002 THRU 25-066 MCEPT

25-061)

OYPICAL)

Detail A
Tip Repair Index
Figure 1 (Sheet 1 of 5)
Fin

TEMPORARY REVISION NO. 55-2

EFFECTIVIP/: MODEL 23/24/25/35/36 SERIES AIRCRAFT


SRM-1

55-35-00

tcOB~f9,1

30/00

LEARJET 20/30 SERIES


STRUCTURAL REPAIR MANUAL

22

12

15

6~

(24-218,

24-230 THRU 24-357; 25-061, 25-067 THRU 25-373;


SUBSEQUENT; 36-001 AND SUBSEQUENT)

35-001 AND

CP/PICAL)

Detail B
Fin

Tip Repair Index


Figure 1 (Sheet 2 of 5)

TEMPORARY REVISION NO. 55-2


EFFECTIVITY: MODEL 23/24/25135/36 SERIES AIRCRAFT
SRM-4

55-35-00

Page

2 of 8

Oct 30/00

LEARJET 20/30 SERIES


STRUCTURAL REPAIR MANUAL

ITEM
NO.

Fin

123311017

CODE

2431105

2589012

1 Fairing,

FINISH

REPAIR

CODE

F10. NO.

Tip Instl.

Fairing,

QAOE

UATERIAL

DESCRIPTION

NO.
2431105

EFF

DWG.

Fin Fwd

6061-T4

F4-1

Replace
Replace

Fin Lower Fwd

2024-T4 Clad

0.040

F4-1

Lower Fwd

6061-T4

0.071

F-l ext

.Fairing, Fin

Replace

0.032

F-4 int
3

2431105

Fairing,

Fin

2589012

Fairing,

Fin

Upper

Fwd

6061-T42

0.040

F4-1

Replace

Upper

Fwd

6061 -T4

0.071

F-l ext

Replace

F-4 int
4

2331019

2331056
5

\2431107

Fairing

2024-T42 Clad

0.040

F4-4

Replace

Bulkhead Assy., Fwd Fin Fairing

2024-T42

0.040

F4-1

Replace

6061-T6

F4-1

Replace

0.032

F4-1

Replace

.Bulkhead

IRib,

Assy.,

Fwd Fin

Canted

2431106

Rib

2024-T42 Clad

2331020

.Bulkhead Assy., Fairing

2024-T42 Clad

0.050

F4-1

Replace

2531020

1 Bulkhead Assy., Fairing

2024-T42 Clad

0.050

F4-1

Replace

2431108

2024-T42 Clad

0.032

F4-1

Replace

0.050

F4-1

Angle, LH

10

2331021

Rib

ii

(2393005

Rib

Fin

Assy.,

Fin

Fairing

10

Fairing

11

2024-T42

Replace

Replace
1

Replace

IAngle

11

2024-T3

0.040

2331 022

.Filler

ii

2024-T3

0.040

F4-1

Replace

11

2024-T42 Clad

0.040

F4-1

Replace

2024-T42 Clad

0.040

F4-1

Replace

2331022

1. Rib
.Rib

12

12331022

12631108

14

12331021

16

Assy,.

2389005

13

15

a RH

~2631108
12331017

Rib

Assy.,

Fin

Fairing

12

Assy.,

Fin

Fairing

13

2024-T42 Clad

0.040

F4-6

Replace

14

2024-T42

0.050

F4-1

Replace

F4-6

Replace

F-l ext

Replace

Bulkhead Assy., Fin


Bulkhead

Fairing,

Assy.,

Fin

Fin

Upper

Fairing
Fairing

Aft

Aft

13

2024-T42

0.050

0.032

6061-T4

16

Center

Fi4-1 int
17

12431101

.Fairing,

Fin

Upper

Center

Replace

F-l ext

0.071

2024-T42

16

F14-1 int
18

2331024

.Fairing,

5ply I

fiberglass

10

Fin Center

Replace

#182
19

2331054

.Fairing,

2024-T42 Clad

17

Fin Center

F-l ext

0.032

Replace

Fi4-1 int
20

2631102

Fairing,

2024-T42

13

Fin Center

F4ext

0.032

Replace

F4-6 ext

21

12331018
2331018

.Fairing Assy.,

15

Fin Aft

fiberglass

15

Burkhead

5ply

Replace

#181

Fin

Tip Repair Index

Figure

(Sheet

3 of

TEMPORARY REVISION NO. 55-2


EFFECTIVITY: MODEL 23/24/25/35/36 SERIES AIRCRAFT
SRM-P

5)

55-35-00

tcO8~9,t

30/00

LEARJET 20/30 SERIES

STRUCTURAL REPAIR MANUAL

ITEM

DWG.

NO.

NO.
2331018

EFF

Stiffeners

15

Rib

15

Bulkhead

2331052

15

Fairing Assy.,

050

Fin Aft

FINISH

REPAIR

CODE

FIG. NO.

GAGE

CODE

2331018

22

MATERIAL

DESCRIPTION

2024-T42Clad

0.050

F4-1

Replace

2024-T42 Clad

0.050

F4-1

Replace

2024-T42 Clad

0.050

F4-1

Replace
Replace

18

2331 052

Bulkhead

18

2024-T42

0.040

F4-1

Replace

2488502

Bulkhead

18

2024-T42

0.040

F4-1

Replace

18

2024-T42

0.040

F4-1

Replace

18

2024-T3

0.032

2331 053

Rib

2331050

Conduit

23

Clip

100

.Fairing Assy.,

104

.Bulkhead

Replace
Replace

17

17

Skin

F4-6

Replace

0.040

F4-6

Replace

0.032

F4ext

Replace

2024-T42

0.040

2024-T42Clad
6061-T42

17

Bulkhead

26311 03
26311 01

Fin Aft

17

F4-6 int
24

2332021

.Fairing, Bullet, Center Section

fiberglass

ply

Replace

#181
25

2312020

.Duct

Assy., Dorsal Air Intake

20

fiberglass

ply

Replace

#181

26

Duct

2512020

Assy., Dorsal Air Intake

fiberglass

21

ply

Replace

#181

27

2612020

.Duct

Assy., Dorsal Air Intake

22

fiberglass

ply

Replace

#181

EFFECTIVIN

AIRCRAFT SERIAL NUMBERS

CODE
1

23-001 THRU 23-099; 24-100 THRU 24-357; 25-001 THRU 25-373; 35-001 AND SUBSEQUENT;
36-001 AND SUBSEQUENT

23-003 THRU 23-099; 24-100 THRU 24-229 EXCEPT 24-218; 25-002 THRU 25-066 EXCEPT 25-061

24-018, 24-230 THRU 25-357; 25-061, 25-067 THRU 25-373 EXCEPT U/K CERTIFIED AIRCRAFT,
35-001 THRU 35-612, 35-614, 35-618 THRU 35-643, 35-645 AND SUBSEQUENT EXCEPT U/K CERTIFIED

AIRCRAFT;

36-001 AND SUBSEQUENT EXCEPT U/K CERTIFIED AIRCRAFT.

25-135 AND SUBSEQUENT U/K CERTIFIED

AIRCRAFT; 35-613, 35-615 THRU 35-617 AND 35-644,

35-236 AND SUBSEQUENT U/K CERTIFIED AIRCRAFT;36-045 AND SUBSEQUENT U/K CERTI-

FIED AIRCRAFT
5

23-003 THRU 23-005

23-016 THRU 23-099; 24-100 THRU 24-217 AND 24-219 THRU 24-229; 25-002 THRU 25-060 AND 25062 THRU 25-066

Fin

Tip Repair Index


Figure 1 (Sheet 4 of 5)

TEMPORARY REVISION NO. 55-2

EFFECTIVITY: MODEL 23/24/25/35/36 SERIES AIRCRAFT


SRM-4

30/00

LEARJET 20/30 SERIES


STRUCTURAL REPAIR MANUAL

EFFECTIVITY

AIRCRAFT SERIAL NUMBERS

CODE
7

24-218, 24-230 THRU 24-357; 25-061, 25-067 AND SUBSEQUENT; 35-011 AND SUBSEQUENT;
36-001 AND SUBSEQUENT

23-003 THRU 23-099; 24-100 THRU 24-344; 25-002 THRU 25-006, 25-287 THRU 25-373

24-345 THRU 24-357; 25-007 THRU 25-286; 35-001 AND

10

23-003 THRU 23-015

11

23-016 THRU 23-099; 24-100 THRU 24-289; 25-002 THRU 25-152; 35-001 AND

SUBSEQUENT;

36-001 AND SUBSE-

QUENT

35-002; 36-001 AND

36-002
12

24-290 THRU 25-357; 25-153 THRU 25-373; 35-003 THRU 35-621; 36-002 THRU 36-055

13

35-622 AND SUBSEQUENT; 36-056 AND SUBSEQUENT

14

23-003 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-373; 35-002 THRU 35-621; 361002
THRU 6-055

15

23-002 THRU 23-015

16

23-016 THRU 23-099; 24-100 THRU 24-229 EXCEPT 24-218; 25-002 THRU 25-066 EXCEPT 25-061

17

23-01 6 THRU

23-099; 24-100 THRU 24-357; 25-002 THRU 25-373; 35-001 THRU 35-621; 36-001

THRU 36-055
18

23-016 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-373; 35-001 THRU 35-624; 36-001

THRU 36-055
19

35-625 AND SUBSEQUENT; 36-056 AND SUBSEQUENT

20

23-002 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-048

21

25-049 THRU 25-257; 35-492 AND SUBSEQUENT WITH DORSAL MOUNTED OXYGEN

CYLINDER,

36-035 AND SUBSEQUENT WITH DORSAL MOUNTED OXYGEN CYLINDER


22

35-001 AND SUBSEQUENT WITHOUT DORSAL MOUNTED OXYGEN

CYLINDER;

36-001 AND

SUBSEQUENT WITHOUT DORSAL MOUNTED OXYGEN CYLINDER

Fin Tip

Figure

Repair Index
(Sheet 5 of 5)

TEMPORARY REVISION NO. 55-2

SRM-4EFFECTIVJTY:

MODEL 23/24/25/35/36 SERIES AIRCRAFT

55-35-00

Page

5 of 8

Oct 30/00

LEARJET 20/30 SERIES


STRUCTURAL REPAIR MANUAL

is

10
12

T
27

ii

18

11

5
7

.~aSfl

26
24

22
16
3

25
19

21
15

29

iDetail A
Fin

Tip Repair
Figure 2 (Sheet

TEMPORARY REVISION NO. 55-2


EFFECTIVITY: .MODEL 28/29/31 SERIES AIRCRAF=T
SF~M-4

Index
1 of

-3)

55-35-00

30/00

LEARJET 20/30 SERIES


STRUCTURAL REPAIR MANUAL

ITEM
NO.

EFF

DWO.
I

DESCRIPTION

105

FINISH I

REPAIR

F10. NO.

MATERIAL

GAGE

2024-742 Clad

0.032

F4-1

Replace

2024-742 Clad

0.050

F4-1

Replace

2024-742 Clad

0.032

F4-1

Replace

2024-73 Clad

0.040

F4-1

Replace

CODE

CODE

NO.

FinTipinstl.

12431106

IRib

2331020

Bulkhead

2431108

LH

(2331022

Rib

Assy.,

Fin

Fairing

2631108

Rib

Assy.,

Fin

Fairing

.Angle,

12331021

.8ulkhead

12631107

Bulkhead

12331054

.Fairing,

Assy., Fairing
RH

F4-6

2024-T42Clad

0.040

Assy.,

Fin

Fairing Aft

2024-742 Clad

0.050

F4-1

Assy.,

Fin

Fairing Aft

2024-742 Clad

0.050

F4-6

2024-742 Clad

0.032

Fin Center

Replace

Replace
I

F-l ext

Replace
Replace

F14-1 int
9

12631102

1 Fairing,

2024-742 Clad

Fin Center

F4 int

0.032

Replace

F4-6 art
10

12331050

.Fairing Assy.,

2331 052

Bulkhead

2488502
053
2331050
11

12631 i 00

Fin Aft

I
2024-742

Bulkhead

1 Rib
Conduit

Clip

Fairing Assy., Fin

Aft

0.040

I
F4-1

Replace
Replace

2024-742

0.040

F4-1

2024-742

0.040

F4-1

2024-73

0.032

1
I

2631104

i.. Bulkhead

2024-742

0.040

F4-6

26311 03

Bulkhead

2024-T42C\ad

0.040

F4-6

6061-742

0.032

2631101

Skin

Replace

Replace

Replace

Replace

Replace
I

Replace

Replace

F4 ext

F4-6 int
12

12332021

Fairing, Bullet,

Center Section

fiberglass

6ply

Replace

#i81
13

2512020

Duct

Assy., Dorsal

Air Intake

fiberglass

5ply

Replace

#181
14

12612020

Duct

Assy., Dorsal

Air Intake

fiberglass

5ply

Replace

Replace

#181
15

2431105

16

2831106

17

2831106

18

2831106
2831107

Fairing,

Fin Lower Forward

2024-74 Clad

0.040

2024-742 Clad

0.040

F4-1

2024-742 Clad

0.040

F4-1

Lens Retainer

2024-T42Clad

0.040

F4-1

Lens Retainer

2024-742 Clad

0.040

F4-1

Replace

Rib, Canted
Retainer

19

28311 06

.Mounting

20

2831106

Angle

21

12831106

Bracket

Rib

Replace

Replace

Replace

2024-f42Clad

0.040

F4-1

Replace

2024-742 Clad

0.040

F4-1

Replace

2024-742Clad

0.040

F4-1

Replace

Tip Repair Index


Figure 2 (Sheet 2 of 3)
Fin

TEMPORARY REVISION NO. 55-2


EFFECTIVITY: MODEL 28/29/31 SERIES AIRCRAFT
SRM-4

55-35-00~""Oct

30/00

LEARJET 20/30 SERIES


STRUCTURAL REPAIR MANUAL

ITEM

DWG.

NO.

NO.

22

2831106

FINISH

REPAIR

CODE

CODE

FIO. NO.

Replace

EFF

DESCRIPTION
Doubler

GAGE

MATERIAL

2024-T42 Clad

0.040

F4-1

0.040

F4-1

Replace

23

2831106

Retainer

2024-T42 Clad

24

2831106

Rib

2024-T42 Clad

0.040

F4-1

Replace

25

2831106

Angle

2024-T42 Clad

0.040

F4-1

Replace
Replace
Replace

28311 06

26

27

2431105

Angle

Fairing,

Fin

Upper

Fwd

EFFECTIVITY

2024-T3 Clad

0.040

F4-1

6061-T42

0.040

F4-1

AIRCRAFT SERIAL NUMBERS

CODE
1

28-001 THRU 28-005; 29-001 THRU 29-004; 31-001 AND SUBSEQUENT

28-001 THRU 28-005; 29-001 THRU 29-004

31-001 AND SUBSEQUENT

31-001 AND SUBSEQUENT WITH DORSAL MOUNTED OXYGEN CYLINDER

31-001 AND SUBSEQUENT WITHOUT DORSAL MOUNTED OXYGEN CYLINDER

Tip Repair Index


Figure 2 (Sheet 3 of 3)
Fin

TEMPORARY REVISION NO. 55-2


EFFECTIVITY: MODEL 28/29/31 SERIES AIRCRAFT
SRM-4

55-35-00

Page

8 of 8

Oct 30/00

Learjet

STRUCTURAL REPAIR MANUAL


.FIN TIP

STRUCTURAI, IDENTllcICATION

A
z,

Oi

a
O

Oto

cs

NOE: Please

Ap~

see

fd;
C:

si

the

TEMPORARY
REVSON

tluu 23-099; 24-~L00 ffiru 24-229


excet~ 24-218:
25-002 ftuu_ 25-066
25-.0hl)

that revises this page.

Detail A
(TYPICAL)

5-loA

Fin

Tip Repair Index


Figure 1 (Sheet 1 of 5)
EFFECTIVITY:
SRMI

MODEL

23/24/25/35/36SERIES AIRCRAFT

55-35-00

Page

May 25/92

Learjet

STRU~TURAL REPAIR MANUAL


FIN TIP

STRUCTURAL IDENTIFICATION

P
O
O

i?

13

fi,

9)

~B

(24-218. 24-230 thru 24-357; 25-061, 25-067 thru 25-373:


35-001 and Subseauen_t: 36-001 and

Detail B

(TYPICAL)
522C-1

EFFECTIVITY:
SRM~

Fin Tip Repair Index


Figure 1 (Sheet 2 of 5)

MODEL 23/24/25/35/36SERIES AIRCRAFT

55-35-00

Page 2
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM
NO.

DWG.
NO.

2331017

2431105

(FINISH

MATERIAL

GAGE

2024-T42 Clad

0.032

F4-1

2024-T4 Clad

0.040

F4-1

6061-T4

0.071

REPAIR
FIG. NO.

CODE

Fairing, Fin Lower Fwd


Fairing, Fin Lower Fwd

2589012

I
EFF.

Fin Tip Instl.


Fairing, Fin Fwd

2431105
1

I
DESCRIPTION

Replace
Replace
Replace

F-l art

Fl 4-1 int
3

2431105

2589012

Fairing, Fin Upper Fwd


Fairing, Fin Upper Fwd

2024-T4 Clad

0.040

F4-1

Replace

6061-T4

0.071

F-l art

Replace

F14-1int
4

2331019

Bulkhead

2331056

Bulkhead

Assy.,
Assy.,

Fwd Fin
Fwd Fin

Fairing
Fairing

2024-T42 Clad

0.040

F4-4

2024-T42

0.040

F4-1

24311 07

Rib, Canted

6061-T6

2431106

Rib

2024-T42 Clad

0.032

F4-1

2331020

Bulkhead

2024-T42 Clad

0.050

F4-1

2531020

2024-T42 Clad

0.050

F4-1

2431108

2024-T42 Clad

0.032

F4-1

10

2331021

10

2024-T42 Clad

0.050

11

2393005

Assy., Fairing
Bulkhead Assy., Fairing
Angle LH, RH
RibAssy., Fin Fairing
Rib Assy., Fin Fairing

2393005

IAngle

11

2024-T3

0.040

IFiller

11

2024-T3

0.040

2331022

2331022

13

2631108

14

2331021

15

2631108

16

2331017

Rib
Rib

1
1

Assy., Fin Fairing


Rib Assy., Fin Fairing
Bulkhead Assy., Fin Fairing Aft
Bulkhead Assy., Fin Fairing Aft
Fairing, Fin Upper Center

F4-1

11

2331 022
12

F4-1

I
F4-1

11

2024-T42 Clad

0.040

F4-1

12

2024-T42 Clad

0.040

F4-1

13

2024-T42 Clad

0.040

F4-6

14

2024-T42 Clad

0.050

F4-1

13

2024-T42 Clad

0.050

F4-6

15

6061-T4

0.032

F-l art

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

F14-1 int
17

2431101

Fairing, Fin Upper Center

16

1 2024-142 Clad

0.071

F-l art

Replace

F14-1int
18

1 2331024

Fairing, Fin Center

10

Ifiberglass

ply

Replace

#182
19

1 2331054

Fairing,

Fin Center

2024-T42 Clad

17

0.032

F-l art

Replace

F14-1lnt
20

Fairing, Fin

2631102

Center

13

2024-T42 Clad

0.032

F4 art

Replace

F4-6 int
21

Fairing Assy., Fin

2331018

Aft

15

I
I

2331018

Bulkhead

15

fiberglass

2331018

Stiffeners

15

2024-T42 Clad

0.050

F4-1

2331018

Rib

15

2024-T42 Clad

0.050

F4-1

2331052

Bulkhead

15

2024-T42 Clad

0.040

F4-1

ply I

Replace
Replace

#181

Replace
Replace
Replace

Fin Tip Repair Index


Figure 1 (Sheet 3 of 5)

EFFECTIVITY:
SRM~

MODEL 23/24/25/35/36SERIES AIRCRAFT

55-35-00

Page 3
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

NO.
22

23

DWG.
NO.

I
DESCRIPTION

Fairing Assy.,

Fin Aft

I
MATERIAL

EFF.

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

2631104

IBulkhead

17

2024-T42

0.040

F4-6

Replace
Replace
Replace
Replace
I Replace
I Replace
i Replace

2631103

Bulkhead

17

2024-T42 Clad

0.040

F4-6

Replace

2631101

Skin

17

2024-T42 Clad

0.032

F4 art

Replace

2331050

18

2331 052

IBulkhead

18

2488502

IBulkhead

2331 053

IRib

2331050

2631100

Conduit

Clip
Fairing Assy., Fin Aft

2024-T42

0.040

F4-1

18

2024-T42

0.040

F4-1

18

2024-T42

0.040

18

2024-T3

0.032

17

F4-1

1
I

F4-6 int
24

2332021

25

2312020

Duct

Fairing, Bullet, Center Section


Assy., Dorsal Air Intake

20

fiberglass

26

2512020

Duct

21

Ifiberglass

2024-T42 Clad

j
ply I

0.032
5

I
I

Replace
Replace

Replace

Replace

#181

Assy.,

Dorsal Air Intake

ply I

#181

27

2612020

Duct

Assy., Dorsal Air

Intake

22

fiberglass

ply I

#181

Fin Tip Repair Index


Figure 1 (Sheet 4 of 5)

EFFECTIVITY:
SRM-b

MODEL 23/24/25/35/36SERIES AIRCRAFT

55-35-00

Page 4
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
CODES
1

EFFECTIVITIES
23-001 THRU

23-099; 24-100 THRU 24-357; 25-001 THRU 25-373; 35-001 AND SUBSEQUENT;

36-001 AND SUBSEQUENT


2
3

5
6
7

8
9
10

11

23-099; 24-100 THRU 24-229 EXCEPT 24-218; 25-002 THRU 25-066 EXCEPT 25-061
24-018, 24-230 THRU 24-357; 25-061, 25-067 THRU 25-373 EXCEPT U/K CERTIFIED AIRCRAFT,
35-001 THRU 35-612, 35-614, 35-618 THRU 35- 643, 35-645 AND SUBSEQUENT EXCEPT U/K
23-003 THRU

CERTIFIED AIRCRAFT; 36-001 AND SUBSEQUENT EXCEPT U/K CERTIFIED AIRCRAFT


25-135 AND SUBSEQUENT U/K CERTIFIED AIRCRAFT; 35-613, 35-615 THRU 35-617 AND 35-644,
35-236 AND SUBSEQUENT U/K CERTIFIED AIRCRAFT; 36-045 AND SUBSEQUENT U/K CERTIFIED AIRCRAFT
23-003 THRU 23-015
23-016 THRU 23-099; 24-100 THRU 24-217 AND 24-219 THRU 24-229; 25-002 THRU 25-060 AND
25-062 THRU 25-066
24-218, 24-230 THRU 24-357; 25-061, 25-067 AND SUBSEQUENT; 35-001 AND SUBSEQUENT;
36-001 AND SUBSEQUENT
23-003 THRU 23-099; 24-100 THRU 24-344; 25-002 THRU 25-006, 25-287 THRU 25-373
24-345 THRU 24-357; 25-007 THRU 25-286; 35-001 AND SUBSEQUENT; 36-001 AND SUBSE-

QUENT
23-003 THRU 23-015
23-016 THRU 23-099; 24-100 THRU 24-289; 25-002 THRU 25-152; 35-001 THRU 35-002; 36-001

15

AND 36-002
24-290 THRU 24-357; 25-153 THRU 25-373; 35-003 THRU 35-621; 36-002 THRU 36-055
35-622 AND SUBSEQUENT; 36-056 AND SUBSEQUENT
23-003 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-373; 35-002 THRU 35-621; 36-002
THRU 36-055
23-002 THRU 23-015

16

23-016 THRU

17

23-016 THRU

12
13
14

18
19
20
21
22

23-099; 24-100 THRU 24-229 EXCEPT 24-218; 25-002 THRU 25-066 EXCEPT 25-061
23-099; 24-100 THRU 24-357; 25-002 THRU 25-373; 35-001 THRU 35-621; 36-001

THRU 36-055
23-016 THRU 23-099; 24-)00 THRU 24-357; 25-002 THRU 25-373; 35-001 THRU 35-624; 36-001
THRU 36-055
35-625 AND SUBSEQUENT; 36-056 AND SUBSEQUENT
23-002 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-048
25-049 THRU 25-257; 35-492 AND SUBSEQUENT WITH DORSAL MOUNTED OXYGEN CYLINDER,
36-035 AND SUBSEQUENT WITH DORSAL MOUNTED OXYGEN CYLINDER
35-001 AND SUBSEQUENT WITHOUT DORSAL MOUNTED OXYGEN CYLINDER; 36-001 AND
SUBSEQUENT WITHOUT DORSAL MOUNTED OXYGEN CYLINDER

Tip Repair Index


Fi~re 1 (Sheet 5 of 5)
Fin

EFFECTIVITY:
SRM~

MODEL 23/24/25/35/36SERIES AIRCRAFT

55-35-00

Page 5
May 15/92

Lealietl
STRUCTURAL REPAIR MANUAL
FIN TIP

STRUCTURAL IDENTIFICATION

--r

oo;

U~

Detail A

Fin Tip Repair Index


Figure 2 (Sheet 1 of 3)

EFFECTTVITY:
SRM-4

MODEL28/29/31 SERIESAIRCRAFT

55-35-00

Page 6
May 15/92

Learjet
STRUCTLIRAL REPAIR MANUAL
ITEM

NO.

DVVG.
NO.

DESCRIPTION

2431108

2331022

2631108

2331021

2631107

2331054

Tip Instl.
Rib
Bulkhead Assy., Fairing
Angle LH, RH
Rib Assy., Fin Fairing
Rib Assy., Fin Fairing
Bulkhead Assy., Fin Fairing Aft
Bulkhead Assy., Fin Fairing Aft
Fairing, Fin Center

2631102
2331050

Fairing, Fin Center


Fairing Assy., Fin Aft

2431106

2331020

IFINISH

REPAIR

CODE

FIG. NO.

MATERIAL

GAGE

2024-T42 Clad
2024-T42 Clad

0.032
0.050

F4-1
F4-1

Fin

2431105
1

I
EFF.

1
1

2024-T42 Clad

0.032

F4-1

2024-T42 Clad

0.040

0.040

2024-T42 Clad
2024-T42 Clad

2024-T42 Clad

0.050

2024-T42 Clad

0.032

F4-1
F4-6
F4-1
F4-6
F-l ext

2024-T42 Clad

0.032

0.050

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

F14-lint
10

2331 052

Bulkhead
Bulkhead

2024-T42

0.040

2488502

0.040

F4-1

2331 053

Rib

2024-T42
2024-T42

0.040

F4-1

2024-T3

0.032

2331050
11

1 2631100
2631104

Conduit

Clip

Fairing Assy.,

Fin Aft

2631103

Bulkhead
Bulkhead

2631101

Skin

F4-1

I
0.040

3
3

2024-T42 Clad

0.032

I Replace
F4-6
F4-6

0.040

Replace

I Replace

2024-T42
2024-T42 Clad

I Replace
Replace
Replace
Replace

F4 ext

Replace
Replace
Replace

F4-6 int
12

2332021

2024-T42 Clad

2512020

Fairing, Bullet, Center Section


Duct Assy., Dorsal Air Intake

13

fiberglass

14

2612020

Duct

fiberglass

0.032
5

Replace

ply I

I Replace

#181

Assy.,

Dorsal Air Intake

ply I

I Replace

#181
15

2431105

16

2831106

17

2831106

18

2831106
2831107

Fairing, Fin lower Fwd


Rib, Canted

2024-T4 Clad

0.040

0.040

F4-1

Retainer
Lens Retainer
Lens Retainer

2024-T42 Clad
2024-T42 Clad

0.040

F4-1

0.040

F4-1
F4-1

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

0.040

19

2831106

Mounting

20

2831106

Angle

21

2831106

2831106

23

2831106

Rib
Doubler
Retainer

22
24

2831106

Rib

Angle
Angle
Fairing,

2024-T42 Clad

0.040

F4-1

2024-T42 Clad

0.040

F4-1

2024-T42 Clad

0.040

F4-1

25

2831106

26

2831106

27

2431105

Bracket

Fin

1
1

Upper

Fwd

0.040

F4-1
F4-1

0.040
0.040

F4-1
F4-1

0.040
0.040
0.040

F4-1
F4-1

I Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Fin Tip Repair Index


Figure 2 (Sheet 2 of 3)

EFFECTIVITY:

MODEL28/29/31 SERIESAIRCRAFT

55-35-00

Page 7
SRM-4

May 15/92

Learjet

STRUCIURAL REPAIR MANUAL


CODES
1

2
3

EFFECTIVITIES
28-001 THRU 28-005; 29-001 THRU 29-004; 31-001 AND SUBSEQUENT
28-001 THRU 28-005; 29-001 THRU 29-004
31-001 AND SUBSEQUENT

31-001 AND SUBSEQUENT WITH DORSAL MOUNTED OXYGEN CYLINDER

31-001 AND SUBSEQUENT WITHOUT DORSAL MOUNTED OXYGEN CYLINDER

Tip Repair Index


Figure 2 (Sheet 3 of 3)
Fin

EFFECTIVITY:
SRM-4

MODEL28/29/31 SERIESAIRCRA~

5535-00

Page 8
May 15/92

Learjetl
Learjet
STRUCTURAL REPAIR MANUAL
FIN TIP

i.

ALLOWABT~E DAMAGE

ACLOWABLE DAMAGELIMITS

All dimensions

NOTE:
A.

are

in inches unless otherwise

Fasteners

(1) Loose
tions

or

failed rivets
the

on

are

remaining

performed
fer to Chapter 51
(2) Loose

or

trations

performed

joint

progressive joint failure. A careful inspection must be


spread from the area of the loose or failed rivet. (Re-

failure has not

for definition of rivet failure.)

or failed screw can cause increased stress concenand


lead
to
surrounding
progressive joint failure. A careful inspection must be
to ensure that the joint failure has not spread from the area of the loose or failed screw.

failed

on

not allowed. A loose or failed rivet can cause increased stress concentra-

rivets and lead to

to ensure that

B.

specified.

screws are not

allowed. A loose

screws

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired, and refinished in accordance


C.
D.

re-

Chapter 51.

Deformation

(1) Deformation of the vertical stabilizer fin tip is not allowed.


Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specifled, (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

with

more

than

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or strtchtral area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square feat, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component reF.

G.

H.

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(See Figure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTIVITY:
SRM-L

ALL

55-35-00

Page 101
May 15/92

STRUCTURAL REPAIR MANUAL

Nominal Thickness

Minimum :Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025
0.032

0.0225

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFFECTIVITY:
sran-l

ALL

101

55-35-00

Page 102
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


FIN TIP
i.

REPAIR

APPROVED REPAIRS

A.

Refer to

EFFECTIVITY:

Chapter 51

ALL

for

typical repairs for the vertical stabilizer fin tip.

55-35-00

Page 201
SRM-L

May 15/92

STRUCTURAL REPAIR MANUAL


RUDDER
1.

TRIM TAB

STRUCTURAL IDENTIFICATION

DESCRIPTION

NOTE

The

the

following structural data covers the basic non-modified aircraft. When applicable, refer to
appropriate kit drawing for additions, modifications and changes to the structural compo-

nents and assemblies.

A.

The rudder is mounted on a torque tube with a bellcrank attached to its lower end. The bellcrank provides attach points for the rudder control cables. Counterbalance weights are located in the rudder

leading edge.

A rudder trim tab is located

actuator located in the rudder


access to

the

on

the rudder lower

leading edge.
hinge points, balance weights, and

Access

covers on

trailing edge and is controlled by an


leading edge of the rudder provide

the

trim tab actuator.

ii)

ii:

J~

,C
..i:

I!
7

re

15

23-099: 24-100 thru 24-191~ 25-002 thru 25-010)

Detail A
540B

Rudder

Trim Tab

Figure
EFFECTTVITY:
SRM4

NOTED

Repair Index

i (Sheet 2 of 3)

55-40-00

Page 1
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

I
I

2333000
1

2333000

I
DESCRIPTION
Rudder 8 Trim Tab

I
EFF.

Assembly

I
MATERIAL

GAGE

IFINISH

REPAIR

CODE

FIG. NO.

51-70-04

SparAssy.
Spar

1
1

2024-T42 Clad

0.050

F4-1

2333007

Rib, Stub

2024-T42 Clad

0.032

F4-1

51-70-03

2333006

2024-T42 Clad

0.032

F4-1

51-70-03

2333006
2333006

Rib
Rib

2024-T42 Clad
2024-T42 Clad

0.032

F4-1

51-70-03

0.032

F4-1

51-70-03

2333000

2333006

Rib
Rib

2024-T42 Clad

0.032

F4-1

51-70-03

2333006

Rib

2024-T42 Clad

0.032

F4-1

51-70-03

2333006

F4-1

51-70-03

0.032

F4-1

10

2333006
2324011

Fairing

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

0.032

Rib
Rib

11

2433000

Skin, Lower Leading Edge

2024-T42 Clad

0.032

0.025

51-70-03

I Replace
Flext

51-70-02

F14-lint
12

Skin, Upper Leading Edge

2433000

2024-T42 Clad

0.032

Flext

51-70-02

Fi4-1int
13

2433000

Door, Leading Edge

2024-T42 Clad

0.032

14

2433000

Skin, Trailing Edge

2024-T3 Clad

0.040

Flext
F14-1int
F4-6ext

Replace
Replace

F4-lint
15

Spar, Aft

2433000

16

2433000

17

2433000

18

2433000
2433000
2333007

19

1 2333007

20

2333007

Hinge
1

2333007

2333007

23

2333007

2333007

24

2333007

25

2333007
2333007

2333007

27

2333007

Assy.

2024-T42 Clad
2024-T3 Clad

0.040

F4-1
F4-1

Replace
Replace
Replace
Replace

2024-T42 Clad

0.032

F4-1

Replace

2024-T42 Clad

0.032

F4-1

Replace

2024-T42 Clad

0.032

F4-1

Replace

2024-T42 Clad

0.032

Flext
F14-1 int

Replace

2024-T42 Clad

0.032

F4-1

Replace

1
1

Assy.

Bracket
Bracket

0.050

Assy.

1
1
1

2024T42 Clad

2024-T42 Clad

0.032
0.032

F4-1

Rib, Trailing Edge

F4-1

Replace
Replace

Bracket Assy.
Bracket
Rib

2024-T42 Clad
2024-T42 Clad

0.032
0.032

F4-1
F4-1

Replace
Replace

1
1

Rudder

Trim Tab

Figure
EFFECTIVITY:

0.050

26

0.063

Hinge

Replace

Rib

2333007

F6lint
F4-1
F4-1

2024-T3 Clad

Bracket

Rib

F4-4ext

1 2024-T42 Clad

RudderHorn
Skin

0.032

Bracket

2333007
22

Bracket

Assy.

2024-T42 Clad

Hinge Bracket Assy.

2333007
21

Bracket, Actuator
Support, Actuator
Support, Actuator

1 Doubler
Hinge Bracket
Bracket
1

2333007

NOTED

Repair Index

(Sheet 2 of 3)

5540-00

Page
SRM-I

May 15/92

Learjet
STRUCTURAL REPAIR:MANUAL
ITEM

NO. I

NO.

28

2333007

29

2333007
2333005
2333005
2333005
2324010
2333005
2333005
2333005

30

DWG.

DESCRIPTION
Balance Weight
Balance Weight
Tab Assy.
Rib
Rib
Tab Horn
Channel Spar
Rib

Filler

2333005

Skin, LH

CODES

2024-T42 Clad

0.032

F4-1

Replace

2024-T42 Clad

0.032

F4-1
F4-1
F4-4
F4-1

51-70-03

2024-T42 Clad
2024-T42 Clad
MS20001 PX4-

1816
2024-T3 Clad

1
1

2024-T42 Clad

8 RH

1 2024-T3 Clad

I
0.032
0.032

Replace

Replace
Replace
1

51-70-02

0.025\

F4-1

Replace

0.032

F5ext

51-70-02

0.100

Ffi-lint
F4

Replace

EFFECTIVITIES

23-003 THRU 23-099; 24-100 THRU 24-191; 25-002 THRU 25-010


25-002 THRU 25-010

Rudder

Trim Tab

Figure

SRM-4

Replace

EFFECTIVITY:

Spoiler Strip (6 ea.)

REPAIR
FIG. NO.

CODE

I Replace

Grade G Lead
5% Sb Lead

(FIN1SH
GAGE

MATERIAL

Hinge

2333005

2333000

I
EFF.

NOTED

Repair Index

(Sheet 3 of 3)

55-40-00

Page 3
May 15/92

Learjet
Lest-jet

STRUCTU RAL REPAIR MANUAL


RUDDER

TRIM TAB

STRUCTURAL IDENTIFICATION

OIc~
i

~h
44-292 th~7L24-257. 25-011 thru 25-373; 28-001 thru 28-005: 29-001 thru 29-004:

31-001 and Subseauent; 35-002 and Subseauent; 36-002 and Subseauent)

Detail A
Rudder

534C

Trim Tab

Figure
EFFECTIVITY:

NOTED

Repair Index

2 (Sheet 1 of 3)

55-40-00

Page 4
SRM-4

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.
2633001

2633003
2433001
2433001

2333000

I
DESCRIPTION
Rudder 8 Trim Tab Assembly

Spar Assy.
Spar
Tapered Shim
Rib Assy.

i
EFF.

2024-T3 Clad

0.050 1

2024-T3 Clad

0.040

Rib

2024-T42 Clad

Doubler

2024-T42 Clad

0.032 1
0.032
0.032

2024-T42 Clad

2333007
2333006

Rib
Rib

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

Shim

2433001

Tapered

2333006

Rib

2333006
2333006

Rib
Rib

Angle
Rib Assy.

2433001
2633003

2633003

Rib
Gusset
Rib

2633002
11

1 2633002
2633002
2633003

0.032 1

51-70-03

Replace
Replace

1
1

51-70-03
51-70-03

Replace

1
1
1

51-70-03

2024-T42 Clad
2024-T42 Clad

0.032 1
0.032 1
0.032 1

51-70-03

2024-T3 Clad

0.050

Replace

2024-T42 Clad
2024-T3 Clad

0.032 1
0.032

51-70-03

1
1

2024-T42 Clad

0.032 1

51-70-03

0.032

51-70-03

Replace

Spar

2024-T3 Clad

0.032

2024-T3 Clad

0.050

1
1

Filler
Rib

Replace
Replace

2024-T42 Clad

51-70-03

2024-T3 Clad

0.032 1
0.040

Doubler, LH

8 RH

Leading Edge 8 Balance


Weight Instl.
Skin, Upper
Balance Weight
Gang Channel

2633003

Rib

2633003

Rib
Bracket Assy.
Bracket
Plate
Safety Wire Bracket
Filler
Hinge Bracket Assy.

2633003
2633007
2633007
2333007
2633003
13

Replace

0.032 1

1 2633003

Assy.

2024-T42 Clad

5% Sb Lead

(Make

0.032 1

51-70-02

Replace

1
I

I Replace
I Replace

from

2024-T42 Clad

0.032 1

2024-T42 Clad

0.032

0.160

2024-T3 Clad
2024-T42 Clad

0.063

1
1

2024-T3 Clad

0.032

1
1

Replace

I
I

Replace
Replace
Replace

Replace

Bracket

2024-T42 Clad

0.032

Plate

0.160

Skin, Center

2024-T3 Clad
2024-T42 Clad

Balance Weight
Channel

5% Sb Lead

(Make

Gang

2633003

51-70-03

Replace
Replace
Replace
Replace

2333007
2633002

2333007

2633002

I Replace

NAS689-1 4-6)
12

51-70-04

2333007

2433001
2433001
2633003
2333007
2433001

2633003

2433001

REPAIR
FIG. NO.

Bracket

IFINISH
CODE

2333007

10

GAGE

MATERIAL

0.032

from

NAS689-1 4-6)

Trim Tab Repair Index


Figure 2 (Sheet 2 of 3)

Rudder

EFFECTIVITY:
SRM~

NOTED

5540-00

Page 5
May 15/92

STRUCTURAL REPAIR MANUAL


DWG.
NO.

ITEM

NO.

Rib

2633003

14

Balance Weight

2633003

Angle
Angle
Hinge Bracket Assy.

1 2633003
2633003
2333007
2633003

2333007
2333007

1 2633003
2633003

2633003
2633003
2633003

20

2433001

2024-T3 Clad

2024-T42 Clad
2024-T3 Clad
2024-T3 Clad

0.032

2024-T42 Clad
2024-T3 Clad
2024-T42 Clad
2024-T42 Clad

0.032

Hinge Bracket Assy.

1
1
1

I
1

51-70-02

6061-T6
2024-T3 Clad

0.032
0.032

Replace

2024-T42 Clad
2024-T3 Clad
2024-T3 Clad

0.032
0.032
0.040

1
1

Bracket Assy.
Bracket

1
1

Rib

2024-T42 Clad
2024-T42 Clad
Grade B Lead

Spar

Weight Assy.

Skin, LH 8 RH

Trailing Edge
Hinge

1
1

Extrusion

Rib

I
I

0.025

Replace
Replace
Replace
Replace
Replace

0.032

0.050

0.063

2024-T42 Clad
S-657
MS20001 -4
2024-T42 Clad

Replace

I
I

0.032 1

0.032
0.032

Replace
Replace
Replace
Replace

1
1

51-70-02

1
1

I
0.032 i

1
1

51-70-02

51-70-02
51-70-03

EFFECTIVITIES
24-192 THRU 24-257; 25-011 THRU 25-373, 28-001 THRU 28-005; 29-001 THRU 29-004;
31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT

Rudder

Trim Tab

Figure
EFFECTIVITY:

2333009

51-70-02

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

S-634

CODES

2024-T42 Clad

2333009

S-717
S-520

I Replace

0.040 1

2333009

1
I

2333009

Replace
Replace
Replace
Replace

5% Sb Lead
2024-T3 Clad

Tab Horn

2333009

0.160

Angle

Balance

0.032

0.032 1

2333009

Replace
Replace
Replace

0.160

0.063

Rib

2333009

Replace
Replace
Replace

Replace
Replace
Replace

2333009

2393009

SRM~

0.032
0.032

Clip
Fairing
Tab Assy.

2433000

0.032

2024-T3 Clad

2433001
2324011
2333009

18

19

2024-T42 Clad

Rib

2433001

2433000

Replace
Replace

Plate
Filler

Balance Weight
Skin, LH 8 RH
Trailing Edge Extrusion
Angle, LH 8 RH
Actuator Support, Upper 8 Lower

17

0.032

Filler

2633002

2024-T42 Clad
5% Sb Lead

REPAIR
FIG. NO.

CODE

Angle

2633003
2633003

IFINISH
GAGE

Assy.

Bracket
Plate
Safety Wire Bracket
Skin, Lower
Rib Assy.
Rib

2333007
2333007
2633002
16

Bracket

2633003
15

2633002
2633003
2633003

Bracket

I
MATERIAL

Assy.

Rib

2633003

I
EFF.

DESCRIPTION

NOTED

Repair Index

2 (Sheet 3 of 3)

55-40-00

Page 6
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


RUDDER
1.

TRIM TAB

ALLOWABLE DAMAGE

ALLOWABLE DAMAGE LIMITS

All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose

failed rivets

or

are

the

not allowed. A

loose

or

failed rivet

rivets and lead to

can cause increased stress concentrafailure. A careful inspection must be

remaining
progressive joint
performed to ensure that joint failure has not spread from the area of the loose or failed rivet. (Refer to Chapter 51 for definition of rivet failure.)
tions

on

(2) Loose

or

trations

failed

screws are

surrounding

not allowed. A loose

or

failed

and lead to

screw can cause

increased stress

concen-

failure. A careful

progressive joint
inspection must be
that
failure
has
the
from
to
not
the
of
the
loose
ensure
area
or failed screw.
joint
performed
spread
B.

on

screws

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired,
C.
D.

and refinished in accordance with

Deformation

(1) Deformation of the rudder or trim tab is not allowed.


Corrosion(SeeFigure 101.)
(3) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

Chapter

re-

51.

more

than

specified.

Dents

(1) Dents

are

permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
depth, do not exceed 10% of total surface area in one (1) square foot, and are not

(2.54 mm) in

closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component reF.

G.

I-I.

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings andForgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTIVITY:
SRM-4

ALL

55-40-00

Page 101
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.080

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0~076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFFECTIVITY:
SRM-4

ALL

101

55-40-00

Page 102
May 15/92

Leariet
Learjet

TEMPORARY REVISION NO. 55-1


LRajet Model 20/30 Series Structural Repair Manual (SRM-4).

MANUAL AFFECTED:

Insert

FILING INSTRUCTIONS:

adjacent

to

55-40-00, page 201, dated May 15/92 and retain until fur-

ther notice.

procedures to replace rudder


replace rudder trim tab hinge.
Add

REASON:

Add

INSTRUCTIONS:

trim tab

hinge pin,

line

ream

rudder trim tab

hinge,

and

paragraphs B. Rudder Trim Tab Hinge Pin Replacement, C. Line Ream Rudder
Hinge, and D. Rudder Trim Tab Hinge Replacement, to 55-40-00 page 201,

Trim Tab
as

follows:

RUDDER
1.

TRIM TAB

REPAIR

Repairs
WARNING:

A CONTROL SURFACE BALANCE CHECK MUST BE PERFORMED FOLLOWING

REPAIRS OF THE RUDDER OR THE RUDDER TRIM TAB. (REEER TO SEC~ION II


OF THE BASIC LEARJET SERVICE MANUAL FOR MODEL 23, 24 AND 25 SERIES
AIRCRAFT. REFER TO CHAPTER 27 OF THE BASIC LEARTET MAINTENANCE
MANUAL FOR MODEL 28, 29, 31 35 AND 36 SERIES AIRCRAFT.)
A.
B.

Chapter 51 typical repairs, and for allowable wear and repair


tings, pulleys, attaching parts and rudder components.
Replacement of Rudder Trim Tab Hinge Pin (See Figure 201.)
(1) Remove cotter pins from rudder trim tab hinge halves.

Refer to

CAUTION:

data for the rudder

system fit-

USE EXI~REME CARE NOT TO DAMAGE RUDDER SKIN WHEN REMOVING


AND INSTALLING RUDDER TRIM TAB HINGE PIN.

Carefully remove hinge pin from hinge.


Separate hinge halves.
(4) Using larger replacement hinge pin (P/N 2333009-035), attempt
tangs of both hinge halves.

(2)
(3)

NOTE:

If

hinge pin will slide freely through all tangs

to slide

of both

hinge pin through

hinge halves, proceed

to

all

step

(5).

hinge pin will


paragraph C.

If

not slide

freely through all tangs

of both

hinge halves, proceed

to

(5) Position hinge halves together and insert hinge pin.


(6) Install cotter pins at top and bottom of hinge to retain hinge pin.
(7) Measure rudder trim tab free play. (Refer to Section II of the basic Leajet Service Manual for
Model 23, 24 and 25 Series Aircraft. Refer to Chapter 27 of the basic Leajet Maintenance Manual
for Model 28, 29, 31, 35 and 36 Series Aircraft.) If free play limits can not be obtained, replace
hinge. (Refer to Replacement of Rudder Trim Tab Hinge, this section.)

TEMPORARY REVISION NO. 55-1

55-40-00

Page
SRM-4

1 of 4

Feb 13/98

Leariet I
~3 Learjet
STRUCTURAL REPAIR MANUAL
C.

Line Ream Rudder Trim Tab

Hinge

USE EXTREME CARE NOT TO

CAUTION:

SCRATCH, DENT, OR DAMAGE RUDDER TRIM


TAB WHEN POSITIONING IN VISE OR WHILE REAMING HINGE HALF.

(1) Place rudder trim tab in vise

to ream

hinge half.

MAINTAIN A SLOW DRILL MOTOR SPEED AND SUPPORT DRILL SHAFT

CAUTION:

TO AVOID HARMONIC VIBRATION.

(2) Using
in

4-inch, then

tangs

of both

6-inch and

hinge

finally

20-inch No. 40 (0.098 dia.) drill,

slowly

ream

out holes

halves.

(3) Position hinge halves together and carefully insert a 2333009-035 hinge pin.
(4) Install cotter pins at top and bottom of hinge to retain hinge pin.
(5) Measure rudder him tab free play. (Refer to Section II of the basic Leajet Service Manual for
Model 23, 24 and 25 Series Aircraft. Refer to Chapter 27 of the basic
for Model 28, 29, 31, 35 and 36 Series Aircraft.) If free play limits
D.

hinge. (Refer to Replacement of Rudder Trim Tab Hinge,


Replacement of Rudder Trim Tab Hinge (See Figure 201.)

Leajet
can

Maintenance Manual

not be

obtained,

replace

this section.)

(1) Remove rudder hom aircraft. (Refer to Section II of the basic Leajet Service Manual for Model
23, 24 and 25 Series Aircraft. Refer to Chapter 27 of the basic Leajet Maintenance Manual for
Model 28, 29, 31, 35 and 36 Series Aircraft.)
(2) Disconnect trim tab actuator push-pull tube and bonding jumper from tab and trim tab actuator.
(3) Remove hinge halves from rudder and trim tab by drilling out rivets using a No. 30 (0.128 dia.)
drill.

hinge assembly (P/N 2333009-033) between the spar flange and trim tab skin with
hinge end 0.030 inch below the upper skin edge and with centerline of hinge 0.11 inch
square
forward of leading edge of trim tab.
Mark rivet locations on upper and lower ends of hinge half.
Remove hinge assembly and drill a No. 30 (0.128 dia.) hole at each marked location.
Position hinge assembly to trim tab and cleco in place. Using trim tab skin rivet holes as a pattern, drill a No. 30 (0.128 dia.) hole in hinge half at each skin hole location, except where the
bonding jumper attaches. Drill a No. 19 (0,166 dia.) hole at jumper attach point.
Secure hinge assembly to trim tab with rivets (P/N MS20426AD4-6).
Position trim tab on rudder with hinge assembly between rudder skin and spar flange. Adjust
trim tab for proper clearances between rudder tab and rudder as shown. (See Figure 201.)
Place a straightedge on rudder trailing edge and adjust rudder trim tab until both the rudder and
rudder trim tab trailing edges are aligned.
With trim tab properly positioned, mark rivet locations at upper and lower ends of hinge assembly. Remove trim tab from rudder and drill a No. 30 (0.128 dia.) hole at each location.
Position trim tab to rudder and cleco in place. Using remaining holes in rudder as a pattern, drill

(4) Position

new

cut

(5)
(6)
(7)

(8)
(9)
(10)
(11)
(12)

a No. 30 (0.128 dia.) hole at each location except the second from the bottom. Drill a No. 19 (0.166
inch dia.) hole at this location for bonding jumper attachment.
(13) Secure trim tab to rudder with rivets (P/N MS20426AD4) and connect bonding jumper to trim

tab.

(a) Check electrical resistance between trim tab and aircraft

greater

than the value

structure. Resistance shall not be

specified in Chapter 20 of the applicable Leajet Wiring Manual.

(14) Install push-pull tube.


(15) Check rudder balance and install rudder on aircraft. (Refer to Section II of the basic Leajet Service Manual for Model 23, 24 and 25 Series Aircraft. Refer to Chapter 27 of the basic Learjet Maintenance Manual for Model 28, 29, 31, 35 and 36 Series Aircraft.)
TEMPORARY REVISION NO. 55-1

55-40-00

Page 2 of 4
SRM-4

Feb 13/98

Learjet
STRUCTURAL REPAIR MANUAL
B
A

0.22

to 0.40 Inch
Clearance required
between Rudder and Tab

~---i.

lI

0.22 to 0.44 Inch

Clearance

required

between Tab and


Tailcone
Tailcone

(TRIM TAB CLEARANCES)

0.030 in.

Tab Skin

Top Edge

(Ren

;r"7
I
c~

:I
L,I

Hinge
Rudder Trim Tab

Detail A
Hinge Replacement
Figure 201 (Sheet 1 o~ 2)

Rudder Trim Tab

TEMPORARY REVISION NO. 55-1

SRM-4

55-40-00
Page 3 of 4
Feb 13/98

tearjet

STRUCTURAL REPAIR MANUAL

Cotter Pin
2333009-033

Hinge Assy
Rudder

Skin(Ref)

MS20426AD4-6(Existing

Fastener
Hole Location)

CFWO

Trim Tab Skin

(ReD

Trim Tab

Spar

2333009-035

Hinge Pin

(VIEW LOOKING DOWN ON TRIM TAB)

Detail B
Hinge Replacement
Figure 201 (Sheet 2 of 2)

Rudder Trim Tab

TEMPORARY REVISION NO. 551

55-40-00

Page 4 of 4
SRM-4

Feb 13/98

STRUCTURAL REPAIR MANUAL


RUDDER
i.

TRIM TAB

REPAIR

APPROVED REPAIRS
WARNING:

A CONTROL SURFACE BALANCE CHECK MUST BE PERFORMED FOLLOWING

REPAIRS OF THE RUDDER OR THE RUDDER TRIM TAB. (REFER TO SECTION II


OF THE BASIC LEARJET SERVICE MANUAL FOR MODEL 23, 24 AND 25 SERIES
AIRCRAFI~. REFER TO CHAPTER 27 OF THE BASIC IIEARJET MAINTENANCE
MANUAL FOR MODEL 28, 29, 31, 35 AND 36 SERIES AIRCRAFT.)
A.

RefertoChapter51 fortypicalrepairs.

EFFECTIVITY:

ALL

NOTE: Please

see

the

TEMPORARY
SRM~

REVISION
that revises

this~age.

55-40-00

Page 201
May 15/92

C H A PT E R

VVIN DOVVS

LAarjet
Learjet

STRUCTURAL REPAIR MANUAL


Chapter
Section

Subject

Subject
WINDSHIELD- STRUCTURAL IDENTIFICATION

Description

Damage

CABIN WINDOW

Description

....56-10-00
1

............................................................................................................................56-10-00

WINDSHIELD ALLOWABLE DAMAGE


Allowable Damage Limits Windshield
Allowable

Limits

...........................................................................56-10-00

Windshield Structure

56-10-00

STRUCTURAL IDENTIFICATION

....................................................56-20-00

Repair Index

(Model 23 Aircraft and Early Model 24 Series Aircraft)


Cabin Window

..................................................56-20-00

Repair Index

(Lafe Model 24 Series Aircraft and Model 25/28/29131/35/36 Series Aircraft)................56-20-00


CABIN WINDOW
Allowable

Allowable

101

106

...........................................................56-10-00

...................................................................~........................................................56-20-00

Cabin Window

Page

ALLOWABLE DAMAGE

Damage Limits
Damage Limits

Cabin Window
Cabin Window Structure................................

6
56-20-00

.........56-20-00

101

56-20-00

102

56- Contents

SRM-I

Page 1
May 15/92

Leariet
~Learjetl

STRUCTURAL REPAIR MANUAL


Chapter

Chapter

Section

Section

Subject

Page

Subject
56-mZE
56-List of Eff.
56-Contents
56-10-00
56-10-00
56-10-00
56-10-00
56-10-00
56-10-00

Pgs.

1
1
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101

102
103
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105

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1
3

6
7

101
102
_

103

Date

Page

Date

jun 1/95
May 15/92
May 25/92
May 15/92
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May 15/92
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May 15/92
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Jun 1/95
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Pages; Destroy Superseded or Deleted Pages.


Asterisk indicates pages revised, deleted, or added by current revision.
of the
The portion of the text affected by the current revision is indicated by a vertical line in the outer margin
Insert Latest Revised

page
56

SRM-4

List of Effective

Pages
Page 1

Jun 1/95

Learjet
STRUCTURAL REPAIR MANUAL
WINDSHIELD- STRUCTURAL IDENTIFICATION

i.

DESCRIPTION

flight compartment windows consist of the pilots and copilots windshield halves.

A.

The

B.

On Model 23 Series Aircraft each windshield half is made up of

C.

panes.
On Model 24/25/28/29 Series Aircraft each windshield half is made up of three laminated layers of
acrylic plastic. Both outer layers are made of stretched acrylic and the middle layer is cast in place

separate, removable,

inner and outer

acrylic.
D.

E.

On Aircraft 31-001 thru 31-029, 35-001 thru 35-670 and 36-001 thru

36463 eauiwed with a standard, nonheated SwedlowTM windshield. the windshield is made up of three laminated layers of acrylic plastic.
Both outer layers are made of stretched acrylic 0.460 (+0.046/-0.030) inch (12 mm [+1.2 mm/-0.76
mm]) thick. The middle layer is cast in place acrylic 0.060 inch (1.5 mm) thick. Overall thickness is
1.04 (+0.09/-0.00) inches (26.4 mm [+2.3 mm/-O.O mm]). The windshield is secured to the fuselage
structure with screws, washers, nuts and retainers.
On Aircraft 31-030 and Subseauent, 35-671 and Subseauent. and 36-064 and Subseauent and arior aircraft
eauitt~ed with an electrically heated SierrannrM windshield. the windshield is made up of four laminated
layers. Two layers of polycarbonate (0.25 inch [6 mm] each) are sandwiched between an outer faceply
(0.12 inch [3 mm] acrylic) and an inner crewshield (0.12 inch [3 mm] acrylic). A spacer is bonded to
the interior side of the windshield. Overall thickness, including spacer and fillers, is 0.950 inch (24
mm). A stopcrack is cut on either side of the windshield through the outer acrylic layer. The stop-

crack is filled with RTV sealant. The windshield has

element consists of

electric

F.

thin

of

an

integral

electric heater and heat

sensors.

The

gold laminated into the windshield. Because of the


color tint. The function of the heater is to provide

heating
layer
gold layer, the windshield has a yellow or gold
windshield defogging. Terminal blocks are embedded in the windshield and provide the means for
wiring the electric heater to the aircraft wiring. The windshield is secured to the fuselage structure
with screws, Hi_LokTM pins, washers, nuts and retainers.
The cabin windows consist of two panes of stretched acrylic with dead air space between them. The
cabin windows are secured to the fuselage structure. The right rear window is removable and serves

G.

the emergency exit.


Refer to Chapter 53 for information

H.

For additional information

as

EFFECTIVITY:
SRM-4

ALL

pertaining to the windshield structure.


pertaining to the windshield refer to the basic Leajet

Maintenance Manu-

56-10-00

Page 1
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


WINDSHIELD

1.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGE LIMITS (WINDSHIELD)


NOTE
A.

All dimensions

are

in inches unless otherwise

specified.

Aircraft eauiatled with Swedlow windshield (See Figure 101.)


The windshield is divided into two

NOTE:

Zone 1
to

represents

the critical

zones

impact

zone

for classification of crack and flaw

and

requires special

criticality.
regard

consideration in

criticality.

some instances repairs may be allowable with respect to the structural integrity of
the windshield, but not allowable with respect to the optical distortion incurred during
the repair process. Optical distortion of the windshield caused by the repair is considered the responsibility of the owner, operator, and/or maintenance facility performing

In

the

repair.

See

Figure 101,

Detail A, for

optical areas of the windshield.

(1) Windshields with any of l:he following discrepancies

are

considered unserviceable and shall be

re-

moved from service.

(a)

Any

crack

or

flaw in the inner

with the laminate

or

or

layer. This includes both cracks parallel


perpendicular to the laminate. However, this does not

outer

transverse cracks

structural

include:
be removed. (Refer to

56 of the

appropriate
Leajet
2) Minor chipping about a fastener hole that can be repaired with the following limitations:
a) Chipped out material depth shall not exceed 0.188 inch.
b) Repairs on inside and outside surfaces of the same hole are not allowed.
c) Repairs on any surface of more than 3 adjacent holes are not allowed.
d) Repairs on more than 20 percent of the total fastener holes is not allowed.
(b) Cracks in the center layer or delamination between the center layer and the inner or outer
structural layers that extend:
1) From the windshield edge to any fastener hole or to the fastener hole line.
2) From any fastener hole to the windshield edge or extending into the windshield viewing
area past the edgr! of the outer windshield retainer.
3) From any fastener hole to an adjacent fastener hole.
(c) Windshield with the following number of total cracks.
1)

Minor surface blemishes which

1)
2)

EFFECTIVITY:
SRM-4

can

Chapter

Maintenance Manual.)

basic

Zone 1

No

more

than 4 holes with center laminate flaws allowed.

Zone 2

No

more

than 25 holes with center laminate flaws allowed.

NOTED

56-10-00

Page 101
May 15/92

Learjet
Learjefl

STRUCTURAL REPAIR MANUAL


(2) Scratches, nicks,

crazing

or

pits requiring

material removal to blend that reduces the windshield

thickness to less than 1.00 inch are not permitted outside the following areas:
(a) Exterior surface of the windshield, within one inch above the defog nozzle, not to exceed the
width of the nozzle.

1)

above the defog nozzle may reduce the miniprovided:


The steepness of the step created by material removal shall be held to a minimum and
under no circumstances extend beyond perpendicular to the surface of the windshield (i.e., penetrated under the defog nozzle).

Material removal within the one-inch


mum

a)

area

windshield thickness to 0.92 inch

b)

The radius at the windshield surface, to the step at the base of the
large as possible. A radius of less than 0.20 inch is not permitted.

c)

The material removed must be transitioned to the center of the windshield with
minimum blend ratio of 20 to 1. This

thickness,
the

defog

must be

completed

at

transition,

distance not

to the

greater

one

step, shall

be

as

inch minimum windshield

than 3 inches from the

edge

of

nozzfe.

(b) The interior surface of the windshield, adjacent

to and

extending

aft from the aft

edge

of the

glareshield.
1)
2)

Minimum windshield thickness of 0.94 inch shall be maintained.


A minimum blend ratio of 20 to 1 shall be maintained in all directions.

having allowable flaws or having been repaired in accordance with the above
procedures, except per paragraph (l)(a) 1), shall be inspected at 1,200-hour intervals using the optical prism technique described in the Learjet NDI manual, windshield inspection (6,000 Landing/
12 yr inspection requirement). A diagram of the discrepant locations shall be maintained to allow
a means to compare progressions of these areas if it occurs. Progression of the flaws beyond the
above limitations will require the windshield(s) to be removed from service.

(3) Any

B.

Aircraft

windshield

esuit?t~ed with electrically heated Sierracin windshield

pits which reduce the outer faceply or the inner crewshield by 0.045
not permitted. In such cases, the windshield shall be replaced.

(1) Scratches

EFFECTIVITY:
SRM-4

or

NOTED

inch

or more are

56-10-00

Page 102
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
WINDSHIELD

ALLOWABLE DAMAGE

Eye

Point

(Normal)
Grid Board (One Inch

Squares)

Rnal Windshield
Trim Line

10 Ft.

Grid Board (One Inch

BL 27.97

Squares)

STA 200.3
WL 38.67

10 Ft.

BL 13
90"

STA 200.3
WL 47.62

f
90"
BL 0.15
BL 0.15

STA 1&1.36

STA 156.41

WL 5552

WL 36.32

Windshield

Figure
EFFECTIVITY:
SRM~

Optical

Areas

101 (Sheet 1 of 3)

AIRCRAET EQUIPPED WITH SWEDLOW WINDSHIELD

5610-00

Page 103
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
WINDSHIELD

3.0

ALLOWABCE DAMAGE

Inches6\

Windshield (ReO

0.20 Inch Radius

1.0 Inch Minimum

Minimum

1.OInch

Defog Nozzle (Ref)


6.92 Inch Minimum
90 Degrees

PerInndicular
plane Line

Twenty (20) to one (1)

I~jr

minimum blend.

Removed material must not extend under

perpendicular plane line.


Screw Locations

Screw Locations

1 thru 6

1 thru 12

~Oo
~oo

Zone 1

a,

~S

"d;;

Zone2

Oa

"ad
00000

Zone 1

No

more

Zone 2

No

more

than 4 holes with interlayer flaws allowed.


than 25 holes with interlayer flaws allowed.

Windshield

Figure

EFFECTIVITY:
SRM-I

Optical

Areas

101 (Sheet 2 of 3)

AIRCRAFT EQUIPPED WITH SWEDLOW WINDSHIELD

56-10-00

Page 104
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


WINDSHIELD

ALLOWABLE DAMAGE

Non-critical Visibility

Prime

Visibility Area
Secondary Visibility

iiiiLii

Blanked-out Area
No

Windshield Retainer

(Optical Critical

Visibility

Areas)

Detail A

Windshield

Figure

EFFECTIVITY:
SRM-4

Optical

Areas

101 (Sheet 3 of 3)

AIRCRA~t;T EQUIPPED WITH SWEDLOW WINDSHIELD

5~-10-00

Page 105
May 15/92

~Zearjet
STRUCTURAL REPAIR MANUAL
2.

ALLOWABLE DAMAGE LIMITS (WINDSHIELD STRUCTURE)

All dimensions

NOTE:
A.

in inches unless otherwise

are

specified.

Fasteners

(1) Loose
tions

or

failed rivets
the

on

are

remaining

performed
(Refer to Chapter 51

to ensure

(2) Loose

or

trations

failed

on

performed

not allowed. A loose

rivets and lead to

that

joint

or

failed rivet

can cause

increased stress concentra-

failure. A careful

progressive joint
spread from

failure has not

the

area

inspection

of the loose

or

must be

failed rivet.

for definition of rivet failure.)

screws are

not allowed. A loose or

failed

screw can cause

increased stress

concen-

and lead to progressive joint failure. A careful inspection must be


surrounding
to ensure that the joint failure has not spread from the area of the loose or failed
screws

screw.

B.

Cracks

(1) Cracks in any fitting

forging are not allowed. Cracked fittings or forgings must be replaced.


fittings and forgings are considered allowable if properly
in accordance with Chapter 51.

or

(2) Cracks in components other than

paired,

and refinished

C.

Deformation

D.

(1) Deformation of the windshield


Corrosion(See Figure 101.)

re-

structure is not allowed.

(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance with Chapter 51, and these repairs do not reduce the original material thickness more than
specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness
E.

more

than

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
~2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch ~2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component reF.

G.

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified.
(Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.

EFFECTIVITY:
SRM~L

ALL

56-10-00

Page 106
May 15/92

Learjet
Learjet

STRUCTURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFFECTIVITY:
SRM-4

ALL

102

56-10-00

Page 107
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


CABIN WINDOW
i.

STRUCTURAL IDENTIFICATION

DESCRIPTION
A.

The cabin windows

panes

are

held

are

made up of two panes of acrylic with a dead air space between them. The two
air tight by a spacer. The outer pane is stretched acrylic 0.414 inch

apart and sealed

(10.51 mm) thick. The inner pane is stretched acrylic 0.252-inch (6.40 mm) thick. The air space between the outer and inner panes is 0.090 inch (2.28 mm). Overall thickness is 0.756 inch (19.20 mm).

EFFECTIVITY:
SRM~

ALL

56-20-00

Fage 3
May 15/92

STRUCTU RAL REPAIR MANUAL


CABIN WINDOW

STRUCTURAL IDENTIFICATION

i,

(RH TYPICAL)

Detail A
c~-i.

-ci~-

(LH TYPICAL)

Detail B

Cabin Window

Figure
EFFECTIVITY:
sRM-4

Repair Index

1 (Sheet 1 of 4)

23-002 THRU 23-099; 24-100 THRU 24-229 EXCEPT 24-218

56-20-00

Page 2
May 15/92

Learjet
~Leariet
STRUCTURAL REPAIR MANUAL
CABIN WINDOW

STRUCTURAL IDENTIFICATION

la

I :
"In

."II"

Detail C
Cabin Window

Repair Index

Figure 1 (Sheet 2 of 4)
EFFECTIVITY:
SRM-I

23-002 THRU 23-099; 24-100 THRU 24-229 EXCEPT 24-218

56-20-00

Page 3
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

2311310
1

EFF.

Cabin Window

Instl., LH Aft
WindowAssy.

1 2311310
2311310

I
DESCRIPTION

MATERIAL

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

1
1

Window

2311310

Filler

2311310

Window, Inner

2311310

lnsert(58 ea.)

Plexiglass
Dacron Acrylic
Plexiglass
Nylon Tube

2024-T42

0.050

2024-T42

0.050

F4-1

2024-T42

0.080

F4-1

2024-T42

0.020

F4-1

2024-T42

0.020

Nylon Tube

0.250

2311310

2311310

2311310

2311310

2311310

Retainer, Bottom
Retainer, Top
Retainer, Outer

Spacer(2 ea.)
Spacer(2 ea.)
lnsert(58 ea.)
Channel (2 ea.)

0.414

0.250

2311310

2024-T42

0.050

F4-1

2311310

IFrame

2024-T42

0.063

F4-1

2311310

IDoubler

2024-T42

0.063

F4-1

10

11

2311330

F4-1

56-20-00

56-20-00

0.276

56-20-00

0.250

Window

Plexiglass

0.414

2311330

Filler

Dacron

0.120

2311330

Window, Inner

2311330

lnsett(58 ea.)

Nylon

2024-T42

0.050

F4-1

2024-T42

0.050

F4-1

2024-T42

0.080

F4-1

2024-T42

0.020

F4-1

2024-T42

0.020

Nylon

0.250

2311330

13

2311330

14

2311330

15

2311330

16

2311330

2311330

Retainer, Bottom
Retainer, Top

IRetainer, Outer
1
Spacer(2 ea.)
Spacer(2 ea.)
lnsert(58 ea.)
Channel(2 ea.)

Aclylic
Plexiglass
Tube

Tube

Replace

I Replace

F4-1

2311330

2024-T42

0.050

18

2311330

Frame

2024-T42

0.063

F4-1

2311330

IDoubler

2024-T42

0.063

F4-1

2311320

F4-1

2388195

Escape Window Instl.


Escape Window Assy.
Escape Window Assy.
1

19

2311320

20

2311320

21

2311320

22

2311320

23
24

Replace
Replace
Replace
Replace
Replace
I Replace
Replace
Replace
Replace

17

2311320

56-20-00

2311330

12

1 Replace
Replace
Replace
Replace
Replace
Replace
I Replace
Replace
Replace
Replace

F4-1

Cabin Window Instl., RH Fwd


Window Assy.

56-20-00

Replace

0.276

2311330

56-20-00

0.120

1
1
1

2311310

F4-1

Frame, Window Outer


Window, Outer

Spacer

2024-T42

0.050

Plexiglass

0.460 1

Replace
1

56-20-00

56-20-00

2024-T4

0.250

Plexiglass

0.276

2311320

Window, Inner
IRetainer, Inner

2024-T4

0.050

I Replace

2311320

ISeal

S-310

I Replace

25

2311320

2024-T30

0.125

2311320

IRetainer, Lower
IRetainer, Upper

26

2024-T4

0.250

1
1

I Replace
Replace

Cabin Window

Figure
EFFECTIVITY:
SRM~

F4-1

Replace

Repair Index

(Sheet 3 of 4)

23-002 THRU 23-099; 24-100 THRU 24-229 EXCEPT 24-218

56-20-00

Page 4
May 15/92

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


CODES

EFFECTIVITIES
23-099; 24-100 THRU 24-229 EXCEPT 24-218

23-002 THRU

23-002 THRU 23-005

23-002 THRU 23-099


24-100 THRU 24-229 EXCEPT 24-218

NOTES
Per MIL-P-8184

Cabin Window

Figure

EFFECTIVITY:
SRM-4

Repair Index

(Sheet 4 of 4)

23-002 THRU 23-099; 24-100 THRU 24-229 EXCEPT 24-218

56-20-00

Page 5
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
CABIN WINDOW

STRUCTURAL IDENTIFICATION

\PI,

(CABIN WINDOW TYPICAL)

~iii,
ii ~-fi

(EMERGENCY EXIT DOOR


WINDOW TYPICAL)

2-bD
2-48

Cabin Window

Repair Index

Late Model 24 Series Aircraft and Model 25/28/29/31/35/36 Series Aircraft

Figure 2 (Sheet

EFFECTIVITY:
SRM-4

NOTED

1 of 2)

56-20-00

Page 6
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

DESCRIPTION
Cabin Window Instl.

2511310
1

Glass

6600115

Assy.

Glass, Outer

6600115

EFF.

MATERIAL

GAGE

Spacer

Glass, Inner

Acrylic I~

0.414

56-20-00

Acrylic

0.252

56-20-00

Replace

2511313

Gasket

Dacron Silastic

0.040

2511312

Retainer

2024-T3 Clad

0.050

2511311

2511311

2511311

2511311

2411310
6600115

Glass, Outer

66001 15

2024-T42 Clad

0.063

2024-T3 Clad

0.032

2024-T42 Clad

0.063

2024-T3 Clad

0.032

Replace
Replace
Replace
Replace
Replace
Replace

Acrylic

0.414

56-20-00

Acrylic 1~

0.252

56-20-00

Replace
Replace

1
1
1

6600115

Spacer

6600115

Glass, Inner

Replace

Replace

2511313

Gasket

Dacron Silastic

0.040

2511325

Skin, Internal

2024-T3

0.063

CODES

FIG. NO.

Replace

66001 15

Retainer, Lower

REPAIR

CODE

6600115

Clip(2 ea.)
Retainer, Upper
Clip(2 ea.)
Escape Hatch Instl.
Glass Assy.

FINISH

EFFECTIVITIES

24-218, 24-230 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004;
31-001 AND SUBSEQUENT; 35-002 AND SUBSEQUENT; 36-002 AND SUBSEQUENT
24-218, 24-230 THRU 24-236; 25-061, 25-067 THRU 25-069

1
2

NOTES

Per MIL-P-25690.

Cabin Window

Repair Index

Late Model 24 Series Aircraft and Model 25/28/29/31/35/36 Series Aircraft

Figure 2 (Sheet 2 of 2)
EFFECTIVITY:

NOTED

56-20-00

Page
SRM-4

May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


CABIN WINDOW
1.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGE LIMITS (CABIN WINDOW)


All dimensions

NOTE:

are

in inches unless otherwise

specified.

On Aircraft 23-003 and Subseauent, and 24-001 thru 24-217, 24-219 thru 24-229
large cabin windows, the cabin windows are assembled from a 0.414-inch thick outer

plastic,

0.276-inch thick inner

acrylic plastic,
acrylic plastic.

and

0.09[)-inch thick spacer, sealed

with

acrylic
air tight

between the inner and outer

On 20/30 Series Aircraft eauitlzled with small cabin windows, the cabin windows are assembled
from a OA1Pinch thick outer acrylic plastic, a 0.252-inch thick inner acrylic plastic and a

0.090-inch thick spacer, sealed air


A.

tight between the inner and

outer

acrylic plastic.

Evaluation

(1) Inspect cabin windows for damage and evaluate any damage found by the following steps:
ta) Following manufacturers operating instructions, determine thickness of acrylic plastic adjacent to scratch, chip or pit using ultrasonic thickness gage.
Measure
tb)
depth of scratch, chip or pit as accurately as possible using a depth gage or other
similar device.

tc) Subtract depth of scratch, chip or pit measured in step tb) from thickness of acrylic plastic
measured in step ta) to determine if repairs are allowable.
NOTE:

On Aircraft 23-003 and Subseauent, and 24-001 thru 24-217, 24-219 thru 24-229
eauit7ped with large cabin windows, repeat acrylic plastic thickness measurement
after

repair

tinner) is

to

met

ensure

or

minimum thickness of 0.400 inch touter) and 0.250 inch

exceeded.

On 20/30 Series Aircraft eauirmed with small cabin windows, repeat acrylic plastic
thickness measurement after repair to ensure minimum thickness of 0.370 inch

touter) and 0.220 inch timer) is


B.

Scratches,Nicks,and
NOTE:

The

met or exceeded.

Pits

following discrepancies are considered unrepairable.


discrepancies shall be removed from service.

Cabin windows with any

one

of

these

(1) On Aircraft 23-003 and Subseauent, and 24-001 thru 24-217. 24-219 thru 24-229 eaui~t7ed with larPe cabin windows, any scratch, nick or pit reducing the outer window thickness to less than 0.400 inch, or
scratch or nick that cannot be repaired without reducing the outer winless
than
0.400 inch shall be removed from service.
to
thickness
dow
with small cabin windows, any scratch, nick or pit reducing the outAircraft
e4uizloed
Series
(2) On 20/30
less
than
0.370 inch, or any sharp-bottomed t"V") scratch or nick that can
er window thickness to
not be repaired without reducing the outer window thickness to less than 0.370 inch shall be reany

sharp-bottomed t"V")

moved from service..

(3) On Aircraft 23-003 and Subseauent, and 24-001 thru 24-217, 24-279 thru 24-229 eauiltzled with Iarae cabin windows, any scratch, nick or pit reducing the inner window thickness to less than 0.250 inch or
be repaired without reducing the inner win
any sharp-bottomed t"V") scratch or nick that cannot
dow thickness to less than 0.250 inch shall be removed from service..

EFFECTIVITY:

ALL

56-20-00

Page
SRM-4

101

Jun 1/95

STRUCTURAL REPAIR MANUAL


(4) On 20/30 Series Aircraft eauitt~ed with standard cabin windows, any scratch, nick or pit reducing the
inner window thickness to less than 0.220 inch or any sharp-bottomed ("V") scratch or nick that
cannot be

repaired

without

reducing

the inner window thickness to less than 0.220 inch shall be

removed from service.

C.

Cracksand

Separations
On Aircraft 23-003 and Subseauent, and 24-001 thru 24-217, 24-219 thru 24-229

NOTE:

.snoitaudewiuae

with large cabin windows, refer to the

applicable Learjet Service

Manual for additional in-

formation.

On 20/30 Series Aircraft eauiwed with standard cabin windows,

perform

the

following eval-

(1) Any continuous crack extending between two (2) or more fastener holes.
(2) Any cracks originating from the radius of the step in the outer window, or any location other than
a

fastener hole.

(3) Any fastener hole crack greater than 0.20 inch in length extending toward the center of the window, or any fastener hole crack greater than 0.35 inch extending in any other direction.
(4) Cracks in more than three (3) adjacent fastener holes.
(5) Cracks in more than five (5) out of ten (10) adjacent fastener holes.
(6) Cracks in more than twelve (12) fastener holes for the entire window.
(7) Two (2) or more cracks originating from the same fastener hole toward the edge, that could result

breaking out of the window.


(8) Any chipping extending more than 0.09
in

section

inch

radially

from the

edge

of holes

on more

than

eight

(8) holes.

perimeter of the window or


edge.
(10) More than two (2) chips in any six (6) inch length.
(9) Any chipping

on

the

inch from the surface

2.

on

machined fillets

extending

more

than 0.09

or

ALLOWABLE DA~UIAGE LIMITS (CABIN WINDOW STRUCTURE)

NOTE:
A.

All dimensions

are

in inches unless otherwise

specified.

Fasteners

(1) Loose

or

failed rivets

are

not allowed. A loose

or

failed rivet

can cause

increased stress concentra-

progressive joint failure. A careful inspection must be


performed to ensure that joint failure has not spread from the area of the loose or failed rivet. (Refer to Chapter 51 for definition of rivet failure.)
tions

the

on

(2) Loose

or

remaining

failed

rivets and lead to

screws are

not allowed. A loose

or

failed

screw can cause

increased stress

concen-

surrounding screws and lead to progressive joint failure. A careful inspection must be
performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
trations
B.

on

Cracks

(1) Cracks in any fitting are not allowed. Cracked fittings must be replaced.
(2) Cracks in components other than fittings are considered allowable if properly
ished in accordance with
C.

Chapter

repaired, and

refin-

51.

Deformation

(1) Deformation of the cabinwindow

EFFECTIVITY:

ALL

structure is not allowed.

56-20-00

Page
SRM~

102

Tun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


D.

Corrosion(See Figure 101.)


(1) Corrosion damage is permissible if the affected

properly repaired, refinished in accordance with Chapter 51, and these repairs do not reduce the original material thickness more than
specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness more than specified.

E.

area

is

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2,54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component reF.

G.

placed.
(SeeFigurelOl.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified.
(Refer to Chapter 51 for protective treatment procedures.)
Structural
(2)
components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(See Figure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.

Scratches

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067
0.076

0.080

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFFECTIVITY:

ALL

101

56-20-00

Page
SRM-4

103

Jun 1/95

CHAPII~E R

VVINGS

Learjet

STRUCTURAL REPAIR MANUAL


Chapter
Section

Subject

Subject

WING ASSEMBLY

STRUCTURAL IDENTIFICATION

...................................................57-00-00

Description

....57-00-00

WING ASSEMBLY ALLOWABLE DAMAGE


Allowable Damage Limits
REPAIR

101

..................................................................................................57-00-00

201

..................................................................................................................................57-00-00

Limitations and

Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57-00-00

Materials and Processes

201
201

........................................................................................................57-00-00

Repair Procedures
Replacement of Upper Wing Skin Fasteners
Lower Wing Skin Extension Access Cover Installation
Spar #1 Repair Access Panel Installation

.........57-00-00
57-00-00

WING-STRUCTURAL IDENTIFICATION

57-11-00

Description
Wing Repair Index -(Model 23/24/25 Series Aircraft)
Wing Repair Index -(Model 28/29/31 Series Aircraft)
Wing Repair Index -(Model 35/36 Series Aircraft)
............................................................................................................................57-1

1-00

57-11-10

.........................................................57-11-20

..............................................................57-11-30

INNER WINGLET

STRUCTURAL IDENTIFICATION
Inner Winglet Repair Index
INNER WINGLET ALLOWABLE DAMAGE.....................................................................57-30-10

57-30-10
1

.........................................................................................,........57-30-10

Damage Limits

101

....................................................................................................57-30-10

REPAIR

210
217

....................................................................57-00-00

Allowable

202
202

..............................................................57-00-00

INNER WINGLET

....................................................................57-00-00

....................................................................................................57-00-00

WING ASSEMBLY
General

Page

...................................................................................................57-30-10

Approved Repairs

....57-30-10

OUTER WINGLET

STRUCTURAL IDENTIFICATION
Outer Winglet Repair Index
OUTER WINGLET ALLOWABLE DAMAGE
Allowable Damage Limits

201

...................................................57-30-20

...................................................................................,.............57-30-20

....................................................................57-30-20

101

....................................................................................................57-30-20

OUTER WINGLET

Approved Repairs
TIP TANK

REPAIR

..................................................................................................57-30-20

201

..................................................................................................................57-30-20

STRUCTURAL IDENTIFICATION

..................................................................57-31-00

Tip Tank Repair Index............


TIP TANK

Allowable
TIP TANK

57-31-00

ALLOWABLE DAMAGE

Damage Limits
REPAIR

57-31-00

.........57-31-00

101

......57-31-00

201

.................................................................................................................57-31-0O

Approved Repairs
FLAP- STRUCTURAL IDENTIFICATION

57-50-00

Flap Repair Index


(Model 23 Aircraft and Early Model 24/25/35/36 Series Aircraft)

................................,.57-50-00

Flap Repair Index


(Late Model 24/25/35/36 Series Aircraft and 28/29/31 Series Aircraft)

57-50-00

FLAP- ALLOWABLE DAMAGE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57-50-00

Allowable

Damage Limits

FLAP- REPAIR

101

....................................................................................................57-50-00

.........................................................................................................................57-50-00

Approved Repairs

57-50-00

201

57-Contents

Pagel
SRM-4

Tan 15/93

Learjet
STRUCTURAL REPAIR MANUAL
Chapter
Section

Subject

Subject

Page

AILERON- STRUCTURAL IDENTIFICATION...................................................................57-60-00

Repair Index (Model 23 Series Aircraf ). . . . . . . . . . . . . . . . . .~. . . . . . . . . . . . . . 57-60-0O


Repair Index (Earlv Model 24 Series Aircraft). . . . . . . . . . . . . . . . . . . . . . . . . . . 57-60-00
Repair Index (Eavlv Model 25 Series Aircraft)
Aileron Repair Index
Aileron

Aileron
Aileron

5
.........57-60-00

13

(Late Model 24/25 Series Aircraft and All Model 28/29/31/35/36 Series Aircraft) .........57-60-00

17

AILERON

ALLOWABLE DAMAGE

Allowable Damage Limits


AILERON- REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57-60-00

Approved Repairs

...................................................................................57-60-00

101

....................................................................................................57-60-00

202

..................................................................................................................57-60-00

STRUCTURAL IDENTIFICATION
.........57-60-10
Aileron Balance Tab Repair Index -(Model 23 Series Aircraft)
Aileron Balance Tab Repair Index -(Model 2412512812913;1/3513 Series Aircraft) ..........57-60-10
AILERON BALANCE TAB ALLOWABLE DAMAGE......................................................57-60-10
AILERON BALANCE TAB

.....................................57-60-10

3
101

Allowable Damage Limits


AILERON BALANCE TAB REPAIR

....................................................................................................57-60-10

Approved Repairs

57-60-10
201

..................................................................................................................57-60-10

AILERON TRIM TAB STRUCTURAL IDENTIFICATION


Aileron Trim Tab Repair Index (Model 23 Series Aircraft)
Aileron Trim Tab Repair Index (Model 24/25/28/29131135136 Series Aircraft) ...............57-60-20
AILERON TRIM TAB ALLOWABLE DAMAGE
..............................................57-60-20

..............................................57-60-20

1
3

...............................................................57-60-20

Allowable

Damage

Limits

AILERON TRIM TAB

101

....................................................................................................57-60-20

REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57-60-20
...........57-60-20

Approved Repairs

201

SPOILER- STRUCTURAL IDENTIFZCATION.....................................................................57-70-00

Spoiler Repair Index


SPOILER

Allowable

..............................................................................................................57-70-00

ALLOWABLE DAMAGE

Damage Limits

.....................................................................................57-70-00

....................................................................................................57-70-00

101

SPOILER- REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57-70-00

Approved Repairs

I,,

..................................................................................................................57-70-00

201

Page2

Learjet

STRUCTURAL REPAIR MANUAL


Chapter

Chapter

Section

Section

subject

Page

Subject

Date

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margin of the

page
57

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Page 1

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~Learjet
STRUCTURAL REPAIR MANUAL
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57

Date

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List of Effective

Pages

Page
srau

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


WING ASSEMBLY
i.

STRUCTURAL IDENTIFICATION

DESCRIPTION

NOTE

The
the

following structural data covers the basic non-modified aircraft. When applicable, refer to
appropriate kit drawing for additions, modifications and changes to the structural compo-

nents and

A.
B.

assemblies.

structural components, allowable damage limits, skin gap tolerances and repair
of aircraft stabilizers.
The wing assembly consists of the leading edge assembly and wing box section, tip tanks or winglets,

This

chapter

covers

ailerons, flaps, and spoilers.


C.
D.

Repair indexes are incorporated in each respective section for the specific components.
Allowable damage limits for each component are given in each respective section.
Chapter
Section

Description

Item

Subject
57-11-00

Wing
Tip Tank
Flap

Aileron

57-60-00

Spoiler

57-70-00

57-31-00
57-50-00

(TYPICAL)
~4-29B1

EFFECTIVITY:
SRM-II

Wing Assembly Structural Identification


Figure 1 (Sheet 1 of 3)
MODEL 23/24/25 SERIESAIRCRAFT

57-00-00

Page 1
May 15/92

Learjetl
STRUCTURAL REPAIR MANUAL
WING ASSEMBLY

STRUCTUnAL IDENTIFICATION

Chapter
Section
Item
1

Description

Subject
57-11-00

Wing
Winglet
Flap

Aileron

57-60-00

Spoiler

57-70-00

57-30-00
57-50-00

(TYPICAL)
~4-90(3-6

EFFECTTVITY:

Wing Assembly Structural Identification


Figure 1 (Sheet 2 of 3)
MODEL28/29/31 SERIESAIRCRAF~

57-00-00

Page 2
SRM~

May 15/92

Leariet

STRUCTURAL REPAIR MANUAL


WING ASSEMBLY- STRUCTURAL IDENTIFICATION

Chapter
Section
Item

Description

Subject
57-11-00

Wing
Tip Tank
Flap

Aileron

57-60-00

Spoiler

57-7(HX)

57-31-00

57-5~00

(TYPICAL)
14-90C-1

EFFECTIVITY:
sRM-4

Wing Assembly Structural Identification


Figure 1 (Sheet 3 of 3)
MODEL35/36SERIES AIRCRAFT

57-00-00

Page 3
May 15/92

~arjei

TEMPORARY REVISION NO. 57-1


Leajet 20/30 Series Structural Repair Manual. (SRM-4)

MANUAL AFFECTED:

Insert

FILING INSTRUCTIONS:

adjacent

to

57-00-00,

Page

101, dated May 15/92, and retain until ~ur-

ther notice

To

REASON:

clarify allowable damage limits for the wing leading edge.


101

1.

paragraph

Revise

INSTRUCTIONS:

as

E., F. and G. in i. ALLOWABLE DAMAGE LIMITS, and

Figure

follows:

ALLOWABLE DAMAGE LIMITS


All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

or

failed rivets
the

on

are

remaining

not allowed. A loose or

failed rivet

can cause

increased stress concentra-

progressive joint failure. A careful inspection must be


failure has not spread hom the area of the loose or failed rivet. (Re-

rivets and lead to

performed to ensure that joint


fer to Chapter 51 for definition of rivet failure.)
(2) Loose

or

failed

screws are

not allowed. A loose

or

failed

screw can cause

increased stress

concen-

surrounding screws and lead to progressive joint failure. A careful inspection must be
to
performed ensure that the joint failure has not spread from the area of the loose or failed screw.
trations

B.

on

Cracks

(1) Cracks in any fitting or forging are


(2) Cracks in components other than

paired,
C.
D.

and refinished

fittings or forgings must be replaced.


considered allowable if properly

are

re-

Deformation
(1) Deformation of the wing structure is not allowed.
Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is

properly repaired and refinished in accororiginal material thickness more than


Chapter
repairs
if
surface
than
corrosion
is
encountered
more
on the lower wing skin, after
However,
specified.
removal of the wing-to-fuselage fairings, contact Leajet Field Service for proper evaluation and
disposition of corrosion damage. (Refer to Chapter 51 for protective treatment procedures.)
Structural components must be repaired or replaced if corrosion repair reduces the original material thickness more than specified.
51, and these

dance with

(2)
E.

not allowed. Cracked

fittings and forgings


in accordance with Chapter 51.

do not reduce the

Dents

(1) Dents to

wing

skins

on

upper surfaces

are

permissible,

if smooth and without

abrupt changes

in

contour, do not exceed 0.100 inch (2.54 mm) in depth, do not exceed 10% of total surface area in
one (1) square foot, and are not closer than 0.50 inch (12.7 mm) to any rivet or structural area.

(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component re-

placed.
(3) Dents in the wing leading edge in general are not allowed, as they may effect the aerodynamic
characteristics of the aircraft. Small smooth dents may be allowable, after a review by Leajet Engineering has been accomplished, depending on location and depth. If the operator chooses not to

repair dents which Leajet Engineering will not approve for continued service, a Flight test to verify aerodynamic acceptability and stall speeds must be performed by Leajet Test Pilots before the
aircraft

can

be returned to service.

TEMPORARY REVISION NO. 57-1

57-00-00

Page
SR~-(

1 of 2

Aug 15/97

Learjet
F.

Scratches(See

FigurelOl.)

(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
Structural
(2)
components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
(3) For procedures to remove scratches from the wing leading edge, refer to the basic Leajet Mainte-

nance

G.

Manual

or

Service Manual.

Nicks(See Figure 101.)


(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to

protective treatment procedures.)


must be replaced or repaired if nicks reduce the original material thickness more than specified.
(3) For procedures to remove nicks from the wing leading edge, refer to the basic Leajet Mainte-

Chapter 51

for

(2) Structural components

nance

Manual

or

Service Manual.

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.040

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

For localized

TEMPORARY REVISION NO. 57-1

SRM-I

(Wing

i,. E.

Only)"

repair areas only.

57-00-00

Page 2 of 2
Aug 15/97

Learjet
~LBarjet

STRUCTURAL REPAIR MANUAL


WING ASSEMBLY

i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGE LIMITS

All dimensions

NOTE:
A.

in inches unless otherwise

are

specified.

Fasteners

(1) Loose

or

failed rivets

are not

allowed. A loose

or

failed rivet

can cause

increased stress concentra-

progressive joint failure. A careful inspection must be


performed to ensure that joint failure has not spread from the area of the loose or failed rivet. (Refer to Chapter 51 for definition of rivet failure.)
tions

the

on

(2) Loose

or

trations

failed

rivets and lead to

screws are

to

not allowed. A loose

or

failed

screw can cause

increased stress

concen-

progressive joint failure. A careful inspection must be


ensure that the joint failure has not spread from the area of the loose or failed screw.

surrounding

on

performed
B.

remaining

screws

and lead to

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired, and
C.
D.

E.

refinished in accordance with

re-

Chapter 51.

Deformation

(1) Deformation of the wing structure is not allowed.


Corrosion(SeeFigure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired and refinished in accordance with Chapter 51, and these repairs do not reduce the original material thickness more than
specified. However, if more than surface corrosion is encountered on the lower wing skin, after
removal of the wing-to-fuselage fairings, contact Learjet Field Service for proper evaluation and
disposition of corrosion damage. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness more than specified.
Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component re-

placed.
F.

Scratches(See Figure 101.)


(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to

Chapter 51

for

protective treatment procedures.)


replaced or repaired

(2) Structural components must be


thickness by more than specified.
G.

if scratches reduce the

material

Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.

NOTE: Please

EFFlCCTNITY:
SRM~

original

ALL

see

the

TEMPORARY
REVISION
that revises this page.

57-00-00

Page 101
May 15/92

Learjet
STRUCTU RAL REPAIR MANUAL
H.

Fittings and Forgings


(1) Fittings or forgings

must be

replaced

if cracked

or

if

fitting

hole (non-bushed) tolerance exceeds

the allowable limits. (Refer to Chapter 51.)


(2) Fittings or forgings with bushing shall be repaired..

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFFECTIVITY:
SRM~

ALL

101

57-00-00

Page 102
May 15/92

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


WING ASSEMBLY

1.

REPAIR

GENERAL
A.

B.

responsibility of the aircraft owner/maintenance facility to determine qualifications of maintenance personnel performing repair procedures. As always, a clean environment and good general
shop practices shall be exercised any time repairs are performed on the aircraft.
Prior to, and after performing, any structural repairs on the wing assembly, ensure serviceability and
reliability of part. If serviceability and/or reliability of any part or repair remains in question or if
guidance is needed in making this determination, contact Leajet Field Service for additional informaIt is the

tion.
C.

equal to, or greater in strength, than the original structure. Technique and material
variation is permissible only so far as to facilitate fabrication and ensure the original strength and useRepairs

must be

fulness of the affected


D.

component.

for structure not included in this section does not necessarily indicate that the structure involved is non-repairable, but that the application of a typical repair procedure to theoretical damage

Repairs

yet been developed.


toChapter 51 for allowable wear and repair data, and

has not
E.

Refer

for standard

repair procedures not speci-

fied in this section.


F.

G.

Fl.

2.

Following any repair or maintenance procedures on the aircraft structure/components, update all aircraft log books as required.
Following any repair or maintenance procedures on the aircraft structure/components, ensure inspection records pertaining to any specific repair-related procedure are identified, properly documented and closely adhered too.
All parts fabricated by the repair facility shall be identified for future reference. Marking of parts shall
be accomplished in a manner which does not effect the serviceability and reliability of the part.

LIMITATIONSAND INSPECTIONS
A.

Limitations

(1) Learjet engineering

approved repairs listed in this section, are limited to those items/areas as out-

lined in step 4., REPAIR PROCEDURES.


(2) Limitations applied to repairs in this section must be followed unless Leajet engineering authority to the contrary is given.
(3) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. Cracks in any fitting or forging are not allowed. Fittings or forgings with
bushing shall be repaired.
(4) Authorized maintenance to the wing leading edge without Learjet factory approval is limited to

removal and installation. A

new

wing leading edge shall be installed

at

an

authorized

Learjet

re-

pair facility.
3.

MATERIALS AND PROCESSES


A.

Materials

(1) Repair materials and required

treatments

or

processes will be listed in the


far

repair procedure.

Ma-

to facilitate fabrication and ensure the

or
permissible only
original strength and usefulness of the affected component.

treatment variation is

terial

B.

so

as

Processes

(1) Refer

EFFECTIVITY:

to

Chapter 51

ALL

for chemical process and treatment

specifications.

57-00-00

Page 201
SRM-4

Jun 1/95

STRUCTURAL REPAIR MANUAL


WING ASSEMBLY- REPAIR

4.

REPAIR PROCEDURES

NOTE:
A.

All dimensions

are

in inches unless otherwise

specified.

Replacement of Upper Wing Skin Fasteners (See Figure 201.)


(1) Mark each fastener having one or more of the following conditions:
(a) Paint on fastener missing (except when it is suspected that the paint
to the

did not

properly

adhere

fastener).

(b) Cracked paint and streaking or black rings around fasteners indicating
(c) Fuel seepage around fastener.
(d) Paint blister on fastener (fuel under paint).

"working"

fastener.

(2) Compare the suspect fastener with the fastener pattern shown in Figure 201.
IF ANY ONE OI; THE FASTENERS IN ANY ONE OF THE INDICATED

CAUTION:

BOXES

REQUIRES REPLACEMENT,

ALL THE FASTENERS CONTAINED

IN THAT BOX MUST BE REPLACED.

REMOVE AND REPLACE EVERY OTHER FASTENER WITHIN THE ROW

AND, UPON COMPLETION, REPLACE

THE REMAINING FASTENERS

WITHIN THE BOX.

(3) Defuel aircraft. (Refer to the basic Leajet Maintenance Manual.)


(4) Close crossflow valve and remove electrical power from aircraft.

(5) Cover upper wing skin with masking tape adjacent

to the

fastener(s) previously marked for

re-

moval.

(6) Remove wing lower

placement

is

CAUTION:

access

panels as required to gain access to wing tank areas where fastener re-

required.
WHEN DRILLING OUT EXISTING FASTENERS, EXERCISE EXTREME CARE
SO THAT HOLES OR COUNTERSINKS DO NOT BECOME DAMAGED. EXDRILL PRESSURE MAY DEFORM THE
CAUSING DAMAGE TO THE FUEL SEAL BARRIER.

CESSIVE

UNDERSTRUCTURE,

(7) Remove existing fasteners marked for removal. Check each hole diameter and material thickness
for

grip length.

Mark this information

on

the

masking tape previously installed.

0.0007 to 0.0012 inch (0.018 to 0.030 mm) interference. On a severely damaged hole, the next oversize fastener should be used.
(9) Using a hole brush, remove sealant and loose particles before drilling and reaming. Pilot drill
hole. Pilot ream and final ream hole to attain the desired diameter.

(8) Select

new

NOTE:

bolts to fit holes with

When

replacing 5/32-diameter

Huck Bolt, with next oversized fastener, pilot drill and


Replacement Fastener Table.)

countersink holes to a 6/32 diameter standard hole. (See


Two-step ream in order to attain the desired hole size.

EFFErrIVITY:

ALL

57-00-00

Page 202
SRM~

lan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


WING AS SEMBLY

(10)

Using grip length previously marked


NOTE:

grip length for any one

The

thickness variance
missible to

as a

use one

on

REPAIR

tape, select the correct bolt length for each location.

fastener may vary from one unit to the next due to material
shimming and sealing during manufacturing. It is per-

result of

grip length shorter or longer than shown.

(11) Dip bolt into sealant and insert bolt in hole.


DO NOT OVER

CAUTION:

TORQUE BOLTS.

OVER

TORQUING

OF BOLTS MAY DE-

FORM THE UNDERSTRUCTURE AND DAMAGE FUEL

LEAKAGE AT

SEAL, CAUSING

ADJACENT FASTENERS.

(12) Install washer and start nut on bolt. Hold bolt from turning and torque nut 20 to 25 inch-pounds
(2.2 to 2.8 Nm) for 3/16-inch diameter bolts, or 50 to 70 inch-pounds (5.6 to 7.9 Nm) for i/i-inch
diameter bolts.
All

NOTE:

torque values are in addition to the drag-torque of the nut.

(13) After all fasteners have been

quired.

Seal

over

replaced, inspect the integral


replaced. (Refer to

fasteners that have been

fuel tank
the basic

sealing and repair as reLearjet Maintenance Man-

ual.)
If seal is not

NOTE:

Seal

(14)

Thoroughly

over

clean

all

damaged, apply an additional layer of sealant over


replaced fasteners and nuts.

shavings

and

foreign particles

from each fuel tank

the

cavity

existing

fillet seal.

in which rework

was

done.

CAUTION:

IT IS ABSOLUTELY ESSENTIAL THAT EACH FUEL TANK CAVITY IN THE


AREA WHERE THE REWORK WAS PERFORMED BE THOROUGHLY IN-

SPECTED FOR CLEANLINESS, AND THAT ALL FOREIGN MATERIAL IS REMOVED PRIOR TO THE FINAL CLOSING OF THE FUEL TANKS. FAILURE
TO THOROUGHLY CLEAN THE

FUEL

TANKS AFTER REWORK MAY

CAUSE THE FUEL SYSTEM COMPONENTS TO MALFUNCTION.

(15) Inspect fuel tank

Learjet

access

opening

seals for

damage. Replace

seal if

(16) Install access covers.


(17) Flush wing fuel tank to remove any remaining foreign particles
ta) Equipment required. (See Figure 202.)
1) Motor-driven pump capable of pumping 10 gpm.
2) A50-micron filter.
3) Holdingtank tone-half of 55 gallondrum).
4) Plumbingnecessary to connect flushingcomponents.
5) Approximately 20 gallonsof fuel.

EFFECTIVITY:

required. (Refer

to the basic

Maintenance Manual.)

ALL

as

follows:

57-00-00

Page 203
SRM-4

~an 15/93

Learjet
STRUCTURAL REPAIR MANUAL
WING ASSEMBLY- REPAIR

CAUTION:

COMPLY WITH ALL STANDARD MAINTENANCE PRECAUTIONS


(REFER TO THE BASIC LEARJET MAINTENANCE MANUAL) WHILE

FLUSHING TANKS.

(b) Position holding tank under applicable wing defuel valve.


(c) On Model 23/24/25/35/36 Series Aircraft, route the hose attached to the pump through the tip
tank, then through one of the wing interconnects and into the wing tank.
(d) On Model 28/29/31 Series Aircraft. route the hose attached to pump into wing tank.
(e) Fill holding tank with approximately 20 gallons of fuel.
(f) Remove bushing and drain valve from defuel valve.

(g) Open defuel

valve.
fuel
for 30 minutes (15 minutes through each interconnect).
(h) Circulate
(i) Repeat procedure on opposite wing tank.

(j) Drainwingsumpsand removehosefromtank.


(k) Close defuel valve and install bushing and drain valve.
(18) Refuel wing tanks and check for leaks.
(19) Fill screw heads and countersinks, flush with wing skin, using sealant.
NOTE:

to fill and smooth over heads of replaced fasteners using Pro-Seal 890B2
EC1751 and allow to cure prior to final paint. It is permissible to machine JPolt stems flush with fastener heads and fill recesses with Pro-Seal 890B2 or EC1751.

It is

optional

sealant

or

(20) Clean wing surface and retouch paint.


(21) The low pressure fuel filters shall be checked for foreign particles

not later than the next 30

flight

hours after this rework.

(22) Restore electrical power to aircraft.


(23) Restore aircraft to normal.

EFFECTIVITY:

ALL

57-00-00

Page 204
SRM-4

Tan 15/93

LEARJET 20/30 SERIES


STRUCTURAL REPAIR MANUAL

TEMPORARY REVISION NO. 57-4

MANUAL AFFECTED:

Leajet Model 20/30 Series Structural Repair Manual (SRM-~.

FILING INSTRUCTIONS: Insert


REASONrTo

adjacent to 57-00-00, page 205, dated Jan 15/93 and retain until further notice..

clarity fastener replacement information.

INSTRUCTIONS: Revise

Replacement of Upper Wing Skin Fasteners illustration

follows:

as

WING
STATION
0.00

~I

\I

WHE~L WUL

I \~I

I\

i
i

~I

LE~DNO

i
I

II

WING

STATION
53.04

u,

A~
i\

C3

Q\\\\

LOWER WING SKIN

~A

\t\

a
\I

ACC~SS COVEAS
WING SPAR ACCESS

L~L-

~----LL

COVERS AND OPENINGS

SPAR 1

~C

SPAR 2

INBD
NVD

SPAR 3

SPAR 5

SPAR 4

SPAR 7

SPAR 6

SPAR 8

TOP VIEW OF LH WING- RN WING OPPOSITE


WING FUEL TANK ACCESS

(TIPICAL)

Replacement of Upper Wing Skin Fasteners


Figure 201 (Sheet 1 of 3)
TEMPORARY REVISION 57-4

57-00-00

Page
SRM-4

1 of 3

P;ug 31/00

LEARJET 20/30 SERIES


STRUCTURAL REPAIR MANUAL

SPARS

SPAR 4

SPAR 3

wsnNe FASTENERS

/"W~Ne
SKIN

NOT REMOVE)

wsn#e HUCK BOLTS (REWORK HOLES PER


REPLACEMENT FASTENER TABLE AS RH1UIRED)

SPAR 6

SPART

SPARE

SPAR1h.

@O

9i

IgP~S)

~1 PLJ

.a\
(4PLS)

(3_PLS)

1~

(4 PLS)

PLS)

(1

(4 PLS)

(2 PLS)

(1_PL)

.c:

i-i

SPAR8

(2

+G

Y
_

:i9 ~PI

4J;T~\\I:

a\\\\B
WING

STATION

T~i

\ie-I-

PLS)\
PLS)
4-t~\(4
\IsU+J

.4\i?\

\i

(GPLS)\

\JiI+J~

(10 PLS)

L-~i

tt~

~o P

r:-

ii
j

(7PLs)

EDGE

+j

Ti

(8 PLS)

(8 PLS)

(10 PLS)

(GPLS)

LEADING

~1

+J

53.04

li~.\ a~ i

iB \9\.
+J

;+J

~c3

(7 PLS)

/c~pis,\+B\+

t"\,

WING

(6PLS)

i~

l.i

INBD
nnrD
Symbol

+J

REPLACEMENT FASTENER TABLE


First Repair/Replacement FastenerData

Qty

Production instl.

Per AIC

Blueprint Fastener
Ref. Data

i3olt

172

Huck P/N B100-T5

NAS1503-7

(1/64 O.S.)

Nut

Washer

Instl Hole Size

MS21042-3

AN960PD10

Huck P/N B100-T5

NAS75036

MS21042-3

AN960PD10

Huck P/N B100-T8

NAS1503-8 IZ

MS21042-4

-3

20

Huck PM B100-T8

NAS1503-712,

MS21042-4

-3

20

Huck P/N 8100-T8

NAS1503-6 I~

MS21042-4

-3

+L

Huck PM 8100-T6

MAS1503-71!

MS21042-3

-2

+C

12

Huck PM B100-T6

NAS1503-7 11

MS21042-3

-2

104

Huck PM B100-T6

NAS1503-7 I!

MS21042-3

-2

38

Huck P/N B100-T6

NAS1503-7 1!

N1521042-3

-2

+A

NOTE: For fastener call-outs

beyond

the second

repair type, call Wichita Field Support Engineering for a disposition.

Replacement of Upper Wing Skin Fasteners


Figure 201 (Sheet 2 of 3)
TEMPORARY REVISION 57-4

Replacement

Fastener Data

+r

Second Repair

57-00-00

Page

2 of 3

Aug

31/00

SRM-4

Instl Csk Size


0.381 Dia
0.381 Dia

Next Oversize

(1/32 O.S.)

100"

NAS1243-7 )8:

100"

NAS1243-S Is:

Existing
Existing Csk
Use Existing Csk
Use Existing Csk
Use Existing Csk
Use Existing Csk
Use Existing Csk

NAS1254-8 Is:

Use

Use

Csk

NAS1254-7 IS
NAS1254-6 le:

NAS1253-8 Is_
NAS1253-7 Is:
NAS1253-6 Is

NAS1253-5 Is:

saDdnx~oo-aol-oe

LEARJFT 20/30 SERIES


STRUCTURAL REPAIR IVIANUAL
Under the following conditions, it may be
necessary to replace all of the fasteners contained
I within a designated boxed area:

r--~

The

UPPER RIB

CHORD(REF)
RIB WEB

(REn\

T[
53.04

It has been found that replacement of a leaking


fastener can cause adjacent fasteners within a
boxed off area to leak. if this occurs we
recommend the following steps:

Il

1.
NUT

BOLT

(REF)

(REF)

IT~
I

fastener is not of the same


listed in the replacement table.

replacement of a single leaking fastener,


subsequent
additional leaking fasteners within the original
repair boxed area.

WING STATION

---I=

or one

After

L--J

2.

V-

additional leaks within the


off repair area shall require
replacement of all rer~aining fasteners. The
is
sequence
replacement
foilowing
recommended:

Subsequently,
original boxed

First, replace every

(REF)

row

III

5.

other fastener within the

in the box.

6~

WING
SKIN

CP/PICAt) (REF)

shimming

and

one

fastener may vary from

one

sealing during manufacturing.

use one

grip length

shorter

or

longer

Inspect fillet seal for damage or breaks. If it is damaged,


and replace seal. if seal is not damaged, apply
an additional layer of sealant over existing fillet seal.
Seal

over

all

replaced fasteners

I~BACB30LU

bolts

may

and nuts.

used

be

as

alternates

by

Sele~ bolts to M holes with a O.OOo7 to 0.0012 inch


(0.018to 0.030 mm) interference fit.

L~ Optional to use Huck Bolt PM


are

B100-T6-X blind fastener

that the proper installation.


available. Assure proper grip and comply with

at this location,

providing

and other pertinent


flag note
factory recommends that screws and

not sure whether or not to replace all the


contact Learjet Technical Services for
assistance,

If you

(REF)

for any

remove

tools

SKIN PANEL STIFFENER


OR SPAR

grip length

It is permissible to
than shown.

Next, replace the remaining fasteners.

The

result of

As a singular corrective action, replace the


additional
tone each) leaking fastener
following the same guidelines as listed above.

STIFFENER TO CHORD
BRACKR.

diameter installed

replacement

type

may be instances where the actual fastener


on the aircraft will be different from
what is shown because of a repair made during
manufacturing of the wing. In these instances the bolt
diameter must agree with the actual diameter of the
hole and use the grip length shown.
There

4.

are

instructions. The
nuts be used at a

minimum of every other location to assure parts are


brought into a proper shear condition. The screws and
nuts must be installed prior to installing Huck Bolts.

fasteners,

NOTES

Optional
fASTENER INSTALLATION

(TYPICAL)

The

following

bolts

are

View A-A

comply

NAS17031-~ (Long Thread)


(Long Thread)

following bolts are afternate for NAS1244-X.


NAS1244-XT(Sho~Thread)
NAS1704-~-R (Long Thread)
NAS1704-~ (No Suffix) (Long Thread)
NAS1704T-ll-R (Long Thread)
(Long Thread)

The

L~

oversize fastener may be used in the event of


severely damaged hole or for future rework.

Replacement of Upper Wing Skin Fasteners


Figure 201 (Sheet 3 of 3)
TEMPORARY REVISION 57-4

SRM-4

57-00-00

Page

3 of 3

Aug

31/00

P/N

with

flag

note

It is

optional

PLT

1006-6-X blind

and

other

pertinent

to use Jo-Bolt P/N PLT 1006-8-X blind

fasteners at this location as

specified by flag

note 10

instructions.

NAS1704T-~
j~ Next

Jo-Bolt

instructions. The factory recommends that screws and


nuts be used at a minimum of every other location to
assure parts are brought into a proper shear condition.
The screws and nuts must be installed prior to
installing Jo-Bolts.

Thread)

NAS1703 T-~-R

s2Dsnmo401M

use

location, providing that the proper


installation tools are available. Assure proper grip and

alternate for NAS1243-X.

NAS1243-XT (Short Thread)


NAS1703-XR (Long Thread)
NAS1703-X (No Suffuc) (Long

to

fastener at this

12.

NAS1603 series bolts (Long Thread) may be used


alternates to NAS1253 series bolts.

as

13.

NAS1604 series bolts (Long Thread) may be used


alternates to NAS1254 series bolts.

as

14.

For cosmetic purposes only, it is permissible to


machine Jo-Bolt stems flush with fastener heads and
fill recesses and smooth over heads of replaced
fasteners using ProSeal 89082 sealant or EC 1751.
Allow to cure prior to final paint.

Learjet

STRUCTURAL REPAIR MANUAL


WING ASSEMBLY

REPAIR

Wing
Station

000

ii i~

~I

u.

Wheel Well

101

Wing Leading
Edge

IC

At
Wing
Station

t,

53.04

1
(Lower Wing

a,,

9dn

Covers and

St)BP

Sppy 45

Spar Y3

Spar ~I
Wing Spar Access

MBD

Spar 42

~nr

46

617

Spar 48

Openings
MP VIEW OF LH WMG

RH WING OPPOSITE

WING FUEL TANK ACCESS (TYPICAL)

Replacement of Upper Wing Skin Fasteners


Figure

EFFECTIVITY:

ALL

(Sheet 2 of 4)

201

NOTE: Please

SRM-4

"C~

see

the

57-00-00

TEMPORARY

Page 205

REVISION

Jan 15/93

that revises this page.

Learjet
STRUCTURAL REPAIR MANUAL
WING ASSEMBLY

Existing Fasteners (Do not Remove)


Existing Huck Bolts (Rework holes per

Replacement

Fastener Table

as

(2 Pls)
Spar #4

Spar #3

required)

b~

Spar iY~

Wing Leading
Edge

(1 Pi))
-I

(9 Pie)

(1 PI)

V
(2PLs)

Pls)

(21Pls)
9

(1P1)

Spar Y1

REPAIR

(f

Pls)
i"

I"

WY
A

~J

15

(8 P1s)

t
n Wu
IJ
8
a

17 Pie)

(6 Pls)

(10 Pie)
10
INBD

Pls)

Upper Wing

aFWD

See NOTES

Skin

on

(7

Sheet 4.

(10 Pie)

Pls

REPLACEMENT FASTENER TABLE


Bolt

Qty

PerA/C
t"

(1/640.8.)

M521012-3

172
8

INAS15D3-6

-3
-3

-2
-2

-6

MS21042-3
M521042-3
MS21012-3

NAS1243-5

-3

-2

12

~1

104

1000

100"

Use ExlstinP: Csk

-3

Replaced Bolt
P/N (Rei)

Instl Csk Size


381 Ma
381 Dia

AN960PD10

1042-4

-112

Instl Hole
Size

I MSZ 104 2-3_L ANS60 PD10


MSL1042-4
MS2104

4
20
20

$B

Washer

Nut

se

1 Huck P/N B100I Huck P/N B100-TB

Exi

Csk IHuck
Huck
Csk
Use
Csk IHuck
Use Exi
Use Existing Csk I Huck
Use Existing Csk

-2

P/N B100P/N B100-Tg


P
B100-Tg
B100-TB
P
P/N B100-T8

Next Ovarslee
(1/32 0. S.

NAS1253-8I~
NAS1253-5

Detail A
Replacement of Upper Wing Skin Fasteners
Figure 201 (Sheet 2 of 4)
NOTE: Please
EFFECTIVITY:

ALL

see

the

TEMPORARY

I- Y~"

REVISION

that revises this page.

57-00-00

Page 206
En 15/93

Learjet

STRUCIURAL REPAIR MANUAL


WING ASSEMBLY- REPAIR

Spar

iY5

5par

Fasteners (Do not Remove)


Existing Huck Bolts (RewoFk holes
Replacement Fastener Table as required)

gnitsixErep

I~

SkinUpper Wing

~s

S~ar 17

Spar

(2P1s)

!4P1s)

(4 Pls)

Ei

1:::

:ti.

i.

\L

1(4 Pie)!

(4 Pie)

53.04

1rt.L~i _t1~E

tP;

18

II

I-

(8 Pls)

s)ul

(6 P19)

(6 PLs)

~NeD

-I9

I-

(6 Pls)

(10 Pls),

See NOTES

on

FwD

Sheet 4

REPLACEMENT FASTENER TABLE

8ty

Symbol
t~

Instl tlole

Bolt

A/C1/64

Per

0. S.

112
8
4
20
20

-112
N

12

104

_ta

NAS1243-6
NAS1243-5

Nut

Washer

Size

Instl Csk Size

MSa1042-3
MSL1042-3
MSLla92-4
1042-4

10
ANgGO
AN960PD10
-3

Use

-3

Use

M521042-4
MS21042-3
2-3
MS21
MS21042-3
M521042-3

-3
-2

-2

-2
-2

381 Dia

100

100"

Replaced Bolt
P/N (Rel)

Next Oversize
(1/32 0. S.

00-

Csk IHuck P

B100-TB

Csk I Iluck P
C
P
Csk IHuck P
Use Exl
Use Existing Csk( Huck P

B100-TB

AS1

100Use Exi

B100-T6
B100-T8
B100-T8

NAS1
NAS1
NASI
NAS1253-5

Detail B
Replacement of Upper Wing Skin Fasteners
Figure 201 (Sheet 3 of 4)
NOTE: Please
EFFECTIVITY:
SRM-4

ALL

see

the

TEMPORARY
REVISION
that revises this page.

57-00-00

Page

207

Tan 15/93

(Ref)Learjet

STRUCTURAL REPAIR MANUAL


REPAIR

WING AS SEMBLY

Upper

drohCbiR

Rib Web

Wing

(9ef)

Nut

Washer

Station

53.04

ct~t111

(Ref)

The grip length for any one fastener may vary from one
unit to the next due to material thickness variance as a resuit of shimming and

Bolt

It is

i/

thanshown.

(Ref)

to

grip length

use one

shorter

or

longer

Inspect

fillet seal for

remove

and

(Ref)
Seal

Skin Panel Stiffener


or

permissible

damage or breaks. If it is damaged,


replace seal. If seal is not damaged, apply an
additional layer of sealant over existing fillet seal.

Stiffener to
Chord Bracket

sealing during manufacturing.

(Ref)

J*;

Soar (Typical)(Ref)

----JI

Skin

(Ref)Uper

over

all

replaced fasteners and nuts.

Wing
BACB30LU bolts may be used

as

alternates

by conforming

withflagnotes.
FASTENER INSTALLATION- TYPICAL
Select bolts to fit holes with

VIEW A-A

r l

If any

I1I

placement,
placed,

ITI
I

one

to 0.030

of the fasteners in any one of the boxes require


all the fasteners contained in that box must be

re-

Optional

re-

at

0.0007 to 0.0012 inch (0.018

to

use

Huck Bolt P/N B100-T6-X blind fastener

this location, providing that the proper installation


tools are available. Assure proper grip and comply with

1+1
I

mm) interference fit.

flag

replace every other fastener within the row and


completion, replace the remaining fasteners within the

note 8 and other

pertinent

instructions. The

factory

Remove and

recommends that

upon
box.

of every other location to assure parts are brought into a


proper shear condition. The screws and nuts must be installed prior to installing Huck Bolts.

screws

and nuts be used

at

minimum

FLAG NOTES

~g
Thefollowingbolts

are

altemateforNAS1243-X.

at

this

NAS1243-XT (Short Thread)

tools

NAS1703-XR

flag

(Long Thread)
NAS1703-X (No Suffix) (Long Thread)
NAS1703T-X (Long Thread)
NAS1703 T-X_R (Long Thread)

are

are

recommends that

and nuts be used at

prior

to

installing Jo-Bolts.

NAS1603 series bolts

nates to NAS1253 series bolts.

Next oversize fastener may be used in the event of


verely damaged hole or for future rework.

It is
ers

repair

made

during manufacturing

as

specified by flag note


(Long Thread)

(Long Thread)

10 instructions.

may be used

as

alter-

may be used

as

alter-

nates to NAS1254 series bolts.

optional to fill and smooth over heads of replaced fasusing ProSeal 890B2 sealant or EC 1751 and allow
to cure prior to final paint.
It is

teners

of

In these instances the bolt diameter must agree


with the actual diameter of the hole and use the grip

length shown,

optional to use Jo-Boit P/N PLT 1006-8-X blind fasten-

at this location

NAS1604 series bolts

a se-

There may be instances where the actual fastener diameter


installed on the aircraft will be different from what is
a

factory

minimum

alternateforNAS1244-~,

(Long Thread)

wing.

of every other location to assure parts are brought into a


proper shear condition. The screws and nuts must be in-

NAS1704T-X

the

instructions. The

pertinent

screws

NAS1244-1(T (Short Thread)


NAS1704-X-R (Long Thread)
NAS1704-X (No Suffix) (Long Thread)
NAS1704T-X-R (Long Thread)

shown because of

10066-X blind fastener

the proper installation


available. Assure proper grip and comply with

note 8 and other

stalled

Thefollowingbolts

to use Jo-Bolt P/N PLT


location, providing that

optional

~g

It is

permissible

to machine

tener heads and fill

recesses

Jo-Bolt

per

stems flush with fas-

flag note

14 instructions.

Replacement of Upper Wing Skin Fasteners


Figure 201 (Sheet 4 of 4)

EFFECTIVITY:
sI~M-a

ALL

NOTE: Please

see

the

TEMPORARY
REVISION
that revises this page.

57-00-00

Page 208
Jan 15/93

STRUCTURAL REPAIR MANUAL


WING ASSEMBLY

REPAIR

interconnect

rWing Tank
Crossflow
Valve

Tip Tank

Def~aef
Valve

Holding

Tank

~lo t or -Drivenaaiii~ijii:

Pump
50-Micron--J

Fue 1

Filter

Wing Tank Flushing Schematic


Figure 202
EFFECTTVITY:

MODEL 23/24/25/35/36SERIES AIRCRAFT

57-00-00

Page
srU~-4

209

Jan 15/93

~Learjet
STRUCTURAL REPAIR MANUAL
WING ASSEMBLY- REPAIR

B.

Lower

Wing Skin Extension Access Cover Installation (Leariet Inst. #2684150-1) (See Figure 203.)
Installation

NOTE:

ers are

procedures

for both LH and RH lower

identical unless otherwise

wing

skin extension

access cov-

specified.

While location of Lower WinP Skin Extension Access Cover Installation #2684150-1
installamay vary (see Detail D), the maximum allowable number of access cover
tions is one per wing extension.

(1) Tools and Equipment


NOTE:

Equivalent substitutes may be used in lieu of the following:


PARTNUMBER

NAME

Countersink (0.339x100")
#19

Drill

USE

MANUFACTURER

Commercially available

Countersink door

Commercially available

Drill holes for

screws

matching nutplates
#30

Drill

Commercially available

Drill holes for rivets

(2) Parts and Materials


NOTE:
NAME

Access Door

Equivalent substitutes may be used in lieu

MANUFACTURER

26&1150-4

Fabricate

2684150-3

NAS1202-3

locally

2024-T3 clad

Fabricate
0.100

Screw (12 ea.)

following:

PARTNUMBER

0.090

Doubler

of the

locally

2024-T3 clad

Commercially available

USE
Closure for

Strengthen
around

Rivet (16 ea.)

4600H-82

MS20426AD4-6

structure

access

hole

Secure door
to lower

Nutplate (12 ea.)

access

hole

assembly
wing surface

STD. Pressed Steel Co.

Secure door

Precision Fasteners Div.

bly to lower wing

Santa Ana, CA

surface

Commercially available

assem-

Secure door to doubler

2684150-1

EFFECTIVITY:

MODEL 35/36SERIES AIRCRAFT

57-00-00

Page 210
SRM-4

Jan 15/93

STRUCTURAL REPAIR MANUAL


WING ASSEMBLY

REPAIR

USE

PART NUMBER

MANUFACTURER

Rivet (28 ea.)

MS20426AD3-6

Commercially available

Attach

Sealant

Pro-Seal 890

Product Research

Seal door

NAME

Corp.

Chemical

5454 San Franado Rd.

to

nutplates

assembly

wing skin

Glendale, CA 91209
Anti-Corrosion Grease

Faying wing skin sur-

Aero Shell #14

face around

(MIL-G-25537)

hole

access

area

to allow for

electrical

bonding for

lighting

strike

protec-

tion.

(3) Repair Procedure: (See Figure 203.)


(a) Fabricate 2684150-4 access door. (See Detail A.)
Fabricate

MATERIAL NOTE:

03) Chemically

access

door out of 0.090

2024-T3 clad aluminum.

treat exterior of door per Fl. Treat interior side per F4-4

except for

portion (mating with doubler) which shall be treated per Fl. (Refer to
Treatment of Structural Materials.)

outer 0.60 inch

Chapter 51,

Protective

(c) Fabricate 2684150-3 doubler. (See Detail B.)


Fabricate doubler out of 0.100

MATERIAL NOTE:
NOTE:

Do not drill

(d) Chemically

screw

2024-T3 clad aluminum.

hole locations in doubler at this time.

treat doubler per F4-4

except apply

Fl to the

area

where doubler mates with

wing

skin.

(e)
(f)

Lay out and mark position of door on wing lower surface. (See Detail D.)
Using access door as a template, mark outline of door on wing surface. (See Detail D.)
NOTE:

Final trim
access

access

opening

to obtain

0.050 inch maximum gap between door and

opening.

(g) Clamp door at center of doubler.


of door to edge of doubler.

Ensure that 0.62 inch

edge margin is maintained

(h) Drill 14 #30 (0.1285) diameter holes for rivets. Cleco holes

as

drilling

from

edge

progresses. (See Detail

C.)
(i)

EFFECTNITY:

Remove door hom doubler and deburr holes. Countersink holes in door for rivets.

MODEL 35/36 SERIES AIRCRAFT

57-00-00

Page 211
SRM~

Tan 15/93

Learjet
LearjeC

STRUCTURAL REPAIR MANUAL


WING AS SEMBLY

REPAIR

door to doubler using MS20426AD4-6 rivets wet with sealer. (See Detail C.)
(k) Epoxy primer and paint door exterior to match as required.
(1) Raise door and doubler up through access opening and then lower into place so that door is

(j)

Attach

access

properly aligned

with cutout.

(m) Drill 12 #19 (0.166) diameter holes

through wing skin and doubler.

Cleco each hole

as

drilling

progresses. (See Detail E.)


(n) Remove door and doubler from wing. Deburr holes and finish per Fl. (Refer to 51-30-04.)
(O) Drill #30 (0.1285) diameter holes, drill holes for rivets securing nutplates to doubler.
(p) Attach nutplates on doubler using MS20426AD3-4 rivets. Ensure nutplates align with holes
drilled in step (n). Fay seal nutplates with Pro-Seal 890 Class B 1/2 sealant.

(q)

Countersink and deburr holes in

wing skin. Epoxy primer and paint wing skin to match as re-

quired.
(r) Apply

light coating

of corrosion

the interior skin surface


CAUTION:

only.

preservative

per MIL-G-25537 around

access

opening

on

(See Detail E.)

TAKE PRECAUTION TO PREVENT SEALANT FROM EXTRUDING INTO

MATING SURFACES OF WING SKIN AND DOOR ASSEMBLY.

bead of Pro-Seal 890 Class B 1/2 sealant around edge of doubler and reposition
assembly in wing skin. Ensure that door is properly aligned in cutout. (See Detail E.)

(s) Apply
er

cov-

(t) Install screws securing cover assembly to wing skin.


(u) Update all aircraft log books to indicate that Lower Wing Skin Extension Access Cover Installation #2684150-1 has been installed.

(v) Restore aircraft

EFFECTIVITY:

to normal.

MODEL 35/36SERIES AIRCRAF~

57-00-00

Page 212
sRM-4

Jan 15/93

~earjet]
STRU~TURAL REPAIR MANUAL
WING AS SEMBLY

I~

assembly (F4-4) except apply Fl only between door assembly and


wing skin faying surface.

REPAIR

Finish -2 door

Finish exterior of -4 door (F1). Finish interior (F4-4) except apply Fl only within
the indicated 0.60 inch dimension between door and doubler.

No

faying

area

25 37.14

-(~C,.,, fC--4B6

I~
Q

surface finish within indicated

except apply AERO SHELL number


anti-corrosion

1.18

grease

per

MIL-G-

s rM

2.36

--j

Full R

Apply parting agent to wing skin and


assembly with sealant applied to door assembly ledge only. Speciai precaution shall be taken to prevent
sealant from extruding into the mating
surface of the wing skin and assembly.

(TYP)2684150-4~

install -2 door

Seal in accordance with

lined in

procedures
Chapter 51, Sealing Metal.

Door

Detai IA

out2.00

6.50

--li-

0.60

4.00

o.lao

26841503
Doubler
i

SVM

Ar"l
--li~-

.040

Section A

FullR

(Typ)

,i,

Detail B
Repro

EFFECTIVITY:

Lower

Wing Skin Extension Access Cover Repair


Figure 203 (Sheet 1 of 4)

MODEL35/36 SERIES AIRCRAFT

57-00-00

Page 213
SRM-4

Tan 15/93

Learjet
LearjetJ

STRUCTURAL REPAIR MANUAL


WING ASSEMBLY- REPAIR

2684150-3
Doubler

0.38 Const.

0.62

~W_L
Section B

(~*P-I

2.50
ZC)

4
1(~I
Maces)

MS20426AD4-6 Rivet

NAS1202-3 Screw

(12 Places)
//h//

C/

;e;;

s~:-

Jr

~"I
0.62

(ReD

~:o:

\J

+It

2684150-4
Door

-I-

2684150-3
Doubler

2684150-2
Access Cover

Assembly

Detail C
Repro

EFFECTIVITY:

Lower

Wing Skin Extension Access Cover Repair


Figure 203 (Sheet 2 of 4)

MODEL 35/36SERIES AIRCRAFT

57-00-00

Page 214
SRM-4

Tan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


WING ASSEMBLY -REPAZR

9~uS.w.s
Spar#l
Existing Access
Cover CTyp)
I-

Al~ernate

26~

access cover

locations (4 places)
Spar 6 and 7 -1
Installation shown below

Spar #2
Sp" 3
Spar #4
-Sp" #5
5~ (-~j]
Spar #6
SEE BUOW
Spar #7
L-)
--Spar #8

FwD

1
OUTED

""Ic~l;

DIMENSION X

LOCATION

Spar 1 and2 1 3.00 inches from spar 2 rivet centerline


Between Spar 3 and 4 3.15 inches from spar 4 rivet centerline
Between Spar 5 and 6 1 3.15 inches from spar 5 rivet centerline
Between

O
i-J I

Between

2.70 inches from spar 6 rivet centerline

j Lt

~1--

il(i/

-1~

~t -k

ii\

Spar 6 and 7

as required to match -2 cover assembly.


Reference Detail E, Section C-C for maximum gap.

Cutout

Lower

0.65 inch

Wing Skin

)feR(~)fuot c

CTypical around

FWD

Spar~
(Ren

(VIEW LOOKING DOWN ON LOWER SKIN)

INBD

_I

Detail D
Repro

EFFECTIVITY:

Lower

Wing Skin Extension Access Cover Repair


Figure 203 (Sheet 3 of 4)

MODEL 35/36 SERIES AIRCRAFT

57-00-00

Page 215
SRM-4

Jan 15/93

STRUCTURAL REPAIR MANUAL


WING ASSEMBLY

REPAIR

No. 19 (0.166) Dia.

Hole (thru 3 and skin)


CSK 1000

Spar6

0-,

(ReD

(12

0.310/0.320 Dia.

places)

~Ii
i-i

I!
-I_j j
_L

II

*00
Access Cover

(II

Assembly

(ReD

gOi

Lower

Wing

skin (ReD

ii
-:-I

I I-:-

Spar

(ReD
2684150-4
Door (ReO

FWD

INBD

~i_

0.050 Max

(Typ)

F
0.65

1
Lower

Wing

skin (Ref)

Section C

(VIEW LOOKING DOWN ON LOWER

SKIN)

Detai IE
Repro

EFFECTIVITY:

Lower

Wing Skin Extension Access Cover Repair


Figure 203 (Sheet 4 of 4)

MODEL 35/36SERIES AIRCRAFT

57-00-00

Page 216
Jan 15/93

Learjetl
STRUCTURAL REPAIR MANUAL
WING ASSEMBLY- REPAIR

C.

Spar #1 Repair
Figure 204.)
NOTE:

Access Panel Installation (Leariet Inst. #12235-021-1 TLHI and 12235-021-2 TRHI)

Installation

procedures for
specified.

both LH and RH spar #1

repair

access

panels

are

identical

(See

un-

less otherwise

(1) Tools and


NOTE:
NAME

Equipment

Equivalent substitutes may be used in lieu of the following:


PART NUMBER

Countersink (100")
Drill

#19

MANUFACTURER

USE

Commercially available

Countersink doubler

Commercially available

Drill cover, doubler and

Spar
Drill

#30

Commercially available

Drill rivet holes

(2) Parts and Materials


NOTE:
NAME

Equivalent substitutes may be used in lieu


PARTNUMBER

Doubler

12235-021-4

12235-021-5

Fabricate

NAS220-8

Nutplate (13 ea.)

M14600H82

locally

USE

Repair access panel

2024-T3 clad

Fabricate
0.063

Screw (12 ea.)

following:

MANUFACTURER

0.080

Cover

of the

locally

Repair access panel

2024-T3 clad

Commercially available

Secure

cover

to spar

Standard Pressed Steel Co.

Secure

cover

to

spar

Jenkintown, PA
Rivet (10 ea.)

CSR902B

Commercially available

Secure doubler to spar

Rivet (26 ea.)

MS20426AD3

Commercially available

Secure

Rivet (7 ea.)

MS20470AD5

Commercially available

Secure doubler and stiffener

890 Class B 1/2

Pro-Seal

nutplates to cover

to

spar

Products Research

Seal

Chemical

doubler

Corp.

nutplates and

5454 San Franado Rd.

Glendale, CA 91209
1223s-o21

EFFECTIVITY:

ALL

57-00-00

Page 217
SRM-4

Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


WING ASSEMBLY

REPAIR

(3) Repair Procedure: (See Figure 204.)


(a) Remove applicable wing outboard leading edge. (Refer

to the basic

Learjet maintenance man-

ual.)

(b) Locate and cut access panel hole in spar 1 web. (See Detail A.)
(c) Chemically treat reworked area for corrosion and touch-up exterior surface with primer.
(d) Carefully remove stiffener from aft side of spar and retain for reinstallation.
(e) Fabricate 12235-021-5 cover. (See Detail B.)
MATERIAL NOTE:

(f)

Fabricate 12235-021-5

cover

out of 0.063 inch 2024-T3 clad aluminum.

Fabricate 12235-021-4 doubler. (See DetailC.) Do not drill


MATERIAL NOTE:

screw

holes in doubler at this time.

Fabricate 12235-021-4 doubler out of 0.080 inch 2024-T3 clad aluminum.

(g) Epoxy prime cover and doubler, and identify for future reference.
(h) Drill #19 (0.166) diameter hole in

center of

cover.

Drill No. 40 (0.09375) diameter holes for

nutplate rivets and install M14600H82 nutplate to cover with MS20470AD3 rivets.
(i) Install an NAS220-8 screw in nutplate. Screw is used as an installation aid to help in holding
cover in position while marking holes and installing cover.
(j) Position cover over access panel hole cutout, providing maximum edge distance obtainable.
Locate and mark 12 hole locations

(k)
(1)
(m)
(n)
(O)

Remove

cover

on spar.
and check hole locations for

minimum

edge distance of 0.200 inch.

on aft side of spar and locate 10 holes. (See Detail A.)


Drill 10 #19 (0.166) diameter holes through spar and doubler.

Position doubler

Remove doubler and countersink ah side of 10 holes drilled in

step (1).

remaining holes for rivets in doubler common to spar.


(p) Apply Pro-Seal 890 Class B 1/2 sealant to doubler and spar mating surfaces. Position doubler
on spar and secure in place, at 12 locations, using CSR902B rivets. (See Detail A.)
(q) Apply Pro-Seal 890 Class B 1/2 sealant to stiffener (previously removed) and doubler mating
surfaces. Position stiffener on doubler and secure in place, at 4 locations, using MS20470AD5
rivets. Install MS20470AD5 rivets at 3 remaining locations through doubler and spar. (See DeDrill

tail A.)

O) Attach M14600H82 nutplates


with holes drilled in

(s)

(t)
(u)
(v)
(w)

using MS20426AD3 rivets. Ensure that nutplates align


nutplates with Pro-Seal 890 Class B 1/2 sealant.
Pro-Seal 890 Class B 1/2 sealant around edge of cover

on cover

seal

step(m). Fay
parting agent and a bead of
(refer to Chapter 51) to form a seal.
Install cover on spar using NAS220-8 screws.
Remove screw from center nutplate of cover.
Install wing outboard leading edge. (Refer to the basic Learjet maintenance manual.)
Update all aircraft log books to indicate that Szlar #1 Ret~air Access Panel InsfaIl~tion
Apply

#12235-

021-1 (LH)I-2 (RH) has been installed.

(x) Restore aircraft

EFFECTIVITY:

ALL

to normal.

57-00-00

Page 218
SRM~

Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


WING ASSEMBLY

REPAIR

~Spar

1 Web (ReB

Cover

Doubler

Center cutout in spar web

W.S.

No. 19 (0.166 dia. hole)

181.10

M14600H82

(Ref)

MS20426AD3 Rivets

10

Nutplate

equally spaced

No. 19 (0.166)

holes thru spar and doubler

lc0.28
I

0.70,

--I-~
~--csn902B

1_7i

1- II

Rivet (10

III

(Typical)

I -1I

fr;

Fls~;

MS20470AD5

I,

Rivet (7

t-

1-

2.60

places)

._IL~.

places)

1.48

Spar 1

0.45 Radius

Web (Ref)

(2 Places)
UP

(VIEW LOOKING AFT)

t,~,

(RH SHOWN, LH OPPOSITE)

Detail A
Repro

EFFECTIVITY:

Spar #1 Repair Access Panel Installation Repair


Figure 204 (Sheet 1 of 2)
ALL

57-00-00

Page 219
SRM-4

Tan 15/93

Learjet
~Learjet]
STRUCTURAL REPAIR MANUAL
WING ASSEMBLY

REPAIR

NOTES:

I~

Seal

nutplates and

890 Class B

doubler

using Pro-Seal

1/2.

Apply fay seal to cover using parting


agent at installation

I~

to affect

Use Pro-Seal 890 Class B 1/2

a cover

on

seal.

all contact

surfaces.

0.80

;-~JLriL*r

(4 Places

30"

(4 Places)

0.50

0.85 Radius

(4 Places)

(2 Places)

-~---o
0.65

Typical

12235-021-5
Cover

Detail B

2.60-

5.80-I

I
t~-1.22

2.45

i-1
12235-021-4
Doubler

Detail C
Spar

Repro

EFFECTIVITY:

ALL

#1

Repair Access Panel Installation Repair


Figure 204 (Sheet 2 of 2)
57-00-00

Page 220
SRMII

Jan 15/93

Learjet
~Learjetl
STRUCTURAL REPAIR MANUAL
WING- STRUCTURAL IDENTImCATION
i.

DESCRIPTION
NOTE

The

the

following structural data covers the basic non-modified aircraft. When applicable, refer to
appropriate kit drawing for additions, modifications and changes to the structural compo-

nents and assemblies.

A.

The

wing assemly

consists of the

leading edge assembly and wing box section, tip

tanks

or

winglets,

ailerons, flaps, and spoilers.


B.

Repair indexes are incorporated

C.

Allowable

D.

damage
Type of Construction
(1) The wing is a fully cantilevered single unit consisting of the leading edge, wing box section, ailerons, flaps, spoilers, and tip tanks or winglets. The multicellular-type wing structure consists of
spars and ribs in each wing half. The upper and lower wing skins are taper-milled so the trailing
edge is thinner than the leading edge. Splice plates join the wing skin halves at the aircraft centerline. The flaps, ailerons, and spoilers are constructed primarily of spars, transverse ribs, and
skins. On Model 28/29/31 Series Aircraft, the winglets are built in two sections. The inboard section
is conventional built-up construction and the outboard section is a bonded assembly consisting of
aluminum skins and a full-depth aluminum honeycomb core.

EFFECI~IVITY:
sRM-4

respective section for the specific components.


component are given in each respective section.

in each

limits for each

ALL

57-11-00

Page 1
May 15/92

Leariet
~Learietl
STRUCTURAL REPAIR MANUAL
WING- STRUCTURAL IDENTIIFICATION

\i

ii

\I

no

ci;

II

IL_~---;1

L_~-----

II

I
I,

.O

II

II

-[O

1~
,i

II
it

I,

IUI

(ii

11

16

II)

13

~Y

II

si

456(3

EFFEC~IVITY:
srec4

~2

Wing Repair Index


Figure 1 (Sheet 1 of 22)
MODEL 23/24/25 SERIES AIRCRAFT

la

57-11-10

Page 1
May 15/92

j~

Leariet

STRUCTURAL REPAIR MANUAL


ITEM
NO.

DWG.
NO.
2320000
2420000

2520000
2320000

2420000
2520000
1

2322044

IFINISH
GAGE

Wing Assembly
Wing Assembly
Wing Assembly
Wing Structural Assy., LH
Wing Structural Assy., LH
Wing Structural Assy., LH
Splice Instl., Spar No.l

6 RH

80

8 RH

81

8 RH

82
1

2024-T42 Clad

0.125

F4-6

2024-T42 Clad

0.125

F4-6

2024-T42 Clad

0.080

F4-6

2024-T42 Clad

0.080

F4-6

2322044

2024-T3 Clad

0.080

F4-6

2322044

Attach

2024-T42 Clad

0.063

F4-6

2024-T42 Clad
2024-T42 Clad

0.080

F4-6

0.080

F4-6

2322080
2322080

2322080
2322080
2322080
2322080

2322080
2322100
2322100
2322100

Angle

Splice Angle, Lower


Splice Angle, Upper
Spar Assy., No. 2 Inboard
Spar Cap, Lower
Spar Cap, Upper
Doubler(2 ea.)

Web

Doubler(2 ea.)
Angle(3 ea.)
Spar Assy., No. 3 Inboard
SparCap, Upper
Spar Cap, Lower

S-622

F4-4

S-623

F4-4

2024-T3 Clad

0.080

2024-T3 Clad

0.080

F4-4

2024-T3 Clad

0.063

F4-4

S512

S-527

S-526

Doubler

2024-T3 Clad

0.100

2024-T3 Clad

0.080

2322100

Angle(5 ea.)

S-512

2322100

Bracket

S-608

2322100

Cover

2024-T3 Clad

0.080
0.080

No. 4 Inboard

Web

2024-T3 Clad

2322120

S-525

2322120

Spar Cap, Upper


Spar Cap, Lower

S-524

2322120

Doubler

2024-T3 Clad

2322120

Stiffener(7ea,)

S-512

S-571

2322140

Replace
Replace
Replace
Replace
Replace

Replace
Replace

inboard

Replace
Replace
Replace
Replace
Replace
Replace

0.063

I
I

F4;4
F4-4

2322140

Web

2024-T3 Clad

0.100

2322140

Filler

2024-T3 Clad

0.125

2322142

S-535

2024-T3 Clad

2322146

Spar Cap, Lower


Access Cover (2 ea.)
Fitting, Forward Main Gear

2322141

Spar Cap, Upper

2322140

F4-4

2322120

Stiffener(7 ea.)
Spar Assy., No. 5

F4-4

Web

2322120

Replace
Replace
Replace
Replace
Replace
Replace

2322100

Spat Assy.,

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

1
1

2322100

2322120

REPAIR

CODE i FIG. NO.

Angle, Lower
Angle, Upper
Angle, Lower
Filler, Upper 8 Lower

2322044

I
MATERIAL

2322044

2322044

I
EFF.

Angle, Upper

2322044

I
DESCRIPTION

2322044
2322044

SS34

Replace
Replace
Replace
Replace

0.100

51-71-00

Replace

Wing Repair Index


Figure 1 (Sheet 2 of 22)
EFFEC~:
SRM~

MODBL211241255ERIES~URCR*FT

6?-1110

Page 2
May 15/92

C.:

Leariet
STRUCTURAL REPAIR MANUAL
ITEM

NO.
6

DWG.
NO.

I
DESCRIPTION

2322203

2322203

Spar Assy., No.

7 Inboard

SparCap, Upper
Spar Cap, Lower

2322203

IFINISH
GAGE

2024-T3 Clad

I S-516

S-517

Doubler

2024-T42 Clad

0.080

2322203

Cover(2 ea.)

2024-T3 Clad

0.080

2322203

Doubler

2024-T42 Clad

0.080

2322203

Filler

2024-T3 Clad

0.160

2322203

Support Assy.
Support, Upper

1
0.080

2322203

2024-T42 Clad

Phenolic

2024-T42 Clad

2024-T42 Clad

2322204

Support, Clamp
Angle, Reinforcing (2 ea.)
Support, Main Gear

2322207

Bracket, Switch

2024-T3 Clad

0.063

2322203

Cover

2024-T3 Clad

0.100

0.080 1

2322203
2322203

2322203

Support Assy., Lower

RH

2024-T42 Clad

2322203

Fairlead

Phenolic

1/8

2322212

Clip
1
Spar Assy., No.
Stop

2024-T42

0.080

S-614

Cover Plate

2024-T3 Clad

0.100

2322212

Spar Web, Inboard

2024-T3 Clad

0.090

S-512

S-512

Stiffener(5ea.)
Stiffenar

Stiffener(5ea.)

10
1

2024-T3 Clad

0.125

2322212

Plate

2024-T3 Clad

0.125

2322212

Plate

2024-T3 Clad

0.063

2322212

Doubler

2024-T3 Clad

0.100

2322212

Web, Outboard

2024-T3

S-518

S-519

2322221
2322222
2441007

I Replace

51-71-00

51-71-00

Replace
Replace

I Replace

1
1
1

S-571

Filler

2422551

Replace

2322212

2422551

2322212

2322212

1
1

2322212

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2322212

0.100

Support

0.063

2322212

3/16

2322203

2322212

REPAIR
FIG. NO.

CODE

0.100

2322203

2322203

I
MATERIAL

Web

2322203

I
EFF.

Spar Cap, Upper


Spar Cap, Lower
Aft Support, Gear
Bearing Plate
Bearing Plate

Act. Pin

0.084

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2024-T4 Plate

0.063 1

11

2024-T4 Clad

0.250

F4-1

51-71-00

12

2024-T3 Clad

0.312

F4-1

51-71-00

51-71-00

Wing Repair Index


Figure 1 (Sheet 3 of 22)
EFFECTIVITY:
SRM-4

MODEL 23/24/25 SERIES AIRCRAFT

57-11-10

Page 3
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

2622230

2322230
2322230
2322230
2322230

2322230
2322230
2322238
2322238

Rib

Assy.
Stiffener(lO ea.)
Filler(G ea.)
Rib Cap, Upper
Support
Attach Angle
Rib Cap, Lower
Attach Angle (4 ea.)
Attach Angle

S-512

2024-T3 Clad

S-599

2024-T42

S-603

S-600

I
I
I

I
I

I
I

1
1

I
I

I
1
1
1
1

I
I
I

1
1

I
I

1
1

I
I

I
I

1
1

I Replace

1
0.050

1
I

2024-T42 Clad

0.080
0.080

S-520

2024-T42 Clad

0.040

2622230

Web

2024-T3 Clad

0.080

2322016

Strip
Strip
Angle
Strip

2024-T3 Clad

0.063

2024-T3 Clad

0.063

2024-T42 Clad

0.063

2024-T3 Clad

0.063

S-603

2322063
2622230

2322293

Attach

Rib

Angle

Assy

Web

2024-T3 Clad

0.063

2322293

Filler

2024-T3 Clad

0.080

2322293

Rib

S-502

S-502

2322293

Cap, Upper
Cap, Lower
Attach Angle (4 ea.)

Rib

2024-T42 Clad

0.080

2322293

Filler

2024-T3 Clad

0.080

S-512

I
1

2322293

Stiffener
Rib

2322290

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2322293

2322293

FIG. NO.

0.100

2024-T42 Clad

2322018

REPAIR

CODE

Bracket
Bracket

(FINISH
GAGE

13

BracketAssy
1

MATERIAL

2627014

2322017

10

I
EFF.

2327014
2627014

I
DESCRIPTION

I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace

2322290

Segment Assy
Tee(2 ea.)

S-596

2322290

Web

2024-T42 Clad

0.100

2322290

Gusset

2024-T3 Clad

0.063

I
I

I Replace

1
1

I
I

2322290

Stiffener

S-571

2322290

Tee

5-569

1
1

2322290

Rib

Replace
Replace
Replace
Replace

2322290

Segment Assy
Tee(2 ea.)

S-596

2322290

Web

2024-T42 Clad

0.100

2322290

Angle

2024-T42 Clad

0.100

S-571

I
j

I Replace

2322290
2322290

Stiffener

Rib

Segment Assy

2322290

Tee

S-596

2322290

Tee

S-597

2322290

Tee

S-598

1
1

2024-T3 Clad

2322290

Replace
Replace
Replace

Filler

0.160

I Replace
I Replace
I

Replace

Wing Repair Index


Figure 1 (Sheet 4 of 22)
EFFECTIVITY:
SRM~

MODEL 23/24/25 SERIES AIRCRAFT

57-11-10

Page 4
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
DWG.
NO.

ITEM

NO.

2024-T42 Clad

S-642
Phenolic

2322290

Fairlead

2322290

Rib

Segment Assy.
I

Web

Tee(2 ea.)
Fitting
Fitting
Fitting

2322275
2322281
2322282

0.125

S-596

201 4-T6

F4-1

51-71-00

201 4-T6

F4-1

51-71-00

201 4-T6

F4-1

Replace

2025-T3 Clad

2322291

Fitting
Fitting
Rib Assy., WS
1
Filler(5 ea.)

201 4-T6

F4-4

201 4-T6

F4-4

2322320
2322320
2322320

53.04

0.100 1

51-71-00
1

51-71-00

Replace
Replace

1
1

2024-T3 Clad

0.160

Filler

2024-T3 Clad

0.125

Spar Tie Angle (12 ea.)

2024-T42 Clad

0.080

Phenolic

2024-T3 Clad

S-592

S-592

6061-T6 Clad

Fairlead

2322320

Replace

2024-T42 Clad

Filler

2322320

Replace
Replace
Replace
Replace
Replace

2322287
2322292

1~

3/16

1
1

I
I
I

0.080

I
I
I
I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2322320

Web, Forward

2322321

Rib

2322321

Rib

2322322

Bracket

2422549

Fairlead(2 ea.)
Stiffener(2 ea.)

Phenolic

S-571

Web

2024-T3 Clad

0.160

I
1
1
I
1

Phenolic

0.188

2024-T42 Clad

0.071

2024-T42 Clad

0.071

1
1

I
I

Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace

2322320
2322320

1 2322330
2322330
2322330

2322330

Cap, Upper
Cap, Lower

Rib Instl., WS 92.52


Fairlead

Angle(2 ea.)
Rib Segment (7 ea.)

0.063

1~

0.125

Riblnstl., WS 125.00

Angle
Angle (2 ea.)

16

2024-T42 Clad

0.071

F4-4

2322340

2024-T42 Clad

0.071

F4-4

2322340

Rib

2024-T42 Clad

0.071

2322330

Fairlead

Phenolic

0.188

Bracket

1 2322340
2322340

S-150-1
14

0.125

0.125

2322290

13

0.125

Phenolic

FIG. NO.

0.080

Phenolic

15

Web

REPAIR

CODE

I
I
I
I
I

14

Fairlead
Tee

IFINISH
GAGE

Fairlead

2322290

12

I
MATERIAL

2422549
2322290

I
EFF.

2422290
2322290

11

I
DESCRIPTION

2322350
2322350

2322350
2322350
2322350
2322350

Segment (7 ea.)

IRiblnstl., WS 157.48
Rib Segment (3 ea.)

Angle
Angle
Angle (2 ea.)
Rib Segment (4 ea.)

F4-4

1
I

1
1

2024-T42 Clad

0.080

F4-4

17

2024-T42 Clad

0.071

F4-4

18

2024-T42 Clad

0.071

F4-4

2024-T42 Clad

0.071

F4-4

2024-T42 Clad

0.063

F4-4

Replace
Replace
Replace
Replace
Replace

Wing Repair Index


Figure 1 (Sheet 5 of 22)
EFFECTIVITY:
SRM~

MODEL 23/24/25 SERIES AIRCRAFT

57-11-10

Page 5
May 15/92

Learjet

STRU%TURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

15

2322070
2322070
2322070

2322070
2322070

Spar Assy., No. 1 Outboard


Spar Cap, Upper
Spar Cap, Upper
Spar Cap, Lower
Spar Cap, Lower

I
EFF.

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

MATERIAL

16
19

S-594

20

S-618

1
I

I
I

S-594

F4-4

S-619

F4-4

Web Plate

16

2024-T3 Clad

16

2024-T4 Clad

2322070

Angle (8 ea.)
Angle

16

2024-T42 Clad

2322070

Filler

16

2024-T3 Clad

16

2024-T42 Clad

16

2024-T42 Clad

I
I

2322073
2322250

F4-4

21
21

7075-0 Clad

0.080

F4-4

2322250

Angle

21

2024-T42 Clad

0.080

F4-4

2322070

Attach

21

2024-T42 Clad

0.064

F4-4

21

S-571

2322564

2322564
2322564

2322264

Outboard

Angle

2322264

22
24

7075-T6 Clad

0.080

F4-4

25

2024-T3 Clad

0.080

F4-4

22

2024-T42 Clad

0.064

F4-1

22

2024-T42 Clad

0.080

F4-1

Angle
BracketAssy.

22

2322264
2322264

Bracket

2024-T42 Clad

2322250

2322264
2322264

1 2322090

23

Bracket, Inbd 8 Outbd

2322257

Stiffener(l2 ea.)
Doubler(2 ea.)
Spar Assy., No. 2 Outboard

2024-T42 Clad

F4-1

0.080

I
F4-1

0.063

S-633

22

S-571

26

2024-T3

0.080

F4-1

2322090

Web Plate

16

2024-T3 Clad

0.050

F4-4

Angle

16

2024-T4 Clad

0.050

F4-4

2322090

Plate

16

2024-T3 Clad

0.050

F4-4

2322090

Angle

16

2024-T6 Clad

0.050

F4-4

16

2024-T42 Clad

0.050

F4-4

2322251
2322251

Attach Angle
Spar Assy., No.
SparWeb
SparWeb
Angle

2 Outboard

7075-T6 Clad

25

2024-T3 Clad

21

2024-T42 Clad

21

S-512

29

2024-T42 Clad

30

2024-T42 Clad

2322257

Angle
Attach Angle
Stiffener(4 ea.)

21

S-571

2322258

Doubler Plate

21

2024-T42 Clad

2322251
2322090

2322090
2322251

Stiffener
Attach

Replace
Replace
Replace
Replace
Replace

21

24

2322251

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

16

2322090

2322090

F4-4
F4-4

0.064

Channel

Angle
Stiffener(G ea.)
Spar Assy., No. 1
Spar
Spar
Angle

Replace
Replace
Replace
Replace

F4-4

0.080

2322250

2322257

I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

F4-4

19

2322070

Connecting Angle
Connecting Angle
Spar Assy., No. 1 Outboard

F4-4

20

2322070

2322073

16

I
DESCRIPTION

F4-4

0.080

F4-4
F4-4

0.080

I
F4-4

0.050

I
0.050

j
F4-4

0.050

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Wing Repair Index


Figure 1 (Sheet 6 of 22)
EFFECTIVITY:

MODEL 23/24/25 SERIES AIRCRAFT

57-11-10

Page
SRM-4

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

Spar Assy., No.


SparWeb
SparWeb
Angle

2322565
2322565
2322565

2322565

2 Outboard

MATERIAL

0.080

F4-4

0.080

F4-4

0.080

F4-4

3-512

2322257

Stiffener

28

S-512

Angle
Stiffener(4 ea.)

22

2024-T42 Clad

22

S-571

Doubler Plate

(9 ea.)

22

2024-T42 Clad

No. 3 Outboard

16

Attach

2322110
2322110
2322110
2322110
2622110
2322252

2322252
2322252
2322257
2622110
2322566
2322566

2322566

2322566
2322257
2622110

SparWeb

Spar Cap, Upper


Spar Cap, Lower
Stiffener(lG ea.)
ClipAngle
Spar Assy., No. 3 Outboard
1
SparWeb
Angle
Stiffener(8 ea.)
ClipAngle
1
Spar Assy., No. 3 Outboard
Spar Web
Spar Web
Angle
Stiffener(l4 ea.)
Clip Angle

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

7075-T6 Clad
2024-T3 Clad

2024-T42 Clad

Spar Assy.,

FIG. NO.

25
27

2322258

REPAIR

CODE

24
22

2322110

IFINISH
GAGE

22

Stiffener

2322257

16

7075-T6 Clad

16

S-510

16

S-511

16

S-512

16

2024-T42 Clad

I
I

I
0.050

F4-4

0.050

F4-4

F4-4

0.080

I
I
I

I
I
I

F4-4

F4-4
F4-4

0.050

21
21

7075-T6 Clad

0.080

F4-4

21

2024-T42 Clad

0.080

F4-4

21

3-571

21

2024-T3 Clad

0.050

F4-4

24

7075-T6 Clad

0.080

F4-4

25

2024-T3 Clad

0.080

F4-4

22

22

2024-T42 Clad

22

S-571

24

2024-T3 Clad

0.050

F4-4

25

2024-T42 Clad

0.080

F4-4

F4-4

0.080

F4-4

2622388

Filler

25

2024-T42 Clad

0.080

F4-4

2622388

Filler

25

2024-T42 Clad

0.100

F4-4

2622376

12322130

2322130
2322130

2322130

2322253

Spar Assy., No. 4 Outboard


Spar Web
Spar Cap, Upper
Spar Cap, Lower
Stiffener

2322130

Attach

Angle

Spar Assy.,

No. 4 Outboard

Channel

2322253

Attach

2322253

Angle
Stiffener(S ea.)

2322253

25

Angle
Filler

2322130

2322253

(4 ea.)

Angle Assy., Spar Attach


1

Angle

Replace
Replace
Replace
Replace

F4-4

Channel

2622376

Replace
Replace
Replace
Replace
Replace

F4-4

2622388

2622376

18

I
EFF.

2322251
2322251

17

I
DESCRIPTION

25

2024-T42 Clad

0.050

25

2024-T3 Clad

0.090

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

16
16

2024-T3 Clad

16

S-513

F4-4

16

S-548

F4-4

16

S-512

F4-4

16

2024-T42 Clad

F4-4

0.080

Replace
Replace
Replace
Replace
Replace

F4-4

0.050

21
21

7075-T6

21

2024-T42 Clad
2024-T42 Clad
S-571

21

21

I
F4-4

0.050
0.080

F4-4

Replace
Replace
Replace
Replace

Wing Repair Index


Figure 1 (Sheet 7 of 22)
EFFECTIVITY:
sRM-4

MOI~EL 23/24/25 SERIES AIRCRAFT

57-11-10

Page 7
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
DWG.
NO.

ITEM

NO.

2322567

SparAssy.,

IFINISH
GAGE

CODE

24

7075-T6

0.080

F4-4

Channel

25

2024-T42

0.050

F4-4

22

2024-T42 Clad

0.050

F4-4

22

2024-T42 Clad

0.050

F4-4

22

S-571

Attach

2322160
2322160

Angle
1

Annle

Stiffener(l5 ea.)
Spar Assy., No. 5 Outboard

2322160
2322160
2322160

2322254
2322254

Spat Cap, Upper


Spar Cap, Lower
Stiffener(S ea.)
Attach Angle
Spar Assy., No. 5 Outboard

2322254

Anale

Stiffener(S ea.)
Angle Angle
Spar Assy., No. 5
Spar
Spar
Attach Angle

2322254

2322568

2322568
2322569
2322160
2322568

Outboard

16

2024-T42

16

S-511

16

S-548

16

S-571

16

2024-T42 Clad

0.050

F4-4

21

7075-T6

0.080

F4-4

21

2024-T42 Clad

0.080

F4-4

21

S-571

21

2024-T42 Clad

23221 70
2322170
2322170
2322255

2322255

F4-4

22

2024-T42 Clad

0.050

F4-4

22

2024-T42 Clad

0.080

F4-4

S-571

2322257
2322170
2322569
2322170
2322569

2322569
2322569
2322257

2024-T3 Clad

6 Outboard

16

16

2024-T42

Spar Cap, Upper


Spar Cap, Lower
Stiffener(lG ea.)
SparAssy., No. 6 Outboard

16

S-514

16

S-515

16

3-512

Channel

Stiffener(S ea.)
Attach Angle
Spar Assy., No. 6
Attach Angle
Attach Angle
Spar
Spar
Stiffener

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.003

F4-4

0.050

F4-4

0.080

F4-4

F4-4

F4-4
F4-4

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

21

1 21

Outboard

F4-4

F4-4

28

Web

I
0.050

0.080

25

2322170

0.080

Shim, Laminated (Max. 0.020)

Spar Assy., No.

F4-4

7075-T6 Clad

2322568

F4-4

2024-T3 Clad

22

2322170

F4-4

25

Stiffener(lS ea.)
Doubler

I
I
I

24

2322567
2322568

F4-4

0.080

I
1
I

22

Angle

21

Channel

2322254

Replace
Replace
Replace
Replace
I Replace

16

Web

2322160

REPAIR
FIG. NO.

22

2322567

2322567

20

No. 4 Outboard

I
MATERIAL

Channel

2322567

I
EFF.

2322567
2322567

19

I
DESCRIPTION

7075-T6

0.080

F4-4

Replace

I Replace

21

S-571

21

2024-T42 Clad

0.050

1"4-4

Replace

31

2024-T42 Clad

0.050

F4-4

32

2024-T42 Clad

0.050

F4-4

24

7075-T6 Clad

0.080

F4-4

25

2024-T3 Clad

0.080

27

S-571

Replace
Replace
Replace
Replace
I Replace
Replace
Replace

22

F4-4

2322388

Doubler Fate

33

2024-T42 Clad

0.050

F4-4

2322032

Doubler

28

2024-T42 Clad

0.090

F4-4

Wing Repair Index


Figure 1 (Sheet 8 of 22)
EFFECTIVITY:
SRM-4

MODEL 23/24/25 SERIESAIRCRAFT

57-11-10

Page 8
May 15/92

Learjet
E~ Learpti
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

21

I
DESCRIPTION

2322205
2322205

Spar Assy., No.


SparWeb

I
EFF.

7 Outboard

I
MATERIAL

IFINISH
GAGE

16
16

2024-T42 Clad
S-531

F4-4

16

S-530

F4-4

2322205

Spar Cap, Upper


Spar Cap, Lower
Stiffener(lS ea.)

16

S-512

F4-4

2322205

Attach

16

2024-T42 Clad

2024-T42/QQ-A-

2322205

2322205

16

Angle

2327001

Bracket

16

2322205

Plate

16
No. 7 Outboard

0.080

F4-4

F4-4

267

0.060

F4-4

2024-T42

0.071

F4-4

Replace
Replace

0.080

F4-4

Replace

2322556

Spar Assy.,
Channel

21

7075-T6 Clad

2322170

Attach

21

2024-T42 Clad

2322567

Stiffener(S ea.)

21

S-571
2024-T42/QQ-A-

21

Angle

F4-4

0.050

2327001

Clip

21

2322256

Angle
Spar Assy., No.
Spar
Spar
Angle
Clip

21

267

2322570
2322570

2322256

2327001

7 Outboard

2322371
22

2322371

1
F4-4

24

7075-T6 Clad

0.080

F4-4

25

2024-T3 Clad

0.080

F4-4

22

2024-T42 Clad

0.050

F4-4

22

2024-T42/QQ-A-

1
I

2322371
2322371
2322373

2322373

2322372
2322372
2322374

2322374
2322374
2322374

16

16

Rib

Web

Cap Assy
Cap, Upper
Rib Cap, Lower
Rib

I
2024-T3 Clad

1
S-787

16

(T42)
(T42)

16

S-787

16

2024-T3 Clad

Replace
Replace
Replace

I
I

I Replace
I Replace

I
1

I
I
I
I

16

I
1

I
I

I
I
I

I
I
I

I
I
I
0.125
0.125

I
2014-T6 Clad

16
16

0.080

2024-T3 Clad

16

1.800

I
2014-T6 Clad

16

1.800

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

17
17

Rib

Replace
Replace

16

Rib

2322374

2322371

S-571

16

2322374

2322371

I
0.050

22

Web

Cap Assy.
Cap, Upper
Rib Cap, Lower
Ring, Clamping (2 ea.)
Filler(2 ea.)
Fitting Assy., Aft
Fitting
Fitting Assy., Fwd
Fitting
IRiblnstl., WS 181.10
Web Assy.

2322371

I Replace

22

Stiffener(l3 ea.)
(Riblnstl., WS 181.10
Web Assy.

2322371

Replace

2024-T3 Clad

267

2322567

Replace
Replace
Replace
Replace
Replace

0.050

2322556

2322570

REPAIR
FIG. NO.

CODE

17

I
2024-T3 Clad

17

17

S-787

17

S-787

(T42)
(T42)

0.080

I
I
I

Replace
Replace
Replace
Replace
Replace

Wing Repair Index


Figure 1 (Sheet 9 of 22)
EFFECTIVITY:
SRM-4

MODEL 23/24/25 SERIES AIRCRAFT

57-11-10

Page 9
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

NO. I

DWG.
NO.

REPAIR
CODE I FIG. NO.

17

2024-T3 Clad

0.125

17

2024-T3 Clad

0.125

1.800

Fitting Assy., Aft


Fitting
Fitting Assy., Fwd
Fitting
Ring Clamping (2 ea.)
Support Instl., Flap Actuator
Bracket Assy.

2322371
2325079
2325079

2325079

17
17

2325079
2325079
2322560

2322560
2322560

Rib

2322560

Assy.,

2322560
2322560

2322560
2322560

Outer

2322560
2322521

Inboard
Rib

2322521

2322521

78

S-534

F4-1

79

)S-5088

F4-1

Replace
Replace

2024-T3 Clad

0.160

F4-1

51-70-00

2024-T42 Clad

0.063

F4-1

2024-T42 Clad

0.063

F4-i

Replace
Replace

2024-T42 Clad

0.090

F4-1

Phenolic

0.188

F4-1

2024-T42 Clad

0.090

F4-1

Phenolic 1~

0.188

F4-1

2024-T42 Clad

0.063

Phenolic

0.188

2024-T42 Clad

0.063

Phenolic Li~

0.188

2024-T42 Clad

2024-T3

Replace
Replace

F4-i

Replace
Replace

Closing

F4-1

Replace
Replace

0.040

F4-1

0.050

F4-1

Replace
Replace

i
16

Bracket Instl., Speed Brake Act.


Bracket Assy., Flap Sector

2322516

Upper

2322516

Bracket

2024-T42 Clad

0.063

F4-1

2322516

Anale

2024-T42 Clad

0.063

F4-1

2024-T42 Clad

0.063

F4-1

2024-T3 Clad

0.063

F4-1

2322516

Support Bracket Assy., Outbd


Support Bracket

2322516

2322516

Replace
Replace

Retainer

2322521

0.160

Rib, Outer
Fairlead, Outboard
Rib Instl., Flap Slot

2322560

1.800

2024-T3 Clad

Rib Assy., Outer

2322560

2014-T6 Clad

Rib, Inner
Fairlead, Outboard

2322560

17

34

Rib, Outer
Fairlead, Inboard
Rib Instl., Outboard Flap
Track Support
Rib Assy., Inner

2322560

Rib, Inner
Fairlead, Inboard

2322560

I
2014-T6 Clad

Fitting, Cylinder Attach


(2 ea.)
Bracket Support, Upper
Bracket Support, Lower
Rib Instl., Inboard Flap
Track Support
Rib Assy., Inner

2325079

Replace
Replace
I Replace
I Replace
I Replace
I Replace
I Replace

I
I

17

Brace, Bracket End


Brace, Bracket End

2325079

27

(FINISH
GAGE

Filler

2322372

26

I
MATERIAL

Clamping Ring (2 ea.)

2322372

25

I
EFF.

2322371

2322373

24

DESCRIPTION

2322374
2322373

23

Doubler

Replace
Replace

Replace
Replace

Wing Repair Index


Figure 1 (Sheet 10 of 22)
EFlFECTrVITY:
SRM-4

MODEL 23/24/25SERIES AIRCRAFT

57-11-10

Page 10
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.
2322516

I
I

I
EFF.

DESCRIPTION

Support Bracket Assy.


Support Bracket

I
MATERIAL

GAGE

IFINISH

REPAIR

CODE

FIG. NO.

Replace
Replace
Replace
Replace

1
1

2024-T42 Clad

0.063

F4-1

2322516

Plate

2024-T42 Clad

0.063

F4-1

2522516

Bracket

2024-T42 Clad

0.063

2322516

Fairlead

Phenolic

2322516

Support Bracket Assy., Inbd


Support Bracket

2322516

3/16

F4-1

2024-T42 Clad

0.063

F4-1

2322516

Doubler

2024-T42

0.080

F4-1

2322516

Door

2024-T42

0.090

F14-1int

2322516

36

2024-T3

0.080

F4-4

2024-T3

0.080

F4-4

37

2024-T3

0.080

F4-4

2322516

Splice Plate (LH Only)


Splice Plate (RH Only)
Doubler(LH Only)
BracketAssy., Support
Bracket, Track Support

2024-T42 Clad

0.063

F4-1

2322516

Plate

2024-T3

0.050

F4-1

2322516

Replace
Replace
Replace

F1 ext

2322516
2322516
2322516

Roller Track

2024-T4

2322516

Bracket, Switch

4130

2322526

LeverAssy, Switch
Weld Assy.

2322516
2322516

Actuator

1. Lever
IStiffener

1
0.050

I
1

I
I

I
I

4130

4130

1~
I~

0.050

F4-1

0.050

F8-1

Plate

38

2024-T3 Clad

0.063

F4-1

2322516

Gussett

39

2024-0 Clad

0.063

F4-1

FittingAssy.
IFittina

S-355

2422513

IBushina

NAS77-4-06

39

2024-0 Clad

0.063

F4-1

39

2024-0

0.063

F4-1

2322513
2322530
2322530

Support Bracket
Support Angle
Bracket Instl., Aileron Hinge
Hinge Bracket Assy., Middle

2322530

Stud

2322530

Hinge Bracket, Middle Inner


Hinge Bracket, Middle Outerl

2322530
2322530
2322530

2322530

2322530
2322530

2322530
2322530

Replace
Replace
Replace
Replace

2422513
2322513

Replace
Replace
Replace
Replace

2322516

2422513

28

2322516

2322516

Replace
Replace
Replace

2024-T42 Clad

2024-T42 Clad

I
I

S-549

2024-T3 Clad

Hinge Arm, Middle


Hinge Bracket Assy., Outbd
Hinge Bracket, Outbd Inner
Hinge Bracket, Outbd Outerl
Arm, Hinge

2024-T4

IAnale
Plate
1

Replace
Replace
Replace
Replace

51-71-00

1
I
1

I
I
I
I

Replace
Replace
Replace
Replace
Replace

0.375 1

51-71-00

51-71-00

1
1

I
I

Replace
Replace

51-71-00

I
I

I
Hex Rod

35

I
I

7/16
0.063
0.063

1
0.090

2024-T42 Clad

0.063

2024-T42 Clad

0.063

2024-T4

Wing Repair Index


Figure 1 (Sheet 11 of 22)
EFFECTTVITY:
SRM4

MODEL 23/24/25 SERIES AIRCRAFT

57-11-10

Page II
May 15/92

Learjet
~Learjetl

STRUCTURAL REPAIR MANUAL


ITEM

NO.

DWG.
NO.

2322530
2322530

2322530
2322550
2322550

Angle,

2322010

2322011

Replace
Replace

51-71-00

Replace

2024-T3 Clad

0.025

I Replace

2024-T3 Clad

0.025

2024-T3 Clad

0.025

I Replace

2024-T3 Clad

0.025

2024-T42 Clad

0.050

2024-T3 Clad

0.090

2024-T42 Clad

0.050

1
1
1

I
I
I

Replace
Replace
Replace
Replace

16

2014-T6

0.128

F4-4

16

0.080

F4-4

I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

i Replace

Support (2 ea.)

Angle
Wing Skin Instl., Upper
Wing Skin

2322550

51-71-00

I
I

Door

2322550

30

Panel

1
j

0.050

Panel

2322550

0.063

PanelAssy.

2322550

0.063

2024-T42 Clad

Panel

2322550

2024-T4 Plate

Panel

2322550

FIG. NO.

PanelAssy.

2322550

REPAIR

CODE

PanelAssy.

2322550

IFINISH
GAGE

Panel

2322550

I
MATERIAL

2024-T42 Clad
2024-T42 Clad

PanelAssy.

2322550

2322550

Rib

2322550

I
EFF.

Hinge Bracket Assy., Inboard


Hinge Bracket, Inbd, Inner
Hinge Bracket, Inbd, Outer
Arm, Hinge
Gap Closure Instl.
Rib Assy.

2322530

29

I
DESCRIPTION

16

16

2322026

Angle
Angle

2014-T6
2024-T6
S548

16

S548

2322042

Filler

16

2024-T3

2322278

IFittina

16

2014-T6

16

S596

40

S612

1
I

17

S612

17

2014-T6

0.250

17

2024-T6

0.080

F4-6

17

2024-T6

0.0801

F4-6

17

S548

F4-4

17

S548

F4-4

17

2024-T3

0.080

F4-4

17

2014-T6

0.080

F4-4

2024-T42

0.063

Replace

2024-T42 Clad

0.050

Replace

2024-T42

0.063

Replace

Doubler

2322012

16

Joint Sheet

2322013
2322025

Support
Angle Support
Wing Skin Instl., Upper
Support
Wing Skin, Upper

2327009
2322010

2322010
2322010

2322028

0.080

F4-4

F4-4
F4-4

0.080

F4-4
F4-4

0.080

I
I

17

I
F4-6ext

Replace
Replace

F4-4int

Joint Sheet, Fwd

2322013
2322025

Joint Sheet, Aft


Angle, Fwd

2322026

Angle,

2322013

Filler

2322042
2322278

IFittina
IBracket

2327038
2327038

41

Bracket

42
43

BracketAssy.
JBracket

41
42

BracketAssy.

2325075
2325075

BracketAssy.

2327038
2327038

Aft

Replace
Replace
Replace
Replace
Replace
Replace

43

Wing Repair Index


Figure 1 (Sheet 12 of 22)

EFFECTTVITY:

MODEL 23/24/25 SERIESAIRCRAFT

57-11-10

Page
SRM~

12

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.
2622030

31

I
DESCRIPTION

Wing Skin Instl.,


Wing Skin

2322031

EFF.

IFINISHI REPAIR
GAGE

MATERIAL

CODE

FIG. NO.

F4 ext

Replace

16

Lower

16

2024-T3

0.180

F4-4int
16

2024-T3

0.080

2322033

Joint Sheet

16

2024-T3 Clad

0.080

F4-6

Stiffener, Lower

2322032

2322033

Joint Sheet

16

2024-T3 Clad

0.080

F4-4

2322042

Filler

16

2024-T3 Clad

0.080

F4-4

2322230

Doubler

16

Assy. (2 ea.)

16

2024-T3 Clad

0.090

F4-4

16

2024-T3 Clad

0.090)

F4-4

2322030

Doubler, Inner
Door, Access
Stiffener(2 ea.)

16

S548

2322030

Cover Plate

57

2024-T3 Clad

0.080

F4-4

2322030

Access Door

2322230
2322030

2322030
2322030
2322259

Door

16

Assy.

Access Door

ISpacer

j Replace
Replace
Replace
Replace

16

2024-T3

0.090

F4-4

16

2024-T3

0.125

F4-4
F4-6ext

Replace
Replace
Replace

16

Assy.

2322031

IDoor

16

2024-T3

0.080

2326015

1. Bracket

16

2024-T3

0.050

Replace
Replace
Replace
Replace
Replace
Replace

F4-4int
2322064
2322064

2322064
2322064
2322064
2322064
2322064
2322064

Door Instl.,
Door

58

Assy.

\Door
IDoubler

1
1

58

)2024-T3

0.0901

F4-4

58

2024-T3

0.090

F4-4

16

2024T3

0.090

F4-4

16

2024-T3

0.090

F4-4

1
1

Is

)2024-T3

0.0901

F4-4

2322064

16

2024-T3

0.090

F4-4

2322064

ISoacer

16

2024-T3

0.080

F4-4

IDoor

16

2024-T3

0.090

F4-4

2322064

IDoubler

58

2024-T3

0.090

F4-4

S160-1

IDoubler

59

2024-T3

0.080)

F4-4

16

2024-T3

0.090

F4-4

16

2024-T3

0.090

F4-4

58

2024-T3

0.080

F4-4

59

2024-T3

0.080

F4-4

2322064
2322064
2322064
157-3
2322064

2322064
157-1

Replace
Replace
Replace

16

DoorAssy.

2322064

2322064

Replace
Replace

16

DoorAssy.
I
1

2322064

Replace
Replace

16

DoorAssy.
IDoor
IDoubler

)Door
IDoubler

2322064

Replace

58

Access

Wing

Door

(2 ea.)
Doubler(2 ea.)
Spacer(G ea.)
ISpacer
Door Assy.
)Door
ISpacer
IDoubler

Replace
Replace
Replace
Replace
Replace
Replace
Replace

59

1
1
1

59

2024-T3

0.090)

F4-4

59

2024-T3

0.080

F4-4

59

2024-T42

0.090

F4-4

Replace
Replace
Replace

Wing Repair Index


Figure 1 (Sheet 13 of 22)

EFFECTIVITY:

MODEL 23/24/25 SERIES AIRCRAFT

57-11-10

Page
SRM-4

13

Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


ITEM
NO.

DWG.
NO.

IDoor

157-7

IDoubler

2322064

1
1

Doubler(2 ea.)
Wing Skin Instl., Lower
Wing Skin

2322029

REPAIR

IFINISH

IGAGE

CODE I FIG. NO.

59

2024-T3

0.090

F4-4

59

2024-T3

0.080

F4-4

59

2024-T42

0.090

F4-4

58

2024-T3

0.090

F4-4

58

2024-T3

0.090

F4-4

58

2024-T3

0.090

F4-4

Replace
Replace
Replace

2024-T3

0.180

F4-6ext

Replace

Replace
Replace
Replace

58

IDoor
ISpacer

2322064
2622030

DoorAssy.

2322064
2322064

Spacer(2 ea.)

2322064

I
MATERIAL

59

DoorAssy.

157-5
2322064

I
EFF.I

DESCRIPTION

17

44

F4-4int

Wing Skin 1~

2322029

45

0.178

2024-T3

Replace

F4 art

F4-4int
46

2024-T3 Clad

0.125

2322042

Filler

17

2024-T3 Clad

0.080

2322261

Doubler Instl., Lower Fwd

17

2322030

SDacer

Replace
Replace

F4-4

2322261

Doubler, Inner

17

2024-T3 Clad

0.090

F4-4

2322033

Joint Sheet

17

2024-T3 Clad

0.080

F4-6

Replace
Replace

2024-T3 Clad

0.080

F4-1

Replace

2024-T3 Clad

0.080

Fl int

Replace

2322562

2322562

Doubler Instl., Lower Aft


Doubler
Door

2322259

17

Instl., Wing Access

47

Door

2322259

17
47

F14-1
2326015

)Bracket

2422110

47

2024-T42

0.050)

F4-1

Replace

F3

Replace
Replace

48

Assy. Instl.
DoorAssy.
Door

2422110

48
48

2024-T4

2326015

Boss, Fuel Probe


IBracket

48

/2024-T42

0.050

2422112

48
48

2024-T3

0.125

F4-4

Replace

48

2024-T4

0.375

F4-4

Replace

49

2024-T3

0.160

F4-4

49

2024-T42

0.050

F4-4

Replace
Replace

44

2024-T3 Clad

0.080

F4-4

44

2024-T42

0.050

F4-4

Replace
Replace

2024-T3 Clad

0.090

F4-4

Replace

2422111

Door Assv.

2422112

~Door

2422112

I~Plate

Assy. Instl.
DoorAssy.

2422114
2326015

IDoor
IBracket
Door

2322259
2322259
2326015

49

1
1

Assy.

44

Door
1
JBracket

1
1

DoorAssy.

2322259

2322259

49

Door

2422114

2422113

2322259

2322259

44

Door
Door

2322259

Assy. (5 ea.)

Door

Door

44
50

50

2024-T3 Clad

0.080

51

2024-T3 Clad

0.080

1
1

I
I

Replace
Replace

Wing Repair Index


Figure 1 (Sheet 14 of 22)
EFFECTIVITY:

MODEL 23/24/25 SERIES AIRCRAF~

57-11-10

Page
sr(M-4

14

Jan 15/93

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

2322259

2322259
2422102

52

2024-T3 Clad

0.080

53

2024-T3 Clad

0.080

Door

54

2024-T3 Clad

0.080

Cover

2622386

Instl., Access Holes

Probe
2422114

FIG. NO.

I
I

55

Nylon

101

I Replace

56

2024-T3

0.190

56

2024-T42 Clad

0.050

1
1

I
I

Replace
Replace

I
I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace

56

IDoorAssv.

56

2422113

Door

56

2024-T3 Clad

0.160

2326015

Bracket

56

2024-T42 Clad

0.050
0.080

2622387

Cover, Access Hole

56

2024-T3 Clad

2322259

Door(G ea.)

56

2024-T3 Clad

0.080

1
1
1
1

Cover, Access Hole (5 ea.)


Cover, Access Hole
Shim, Laminated (0.032)

56

2024-T3 Clad

0.080

56

2024-T3

0.090

Splicelnstl.
Splice, Fwd,
Lower Wing Skin
Splice, Aft,
Lower Wing Skin
StiffenerAssy.

56

2622387

2622389
23221 40

2622016
2622017
2622018
2622015
2622015

IStiffener

2622015

56

0.003

56

2024-T4

0.312

Replace

56

2024-T4

0.160

Replace

Replace
Replace

Replace
Replace

56

Angle(2 ea.)
Stiffener Assy.

2622015

56

S-734

56

2024-T42 Clad

Stiffener

56

S-734

2622015

Angle(2 ea.)
StiffenerAssy.

56

2024-T42 Clad

2622015

56

S-734

Angle (2 ea.)

56

2024-T42 Clad

2622015

StiffenerAssy.

56

IStiffener

2622015
2622376

0.063

1
0.063

56

IStiffener

2622015
2622015

56

2622015

2622015

Replace
Replace
Replace

1
1

56

Bracket, Fuel Probe Sprt.


Door Instl., Wing Fuel

2422114

REPAIR

CODE

55

Filler

2326015

IFINISH
GAGE

Door(G ea.)

ISeal

2622386

I
MATERIAL

52

Door

DoorAssy.

2322259

I
EFF.

DoorAssy.

2322259
2322259

I
DESCRIPTION

Angle(2 ea.)
Leading Edge Instl.

56

S-734

56

2024-T42 Clad

I Replace

0.063

Replace

0.063

1
1

I
I

Replace
Replace

19

Wing Repair Index


Figure 1 (Sheet 15 of 22)
EFFECTIVITY:

MODEL 23/24/25 SERIES AIRCRAFT

57-11-10

Page
SRM~

15

Jan 15/93

Learjet
STRUCTURAL REPAIR MANUAL
ITEM
NO.
32

DWG.
NO.

I
DESCRIPTION
Skin Inbd

2322376

I
EFF.
19

I
MATERIAL
2024-T42 Clad

IFINISH

REPAIR

CODE

FIG. NO.

GAGE
I

I F5-4int

Replace

F5 ext

Skin, Middle

2322376

Skin Outbd

2322376

19

No.181

19

No.181

Fiberglass
Fiberglass
Fiberglass

I
I
I

6Ply
6Ply I
6Ply I

2322376

Cover, Outbd Access

19

No.i81

2322376

Filler

19

2024-T3 Clad

0.028

2322416

Attach Rib

19

2024-T42

0.050

F4-4

2322417

Nose

Rib, Sta 108.66


Nose Rib, Sta 181.275

19

2024-T42

0.050

F4-4

19

2024-T42

0.050

F4-4

61

2024-T42 Clad

0.063

61

6061-0

0.063

61

6061-0

0.063

61

6061-0

0.063

60

2024-T3

0.100

60

6061-0

0.160

60

2024-T3 Clad

0.125

60

2024-T3 Clad

0.025

60

2024-T3 Clad

0.050

60

2024-T3 Clad

0.028

60

6061-0

0.050

60

6061-0

0.032

2322418
2622377

Leading Edge

Instl.

2322377
2322377
2322377

2322377
2322377
2322377
2322377

2322377
2322377
2322377

2322377

I
I
I
I
I
I
I

1
1
1
1
1
1
1
1
1
1

2322416

Attach Rib

61

2024-T42

0.050

F4-4

2322417

Nose Rib, Sta 108.66


Nose Rib, Sta 181.275

61

2024-T42

0.050

F4-4

61

2024-T42

0.050

F4-4

62

6061-T6

0.025

F4-1

62

6061-T6

0.025

F4-1

62

2024-142

0.025

F4-1

62

2024-T41

0.063

F4-1

62

6061-T6

0.050

62

6061-T6

0.050

2322418

2522050
2522050
2522050
2522050
2522050
2522050
2522050
2522050
2522050
2522050

Leading Edge Instl.


Leading Edge Assy.
BaffleAssy.

62

Baffle, Outbd
Baffle, Inbd
Baffle, Inbd, Auxilary

Splice Plate
Tube Assy.

Replace
Replace
Replace
Replace

62

Tube, Anti-ice
Plate, Tube End
IClio

I
I

6061-T6

0.032

63

6061-T6

0.063

2522100

2024-T42

0.050

F4-1

2322416

RibAssy.

62

F4-1

2322416

Rib

62

2024-T42 Clad

0.050

F4-6

2322416

Doubler

62

2024-T3 Clad

0.050

F4-6

62

6061-0

0.063

F4-1

2322377

Replace
Replace

62

62

2322377

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
I Replace
I Replace
I Replace
I Replace
Replace

62

Panel, Access
Rib, Sta 168.72

2522050

Replace
Replace

61

Skin, Inbd
Skin, Middle
Skin, Outbd
Panel, Access
Filler, Lower (2 ea.)
Filler, Upper
Filler, Upper
Filler, Lower
Filler, Upper
Filler, Upper
Filler, Upper
Filler, Upper

2322377

F4-4

Replace
Replace
Replace
Replace
Replace

Skin, Middle

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Wing Repair Index


Figure 1 (Sheet 16 of 22)
EFFECTIVITY:

MODEL23/24/25 SERIESAIRCRAFT

57-11-10

Page
SRM~

16

Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

NO.

DWG.
NO.

I
EFF.

DESCRIPTION

IFINISH

65

2024-T42 Clad

0.050

F4-1

2422015

Panel, Access

64

6061-T6

0.063

Fl ext

2322377

Skin, Outbd

62

6061-T6

0.063

251 4304

Scupper

62

6061-0

0.032

Rib

2322418

REPAIR
FIG. NO.

GAGE I CODE

MATERIAL

Replace
Replace

F1 4-1 int

Replace
Replace

Fl ext
Fl4-1lnt

2422042
33

2422030
2422029

Skin

2422029
2422029
2422031

2522050

Tube Assv.

Baffle Rib

2422083

2422039

2422039

Fairina

1
1

Splice

2422039

2422041

0.063

1
1

I
I

Replace
Replace

66

6061-T6

0.063

66

6061-T6

0.063

66

2024-T42 Clad

0.063

1
1

66

2024-T42 Clad

0.063

66

6061-0

0.025

Replace
Replace
Replace
Replace
Replace

0.050

66

66

6061-T6

1
I

66

2024-T42 Clad

0.050

66

6061-T6

0.032

66

2024-T3

0.063

I
I
I

66

2024-T3 Clad

0.025

Replace
Replace
Replace
Replace

I
I
I
I

Replace
Replace
Replace
Replace

Replace
Replace
Replace

I
I
I

Replace
Replace
Replace

Replace

6061-T6

66

6061-T42

66

66

2014-T6 Clad

0.071

66

2024-T3 Clad

0.063

66

2014-T6 Clad

0.071

66

2014-T6 Clad

0.071

1
1
1
1

66

2024-T3 Clad

0.040

66

S-699

66

2024-T3 Clad

0.063

1
1

Doubler

Fairina

Support Assy.
Support (2 ea.)

66
66

2024-T3 Clad

0.063

2422043

Filler

66

2024-T3

0.063

2422078

Splice Plate
RibAssy.

66

2024-T42 Clad

0.063

1
1

2024-T42 Clad

0.063

2422041

2422082

2422082

Replace
Replace
Replace

1.000(
1.000 1

66

66

Splice

Stiffener(2 ea.)

2422036

0.063

6061-T6

66

Doubler(2 ea.)

2422039
2422039

1
1
1

Fairing Assy.
Splice Assy.

2422039

6061-T6

66

66

Assy.

Shim

2422039

2422039

Rib
1
IAnnle
IShim

2422030

66

66

Plate, Tube End


Tube, Anti-icing
Tube, Anti-icing

2522050

2422030

Anti-lcelnstl.

2522050

2422083

(7 ea.)

IScupper

2422050

2422083

66

1
1

Rib

Rib

2422032

2522050

66

Baffle, Outboard
Baffle, Inboard

2422031

2422038

66

(2 ea.)

IDoubler
IBaffle

2422031
2422032

Leading Edge Instl.


Leading Edge Assy.
Skin Assy.

66
66

Rib

Wing Repair Index


Figure 1 (Sheet 17 of 22)

EFFECTIVITY:

MODEL 23/24/25 SERIES AIRCRAFT

57-11-30

Page 17
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

DESCRIPTION

2422041

Support Assy.

2422041
2422078

(StallStriplnstl.

2422089

Fence

2422086

Fence

2422086
2422086

Fence

Fence

2422086

Fence

2622399

2322555

2322571

2422085
2522050

40

6061-T4

I
I

Replace
Replace

71

6061-T6

0.160

71

6061-T6

0.063

Replace
Replace

73

6061-T6

0.160

73

6061-T6

0.063

I
I

I
I

72

S-5078

74

S-5078

Drain

2422116

IWasher

2422116

Flange

Center Section

Identification Plate

2422039

2422039

IFairina

S-621

1Fi

S-621

1F1

S-707

1F1

Fiberglass
5052-0

1/2

matte

1/4

Fiberglass matte
3003-H14Expanded

1.000
1/2.051

1
1
1
1

I
I
I
I

Replace
Replace
Replace
Replace

2024-T42 Clad

0.032

Replace

75

5052-0

0.063

75

5052-0

0.063

S-905

Replace
Replace
Replace

Tubing

77

Fairing Assy.

77

77

2024-T3

0.063

Doubler

77

2014-T6

0.071

1
1

I
I

2422039

Doubler

77

2024-T3

0.040

2422036

Stiffener

77

S-699

2422039

Replace
Replace
Replace
Replace

75

Elbow
Strake Instl., LH 8 RH

I Replace
I Replace

75

Assy.

2422037

1
I

76

76

2620000

S-5075

76
7

Weld

1
1

Replace
Replace
Replace
Replace

76

75

Replace

1
1

23

Clip

2422116

0.160

23

Insulation

Wing

0.063

55

Drain Instl.,

0.250

6061-T6

55

Replace
Replace

6061-T6

Blade, Vortex Generators


Blade, Vortex Generators
Anti-ice Instl., LH 8 RH

IReinforcement

I
I

70

55

2522050

0.050

70

Vortex Generator Instl.

2522050

2422117

2024-T42 Clad

1
1

70

Insulation
1
ITube

2422117
39

66

70

Blade, Vortex Generators

2422085
38

(3 ea.)

Vortex Generator Instl.

2322571

0.063

73

Trip Strip Instl.


Trip Strips (3 ea.)

2422088

2322555

37

Assy.

Attach Plate

2422086

2024-T3 Clad

71

IFence

2422086

2322555

Assy.

Attach Plate

2422086

I Replace

S-744

66

70

Fence

2422086

36

Assy.

Attach Plate

2422086

FIG. NO.

70

Fence

2422086

REPAIR

CODE

66

70

IStallFencelnstl.

2422086

IFINISH
GAGE

70

StallStrip

2422086
35

1
1

Rib

2422089
34

I
MATERIAL

66

ISuoport
1
Support

2422041

I
EFF.

Replace
Replace
Replace
Replace

Wing Repair Index


Figure 1 (Sheet 18 of 22)
EFFECTIVITY:
SRM~

MODEL 23/24/25SERIES AIRCRAFT

57-11-10

Page 18
May 15/92

Leariet
~Learjet

STRU~TURAL REPAIR MANUAL


ITEM
NO.

DWG.
NO.
2422040
2422040
2422041
2422041
2422041
2422041

2422081
2328001
2328001

I
DESCRIPTION

Strake

Assy.

I
EFF.

I
MATERIAL

IFINISH
GAGE

REPAIR
FIG. NO.

CODE

77

Strake (2 ea.)

77

Support Assy.
Support
Support
Support

77

IPanel
Conduit Instl. Sta 125.0 to 181.10
Conduit

6061-T4

0.063

77

2024-T3

78

S-744

79

S-745

77

6061-T6

0.063

5052-0 Tube

0.035

0.063

1
I
1

I
I
I

I
1

I
I

Replace
Replace
Replace
Replace
Replace
Replace

1
1

F4-4

Replace

Wing Repair Index


Figure 1 (Sheet 19 of 22)
EFFECTIVITY:
sar~

MODEL 23/24/25 SERIESAIRCRAFT

57-11-10

Page 19
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
CODES
1

EFFECTIVITIES
23-002 THRU 23-099; 24-100 THRU
25-002 THRU 25-006

24-357; 25-002 THRU

23-002 THRU 23-029; 24-100 THRU 24-300,


23-002 THRU 23-009; 24-100 THRU 24-338

24-339 THRU

24-357; 25-206 THRU 25-373


23-099; 24-100 THRU 24-131
24-198 THRU 24-357; 25-032 THRU 25-373
23-022 THRU 23-099; 24-100 THRU 24-287;

23-002 AND 23-003

10

24-288 THRU

11

23-002 THRU

12

24-230 THRU

13

23-002 THRU

14

23-002 THRU

15

24-349 THRU

16

23-002 THRU 23-039

17

23-040 THRU

18

25-060 THRU 25-373

6
7

24-309, 24-310; 25-007 THRU

24-357;
23-099;
24-357;
23-099;
23-099;
24-357;

25-002 THRU 25-155

25-156 THRU 25-373


24-100 THRU 24-229; 25-002 THRU 25-069

25-070 THRU 25-373


24-100 THRU
24-100 THRU

24-218; 25-022 THRU 25-051


24-348; 25-002 THRU 25-224

25-225 THRU 25-373

23-099; 24-100 THRU 24-357; 25-002 THRU

19

23-002 THRU 23-005


23-006 THRU 23-099

21

23-040 THRU 23-099; 24-100 THRU 24-103


24-104 THRU 24-357; 25-002 THRU 25-373
23-002 THRU 23-099; 24-100 THRU 24-229 EXCEPT
24-104 THRU 24-263; 25-002 THRU 25-084

23

24

31

24-264 THRU 24-357; 25-085 THRU


25-296 THRU 25-373
24-104 THRU 24-338; 25-002 THRU
24-339 THRU 24-357; 25-206 THRU
23-040 THRU 23-072
23-073 THRU 23-099; 24-100 THRU
24-104 THRU 24-119

32

24-120 THRU 24-263

33

24-291 THRU 24-357; 25-162 THRU 25-373


23-070 THRU 23-099; 25-002 THRU 25-006
24-100 THRU 24-357; 25-002 THRU 25-373
23-002; 23-003; 23-005 THRU 23-099; 24-100 THRU
23-004 ONLY

25

26
27
28
29
30

34
35

36
37
38

25-185

23-002 THRU

20
22

25-373

25-373

24-218; 25-002 THRU

25-066 EXCEPT 25-061

25-373
25-205

25-373
24-103

24-357;

25-002 THRU 25-373

41

24-190 THRU 24-357; 25-030 THRU 25-373


24-269 THRU 24-357; 25-115 THRU 25-373
23-035 THRU 23-039
23-080 THRU 23-089

42

23-090 THRU

43

24-150 THRU 24-357

44

49

23-002 THRU 23-099; 24-100 THRU 24-285; 25-002 THRU 25-154


24-286 THRU 24-357 AND ALL SPARES; 25-155 THRU 25-373 AND ALL SPARES
23-040 THRU 23-099; 24-100 THRU 24-293; 25-002 THRU 25-166
23-080 THRU 23-099; 24-100 THRU 24-159; 25-002 THRU 25-010
24-160 THRU 24-189; 25-011 THRU 25-029
24-190 THRU 24-285; 25-030 THRU 25-154

50

23-040 THRU

39

40

45
46

47
48

23-099; 24-100 THRU 24-149

23-099; 24-100 THRU 24-149; 25-002 THRU 25-010

Wing Repair Index


Figure 1 (Sheet 20 of 22)
EFFECTIVITY:
SRM-4

MODEL 23/24/25 SERIES AIRCRAFT

57-11-10

Page 20
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


CODES

EFFECTIVITIES

51

23-090 THRU

52

23-070 THRU 23-079

53

24-150 THRU 24-285; 25-011 THRU 25-154


24-150 THRU 24-229 EXCEPT 24-218; 25-011 THRU 25-066 EXCEPT 25-061

54

23-099; 24-100 THRU 24-285; 25-002 THRU 25-154

56

24-218, 24-230 THRU 24-285; 25-061; 25-067 THRU 25-154


24-286 THRU 24-357; 25-155 THRU 25-373

57

23-002 THRU 23-024

58

23-002, 23-003, 23-010 THRU 23-039

59

23-004 THRU 23-009

60

23-006 THRU 23-039

61

23-006 THRU 23-099; 24-100 THRU 24-155


24-156 THRU 24-338; 25-002 THRU 24-205

55

62
64

24-156 THRU 24-189; 25-002 THRU 25-029


24-190 THRU 24-229 EXCEPT 24-218; 25-030 THRU 25-066 EXCEPT 25-061

65

25-007 THRU 25-205

66

24-339 THRU 24-357; 25-206 THRU 25-373


DELETED

63

67
68

DELETED

69

DELETED

70

25-290 THRU 25-373

71

25-290 THRU 25-307

72

25-308 THRU 25-312

73

25-290 THRU 25-307

74

25-313 THRU 25-373

75
76

24-238 THRU 24-357; 25-070 THRU 25-373


24-329 THRU 24-357; 25-002 THRU 25-373

77

24-230 THRU

78

24-230 THRU

79

24-357; 25-206 THRU 25-373


24-333; 25-206 THRU 25-373
24-334 THRU 24-357; 25-208 THRU 25-373

80

23-002 THRU 23-099

81

24-100 THRU 24-357

82

25-002 THRU 25-373

Wing Repair Index


Figure 1 (Sheet 21 of 22)

EFFECTIVITY:

MODEL23/24/25 SERIESAIRCRAFT

57-11-10

Page
SRM-4

21

Jan 15/93

STRUCTURAL REPAIR MANUAL


NOTES

Conductive

Coating

per

Chapter 51.

Laminated shim stock, 0.002

or

0.003 lamination per MIL-S-22499

Type

1 Class 1

or

Class 2, 1145-H19 aluminum

sheet.
Condition Normalized.

Learjet Field
Century III fairing.
Contact

Service if

more

than surface corrosion is encountered

on

the lower

wing

skin after removal of

PerMIL-P15035

Wing Repair Index


Figure 1 (Sheet 22 of 22)

EFFECTIVITY:

MODEL 23/24/25 SERIES AIRCRAFT

57-11-10

Page
SRM~

22

Tan 15/93

Learjet

STRUCTURAL REPA~R MANUAL


WING-STRUCTURAL IDLNTIEICATION

5~

-I

(ib~

~1

7-

I i

/I

II:

39>

\lls~9U

II

~01

:II

I,

55

Sr

25

Jr-r~

21
=r

-e

I:I

?t

gCS

;~t

s;~------i

ii
IS

~r
i

L,

Il

yL-~---,-

57

11

50
U

II

I;--

61

I: t-=

t~b o
2

~L65C

EFFECTnsTTY:
SRM~

f
1)

15

Wing Repair Index


Figure 1 (Sheet 1 of 23)
MODEL28/29/31 SERTESATRCRAF~

:I

-s

57-11-20

Page 1
May 15/92

55

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

1
I

2820005

EFF.

IFINISHI REPAIR
GAGE

MATERIAL

CODE

FIG. NO.

12225-0052

Wing Installation
Wing Assy.
Wing Assy.
Wing Struct. Assy., LH
Wing Struct. Assy., LH
Rib Assy. (WS 0.0)

12225-0052

Doubler

7075-n3

0.080

12225-0052

Web

7075-r/3

0.080

12225-0081

Doubler

7075-T73

0.063

12225-0081

Attach Angle (11 ea.)


Filler

7075-T73

0.080

2024-T351

0.250

2024-T3

0.160

2024-T3

0.125
0.100

j
I
I

I
I

12225-0041
5420000
12225-0041
5420000
1

DESCRIPTION

12225-0081
12225-0081

1
2

3
8 RH

8 RH

3
1

Filler(2 ea.)
Filler(4 ea.)

12225-0081

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Replace

I Replace
Replace
I Replace

12225-0081

Doubler

7075-T73

12225-0081

7075-T651

0.100

7075-T651

0.125

12225-0081

Strip
Strip
Stiffener(2 ea.)

1
1
1
1

S-512

12225-0081

Stiffener

2024-T3

0.125

I
1

12225-0090

Cap, Lower
Cap, Upper

i 7075-T731

2.500

7075-T731

2.500

12225-0081

12225-0090

5427020

Bracket

2024-T3 Clad

0.040

5427014

Bracket
Bracket

2024- T42 Clad

0.050

12225-0052

2024-T42 Clad

0.063

12225-0052

Bracket

12024-T3CIad

0.040

12225-0052

Stiffener(2 ea.)

S-502

12225-0052

Stiffener

2024-T42 Clad

0.080

Filler

2024-T3 Clad

0.050

Stiffener

2024-T3 Clad

0.050

S-733

I
1
I
1
1

12225-0052-

L1496

12225-0052
2
3

2822055

IStiffener

2322044

1 2322044
2322044
2322044
2322044

2322044
2322044

1
I

I
I

i 2024-T42 Clad

0.125

F4-6

2024-~42 Clad

0.125

F4-6

2024-T42 Clad

0.080

F4-6

2024-T42 Clad

0.080

F4-6

2024-T;12 Clad

0.0801-F4-6
0.0801 F4-6

1 2024-T42 Clad

2024-T3 Clad

0.080

2322044

Filler, Lower
Filler, Upper

2024-T3 Clad

0.080

F4-6

2322044

Attach

2024-T42 Clad

0.063

F4-6

2322044

Splice Instl., Spar No. 1


Angle, Upper
Angle, Lower
Splice Angle, Upper
Splice Angle, Lower
Splice Angle, Upper
Splice Angle, Lower

2322293
2322293
2322293

Angle
Rib Assy.
Rib Cap, Upper
Rib Cap, Lower

F4-6

_I
1
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

1
1

S-502

S-502

Replace

I Replace

Wing Repair Index


Figure
EFFECTIVITY:
SRM4

1 (Sheet 2 of

MODEL28/29/31 SERIESAIRCRAFT

23)

57-11-20

Page 2
May 15/92

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

I
DESCRIPTION

I
EFF.I

Web

2024-T3 Clad

0.063

2322293

Attach

Angle (4 ea.)
Fiiler(2 ea.)

2024-T42 Clad

0.080

2024-T3 Clad
S-512

2322293

2322293

IStiffener

2322564

2322564

Spar Assy., No. 1


(WS 27 to 181)
Spar
Doubler(Access Cover)
Access Cover

2484039
2322257
12225-0058

Stiffener(12 ea.)
(.RibAssy., FuselageAttach
(4 ea.) (WS 26.0)
Splice, LH 8 RH
Filler(3 ea.)

0.080

2024-T3 Clad

0.080

2024-T3 Clad

0.080

2024-T3 Clad

S-571

0.063

7075-T73
2024-T3 Clad

0.188

12225-0058

Filler

2024-T3 Clad

0.120

12225-0058

Filler

2024-T3 Clad

0.071

12225-0058

Filler

2024-T3 Clad

Fitting
Fitting

201 4-T6

Fitting
Fitting
Fitting

2322275
2322281
2822173

2822171
2822174

0.063

F-4

7075-T6

7075-n3 Plate

S-569

2024-T3 Clad

0.125

12225-0058

Doubler

2024-T3 Clad

0.090

S-774

2024-T42 Clad

0.063

1
0.125

S-775

2024-T42 Clad

1.250

Web

2024-T42 Clad

0.125

Doubler

2024-T3 Clad

0.080

12225-0058

12225-0058

Replace
Replace
Replace
Replace

7075-T73 Plate

12225-0058

Angle

I
I
I
I

Attach

1
1
1
1

S-569

Tee

Replace

51-71-01

12225-0058

51-71-01

Tee(LH Only)
Tee(RH Only)
Doubler(3 ea.)

12225-0058

F4-4

12225-0058

Web

Replace
I Replace
I Replace

F4-1

2024-T3 Clad

12225-0058

1
1
1

Replace
Replace
Replace
Replace

I
I

Tee

I
I
I

201 4-T6

Gusset

12225-0058

1
1
1
I

I
I

12225-0058
2322290

FIG. NO.

1
1

12225-0058

REPAIR

CODE

12225-0065

IFINISH
GAGE

MATERIAL

2322293

2322564

51-71-01

1
F-4

51-71-01

1
I

I
I

I
1
I
1

I
I
I
I

1
1

I
I

S-771

12225-0058

Web

2024-T3 Clad

0.080

12225-0058

Clip

2024-T3 Clad

0.040

12225-0058

Doubler

7075-T6

0.250

1
1

I
I

0.080

I
I
I
1

I
I
I
I

12225-0058

Tee

12225-0058

Tee

S-598

12225-0058

Tee

S-597

12225-0058

Tee

S-771

2024-T3 Clad

12225-0058

Web

1
I

51-71-01

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Wing Repair Index


Figure 1 (Sheet 3 of 23)

EFFECTIVITY:
SRMI

MODEL28/29/31 SERIESAIRCRAFT

57-11-20

Page 3
May 15/92

Leariet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

12225-0005

12225-0005
12225-0005

Rib
1

Assy. (WS 53)

Fairlead

12225-0005

12225-0005

Doubler

I
MATERIAL

(2 ea.)

2024-T3

Phenolic

3/16

Phenolic~

0.250

2024-T42 Clad

0.080

2024-T42 Clad

0.080

7075-T73

0.160
0.160
0.080

I
I
I
I
I
I

0.250

I
I

7075-0 Plate

1.500

7075-0 Plate

0.250

j
j

I
I

Web

7075-T73

12225-0005

Web

7075-T73

7075-T73

7075-0

1
1
1

S-772

S-772

2024-T42 Clad

1
1

12225-0091
12225-0091

12225-0091
12225-0091

12225-0095
2322320

Splice
Splice
Splice
Splice Plate
Rib Cap, Upper
IRibCap,Lower
Angle
Filler

2822166

IBracket

12225-0006

Spar Assy., No. 2, Inbd


(WS O to 53)
ICap, Upper
ICap, Lower

12225-0006
12225-0006

0.080

2024-T3 Clad

0.160

6061-T6

0.063

I
I

I Replace
I Replace

1
1

I Replace
I Replace

1
1

S-5051

S-5051

I
I

Doubler

7075-T73

0.312

Plate

7075-T73

0.125

IStiffener(Qea.)

S-571

12225-0006

Web

7075-T73

0.080

12225-0006

IPlate

7075-T73

0.125

12225-0088

IFitting
Fitting

7075-T73

0.030

7075-T73

2.500

S571

12225-0006

Stiffener

12225-0010

Spar Assy., No.


Outbd (WS 53
No. 2Assy.

12225-0010
12225-0010
12225-0010

IAnnle
IAnale
IDoubler

12225-0010

Doubler

12225-0010

12225-0010

IAnnle

12225-0010

Web

I Replace

1
1
1

I
I
I
I

Replace
Replace
Replace
Replace
I Replace

2 and No. 3,
to

181)

1
I
I

(5 ea.)
Plate (2 ea.)

12225-0010

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

12225-0006

2822148

1
1
1
j

12225-0006
12225-0006

REPAIR
FIG. NO.

CODE

0.160

L~

12225-0005

12225-0091

IFINISH
GAGE

Fairlead
Tie

I
EFF.

Filler

Angle, Spar
Angle

12225-0065

I
DESCRIPTION

12225-0005
12225-0005

32

7075-T73

0.080

7075-T73

0.080

7075-T73

0.100

2024-T42 Clad

0.080

2024-T3 Clad

0.080

S-554

2024-T3

0.080

1
1
1

I Replace
I Replace
I Replace
I Replace
Replace

I Replace

12225-0010

Doubler(2 ea.)

2024-T3 Clad

0.063

Replace
I Replace

12225-0010

Doubler

2024-T42 Clad

0.063

I Replace

Wing Repair Index


Figure 1 (Sheet 4 of 23)
EFFECTIVITY:

MODEL28/29/31 SERIESAIRCRAE~

57-11-20

Page 4
SRM-4

May 15/92

Learjet
Learjet

STRUCTU RAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

12225-0010

1
1

I
I

Fitting
Doubler

Stiffener(2 ea.)

2322257

Stiffener

2322257
12225-0010

12225-0010
12225-0010
12225-0010
12225-0010
12225-0010
12225-0010
12225-0010

12225-0010
12225-0010

12225-0010
12225-0010

12225-0010

IAngle
IAnsle

I
1

Doubler

S-571

7075-T73 Clad

2024-T42 Clad

S-571

S-512

S-571

33

7075-T73

34

2024-T42 Clad

Assy.
Tee, Upper
Tee, Upper

0.080

I Replace
I Replace
I Replace
I Replace
I Replace
I Replace

0.080

1.900

1.900

I
1
1

I
I
I

I
1

I
I

1
1
1

I
I

I
I

I
I

I
I

1
1

I
I
I

0.080

I
I
I

35

S-5054

Tee, Lower
Tee, Lower

S-5054

7075-T73

1.900

Angle, Lower
Angle, Upper (2 ea.)
Angle, Backup

2024-T4 Clad

0.080

2024-T4 Clad

0.080

7075-T73

S571

34

S571

10

7075-T73

10

7075-T73

Stiffener(l4 ea.)
Stiffener(5 ea.)

FIG. NO.

I
1
I
I
I
1

7075-r/3

REPAIR

CODE

No. 3

IFINISH
GAGE

MATERIAL

0.080

Replace

1
1

34

7075-T73

1.900

2822153

IFittina
IFittina

I
I
1

34

7075-T73

2.700

2822168

IFittinn

34

7075-T73

1.900

2024-T42

0.080

2024-T3

0.080

I
I
I

12225-0084
12225-0092

2822152

12225-0010
12225-0010

IFittinn

Fitting(2 ea.)

Doubler(2 ea.)
IDoubler

12225-0010

Doubler(3 ea.)

2024-T4

0.080

12225-0010

Filler

2024-T4

0.188

1
1

12225-0010

Web

2024-T3

0.080

12225-0010

Filler(2 ea.)

2024-T4 Clad

0.187

12225-0010

Filler

2024-T4 Clad

0.312

1
I

I
I

I
I
I
I

IAngle
112225-0060 1 SparNo.4Assy.,Outbd
(WS 53 to 181)
12225-0010

10

I
EFF.

Stiffener

12225-0010

12225-0083

I
DESCRIPTION

34

S-705

S-705

I
I

1
1
I
I

12225-0060

Angle, Lower, LH

7075-T73

0.080

12225-0060

Splice
Stiffener(WS 59)
Stiffener(WS 64)
Stiffener(WS 72)
Stiffener(WS 79)
Stiffener(WS 85)
Stiffener(WS 99)
Stiffener(WS120)
Stiffener(WS132)

201 4-T6

0.080

12225-0060
12225-0060

12225-0060
12225-0060

12225-0060
12225-0060

12225-0060
12225-0060

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

S-705

S-705

S-705

I
I
I
I
I

I
I
I
I
I

I
I
I
I
I

S-705

S-705

S-705

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Wing Repair Index


Figure 1 (Sheet 5 of 23)

EFFECTIVITY:

MODEL28/29/31 SERIESAIRCRAFT

57-11-20

Page 5
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
I

DWG.
NO.

ITEM

NO.

I
I

i
I

I
I

S-705

S-705

2024-T3 Clad

0.063

2024-T3 Clad

0.080

I
i Replace
I Replace
I Replace
I Replace
I Replace
I Replace
I Replace
I Replace
I Replace
I Replace
I Replace
I Replace
Replace
I Replace
Replace
I Replace
I Replace
I Replace
Replace
Replace
I Replace
I Replace
Replace
I Replace
Replace

12225-0097

Stiffener(WS176)
Doubler(WS 86)
Doubler(WS 149)
Filler(WS 73) Upper
Filler(WS 66) Lower
Fi\ler(WS 59) Lower
Filler(WS 59) Upper
I
Filler(WS 66) Upper 8 Lower
Splice(WS 69) Upper
Tee (WS 55) Upper
Angle(WS 120) Upper
Doubler(WS 109)
Doubler(WS 63) Lower
Doubler(WS 179)
Doubler(WS 161)
Channel (WS 139)
Tee(WS 59)

12225-0060

Tee

32

S-570

32

7075-0

12225-0060
12225-0060
12225-0060
12225-0060

12225-0060
12225-0060
12225-0060

12225-0060
12225-0060
12225-0060
12225-0060
12225-0060
12225-0060
12225-0060

12225-0060

2322330

Angle, Upper
Fitting(WS 53) Lower
Fitting (WS 53) Lower
Fitting (WS 53)
Fitting (WS 53)
Fitting (WS 53) Upper
Fitting(WS 53) Upper
Rib Assy. (WS 92)
1
Angle (at Spar #5)
Angle (at Spar #3)
Rib Segment (7 ea.)
Filler (Spar 3 to 4) Lower

12225-0061

1 SparNo.5Assy.,Outbd

12225-0060
2822157
12225-0085
2822158

12225-0085

2822169
12225-0085
2322330
2322330
2322330
2322330

S-705

S-705

12225-0060

12225-0061
12225-0061

2024-T3 Clad

0.040

1
1
1

2024-T3 Clad

0.040

2024-T4

0.250

2024-T4

0.250

2024-T4

0.250

2014-T6

S-770

0.080

0.080

7075-T73
2024-T42 Clad
2024-T42 Clad

0.080

1
1

2024-T3 Clad

0.063

2024-T3 Clad

0.063

2024-T3 Clad

0.080

7075-T73

0.080

0.080

1
1
1
I

Replace
Replace
Replace
Replace
Replace

7075-173

I
1
i 2.000(

7075-T73

3.000

7075-T73

3.000

7075-T73

3.000

7075-T73

2.000

7075-T73

3.000

2024-T42 Clad
2024-T42 Clad

0.071

0.071

2024-T42 Clad

0.071

Replace
Replace
Replace

2024-T3 Clad

0.080

Replace

0.080

1
1
1
1

1
1

181)
Cap(WS 73) Lower
Angle(WS 72 to 181)
Upper
Cap(WS 53 to 72) Upper

(WS
12225-0061

FIG. NO.

12225-0060

REPAIR

CODE

S-705

12225-0060

IFINISH
GAGE

S-705

12225-0060

12

I
MATERIAL

12225-0060

I
EFF.

Stiffener(WS 139)
Stiffener(WS 146)
Stiffener(WS152)
Stiffener(WS 164)
Stiffener(WS 170)

12225-0060

11

I
DESCRIPTION

53 to

S-778

Replace

7075-T73

5-777

Replace
Replace

Wing Repair Index

Figure
EFFECTIVITY:
SRM-I

(Sheet 6 of 23)

MODEL28/29/31 SERIESAIRCRAFT

57-11-20

Page 6
May 15/92

Leariet
STRUCTURAL REPAIR MANUAL
DWG.

ITEM
NO.

I
DESCRIPTION

NO.
12225-0061
12225-0061
12225-0061
12225-0061

Splice(WS 67) Lower


Splice(WS 67) Upper
Splice(WS 83) Upper
Angle (WS 99 to 119)
Lower

12225-0061
12225-0061
12225-0061
12225-0093
28221 60
12225-0096
2822161
12225-0086
2822162
12225-0061

0.080

2014-T6

0.080

1 7075-T73

0.080

7075-T73

0.080

2024-T3

0.063

0.020

1
1
1
1

I
I
I
I
I

2024-T3

0.080

2024-T42

0.040

1
1

I
I

2024-T42 Clad

0.071

2024-T3 Clad

0.071

2024-T42 Clad

0.071

1
1
1

I
I
I

Replace
Replace
Replace

7075-T73

2.800
3.000

11

7075-T73
7075-T73
7075-T73

10

7075-T73

3.500

11

7075-T73

3.500

S-571
7075-n3

12024-T3

1
3

Assy. (WS 125)


Rib(7 ea.)
Doubler (Spar 3 to 4)
Angle (Spar 5)
Rib Assy. (WS 157)
Angle(3 ea.)
Rib(2 ea.)
Rib(5 ea.)
Doubler (Spar 3 to 4)
Rib

2322340
2322340
2322350
2322350

2322350
2322350
2322350

12225-0014
12225-0014
12225-0014
12225-0014
12225-0014

12225-0014
12225-0014
12225-0014
12225-0014

12225-0014
12225-0014
12225-0014

0.125

11
10

181)

10

53 to

Replace
Replace
Replace

1 0.0631

2024-T3 Clad

1 7075-T73

Doubler

Spar (WS

I
I
I

Bracket

1
1

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

12225-0061

12322340

2014-T6

Fitting (WS 53)


Fitting (WS 53)
Fitting (WS 53)
Fitting (WS 53)
Stiffener(l4 ea.)

REPAIR
FIG. NO.

CODE

2322340

15

Doubler(WS149)
Filler(WS 73) Upper
Filler(WS~S)
Fitting (WS 53)
Fitting (WS 53)

IFINISH
GAGE

Doubler(WS164)

12225-0061

14

I
MATERIAL

12225-0061

5426035
13

I
EFF.

3.400
3.500

I
0.100

IRibAssy.(WS1S1)

2024-T42 Clad

0.071

0.080

2024-T42 Clad
2024-T42 Clad

2024-T3 Clad

0.063

I
I

Replace
Replace

2024-T3 Clad

0.050

2024-T3 Clad

0.050

2024-T3 Clad

0.016

2024-T3 Clad

0.063

1
1

I
I

2024-T3 Clad

0.063

2024-T3 Clad

0.063

2024-T3 Clad

0.040

2024-T3 Clad

0.050

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Replace

Replace

0.063

Angle (7 ea.)
Rib(Spar 6)
Filler(3 ea.)
Splice Plate (WS 187)
Angle(WS 187) Upper
Angle(WS 187) Lower
Filler(2 ea.)
Clip(2 ea.)
Angle(2 ea.) Upper
Angle (2 ea.) Lower
Angle(Spar4, WS 185)
Upper 8 Lower

I
I

2024-T3 Clad

0.050

2024-T3 Clad

0.050

2024-T3 Clad

0.050

12225-0014

Splice Angle

2024-T42 Clad

0.063

12225-0014

Rib(7 ea.)

2024-T42 Clad

0.063

1
1

I
I

Replace
Replace
Replace

Wing Repair Index


Figure

EFFECTIVITY:
SRM-4

1 (Sheet 7 of 23)

MODEL28/29/31 SERIESAIRCRAFT

57-13-20

Page 7
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.
12225-0014
12225-0014
12225-0014
12225-0031
12225-0031
5420000L1160
12225-0014

12225-0015
16
17

18

12225-0047
12225-0047
12225-0016
12225-0016

I
DESCRIPTION

(Spar 6 to 7)
(Spar 7 to 8)
Clip (Spar 6 to 7)

2024-T3 Clad

0.080

2024-T42 Clad

0.063

Lower Skin Doubler

Upper Skin Doubler

21

2024-T3

0.016

1~

0.040

2024-T3 Clad

0. 063

Stiffsner(5 ea.)
Spar Assy. (WS 185 to 213)

Replace
Replace

Replace
Replace

I S-571

Na. 2

2024-T3 Clad

1 2024-742 Clad

2024-T3 Clad
2024-T42 Clad
S-571

Stiffener

1 12225-0016

Spar Assy.

2322257

Spar

185 to

8 RH

Splice Doubler

12225-0016
12225-0016

0.080

13

Spar

Replace
Replace
Replace
Replace
Replace

0.040

12

(Rib 8 Upper Skin)


Wing Extension Instl., LH
(WS 185 to 244)

REPAIR
FIG. NO.

CODE

0.080

Shim

12225-0016
2322257

12225-0016

2024-T3 Clad
2024-T8
1 2014-T6

Shim

(WS

20

)FINISH
GAGE

Rib

Splice Angle, Upper


Splice Angle, Lower

12225-0016
12225-0016
2322257
12225-0016
2822411
12225-0016
12225-0016
12225-0016
2322257
1 12225-0016
12225-0016
2826031
12225-0016

MATERIAL

Doubler

12225-0016
12225-0016

12225-0016
12225-0016

19

EFF.

233)

0.050

Replace

0.050

Replace
Replace
Replace
Replace

0.050
0.071

Spar No. 3
Splice Plate
Splice Angle, Lower
Splice Angle, Upper
Stiffener(3 ea.)

i
1
1

Doubler
Stiffener

2024-T3 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
S-571
1 2024-742
(S-734

0.050
0.050

0.050
0.071

(WS 185 to 213)


SparAssy.

Spar No. 4
Splice Plate
Stiffener(3 ea.)

2024-T3 Clad

0.050

2024-T42 Clad
I S-571

0.050

2024-T3 Clad
2024-T42 Clad

0.050

1
1

2024-T42 Clad

0.063

2024-T42 Clad

0.063

0.063

2024-T3 Clad
2024-T3 Clad

S-571

Spar Assy. (WS 185 to 244)


Spar No. 5
Bracket Assy. (WS 215)
SpliceAngle, Upper
(WS 215)
Splice Angle, Lower
(WS 215)
Doubrer(WS 215)
Doubler(WS 193)
Stiffener(3 ea.)

Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.050

Replace
Replace
Replace

0.063

1
1

0.050

Replace
Replace

Replace
Replace
Replace
Replace
Replace

Wing Repair Index


Figure 1 (Sheet 8 of 23)
EFFE~TDIITY:
SRM-4

MODEL28/29/31 SERIESAIRCRAFT

57-11-20

Page 8
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ITEM
NO. I

DWG.
NO.
12225-0016
12225-0016
12225-0016

12225-0016
12225-0016
22

12225-0016
12225-0016
12225-0016
12225-0016

12225-0016
1 2225-00 i 6
12225-0016

2322257
5426040
23

2822430

I
DESCRIPTION

Splice Angle, Upper


(WS 193)
Splice Angle, Lower
(WS 193)
Splice Plate (WS 190)
DoorAssy.
Doubler(WS 239)
1
Spar Assy. (WS 185 to 244)
Fitting, Lower (WS 244)
Fitting, Upper (WS 244)
Fitting, Lower (WS 244)
Fitting, Upper (WS 244)
Splice Plate (WS 190)
Spar No. 6
Stiffener(S ea.)
BracketAssy.
Intercostal

2822430

2822430
24

I
I

12225-0019

12225-0019
12225-0019
12225-0019
12225-0019

12225-0019
12225-0019
12225-0019
12225-0019

IEFF.

Rib

Strap, Upper
Strap, Lower
Strap, LE
Clip(Spar 9)
Rib (Spar 9 to TE)
Angle(SparlO)
Filler

2024-T42 Clad

IFINISH REPAIR
GAGE I CODE I FIG. NO.

0.050

1
1

Replace
Replace

Replace
Replace

1
1

I
I

1
1
1

I
I
I

1
1
1
1

I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

1
1

I
I

I
I

2024-T42 Clad

0.050

2024-T42 Clad

0.050

2024-T3 Clad

0.071

2024-T3 Clad

0.050

2024-T42 Clad

0.071

2024-T42 Clad

0.071

Replace

2024-T42 Clad

0.071

2024-T42 Clad

0.071

2024-T42 Clad

0.050

2024-T3 Clad

0.050

S-571

2024-T4

I
0.050

1 2024-0 Clad

0.050

2024-0 Clad

0.050

2024-0 Clad

0.050

2024-T42 Clad

0.071

2024-T3 Clad

0.080

1 2024-T3 Clad

0.080

1
Clip(Spar 3)
1
Clip(Spar 2)
IRibAssy.(WS244)

I
MATERIAL

2024-T42 Clad

0.063

2024-T42 Clad

0.063

2024-T42 Clad

0.071

2024-0

0.040

2024-T3 Clad

0.063

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

12225-0019

Filler

0.071

2024-T42 Clad

0.071

2024-T42 Clad

0.071

1
1
1

I
I
I

2024-T42 Clad

0.071

2024-T42 Clad

0.063

2024-T42 Clad

0.071

2024-T3 Clad

0.071

2024-T4 Clad

0.063

12225-0019

Nose Rib

2024-T42 Clad

0.040

1
1
1

12225-0019

Angle (Spar 8)
Angle (Spar 7)
Splice (Spar 5)
Angle(Spar 1)
Strap
Angle (Spar 5)
Spacer(Spar 5)
Clip(Spar 6)

1 2024-T3 Clad
2024-T42 Clad

0.050

12225-0019

12225-0019

Filler(LE)
Shim (Spar 2)
Angle(LE)

2024-T3 Clad

0.071

2024-T3 Clad

0.080

1
1

2024-T42 Clad

0.040

1 Replace
I Replace
j Replace

12225-0019
12225-0019
12225-0019
12225-0019
12225-0019
12225-0019

12225-0019
12225-0019

Replace
Replace
Replace

Wing Repair Index


Figure 1 (Sheet 9 of 23)
EFFECTIVITY:
SRM~

MODEL28/29/31 SERIESAIRCRAFT

57-11-20

Page 9
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.
25

26

27

DWG.
NO.

I
DESCRIPTION

12225-0016

SparAssy. (WS

I
MATERIAL

185to 244)
Assy. (WS 210)

Stiffener

S-571

12225-0016

Spar No.

2024-T3 Clad

2322257

Stiffener(7 ea.)

S-571

2024-T42 Clad

0.050

2024-T3 Clad

0.050

S-571

12225-0016

Splice Plate

12225-0016

Spar Assy. (WS

12225-0018

Spar

2322257

Stiffener

12225-0016

12225-0016

12225-0016
12225-0016

29

2822430

2822430
2822430
2822430
2822430

2822430
2822430
2822430
2822430
2822430

No. 8

Clip(Spar 7)
Intercostal (Spar 7
Clip(Spar 7)
Intercostal (Spar 8
Clip(Spar8)

2822430
2822430
2822430
2822430
2822430
2822412

244)

(7 ea.)
SparAssy. (WS 181 to 244)
Spar No. 9
Fitting, Fwd (WS 244)
Fitting, Aft (WS 244)
Stiffener(8 ea.)
Spar No. 10 (WS 181 to 244)
Rib Assy. (WS 213)
Intercostal (Spar 1 to 3)
Clip(Spar 1)
Clip (Spar 2)
Intercostal (Spar 3 to 5)
Clip (Spar 3)
Clip (Spar 4)
Intercostal (Spar 5 to 6)
Clip(Spar 5)
Intercostal (Spar 6 to 7)

12225-0016

28

181 to

Splice
(Spar 8,

0.050

FIG. NO.

I Replace

I Replace

I Replace

Replace

Replace
Replace

1
1

2024-T3 Clad

0.050

2024-T42 Clad

0.071

1
1

I
I

Replace
Replace

2024-T42 Clad

0.071

S-571

2024-T3 Clad

0.040

Replace
Replace
Replace

2024-T42 Clad

0.063

2024-T42 Clad

0.063

2024-T42 Clad

0.050

2024-T42 Clad

0.063

2024-T42 Clad

2024-T42 Clad

1
1

I
1

I Replace
I Replace

Replace

I Replace

0.063

1
1

0.050

2024-T42 Clad
2024-T42 Clad

0.063

I Replace

2024-T42 Clad

0.063

1
i
1

Replace
Replace
I Replace
i Replace
Replace
I Replace
I Replace

2024-T42 Clad

0.063

2024-T42 Clad

0.063

2024-T42 Clad

0.063

to

9)

2024-T42 Clad

0.050

2024-T42 Clad

0.032

Replace
Replace

0.063

244)

REPAIR

CODE

8)

7475-T761

0.080

2024-T42 Clad

0.032

1
1

I
I

Clip(Spar 10)
(Spar 10 to
Trailing Edge)
Splice
(Spar 10, WS 181 to 244)

2024-T42 Clad

0.032

Replace
Replace
Replace

2024-T42 Clad

0.032

Replace

2024-T3

0.080

2024-T3

0.020

1
1

Filler

Replace
Replace
Replace
Replace
Replace
Replace

Intercostal (Spar 9 to 10)

2822430
2822430

to

WS 181 to

IFINISH
GAGE

12225-0016

12225-0016

lntercostal

2822430
2822412

2822412
30

EFF.

2822430

Intercostal

2024-T42 Clad

0.050

2822430

Spacer (Spar 8)
Clip(Spar 8)

2024-T3 Clad

0.120

2822430

1
1

2024-T42 Clad

0.050

2424001

Channel

I 304A Stainless

0.016

1
1
1

I
I
I

Wing Repair Index


Figure I (Sheet 10 of 23)
EFFECTIVITY:
SRM-4

MODEL28/29/31 SERIESAIRCRAFT

57-11-20

Page 10
May 15/92

Leariet
STRUCTURAL REPAIR MANUAL
ITEM

NO. I
31

DWG.
NO.
12225-0062

12225-0062
12225-0062
12225-0062

I
DESCRIPTION

Spar Assy., No. 6 Outbd


(WS 53 to 181)
Spar(WS 53 to 181)
Stiffener(3 ea.)
Stiffener(G ea.)

I
MATERIAL

IFINISH

REPAIR

IGAGE I CODE

FIG. NO.

2024-T3 Clad

I Replace

S-571

S-571

S-644

I
1
1

I
I
I
1

0.080

0.080

1
1

0.080

0.071

1
1

I
I
I
I
I
I
I
I
I

Stiffener

12225-0062

Stiffener

S-557

12225-0062

Channel

2024-T3 Clad

0.080

12225-0062

Doubler(3 ea.)

2024-T3 Clad

0.063

12225-0062

Doubler

0.080

12225-0062

Doubler

2024-T3 Clad
7075-T73
2024-T42 Clad

12225-0062

Doubler

2024-T42 Clad

12225-0062

Doubler

2024-T42 Clad

2322257

Stiffener(2 ea.)
Stiffener(4 ea.)

S-571

S-571

7075-T73

2322257

Angle

Fitting, Lower
2822176
Fitting, Lower
12225-0087
Fitting, Upper
2822175
Fitting, Upper
2822176
Splice Angle, Upper RH
2822176
Splice Angle, Upper LH
12225-0063 1
Spat Assy., No. 7
(WS 53 to 181)
12225-0063
Spar(WS 53 to 181)
12225-0063
Cap, Upper (WS 53 to 76)
12225-0063
Cap, Upper (WS 53 to 76)
12225-0094

7075-T73

1.38

7075-T73

2.200

S-5022

7075-T73

1.000

I
1
1
1
I
1

7075-T73

1.000

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.080

I
1

I
I

Replace
Replace
Replace

1
1

I
5-776

15

S-5059

I Replace
I Replace
I Replace
I Replace
I Replace
I Replace
I Replace
I Replace
I Replace

32

7075-T73

3.000

15

7075-T73

4.000

I
1
1
I
I
I
I
1
1

32

7075-T73

3.400

15

7075-r~3

3.000

32

7075-T73

3.000

15

7075-n3

3.000

2024-T3 Clad

0.050

2024-T73

0.080

7075-r/3

0.080

1
1
1
1
1
1

I
I
I
I
I
I

7075-T73

Filler

7075-T73

12225-0063

Stiffener(lO ea.)

S-571

12225-0063

Stiffener

14

S-571

12225-0063

StiffenerAssy.
Stiffener(4 ea.)
Fitting, Upper Fwd
Fitting, Upper Fwd
Fitting, Upper Aft
Fitting, Upper Aft
Fitting, Lower
Fitting, Lower
Clip
Angle
Angle(2 ea.)

S-571

S-571

12225-0074
2822165
12225-0073

28221 65
12225-0063
12225-0063

12225-0063

32

Filler

2822164

1.380

12225-0063

12225-0073

0.071

I
I

2024-T3 Bar

12225-0063

2322257

Replace

I Replace
I Replace
I Replace
I Replace
I Replace
Replace
I Replace

12225-0062

12225-0062

32

IEFF.I

0.180

0.125

I
I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace

Wing Repair Index


Figure 1 (Sheet 11 of 23)
EFFECTIVITY:
SRM-4

MODEL28/29/31 SERIESAIRCRAFT

57-11-20

Page 11
May 15/92

Learjet
~arjeil
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.
12225-0063
12225-0063
12225-0063

12225-0063
33

12225-0072

12225-0072
12225-0072

12225-0072
2441007

Lower

2014-T6

0.080

Lower

7075-T3

0.080

2024-T3 Clad

0.080

2024-T3 Clad

2024-T3 Clad

S-518

Doubler

Spar No. 8 (WS Oto 181)


Filler(WS O)
Spar Cap, Upper
Spar Cap, Lower
Bearing Plate

0.080

I
I
I
I

Replace
Replace
Replace
Replace

0.125

Replace

I
I

I Replace
I Replace

I
1

S-756

2024-T3

0.312

2024-T4

0.625 1

S-571

2322212

S-571

2322212

Cover Plate

2024-T3 Clad

0.100

2322212

Plate

2024-T3 Clad

0.125

2322212

Plate

2024-T3 Clad

0.063

12225-0072

Doubler

2024-T3 Clad

0.090

12225-0072

Web, Outbd (WS 80 to 181)


Web, Inbd (WS 0 to 80)

2024-T3 Clad

0.090

2024-T3 Clad

0.090

2024-T3 Clad

5-680

12225-0072

68 to

80)

Filler

3
2

5425020

Stop
Stop

2822058

Shroudlnstl., Fuel Cell

2322212

FIG. NO.

1
1
1
1

Stiffener(3 ea.)
Stiffener(2 ea.)

Doubler(WS
Angle

REPAIR

CODE

Plate

IFINISH
GAGE

2322212

12225-0072

F4-1

0.100

2024-T3 Clad

0.125

1
1

I
I

I Replace
I Replace

1
1
1
1
1
1
1
I
1
I

I
I
I
I
I
I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

I
I
I
I

Replace
Replace
Replace
Replace

Replace
Replace

2024-T3 Clad

0.063

2822057

Rib

2024-T3 Clad

0.063

2822057

Rib

2024-T3 Clad

0.063

2822057

Angle(G ea.)

2024-T42 Clad

0.063

2024-0 Clad

0.063

Phenolic

0.188

2024-0 Clad

0.063

Phenolic

0.188

2024-T42 Clad

0.063

F4-1

2024-T42 Clad

0.063

F4-1

2322560

2322560

2322560
2322560

2322560
2325079

2325079
2325079

Rib

51-71-05

I
I

Shroud

2322560

51-71-05

2822057

2322560

36

I
MATERIAL

Bearing

2322212

35

Angle,
Angle,
Angle

I
EFF.

2322221

12225-0072

34

I
DESCRIPTION

1
1

Instl., Outbd Flap Track

Support
Rib Assy.,

Inner

Rib, Inner
Fairlead, Outboard
Rib

Assy.,

Outer

F4-1

Rib, Outer
Fairlead, Outboard

Flap Actuator Support


Bracket, Upper
Bracket, Lower

F4-1

Replace

I Replace

2325079

Brace

16

S-534

2325079

Brace

17

S-5088

2325079

Fitting

2024-T3

1
1

I
I
0.160

F4-1

Replace
Replace
Replace
Replace

F4-1

51-71-02

F4-1

Wing Repair Index


Figure 1 (Sheet 12 of 23)
EFFECTIVITY:

MODEL28/29/31 SERIESAIRCRAFT

57-11-20

Page
SRM-4

12

Jun 1/95

Learjet
STRUCTURAL REPAIR MANUAL
ITEM
NO.

DWG.

NO.
2322516

37

I
DESCRIPTION
Bracket Instl., LH 8 RH,
Actuator

12322516

Bracket

Assy.,

LH

Spoiler Actuator
Weld Assy., LH

2322516

I
EFF.

I
MATERIAL

36

RH,

1
1

36

8 RH

36

I
I

I
I

Plate

36

2024-0 Clad

0.063

2322516

Bracket

36

2024-0 Clad

0.063

36

Phenolic

36
36
36

2322516

Fairlead (2 ea.)

2322516

Support Bracket,

2322516

LH 8 RH (2 ea.)
Support Angle, LH

8 RH

2322516

Door, LH 8 RH

2322516

Support Bracket Assy.


(LH Only)
Support Bracket
Support Bracket ILH Onlyl
Fitting Assy.
Bracket Assy., LH 8 RH

2322516

2422513
2322516
2322516

2322516

IStiffener

2322516
2322516

3122004
2322516

Support Angle,

2322516
2322516

0.063

2024-T42 Clad

0.063

2024-T3 Clad

0.080

1
1
1

I
I
I

Replace
Replace
Replace

Replace
Replace

51-71-00

0.063

0.063(

36

36

I Replace

2024-T42 Clad
2024-T42 Clad

0.063

36

S-735

0.063

36

2024-T3 Clad

0.063

/2024-T3Clad

0.063

F4-4

2024-T3 Clad

0.063

F4-4

38

37

LH 8 RH

Fitting Assy.
Bracket Assy.,

37

0.063

LH

RH

Anale

Phenolic

1
1
1
1

I
I
I
I

3/16

2024-T42 Clad

0.063

2024-T3 Clad

37

Bracket, LH 8 RH
1

2024-T42 Clad

2024-T42 Clad

Door, LH 8 RH

2322516

Replace
Replace
Replace
Replace
I Replace
Replace

37

2322516

2024-T42 Clad

36

Actuator

Fairlead(2 ea.)

2322516

3/16

Replace
Replace
Replace

36

RH
Gusset, LH
1
RH
Gusset, LH
Bracket Instl., LH 8 RH, Spoiler

2322516

2422513

36

36

Anale
Plate

Replace

I Replace

36

Bracket, LH 8 RH

2322516

REPAIR
FIG. NO.

CODE

Spoiler

2322516

2322516

37

37

0.080

I Replace
I Replace
I Replace
1 51-71-00
I Replace
I Replace
I Replace
I Replace

1
1
I

37

2024-T42 Clad

0.063

37

2024-T42 Clad

0.063

1
1

2322516

Plate

37

2024-T3 Clad

0.063

2322516

Gusset, LH 8 RH

37

2024-T3 Clad

0.063

F4-4

Replace

6022501

Fitting,

LH 8 RH

37

7075-T7451

2.5001

F4-4

Replace

6022511

Fitting, LH

3 RH

37

3.000

F4-4

6022512

Bracket

Replace
Replace
Replace

AL Sheet

7075-T7451
Bare Plate

Assy.,

LH 8 RH

37

Bracket, LH 8 RH

6022512
38

IFINISH
GAGE

2322560

Rib Instl., Inbd

37

2322560

2024-T42 Clad

I
0.063

F4-4
F4-4

Flap Track

Support
2322560

Rib Inner

Rib Outer

1 2024-0 Clad

0.063

2024-0 Clad

0.063

Replace
Replace

Wing Repair Index


Figure 1 (Sheet 13 of 23)
EFFECTIVITY:

MODEL28/29/31 SERIESAIRCRAFT

57-11-20

Page
SRM-4

13

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


DWG.
NO.

ITEM
NO.

5420000\18-1

39

I
DESCRIPTION

Spar Assy., No. 7, Inbd


(WS 0 to 53)
Spar Assy., No. 7, Inbd

12225-0011

I
MATERIAL

EFF.

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

20
19
1

Phenolic

0.188

Filler

7075-T73

0.188

I
I

12225-0011

Cover

7075-T73

0.080

12225-0011

Cover

7075-T73

0.100

I
I

Fairlead

12225-0011
12225-0011

12225-0011

Support

2024-T42 Clad

0.063

1
1

122250011

Stiffener

7075-T73

0.080

12225-0011

2024-T3 Clad

0.100

12225-0011

Filler(2ea.)
Fiiler(2 ea.)

7075-T73

0.188

12225-0011

Stiffener

7075-T73

0.080

12225-0011

Web

7075-T73

0.080

12225-0011

Cover

7075-T73

0.080

1
1

I
I

12225-0011

Spar Cap Lower


Actuator Support Fitting

Replace
Replace
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace

51-71-05

ILdgTrunnionAssy.

21

51-71-05

ILdgTrunnionAssy.
Ldg Trunnion Assy.
1

20

51-71-05

2822163

22

51-71-05

2322207

0.063

12225-0011

/SparCapUpper

1
I

I
I

Replace
Replace
Replace
Replace

12225-0070

S-765

5420000L1437
12225-0011V1-2

41

Splice,

2822180

40

Bracket
Lwr Aft

Wing Skin

2024-T3 Clad

S-766

2822178

Doubler

7075-T73 Plate

0.312

2822178

Doubler, Aft

7475-7651

0.312

j
1

0.188

12225-0009

1 SparAssy.,No.5,lnbd
(WS

12225-0009
12225-0009

O to 53)
Filler(2 ea.)
Spar Cap, Upper
Spar Cap, Lower

1
1

7075-T73

S-5053

0.125

1
1

I
I

0.080

S-5053

12225-0009

Web

7075-T73

0.125

12225-0009

Doubler

7075-T73

12225-0009

Stiffener

7075-T73

12225-0009

Bracket

12225-0009

12225-0009

12225-0009

Access Cover, Outbd


Access Cover, Inbd

(2024-T42Clad

7075-T73

7075-T73

2024-T3 Clad

I
i
I
I
I

Replace
Replace
Replace
Replace
Replace

6.000 1

51-71-05

51-71-05

I
I

Replace
Replace
Replace
Rep~ace

11

5426029
5426029

Tube

5052-0

0.028

5426029

Plate

6061-T6

0.063

28221 59

Splice,

2822179

Lwr Fwd

Wing

Skin

7075-T4

Replace
Replace
Replace
Replace
Replace

0.040(
0.100 1
0.100 1
0.190 1

Filler(WS21)
Fitting
Fitting

12225-0008

42

12225-0042

Splice

7075-T73

0.312

12225-0042

JSp\ice

7075-T73

0.1251

Wing Repair Index


Figure 1 (Sheet 14 of 23)
EFFECTIVITY:

SRM-4

MODEL28/29/31 SERIESAIRCRAET

57-11-20

Page 14
Jun1/95

Learjet
L8arjet

STRUCTURAL REPAIR MANUAL


ITEM
NO.
43

DWG.
NO.

I
DESCRIPTION

Spar Assy., No. 4, Inbd


(WS 0 to 53)
Spar Cap, Upper
Spar Cap, Upper
Spar Cap, Lower
Spar Cap, Lower
Stiffener(7 ea.)

12225-0008

12225-0008
12225-0008
12225-0008
12225-0008
12225-0008
12225-0008

IFiller

12225-0008

Web

12225-0082

2822155

Fitting
Fitting
Fitting

2822154

IFitting

12225-0082

Fitting

2822156
12225-0065

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

MATERIAL

Stiffener(2 ea.)

12225-0008

I
EFF.

IStiffener

10

S-762

23

S-5055

10

S-5761

23

I
I

S-5053

1
1
1

S-769

7075-T73

0.080

0.190

/2024-T3

I Replace

1
1
1

7075-n3

0.080

10

7075-T73

9.000

10

7075-T73

6.000

23

7075-T73

2.100

23

3.000

1
1

23

7075-n3
7075-T73

2.100

24

7075-T73

1 0.125)

25

7075-T73

0.125

Replace
Replace
Replace
I Replace
I Replace
I Replace
Replace
I Replace
I Replace
I Replace
I Replace

I Replace
I Replace

542000044

L1 469

Stiffener

12225-0007

No. 3

Spar
Assy.,
(WS 0 to 53)
Spar Cap, Lower
Spar Cap, Lower
Spar Cap, Upper
Spar Cap, Upper
Stiffener(2 ea.)

12225-0007

12225-0007
12225-0007
12225-0007

12225-0007

S-5053

/S-759

1
1
1

S-5052

7075-T73

0.080

I Replace

7075-T73

0.080

7075-T3

0.080

Stiffener(2 ea.)

7075-T73

0.080

2024-T3

0.190

Filler

12225-0067
2822151

2822167
12225-0007

Doubler

12225-0007

Bracket

Hinge

2322530

Bracket

7075-T3

Web(2 ea.)
Fitting(2 ea.)

Fitting
Fitting
Fitting
Fitting

2822150

10

7075-T73

2.700

11

7075-n3

3.000

11

7075-T73

1.900

11

7075-T73
2024-T3 Clad

1.900

1
1

Hex Rod

2322530

Hinge Bracket, Middle Inner


Bracket Hinge,

2024-T42 Clad

2024-T42 Clad

S-549

Middle Outer

I.Anale

2322530

2322530

Plate

Arm, Hinge, Middle

1
1

0.063

Stud

2322530

0.080

2024-T3 Clad

Assy.,

7075-T73

26

Middle

0.080

i 2024-T3 Clad
2024-T4

Replace

10

2322530
2322530

I Replace
I Replace
I Replace

Stiffener

12225-0007

I
I
I

Replace

Stiffener

12225-0053

45

S-759

12225-0007
12225-0008

12225-0007
12225-0007

Inbd

Replace
Replace

Replace
Replace
Replace
I Replace
Replace
I Replace
Replace
I Replace
I Replace
Replace

51-71-00

7/16

0.063

Replace
Replace

0.063

Replace
Replace
Replace

0.375 1

51-71-00

1
0.090

Wing Repair Index


Figure 1 (Sheet 15 of 23)
EFFECTIVITY:

MODEL28/29/31 SERIESAIRCRAFT

57-11-20

Page
SRM-4

15

Tun 1/95

STRUCTURAL REPAIR MANUAL


ITEM
NO.

DWG.
NO.

Outboard

REPAIR

51-71-00

Replace

Bracket, Hinge,

2322530

Outboard Inner

2024LT42 Clad

0.063

2024-T42 Clad

0.063

Replace

2024-T4

51-71-00

51-71-00

Replace

Hinge,

2322530

Outboard Outer

Arm, Hinge

2322530

Bracket

2322530

Assy., Hinge,

Inbd

Bracket, Hinge,

2322530

Inboard, Inner

2024-T42 Clad

2024-T42 Clad

2024-T4

0.063

Hinge,

2322530

Inboard, Outer
Arm, Hinge
Wing Skin Instl., Lower,

2322530
12225-0004

0.063

Replace

51-71-00

Replace
Replace
Replace
Replace

LH 8 RH

7475-T76

0.239

2322042

Filler

2024-T3

0.080

12225-0065

Filler, Stiffener

2024-T3

0.080

12225-0065

Stiffener(8 ea.)
Filler, Spar

S734

7075-T3

Wing Skin, LH

12225-0044

12225-0065
2822386
2622386

8 RH

Bracket

Assy.
I

Filler

2622386

Door

2622386

Replace

I
i
1

I
I
I
I

Replace
Replace
Replace
Replace

i
1

i
I

Replace
Replace

1
i

I
I

1
1

I
I

Replace
Replace
Replace
Replace
Replace

S-646

2024-T3

0.190

2024-T3 Clad

0.080

2024-T3

0.080

2822054
2822053

Door

2024-T3 Clad

0.160

2826010

Support

2024-T42 Clad

0.050

2024-T3

0.080

2024-T3 Clad

0.050

2024-T3 Clad

0.080

2024-T3 Clad

0.080

2024-T3

0.090

2014-T62

0.255

12225-0051
12225-0051
2326015
2322259

2622387
2622389
12225-0046

Doorlnstl.

IDoor
Bracket, Fuel Probe

Door(ll ea.)
Cover, Access (5 ea.)
Cover, Access
Wing Skin Instl., Upper,
I

LH 8 RH
12225-0045

Replace

0.080

1.. Bracket
Doorlnstl., Fuel Probe

2622386

Access Cover Instl.

IBracket

2622386

47

IFINISH

GAGE I CODE I FIG. NO.

MATERIAL

BracketAssy., Hinge,

2322530

46

EFF.\

DESCRIPTION

1
1

Wing Skin

Replace

F4 ext

F4-4int
12225-0045

Wing Skin

Replace

F4 ext

0.239

7475-T76

F4-4int

12225-0065

Stiffeners(ll ea.)
Stiffeners(2 ea.)

12225-0065

Stiffeners

12225-0065

12225-0076

S-734

S-783

10

Fitting

I
I

0.080

2024-T3
4130 STL

I
I

F8

Replace
Replace
Replace
Replace

Wing Repair Index


Figure 1 (Sheet 16 of 23)
EFFECTNITY:

MODEL28/29/31 SERIESAIRCRAFT

57-11-20

Page 16
SRM-4

Jun 1/95

Learjet i
~sariet

STRUCTURAL REPAIR IWANUAL


ITEM
NO. I

DWG.
NO.

I
I

2327038
12225-0065
2327009
12225-0056
12225-0049

IBracket
Bracket

2827038

2827038

Bracket

MountingAssy.

5427021

Mounting

12225-0055

Splicelnstl.

12225-0042

Splice, Fwd,

12225-0043
12225-0057

2422039
1

2422039

2422036
12225-0057
12225-0057

12225-0057
12225-0057
12225-0057
12225-0057

4130 STL

-I

2024-T4

0.312

2024-T4

0.312

I
I
I
I

0.080

201 4-T6

0.312

2014-T6

0.125

2014-T4

0.270

i Replace

29

Replace
Replace
Replace
Replace
Replace

Replace

I
2024-T3 Clad

0.063

29

2014-T6 Clad

29

2024-T6 Clad

0.071 1
1 0.040(
0.071 1

29

1
1
i

29

2014-T6 Clad

1
I

29

6061-T6

0.063

I
i

29

6061-T6

0.050

29

6061-T6

0.040

29

6061-T42

29

6061 -T6

1
1 0.040)

29

S-699

29

0.040

29

6061-T6

0.063

Filler

29

6061-T6

0.080

12225-0057

Clip
Fairing Assy.

29

6061-T6

0.040

Skin, L.E.

1 Replace

2024-T42

JBa~\e(3ea.)

12225-0047

Replace

Replace

29

Closure

12225-0047

Replace

Filler

12225-0047

Angle (3 ea.)

IFairina
ISDlice
IStiffener

0.040

0.063

12225-0057

12225-0047

F4-4

Replace
Replace
Replace
Replace
Replace

2024-T3 Clad

27

28

12225-0057

12225-0047

F8

1
I
1

2024-T42 Clad

Assy. (2 ea.)

IBracket
Bracket

I
I

0.080

Fairina

Bracket

1
1

0.063

2024-T3

28

Doubler
1
1
Splice
IStiffener

2422039

2024-T42

27

Doubler(2 ea.)

2422039
2422039

Lower Wing Skin


Splice, Fwd,
Lower Wing Skin
Splice, Aft,
Lower Wing Skin
LeadingEdgeinstl.
Fairing Assy.

12225-0042

Bracket

5427021

4130 STL

IFINISHI REPAIR
GAGE I CODE 1 FIG. NO.

BracketAssy.

5427019

50

Filler

5427019

49

I
MATERIAL

23

Splicelns~l.
Splice, Fwd,
Upper Wing Skin
Splice, Aft,
Upper Wing Skin
Bracket Assy.
r

12225-0050

IEFF.

Fitting
BracketAssy.

2822172

2327038

48

r
DESCRIPTION

29

1
1
1

0.063

1
1
I
1

0.071

0.063

29

2024-T3

29

201 4-T6

29

S-699

29

6061-T6

Replace
Replace
I Replace
1 Replace
Replace
I Replace
I Replace
Replace
I Replace
I Replace
I Replace
I Replace
Replace
I Replace
I Replace
I Replace
Replace
I Replace
I Replace
I Replace

Wing Repair Index


Figure 1 (Sheet 17 of 23)
EFFECTIVITY:

MODEL28/29/31 SERIESAIRCRAFT

57-11-20

Page
SRM-I

17

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


ITEM
NO.

DWG.

NO.

I
I

I
EFF.

DESCRIPTION

i
j

29

12225-0047

ISupportAssy.
Angle (2 ea.)
SparAssy.

12225-0047

29

12225-0047
12225-0047

2422029

I
2024-T3

0.063

12024-13

0.063

29

\FINISH\ REPAIR
CODE
FIG. NO.

i
1

29

Soar

Stiiffener (5 ea.)
Skin Assy.

12225-0047

GAGE

MATERIAL

S-571

29

29

j
1

29

6061-T6

0.063

29

6061-T6

0.063

29

2024-T42

0.025

2822034

Channel(lOea.)
Support

29

2024-T42

0.063

12225-0057

Rib

29

6061-T6

0.071

1
I

12225-0057

Bumper
Support Assy.
Support(3 ea.)

29

Skin

2422029
2422029

(2 ea.)

IDoubler

2822033

2422041
2422041

29

ISlice

2422041
12225-0057

Bracket

12225-0057

IBracket
Attach Rib Assy.

12225-0057

Assy. (9 ea.)

2024-0

29

2024-T3

6061-0

29

12225-0057

29

6061-T6

12225-0057

29

6061-0

29

12225-0057

TubeAssy.

29

12225-0057

Tube(2 ea.)
Clip

29

2822033
12225-0057
12225-0057

2822032
2822032
2822032

29

6061-T6

Tube

29

6061-T6

Sleeve

29

ITube

2822032

2822032

Spacer
Leading Edge

2822183

1
Instl.

0.080

/5052-0

1
I

Replace
Replace
Replace
Replace
Replace
I Replace
Replace
Replace
I Replace
I Replace
I Replace
I Replace
I Replace
Replace
Replace
Replace
Replace
Replace
Replace
I Replace
I Replace
I Replace

0.035
0.040

6061-T4

29

0.035

6061-T6

29

Assy. (3 ea.)
Plate Assy.
Plate(2 ea.)

0.040\
I
i 0.063\
I

Reducer(3 ea.)

12225-0057

29

(Plug

1
0.050\
0.063

6061-T6

Vent Tube Assy.


I~Tube

12225-0057

0.250

29
29

Attach Rib

12225-0057

Sponge

29
29

Sil.

I
I

1 0.0401
0.040/
0.035 1

I
I
I

I
j
I

29

5052-0

0.063)

29

5052-0

0.035

29

5052-0

0.063)

6061-T6

0.063

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

30

12225-0047

Skin, L.E.

30

12225-0047

Fairing Assy.

30

12225-0047

j
I

Replace
Replace
Replace

30

2024-T3

0.063

12225-0047

I.~Solice

30

2014-T6

0.071

12225-0047

1~. Stiffener

30

S-699

1
I

Replace
Replace
Replace
I Replace
j Replace
j Replace
Replace

Support Assy.
Angle(2 ea.)
Skin Assy., L.E.

12225-0047
12225-0047
2422029
2422029

2422029

Skin (2 ea.)
Doubler

30

30

2024-T3

0.063

30

30

16061-T6

30

6061-T6

1 0.0631
0.063

Wing Repair Index


Figure 1 (Sheet 18 of 23)
EFFECTIVITY:

MODEL28/29/31 SERIESAIRCRAFT

57-11-20

Page
SRM-4

18

Jun 1/95

Learjet I

STRUCTURAL REPAIR MANUAL


ITEM
NO.

DWG.
NO.

I
DESCRIPTION

BracketAssy.
Angle(2 ea.)
Clip
Fairing Assy.

2422034
2422034
2422034

2422039

2422039

IFINISH
GAGE

1
1

I
I
I
I
I
I
I
I
I
I
I
I
I

0.063

2024-T3

0.050

30

2024-T3 Clad

0.063

30

2014-T6 Clad

0.071

Doubler

30

2024-T6 Clad

0.040

2422039

ISolice
IStiffener

1
1

30

12014-T6Clad

0.071

5-699

REPAIR
FIG. NO.

CODE

2024-T3

2422039

1
I

0.050

1
I
1
I
1
1

2422043

Filler

30

2024-T3

0.063

2822181

Closure

30

6061-T42

0.040

281 9057

Anti-lcelnstl.

I
1
1
I

I
I
I
I

1... Support

2422041

SupportAssy.
Support (3 ea.)

2422041
2422041

ISlice

2422041

Bracket

2819058

281 9058

Assy.

2819058

IPlun

281 9058

Bracket

281 9058
2819058
2819058
2822032

2822032

Angle(3 ea.)
Baffle (3 ea.)
Sleeve Assy. (5 ea.)
Plate Assy.
Plate(2 ea.)

2822032

2822032

ITube

2822033

Channel

12225-0022
12225-0022
12225-0022

12225-0022
12225-0022

12225-0022
12225-0022

NAV

0.063

2024-T3

30

Light Structure
(2 ea.)

Skin

Rib, Removable
Rib, Lens
Rib, Closure (2 ea.)

Clip(2 ea.)
Spacer(2 ea.)
Spacer

I
6061-T62

0.071

I
6061-T62

0.063

30

6061-T6

0.040

1
I

I
I

30

6061-T62

0.035

30

6061-T62

0.040

30

5052-0

0.035

30

6061-T6

0.050

30

6061-T6

0.040

30

6061-T6

0.040

30
29

1
1

I
I

1
1
1

29

5052-0

0.063

29

5052-0

0.035

30

2024-T42

0.025

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

I
I

1
1

Replace
Replace
Replace
I Replace
Replace
I Replace
Replace
Replace
j Replace

1
1
1
1

I
I
I
I

1
1

I
I

1
1

6061-T6

0.063

31

6061-T6

0.063

6061-T6

0.063

6061-T6

0.063

2024-T3

0.063

2024-T42

0.063

1
1
I

I
I
I

2024-T42

2620000

Identification Plate

S-905

2322550

Gap

Closure Instl.

12225-0022

0.040

6061-T62

30
30

Tube(4 ea.)
Reducer (3 ea.)

2819058

2024-T3

30

30

Clip
TubeAssy.

281 9058

0.063

30

30

Attach Rib

2819058

2024-T3

30

Attach Rib

2819058

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

30

Assy. (11 ea.)

Rib

281 9058

30
30

IBracket

281 9058

30

30

Support Assy.

2422041

52

30

30

I
MATERIAL

30

Doubler(2 ea.)

2422036

51

30

Fairinn

2422039

I
EFF.

0.025

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Wing Repair Index


Figure 1 (Sheet 19 of 23)

EFFECTIVITY:

MODEL28/29/31 SERIESAIRCRAFT

57-11-20

Page 19
SRM-4

Tun 1/95

Leariet
~Learjetl

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

53

I
DESCRIPTION

2322550

2322550

I
I

Panel

Replace

2024-T3 Clad

0.025

Replace

2024-T3 Clad

0.025

2024-T42 Clad

0.050

2024-T3 Clad

1
1
0.090 1

I
I

2024-T42 Clad

0.050

Replace
Replace
Replace
Replace

I
I
I

Replace
Replace
Replace

Angle

Rib

Instl., Flap Slot Inbd

2322521

Rib

2312039

Bracket

2024-T42 Clad

Assy. (RH Only)

IBracket

I
2024-T3

Blade, Vortex Generators


Blade, Vortex Generators
Doubler, LH 8 RH
Stall Fence, (WS 185.58)

2322555
2322571

12225-0106
2822035

S-707

2014-T3

\Sta\\Fence

16061-T6

Plate

6061-T6

5-5078

5-5078

)S-5078

Assy.,

Fwd

Assy.,

Lwr

Assy.,

Ctr

Assy.,

Aft

LH 8 RH

2822035

Stall Fence

2822035

Stall Fence

5422169

Wing Fence, Leading Edge,

5422159

Stall Fence

5422159

StallFence

LH 8 RH

LH 8 RH

Assy.

Attach Plate

Replace
Replace

Replace

Replace

Fl

Replace

Replace

0.063

1
1

I
I

Replace
Replace

0.250

Replace

6061-T6

0.125

6061-T6

6061-T6

Strip Instl., (WS 102.2)


3

LH 8 RH
5422158

0.160)
0.062 1

F1

LH 8 RH

Stall

2822035

Stall Fence

Replace
Replace
Replace
Replace

0.100

2822035

5422156

LH 8 RH

5422157

0.032

i
S-621

Stall Fence

5422159

2822035

2822035

0.040

Vortex Generator Instl.,


LH 8 RH

59

0.025

Door

2322555

58

2024-T3 Clad

2322550

231 2039

57

Replace

Closing

56

Angle, Pnl Support (2 ea.)

2322521

55

2322550
2322550

54

0.025

Replace

Panel

2322550

2024-T3 Clad

Assy.

~PanelAssy.

2322550

0.050

Panel
~Panel

2322550

2024-T42 Clad

Panel

PanelAssy.

2322550

REPAIR
FIG. NO.

CODE

PanelAssy.

2322550

IFINISH
GAGE

Rib

2322550

I
MATERIAL

RibAssy.

2322550
2322550

IEFF.

StallStrip
Stall Strip Instl., LH

3
8 RH

Wing Repair Index


Figure 1 (Sheet 20 of 23)
EFFECTIVITY:

sRM-a

MODEL28/29/31 SERIESAIRCRAFT

57-11-20

Page 20
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ITEM
NO.
60

DWG.
NO.
5422002
3122002

3122003
61

15422002
2422086

62

2422086
2422086

Stall

(3 ea.)
Wing Center Section

Fence

Drain

2422116

Attach Plate

Clip

Replace
Replace

Replace

1 0.312)

6061-T6

0.032

6061-T6

0.160

6061-T6

0.063

S-5078

Replace
Replace
Replace

Replace

2024-T42 Clad

0.032

Flange Weld Assy.

Washer
Elbow

0.090

FIG. NO.

CODE

Fence Assy.

2422116

6061-T6

/6061-T6

GAGE

IFence

2422117

3
3

Stall Fence Instl.

Drain Instl.,

IFINISHI REPAIR

I
MATERIAL

StallTriangle

2422086

2422116

100.08 8 203.0)

Stall Strip (WS 238.8)


Stall Strip Instl., (WS 148.15)
LH 8 RH

2422086
2422117

Strip (WS

I
EFF.

DESCRIPTION

5052-0

5052-0

Tubing

0.063 1
1 0.0631

Replace
Replace

Wing Repair Index


Figure I (Sheet 21 of 23)
EFFECTIVITY:

MODEL28/29/31 SERIESAIRCRAFT

57-11-20

Page 21
SRM-4

Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


CODES
1

EFFECTIVITIES
2&001 THRU 28-005; 29-001 THRU 29-004; 31-001 AND SUBSEQUENT
2&001 THRU 2&005; 29-001 THRU 29-004
31-001 AND SUBSEQUENT.

2&001 THRU 28-004; 29-001 THRU 29-002; 31-001 AND SUBSEQUENT


31-001 THRU 31-046

31-047 AND SUBSEQUENT

DELETED

29-002 THRU 29-004; 31-001 AND SUBSEQUENT


2&001 THRU 28-005; 29-001
2&001 THRU 2&004; 29-001
2&005; 29-002 THRU 29-004
31-001 THRU 31-013

9
10
11
12

13

31-043 AND SUBSEQUENT

14

28-004, 2&005; 29-001


28-004, 2&005; 24001; 31-001 AND SUBSEQUENT
2&001 THRU 28-005; 29-001 THRU 29-003
29-004; 31-001 AND SUBSEQUENT

15

16
17

18

DELETED

19

31-001 THRU 31-042, 31-058 AND SUBSEQUENT


31-043THRU31-057
31-001 THRU 31-014

20
21
22
23
24
25
26

27

28
29
30

31-015 THRU 31-042, 31-058 AND SUBSEQUENT


2&005; 24002 THRU 29-004; 31-001 AND SUBSEQUENT
2&001 THRU 2&005; 29-001 THRU 29-004; 31-014 AND SUBSEQUENT
31-001 THRU 31-013
29-001 THRU 29-004; 31-001 AND SUBSEQUENT
2&001 THRU 28-005; 29-001 THRU 29-004; 31-001 THRU 31-048
31-049 AND SUBSEQUENT

28-001 THRU 28004; 29-001 THRU 29-002


29-003 AND 29-004; 31-001 AND SUBSEQUENT

31

31-013 THRU 31-020

32

2&001 THRU 28-003

33

37

2&004; 29-001 THRU 29-004; 31-001 AND SUBSEQUENT


2&005; 24001 THRU 29-004; 31-001 AND SUBSEQUENT
2&004 AND 28-005; 29-001 THRU 29-004; 31-001 AND SUBSEQUENT
2&001 THRU 28-005; 29-001 THRU 29-004; 31-001 THRU 31-088
31-089 AND SUBSEQU ENT

38

31-001THRU31-088

34
35
36

Wing Repair Index


Figure 1 (Sheet 22 of 23)
EFFECTIVITY:

MODEL28/29/31 SERIESAIRCRAFT~

57-11-20

Page 22
SRM-t

Jun1/95

Learjet
~Learjetl

STRUCTURAL REPAIR IVIANUAL


NOTES

Chem Film per 51-30-04, Protective Treatment of Structural Materials.


Finish F4-6 and

apply top coat

Laminated shim stock, 0.002

of 6160 Matterhorn White

or

Alumigrip

0.003 lamination per MlL-S-22499

Urethane Enamel.

Type 1, Class

or

Class 2, 1145-H19 aluminum

sheet.

Condition Normalized.
Per MlL-P-15035

Wing Repair Index


Figure 1 (Sheet 23 of 23)
EFFECTIVITY:

MODEL28/29/31 SERIESAIRCRAFT

57-11-20

Page 23
SRM-4

Jun1/95

~"YL
tvuuc

tl

19)

j/

U
N

It
I

II

I,

ii-I
I
I

I~

I,

(L

011

II

C""

!1

Cj

-5----,--~

i-~4

le~
I

I~

,I;J(---f-l-/-------~=I-

c-

c~l

~e

I~n

--2_-------1_~--111--

=-,i;-------

I~
I-

I
I
2,-

,I

-,-s~--;-J

i_

333r~

~sse

AOICR4F~
57~11_30
Page Z

Eny Is~

CE3~

re

zr

Learjet
STRUCTURAL REPA1R MANUAL
ITEM

DWG.

NO.

NO.
2620000
2620000

2322044

2322044
2322044

2322044
2322044

2322044
2322044
2322044
2322044
2

2322080

2322080
2322080
2322080
2322080
2322080
3

2322100
2322100
2322100
2322100

2322100
23221 00
2322100

2322100
23221 00
2322100
4

2322120
2322120

I
DESCRIPTION

Wing Assembly
Wing Structural Assy., LH 8 RH
Splice Instl., Spar No. 1
Angle, Upper
Angle, Lower
Angle, Upper
Angle, Lower
Filler, Upper Lower
Attach Angle
Splice Angle, Lower
Splice Angle, Upper
SparAssy., No. 2 Inboard
Spar Cap, Lower
Spar Cap, Upper
Doubler(2 ea.)

Angle(3 ea.)
Spar Assy., No. 3 Inboard
Spar Cap, Upper
Spar Cap, Lower
Doubler
Web

Angle
Angle
Angle
Angle
Angle

MATERIAL

2024-T42 Clad

0.125

2024-T42 Clad

0.125

0.080

1 2024-T42 Clad
2024-T42 Clad
2024-T3 Clad

2024-T42 Clad

0.063

i 2024-T42 Clad

0.080

2024-T42 Clad

0.080

0.080

S-622

S-623

2024-T3 Clad

0.063

2024-T3 Clad

0.080

1
1

S-527

S-526

2024-T3 Clad

0.100

0.080

2024-T3 Clad
S-512

S-512

S-512

S-512

I
I

I Replace
I Replace

2322120

S-524

2322120

Doubler

2024-T3 Clad

S-571

S-545

1 2024-T3 Clad

Web

2322140

Filler

Spar Cap, Lower


(2 ea.)
Fitting, Forward Main

S-535

2024-T3 Clad

2322142

Access Cover

2322146
2322141

Spar Cap, Upper

Gear

0.080

Replace

1
1

0.063

F4-4

I Replace
Replace
I Replace

2322140

2322140

Replace
Replace
Replace
Replace
Replace
Replase
Replace
Replace
Replace

S-525

2622388

Replace
Replace

F4-4

12322140

F4-4
F4-4
F4-4
F4-4

jS-512

Replace
Replace
Replace
Replace
Replace
Replace
Replace
I Replace
I Replace
Replace
Replace
Replace

I
I
I
I
I

1
1
1
1

0.080

Stiffener(7 ea.)
Attach Angle, Spar to Rib
SparAssy., No. 5 Inboard

FIG. NO.

Spar Cap, Upper


Spar Cap, Lower

2322120

REPAIR

CODE

S-512

No. 4 Inboard

IFINISH
GAGE

Web

SparAssy.,

EFF.

Web

2322120

1 2024-T3 Clad
2024-T3 Clad

\S-534

0.100

1-

0.125

0.100

I Replace
I Replace
I Replace

I Replace

Replace

1 51-71-00

Wing Repair Index


Figure 1 (Sheet 2 of 18)
EFFECTIVITY:
SRM4

MODEL35/36SERIES AIRCRAFT

57-11-30

Page 2
May 15/92

I Learjet
Learjetl
STRUCTURAL REPAIR MANUAL
ITEM
NO.
6

DWG.
NO.
2322203
2322203

DESCRIPTION

ISparAssy.,

2024-T3 Clad

S-516

S-517

Doubler

2024-T42 Clad

0.080

2322203

Cover

2024-T3 Clad

0.080

2322203

Doubler

2322203

Filler

2024-T42 Clad
2024-T3 Clad

0.160

2322203

SupportAssy.

1
1

2024-T42 Clad

0.080

Phenolic~

2024-T42 Clad
2024-T42 Clad

0.063

2322207

Support, Clamp
Angle Reinforcing (2 ea.)
Support, Main Gear
Bracket, Switch

0.063

2322203

Cover

2024-T3 Clad
2024-T3 Clad

2322203

Support Assy., Lwr (RH Only)

1 2024-T42 Clad
Phenolic [i~

0.080

2322203

2322203
2322204

(2 ea.)

Support, Upper

1
1

2322203

Spar Assy., No.


Stop(2 ea.)

Cover Plate

Spar Web, Inboard

Stiffener(5ea.)

Filler
Plate
Plate

23222 i 2

Doubler

2322212

Web, Outboard

2422551
2322221
2622376
2622376
2622376
2441007

1
2

Spar Cap, Upper


Spar Cap, Lower
Support, Gear Act. Pin, Aft
Angle Assy., Spar Attach
i.... Angle

2322230
2322230

Bearing Plate
Assy.
Stiffener(lO ea.)
Filler(G ea.)
Rib Cap, Upper
Support

2322230

Attach

2622230
2322230
2322230

Replace
Replace
Replace
Replace

3/16
0.100

51-71-00

Replace

0.100

I Replace

1/8

51-71-00

I Replace

2322212
2322212
2322212
2322212

2422551

0.080

Replace
Replace
Replace
Replace
Replace
Replace
Replace

1
1

2322212
2322212
2322212

0.100

2322203

2322212

REPAIR
FIG. NO.

Spar Cap, Upper


Spar Cap, Lower

2322203
2322203

FINISH
CODE

GAGE

2322203
2322203

No. 7 Inboard

MATERIAL

Web

2322203

EFF.

Rib

Angle

1
1

S-614
2024-T3 Clad
2024-T3 Clad
S-571
2024=r3 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad

0.100
0.090

0.125
0.125
0.063
0.100

S-5091
S-5091

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
51-71-00

S-603

2024-T3 Clad
2024-T3 Clad

0.090

Replace
Replace

0.312 1

51-71-00

1
1

S-512

0.100

2024-T3 Clad
S-599

2024-T42

0.050

S-603

Replace
Replace
Replace
Replace
Replace

Wing Repair Index


Figure 1 (Sheet 3 of 18)
EFFECTIVITY:
SRM~I

MODEL 35/36SERIES AIRCRAFT

57-11-30

Page 3
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
DWG.
NO.

ITEM

NO.

DESCRIPTION

2322230

Rib

2322238

Attach

BracketAssy.

1
1

2024-T42 Clad

0.040

2024-T3 Clad

0.080

2322016

Strip
Strip
Angle
Strip

2024-T3 Clad

0.063

2024-T3 Clad

0.063

2024-T42 Clad

0.063

2024-T3 Clad

0.063

Attach

S-603

2622230

2322293

Rib

Angle
Assy.

2024-T3 Clad

0.063

Filler

2024-T3 Clad

0.080

2322293

Rib

S-502

S-502

2322293

Cap, Upper
Cap, Lower
Attach Angle (4 ea.)

Rib

2024-T42 Clad

0.080

2322293

Filler

2024-T3 Clad

0.080

S-512

I
1

Stiffener

1
1

I
I

1
1

I
I

1
1

I
I

Web

2322290

I
I

2322293

2322293

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2322293

2322293

FIG. NO.

I
I

S-520

Web

2322063

REPAIR

CODE

I
0.080

2622230

2322018

2024-T42 Clad

IFINISH
GAGE

S-600

Bracket
Bracket

I
MATERIAL

2627014

2322017

10

Cap, Lower
Angle (5 ea.)

2327014
2627014

I
EFF.

Rib

1
1

I
I

I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace

2322290

Segment Assy.
Tee(2 ea.)

S-5g6

2322290

Web

2024-T42 Clad

0.100

2024-T3 Clad

0.063

j
I

I
I

I Replace

1
1

I
I

2322290

Gusset

2322290

Stiffener

S-571

2322290

Tee

S-569

I
1
1

2322290

Rib

Segment Assy.
Tee(2 ea.)

2322290

S-596

2322290

Web

2024-T42 Clad

0.100

2322290

Angle

2024-T42 Clad

0.100

S-571

2322290
2322290

Stiffener

Rib

Segment Assy.

I
1
I

I Replace
I Replace

I Replace

2322290

Tee

S-596

Tee

S-597

2322290

Tee

2422549

Filler
Fairlead

2322290

Fairlead

2322290

Web

2322290
2322290

S-598

2024-T3 Clad

Phenolic

32

Tee
Fairlead

Replace
Replace
Replace
Replace

Replace
Replace
Replace

2322290
2322290

I Replace

1~

0.160
0.125

Phenolic

0.125

2024-T42 Clad

0.080

S-642

Phenolic

0.125

Replace
Replace
Replace
Replace
Replace
Replace

Wing Repair index


Figure 1 (Sheet 4 of 18)
Em~ECTNITY:
SRM-4

MODEL 35/36SERIES AIRCRAFT

57-11-30

Page 4
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

I
Rib

2322290

Tee(2 ea.)
Fitting
Fitting
Fitting

2322290
2322275
2322281
2322282

2322292

(RibAssy.,WS53.04

0.125

1
I

I
I

I
I

I
i

1
1

51-71-00

51-71-00

0.100 1

51-71-00

Replace
Replace

2025-T3 Clad

I
0.160

2024-T3 Clad

0.125

2024-T42 Clad

0.080

Phenolic 1~

Angle (12 ea.)

2322320

Web, Forward

2024-T3 Clad

2322321

Rib

S-592

S-592

Cap, Upper
Cap, Lower

2322321

Rib

2322322

Bracket

51-71-00

2024-T3 Clad

Tie

Replace
Replace

Spar

FIG. NO.

1
1

1 6061-T6 Clad

1
I

Replace
Replace
Replace
Replace

3/16

0.080

Replace
Replace
Replace
Replace

I
I

I
I
0.063

2422549

Fairlead

Phenolic

2322320

Stiffener

S-571

2322320

Stiffener

S-571

2024-T3 Clad

0.160

Replace
Replace
Replace
Replace

2322330

Web

Rib Instl., WS 92.52

0.125

2322330

Rib

2024-T42 Clad

0.071

Replace

2322330

Fairlead

Phenolic

0.188

2322330

Angle (2 ea.)

2024-T42 Clad

0.071

Replace
Replace

2322330

Rib

2024-T42 Clad

0.071

2322330

Filler

2024-T3 Clad

0.080

1
1

i
I
I

2024-T42 Clad

0.071

2024-T42 Clad

0.071

0.071

1
I
0.071(

I
I

2322340
2322340

2322340
2322340

Segment

Segment (6 ea.)

IRiblnstl., WS 125.00
Rib

Segment
Angle(2 ea.)
Rib Segment (7 ea.)

2024-T42 Clad

Fairlead

Phenoiic

S-l 50-1

Bracket

Clip

2322350

IRiblnstl., WS

2322350

Rib

2322350
2322350
2322350

33
157.48

Segment (3 ea.)
Angle (2 ea.)
Angle
Rib Segment (4 ea.)

Replace
Replace

2322330

2322340
14

S-596

Filler

2322320

13

2024-T42 Clad

2322320

Fairlead

REPAIR

CODE

1
1

Filler(5 ea.)

2322320

IFINISH
GAGE

2322320
2322320

12

I
MATERIAL

Fitting
Fitting

2322291

I
EFF.

Filler

2322287

2322320

Segment Assy.

Web

2322290

11

I
DESCRIPTION

I~

0.188

12024-T42

Replace
Replace
Replace
Replace
Replace
Replace

2024-T42 Clad

0.080

2024-T42 Clad

0.071

34

2024-T42 Clad

0.071

F4-4

Replace
Replace
Replace

2024-T42 Clad

0.063

F4-4

Replace

I
F4-4

Wing Repair Index


Figure 1 (Sheet 5 of 18)
EFFECTIVITY:
SRM~

MODEL 35/36SERIESAIRCRAFT

57-11-30

Page 5
May 15/92

Leariet
STRUCTURAL REPAIR MANUAL
ITEM

NO.
15

DWG.
NO.
2322564
2322564
2484039
2484039

Cover

DoublerAssy.

2622040

2622376
2622376

0.080

2024-T3 Clad

0.080

2024-T3 Clad

0.063

2021-T3 Clad

0.080

FIG. NO.

1
1

I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.063

Replace

0.080

I
I

I
I

Replace
Replace
Replace
Replace

I Replace

j
1
1

I
I
I

2024-T3 Clad

0.080

2024-T42 Clad

0.080

2024-T42 Clad

Anale

2622376

Filler

2024-T42 Clad

1 2024-T3 Clad

0.090

2322257

Stiffener

S-571

2322257

Stiffener(ll ea.)
Spar Assy., No. 2 Outboard
Stiffener(4 ea.)

S-571

I
I

S-571

2024-T42 Clad

0.063

2024-T3 Clad

0.100

2322565

REPAIR

CODE

2622376

2322257

2322258

Doubler Plate

2622388
2622388

Filler

Filler

2024-T3 Clad

2322565

Spar

2024-T4 Clad

2322565

Angle

2024-T42 Clad

0.080

2322565

Angle

2024-T42 Clad

0.080

2622388

Channel

2024-T42 Clad

0.080

2622376

Angle Assy., Spar

1 2024-T42 Clad

0.050

2024-T3 Clad

0.090

1
1

Replace
Replace
Replace
I Replace
I Replace
I Replace

2622376

Anale

2622376

Filler

2622388
2622032
2622388
2322566
2322566
2322257
2622376
2622376

Attach

0.080

5-571

2024-0 Clad

0.080

Doubler

2024-T3 Clad

0.090

Shim

2024-T3

0.020

2024-T5 Clad

2024-T42 Clad
S-571

1
1

1
1

I Replace
0.080

Replace

I
I

I Replace
I Replace

2024-T42 Clad

0.050

Replace

2024-T3 Clad

0.090

1
1
1
1
1

I Replace
I Replace
I Replace
I Replace
I Replace

2622388

Channel

2024-T42 Clad

0.080

2622398

2024-T3 Clad

0.080

2622388

Filler
Filler

2024-T3 Clad

0.100

2622388

Shim

2024-T3 Clad

0.020

(2 ea.)

Replace
Replace
Replace

Anale
Filler

Replace
Replace
Replace
Replace

Spar Assy., No. 3 Ourboard


Spar
Angle
Stiffener(l4ea.)
Angle Assy., Spar Attach

2322566

2622376

(9 ea.)

Stiffener
Channel

2322257

17

Angle, Spar Attach


Angle(2 ea.)
Angle Assy., Spar Attach

2622381

2024-T3 Clad

Doubler

IFINISH
GAGE

1
4

2622040

I
MATERIAL

Cover

2622040

I
EFF.

Spar Assy., No. 1 Outboard


Spar
Doubler(2 ea.)
Cover Assy. (2 ea.)

2322564

16

I
DESCRIPTION

Wing Repair Index


Figure 1 (Sheet 6 of 18)
EFFECTTVITY:

MODEL35/36SERIES AIRCRAF~

57-11-30

Page
SRM-4

May 15/92

Leariet
STRUCTURAL REPAIR MANWAL
DWG.
NO.

ITEM
NO.

2322567

18

I
I

ISparAssy.,

2322567
2322257
2622376
2622376

2622376

2024-T42 Clad
2024-T4 Clad

1
1
i

S-571

0.080

I
I
I

1 2024-T3 Clad

0.090

2024-T3 Clad

0.080

Filler

2622388

Shim

2622032

Doubler

(2 ea.)
1

Filler

Spar Assy.,
Angle

No. 5 Outboard

2024-T42 Clad

0.050

2024-T3 Clad

0.100

0.080

2024-T42 Clad
2024-T3 Clad

2024-T3 Clad

0.090

2024-T3 Clad

0.090

2024-T42 Clad

0.080

2024-T4 Clad

I
I

I Replace
I Replace

Replace
Replace

Replace
Replace
Replace
Replace
I Replace
I Replace
I Replace

1
1

I
I

0.020

Replace

Stiffener(l5 ea.)
Stiffener(2 ea.)

3-571

S-571

2622040

Doubler

2024-T3 Clad

0.080

F4-4

2622040

Cover

2024-T3 Clad

0.040

F4-4

2622040

Angle

2024-0 Clad

0.080

2322568

Doubler

10

2024-T3 Clad

0.050

Replace
Replace
Replace
Replace
I Replace
Replace
Replace
I Replace
I Replace

2622376

Angle Assy., Spar

2024-T~2 Clad

0.050

I Replace

2024-T3 Clad

0.090

2322568

Spar
Shim, Laminated (Max. 0.020)

2322568
2322257

2322257

20

1
1

Filler

Channel

2322568

i
IFINISH REPAIR
JGAGE I CODE 1 F\G. NO.

2622388

2322568

MATERIAL

Anale

2622388

2622032

No. 40utboard

Filler

2622388

I
EFF.

Angle
Spar
Stiffener(16 ea.)
Angle Assy., Spar Attach

2322567

19

I
DESCRIPTION

2622376

Anale

2622376

Filler

Attach

Fitting

2024-T3 Clad

1.600

2622388

Channel

2024-0 Clad

0.080

2622388

Filler

2024-T3 Clad

0.080

2622388

Filler

2024-T3 Clad

2622390

Fitting
Spar Assy., No.
1
Spar

2024-T3

2322569

6 Outboard

Stiffener

2322257

Stiffener(ll ea.)
Angle Assy., Spar

2622376

I
I

Replace
Replace
Replace

1
1
1
I

I Replace
I Replace
Replace
I Replace

Replace

Replace
Replace

1
0.100)
1.600 1

2024-T4 Clad

11

3-571

3-571

Attach

Anale

2024-T42 Clad

0.050

2622376

Filler

2024-T3 Clad

0.090

2024-T3 Clad

2322257

Stiffener

S-571

2622388

Channel

Shim

Replace
Replace
Replace
Replace
Replace

2622376

2622388

Replace

1
1

2322257

2622390

2322569

0.020

2024-T42

0.080

2622388

Doubler Plate

2024-T3 Clad

0.050

2622388

Filler(2 ea.)

2024-T42 Clad

0.080

Wing Repair Index


Figure 1 (Sheet 7 of 18)
EFFECTNITY:
sRM-e

MODEL 35/36SERIES AIRCRAI~T

57-11-30

Fage 7
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

21

2322570

2322570
2622390

Spar Assy., No. 7 Outboard


Spar
Fitting, Spar No. 7
Stiffener(l3 ea.)

REPAIR

CODE

FIG. NO.

2024-T4

1
1

1
I

I
I
I

S-571

2024-T3 Clad

0.020

2327001

Clip
Angle Assy., Spar Attach

2024-T42 Clad

0.050

2024-T42 Clad

0.050

2024-T3 Clad

0.090

IFINISH
GAGE

MATERIAL

Shim

2622376

Replace
Replace
Replace
Replace
Replace

I
I

2622388

Filler

2024-T3 Clad

0.100

2622388

Filler

2024-T3 Clad

0.080

2622390

Fitting, Spar No.


Fitting, Spar No.

2024-T3 Clad

1.600

2622390

2024-T3 Clad

1.600

1
1
1
1

2622388

Channel

2024-T42 Clad

0.080

Replace
Replace
Replace
Replace
Replace
Replace
Replace

2024-T3 Clad

0.080

Replace

3003-0

S-727

S-727

1
1

I
I

I
I

Replace
Replace
Replace

2622376
2622376

2622374

Angle
Filler

IRiblnstl.,
Web

2622374

Vent Tube

2622378

2622378

2622376

1. Stiffener

2622378

2622378

2622378
1

Soar

Angle, Spar

2024-T42 Clad

0.063

0.040

I
1

I
I
I

1
I
1

I
I
I

Replace
Replace
Replace

I
1

I
I

Replace
Replace
Replace

1
I

Replace
Replace

Replace

2024-T42 Clad

S-512

S-571

2024-T42 Clad

I
I
0.050

Replace
Replace
Replace
Replace

2024-T42 Clad

S-571

2024-T42 Clad

0.050

2024-T42 Clad

0.040

S-571

2024-T42 Clad

0.040

0.050

1
I

Attach

0.063

Stiffener

0.063

2024-T42 Clad

Angle, Spar Attach


Spar Assy., No. 5

2622376

2622376

1.. Stiffener

2024-T42 Clad

Spar

2622378

2322257

No. 2

Angle, Spar Attach


SparAssy., No. 4

2622378

1
1

IStiffener

2622376

2622378

Attach

Angle, Spar Attach


Spar Assy., No. 3
Spar

2622376

2322257

Soar

2322257

I
I
I

Anale

Stiffener

I
I

0.032

Soar

2622378

2322257

Wall)
Cap, Upper
Rib Cap, Lower
Wing Extension Assy.
Spar Assy., No. 1

Spar Assy.,

2622378
2622378

OD

Cover(2 ea.)
Angle Assy., Spar

2622378
2622376

(0.250

Rib

2622374
2622370

WS 181.10

2622374

2622374
23

I
EFF.

2622388

2322257

22

I
DESCRIPTION

2024-T42 Clad

S-571

2024-T42 Clad

0.040

I
0.050

Replace
Replace
Replace

Wing Repair Index


Figure 1 (Sheet 8 of 18)
EFFECTIVITY:

MODEL 35/36SERIESAIRCRAFT

57-11-30

Fage 8
SRM~

May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ITEM
NO. r

DWG.
NO.

I
I

Spat Assy., No.


Spar

2622378
2622378
2322257

2622378

2622378
2322257
2622376
2622375

2622375

Rib Instl., WS 205.147


Rib Cap, Lower
Web

Cap, Upper
(Max. 0.094) (2 ea.)

Rib

2322372

Fitting, Tip Tank Fwd Attach


Fitting, Tip Tank Aft Attach
Angle, Spar Attach (9 ea.)
Filler(A/R)
Clamping Ring (2 ea.)
Shim(Max. 0.040) (2 ea.)

2322371
2622376

2622371
2622371
2622371

0.050

2024-T42 Clad

S-571

2024-T42 Clad

0.050

Replace
I Replace
I Replace

0.032

1
I
1

Replace
I Replace
r Replace

2024-T42 Clad

S-571

2024-T42 Clad

S-727
2024-T3 Clad

S-727

I
0.050

51-71-00

51-71-00

1
i

Replace
I Replace
Replace
Replace
I Replace

0.050

2024-T42 Clad
2024-T3 Clad

2024-T3 Clad

0.160

2024-T3 Clad

0.090

2014-T6 Clad

0.071

Replace

2014-T6 Clad

0.090

I Replace

2024-T3 Clad
2024-T3 Clad

0.090

0.071

I Replace
Replace

I Replace
Replace
I Replace

0.090

1
1
1
1
1

Door

Doubler

DoorAssy.

2622384

Door

2024-T3 Clad

0.090

2622384

Doubler

2024-T3 Clad

0.071

2622384

Bracket

2024-T3 Clad

0.050

6061-0

0.063

2622372
2622372

Replace
I Replace
Replace
Replace

0.080

2622384

Access

0.050

2622384
2622384

2024-T42 Clad

Replace
Replace
I Replace

Access DoorAssy.

2622384

Skinlnstl., Upper
Skin, Upper
Skinlnstl., Lower
Skin, Lower

2622371

0.040

Filler

2622376

S-571

Shim

2622376

2024-T42 Clad

2622375

2622376

2622375

2322373

IFINISH REPAIR
GAGE I CODE I FIO. NO.

Angle, Spar Attach


Spar Assy., No. 8
Spar
Stiffener(2 ea.)
Angle, Spat Attach

2622378

I
MATERIAL

IStiffener

2622376

2622375

Angle, Spar Attach


Spar Assy., No. 7
Spar

2622378

I
EFF.

IStiffener

2622376

2322257

I
DESCRIPTION

Leading Edge Inst.

12

Skin

12

F14-1int

Replace

F1 ext
2622372

12

Access Panel

0.063

16061-0

F14-1int

Replace

F1 ext

2622373
2514304

Rib

IScuooer

12

2024-T42 Clad

12

6061-0

0.050

F4-1

0.032

F14-1lnt

Replace
Replace

F1 ext

Wing Repair Index


Figure
EFFECTZVITY:
SRMII

MODEL35/36 SERIESAIRCRAFT

(Sheet 9 of 18)

57-11-30

Page 9
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

Skin

2622034

Filler

2024-T42 Clad

0.050

6061-T6

0.063

2024-T3 Clad

0.032

2024-T3 Clad

0.063

SuDDort

2024-0 Clad

2422041

ISuDDort

S-745

SupportAssy.

Fairing Assy.

2422039

IFINISH

REPAIR

CODE

FIG. NO.

I
I

1
1

I
I

0.063

Replace
Replace
Replace
Replace
Replace

Fairina

2024-T3 Clad

0.063

2422039

Doubler

2014-T6 Clad

0.071

1
1

I
I

2422038

IScuooer

6061-0

0.032

13

2024-T42 Clad

0.025

13

2024-T42 Clad

0.025
0.032

I
I
I
I

Trailing Edge Instl.

Intercostal, Fwd
Intercostal, Aft
Intercostal, Fwd
Intercostal, Aft
Rib, Inboard
Rib, Outboard
Angle, Attach (3 ea.)

2622382

2622382
2622382
2622382

2622382
2622382
2622382

14

2024-T42 Clad

14

2024-T42 Clad

0.032

2024-T42 Clad

0.025

1
1
1
1

2024-T42 Clad

0.025

2024-T3 Clad
S-639

0.032

2622383

Trailing Edge Filler


Shim(Max. 0.040)
Skin, Upper

2024-T3

0.071

2622383

Skin, Lower

2024-T3

0.090

i
1

2024-T3 Clad

0.032

2622382
2622382

Door

2325079
2325079

2325079
2322560
2322560

2322560

Rib

2322560
2322560
2322560

35

S-534

F4-1

36

S-5088

F4-1

Replace
Replace

2024-T3 Clad

0.160

F4-1

51-70-00

2024-T42 Clad

0.063

F4-1

2024-T42 Clad

0.063

F4-1

Replace
Replace

2024-T42 Clad

0.090

F4-1

Phenolic

0.188

F4-1

Assy., Outer

Rib, Outer
Fair\ead, \nboard
Rib Instl., Outboard Flap

2024-T42 Clad

0.090

F4-1

Pheno\ic

0.188)

F4-1

Track

Support

Replace

Rib, Inner
Fairlead, Inboard

2322560

Fitting, CylinderAttach
Bracket Support, Upper
Bracket Support, Lower
Rib Instl., Inboard Flap
Track Support
Rib Assy., Inner

2325079
2325079

1
1

Brace, Bracket End


Brace, Bracket End

2325079

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Support Instl., Flap Actuator


BracketAssy.

2325079

2322560

Access Door Instl.

2622379

2622384

Replace
Replace
Replace
Replace

2422039

2622380

25

GAGE

2422041

2422041

24

Plate

2422043

I
MATERIAL

Nose Rib

2622035

I
EFF.

Leading Edge Instl.

2622033

2422043

I
DESCRIPTION

Replace
Replace
Replace
Replace

Wing Repair Index


Figure 1 (Sheet 10 of 18)
EFFECTIVITY:

MODEL35/36 SERIESAIRCRAFT

57-11-30

Page
SRM-I

10

Jun 1/95

Leariet
Learjet

STRUCTURAL REPAIR MANUAL


ITEM
NO.
26

DWG.
NO.

I
DESCRIPTION

2322560

Rib

Assy., Inner
Rib, Inner
Fairlead, Outboard
Rib Assy., Outer
Rib, Outer
Fairlead, Outboard
Rib Instl., Flap Slot

2322560
2322560
2322560
2322560
2322560
2322521

Inbd
27

Rib

2312039

Bracket

2322516
28

2322516

2322516

1
1

2322516

2322516

2322516
2322516

2322516
2322516
2322516
2322516

2322516
2322516
2322516
2322516

2024-T42 Clad

Phenolic

37
37

37

1
1

Plate

Bracket
Fairlead (2 ea.)
Support Bracket,
LH 8 RH (2 ea.)
Support Angle, LH 8 RH

2024-T42 Clad

0.040

2024-T3

0.032

1
I
1

I Replace
I Replace
I Replace

I
1

I Replace

1
1
1

I
I
I

Replace
Replace
Replace

1
1

Replace
2024-0 Clad

0.063

37

2024-0 Clad

0.063

37

Phenolic

37

2024-T42 Clad

0.063

37

2024-T42 Clad

0.063

37

2024-T3 Clad

0.080

2024-T42 Clad
2024-T42 Clad

0.063

0.063

Replace
Replace

51-71-00

3/16

37
37
37

37

I Replace

2024-T42 Clad

0.063

1
Anale
I~.Stiffener
1
Plate
Gusset, LH 8 RH
Bracket Instl., LH 8 RH, Spoiler
Actuator
Fairlead (2 ea.)
Support Angle, LH 8 RH

37

2024-T42 Clad

0.063

37

S-735

0.063

37

2024-T3 Clad

0.063

37

2024-T3 Clad

0.063

Phenolic

38

2024-T42 Clad
2024-T3 Clad

38

Fitting Assy.
Bracket Assy., LH

38

8 RH

Plate

1
1

I
I

I
F4-4

3/16
0.063
0.080

1
1
1

I
I

Replace
Replace
Replace

51-71-00

I
I

Replace
Replace
Replace
Replace

38

Replace
Replace
Replace
Replace
Replace

38
38

Door, LH 8 RH

Bracket, LH 8 RH
Anale

Replace
Replace
Replace

37

2422513

2322516

Replace
Replace

0.188

37

2322516

Replace
Replace

37

2322516

2322516

0.063

1~

Bracket, LH 8 RH

2322516

FIO. NO.

15
15

Door, LH 8 RH

2322516

0.188

Support Bracket Assy.


(LH Only)
Support Bracket
Support Bracket (LH Only)
Fitting Assy.
Bracket Assy., LH 8 RH

2422513

0.063

Phenolic

Bracket Instl., LH 8 RH, Spoiler


Actuator
1

2322516

2322516

2024-T42 Clad

Assy. (RH Only)

2322516

2322516

1
1

CODE

BracketAssy., LH 8 RH,
Spoiler Actuator
Weld Assy., LH 8 RH

2322516

GAGE

IBracket

231 2039

IFINISH( REPAIR

MATERIAL

Closing

2322521

I
EFF.

38

2024-T42 Clad

0.063

38

2024-T42 Clad

0.063

38

2024-T3 Clad

0.063

Wing Repair Index


Figure I(Sheet II of 18)
EFFECTIVITY:

MODEL35/36 SERIES AIRCRAFT

57-11-30

Page
SRM-I

11

Jun 1/95

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

I
DESCRIPTION

2322516

Gusset,

6022501

EFF.

LH 8 RH

I
MATERIAL

38

2024-T3 Clad

Fitting,

LH 8 RH

38

7075-T7451

6022511

Fitting,

LH 8 RH

38

17075-T7451

6022512

Bracket

38

AL Sheet
Bare Plate

29

Assy.,

LH 8 RH

6022512

Bracket, LH 8 RH

2322530

Hinge Bracket Assy.,

2322530

Stud

2322530

Hinge Bracket,
Hinge Bracket,

2322530

38

Middle

Middle

Outerl

2322530
2322530

Arm, Hinge, Middle

2322530

Hinge Bracket Assy., Outbd


Hinge Bracket, Outbd Inner
Hinge Bracket, Outbd Outer
Arm, Hinge
Hinge Bracket Assy., Inbd
Hinge Bracket, Inbd, Inner

2322530
2322530
2322530
2322530

2322530
2322530
2322530

2322550
30

2322550
2322550

2322550
2322550

2322550

2322550
2322550
2322550

2322550
31

2327038

0.063

2024-T42 Clad

0.063

2024-T42 Clad

0.063

S-549

2024-T3 Clad

0.090

2024-T4

0.375 i

51-71-00

7/16

Replace
Replace
Replace
Replace
Replace

2024-T42 Clad

0.063

2024-T42 Clad

0.063

51-71-00

51-71-00

Replace
Replace
1

2024-T4

I
0.063

2024-T4

Gap Closure
RibAssy.

Instl.

F4-4
F4-4

2024-T42 Clad

51-71-00
51-71-00

Replace
Replace

51-71-00

Replace

Replace

2024-T42 Clad

0.050

2024-T3 Clad

0.025

2024-T3 Clad

0.025

2024-T3 Clad

0.025

Panel

1
1

Panel

Replace

Panel

Replace

Panel

2024-T3 Clad

0.025

Angle, Panel Support (2 ea.)

2024-T42 Clad

0.050

Door

2024-T3 Clad

0.090

2024-T42 Clad

0.050

2024-T3

0.080

2014-T6

S-596

BracketAssy.

2322278

Replace
Replace
Replace

2327038

2322042

F4-4

Hinge Bracket, Inbd, Outer


Arm, Hinge

2327009

2422028

Replace

0.063

Angle
Wing Skin Instl., Upper
Wing Skin
Filler, Tapered
Fitting
Support

2622010

F4-4

2024-T42 Clad

PanelAssy.
1

2.500

PanelAssy.

2322550

Replace

PanelAssy.

2322550

F4-4

3.000

PanelAssy.

2322550

0.063

Hex Rod

Rib

2322550

FIG. NO.

Middle Inner

2322530

REPAIR

CODE

I
2024-T42 Clad

IFINISH
GAGE

Replace
Replace
Replace
Replace

Replace
Replace
Replace
Replace

Replace

1
1

F4-4
F3

IBracket

2024-T42

0.063

Wing Repair Index


Figure 1 (Sheet 12 of 18)
EFFECTIVITY:

MODEL35/36 SERIESAIRCRAFT

57-11-30

Rage
SRM-4

12

Jun 1/95

~j Learjet
STRUCTURAL REPAIR MANUAL
ITEM
NO.

DWG.

NO.

2622013
2622014

2327038

IBracket

2622012
2622012
2622012
2622012
2622012
2622012

0.250

2014-T6

0.160

2024-T42

S-736

Replace

0.063

2024-T42 Clad

0.125

Replace
Replace
Replace

2024-T42 Clad

0.063

Replace

2024-T42 Clad

0.063

2024-T42 Clad

0.063

S-734
S-736

1
1
1

1
1

Bracket

Shim

Stiffener(4 ea.)
1
SpliceAngle
Fitting
Fitting

Bracket, Fuel Probe Supportl


Door Instl., Wing Fuel

2326015
2422114

Probe
2422114

IDoorAssv

2422113

2326015

2622387
2322259
2622387
2622389

2322140
2622016
2622017
2622018

Replace
Replace
Replace

I
S-734

I
I

0.020

1
I
I
1

I
1

2024-T42 Clad

0.063

I
I

I
I

I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace

Filler

2622386

0.050

2024-T3 Clad

1
1

Cover Instl., Access Holes

2622386

Filler, Tapered

2622020

Replace
Replace

2622015
2622019

I
I

2024-T3 Clad

Wing Skin Instl., Lower


Wing Skin

2322042

2622015

Replace

Shim, Laminated (max. 0.032)

2622030

Replace

Stiffener

2322029

FIG. NO.

2014-T6

2322140
2622030

REPAIR

CODE

2622012
2627018
32

Stiffener(l2 ea.)

2622012

IFINISH
GAGE

18

Clip
BracketAssy.
Angle (2 ea.)
BracketAssy.
Angle(2 ea.)
BracketAssy.
Angle (2 ea.)

2622012

I
MATERIAL

Stiffener

2622012

IEFF.

Splicelnstl.
Splice, Fwd
Upper Wing Skin
Splice, Aft
Upper Wing Skin
Bracket Assy. (LH Only)

2622011

2327038

I
DESCRIPTION

2024-T3

0.190

2024-T42 Clad

0.050

1
1
1
1

I
I

Replace
Replace

Door

2024-T3 Clad

0.160

Bracket

2024-T42 Clad

0.050

Cover, Access Hole


Door(G ea.)
Cover, Access Hole (5 ea.)
Cover, Access Hole
Shim, Laminated (Max. 0.032)

2024-T3 Clad

0.080

2024-T3 Clad

0.080

2024-T3 Clad

0.080

2024-T3

0.090

Splicelnstl.
Splice, Fwd,
Lower Wing Skin
Splice, Aft,
Lower Wing Skin

1
1

2024-T4

0.312

Replace

2024-T4

0.160

Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace

Wing Repair Index


Figure 1 (Sheet 13 of 18)
EFFECTIVITY:

MODEL35/36 SERIES AIRCRAFT

57-11-30

Page
SRM-4

13

Jun 1/95

Learjet
STRUCTURAL REPAIR NIANUAL
ITEM

DWG.

NO.

NO.

StiffenerAssy.

2622015

2622015

2622015

2622015
2622050
33

S-734

2024-T42 Clad

StiffenerAssy.

2322377

S-734

2024-T42 Clad

Replace
Replace

0.063

Replace
Replace

0.063 1

1
I

Replace
Replace

Replace
Replace

S-734

2024-142 Clad

0.063

19

6061-0

0.063

F4-1

19

6961-0

0.063

F4-1

19

6061-T6

0.025

F4-1

19

6061-T6

0.025

F4-1

Replace
Replace

19

~Baffle, Indb

2522050

1
1

0.063

19

Outbd

2522050

FIG. NO.

19

"BBfffeAssy.

2522050

\TubeAssy.

Replace
Replace

19
19

6061-T6

0.050

19

6061-T6

0.050

2522050

..Tube, Anti-ice
Plate, Tube End
Rib, Inbd Auxiliary

19

2024-T41 Clad

0.050

2522050

Splice Plate

19

2024-T41

0.063

F4-1

0.032/

F4-1

19

6061-T6

0.063

2622418

Rib

19

2024-T42 Clad

0.050

2622373

Rib

19

2024-T42 Clad

0.050

F4-1

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2322416

RibAssy.

19

2024-T42 Clad

0.050

F4-6

Replace

2522050

2522050

2522050

JClip
Panel, Access

2322377

2422042

2422030
2422029

Leading Edge Instl.


Leading Edge Assy.
Skin Assy.
Skin(2 ea.)

2422029

2422029

IDoubler

2422031

2422032

2422032
2422038

IScupper

F4-1

20
20
20

\6061-T6

1
1

20

6061-T6

0.063

20

6061-T6

0.063

20

6061-T6

I
I
I

Rib

Rib(7 ea.)

1
1

Inbd

2422031

/6061-T6

F4-1

20

Baffle, Outbd

2422031

19

19

Rib

2322416
34

Skin, Outbd
Skin, Middle

2322377

REPAIR

CODE

Angle(2 ea.)
Leading Edge Instl.
Leading EdgeAssy.

2522050

2522050

1
1

IStiffener

2622015

2024-T42 Clad

Angle(2 ea.)
StiffenerAssy.

2622015

S-734

IStiffener

2622015

Angle (2 ea.)

I~Stiffener

2622015

2622015

Angle (2 ea.)
StiffenerAssy.

2622015

IFINISH
GAGE

MATERIAL

IStifiener

2622015
2622015

I
EFF.

DESCRIPTION

0.063\

Replace
Replace

20

20

2024-T42 Clad

0.063 1
0.063 1

20

\2024-T42C\ad
)6061-0

0.063\
0.025j

20

Replace
Replace
Replace
Replace

Replace

Wing Repair Index


Figure 1 (Sheet 14 of 18)
EFFECTIVITY:

MODEL 35/36 SERIES AIRCRAFT

57-11-30

Page
SRM-4

14

Jun 1/95

STRUCTURAL REPAIR MANUAL


DWG.
NO.

ITEM
NO.

2422050
2522050
2522050
2522050

2522050

Anti-lcelnstl.
Tube Assv.
j
Plate, Tube End

2422030

1... Shim

2422030

Shim

2422039
2422039

2422039
2422039

2422039

2422041

1.00

22

Replace
Replace
Replace

2024-T42 Clad
6061-T6 Bare
2024-T3
2024-T3 Clad

Replace
j Replace
I Replace
I Replace

0.050
0.032

0.063

0.025

SPlice

Stiffener(2 ea.)

2014-T6 Clad

0.071

2024-T3 Clad

0.063

2014-T6 Clad

0.071

2014-T6 Clad

0.071

Fairina

1. Suppo~tAssy.

s-s99

Replace
I Replace
I Replace
Replace
I Replace

1
1

0.040

2024-f3 Clad

Doubler

2024-T3 Clad

0.063

I Replace
Replace

2024-T3 Clad

0.063

2422043

Filler

2024-T3

0.063

2422078

Splice Plate
~RibAssy.

2024-T42 Clad

0.063

I Replace
I Replace
I Replace

2024-T42 Clad

0.063

I Replace

1
1
1 0.0631

I Replace
1 Replace
i Replace

Support(2 ea.)

2422041
2422041

2422041
2422078

1
i

6022003

2024-73 Clad

2024-f42 Clad

0.050

20

2024-T42 Clad

0.063

Fence

39

6061-T4

38)~

~7>

0.250
0.250 1

Fence

23

6061-T6

0.160

2422086
2422086
2422086

Attach Plate

23

6061-T6

0.063

2422086
2422086
2422086
2422086

Replace

F21

Replace
Replace

23

2422086

Fence

23

Assy.

28

Stall Fence Instl., LH 8 RH

2422086

Rib

StallStrip
Stall Strip

2422089

S-744

Plate

Stall Strip )nst)., LH 3 RH

2422089

2422086

SupportAssy.
\.Support
i
Support

2422078

Rib

2422082

6061-T6

1
1
1

2422082

36

20

Doubler(2 ea.)

2422041

35

1.00

Splice

2422039

0.050

6061-T62

2422039
2422036

6061-T6

Fairina

2422039

20
21

1~. FairingAssy.
SpliceAssy.

CODE

Rib

Angle

REPAIR
FIO. NO.

IFINISH
GAGE

20

BaffleRibAssy.

2422083

I
MATERIAt

20

Tube, Anti-icing
j Tube, Anti-icing

2422083

2422083

I
EFF.

DESCRIPTION

Replace
Replace

24

Assy.

Fence

24

6061-T6

Attach Plate

24

(6061-T6

Fence Assy.
Fence
Attach Plate

Replace
i Replace

1 0.1601
0.063 1

1 Replace
I Replace

0.160

0.063

26

26

6061 -T6

26

6061-T6

Wing Repair Index


Figure 1 (Sheet 15 of 18)
EFFECTIVITY:

SRM-4

MODEL35/36 SERIESAIRCRAFT

57-11-30

Page 15
Tun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


ITEM
NO.

DWG.
NO.
2422086

2622399
2422088

38

2422085
2522050

Fence(3 ea.)
Trip Strip Instl., LH RH
Trip Strips (3 ea.)

25

S-5078

27

(S-5078

Fiberglass

5052-0

0.063

Replace

2024-T3 Clad

0.063

Replace

2024-T3 Clad

0.063

2024-T42 Clad

0.032

2024-T42 Clad

0.040

2024-T42 Clad

1
1

I
I

S-306

Replace
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace

2422548

IFairina

RH

1/2

1/4

Fiberglass rnatte
Expanded

1.00

3003-H14

IFairing
Fairing Support
1

matte

Fairing Instl., Wing Leading


Edge, LH 8 RH

2322540

1
1

Angle (2 ea.)
Fairing Support
Angle(2 ea.)
Lower Fairing Instl., LH
Fairing(2 ea.)
Splice Angle
Seal Angle

1
1
1

8 RH

2322540

1
1

Door Seal

2024-T42 Clad

0.050

Stiffener

2024-T42 Clad

0.032

0.050

Bulkhead

2322540
2322540

(2 ea.)
Bulkhead Assy.

Replace

2322540
2322540

j
I
I

6061-T6

Upper Fairing Instl.,


Fairing Assy.

2322540

1
1
1

Replace

2422548

i
1

2322540

Replace

2422548

2422034

0.032

6061-T62

Reinforcement

2422034

Insulation

2422034

FIG. NO.

1120.051

1
1

2422034

REPAIR

CODE

Replace
Replace
Replace
Replace

2522050

2422033

IFINISH
GAGE

2522050

2422035

S-5075

28

1
ITube

LH

I
MATERIAL

28

Anti-ice Instl., LH 8 RH
Insulation

2422085

I
EFF.

IFence

2422086
37

I
DESCRIPTION

2322540

Bracket

2322540

Gap

Cover

2024-T42 Clad

0.032

2322540

Attach

Angle

2024-142 Clad

0.050

2322540

Seal

Angle

2024-T42 Clad

0.050

I
I

2322540

Bulkhead Assy.
Bulkhead

1
1

2024-T42 Clad

0.050

Attach

2024-T42 Clad

0.050

2024-T42 Clad

1
1
1

I
i
I

S905

I
I

I
I

I
I

2322540
2322540

2322540

1
1

Assy.

Angle
Splice Angle

0.040

2620000

Identification Plate

2622571

Vortex Generator Instl.

29

2322571

Blade, Vortex Generators


Blade, Vortex Generators
Conduit, W/S 125 to 174
Conduit, W/S 125 to 196

29

S707

1F1

29

S621

1F1

30

5052-0

0.035

31

5052-0

0.035

2322555
2618042
2328001
2627019
2627019
2627019

Bracket Instl.

Bracket

2024-T3 Clad

0.050

Support(2 ea.)

6061-T4

0.040

I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repalce

Wing Repair Index


Figure 1 (Sheet 16 of 18)
EFFECTIVITY:

MODEL35/36 SERIES AIRCRAFT

57-11-30

Page 16
SRM-4

Jun 1/95

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

FINISH

DESCRIPTION
Drain Instl.,

2422117
2422117

Clip

2422116

Drain

Center Section

2422116

Elbow

GAGE

2024-T42 Clad

0.032

Replace

5052-0

0.063

5052-0

Replace
Replace

1
1

35-002 AND

35-088 AND SUBSEQUENT; 36-023 AND SUBSEQUENT


35-116 AND SUBSEQUENT; 36-033 AND SUBSEQUENT
35-414 AND SUBSEQUENT; 36-048 AND SUBSEQUENT

5
6
7

35-644 AND SUBSEQUENT; 36-059 AND SUBSEQUENT


35-002 THRU 35-643; 36-001 THRU 36-058
35-002 THRU 35-011;36-001 THRU 36-006
35-012 AND SUBSEQUENT; 36-007 AND SUBSEQUENT

35-160 AND SUBSEQUENT; 36-039 AND SUBSEQUENT

10

35-669 AND SUBSEQUENT; 36-064 AND SUBSEQUENT


35-002 THRU 35-083; 36-001 THRU 36-020

11

12

13
14
15

16
17
18

19

20

0.063

SUBSEQUENT; 36-001 AND SUBSEQUENT

1
3

Tubing

EFFECTIVITIES

2
4

CODE

35-002 THRU 35-159; 36-001 THRU 36-038


35-002 THRU 35-045; 36-001 THRU 36-016
35-046 AND SUBSEQUENT; 36-017 AND SUBSEQUENT
35-117 THRU 35-140; 36-033 AND 36-034
35-637 AND SUBSEQUENT; 36-058 AND SUBSEQUENT
35-083 AND SUBSEQUENT; 36-022 AND SUBSEQUENT
35-664 AND SUBSEQUENT; 36-064 AND SUBSEQUENT
35-002 THRU 35-066; 36-002 THRU 36-017
35-067 AND SUBSEQUENT; 36-018 AND SUBSEQUENT

22

35-548 THRU 35-588, 35-601 AND SUBSEQUENT; 36-054, 36-056 AND SUBSEQUENT
35-117 AND SUBSEQUENT; 36-033 AND SUBSEQUENT

23

35-279 AND

24

35-279 THRU 35-307

25

35-308 THRU 35-324; 36-045


35-279 THRU 35-324; 36-045

21

26

SUBSEQUENT; 36-045 AND SUBSEQUENT

28

35-325 AND SUBSEQUENT; 36-046 AND SUBSEQUENT


35-669 AND SUBSEQUENT; 36-064 AND SUBSEQUENT

29

35-002 THRU

27

30
31
32
33
34

35-278; 36-001 THRU 36-044


35-002 THRU 35-013; 36-001 THRU 36-007
35-014 AND SUBSEQUENT; 36-008 AND SUBSEQUENT
35-002 THRU 35-115; 36-001 THRU 36-032
35-002 THRU 35-037; 36-001 THRU 36-013, 36-015 AND 36-016
35-203 AND SUBSEQUENT; 36-043 AND SUBSEQUENT

36

35-002 AND SUBSEQUENT; 36-002 THRU 36-047


35-409 AND SUBSEQUENT; 36-048 AND SUBSEQUENT

37

35-002 THRU

38

35-677 AND SUBSEQUENT; 36-064 AND SUBSEQUENT


35-669 THRU 35-676

35

39

REPAIR
FIG. NO.

MATERIAL

Flange Weld Assy.

Washer

2422116

CODES

Wing

EFF.

35-676; 36-001 THRU 36-063

Wing Repair Index


Figure 1 (Sheet 17 of 18)
EFFECTIVITY:

SRM-4

MODEL35/36 SERIESAIRCRAFT

57-11-30

Page 17
Juna/95

~Learjetl
STRUCTURAL REPAIR MANUAL
NOTE

Apply conductive coating

per

Laminated shim stock, 0.002


sheet.

Chapter
or

51.

0.003 lamination per Mll-S-22499

Type 1, Class

or

Class 2, 1145-H19 alumi-

num

Condition Normalized.

Learjet Field Service if


Century III fairing.

Contact
the

more

than surface corrosion is encountered

on

the lower

wing

skin after removal of

Per Mll-P-15035.

6061-T6 Alternate material.


PH13-8Mo Stainless Steel Bar

Wing Repair Index


Figure 1 (Sheet 18 of 18)
EFFECTIVITY:

MODEL35/36 SERIESAIRCRAFI~

57-11-30

Page 1S
SRM-4

Jun 1/95

Learjet
Learjetl

STRUCTURAL REPAIR MANUAL


INNER WINCLET

STRUCTURAL IDENTIFICATION

20)
28) (27)

31

(17)

(19
(16

18

23
37

1\

S-T

*",a 4

33

,t\

I
i),

,t
I

5)

,e

(13)

(4

11

29)

Repro

Inner Winglet

Figure

EFFECTIVZTY:
SRM-4

10)(22)

(6

31

(30

Repair Index

1 (Sheet 1 of 3)

MODEL28/29/31 SERIESAIRCRAFT

57-30-10

Page 1
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

I
DESCRIPTION

Wing Extension

12225-0015

IEFF.

MATERIAL

IFINISH REPAIR
GAGE I CODE I FIG. NO.

Six Foot Instl.

LH 8 RH

Inner Winglel Instl.

12225-0059
1

12225-0059

12225-0059

12225-0059

12225-0059

12225-0059

Leading Edge
Upper

2024-T42 Clad

0.063

2024-T42 Clad

0.063

Lower

2024-T42 Clad

0.063

Upper

2024-T42 Clad

0.063

Lower

2024-T42 Clad

0.063

2024-T3

0.125

Rib

Rib

2024-T42 Clad
2024-T42 Clad

0.040

Skin,
Skin,
Skin,
Skin,
Skin,

12225-0059
6

12225-0059
1 12225-0059

12225-0059

12225-0059

10

12225-0059

11

12225-0059

12

12225-0059

2024-T4

0.500

Angle

2024-T42 Clad

0.071

Stiffener

1
1

2024-T42 Clad
2024-T42 Clad

0.040

Stiffener

Stiffener
Doubler
Angle, LH

0.040

2024-T42 Clad
2024-T42 Clad

2024-T42 Clad

0.063

IFiller
1

0.040

0.040

13

1 12225-0059

14

12225-0059

15

12225-0059

Angle

2024-T42 Clad

0.063

16

12225-0059

Stiffener

2024-T42 Clad

0.040

17

12225-0059

Stiffener

2024-T42 Clad

0.040

2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42

18

12225-0059
12225-0059

Stiffener

20

12225-0059

21

12225-0059

Stiffener
Stiffener

12225-0059

Clip

12225-0059

Clip

Stiffener
Stiffener

Clip
Clip
Clip

2024-T42 Clad

0.063

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

22

12225-0059

12225-0059
23

12225-0059

24

12225-0059

12225-0059
12225-0059

Stiffener

I
I
i
I
I

1
1
1
1
1

I
I
I
I
I

I
I

0.032

19

1
1
1
1
1
1

Clad

0.040

Clad

0.040

I
1
1
1
1
1

I
I

Clad

0.040

Clad

0.040

Clad

0.063

Clad

0.063

0.040

2024-T42 Clad

0.063

1
1
1

2024-T42 Clad
2024-T42 Clad

Replace
I Replace

0.063

I Replace

0.040

1
1
1

I Replace
I Replace
Replace
I Replace
I Replace

Stiffener

12225-0059
12225-0059

Stiffener
Stiffener

12225-0059

Shim

12225-0059

Shim

0.040

0.040
0.040
0.040

0.040

Replace

1
1

25

12225-0059

Clip

26

12225-0059

Shim

Strap
Strap

0.100

2024-T42 Clad
2024-T42 Clad

I
1
1

0.100

2024-T42 Clad

0.050

2024-T42 Clad

0.050

27

12225-0059

28

12225-0059

29

12225-0059

30

12225-0059

Stiffener
Stiffener

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2024-T42 Clad
2024-T3 Clad

0.063
0.016

Replace

I Replace
I Replace
I Replace
I Replace
I Replace

Winglet Repair Index


Figure i (Sheet 2 of 3)

Inner

EFFECTNITY:
SRM~

MODEL28/29/32 SERIESAIRCRAFT

57-30-10

Page 2
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM I
NO.

DWG.
NO.

12225-0059

31

12225-0059

Splice
Splice
Splice
Splice
Angle

Strap,
Strap,
Strap,
Strap,

IEFF.

DESCRIPTION
Inbd, Fwd
Outbd, Fwd
Inbd, Aft
Outbd, Aft

I
MATERIAL

IFINISHI REPAIR
GAGE

7075-T3

0.040

7075-T73

0.040

7075-n3

0.040

7075-T3

0.040

32

12225-0059

33

12225-0059
12225-0059

2024-T42 Clad

0.063

34

12225-0059

Rib

2024-T42 Clad

0.050

35

12225-0059

Splice Strap
Splice Strap
Front Spar Fitting
Rear Spar Fitting

301 Stainless

0.040

301

7075-T4

7075-T4

12225-0059
36

2822621

37

2822622

CODES

Stainlessl~

0.040

CODE

1
1
1
1

FIG. NO.

I Replace
I Replace
I Replace
I Replace
I Replace
Replace
I Replace
Replace
Replace
Replace

EFFECTIVITIES

28-001 THRU

31-058 AND SUBSEQUENT

28-005;

29-001 THRU 29-004; 31-001 AND SUBSEQUENT

NOTES

Solution heat treat and age to -T73 after rough machining. Cross section during heat treat not to exceed 0.75 at
any point. Part will be hand forged. Optional to solution heat treat and age to -T73 after machining to finish dimen-

sion.
Condition 1/2 hard.

Inner Winglet

Figure
EFFECTIVITY:

Repair Index

1 (Sheet 3 of 3)

MODEL28/29/31 SERIESAIRCRAFT

57-30-10

Page
SRM-4

May 15/92

Learjet
STRUCTU RAL REPAIR MANUAL
INNER WINGLET

i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGE LIMITS

All dimensions

NOTE:
A.

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

or

failed rivets
the

on

performed
fer to Chapter 51
(2) Loose

or

trations

ensure

failed

on

performed

not allowed. A loose or failed rivet can cause increased stress concentra-

are

remaining

to

B.

are

rivets and lead to

that

joint

progressive joint failure. A careful inspection must be


spread from the area of the loose or failed rivet. (Re-

failure has not

for definition of rivet failure.)

screws are

surrounding

not allowed. A loose or failed screw

to ensure that the

can cause

increased stress

failure. A careful

concen-

must be

inspection
progressive joint
joint failure has not spread from the area of the loose or failed

screws

and lead to

screw.

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired,

and refinished in accordance with

C.

Deformation

D.

(1) Deformation of the inner winglet


Corrosion(SeeFigure 101.)

or

inner

Chapter

re-

51.

winglet structure

is not allowed.

(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness
E.

more

than

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component reF.

G.

H.

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTTVITY:
SRM-4

ALL

57-30-10

Page 101
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.320

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure 101
EFFECTIVITY:
SRM~

ALL

57-30-10

Fagel02
May15/92

Learjet
Learjetl
STRUCTURAL REPAIR MANUAL
INNER WINGLET

i.

REPAIR

APPROVED REPAIRS
A.

Refer to

Chapter

51 for allowable

wear

and

repair

data for the various

components attached

to the

winglet.

EFFECTIVITY:
SRM-4

ALL

57-30-10

Page 201
May 15/92

Learjet
Ledrjetl
STRUCTURAL REPAIR MANUAL
OUTER WINGLET

STRUCTURAL IDENTIFICATION

15

\u

(8
9
2

11

..~iS
10

~C

(3

Olll(t
t

~cS

\\\i:
6

t;

\\U

12

13r,

r---

Repro

EFFECTIVITY:

Outer

Winglet Repair Index


Figure 1 (Sheet 1 of 2)

MODEL28/29/31 SERIESAIRCRAFZ~

57-30-20

Page 1
May 15/92

Learjet
~fl

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

DESCRIPTION

12225-0015

Wing

EFF.

MATERIAL

GAGE

FINISH

REPAIR

CODE

FIG. NO.

Extension Six Foot Instl.

LH 8 RH
12225-0059

Inner Instl.

Winglet Assy.

Winglet,
Outer

2822650

2822650

2822650

Skin, Inboard
Skin, Outboard
Skin, Leading Edge
Honeycomb Core, Inboard
Honeycomb Core, Outboard
Doubler, Upper
Doubler, Lower

2822650

Clip,

2822650

Conduit, Strobe

2822650

2822650

2822650

2822650
2822650

Doubler

2024-T3 Clad

0.032

2024-T3 Clad

0.032

6061-T6

0.032

0.800

0.800

Replace
Replace
Replace
Replace
Replace
Replace

2024-T42 Clad

0.032

2024-T42 Clad

0.040

Replace

2024-T42 Clad

0.032

Poly Tubing

Replace
Replace

1/16

Wall

PanAssy.

2822650

Pan Strobe

2822657

2822656

10

2822651

11

2822652

12

2822653

13

2822655

14

2822656

15

2822650

16

1 No. 15401

2024-T42 Clad

0.032

2024-T351 Clad

0.090

2024-T351 Clad

0.150

A356

Mounting Plate, Doubler


Trailing Edge
Winglet Tip
Winglet Rib
Closure Fitting T.E.
Mounting Plate
Weight

2024-T42 Clad

2024-T351 Clad

2024-T3 Clad

Lead 95%

Diverter Base

Antimony

CODES

0.071

5%

Replace
Replace

EFFECTIVITIES
28-001 THRU

0.032

Replace
Replace
Replace
Replace
Replace
Replace
Replace

~8-005;

29-001 THRU 29-004; 31-001 AND SUBSEQUENT

NOTES
AL-1/8-5056-.001 N-4.5 LB Hexcel

Outer

Winglet Repair Index


Figure 1 (Sheet 2 of 2)

EFFECTIVITY:
SRM4

MODEL28/29/31 SERIESAIRCRAFT

57-30-20

Page 2
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
OUTER WINGLET
i.

ALLOWABLE DAMAGE

ALLOWABLE DA~MAGELIMITS

All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

or

on

failed rivets
the

are

remaining

to ensure that

performed
fer to Chapter 51
(2) Loose

or

failed

not allowed. A loose

rivets and lead to

joint

or

failed rivet

can cause

increased stress concentra-

failure. A careful

progressive joint
inspection must be
from
of
the
the
loose
area
or failed rivet. (Respread

failure has not

for definition of rivet failure.)

screws are not

allowed. A loose

or

failed

screw can cause

increased stress

failure. A careful

concen-

progressive joint
inspection
surrounding
performed to ensure that the joint failure has not spread from the area of the loose or failed
trations
B.

screws

on

and lead to

must be
screw.

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired,
C.
D.

and refinished in accordance with

Deformation

(1) Deformation of the outer winglet or outer winglet structure is not allowed.
Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

Chapter

re-

51.

more

than

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component re-

placed.
F.

G.

Fl.

Scratches(See Figure 101.)


(1) Scratches are permissible if the affected

EFFECTIVITY:
SRM-4

area

is sanded

smooth, refinished

in accordance with

Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittingsand Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

ALL

57-30-20

Page 101
May 15/92

STRUCTURAL REPAIR MANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFFECTIVITY:
SRM-4

ALL

101

57-30-20

Page 102
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


OUTER WINGLET
i.

REPAIR

APPROVED REPAIRS

A.

Refer to

Chapter

51 for allowable

wear

and

repair

data for the various

components

attached to the

winglet.

EFFECTIVITY:
SRM~

ALL

57-30-20

Page 201
May 15/92

Learjet
~Learjet
STRUCTURAL REPAIR MANUAL
TIP TANK

STRUCTURAL IDENTIFICATION

~s

is

13

~3

Is

27

81

111
4;

8\

20

(TYPICAL)

Repro

EFFECTIVITY:
SRM-4

Tip Tank Repair Index


Figure 1(Sheet 1 of 10)
MODEL 23/24/25/35/36 SERIES AIRCRAFT

57-31-00

Fage 1
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

2423100

Tip Tank lnsti., LH 6 RH


Tip Tank Instl., LH 8 RH
Tip Tank Instl., LH 8 RH
Tip Tank Assembly
Tip Tank Assembly

2523001

TipTankAssembly

11

2323000
2423000
2623000

2323001

I
EFF.

DESCRIPTION

2024-T3 Clad

0.090

1 2024-T3 Clad

0.090

Upper, RH

8 LH

2024-T3 Clad

0.090

Lower, RH

8 LH

2024-T3 Clad

0.090

2024-T3 Clad

A/R

2623000

Shim

2323001

Doubler

2623000

Lower, RH

FIG. NO.

CODE

8 LH

Upper,

2623000

2323001

IFINISH I REPAIR
GAGE

RH 8 LH

Strap,
Strap,
Strap,
Strap,

2323001

MATERIAL

1
1
1

I
I

2323001

Assy.
Doubler(2 ea.)

8
8

2024-T3 Clad

0.125

F4-6

2323001

Spacer(2 ea.)

2024-T3 Clad

0.160

F4-6

I Replace
Replace
I Replace
I Replace
I Replace
Replace
Replace
Replace

2323000
V152-1

Splice Plate

10

12024-T3

0.090

Replace

F4ext
F4-1 int

2323000
Filler

V152-2

Scupper

2423012
2

Bulkhead

2323060

Assy.

2323060

Angle(2 ea.)
Bulkhead Assy. (RH Only)

2323060

12024-T3

0.090

6061-0

0.025

Bulkhead Sta. 15.00

2323060

10

F4-1

12

6061-T6

0.050

F4-4

14

6061-T6

0.050

F4-4

2323060

Bulkhead Sta. 15.00

6061-T6

0.050

F4-4

2323059

Bulkhead Sta. 15.00


Bulkhead Sta. 15.00 (LH
Bulkhead

13

6061-T6

0.050

F4-4
F4-4

2323059

24231 50

Bulkhead

2423150
2423150

Bulkhead

Replace
I Replace
I Replace
Replace
Replace

Only)

(LH Only)
Assy. (RH Only)

6061-T6

0.050

15

6061-T6

0.050

16

16061-T6

0.050

Replace
Replace
Replace
Replace
I Replace

I Replace

16

24231 50

Bulkhead

16

6061-T6

0.050

2423150

Web

16

2024-T3

0.050

2323001

Filler

61

6061-T6

0.020

51-70-02

Replace

F4ext
F4-4int

Nose

2323062

Cap Assy.

17

Retainer-Lens

2323062

17

6061-T4

0.040

Replace

F1 ext
F14-1 int

2323062

2323062

Bracket, Taxi Light

2323071

2323071
2423100

2423100

Spacer

17

Phenolic

0.250

2024-T4

0.040

Nose

18

6061-T6

0.080

Nose

6061-T6

0.080

19

6061-T6
6061-T6

Cap
Cap, LH Only
Nose Cap, LH
Nose Cap, LH

20

1
F4-1

0.090
0.090

I Replace
Repalce
I Replace
I Replace
1

51-70-02

51-70-02

Tip Tank Repair Index


Figure 1 (Sheet 2 of 10)
EFFECTNITY:
SRM~

MODEL

23/24/25/35/36SERIES AIRCRAFT

57-31-00

Page 2
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM
NO.
4

DWG.
NO.

1
1

2323073
2323073

19

Nose

19

Cap Assy. (RH Only)

IFINISH
GAGE

2024-T4

0.050

CODE

REPAIR
FlG. NO.

F4-1

Replace

Retainer, Lens

19

6061-T4

0.040

Spacer

19

Phenolic

0.250

Replace
Replace

I
I

Replace
Replace

2323025

Bulkhead

Assy.,

Sta. 46.00

Bulkhead

6061-T6

0.050

2323025

Bulkhead, Ring

6061-T6

0.050

Bulkhead

Assy.,

F4

2323025

Sta. 46.00

Weldment

2423140

Ring

S-715

2423140

Cover

2024-T3 Clad

0.050 1

51-70-02

Web

2323001
2323001

Skin,
Skin,
Skin,
Skin,

T6

Replace

2024-T3 Clad

0.050 1

51-70-02

Sta. 46.00 to 84.31


Sta. 46.00 to 84.31

6061-T6

0.050 i

51-70-02

10

6061-T6

0.080 i

1
1

Sta. 46.00 to 84.31

11

6061-T6

0.080 1

51-70-02

51-70-02

2523001

2423100

46.00 to 84.31

6061-T6

0.080 1

51-70-02

84.31 to 113.20

6061-T6

0.050 1

51-70-02

84.31 to 113.20

10

6061-T6

0.080 1

51-70-02

2523001

Sta.
1
ISkin, Sta.
ISkin, Sta.
ISkin, Sta.

84.31 to 113.20

11

6061-T6

0.080 1

51-70-02

24231 00

ISkin, Sta.

84.31 to 113.20

6061-T6

0.090 1

51-70-02

2423103

IFairing

2024-T42

0.020

2323001

2323001

Bracket, Taxi Light (RH Only)

I
MATERIAL

2323062

2423140

I
EFF.

2323062

2423140

I
DESCRIPTION

39

F14-1int

Replace

F1 art
2323049
9

Junction Box Instl.

2323049

Door

2323049

Tube

(0.250
Wall)
Weld Assy.

2323049

OD

21

21

2024-T42

21

5052-0 Clad

0.063

Replace

0.035

F4-4

Replace

21

2323049

Can

21

6061-T42

0.091

2323049

Doubler

21

6061-T42

0.063

I
F4-4

2323049

Fittina

21

6061-T6 Bar

1.500

2323049

Fittina

21

6061-T6 Bar

1.250

1
1

I
I

21

6061-T6 Bar

1.000

7/16

I
1

1
1

I
I

Fitting (2 ea.)

2323049

2323069

Tube(0.250
Wall)

2323069
2323069

Junction Box Instl.

Fittina

OD

Replace
Replace
Replace
Replace
Replace

22
x

0.035

22

5052-0 Clad

22

6061-T6 Rod

2323049

Daor

22

6061-T6

0.080

2323069

Door

22

6061-T6

0.080

2323069

Can

Assy.

22

2323049

Doubler

22

6061-T42

0.063

6061-T42

0.091

Replace
Replace
Replace
Replace

F4-4
F4-4

2323069

ICan

22

2323049

Fittina

22

6061-T6 Bar

1.500

I
I

2323049

Fittina

22

6061-T6 Rod

1.250

2323069

Fittina

22

6061-T6 Rod

0.750

2323049

IFittina

18

6061-T6

1.000

2323049

IFittina

10

6061-T6

1.250

1
1
1
1

I
I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace

Tip Tank Repair Index


Figure 1 (Sheet 3 of 10)
EFFECTIVITY:

MODEL 23/24/25/35/36 SERIES AIRCRAFT

57-31-00

Page 3
SRM-4

Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

NO.

DWG.
NO.
2423080

2323069
2423080

Door

2323069

Tube

(0.250
Wall)
Tube Assy.
Tube (0.250
Wall)

2423080
2423080

2323049
2323049

2323069
2423072

10

1 416-378
2323010
2323010
416-50

2323070
2323070
416-378-1

457-24
2423160
11

2423162

2423160
2623162
2423102
2423102

2423102
24231 02

2423102
2323006
2323006
2323006

I
I
I
I
I

Replace
Replace
Replace
Replace
Replace

I
I

I
I

Replace
Replace

Replace

Replace

31

6061-T6 Rod

31

6061-T6

0.070

29

6061-T6

0.080

31
OD

I
1
1
1

5052-0 Clad

30

7/16

0.035
5052-0 Clad

31
29

Assy.

29

(0.500 OD x
0.049 Wall)
Filler Cap Instl.
Cap 8 Adapter Assy.

1
1

29

6061-T42

0.063

29

6061-T42

0.063

29

6061-T6 Bar

1.500

29

6061-T6 Rod

0.750

29

6061-T6 Rod

0.750

31

6061-T6

0.875

31

6061-T6

Replace
Replace
Replace
Replace
Replace

I
1
1

Tube

24

I
0.063

6061-T6

I
I

0.063

6061-T6

25

Cap Adapter Assy.


Cap 8 Adapter Assy.
Mounting Instl., LH RH
1
Fitting
Mounting
Mounting, Fwd
Tube Assy.
1
Tube (2.00 OD x 0.083

Plate

I
1

I
I

I
I

Replace
Replace
Replace

51-71-00

Replace

Replace
Replace
Replace
Replace

25

Doubler

Ring
Tube Assy.
1
Ring
Tube(2.00 OD
Wall)
Flapper Assy.
1
Ring

23

24

Adapter
Filler Cap
Filler Cap Instl.
1

Replace

17

17

Doubler

Wall)
2423102

FIG. NO.

0.035

ICan
IPan
1
Fitting
1
Fitting
1
Fitting
IFittinO

2423074
2323010

OD

Junction Box

2423081

2423081

1
1

Junction Box

2423080
2423081

31

1
Fitting
IFlanFle

2323069

REPAIR

CODE

7/16

6061-T6 Rod

30

Fitting
Fitting Assy.

2423080

IFINISH
GAGE

29

Junction Box Instl.

2323069

I
MATERIAL

EFF.

DESCRIPTION

26

27

6061-T6

0.050

I
2024-T42 Clad

0.080

Replace

3
3

6061-T6

6061-T6

1
0.080

Replace
Replace

6061-T6

0.080

Replace

6061-T6

Replace

I
I

Replace
Replace

0.083

3
3

6061-T6

0.063

6061-T6

0.063

Tip Tank Repair Index


Figure 1 (Sheet 4 of 10)
EFFECTIVITY:

MODEL 23/24/25/35/36 SERIES AIRCRAFT

57-31-00

Page$
SRM-4

Jan 15/93

Learjet
STRUCTU RAL REPAIR MANUAL
DWG.
NO.

ITEM

NO.
12

I
I

2323027

Bulkhead Assy.,
Ring, Lower
Ring, Upper
Angle

2323027

Doubler

2323027
2323027
2323027

2323027

Ring,

Bulkhead

Bulkhead

Assy.,

FIG. NO.

44

6061-T6

0.050

6061-T6

0.050

1
1

I
I

I
I
I
I

Replace
Replace
Replace
Replace

6061-T6

0.063

46

6061-T6

0.050

6061-T6

0.125

6061-T6

0.063

1
1
1
1

6061-T6

0.050

Replace

I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace

Replace
Replace

Sta. 113.60

2024-T42 Clad

0.063

2024-T42 Clad

0.063

2423110

Web

2024-T3 Clad

0.050

1
1
1

2423110

Doubler

2024-T3 Clad

0.050

47

2024-T3

0.125

48

S715

49

7075-T35

2.000

1
I
1

I
I
I

40

6061-T6

0.050

Replace

40

6061-T6

0.050 1

51-70-02

40

6061 -T6

0.063

Replace

40

6061-T6

1.000

40

6061-T6

0.090

I
I

40

6061-T6

0.050

40

6061-T6

0.125

62

6061-T6

0.080

1
1
1
1
1

Replace
Replace
Replace
Replace
Replace

ISoacer

2323026

Ring, Weldment
Ring, Bulkhead
Bulkhead Assy., Sta.
Ring, Lower
Ring, Upper
Angle
Fitting

2323026

Bulkhead

2423110
2423013
2323026

2323026
2323026
2323026

Ring,

2323026

Bulkhead

Segment

ISoacer
2323001\/651 Doubler
2423130

Bulkhead

Assy.,

40

83.85

2323027

Sta. 83.85

41

2423130

Support

41

2024-T42 Clad

0.063

Replace

2423130

Web

41

2024-T3 Clad

0.050 1

51-70-02

41

2024-T42 Clad

0.063

41

7075-T35

2.000

51

6061-T6

0.080

16

6061-T6

0.080

1
1
1
1

I
I
I

Replace
Replace
Replace
Replace

Support
Ring, Bulkhead

2423130
2423013

2523002

IBulkhead, Sta. 146.42


JBulkhead, Sta. 146.42

2323064

2323024

REPAIR

CODE

Support
Support

2423110

15

IFINISH
GAGE

2423110

2423110

14

I
MATERIAL

Bulkhead

2323027

2423110

I
EFF.

Sta. 113.60

ISDacer

2323027

13

I
DESCRIPTION

Tailcone

Assy.

2323064

Skin

6061-T6

0.040

2323064

Bulkhead, Fwd
Bulkhead, Aft

6061-T6

0.050

1
1
1
1
1
1
I
I

I
I

2323064

2323064

Angle, Skin Attach (2 ea.)


Angle, Skin Attach
Angle, Fin, Cone

2323064

Skin, Fin

2323064
2323064

2323064
2323064

ITio. Fin
1
Tip, Fin

6061-T6

0.050

53

2024-T3

0.040

54

2024-T3

0.040

2024-T42

0.040

2024-T3

0.040

55

56

Fiberglass
Epoxy Molding

I
I

I
I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Tip Tank Repair Index


Figure 1 (Sheet 5 of 10)
EFFECTIVITY:
SRM-4

MODEL 23/24/25/35/36SERIES AIRCRAFT

57-31-00

Page 5
May 15/92

Learjet
LAarjrl
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

ITio. Fin

2323064
2323064

2323064
2323064

2523003

Clip, Rib Connecting


Spar, Fin
Angle, Bulkhd Attach
Tailcone Assy.
1
Fin Assy.

2323064

2323064

2323064
2323064
2323064
2523003

Skin. Fin

I
EFF.

Rib, Tank BL12.00


Rib Segment, Root, Fwd
Rib Segment, Root, Aft
Rib, Fwd Closing

2323064

I
MATERIAL

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

I Replace

2024-T42

0.040

2024-T42

0.050

2024-T42

0.050

1
1

I
I

2024-T42

0.040

2024-T3

0.063

2024-T42

0.071

2024-T42

0.040

1
1
1
1

I
I
I
I

Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.040 1

51-70-02

57

Polyurethane

52

52

52

2024-T3 Clad

1
1

58

2323064

ITip. Fin
1
Tip. Fin

2323064

ITio. Fin

Fiberglass
Epoxy Molding
Polyurethane

59
60

I
I
I

I
I
I

I Replace
I Replace
I Replace

2323064

Rib, Tank, BL12

52

2024-T42 Clad

0.040 1

51-70-03

2323064

Root Rib

52

2024-T42 Clad

0.050 1

51-70-03

52

2024-T42 Clad

0.050 1

51-70-03

52

2024-T42 Clad

0.040 1

51-70-03

52

2024-T3 Clad

0.063

Replace

52

2024-T42 Clad

0.071

51-70-03

0.040

I Replace

Segment, Fwd
Root Rib Segment, Aft
Rib, Fwd Closing
Clip, Rib Connecting

2323064
2323064
2323064

2323064
2323064

Soar, Fin

2523003

Angle, Bulkhead
Angle, Mounting

2523003

Doubler

2523003

Attach

Angle, Skin Attach


Angle, Fin to Cone
Angle, Fin to Cane
Angle, Skin Attach
Bulkhead, Aft

2323064

2323064
2323064

2523003

52

2024-T3 Clad

25

S-512

52

2024-T42

0.040

52

2024-T3 Clad

0.040

52

2024-T42 Clad

0.040

52

2024-T42 Clad

0.040

52

51-70-04

2024-T3 Clad

0.040

1
1
1
1
1

I
I
I
I
1

Replace
Replace
Replace
Replace
Replace

52

2024-T42 Clad

0.040 1

Skin, Tailcone

52

6061-T6

0.040 1

1
1

51-70-03

2523003

2523003

Bulkhead

52

6061-T6

0.050 1

51-70-03

I Replace
I Replace
I Replace

Replace

Replace
Replace
Replace
Replace

2523003

Bulkhead Attach,
Lower

52

2024-T3 Clad

0.040

52

2024-T42 Clad

0.040

52

2024-T42

0.063

1
1

2523003

Cover, Access
Bracket, Mounting
Tube (3.25 OD x 0.035

Wall)
Ring

52

6061-T6

2523003

52

6061-T6

0.040

2523003

2323045

1 2323045

51-70-02

Angle,

2523003

16

I
DESCRIPTION

Access Door Instl.

I Replace

35

Door

6061-T6

0.063

F4-4

2323045

Doubler

6061-T6

0.063

F4-4

2323045

Door

6061-0

0.080

2323045

Doubler

6061-0

0.080

2422037

IStrakelnstl.

63

Tip Tank Repair Index


Figure 1 (Sheet 6 of 10)
EFFECTIVITY:
SRM~

MODEL 23/24/25/35/36 SERIES AIRCRAFT

57-31-00

Page 6
May 15/92

L~arjet

STRUCTURAL REPAIR MANUAL


ITEM

NO.
17

DWG.
NO.

I
DESCRIPTION

(2 ea.)
Fairing Assy.

2422039

1
Fairina
IDoubler
IDoubler

2422036

Stiffener

2422039
2422039

FIG. NO.

6061-T6

0.063

Replace

1
1
1

63

2024-T3 Clad

0.063

63

201 4-T6

0.071

1
1

I
I

63

2024-T3

0.040

Replace
Replace
Replace

63

S-699

51-70-04

63

SuoDort

63

2024-T3 Clad

I Replace

2422041

ISuooort

64

S-744

51-70-04

2422041

ISuoport
Strake Assy.

65

5-745

51-70-04

2422040
2622037

63

6061-T4

0.063

Replace

6061-T6

0.063

Replace

1
1
1

I Replace
I Replace
I Replace

66

Panel

66

(2 ea.)
Fairing Assy.

2422039

0.063

63

Strake (2 ea.)
IStrakelnstl.

2622036

66

2422039

66

2024-T3 Clad

0.063

2422039

66

201 4-T6

0.071

2422039

IDoubler
Doubler

66

2024-T3

2422036

IStiffener

66

S-699

Fairinn

0.040
1

2422041

SuDoort

66

2024-T3 Clad

Replace

2422041

ISuoport

67

5-744

51-70-04

2422041

ISuoport

68

S-745

51-70-04

2622038
2323001
2423100
2423100

2323001
2323001
2423100
2423100

20

2323059

21

2323059

66

6061-T4

0.063

Replace

6061-T3

0.050 1

51-70-02

Sta. 15.00 to 46.00

16061-T3

0.080 1

51-70-02

Sta. 15.00 to 46.00

19

6061-T3

0.080 1

51-70-02

Sta. 15.00 to 46.00

20

6061-T3

0.090 1

51-70-02

Sta. 113.20 to 149.94

6061-T3

0.080 1

51-70-02

Sta. 113.20 to 149.94

6061-T3

0.080 1

51-70-02

Sta. 113.20 to 149.94

19

6061-T3

0.080 1

51-70-02

Sta. 113.20 to 149.94

20

6061-T3

0.090 1

51-70-02

Bulkhead Sta. 29.50

40

6061-T6

0.050

F4-4

Bulkhead Sta. 65.00

40

\6061-T6

0.050

F4-4

Skin,
Skin,
Skin,
Skin,
Skin,
Skin,
Skin,
Skin,

2323001

0.063

66

Assy.
Strake (2 ea.)

Strake

2622038

Sta. 15.00 to 46.00

2323059

Bulkhead Sta. 98.63

42

6061-T6

0.050

F4-4

2423120

Bulkhead Sta. 98.86

43

6061-T6

0.050

F4-4

23

2323059

Bulkhead Sta. 121.00

50

6061-T6

0.050

F4-4

24

2323059

1
1

Bulkhead Sta. 130.80

50

6061-T6

0.050

F4-4

22

Access Door Instl.

2423101
25

51-70-04

66

Support Assy.

2422041

19

REPAIR

CODE

2422041

2422040

18

IFINISH
GAGE

63

Support Assy.

2422041

I
MATERIAL

63

Panel

2422081
2422039

I
EFF.

Replace
I Replace
Replace
Replace
Replace
Replace

2423101

Doubler

6061-T6

0.080

F4-4

2423101

Door

6061-T6

0.080

F4ext

Replace
Replace

F4-4int
2323045

Access Door Instl.

36

Tip Tank Repair Index


Figure 1 (Sheet 7 of 10)
EFFECTIVITY:

MODEL

23/24/25/35/36SERIES AIRCRAFT

57-31-00

Page
SRM~

Jan 15/93

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

NO.
26

DWG.
NO.

REPAIR

CODE

FIG. NO.

Replace
Replace
Replace
Replace

6061-T6

0.063

F4-4

6061-T6

0.063

F4-4

Door

34

6061-T6

0.080

F4-4

Doubler

34

6061-T6

0.080

F4-4

18

6061-T6

0.063

F4-4

18

6061-T6

0.063

F4-4

2323045

Access Door Instl.


1
IDoor

18

Doubler

38

6061 -T6

0.063

F4-4

Doubler

38

6061-T6

0.063

F4-4

2323045

Door

39

6061-T6

0.080

F4-4

2323045

Doubler

39

6061-T6

0.080

F4-4

2323045

Door

6061-T6

0.063

F4-4

2323045

Doubler

6061-T6

0.063

F4-4

39

6061-0

0.080

39

6061-0

0.080

6061-T6

0.050

IDoor

2323041
2323041

Doubler

2323045

Door

Support

Replace
Replace
Replace
Replace

35

Access Door Instl.

2323045
2323045

Replace
Replace

37

Access Door Instl.


1
lDoor

2323045

2323045

29

IFINISH
GAGE

2323045

2323045

I
MATERIAL

Doubler

2323043

I
EFF.I

Door

2323045

2323070
28

I
DESCRIPTION

2323045

2323043
27

Replace
Replace
Replace
Replace

32

Inst.

32

Door

Replace

F4ext
F4-4int

Replace
Replace
Replace
Replace

Replace
Replace
Replace

2323041

DaublerAssy.

32

2323041

Doubler

32

6061-T6

0.063

F4-4

2323041

Bracket

32

6061-T6

0.071

F4-4

32

6061-T6

0.040

F4-4

2323041
2323067
2323067
2323067
2323068

Channel

(2 ea.)

33

IPumplnstl.
Bracket Assy.

33

Bracket

ICover

33

6061-T6

0.063

33

2024-T42

0.032

F4-6ext

39

2024-T42

0.020

F14-1int

F4-4int
2423103

IFairing

Replace

F1 art

Tip Tank Repair Index


Figure 1 (Sheet 8 of 10)
EFFECTIVITY:

MODEL 23/24/25/35/36 SERIES AIRCRAFT

57-31-00

Page
SRM-4

Jan 15/93

~Learjet
STRUCTURAL REPAIR NIANUAL
CODES
1
2
3

EFFECTIVITIES
23-002 THRU

23-099; 24-100 THRU 24-229 EXCEPT 24-218; 25-002 THRU 25-066 EXCEPT 25-061
24-218, 24-230 THRU 24-357; 25-061, 25-067 THRU 25-373
24-218, 24-230 THRU 24-357; 25-061, 25-067 THRU 25-373; 35-002 AND SUBSEQUENT; 36-002
AND SUBSEQUENT

24-100 THRU 24-229 EXCEPT 24-218; 25-002 THRU 25-066 EXCEPT 25-061
35-002 AND SUBSEQUENT; 36-002 AND SUBSEQUENT

23-002 THRU

23-040 THRU

23-099; 24-100 THRU 24-357; 25-007 THRU 25373


23-099; 24-100 THRU 24-229 EXCEPT 24-218; 25-002 THRU 25-066 EXCEPT 25-061
24-140 THRU 24-229 EXCEPT 24-218; 25-002 THRU 25-066 EXCEPT 25-061

23-002 THRU 23-099

10

24-100 THRU 24-229 EXCEPT

11

25-002 THRU 25-006

12

23-002 THRU 23-065

13

23-066 THRU 23-099

14

23-002 THRU 23-008

15

24-218; 25-007 THRU 25-066 EXCEPT 25-061

24-218, 24-230 THRU 24-244; 25-061, 25-067 THRU 25-079


24-357; 25-080 THRU 25-373; 35-002 AND SUBSEQUENT;

16

24-245 THRU

17

QUENT
23-002 THRU 23-051

18

23-052 THRU 23-099

19

24-218, 24-230 THRU 24-357; 25-061, 25-067 THRU 25-373; 35-002 THRU 35-663; 36-002 THRU

36-002 AND SUBSE-

36-063
20

35-664 AND

21

23-011 THRU 23-051

22
23

23-052 THRU 23-099; 24-100 THRU 24-264; 25-002 THRU 25-103


23-002 THRU 23-030

24

23-031 THRU 23-051

25

23-052 THRU 23-099; 24-100 THRU


36-002 AND SUBSEQUENT

26

24-100 THRU 24-229 EXCEPT 24-218

27

25-002 THRU 25-357; 35-002 AND

SUBSEQUENT;

36-064 AND SUBSEQUENT

24-357; 25-002 THRU 25-373; 35-002 AND SUBSEQUENT;

30

SUBSEQUENT; 36-002 AND SUBSEQUENT


DELETED
24-265 THRU 24-357; 25-104 THRU 25-373; 35-002 AND SUBSEQUENT; 36-002 AND SUBSEQUENT
24-265 THRU 24-294; 25-104 THRU 25-170; 35-002 THRU 35-003; 36-002

31

24-295 THRU

28

29

24-357; 25-171 THRU 25-373; 35-004 AND SUBSEQUENT;

36-003 AND SUBSE-

QUENT
32

23-011 THRU 23-016

33

23-017 THRU 23-069

34

24-100 THRU

35
36

24-357; 25-080 THRU 25-373; 35-002 AND SUBSEQUENT; 36-002 AND SUBSEQUENT
23-002 THRU 23-099; 24-218, 24-230 THRU 24-357; 25-061,25-067 THRU 25-373; 35-002 AND
SUBSEQUENT; 36-002 AND SUBSEQUENT
23-002 THRU 23-099; 24-100 THRU 24-357; 25-080 THRU 25-373; 35-002 AND SUBSEQUENT;
36-002 AND SUBSEQUENT

37

23-070 THRU 23-099; 24-218, 24-230 THRU 24-357; 25-061,25-067 THRU 25-373; 35-002 AND
SUBSEQUENT 36-002 AND SUBSEQUENT

38

23-070 THRU 23-099

Tip Tank Repair Index


Figure 1 (Sheet 9 of 10)
EFFECTNITY:

MODEL 23/24/25/35/36 SERIES AIRCRAFT

57-31-00

Page 9
SRM-4

Tan 15/93

Learjet
Learje~l

STRUCTURAL REPAIR MANUAL


CODES

EFFECTIVITIES
24-100 THRU 24-357; 25-007 THRU 25-373; 35-002 THRU 35-663; 36-002 THRU 36-063
23-002 THRU 23-099; 24-100 THRU 24-230; 25-002 THRU 25-006
24-231 THRU 24-357; 25-007 THRU 25-373; 35-002 AND SUBSEQUENT; 36-002 AND SUBSE-

39
40
41

QUENT
23-002 THRU 23-099; 24-100 THRU 24-229; 25-002 THRU 25-006
24-218, 24-230 THRU 24-244; 25-007 THRU 25-079
23-002 THRU 23-099; 24-100 THRU 24-229 EXCEPT 24-218

42
43

44

47

DELETED
25-002 THRU 25-066 EXCEPT 25-061
24-100 THRU 24-217; 25-002 THRU 25-066 EXCEPT 25-061

48

24-218, 24-230 THRU 24-357; 25-061, 25-067 THRU 25-241; 35-002 THRU 35-171; 36-002 THRU

45

46

36-038

25-373; 35-172 AND SUBSEQUENT; 36-039 AND SUBSEQUENT


23-099; 24-100 THRU 24-230; 25-002 THRU 25-066 EXCEPT 25-061
23-002 THRU 23-099; 24-100 THRU 24-244; 25-002 THRU 25-079
25-002 THRU 25-006; 35-240 AND SUBSEQUENT; 36-044 AND SUBSEQUENT

49

25-242 THRU

50

23-002 THRU

51
52
54

24-100 THRU 24-189; 25-001 THRU 25-029


24-190 THRU 24-357; 25-030 THRU 25-373

55

24-328 THRU

53

24-356; 25-007 THRU 25-267


24357; 25-268 THRU 25-318

56

25-319 THRU 25-373


25-002 THRU 25-007; 35-002 THRU 35-224; 36-002 THRU 36-044
35-225 THRU 35-350; 36-045

57
58
59

35-351 AND SUBSEQUENT; 36-045 AND SUBSEQUENT


23-002 THRU 23-008

60
61

24-101 THRU 24-109


24-329 THRU 24-357; 25-206 THRU 25-373
24-229 THRU 24-233; 25-206 THRU 25-207
24-334 THRU 24-357; 25-208 THRU 25-373
35-067 AND SUBSEQUENT; 36-018 AND SUBSAEQUENT
35-067 THRU 35-082; 36-018 THRU 36-020
35-083 AND SUBSEQUENT; 36-021 AND SUBSEQUENT

62
63

64
65
66
67
68

NOTES
Per MIL-P-15035

Tip Tank Repair Index


Figure 1 (Sheet 10 of 10)
EFFECTIVITY:

MODEL 23/24/25/35/36SERIES AIRCRAFT

57-31-00

Page
SRM-4

10

Jan 15/93

Learjet
STRUCTURAL REPAIR MANUAL
TIP TANK- ALLOWABLE DAMAGE

i.

ALLOWABLE DAMAGELIMITS

All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose

or

failed rivets

are

not allowed. A loose

or

failed rivet

can cause

increased stress concentrainspection must be

failure. A careful

rivets and lead to

on
progressive joint
remaining
performed to ensure that joint failure has not spread from the area of the loose or failed rivet.
fer to Chapter 51 for definition of rivet failure.)

the

tions

(2) Loose

or

trations

failed

on

screws are not

surrounding

allowed. A loose

screws

and lead to

or

failed

progressive joint

performed to ensure that the joint failure has not spread


B.

screw can cause

increased stress

failure. A careful

from the

area

(Re-

concen-

inspection must be

of the loose

or

failed

screw.

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired,
C.
D.

and refinished in accordance with

Deformation

(1) Deformation of a tip tank or the tip tank stntcture is not allowed.
Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

re-

Chapter 51.

more

than

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to
F.

G.

H.

rivet

or

structural

area.

Such dents shall be

repaired

or

the

component

placed.
Scratches(SeeFigure 101.)
(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.

EFFECTIVITY:

MODEL

23/24/25/35/36SERIES AIRCRAFT

57-31-00

Page
SRM~

re-

101

May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125
0.190

0.120

0.250

0.180
0.237

Allowable Material Thickness

Figure 101
EFFECTIVITY:
s~M-a

MODEL 23/24/25/35/36SERIES AIRCRAFT

57-31-00

Page 102
May 15/92

Laarjet
Learjet

STRUCTURAL REPAIR MANUAL


TIP TANK
i.

REPAIR

APPROVED REPAIRS
A.

Refer to
and

Chapter 51 for typical repairs,


attaching parts.

Em~CTIVITY:

and for allowable

MODEL 23/24/25/35/36 SERIES AIRCRAFT

wear

and

repair

data for the

tip tank fittings

57-31-00

Fage 201
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


FILAP-STRUCTLTRAL IDENTIFICATION

~s)

(17)

(a)

~9)

(50)

(1)

(24)

(52)

(23)

(5j
51

5~

f
-~I--

I I

II

I!

II

II

rl

II

--J__

I_I-------__
19

60

61

II

s2

C-

II

33

I I

11

63

II

11

I
II

ii

II

II

II

63

II

-.li---___

1$----- -Z

39

i I
r---------:

---c--r

iT
II

I,

1-

111

tt

-1

I-

6E

-ti--

I--

I!!

I
II

II

--k-+1--

ii

-I

II

II

_7_
I

-1~1------

II

II

,I

-----C1---

II-

-I?-

Il

Il

I I

II

II

_~

II

I~I

I-

i~ I;

~---lr-------lr---If

Ir
II

I,

--~----II

n------,7-II
I I

II

II

--H-----

-J---.
jj

ii

r---

II

I I
II

(si
s

7I---

II

(5i;

,I

ii

(56)

(I

I
_~

7r-

-SL---__,

S~--

f I--

II

__~___

--71-

rl

-L

I I
II

II
u

26

5~

(1~

(T~
LH

;i

I----

.i
II

II

-II__

~-?1--

~-----f-----

II
I

II

,I

It

I1
II

I
I

t7

II
I

I
~23-002 thn.

25-002 thnr 25-2_05: 3~002

th~l 24-328:
fhru 35-059:

I I

I)
I

1~

EFFECTNITY:
SRM-4

__

II

i,
I

II

(I

LI

ii

II

II

I\

II

(I

I\
II

I
I

ii

II

Ij

II

II

II

II
II

II

LH

Page

ii

yi

I
I

It

ii

_S,--~=r--, 1;-~----==5 I~-

L,

May 15/92

-;t

57-so-oo

II

II

I\

--I i

II

II

__

t(--

LL---~---------

II

Flap Repair Index


Figure 1. (Sheet 1 of4)
NOTED

---Ilt

---i~c-

36002~m( 36-037)

6MX]-I

Jt
II

1~
jl jrl fi--II:fi

-a-

=--=--------t---;

15

ii

I---

;t

T7--itrY.-I

c~

Opposite

Fi;t~-

II,-~-It

_~L
_

--Tt

I""":"
II: 5Si II
iE~

II

--1C

ic 1
ii

II
II

II

RH

iJ,I:lc----it---

L1---_
1I1

~i) ~j)

Flap Upper Surface

IL_

ii
II

16

II

~ap Lower Surface

RH

Opposite

?I

II
II
II

ii

II
I
I

L?

LI

LI

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

2325022
2325022

Track

2325022

Track

2325022

Track

2325000

2
3

Assy.,

2325010

I
MATERIAL

IFINISHI REPAIR
CODE
FIG. NO.

GAGE

51-71-00

51-71-00

51-71-00

Inboard

Flap Assy., LH

2325010
4

I
EFF.

Flap Instl.
Flap Nose Roller
Track Assy., Outboard

2325000
1

I
DESCRIPTION

6 RH

Skin, Upper Trailing Edge

2024-T3 Clad

F14-1int

0.025

51-70-02

Flext
5

2325010

Skin, Lower Trailing Edge

2024-T3 Clad

0.025

F16lint
F1 ext

51-70-02

2325010

Skin, Leading Edge

2024-T42 Clad

0.032 1 F16lint

51-70-02

Fl art
7

2325010

2325010

2325010

10

2325010

11

2325010

12

2325010

13

2325010

14

2325010

Stringer, Lower
Spar Cap, Lower
Stringer, Lower
IStringer, Lower

2425111
15

2325010
2425111

16

2325010

17

2325010

18

2325010

19

2325010

2325010

2325010
20

2325010

21

2325010

22

2325010

23

2325010

24

2325010

25

2325010

26

2325010

27

2325010

28

2325010

29

2325010

Rib, Attach, Outboard (2 ea.)


Rib, Attach, Inboard (2 ea.)

1
i

St~inger, Lower
Fairing Support
Fairing Support
Fairing, Flap
Fairing, Flap
Stringer, Upper Inboard
Stringer, Upper Inbaard
Stringer, Lower Inboard
Stringer, Upper Outboard
Bracket, Inboard (2 ea.)
Clip(2 ea.)
Stringer, Upper
Spar Cap, Upper
Rib, Leading Edge
Spar
Stringer, Upper
Trailing Edge Extrusion
Rib, Inboard
Rib, Leading Edge
Rib, Leading Edge
Rib, Leading Edge
Nose Roller Support, Inboard

1
1

30

2325010

31

2325010

Rib, TrackAttach

32

2325010

Nose Roller

Support, Inboard

S-559

2014-T6 Clad

S-559

S-554

2024-T42

I
0.062

I
I
0.050

F4-1

Replace
51-70-04

F4-1

51-70-04

F4-1

51-71-00

F4-1

51-71-00

F4-1

51-70-04

Replace
Replace
Replace
Replace

2024-T42

S-559

6061-0 Clad

0.032

F4-1

2024-T42 Clad

0.032

F4-1

6061-T4 Clad

0.032

F4-1

6061-T4 Clad

0.032

S-559

2024-T42 Clad

2024-T42 Clad

S-559

2024-T42 Clad

0.050

F4-1

I
0.062

F4-1
F4-1

0.062

F4-1

51-70-04

F4-1

F4-1

51-70-04

51-70-04
51-70-04

F4-1

51-70-04

0.050

F4-1

51-70-04

2024-T42

0.050

F4-1

51-70-04

2024-T42 Clad

0.050

F4-1

51-70-03

2024-T3 Clad

0.062

F4-1

2024-T42 Clad

0.032

F4-1

Replace
Replace

F4-1
F4-1

2024-T42 Clad

0.040

2024-T3 Clad

0.032

2
1

18-639
i 2024-T42 Clad
2024-T42 Clad

2024-T42 Clad

51-70-04

F4-1

0.0401

~4-1

1 51-70-03

0.032

F4-1

51-70-03

0.032

F4-i

51-70-03

2024-T42 Clad

0.040

F4-1

51-70-03

2024-T3 Clad

0.125

2024-T42

0.050

F4-1

301 Stainless~

0.080

F4-1

51-70-04

Replace

I Replace
Replace
Replace

map Repair Index


Figure 1 (Sheet 2 of 4)
EFFECTIVITY:
SRM~

NOTED

57-50-00

Page 2
May ~5/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM I
NO.

DWG.
NO.

I
DESCRIPTION
Nose Roller

Support, Inboard

I
EFF.

I
MATERIAL

GAGE

IFINISH
CODE

REPAIR
FIG. NO.

33

2325010

34

2325010

Rib, Leading Edge

1 2024-T42 Clad
2024-T42 Clad

35

2325010

Doubler

2024-T42 Clad

0.040

F4-1

2325010

Spacer(3 ea.)

2024-T3

0.062

F4-1

36

2325010

Access Cover

2024-T42 Clad

0.050

F14-1int

37

2325010

Doubler

2024-T42 Clad

0.032

F4-1

Replace

38

2325010

Rib, Leading Edge


Bracket, Outboard (2 ea.)

2024-T42 Clad

0.040

F4-1

51-70-03

2024-0 Clad

0.050

F4-1

Replace

2325010

Clip(2 ea.)

2024-T42

0.050

F4-1

51-70-04

40

2325010

Nose Roller

Outboard

301 Stainless~

0.080

F4-1

41

2325010

Nose Roller

Outboard

2024-T3 Clad

0.125

F4-1

42

2325010

Track Attach

2024-T42

0.050

F4-1

43

2625015

2024-T42 Clad

0.040

F4-1

51-70-03

2325010

Leading Edge
Leading Edge

44

1
1

2024-T42 Clad

0.032

F4-1

51-70-03

45

2325010

Outboard

2024-T42 Clad

0.040

F4-1

51-70-03

46

2325010

2024-T42 Clad

0.025

F4-1

51-70-03

2325010

2024-T42 Clad

0.025

F4-1

51-70-03

48

2325010

2024-T42 Clad

0.025

F4-1

51-70-03

49

2325010

2024-T42 Clad

0.025

F4-1

51-70-03

50

2325010

2024-T42 Clad

0.025

F4-1

51-70-03

51

2325010

2024-T42 Clad

0.025

F4-1

51-70-03

52

2325010

Trailing
Trailing
Trailing
Trailing
Trailing
Trailing
Trailing

47

1
1
1
1

2024-T42 Clad

0.025

F4-1

51-70-03

53

2325010

Rib,
Rib,
Rib,
Rib,
Rib,
Rib,
Rib,
Rib,
Rib,
Rib,
Rib,
Rib,

Replace
Replace
Replace

2024-T42 Clad

0.025

F4-1

51-70-03

54

2325010

2024-T42 Clad

0.025

F4-1

55

2325010

0.0251

F4-1

56

2325010

1 2024-T42 Clad
2024-T42 Clad

0.025

F4-1

51-70-03

57

2325010

2024-T42 Clad

0.025

F4-1

51-70-03

58

2325010

2024-T42 Clad

0.025

F4-1

51-70-03

59

2325010

2024-T42 Clad

0.032

F4-1

51-70-03

60

2325010

2024-T42 Clad

0.032

F4-1

51-70-03

61

2325010

2024-T42 Clad

0.032

F4-1

51-70-03

62

2325010

2024-T42 Clad

0.040

F4-1

51-70-03

63

2325010

S-575

F4-1

64

2325010

2024-T4

0.750

F4-1

Replace
Replace

65

2325010

2024-T42 Clad

0.040

F4-1

51-70-03

66

2325010

2024-T42 Clad

0.032

F4-i

51-70-03

67

2325010

2024-T42 Clad

0.032

F4-1

51-70-03

68

2325010

2024-T42 Clad

0.032

F4-1

51-70-03

0.050(

F4-1

0.040 1

Replace
i

51-70-03

Replace
Replace
Replace

F1 art

39

2325010

1
1
1

1
1
1
1

Support,
Support,

Edge
Edge
Edge
Edge

Edge
Edge
Edge
Trailing Edge

Rib,TrailingEdge
Rib, Trailing Edge
Rib, Trailing Edge
Rib, Trailing Edge
Rib, Trailing Edge
Rib, Leading Edge
Rib, Leading Edge
Rib, Leading Edge
Rib. Leading Edge
Reinforcing Angle (4 ea.)
Reinforcing Channel (2 ea.)
Rib, Leading Edge
Rib, Leading Edge
Rib, Leading Edge
Rib, Leading Edge

51-70-03

51-70-03

Flap Repair Index


Figure 1 (Sheet 3 of 4)
EFFECTIVITY:
SRM~

NOTED

57-50-00

Page 3
May 15/92

Learjet
Learjetj
STRUCTURAL REPAIR MANUAL
CODES

EFFECTIVITIES

35-059; 36-002

23-002 THRU 23-099; 24-100 THRU


THRU 36-017

23-040 THRU 23-099; 24-100 THRU 24-328; 25-002 THRU 25-205; 35-002 THRU 35-059; 36-002
THRU 36-017

24-270 THRU

23-002 THRU 23-099; 24-100 THRU 24-229; 25-002 THRU 25-061


24-230 THRU 24-328; 25-062 THRU 25-205; 35-002 THRU 35-059; 36-002 THRU 36-017

24-328; 25-002 THRU 25-205;

35-002 THRU

24-328; 25-115 THRU 25-205; 35-002 THRU 35-059; 36-002 THRU 36-017

NOTES:
Condition 114 hard.

map Repair Index


Figure 1 (Sheet 4 of 4)
EFFECTIVITY:
SRM-P

NOTED

57-50-00

Page 4
MaY 15/92

Learjet

STRUCTURAL REPAIR MANUAL


FLAP-STRUCTURAL IDENTIFICATION
46
47

48

49

50

24

51

52

(23
54

II

56

II

III
II
I
~-I--

r------n
~1-

Yi~

--IIII
Il
II
-J
I------

I,

I
-Ir

Ir

L_

II

I,--

iI

__

59);1

I,

60

-1

--+1--

rt

63

!L

II

I
1,1

II

68

---~ZZ
11

87

69

II

i~

f
77 fl-

ii

if

II
__

--I,
II

___

11

I_

~L______
t

r-

II
,I

____~__ _~

I I
-I~--------

Ir---------t

I;nen,

ct

it~-----_=

LI

II

-il----_

63

I;-rt
I

II

--J---

-r------rl--

II

-CC--+1--

II

a--i

FI-----

II

64

:~-----_ -f
r

~O
I

I-

,i(ss

61

II

-II- -~-I-

TII I

i,I

Il

I!

-~i---

_1-

s3

II

~I
II

I
1

I I

_--

1~-

II;

II
_

~Cvr.
I I

s;-----

II

II
II

?r

III

_-

55

rl

L~

22
70

71

74

12

73

75

78

36

35

78

79

80

38

81

20

39

40)
LH

Flap Upper

Surface

r(

r--2

__

II
II

14)

I I

ri

I
II

ICI

I I

I I

rr

I I

Ir
ii !I!

tb

II,

-II

llt-

--r~-I
!_

II

rl
I_I

__IC-

$I-

-----~c---

--tih-

-----Tt---

II
II

~1-

I I

-rt
II

T1--

~r17?-

II

I
I

15

(I

II

II
II

It
I

It
I

II

I
I

ii
II

II

_IL----------L-

I
I

11

I I

II

I I

II

II

IJ

II
I

I
I_I

II

_=_~I-_

-L1--T---II

iI
(1

71-

I I

;1
II

II

Li

LI

1_1

!I

II

I I

I
I

I I

iI

II

II

II

-I

III

__LL

I I

II
II
I
II

I I

=il

II-

LL

L~
1_1

ft

L_

I-------fl---II

(41

I-1-----

(45

~4

18)

44

11

C~posite

RH

13)
C

42

II
i

I I

II

I
IJ

II

II

I-I

LR.Flap

Inver

Surface

1181

q?posite
123-328 thru 24-357: 25-205 thru 25-373: 28-001

4-60C

EFFECT~VITY:

~hnr 28-00~: 29-001 fhtu 29-004: 35-060 and


Subseauenf; 36-018 and Subseauent; 31-002 and

nap Repair Index


Figure 2 (Sheet 1 of 5)

NOTED

Subseauenf)

57-50-00

Page 5
May 15/92

Learjet I

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

2325000
1

I
EFF.

IFINISH
GAGE

REPAIR
FIG. NO.

CODE

51-71-00

51-71-00

51-71-00

ITrack
Trade Assy., Inboard

2325022

ITrack

Flap Assy., LH 8 RH
Skin, Upper Trailing Edge

2625010

MATERIAL

2325022

2325022

2625010
4

DESCRIPTION

Flap Instl.
Flap Nose Roller
Trade Assy., Outboard

2325000
2325022

I-

1
2024-T3 Clad

F1Q-lint

0.032

51-70-02

Fl ext
5

1 2625010

Skin, Lower Trailing Edge

2024-T3 Clad

F1Clint

0.025

51-70-02

F1 ext
6

2625010

Skin, Leading Edge

2024-T42 Clad

F14-lint

0.050

51-70-02

F1 ext

2625010

IShim

2024-T3

0.040

2625010

IShim

2024-T3

0.040

1
1

2625010

IShim

2024-T3

0.040

2625010

IShim

2024-T3

0.040

2625010

IShim

2024-T3

0.040

1
1

2325010

S-559

2625015

2014-T6 Clad

2325010

10

2325010

11

2625024

(Stringer, Lower
Spar Cap, Lower
1
IStringer, Lower
Stringer, Lower
1
IFitting, Outboard

12

2625023

IFitting,

13

2325010

inboard

14

2425111

15

2425111

16

2325010

17

2325010

18

2625015

19

2625015

20

2625010

21

2325010

22

2625015

Doubler, Outboard

23

2625015

24

2625015

1
1

Stringer
Stringer
Trailing Edge Extrusion
Trailing Edge Extrusion
Rib,
Rib,
Rib,
Rib,

Nose Roller

2325010

3125001
26

2325010

27

2325010

28

2325010

29

2625010

1
1
1

30

2325010

S-559

2024-T42 Clad

IStringer, Lower
Fairing Support
1
Fairing, Flap
1
IStringer, Upper Inboard
Stringer, Upper Inboard
1
Stringer, UpperOutboard
Doubler, Inboard
1
Spar
1
Spar Cap, Upper
1

25

1
1
1

I Replace
I Replace
I Replace
j Replace
I Replace
F4-1

I
I

I
I
1

S-559

2024-T42 Clad

1 6061-T4 Clad

F4-1

51-70-04

F4-1

0.063

I
I
I

51-70-04

1
1
F4-1

0.032

0.032

F4

F4-1

51-71-00
51-71-00
51-70-04

Replace
Replace

S-559

2024-T42 Clad

S-559

2024-T42 Clad

0.063

F4

51-70-04

2024-T42 Clad

0.063

F4

51-70-03

2024-T3 Clad

0.063

F4-1

2024-T3 Clad

0.040

51-70-04

F4-1

0.063

51-70-04

2024-T3 Clad

0.032 1

2024-T3 Clad

0.032 1

I
1
i

51-70-04

Replace
Replace
51-70-04
51-70-04

5-639

2024-T351

0.312

F4

Replace
Replace
51-70-03

F4-1

Inboard

2024-T42 Clad

0.040

F4-1

Leading Edge
Leading Edge
Leading Edge

2024-T42 Clad

0.032

F4-1

2024-T42 Clad

0.032

F4-1

2024-T42

0.040 1

2024-T3 Clad

0.125

Support, Inboard

51-70-04

I Replace

0.071

F4-1

51-70-03

i
i

51-70-03
51-70-03

Replace

map Repair Index


Figure 2 (Sheet 2 of 5)
EFEECTNITY:
SRM4

NOTED

57-50-00

Page 6
May 15/92

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


ITEM
NO.

DWG.
NO.

DESCRIPTION

I
EFF.

I
MATERIAL

IFINISH
GAGE

301

Stainlessl~

0.012

F4-1

Inboard

301 Stainless~

0.080

F4-1

Support, Inboard

2024-T42 Clad

0.050

F4-1

Rib

2024-T42 Clad

0.040

F4-1

Rib, Leading Edge

2024-T42 Clad

0.040 1

2024-T42 Clad

0.050

2024-T42 Clad

0.032

31

2325010

32

2325010

IRubStrip
Nose Roller Support,
1

33

23250 i 6

34

2325010

IReinforcement, Leading

35

2625015

36

2625015

AccessCover

37

2325010

Doubler

Nose Roller

Edge

REPAIR
FIG. NO.

CODE

Replace
Replace
Replace
Replace

51-70-03

Replace
Replace

51-70-03

F4-1

38

2625015

2024-T42 Clad

0.040 1

2325010

Rib, Leading Edge


Backing Plate

39

2024-T3 Clad

0.050

40

2325010

Nose Roller

301 Stainless~

0.080

41

2325010

2024-T3 Clad

0.125

42

2325010

301 Stainless~

0.012

43

2625015

2024-T42 Clad

0.040 1

44

2325010

2024-T42 Clad

0.032

F4-1

51-70-03

45

2325010

2024-T42 Clad

0.040

F4-1

51-70-03

46

2325010

2024-T42 Clad

0.025

Fdl

47

2325010

2024-T42 Clad

0.025

F4-1

48

2325010

2024-T42 Clad

0.025

F4-1

51-70-03

49

2325010

2024-T42 Clad

0.025

F4-1

51-70-03

50

2325010

2024-T42 Clad

0.025

F4-1

51-70-03

51

2325010

2024-T42 Clad

0.025

F4-1

51-70-03

52

2325010

2024-T42 Clad

0.025

F4-1

51-70-03

53

2325010

2024-T42 Clad

0.025

F4-1

51-70-03

54

2325010

2024-T42 Clad

0.025

F4-1

55

2325010

2024-T42 Clad

0.025 1

F4-1

56

2325010

2024-T42 Clad

0.025

F4-1

51-70-03

57

2325010

2024-T42 Clad

0.025

F4-1

51-70-03

58

2325010

2024-T42 Clad

0.025

F4-1

51-70-03

59

2325010

2024-T42 Clad

0.032

F4-1

2024-T42 Clad

0.032 1

2024-T42 Clad

0.032

2024-T42 Clad

0.032 1

2024-T42 Clad

0.032

2024-T42 Clad

0.032 1

2024-T42 Clad

0.040

2024-T42 Clad

0.040 1

51-70-03

S-575

2024-T4

0.750

Replace
Replace

F4-1

63

2325010

64

2325010

Support, Outboard
Nose Roller Support, Outboard
1
IRubStrip
Rib, Leading Edge
1
Rib, Leading Edge
1
Rib, Outboard
1
Rib, Trailing Edge
1
Rib, Trailing Edge
Rib, Trailing Edge
1
Rib, Trailing Edge
1
Rib, Trailing Edge
Rib, Trailing Edge
Rib, Trailing Edge
Rib, Trailing Edge
Rib, Trailing Edge
1
Rib, Trailing Edge
1
Rib, Trailing Edge
1
Rib, Trailing Edge
1
Rib, Trailing Edge
1
Rib, Trailing Edge
1
Rib, Trailing Edge
1
Rib, Trailing Edge
1
Rib, Trailing Edge
1
Rib, Trailing Edge
Rib, Trailing Edge
1
Rib, Trailing Edge
1
Rib, Trailing Edge
1
1
Reinforcing Angle
1
Reinforcing Channel

65

2325010

1. Rib

2024-T42

0.040

2625046

Rib

2024-T42

0.040 1

2325010

IRib

2024-T42

0.032

2625046

Rib

12024-T42

2625046
60

2325010
2625046

61

2325010

2625046
62

2325010
2625046

66

Replace
Replace
Replace
Replace

51-70-03

I
F4-1

51-70-03

51-70-03

51-70-03

51-70-03

1
F4-1

51-70-03
51-70-03

1
F4-1

51-70-03
51-70-03

1
F4-1

0.032 1

51-70-03

51-70-03
51-70-03

F4-1

51-70-03

51-70-03

51-70-03

F4-1

51-70-03

Flap Repair Index


Figure 2 (Sheet 3 of 5)

EFFECTIVITY:

NOTED

57-50-00

Page 7
SRM-4

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM
NO.
67
68
69

DWG.
NO.

I
DESCRIPTION

I
EFF.

MATERIAL

I
IFINISH
IGAGE CODE

REPAIR

FIG. NO.

F4-1

51-70-03

2325010

Rib

2024-T42

0.032

2625046

Rib

2024-T42

0.032 1

2325010

Rib

2024-T42

0.032

2625046

Rib

2024-T42

0.032 1

2325010

Rib

2024-T42

0.032

2625046

Rib

2024-T42

0.032 1

51-70-03

2024-T42

0.032 1

51-70-03

2024-T42

0.032 1

51-70-03

2024-T42

0.032 1

51-70-03

2024-T42

0.040 1

51-70-03

S-575

2024-T4

I
I
I

Replace
Replace
Replace

70

2625046

71

2625046

72

2625046

73

2625046

74

2325010

75

2325010

Rib,
Rib,
Rib,
Rib,

Leading Edge
Leading Edge
Leading Edge
Leading Edge
Reinforcing Angle
Channel, ActuatorAttach

Reinforcing Angle
Rib, Leading Edge
Rib, Leading Edge
Rib, Leading Edge
Rib, Leading Edge
Rib, Leading Edge

76

2325010

77

2625046

78

2625046

79

2625046

80

2625046

81

2625046

82

2625015

Doubler

83

2625015

84

2625015

85

2625015

86

2625015

87

2625015

Channel,
Channel,
Channel,
Channel,
Channel,

Reinforcing
Reinforcing
Reinforcing
Reinforcing
Reinforcing

1
F4-1

51-70-03
1

F4-1

0.750

51-70-03
51-70-03
51-70-03

S-575

2024-T42

0.040 1

51-70-03

2024-T42

0.032 1

51-70-03

12024-T42

0.032 1

2024-T42

0.032 1

1
1

51-70-03

4
4

2024-T42

0.032 1

51-70-03

2024-T3 Clad
2024-T42 Clad

0.040

0.050

2024-T42 Clad

0.050

2024-T42 Clad

0.050

2024-T42 Clad
2024-T42 Clad

0.050

1
1
1
1

I
I
I
I

Replace
Replace
Replace
Replace
Replace
Replace

0.050

51-70-03

map Repair Index


Figure 2 (Sheet 4 of 5)
EFFECTIVITY:
SRM4

NOTED

57-50-00

Page 8
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
CODES

EFFECTIVITIES
23-328 THRU 24-357; 25-205 THRU 25-373; 28-001 THRU 28-004; 29-001 THRU 29-004; 35-060
AND SUBSEQUENT; 36-018 AND SUBSEQUENT; 31-001 AND SUBSEQUENT

i
2

24-351 THRU 24-357; 25-227 THRU

AND SUBSEQUENT; 36-033 AND SUBSEQUENT; 31-001 AND SUBSEQUENT


24-328 THRU 24356; 25-205 THRU 25-269 AND 25-271; 35-060 THRU 35-230; 36-018 THRU 36-

25-373;

28-001 THRU

28-005; 29-001 THRU 29-004; 35-127

044
4

24-357; 25-270,
SUBSEQUENT;
24-357; 25-270,
SUBSEQUENT;

25-272 THRU

25-373; 28-001 THRU 28-005; 29-001 THRU 29-004; 35-231 AND


SUBSEQUENT; 31-001 AND SUBSEQUENT
25-272 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004; 35-231 AND
36-045 AND

36-045 AND SUBSEQUENT

31-001 AND SUBSEQUENT

NOTES:
Condition 1/4 hard.

map Repair Index


Figure 2 (Sheet 5 of 5)
EFFECTIVITY:
SRM~

NOTED

57-50-00

Page 9
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


FLAP

i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS
All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

or

on

failed rivets
the

are

remaining

to ensure that

performed
fer to Chapter 51
(2) Loose

or

failed

not allowed. A loose

rivets and lead to

joint

or

failed rivet

can cause

increased stress concentra-

failure. A careful

inspection must be
progressive joint
the
loose
of
from
the
or failed rivet. (Rearea
spread

failure has not

for definition of rivet failure.)

screws are

not allowed. A loose or failed

screw can cause

increased stress

failure. A careful

concen-

must be

on surrounding screws
inspection
progressive joint
performed to ensure that the joint failure has not spread from the area of the loose or failed

and lead to

trations
B.

screw.

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired,

and refinished in accordance with

Chapter

re-

51.

C.

Deformation

D.

(1) Deformation of the flaps or flap structure is not allowed.


Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with

Chapter 51,

and these

repairs do

not reduce the

original

material thickness

fied. (Refer to Chapter 51 for protective treatment procedures.)


(2) Structural components must be repaired or replaced if corrosion
rial thickness more than specified.
E.

repair reduces

than

speci-

original

mate-

more

the

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component re-

placed.
F.

Scratches(See Figure 101.)


(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Re-

protective treatment procedures.)


must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(See Figure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings andForgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.
fer to

Chapter 51

for

(2) Structural components

G.

H.

EFFECTIVITY:
SRM-4

ALL

57-50-00

Page 101
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.120

0.125

0.190
0.250

0.180
0:237

Allowable Material Thickness


Figure 101

EFFECTNITY:
SRM~

ALL

57-50-00

Page 102
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


FLAP-REPAIR

i.

APPROVED REPAIRS

A.

Refer to

tings

EFFECTIVITY:
SRM~

Chapter 51 for typical repairs,


attaching parts.

and for allowable

wear

and

repair data

for the

flap system fit-

and

ALL

57-50-00

Page 201
May 15/92

eg
Cj
34

40

39
U

59

51

u,
,r,
55
v

w"

34

32

i
I

ii

I
1
I

:I

~t,

--LI-I

42

~36)

i/v,

IpP

jI

ii

31

38

60

42

I
1

M
41

O~
;i:

I
i

51

II

--------LL_______

fr

.J
II
I

I~I

VI

i-----

;!I

Ii

,_____

i
1

II

r
m

Zj

48

54

41

46

r---------------1?-

rl

I--~

~I
i i

3b

n,1

=129

10

11

E,

p.

311

12

16

17

18

19

21

22

26

24

23

25

27

33

~1
i,

p,

70s

~I

:I

_i~-___

45

-f~-

~i

iilB

(23-002 THRW 23-049)

~r8

~LI

20

Detail A

22

21

Ib

Learjet
STRUCTURAL REPAIR MANUAL
DWG.
NO.

ITEM
NO.

Aileron

2322550

2324011

2324011

IFINISH

REPAIR

CODE

FIG. NO.

GAGE

6 RH

Assy.

2024-T3 Clad

1
1

0.032

Bracket

2024-T42 Clad

0.063

F4-1

Channel

2024-T42 Clad

0.040

F4-1

0.0321

F4-1

Skin,
Skin,
Skin,
Skin,

2324011

2324011

L. E.

L. E.
L. E.
L. E.

(LH Only)
(LH Only)
(RH Only)
(RH Only)

Replace
Replace
Replace
Replace

2324011

51-70-02

12024-T3Clad

2024-T3 Clad

0.040

F4-1

51-70-02

2024-T3 Clad

0.032

F4-1

51-70-02

2024-T3 Clad

0.040

F4-1

51-70-02

2024-T42 Clad

0.040

F4-1

51-70-03

2324011

Rib
1
IDoubler

2024-T3

0.040

F4-1

51-70-03

2424001

2024-T3 Clad

0.040

F16lint

Replace

2324011

I
MATERIAL

2324011

2324011
4

I
EFF.

Filler(LH Only)
Bracket Assy. (LH Only)

2324011

Instl., LH

Aileron Structure

2324011
1

I
DESCRIPTION

Fairing, Inboard Hinge (2 ea.)

F1 art

2324011
6

2324011

2324011

Rib

2324011

i
j

2324011

2324011
9

Assy.

Rib

Weight
Balance Weight (2 ea.)
Rib Assy.

Balance

2024-T42 Clad

Antimony Lead
Antimony Lead

8
1

51-70-03

F4-1

0.040

51-70-03

1
1

51-70-03
51-70-03

51-70-03

Rib

2024-T42 Clad

0.025

F4-1

Clip(LH Only)

2024-T42 Clad

0.050

F4-1

Replace
51-70-02

2324011

2324011

Skin

2024-T3 Clad

0.032

Fi6lint

2324011

Skin

2024-T3 Clad

0.040

F14-1int

51-70-03

F1 art
51-70-02

F1 art
10

2324011

11

2324011
2324011
2324011

12

2324011

Lead

Antimony

Rib, Nose

2024-T42 Clad

Clip Assy.
Clip
Yoke Support, Actuator
Fairing, Center Hinge

1:2024-T42 Clad

I S-611

Balance

Weight

I
I

Replace

I
F4-1

0.050

2024-T3 Clad

I
0.063

I
0.040

51-70-03

I
F4-1

Replace
Replace

F4-1

51-70-03

F16lint

51-70-00

Fl art

2324011

2324011
13

Bracket

Assy.

Bracket, Yoke Support


Bracket, Yoke Support

2324011

Rib

2324011

5-611

2024-T42 Clad

Assy.

Rib

2324011

Antimony Lead

Balance

15

2324011

Rib

23240 i i

Rib

16

2324011

Balance

EFFECTIVITY:

2024-T42 Clad

Antimony

Aileron

Repair Index

(Sheet 2 of 4)

Figure
MODEL23 SERIESAIRCRAFT

Lead

Replace
Replace

51-70-03

F4-1

0.071

I
2024-T42 Clad

2324011

Weight

14

Weight
Assy.

I
F4-1

0.040

51-70-03

Replace

51-70-03

F4-1

0.025

51 -70-03

Replace

57-60-00

Page 2
May 15/92

Learjet
Ledljet
STRUCTURAL REPAIR MANUAL
ITEM
NO.
17

DWG.
NO.

I
DESCRIPTION
Skin

2324011

I
EFF.
2

IFINISH

REPAIR

CODE

FIG. NO,

GAGE

MATERIAL
/2024-T42Clad

0.032 1 F14-lint

51-70-03

Fiext

2024-T42 Clad

Skin

2324011

F16lint

0.040

51-70-03

F1 ext
18

2324011

Rib

19

2324011

Balance

20

2324011

21

2324011

22

2324011

Weight

Spacer (2 ea.)
Doubler(2 ea.)
Access Cover (2 ea.)

2024-T42 Clad

Antimony

2024-T3 Clad

0.032

F4-1

51-70-03

2024-T3 Clad

0.032

F4-1

Replace

2024-T3 Clad

0.064

F1Clint

Replace

Lead

0.025

Replace

F4-1

51-70-02

F1 art
23

Rib

2324011

24

2424001

Assy.

Rib

2324011

Fairing, Outbd Hinge (2 ea.)

2024-T42 Clad

0.040 1

2024-T42 Clad

0.040

F4-1

51-70-03

2024-T3 Clad

0.040

F1l-lint

Replace

51-70-03

F1 art
25

2324011

Rib

26

2324011

Balance

27

2624010

Skin

Weight

2024-T42 Clad

Antimony

2024-T3 Clad

Lead

F4-1

0.040

51-70-03

I Replace
F16lint

0.032

51-70-02

F~ext
2624010

Skin

2024-T3 Clad

F14-lint

0.040

51-70-02

F1 art
28

2324011

Access Door

(LH Only)

2024-T42 Clad

F1Clint

0.040

Replace

F1 art
29

2424001

30

2324011

31

2324011

32

2324011

Clip

2024-T42

0.040

F4-1

1
1

Rib, Inboard Closing


Rib, Middle Hinge

2024-T42 Clad

0.025

F4-1

2024-T42 Clad

Rod

Tube

2324011
2324011

Assy.,

Tab Actuator

Assy.,

Tab Actuator

Tube, Tab Actuator

4130 STL Norm.

Stringer
Fairing

S-559

2024-T42 Clad

0.025

2024-T42 Clad

0.032

33

2434011

34

2434011

35

2423011

Doubler

36

2324011

Rib

Assy. (LH Only)

Rib

2324011

F4-1

0.050

F8-1

F8-1

0.035

F8-1

Replace
Replace
Replace
Replace
Replace
Repace
Replace
Replace
Replace

F4-1
F4-1
F4-1

2024-T42 Clad

0.025

F4-1

51-70-03
51-70-03

37

2324011

Rib(RH Only) (2 ea.)


Spar(LH Only)

38

2324011

Rib

2024-T42 Clad

0.025

F4-1

51-70-03

39

2324011

2024-T3 Clad

0.025

F4-1

40

2324011

S-639

2324001

2024-T42 Clad

0.025

F4-1

51-70-03

2024-T42 Clad

0.025

F4-1

51-70-03

2324011

Clip
Trailing Edge Extrusion
Spoiler Tabs

2024-T3 Clad

0.040

F4

Replace
Replace
Replace

41

2324011

Rib

2024-T42 Clad

0.025

F4-1

51-70-03

42

2324011

2024-T42 Clad

0.050

F4-1

2024-T42 Clad

0.025

F4-1

Replace
Replace

2024-T42 Clad

0.0251

2024-T3 Clad

0.050

43

2324011

Clip(LH Only) (2 ea.)


Clip
Rib, Trailing Edge

44

2324011

Skin

2324011

F7-6

F4-1

F14-lint

51-70-03

51-70-02

F1 art

Aileron

Repair Index

(Sheet 3 of 4)

Figure
EFFECTIVITY:
SI~M4

MODEL 23SERIESAIRCRAFI~

57-60-00

Page 3
May 15/92

Learjet I
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.
Skin

2324011

45

DESCRIPTION

EFF.
6

MATERIAL
2024-T3 Clad

FINISH

REPAIR

GAGE

CODE

FIG. NO.

0.050

F14-lint

51-70-02

F1 art
46

2324011

Rib, Trailing Edge

2024-T42 Clad

0.025

F4-1

51-70-03

47

2324011

2024-T42 Clad

0.032

F4-1

51-70-03

48

2324011

2024-T3 Clad

0.040

F4-1

49

2324011

2024-T3 Clad

0.040

F4-1

2024-T3 Cl~id

0.040

F4-1

2324011

Spar
Spar
Spar
Spar
Spar

2024-T3 Clad

0.040

F4-1

Replace
Replace
Replace
Replace

50

23240 i i

Rib

2024-T42 Clad

0.025

F4-1

51 -70-03

51

2324011

Spar

2024-T42 Clad

0.032

F4-1

51-70-03

52

2324011

Seal

2324011

2324011

Cap, Lower
Cap, Upper
Cap, Upper (LH Only)
Cap, Upper (RH Only) (2)

Assy.

Hat Section

2024-T4Clad

0.020

F4-1

0.020

F4-1

Channel

Replace
Replace
Replace
Replace

2024-T4Clad

53

2324011

Trailing Edge Extrusion

S-639

54

2324011

Rib

2024-T42 Clad

0.025

F4-1

51-70-03

55

2324011

Rib

2024-T42 Clad

0.025

F4-1

51-70-03

56

2324011

Skin, Upper

2024-T3 Clad

0.025

F14-lint

51-70-02

2324011

Flext
57

Skin, Lower

2324011

2024-T3 Clad

0.025

F4-lint

51-70-02

F1 ext
58

2324011

Trailing Edge

2024-T3 Clad

0.025

F7-6

59

2324011

SpoilerTab

2024-T3

0.040

F4

Replace

60

2324011

Conduit

S-5052

0.035

F4-1

61

2324011

2024-T42 Clad

0.040

F4-1

62

2324011

2024-T4

0.063

F4-1

2024-T4

0.375

F4-1

Replace
Replace
Replace
Replace

Link(LH Only)
(LH Only)
Arm (LH Only)
Arm

2333008

CODES

Extrusion

51-70-02

EFFECTIVITIES

23-002 THRU 23-099

23-002 THRU 23-034

23-050 THRU 23-099

23-035 THRU 23-049

23-035 THRU 23-099

23-002 THRU 23-049

23-002 THRU 23-065

23-066 THRU 23-099

Aileron Repair Index


Figure 1 (Sheet 4 of 4)

EFFECTIVITY:
SI~M-4

MODEL 23 SERIESAIRCRAFT~

57-60-00

Page 4
May 15/92

39

39

42

40

J
I

53

39

59

rr-r,

/j

r
r

;---i-----~

;i,

(351
35

1
II

~e

30

N1

~7

r60

lr

31

~J

I!/

n,

42

37
i

r----I

44

43

~F--=T--i
II

ij

~j)

46

c~j

41

I
I

iP
I

qq

I,

r-----------------1~--

____-_LC------

_P

:7

55
OLc~i

jP

II
I

50

Il

51

I
I

IL.

rr

52

r-----

II

II

_,

I
II

I_

Ii

___~--J

20
(V

I,

,I

~/v

o,~

~D

Ox

~X1
1~

2)13

10

11

12

~M

\6

\1

18

19

21

22

23

24

25

26

21

r"

g,

,J~

vl

~v18

~I

(b

r
C--p

C~CI

Ir

28
C

re,

u,

57

Learjet
~si
STRUCTURAL REPAIR MANUAL
DWG.
NO.

ITEM
NO.

Aileron Instl., LH 6 RH
Aileron Structure Assy.

2322550

2324011
1

2324011

232401 i

Filler(LH Only)
Bracket Assy., (LH Only)

I
MATERIAL

EFF.

IFINISH

REPAIR
FIG. NO.

CODE

GAGE

1
1

2024-T3 Clad

I Replace
I Replace

0.032

2324011

Bracket

2024-T42 Clad

0.063

F4-1

2324011

Channel

2024-T42 Clad

0.040

F4-1

Replace
Replace

0.040

F16lint

51-70-02

2324011

I
DESCRIPTION

Skin, L. E., (LH Only)

1 2024-T3 Clad

F1 art
2324011

ext

Skin, L. E., (RH Only)

2024-T3 Clad

F1Clint

0.040

51-70-02

F1 art
23240 i 1

2324011
5

2424001

Rib
I
IDoubler

Fairing,

Inboard

Hinge (2 ea.)

2024-T42 Clad

0.040

F4-1

51 -70-03

2024-T3

0.040

F4-1

51-70-03

2024-T3 Clad

0.040

F14-lint

Replace

F1 art
2324011
6

2324011

2324011

2324011

Rib Assy.

Rib

2024-T42 Clad

Balance

Antimony Lead

Rib

Weight (2 ea.)
Assy.

51-70-03

F4-1

0.040

51-70-03

51-70-00

51-70-03

2324011

Rib

2024-T42 Clad

0.025

F4-1

2324011

Clip(LH Only)

2024-T42 Clad

0.050

F4-1

Replace

2024-T3 Clad

0.040

F14-lint

51-70-02

Antimony Lead
2024-T42 Clad

2324011

Skin

10

2324011

Balance

11

2324011

Rib, Nose

2324011

Clip Assy.
Clip
Yoke Support, Actuator
Fairing, Center Hinge

51-70-03

F1 art

2324011

2324011

12

Weight

2024-T42 Clad

S-611

2024-T3 Clad

F4-1

0.063

I Replace

I
I
F4-1

0.050

I
0.040

51-70-03

I Replace
Replace

F4-1

51-70-03

F14-lint

51-70-00

F1 art
2324011

13

Bracket

Assy.

Bracket, Yoke Support

2324011
2324020

2324011

Rib

232401 i
14

2324011

Balance

15

2324011

Rib

Weight

16

2324011

Balance

17

2324011

Skin

1 2024-T42 Clad
356 AL

Weight

Alloy

I
2024-T42 Clad

Antimony

Lead

2024-T42 Clad

Antimony

2024-T42 Clad

Lead

F4-1

0.071

1
F4-1

0.040

I
0.025

Replace

I Replace

i
1

Assy.

Rib

232401 i

2
3

Fitting
Rib Assy.

51-70-03

51-70-03

I Replace
1
F4-1

51-70-03

51-70-03

I Replace
0.040

F16lint

51-70-03

F1 ext
18

2324011

Rib

2024-T42 Clad

19

2324011

Balance

Antimony Lead

2324011

Weight (2 ea.)
Spacer(2 ea.)

20

1
1

2024-T3 Clad

0.025

F4-1

Replace

1
0.032

F4-1

51-70-02
51-70-03

Aileron Repair Index


Figure 2 (Sheet 2 of 4)

EFFECTTVITY:

24-100THRU 24-154

57-60-00

Page 6
May 15/92

Learjet
~Learjet
STRUCTURAL REPAIR MANUAL
ITEM
NO.

I
I

DWG.
NO.

I
DESCRIPTION

EFF.

MATERIAL

IFINISH

REPAIR

GAGE I CODE

FIG. NO.

21

2324011

Doubler(2 ea.)

1 2024-T3 Clad

22

2324011

Access Cover

2024-T3 Clad

0.064

23

2324011

2024-T42 Clad

0.040 1

2024-T42 Clad

0.040

F4-1

51-70-03

2024-T3 Clad

0.040

Flblint

Replace

(2 ea.)

0.032)

F4-1

Replace
Replace

51-70-03

F16lint

Fl ext

Assy.

Rib

2324011
24

Rib

2424001

Fairing, Outbd Hinge (2 ea.)

F1 art
Rib

25

1 2324011

26

2324011

27

2624010

Skin

28

2324011

Access Door

Balance

Weight

2024-T42 Clad

Antimony

1
1

0.040

F4-1

51-70-03

2024-T3 Clad

0.040

F14-lint

51-70-02

2024-T42 Clad

0.040

Fi4-1int

Lead

Replace
F1 ext

(LH Only)

Replace

Flext

33

2324011

IClip
Support Angle
1
Rib, Inboard Closing
Gussett (LH Only)
1
Splice Plate (LH Only)
Clip(LH Only)
Clip(LH Only)
1
Splice Plate (LH Only)
1
Filler(LH Only)
1
Rib, Middle Hinge
1

34

2324011

29

2424001
2324001

30

232401 i

31

2324011

32

2324011
2324011
2324011
2324011
2324011

2324011

Rod

Assy., Tab Actuator


Tube Assy., Tab Actuator

2324011
35

2434011

Tube, Tab Actuator

Fairing

2024-T42

0.040

F4-1

20244-T42

0.063

F4-1

F4-1

2024-T42 Clad

0.025

2024-T4

0.040

F4-1

2024-T3 Clad

0.050

F4-1

2024-T3

0.032

F4-1

2024-T3 Clad

0.050

F4-1

2024-T3 Clad

0.032

F4-1

2024-T42 Clad

0.063

F4-1

2024-T42 Clad

0.050

F4-1

F8-1

I
1 4130 STL Norm.

0.0351

F8-1

2024-T42 Clad

0.025

F8-1

F1Q-lint

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repace
Replace

F1 ext
36

2324011

2324011

Rib

Assy., (LH Only)

Rib

51-70-03

2024-T42 Clad

0.025

F4-1

51-70-03

Rib(RH Only) (2 ea.)


Spar(LH Only)

2024-T42 Clad

0.025

F4-1

51-70-03

2024-T42 Clad

0.025

F4-1

51-70-03

37

2324011

1
1

38

2324011

Rib

2024-T42 Clad

0.025

F4-1

51-70-03

39

2324011

2024-T3 Clad

0.025

F4-1

40

2324011

S-639

41

2324011

2024-T3 Clad

0.040

2324011

2024-T3 Clad

0.100

F4

42

2324011

Clip
Trailing Edge
Spoiler Tabs
Spoiler Tabs
Clip

2024-T42 Clad

0.025

F4-1

Replace
Replace
Replace
Replace
Replace

43

2324011

Rib

2024-T42 Clad

0.025

F4-1

51-70-03

44

2324011

2024-T42 Clad

0.050

F4-1

Replace

2324011

Clip(LH Only) (2 ea.)


Rib, Trailing Edge
Rib, Trailing Edge
Spar

45

1
1
1

2024-T42 Clad

0.025

F4-1

51-70-03

2324011

46

2324011

47

2324011

Extrusion

2024-T42 Clad

1 2024-T42 Clad

F7-6
F4

0.025

F4-1

0.0321

F4-1

51-70-03

51-70-03

Aileron Repair Index


Figure 2 (Sheet 3 of 4)

EFFECTNITY:

24-100THRU 24-154

57-60-00

Page
SRM~

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

DESCRIPTION

EFF.

MATERIAL

GAGE

FINISH
CODE

REPAIR
FIG. NO.

2324011

Spar Cap, Lower


Spar Cap, Upper
Spar Cap, Upper (RH Only)

0.040

F4-1

50

232401 i

Rib

2024-T3 Clad
2024-T42 Clad

Replace
Replace
Replace

0.025

F4-1

51-70-03

51

2324011

Spar

2024-T42 Clad

0.032

F4-1

51-70-03

52

23240 i 1

Seal

48

2324011

49

2324011

2324011

2024-T3 Clad

0.040

F4-1

2024-T3 Clad

0.040

F4-1

Assy.

Hat Section

2024-T4Clad

0.020

F4-1

2024-T4Clad

0.020

F4-1

S-639

Channel

2324011

53

2324011

Trailing Edge

Extrusion

Replace
Replace
Replace
Replace

54

2324011

Rib

2024-T42 Clad

0.025

F4-1

55

2324011

Rib

2024-T42 Clad

0.025

F4-1

51-70-03

56

2324011

Skin, Upper

2024-T3 Clad

0.025

F1Clint

51-70-02

57

2324011

Skin, Lower

2024-T3 Clad

0.025

F4-1int

51-70-03

F1 art
51-70-02

F1 ext

58

2324011

59

2324011

Trailing Edge Extrusion


Spoiler Tab
SpoilerTab

2324011

2024-T3 Clad

0.025

F7-6

51-70-02

2024-T3

0.040

F4

2024-T3

0.100

F4
F4-1

Replace
Replace
Replace

60

232401 i

Conduit

S5052-0

0.035

61

2324011

2024-T42 Clad

0.040

F4-1

62

2333008

2024-T4

0.375

F4-1

Replace
Replace

63

2324011

Link(LH Only)
Arm (LH Only)
Rib, Trailing Edge

2024-T42 Clad

0.025

F4-1

51-70-03

CODES

EFFECTIVITIES

24-100 THRU 24-154

24-100 THRU 24-121 AND 24-123

24-122, 24-124 THRU 24-154

24-100 THRU 24-129

24-130 THRU 24-154

24-100 THRU 24-109

24-110 THRU 24-154

Aileron

Figure
EFFECTIVITY:
SRM-4

24-100 THRU 24-154

Repair Index

2 (Sheet 4 of 4)

57-60-00

Page 8
May 15/92

;1
1)

.138

39

u,
--1
jr]

51

C)

rJ

~t:

0~

64

Ij
II
IiIV

r!

___~

M
j

35
N

II
1

(D

32

jO~i"""

a3

36

42

.I"I

1111

I
I

38

III
1

60

Ii

E--

I
I

63

143II

33

I
1

i,

(8

Co

as

I_

jcr

50

II
I

51

~p
v

D.

28

rP

t-----

-=----r~

-------rr
I

BI

(I 26 s
:r-=-,
!iVe

ii

\D

"o"

h3\P

L)
II

29

e~1

II

(r

Il

1)

4)(5)(6) (7)

(()(5) (10) (11)

(12)

(r3) (11)

V5) U6) C11)

~P"

J----zi--i
t

I1[J

I:

ii
1

r------- ---------1

5d

42

31

---~e

11

~p

lp
i

Us

22

23

24

25

26

21

~I

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

2424000

2324011

2324011

REPAIR

CODE

FIG. NO.

1
1

Filler(LH Only)
Bracket Assy. (LH Only)

2024-T3 Clad

1
I

0.032

I
I

Bracket

2024-T42 Clad

0.063

F4-1

Channel

2024-T42 Clad

0.040

2024-T3

0.063

F4-1
F4-1

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

2024-T3 Clad

0.040

F14-1int

51-70-02

0.040

F1 ext
F14-1int
F1 art

51-70-02

Bracket

2024-T42 Clad

0.063

F4-1

Channel

2024-T42 Clad
2024-T3

0.040

F4-1
F4-1

2424001

Clip

2324011
2324011
2324011

Bracket

Assy.

Clip

Skin, L. E. (LH Only)

2324011

Skin, L. E. (RH Only)

2324011

Rib

2324011

2324011
2424001

2424001
5

IFINISH
GAGE

2324011

2424001

I
MATERIAL

232401 1
2324011

I
EFF.

Aileron Instl., LH 8 RH
Aileron Assy.

2322550
1

I
DESCRIPTION

Assy.

IAnale

2424001

Fairing,

Inboard

Hinge (2 ea.)

2024-T42 Clad

0.040

F4-1

2024-T3

0.040

F4-1

0.063

2024-T3 Clad

Rib
Doubler
Rib Assy.
Rib

2324028

2024-T42 Clad

5-608

2024-T3 Clad

51-70-03

51-70-03

51-70-03

51-70-03

F4-1

0.040

51-70-03

F14-lint

0.040

51-70-03

Replace

F1 art
6

2324011

2324011

Assy.

Rib

2324011

2424001

Rib

2424001

Doubler
Rib Assy.

IAnale

2324011

2324011

1
1

Balance Weight
Rib Assy.

(2 ea)

1
1

0.040

F4-1

I
I

2024-T42 Clad

0.025

2324011

Clip(LH Only)

2024-T42 Clad

0.050

Skin

10

2324011
2324011

1
1

2324011

Balance Weight
Rib Assy., Nose
Rib

11

2324011

2324011

1
1
1
1

Clip Assy.
Clip
Yoke Support, Actuator
Fairing, Center Hinge
Fitting
Rib Assy.

2324011

2324020
2324011
2324011

2324011

Balance

15

2324011

Rib

Antimony Lead
I

Rib

14

1 2024-T3 Clad

Weight

2024-T42 Clad

S-611

2024-T3 Clad

356 Al

Alloy

0.050

2024-T42 Clad

Antimony

2024-T42 Clad

Lead

51-70-03

51-70-00

51-70-03
51-70-03

F14-1int
F1 art

51-70-02

Replace

I Replace
1

51-70-03
51-70-03

I Replace
F4-1

Replace

F4-1

51-70-03

0.040 1

51-70-00

I Replace

51-70-03

F4-1
F4-1

51-70-03

F4-1

0.063

0.040

2024-T42 Clad

51-70-03

51-70-03
51-70-03

F4-1

0.040

Rib

1
F4-1

2324011

2324011

13

I
0.040

I
2024-T42 Clad
S-608
Antimony Lead

12

I
2024-T42 Clad
2024-T3

Rib

2324028

i
0.040

1
F4-1

51-70-03

I
0.025

F4-1

51-70-03

Replace
51-70-03

Aileron Repair Index


Figure 3 (Sheet 2 of 4)

EFFECTTVITY:
sRM-a

24-155 THRU24-229 EXCEPT24-218

57-60-00

Page 10
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

NO.

DWG.
NO.

I
DESCRIPTION

I
MATERIAL

EFF.

IFINISH
GAGE

CODE

REPAIR
FIG. NO.

Fi4-1int

51-70-03

16

2324011

Balance

Antimony Lead

17

2324011

Skin

2024-T42 Clad

0.040

18

2324011
232401 1

Rib

0.025

Weight (2 ea.)
Spacer(2 ea.)
Doubler(2 ea.)
Access Cover (2 ea.)

2024-T42 Clad
Antimony Lead

Weight

Replace
Flext

19
21

2324011
2324011

22

2324011

23

2324011
2324011

20

Balance

232401 1
2424001

Rib

0.032
0.032

2024-T3 Clad

0.064

Assy.

0.040

F4-1

Fairing, Outbd Hinge (2 ea.)

25

2324011
2324011

Rib Assy.
Rib

4
4

2424001

Doub\er
Rib Assy.
Rib

2324028

Angle

26
27

2324011
2624010

Balance
Skin

28

2324011

Access Door

29

2424001

30

2324001
2324028

I
0.040

I
2024-T3

I
0.0401
I
0.040
I

F4-1

2024-T3 Clad

0.040

2024-T42 Clad

0.040

2024-T42

1
1

20244-T42
2024-T42 Clad
2024-T42 Clad

0.040
0.063
0.025
0.025

2024-T42 Clad

0.025

2024-T4

0.040

51-70-03

51-70-03

51-70-03
51-70-03

Replace
1

F4-1

51-70-03

F14-lint
F1 ext

0.040

2024-T42 Clad
S-608
Antimony Lead

51-70-03

F4-1

0.040

2024-T42 Clad

(LH Only)

I
2024-T42 Clad
S-608
2024-T3 Clad

2324011

Weight

2024-T3

24

Replace
Replace

F14-1int
F1 art
F4-1

51-70-03

0.040

IAnale

2424001

51-70-02

F4-1

2024-T42 Clad

2324028

2324011

4
5

Rib

2424001

2024-T3 Clad
2024-T3 Clad

Replace

F4-1

Rib Assy.
Rib
Doubler

51-70-03

51-70-03

51-70-03
51-70-03

F4-1

51-70-03
51-70-03

I Replace
F16lint
Fl art

51-70-02

(F14-lintl Replace
Fl art

2324011
2324028
31
32

2324011
2324011

33

2324011
2324011
2324011
2324011

34

2324011

IClip
Support Angle (LH Only)
Rib, Inboard Closing (LH Only)
1
Rib, Inboard Closing (RH Only)
1
Clip(RH Only)
Gussett (LH Only) (2 ea.)
1
1
Splice Plate (LH Only)
Clip(LH Only)
Splice Plate (LH Only)
1
Filler(LH Only)
Filler

2324011
35

2324011
2434011

36

2324011

Tube, Tab Actuator

2324011
2324028

Fairing
Rib Assy. (LH Only)
Rib

2324011
37

Assy., Tab Actuator


Tube Assy., Tab Actuator

Rod

Rib(RH Only) (2 ea.)


Spar(LH Only)

F4-1
F4-1

I
F4-1

2024-T3 Clad

0.050

2024-T3 Clad

0.050

F4-1
F4-1
F4-1

2024-T3 Clad
2024-T42 Clad

0.032

F4-1

0.063

F4-1

2024-T42 Clad

0.040

1
1

I
I
4130 STL Norm.
2024-T42 Clad

1
1
1

I
I

I
2024-T42 Clad

2024-T42 Clad
2024-T42 Clad

F8-1
F8-1
F8-1
F4-1

0.035
0.025

F4-1

I
I

I
0.025
0.025
0.025 1

1
F4-1

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repace
Replace
51-70-03
51-70-03

F4-1
1

51-70-03
51-70-03

Aileron Repair Index


Figure 3 (Sheet 3 of 4)

EFFECTIVITY:
SRM~L

24-155THRU 24-229 EXCEPT24-218

57-60-00

Page 11
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

0.025

F4-1

51-70-03

F4-1

2324011

Clip
Trailing Edge

0.025

S-639

2324011
2324011

Spoiler Tabs
Clip(3 ea.)

2024-T3 Clad

0.100

F4

Rib

Clip(LH Only) (3 ea.)


Rib, Trailing Edge
Clip
Rib, Trailing Edge
Clip
Spar
Filler(LH Only) (3 ea.)
Filler(RH Only) (2 ea.)
Spar Cap, Upper
Spar Cap, Upper (RH Only) (2)
Soar Cap, Lower

Clad
Clad
Clad
Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
2024-T42 Clad
2024-T42 Clad

0.025

2324011
2324011
2324028

2024-T42
2024-T42
2024-T42
2024-T42

F4-1
F4-1
F4-1

Replace
Replace
Replace
Replace

47

2324028
2324028
2324028
2324028

48

2324011

2324011
2324027

2324027
2324027
2324028
2324028

51
52

53

2324011
2324011
2324011

54
55

56

2324028
2324027

57

Extrusion

Rib

2324011

1
1
1

1
1
1

1
i
1
1

Spar
SealAssy.

HatSection

2024-T4Clad

Channel

0.025
0.050

R-6

Replace

0.025 i

51-70-03

0.025
0.025

0.040

F4-1

0.040

F4-1

I
I

0.025 1

51-70-03

0.032 1

51-70-03

I
F4-1
F4-1

0.020

Rib

2024-T42 Clad

0.025

F4-1

Rib

0.025

F4-1

Clip

Skin, Upper
Skin, Lower

2324027

58

2324011

Trailing Edge

2024-T42 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
2024-T3 Clad

59

SpoilerTab

2024-T3

0.100

F4

60

2324011
2324011

Conduit

55052-0

0.035

F4-1

61

2324011

2024-T42 Clad
2024-T4

0.040

F4-1
F4-1

63

2333008
2324011

64

2324029
2324028

CODES

Link(LH Only)
(LH Only)
(LH Only)
Rib, Trailing Edge
Clip
Angle

Arm
Arm

0.020

0.025

I Replace
Replace
Replace

I Replace

51-70-03
51-70-03

I Replace

0.025 1

1
1

51-70-02

0.025 1
0.025 1

51-70-02

0.063

2024-T4
2024-T42 Clad

0.025

2024-T3 Clad

0.025

3034-T42 Clad

0.040

Replace
Replace
Replace
Replace
Replace

1
1
1 0.040)
0.040

2424001

2324011

51-70-03

0.040

2324011

Extrusion

51-70-03

I Replace

0.032 1

2024-T4Clad
S-639

Replace
1

51-70-03

0.025 1

Trailing Edge Extrusion

62

REPAIR
FIG. NO.

2024-T42 Clad

41

50

IFINISH
GAGE I CODE

2024-T3 Clad

40

49

I
MATERIAL

2324011

46

I
EFF.

2324011

39

45

I
DESCRIPTION
Rib

38

42
43
44

Replace
Replace
Replace
Replace
Replace

F4-1
F4-1

0.375

51-70-02

51-70-03

I
I

Replace
Replace

EFFECTIVITIES

24-155 THRU 24-229 EXCEPT 24-218

24-155 THRU 24-170

24-171 THRU 24-229 EXCEPT 24-218

24-155 THRU 24-159

24-160 THRU 24-229 EXCEPT 24-218

24-167 THRU 24-229 EXCEPT 24-218

Aileron Repair Index


Figure 3 (Sheet 4 of 4)

EFFECTIVITY:
SRM-4

24-155THRU24-229 EXCEPT24-218

57-60-00

Page 12
May 15/92

%r
s

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rn

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39

33

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n,
ul
o

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CD

i:

~pl

ii

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rrc(

I
I

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38

S~

28

L-

r--.

t-

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1
I

II

Il

I)
I

II

ii

II

Ei

VJ

50

IO

ii
r
I-----L

,.jn

II

~---------c---------l-----ii---t

1P

1
I

55

Iy

11i
(2

I~TI

12

29

37I
I

bll

ed
P,

36

II

35

v, (D
(D

Ili i I

~CO

JO

,I

:I

I iii

_.P__~

____I

Ii

aoII

t n

E+
~II

-r

a
o
2)(3)

(4)(5)(6) (7)

(6)(9)(10)

(11)

(12)

(13) (18)

(15)

(16) (11)

(18)

(15)

(21) (22) (23) (2()(25)(26

"rn

Yr

\DrO

~3WO

Ib~

Learjet
~Learietl
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

2324027
2324011

2324028

2324027

2324028

1
1
1
1

5
6

IAnale

2324028

IAnale

2324028

2324028

1
1

2024-T3 Clad

0.040

2024-T42 Clad

0.063

2024-0 Clad

Fairing, Inboard Hinge (2 ea.)


Rib Assy.

2024-T42 Clad

S-608

Replace
Replace

0.040 1

51-70-02

51-70-03

0.040 1

51-70-03

I Replace

Replace

51-70-03

0.040 1

51-70-03

51-70-03

51-70-03

Repalce
Replace
Replace

0.040

2024-T42 Clad
S-608

5%

ISpar

2024-T42

2324028

IAngle

2324011

S-608
2024-T3

2324011

ISpacer

2024-T3

0.032

F1Clint
F1 art
F4-1

2324011

IDoubler
1
Rib

2024-T42

0.040

F4-1

2024-T42 Clad

0.025 1

1
1

2024-T42 Clad
2024-T42 Clad
Antimony Lead

0.050

Weight

Access Door

2324028

Clip(LH Only)

2324011
2324027

Skin

10

2324027

11

2324028

Balance Weight
Rib, Nose

12

2324020

IFitting,

13

2324028

Rib

14

2324028

Balance

2324028

ISpar

15

2324028

Rib

2324028

Angle

16

2324028

Balance

17

2324027

Skin

18

2324028

Rib

2324028

IAngle

2324028

LH

Antimony

Balance

Weight
I

Weight

I
0.040

I
0.064

51-70-02

Replace

I Replace

Antimony

2024-T42

0.040

Replace

0.025 1

51-70-03

2024-T42 Clad
2024-T42 Clad

0.032

Replace

Antimony

I Replace

Lead

Lead

2024-T42 Clad

1
1

2024-T42 Clad
S-608

5%

51-70-00

0.050 1

51-70-03

51-70-03

I Replace

0.040 1
0.025 1

51-70-03

Replace

I Replace

0.032 1

51-70-02
51-70-03

Replace
Replace

Antimony

Spacer

21

2324011

2024-T3 Clad

0.040

2324028

1
1

Doubler

22

Access Cover

2024-T3 Clad

0.071

EFFECTIVITY:

51-70-03

0.050 1

2324028

Figure

1
F4-1

0.040 1

20

Aileron

Replace
Replace

2024-T42 Clad
Al Casting
2024-T42 Clad

Weight

Lead

SRM-d

F4-1

2024-T3 Clad

Rib
Balance

REPAIR
FIG. NO.

CODE

Lead

19

IFINISH
GAGE

Clip(LH Only)
Support Angle (LH Only)
Skin, Leading Edge
Rib Assy.

2324028
2424001
2324028
2324028

I
MATERIAL

Rib

2324028

I
EFF.

Aileron Instl., LH 8 RH
Aileron Assy.

2322550
1

I
DESCRIPTION

2024-T3 Clad

F4-1

Repair Index

4 (Sheet 2 of 4)

25-002 THRU 25-067EXCEPT25-061

57-60-00

Page 14
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM
NO.
23

DWG.
NO.

I
DESCRIPTION

2324028

Rib

Assy.

2324028
2424001

IAnale

24

2324011

Fairing,

25

2324028

Rib Assy.

26

I
EFF.

Rib

Outboard

Hinge (2 ea.)

51-70-03

0.040 1

51-70-03

1
1

2024-T3 Clad

0.040

2324028

Angle

2024-T42 Clad
2024-T42 Clad

Balance

Antimony

2024-T3 Clad
2024-T42 Clad
2024-T42 Clad
2024-T3 Clad
2024-T42 Clad
2024-T42 Clad
2024-T3 Clad
2024-T3 Clad

Weight
Skin, Leading Edge
Access Door (LH Only)

27

2324028
2324027

29

2324028

Bracket

232401 i

Clip

Channel

30

2324028
2324028

31

2324011

32

2324011

33

2434001

34

2324011

35

2324011
2324011
2324011

Rib, Inboard Closing (LH Only)


Gusset

Clip
(Fairing
Fairing

1
1
1

Push Rod

Assy.
Conduit(LH Only)

Rib

1
1

51-70-03

0.040 1

51-70-03

0.032

Replace

I Replace

Lead

Replace
Replace

F16lint
F1 art

28

36

Rib

1
1
1

REPAIR
FIG. NO.

CODE

2024-T42 Clad
S-608

2324028
2324028

IFINISH
GAGE

I
MATERIAL

0.040 1
0.063

0.063

I
F4-1

Replace
Replace

Replace

1
1

0.040

I
I

0.035

F4-1

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

0.025

F4-1

51-70-03

0.025

F4-1

0.025

F4-1

Replace
Replace

0.025

I 6061-0
2024-T42 Clad
4120 STL Norm
S-5052-0
2024-T42 Clad
2024-T42 Clad
2024-T42
2024-T42 Clad
2024-T42 Clad
2024-T3 Clad

51-70-02

1
1

0.040

0.040

F4-1

0.050

F4-1

0.020

0.025

0.035

2324028

Clip(LH Only)
Rib(RH Only) (2 ea.)
Spar(LH Only)
Rib(LH Only)
Clip
Trailing Edge Extrusion
Tab Angle

S-706

41

2324028

Rib

42

2324011

0.025 1
0.050

43

2324028

Clip(LH Only)
Rib, Trailing Edge

2024-T42 Clad
2024-T42 Clad

44

2324011

Filler

0.025 1
0.040

F4-1

Replace

45

Rib, Trailing Edge


Rib, Trailing Edge

0.025

F4-1

46

2324011
2324011

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad

2024-T42 Clad

0.025

F4-1

51-70-03
51-70-03

47

2324028

2024-0 Clad

0.032 1

51-70-03

2324028

2024-T3 Clad

0.050

49

2324027

Spar
Filler(LH Only)
Spar Cap, Upper
Spar Cap, Upper, RH (2ea.)
Spar Cap, Lower (LH Only)

48

1
1

2024-T3 Clad
2024-T3 Clad
2024-T3 Clad
2024-T42 Clad

0.040

0.040

Replace
Replace
Replace
Replace

2324011

2324011
37

2324028

38

2324028

39

2324028

40

2324011

1
1
i

2324027

1
i

50

2324028

Rib

51

2324011
2324028

Spar
Spar

2324027

1
1

S-639

1
I

2024-T42 Clad
2024-T42 Clad

i
1

0.040
0.025 1
0.025 1

I Replace
I Replace

I
I F14-1int

Replace

0.025 1
0.032 1

51-70-03

51-70-03

F4-1

Replace

0.040

0.032

51-70-03

51-70-03

51-70-03

51-70-03
51-70-03

F4-1

Aileron Repair Index


Figure 4 (Sheet 3 of 4)

EFFECTIVITY:

25-002 THRU 25-067EXCEPT25-061

57-60-00

Page
SRM~

15

May 15/92

Learjet
STRUCTURAL REPAIRMANUAL
ITEM

DWG.

NO.

NO.

52

2324028

53

2324028

54

2324011

55

56

I
DESCRIPTION

IFINISH

EFF.

MATERIAL

GAGE

REPAIR
FIG. NO.

CODE

Spar
Spar

2024-T42 Clad

0.025 1

0.025

Rib

2324028

1
1

Rib

2324027

57

2324027

Skin, Upper
Skin, Lower

58

2624011

59

2324028

Trailing Edge
Tab Angle
Angle
ISealAssy.

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T3 Clad
2024-T3 Clad
S-639

5-706

2024-T4Clad

0.020

F4-1

2024-T4Clad

0.020

F4-1

2324028
2324011
2324011
232401 i

60

CODES
1

2024-T42 Clad

1
1

Hat Section
Channel

F4-1

0.025

51-70-03

Replace
51-70-03

0.025 1

0.025 1

51-70-02

0.025 1

51-70-02

I
1

1
I

I
I

0.040

5170-03

Replace
Replace
Replace
Replace
Replace
Replace

EFFECTIVITIES
25-002 THRU 25-067 EXCEPT 25-061

25-002 THRU 25-011

25-012 THRU 25-067 EXCEPT 25-061

Aileron Repair Index

Figure 4 (Sheet 4
EFFECTIVITY:
SRM4

25-002 THRU 25-067EXCEPT25-061

of 4)

57-60-00

Page 16
May 15/92

i ;i i

Cj

9
a

V)
--I
39
UI

33

39

II
33

34

62

[411

34

34

rl

ii

Y-

v17

i,

so

LJ

1
rc~

cn
v

.i-LI
I

v,

O"

E
u.~

31

:I

El

35

i,

21

1--

r--------r

2(1

_ic;:P
M

I
I

i
I

,z

vi
i

js

I:

III

,1

I
I

V1
4

(b
I

1
I

(9

-I---i~;-lt-------

sl

60

50

I
I

r]

(9

II

51
I

It

II

in
52

II:/v
li/

~1CJ

,I

i,

JI

V1

II

I II]: :I

C:

C)

53

61

--P----i 1______

ij

,I

X1.I
~----r-

;t~

a
.I

Il
1

jl

t
63

I,
II

ao

31CI
ct

I:

Z
1)(3)

(9)(9)(19)

(11)

(12)

(1)) Ut)

(19)

(16) (13)

(sl

(19)

(21)(29)(93

E,
I

g
v,

~Dr-l

~Oy

Learjet

STRUCTURAL REPAIR MANUAL


ITEM

DWG.

NO.

NO.

2424000
1

23240 1 1

2324028

2324011

Aileron Structure

IFINISH
GAGE

MATERIAL

REPAIR
FIG. NO.

CODE

1
1
1

Assy.

(LH Only)
Support Angle (LH Only)

2024-T3 Clad

0.032

2024-T42 Clad

0.063

Skin, Leading Edge

2024-T42 Clad

0.040

Filler

I
EFF.

Aileron Instl., LH 8 RH
Aileron Assy.

2422550
2424000

I
DESCRIPTION

1
1

Replace
Replace

F16lint

51-70-02

F1 ext
2424001

Rib

232401 i

Angie
Angle
I
Fairing, Inboard Hinge (2 ea.)

2424001

2324028

2424001
5

Assy.

Rib

2424001

51-70-03

0.040 1

51-70-03

I
I

Replace
Replace
Replace

Replace

51-70-03

0.040 1

51-70-03

2024-T42 Clad

S-608

S-612

2024-T3 Clad

0.025

2024-T3 Clad

0.040

F14-lint
F1 ext

Fairing, Inboard Hinge (2 ea.)


Rib Assy.

2424001

Rib

2424001

Angle
Angle

2324028
2424001

Balance

Weight

2024-T42 Clad

S-608

1
1

S-612

5%

I
I

I
I

I
1

51-70-03

51-70-03

AntimonyLead

2424002

2324001

Rib

2024-T42 Clad

0.025 1

2324011

Clip(LH Only)
Skin, Leading Edge
Balance Weight

2024-T42 Clad

0.050

2024-T42 Clad

0.040 1

Antimony

2424000

10

2324011

11

1 2324011

12

2424030

Lead

51-70-03

F4-1

Replace
1

2024-T42 Clad

Al

Al

1 2324011

Rib

12

2024-T42 Clad

0.050

2424001

Rib

13

2024-T42 Clad

0.050 1

14

2324011

Balance

Antimony Lead

15

2324011

Rib

2024-T42 Clad

16

2324011

BalanceWeight

Antimony Lead

17

2424000

Skin

2024-T42 Clad

2424033
13

18

2324011

Rib

19

2424002

Balance

20

2324011

2324011

22

2324028

23

2424001

2324028
2424001
2424001

Weight (2 ea.)

SDacer

Clip(LH Only)
Doubler(2ea.)
Access Cover (2 ea.)
Rib Assy.

2324011
21

Weight

F4-1

0.050

I
I

j
I

I
I

51-70-03

1
1
F4-1

51-70-00

51-70-03

Replace
51-70-03

F4-1

0.040 1

51-70-00
51-70-03

F4-1

0.025

51-70-02

I Replace

Rib, Nose
Fitting, LH
Fitting, LH

Casting
Casting

Replace

Replace
1

51-70-03

51-70-02

2024-T42 Clad

5%

2024-T3 Clad

0.032

F4-1

51-70-03

2024-T42 Clad

0.025

F4-1

2024-T3 Clad

0.040

F4-1

Rib

2024-T42 Clad

Angle
Angle

S-608

S-612

Replace
Replace
Replace

51-70-03

0.040 1

51-70-03

I
I

Replace
Replace

0.071

Replace

F4-1

0.025

2024-T3 Clad

1
1

AntimonyLead

Aiieron Repair Index


Figure 5 (Sheet 2 of 5)

EFFECTIVITY:
SRM4

NOTED

57-60-00

Page 18
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

24

2424001

25

2424001

I
DESCRIPTION

Fairing, Outboard Hinge (2 ea.)


Rib Assy.

2324028
2324011

27

2324011

IAnale

Angle
BalanceWeight
Skin, Leading Edge

2424001
26

I
MATERIAL

Rib

2424001

I
EFF.

IFINISH
GAGE

2024-T3 Clad

0.040

2024-T42 Clad

S-608

S-612

Antimony

2024-T3 Clad

Lead

REPAIR
FIG. NO.

CODE

I
0.040 i

I
I
I

I
I
I

Replace

51-70-03

51-70-03

I Replace
I Replace
I Replace
F14-lint

0.040

51-70-02

F1 ext
2624010
28

Skin, Leading Edge

2324011

Access Door

(LH Only)

2024-T3 Clad

0.040 1

2024-T42 Clad

0.040

1
F14-lint

51-70-02

Replace

F1 art
29

30

2424001

Bracket

2024-T3 Clad

0.063

2424001

Clip

2024-T3 Clad

0.063

2324011

Channel

2024-0 Clad

0.040

I
I

2324028

Rib, Inboard Closing, LH


Rib, Inboard Closing, RH

2024-T42 Clad

0.025

1
1
1

2024-T42 Clad

0.025

F4-1

Gusset(LH Only) (2 ea.)


Clip(LH Only)
IFairing

2024-T3 Clad

0.040

F4-1

2024-T3 Clad

0.050

6061-0

0.020

2024-T42 Clad

0.025

2324011

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

31

2324011

32

2324011

33

2434001

34

2324028

Clip,

35

2324028

Rib

2024-T42 Clad

0.025

36

2324011

Rib

2024-T42 Clad

0.025

F4-1

2324011

Clip(LH Only)
Spar(LH Only)
Rib(LH Only)
Clip
Trailing Edge Extrusion

2024-T42 Clad

0.025

F4-1

2024-T42 Clad

0.040 1

51-70-03

2024-T42 Clad

0.025 1

51-70-03

2024-13 Clad

0.025

S-639

Replace
Replace

51-70-03
51-70-03

37

2324028

Rib Attach

38

2324028

39

2324028

40

2324011

41

2324028

Rib

42

2324011

43

2324028

Clip(LH Only)
Rib, Trailing Edge

44

2424000

Doubler

45

2324028

(2 ea.)

F4-1

1
1

I
I
I

51-70-03

Replace

F7-6

2024-T42 Clad

I
0.025 1

2024-T42 Clad

0.050

F4-1

2024-T42 Clad

0.025 1

302 Stainless

0.016

Replace

2024-T42 Clad

0.025 1

51-70-03

Replace

46

2324028

Rib, Trailing Edge


Rib, Trailing Edge

2024-T42 Clad

0.025 1

51-70-03

47

2324028

Spar

2024-T42 Clad

0.032 1

51-70-03

48

2324028

Filler

10

2024-T3 Clad

0.050

2324028

11

2024-T3 Clad

0.025

11

2024-T3 Clad

0.025

2024-T3 Clad

0.040

I
I
I

Replace
Replace
Replace

1
1
1

Replace

2024-T42 Clad

0.025 i

51-70-03

49

2324028

Filler(LH Only) (3 ea.)


Filler(RH Only) (2 ea.)
SparCap

50

2324028

Rib

2324028

51

2324028

Spar

2024-T42 Clad

0.032 1

51-70-03

52

2324028

Rib

2024-T42 Clad

0.025 1

51-70-03

53

2324028

2024-T42 Clad

0.050

Replace

54

2324011

Rib

2024-T42 Clad

0.025 1

51-70-03

55

2424001

Rib

2024-T42 Clad

0.025 1

51-70-03

56

2424000

Skin, Upper

2024-T3 Clad

0.025 1

51-70-02

Anale

Aileron Repair Index


Figure 5 (Sheet 3 of 5)

EFFECTIVITY:

NOTED

57-60-00

Page
SRM4

19

~an 15/93

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

IFINISH

REPAIR

CODE

FIG. NO,

GAGE

MATERIAL

EFF.

DESCRIPTION

57

2424000

Skin, Lower

2024-T3 Clad

0.025 1

51-70-02

58

2624011

S-639

59

2324028

Trailing Edge
Tab Angle, LH
Tab Angle, RH

S-706

I
I

Replace
Replace
Replace
Replace
Replace

2324028
60

2324011
2324011

2424001

1
2024-T4Clad

Hat Section

2324011

S-706

ISealAssy.

2024-T4Clad

Channel

ISealAssy.

2324011

HatSection

2024-T4Clad

0.020

2324011

Channel

2024-T4Clad

0.020

61

2424001

Shim

1~

0.125

62

2434011

2024-T42 Clad

0.025

2324028

Fairing
1
IAngle

63

2024-T42

0.040

64

2324011

IConduit

S-5052

0.035

Aileron

Figure

EFFECTIVITY:

NOTED

F4-1

0.020

I
F4-1

0.020

I
F4-1
F4-1

I
F4-1

I
F4-1

Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace

Repair Index

5 (Sheet 4 of 5)

57-60-00

Page
SRM-4

20

Jan 15/93

Learjet
STRUCTURAL REPAIR MANUAL
CODES
1

EFFECTIVITIES
24-230 THRU

24-357; 25-061,25-067 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU


SUBSEQUENT; 35-002 AND SUBSEQUENT; 36-002 AND SUBSEQUENT
24-230 THRU 24-357; 25-061, 25-067 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU
31-001 THRU 31-014; 35-002 THRU 35-656; 36-002 THRU 36-059
31-015 AND SUBSEQUENT; 35-657 AND SUBSEQUENT; 36-060 AND SUBSEQUENT
24-218, 24-230 THRU 24-354; 25-061 25-067 THRU 25-209; 35-002 THRU 35-086; 36-002 THRU
24-218,
29-004;
24-218,
29-004;

2
3
4

31-001 AND

36-021
24-355 THRU 24-357 AND ALL

SPARES;

25-010 THRU 25-373 AND ALL

SPARES;

28-002 THRU

28-005; 29-002 THRU 29-004; 31-001 AND SUBSEQUENT; 35-087 AND SUBSEQUENT AND ALL

SPARES; 36-002 AND SUBSEQUENT AND ALL SPARES


25-292 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004; 31-001 AND
35-002 AND SUBSEQUENT; 36-002 AND SUBSEQUENT

SUBSEQUENT;

24-356 AND 24-357; 25-235 THRU 25-373; 35-154 AND


QUENT

24-218, 24-230 THRU 24-337; 25-061, 25-067 THRU 25-272


24-338 THRU 24-357 AND ALL SPARES; 25-213 THRU 25-373 AND ALL SPARES; 28-001 THRU
28-005; 29-001 THRU 29-004; 31-001 AND SUBSEQUENT; 35-002 AND SUBSEQUENT; 36-002

SUBSEQUENT;

36-039 AND SUBSE-

AND SUBSEQUENT
10

24-332 AND

11

24-334 THRU

AND
12

13

24-333; 25-207 AND 25-208; 35-075 THRU 35-083


24-357; 25-209 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004; 31-001

SUBSEQUENT;

35-084 AND

SUBSEQUENT;

36-021 AND SUBSEQUENT

24-218, 24-230 THRU 24-357; 25-061, 25-067 THRU 25-354; 28-001 THRU 28-005; 29-001 THRU
29-003; 35-002 THRU 35-463; 36-002 THRU 36-050
25-355 THRU 25-357; 29-004; 31-001 AND SUBSEQUENT; 35-464 AND SUBSEQUENT; 36-051
AND SUBSEQUENT

NOTES
Condition Annealed

Laminated shim stock, per

MlL-S-22499,

2024

aluminum, 0.002

or

0.003

lamination, Comp 1, Type 1, Class 2.

Aileron Repair Index


Figure 5 (Sheet 5 of 5)

EFFECTIVITY:

NOTED

57-60-00

Page
sIiM~

21

Jan 15/93

Learjet
~Learjet
STRUCTURAL REPAIR MANUAL
AILERON
i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS

All dimensions

NOTE:
A.

in inches unless otherwise

are

Fasteners

(1) Loose
tions

or

failed rivets
the

on

not allowed. A loose or failed rivet can cause increased stress concentra-

are

remaining

rivets and lead to

to ensure that

performed
fer to Chapter 51
(2) Loose

or

trations

joint

progressive joint failure. A careful inspection must be


spread from the area of the loose or failed rivet. (Re-

failure has not

for definition of rivet failure.)


failed screws are not allowed. A loose

on

performed
B.

specified.

surrounding
to

ensure

that the

or

failed

and lead to

screw can cause

increased stress

failure. A careful

progressive joint
joint failure has not spread from the area of the

screws

inspection

loose

or

concen-

must be

failed

screw.

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired,
C.
D.

and refinished in accordance with

Deformation

(1) Deformation of the aileron or structure is not allowed.


Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

Chapter

re-

51.

more

than

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component re-

placed.
F.

Scratches(See Figure 101.)


(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Re-

protective treatment procedures.)


must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(See Figure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.
fer to

Chapter 51

for

(2) Structural components

G.

H.

EFFECTTVITY:
SRM~

ALL

57-60-00

Page 101
May 15/92

STRUCTURAL REPAIR MANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure
EFFECTTVITY:

ALL

101

57-60-00

Page
SRM~

102

May 15/92

Learjet
Learjet
STRUCTURAL REPAIR MANUAL
AILERON- REPAIR

i.

APPROVED REPAIRS

WARNING:

A CONTROL SURFACE BALANCE CHECK MUST BE PERFORMED FOLLOWING

REPAIR OF THE AILERON OR THE AILERON TRIM TAB.


A.

Chapter 51 for typical repairs,


fittings and attaching parts.
Refer to

EFFECTTVITY:
SRM-4

ALL

and for allowable

wear

and

repair data

for the aileron system

57-60-00

Page 201
May 15/92

f~ Learjet
Learjetl
STRUCTU RAL REPAIR MANUAL
AILERON BALANCE TAB

STRUCTURAL IDENTIFICATION

i
r

Ij

d
.Detail A
Aileron Balance Tab

Figure
EFFECTIVITY:
SRM-4

MODEL 23 SERIES AIRCRAE~

Repair Index

(Sheet 1 of 2)

57-60-10

Page 1
May 15/92

Learjet
~Leariet

STRUCTURAL REPAIR MANUAL


ITEM

DWG.
NO.

NO.

2324011
1

2324011
2324011

DESCRIPTION
Aileron Balance Tab
Arm

Assy.,

EFF.
LH 6 RH

Assy.

MATERIAL

GAGE

2024-T42 Clad

0.063

0.090

FINISH

REPAIR

CODE

FIG. NO.

1
1

Arm

51-71-04

2324011

Filler

2024-T3 Clad

2324011

Trailing Edge

S-639

2324011

Skin, Lower

2024-T42 Clad

F7-6
0.025

F16lint

51-70-02

F1 art
2324011

Skin, Upper

2024-T42 Clad

0.025

Ft4-iint

51-70-02

F1 art
4

2324011

Rib, Inbd

2024-T42 Clad

0.025

2324011

2024-T42 Clad

0.032

232401 1

Spar
Hinge
Clip
Clip(LH Only)

2024-T3 Clad

0.025

2024-T42 Clad

0.040

Rib, Middle
Rib, Outbd

2024-T42 Clad

0.025

2024-T42Clad

0.025

2324011
2324011

2324011

2324011

CODES

Replace
Replace

EFFECTIVITIES
23-002 THRU 23-099

NOTES
Make from MS20001-4-2080

Aileron Balance Tab

Figure
EFFECTIVITY:

MODEL 23 SERIES AIRCRAFT

Repair Index

1 (Sheet 2 of 2)

57-60-10

Page 2
May 15/92

Learjet
~ttl

STRUCTURAL REPAIR MANUAL


STRUCTURAL IDENTIFICATION

AILERON BALANCE TAB

s~

t-n/
I

111

r-

lr::

Fr~i

I :Jr

~V1

I
II

(TYPICAL)

.Detail A
Aileron Balance Tab

Figure
EFFECTIVITY:
SRM-4

Repair Index

2 (Sheet 1 of 2)

MODEL 24/25/28/29/31/35/36 SERIES AIRCRAFT

57-60-10

Page 3
May 15/92

Learjet I
STRU~TURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

Aileron Balance Tab

Assy.,

I
EFF.

DESCRIPTION
LH 8 RH

2324028

Clip

2324028
2324011

Filler

2324011

Arm

2324011

2324028
2324028

2324028
2324011
5

2324011

2324011

2324011
2324011

2324011

2324011
2324011

10

2324011
2334001

11

Assy.

Arm

2024-T3 Clad
2024-T3 Clad

3
4

Assy.

REPAIR

CODE

FIG. NO.

Replace
Replace

0.063 1

51-71-00

0.063 1

51-71-00

Replace
51-71-00

Replace
Replace
Replace
Replace

0.025

0.090

I
2024-142 Clad
2024-T42 Cald

Arm
Arm

IFINISH
CAGE

1
2

2324011

I
MATERIAL

Replace

Arm

2024-T42 Clad

0.063 1

Arm

2024-T42 Cald

0.063 1

1
1

1
1
I
1

I
I
I Replace
I Replace

BalanceTabAssy.
Spar

2024-T42 Clad

0.032

Rib, \nbd
Rib, Outbd

2024-T42 Clad

0.025

2024-T42 Clad

0.025

Clip
Trailing Edge

2024-T3 Clad

0.032

Extrusion

S-63

Rib

Skin, Upper
Skin, Lower

2024-T42 Clad
2024-T42 Clad

2024-T42 Clad

6061-0

Fairing

51-71-00

0.025
0.025 1
0.025 1
0.020

1
1
F1 Ext

51-70-02
51-70-02

Replace

F14-1lnt

CODES
1
2
3

EFFECTIVI~1ES
24-100 THRU

24-357; 25-002 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004; 31-001
AND SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT
24-155 THRU 24-257; 25-002 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004; 31-001
AND SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT
24-155 THRU 24-257; 25-060, 25-061,25-064 THRU 25373; 28-001 THRU 28-005; 29-001 THRU 29004; 31-001 AND SUBSEQUENT; 35-001 AND SUBSEQUENT; 36-001 AND SUBSEQUENT
25-002 THRU 25-066 EXCEPT 5-060, 25-061 AND 25-064

Aileron Balance Tab

Repair Index
Figure 2 (Sheet 2 of 2)

EFFECTNZTY:
SRM-4

MODEL 24/25/28/29/31/35/36 SERIES AIRCRAFT

57-60-10

Page 4
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
AILERON BALANCE TAB
i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS
All dimensions

NOTE:
A.

are

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

or

failed rivets
the

on

are

not allowed. A loose

or

failed rivet

can cause

increased stress concentra-

progressive joint failure. A careful inspection must be


that joint failure has not spread from the area of the loose or failed rivet. (Re-

remaining

rivets and lead to

performed to ensure
fer to Chapter 51 for definition of rivet failure.)
(2) Loose

or

failed

screws are

not allowed. A loose

or

failed

screw can cause

increased stress

concen-

progressive joint failure. A careful inspection must be


performed to ensure that the joint failure has not spread from the area of the loose or failed screw.
trations
B.

on

surrounding

screws

and lead to

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired, and

refinished in accordance with

C.

Deformation

D.

Corrosion(See Figure 101.)


(1) Corrosion damage is permissible if the affected

(1) Deformation of the aileron balance tab

or

re-

Chapter 51.
structure is not allowed.

properly repaired, refinished in accordance


with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness more than specified.

E.

area

is

Dents

permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
mm) in depth, do not exceed 100/o of total surface area in one (1) square foot, and are not

(1) Dents
(2.54

are

closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to

rivet

or

structural

area.

Such dents shall be

repaired

or

the

component

re-

placed.
F.

Scratches(See Figure 101.)


(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Re-

protective treatment procedures.)


(2) Structural components must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
Structural
(2)
components must be replaced or repaired if nicks reduce the original material thickthan
more
ness
specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.
fer to

G.

H.

EFFECTIVITY:

Chapter 51

ALL

for

57-60-10

Page
SRM-4

101

May 15/92

Learjet 1
STRU~TURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)
0.016

0.0135

0.020

0.0175

0.025

0.0225
0.0295

0.032
0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.1:80

0.250

0.237

Allowable Material Thickness

Figure
EFFECTIVITY:
SRM~

ALL

101

57-60-10

Page 102
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


AILERON BALANCE TAB
i.

APPROVED REPAIRS

A.

Refer to

Chapter 51 for typical repairs, and for allowable


fittings, pulleys, attaching parts and aileron components.

EFFECTIVITY:
SRM~

REPAIR

ALL

wear

and

repair

data for the aileron system

57-60-10

Page 201
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
AILERON TRIM TAB

STRUCTURAL IDENTIFICATION

,1Lk,

rqiLi

----i-

6)

(5)

(al

(9

Detail A
Aileron Trim Tab

Figure
EFFECTIVITY:
SRM-I

MODEL 23 SERIES AIRCRAF~

Repair Index

1 (Sheet 1 of 2)

57-60-20

Page 1
May 15/92

Learjet I
Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.

DWG.
NO.

I
EFF.

DESCRIPTION

REPAIR

CODE

FIG. NO.

I Replace

2324011

Horn

S-634

2324011

S-639

2324011

Trailing Edge
Skin, Upper and

2024-T3 Clad

0.025

232401 i

Tab Rib, Inbd

2024-T42 Clad

0.025

2324011

2024-T3 Clad

0.032

2324011

Angle
Angle

2024-T3 Clad

2324011

Rib, Middle

2024-T42 Clad

2324011

Hinge Half I~
Tab Spar
Hinge Half I~

2024-T42 Glad

Aileron Trim Tab

2324011

Assembly

Lower

IFINISH
GAGE

MATERIAL

51-71-04

F7-6

Replace

F1Clint

51-70-02

F1 art

2324011

10

2324011

11

232401 i

CODES

2024-T42 Clad

Tab Rib, Outbd

0.032

1
1
1

I Replace
I Replace

0.025

0.025

1
1
I

I Replace
Replace
Replace
I Replace

0.025

I
2024-142 Clad

0.025

Replace

51-70-03

EFFECTIVITIES
23-002 THRU 23-099

NOTES
Makefrom MS20001Y4-1305
Make from MS20001 PX4

Aileron Trim Tab

Figure
EFFECTIVITY:

MODEL23 SERIESATRCRAFT

Repair Index

(Sheet 2 of 2)

57-60-20

Page 2
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL


STRUCTURAL IDENTIFICATION

AILERON TRIM TAB

i2~

(13~

e
_

ill

_;I

~s

I;
(TYPICAL)

Detail A
Aileron Trim Tab

Figure
EFFECTIVITY:
SRM~

MODEL

Repair Index

(Sheet 1 of 2)

24/25/28/29/31/35/36 SERIES AIRCRAFT

57-60-20

Page 3
May 15/92

Learjet

STRUGTURALREPAIRMAMUAL
DWG.
NO.

ITEM

NO.

2324028

2324028
2324011
3

2324011
2324011

2324011

2324011

2324011
2324011

2324011

10

2324011
23240 i 1

11
12

Assembly

Tab

Assy.

Angle
Angle
Angle

Tab Rib, Outbd


Horn

Tab

Tab Channel

2324011

Tab Rib, Inbd


Rib

2324011
2324011

Skin, Upper
Skin, Lower

14

2324001
2324011
2324029

CODES

MATERIAL

GAGE

FINISH

REPAIR

CODE

FIG. NO.

Clip

2324011

16

Aileron Trim Tab

EFF.

Spar
Weight Support

13
15

DESCRIPTION

i
1

Trailing Edge Extrusion


Fairing
Balance Weight
Balance Weight

1
2
3
4

2024-T3 Clad

0.025

Replace

2024-T3 Clad
2024-T42 Clad
2024-T3 Clad
2024-T42 Clad
5-634

0.032

Replace
Replace
Replace
Replace

2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T3 Clad
2024-T3 Clad
S-639
6061-0

Antimony Lead
Antimony Lead

0.050

0.032
0.025

F5

51-71-00

0.025

Replace
Replace
Replace
Replace
Replace

0.025

51-70-03

0.025

51-70-02

0.025
0.025
0.025
0.025

0.020

Replace
Replace
Replace
Replace

EFFECTIVITIES

24-100 THRU 24357; :25-002:-TMRU 25-373;:28-001 THRU 28-005; 28-001 THRU 28-004; 31-001
AND SUBSEQUENT; 35-002 AND SUBSEQUENT; 36-002 AND SUBSEQUENT

25-002 THRU 25-067 EXCEPT 25-061

24-100 THRU 24-357; 25-002 THRU 25-369; 28-00! THRU 28-005; 29-001 THRU 29-004; 35-002
THRU 35-514; 36-002THRU 36-054
25-370 THRU 25-373; 31-091 AND SUBSEQUENT; 35-515 AND SUBSEQUENT; 36-055 AND SUB-

SEQUENT

Aileron Trim Tab

Figure
EFFECTIVITY:
SRM4

Repair Index

2 (Sheet 2 of 2)

MODEL 24 /25/28 /29/31/35/36 SERIES AIRCRAFT

57-60-20

Page 4
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
AILERON TRIM TAB
i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS

All dimensions

NOTE:
A.

in inches unless otherwise

specified.

Fasteners

(1) Loose
tions

or

failed rivets
the

on

performed
fer to Chapter 51
(2) Loose

or

trations

ensure

failed

on

performed

rivets and lead to

that

joint

progressive joint failure. A careful inspection must be


spread from the area of the loose or failed rivet. (Re-

failure has not

for definition of rivet failure.)

screws are

surrounding
to

not allowed. A loose or failed rivet can cause increased stress concentra-

are

remaining

to

B.

are

ensure

not allowed. A loose or failed

that the

and lead to

screw can cause

increased stress

failure. A careful

progressive joint
joint failure has not spread from the area

screws

inspection

of the loose

or

concen-

must be

failed

screw.

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired,
C.
D.

and refinished in accordance with

Deformation

(1) Deformation of the aileron trim tab or structure is not allowed.


Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

re-

Chapter 51.

more

than

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component re-

placed.
F.

Scratches(See Figure 101.)


(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Re-

protective treatment procedures.)


must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.
fer to

Chapter 51

for

(2) Structural components

G.

H.

EFFECTIVITY:
SRM-4

ALL

57-60-20

Page 101
May 15/92

Learjet
STRUCTURAL REPAIR MANUAL

Nominal Thickness

Minimum Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.032

0.0225

010295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure 101
EFFECTNITY:
sacd

ALL

57-60-20

Page 102
May 15/92

Learjet
Learptj

TEMPORARY REVISION NO. 57-3


This

NOTE:

57-2. Re-

Temporary Revision No. 57-3 supersedes and replaces Temporary Revision No.
Temporary Revision No. 57-2 from the manual.

move

Leajet Model 20/30 Series Structural Repair Manual (SRM-4).

MANUAL AFFECTED:

Insert

FILING INSTRUCTIONS:

adjacent

to

57-60-20, page 201, dated May 15/92 and retain until fur-

ther notice.

REASON:

replace aileron
hinge.

Add

pr6cedures

place

aileron trim tab

trim tab

hinge,

ron

Trim Tab

201,

as

ream

aileron trim tab

hinge,

and

re-

Line Ream Aileto 57-60-20

page

follows:
AILERON TRIM TAB

1.

line

paragraphs B. Replacement of Aileron Trim Tab Hinge Pin, C.


Hinge, and D. Aileron Trim Tab Hinge Replacement,

Add

INSTRUCTIONS:

to

REPAIR

Repairs
A CONTROL SURFACE BALANCE CHECK MUST BE PERFORMED FOLLOWING

WARNING:

REPAIRS OF THE AILERON TRIM TAB. (REFER TO SECTION II OF THE BASIC

LEARJET

SERVICE MANUAL FOR MODEL 23, 24 AND 25 SERIES AIRCRAFT. RELEARJET MAINTENANCE MANUAL FOR

FER TO CHAPTER 27 OF THE BASIC

MODEL 28, 29, 31 35 AND 36 SERIES AIRCRAE~.)


A.

B.

Chapter 51 typical repairs, and for allowable wear and repair


tinge, pulleys, attaching parts and aileron components.
Replacement of Aileron Trim Tab Hinge Pin (See Figure 201.)
(1) Remove attaching parts securing trim tab linkage to wing.
Refer to

CAUTION:

data for the aileron

system fit-

USE EXTREME CARE NOT TO DAMAGE WING SKIN WHEN REMOVING


AND INSTALLING AILERON TRIM TAB HINGE PIN.

Carefully remove hinge pin from aileron trim tab hinge.


Separate hinge halves.
(4) Using larger hinge pin (P/N 2324011-325), attempt to slide hinge pin through tangs of both hinge

(2)

(3)

halves.

NOTE:

If

hinge pin will slide freely through all tangs of both hinge halves, proceed

to

step

(5).
If

hinge pin will


paragraph C.
(5)
(6)
(7)
(8)

not slide

freely through

all

tangs

of both

hinge halves, proceed

to

hinge halves together and carefull)) insert oversized hinge pin.


Crimp tangs at both ends of hinge to retain hinge pin.
Position trim tab linkage to lower surface of wing and secure with attaching parts.
Measure aileron trim tab free play. (Refer to Section II of the basic Leajet Service Manual for
Model 23, 24 and 25 Series Aircraft. Refer to Chapter 27 of Ihe basic Leajet Maintenance Manual
for Model 28, 29, 31, 35 and 36 Series Aircraft.) If free play limits can not be obtained, replace
hinge per paragraph D.
Position

TEMPORARY REVISION NO. 57-3

57-60-20
1 of 4

Page
SRM-4

Mar

30/98

Learjet

STRUCTURAL REPAIR MANUAL


C.

LineReamAileronTrimTab
CAUTION:

Hinge

USE EXTREME CARE NOT TO SCRATCH, DENT, OR DAMAGE AILERON TRIM


TAB WHEN POSITIONING IN VISE OR WHILE REAMING HINGE HALF.

(1) Place aileron trim tab in vise to ream hinge half.


(2) Secure aileron in full up position to ream hinge half.
CAUTION:

MAINTAIN A SLOW DRILL MOTOR SPEED AND SUPPORT DRILL SHAET


TO AVOID HARMONIC VIBRATION.

a 6-inch and finally a 20-inch No. 40 (0.098 dia.) drill, slowly ream out holes
of
both
hinge halves.
tangs
(4) Position hinge halves together and carefully insert a 2324011-325 hinge pin.
(5) Crimp tangs at both ends of hinge to retain hinge pin.
(6) Measure aileron trim tab free play. (Refer to Section II of the basic Leajet Service Manual for
Model 23, 24 and 25 Series Aircraft. refer to Chapter 27 of the basic Leajet Maintenance Manual
for Model 28, 29, 31, 35 and 36 Series Aircraft.) If free play limits c~n not be obtained, replace
hinge. (Refer to Replacement of Aiieron Trim Tab Hinge, this section.)
Replacement of Aileron Trim Tab Hinge (See Figure 201.)
(1) Remove aileron from wing. (Refer to Section II of the basic Learjet Service Manual for Model 23,
24 and 25 Series Aircraft. Refer to Chapter 27 of the basic Learjet Maintenance Manual for Model

(3) Using

Cinch, then

in

D.

28, 29, 31, 35 and 36 Series Aircraft.


(2) Disconnect trim tab actuator push-pull tube and bonding jumpe~ from trim tab.
(3) Remove hinge pin and separate hinge halves,
(4) Remove hinge halves ~om aileron and trim tab by drilling out rivets using a No. 30 (0.128 dia.)
drill.

(5) Position new hinge assembly (P/N 2324011-322) on trim tab between spar flange and skin.
(6) Align hinge flush with inboard tab skin edge and with centerline of hinge 0.06 inch forward of

leading edge of skin.


(7) Mark rivet locations on inboard and outboard ends of hinge half.
(8) Remove hinge assembly and drill a No. 30 (0.128 dia.) hole at each marked location.
(9) Position hinge assembly to trim tab and cieco in place. Using trim tab skin rivet holes as a pattern,
drill a No. 30 (0.128 dia.) hole in hinge half at each skin hole location, except where the bonding
jumper attaches. Drill a No. 19 (0.166 dia.) hole at jumper attach point.
(10) Secure hinge assembly to trim tab with rivets (P/N MS20426AD4-6).
(11) Attach opposite hinge half (P/N 2324011-324) using hinge pin (P/N 2324011-325). Crimp end

pin. Ensure hinge halves are free of binding.


hinge assembly between spar flange and skin. Adjust trim tab
with proper clearances between trim tab and aileron. (See Figure 201.)
Place a straightedge on aileron trailing edge and adjust aileron trim tab until both the aileron and
trim tab trailing edges are aligned.
With trim tab properly positioned, mark rivet locations at inboard and outboard ends of hinge assembly. Remove trim tab from aileron and drill a No. 30 (0.128 dia.) hole at each location.
Position trim tab to aileron and cleco in place. Using remaining holes in aileron as a pattern, drill a
No. 30 (0.128 dia.) hole at each location except the fourth from the outboard end of hinge. Drill a
No. 19 (0.166 dia.) hole at this location for bonding jumper attachment.
Secure trim tab to aiIeron with rivets (P/N MS20426AD4) and connect bonding jumper to trim
tangs of 2324011-322 hinge half to

(12) Position trim tab

(13)
(14)
(15)

(16)

on

secure

aileron with

tab.

(a) Check electrical resistance between trim tab and aircraft

greater
(17) Install

than the value

push-pull

Chapter

20 of the

structure. Resistance shall not be

applicable Learjet Wiring Manual.

tube.

TEMPORARY REVISION NO. 57-3

SRM-4

specified

in

57-60-20
Page 2 of 4

Mar30/98

Leariet
Learjetl
STRUCTURAL REPAIR MANUAL
(18) Check aileron balance and install aileron on aircraft. (Refer to Section II of the basic Learjet Service Manual for Model 23, 24 and 25 Series Aircraft. Refer to Chapter 27 of the basic Leajet Maintenance Manual for Model 28, 29, 31, 35 and 36 Series Aircraft.)

Screw
Aiieron Trim Tab

Bonding Jumper

Hinge

Nut

Cotter Pin

Washer
Bolt

Push-Pull Tube

B
B

J
Hinge mounted flush with
inboard tab skin

edge.

(Model 23 Series Aircraft)

r--"

mounted flush with


inboard tab skin edge.

CINBO
IModri

i.28.2L31.35.nd36~

6~rmafi)

Detail A
Alieron Trim Tab Hinge Replacement
Figure 201 (Sheet 1 of 2)

TEMPORARY REVISION NO. 57-3

57-60-20

Page 3 of 4
Mar 30/98

SRM-4

Learjet
STRUCTURAL REPAIR MANUAL

0.12 (+0.00/-0.05)

cTypicai)

Aileron

(Ref)

(TRIM TAB CLEARANCES)

2324011-324
Hinge Half

Q,

MS20426AD4-6
(Existing Fastener
Hole Location)

Aileron Skin

0.06 in.

(ReO

I-

Trim Tab Skin

(Ref)
2324011-322
Hinge Half
2324011-325
Hinge Pin

--Trim Tab Spar

II

f~a"
Rnro

(VIEW LOOKING INBOARD)

Detail B
Alieron Trim Tab

Hinge Replacement
Figure 201 (Sheet 2 of 2)

TEMPORARY REVISION NO. 57-3

57-60-20

Page 4 of 4
SRM-4

Mar 30/98

Learjet
~Learjet
STRUCTURAL REPAIR MANUAL
AILERON TRIM TAB
i.

APPROVED REPAIRS
A.

Refer to

Chapter 51 for typical repairs, and for allowable


fittings, pulleys, attaching parts and aileron components.

EFFECTIVITY:
SRM~

REPAIR

ALL

NOTE: Please

wear

see

REVISION
I- -yl~ethat revises
this

and

the

page.

repair

data for the aileron system

57-60-20

Page 201
May 15/92

Learjet

STRUCTURAL REPAIR MAMUAL


SPOILER- STRUCTURAL IDENTIFICATION

24
27
TT?

(26

rr:

3\

30

32

28

--tfl~lC

II;
1

14

11
L;

tl-

fljp,

I
I5

I;

~e

91

15

17

tsIII

I~h--------?;ti--

siIIIIII

ii!

I
iJ_I________ ___lii___ _---_--1__FI----L------1+-----

38

44

40

Spoiler Rep~iir Index


Figure 1 (Sheet 1 of 5)
ALL

29

II

_L3L_

43

EFFECTIVITY:

22

-1-h~

f-

_L__LI_--L~

461C

21

i~i

ii

L1

____

tji

18

~C.

____

57-70-00

Page 1
May 15/92

i:
I--

f3
41

25

42

39

12

28

37) (46

__j__

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

DWG.

NO.

NO.

I
I

I
DESCRIPTION

I
EFF.

I
MATERIAL

GAGE

IFINISH

REPAIR

CODE

FIG. NO.

Spoiler Trailing Edge Structure,

2322510
2322510
2422510

LH 8 RH

Spoiler Assy.
Spoiler Assy.

2
3

2322510

Rib

2024-T42 Clad

0.032

F4-1

2322510

Rib

2024-T42 Clad

0.032

F4-1

2322510

Filler

2024-T3 Clad

0.020

F4-1

Angle
Arm Assy.,

2024-T3 Clad

0.040

F4-1

2322510
4

1 2322510

Inboard

Sleeve

2322510

Clip, Bonding Jumper


Arm Hinge, Inboard
Gap Cover (3 ea.)

2322510

2322510

2322510

4130 Steel

2024-T42 Clad

0.025

I Replace

2024-T4

0.312 1

2024-T3

0.063

2024-T3

2322510

Angle

2422512

Shim, Laminated (Max. 0.032)

0.040

1
1

2322510

Rib

2024-T42 Clad

0.032

F4-1

2322510

Rib

2024-T42 Clad

0.032

F4-1

2322510

Rib

2024-T42 Clad

0.032

F4-1

2322510

Rib

2024-T42 Clad

0.032

F4-1

2422510
2422510

F4-1
F4-1

51-70-04

F4-1

51-71-00

0.312

F4-1

51-71-00

0.312

F4-1

Rib

2024-T42 Clad

0.032

2024-T3 Clad

0.032

1
1

I
I

1
1

2422510

Intercostal, Inboard

2024-T42 Clad

0.032

2422510

2024-T3 Clad

0.032

2422510

Clip
Angle Support

10

4130

Steell~

0.050

11

2422510

Rib

2024-T42 Clad

0.032

12

1 2322510

Filler

2024-T3 Clad

S-575

Center

2024-T42 Clad

0.312

Center

17

2024-T42 Clad

18

4130 Steel

13

IAngle

2322510

2422510

2322510

1
Hinge Arm, Center
IShim, Laminated (Max. 0.032)
IAngle

S575

2422510

Rib

2024-T42 Clad

2422510

ICam
1
Rub Block

S634

2422541
2422512
14

Hinge Arm,
Hinge Arm,

0.020

I
0.032

0.025

1
1

15

2422510

Intercostal, Outboard

Phenolic
2024-T42 Clad

16

2322510

Rib

2024-T42 Clad

0.032

17

2322510

Rib

2024-T42 Clad

0.032

18

2322510

Rib

2024-T42 Clad

0.032

2322510

Angle
Filler(3 ea.)
Strap (3 ea.)

2024-T3 Clad

0.040

11

2024-T3 Clad

0.040

2422510

19

2322510
2422510

12

0.032

51-71-00

I Replace
I Replace
I Replace
Replace
Replace

Clip

2322510

51-71-00

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

1
1

Replace
Replace
Replace
Replace

51-71-00

I Replace
F4-1

Replace
Replace

I Replace
I Replace
-I Replace
F4-1
Replace
F4-1
Replace
F4-1
Replace
F4-1
Replace
F4-1
Replace
I Replace

Spoiler Repair Index


Figure 1 (Sheet 2 of 5)
EFFECTNITY:

ALL

57-70-00

Page 2
SRM-I

May 15/92

-:Ti

Learjet
~Learjet

STRUCTURAL REPAIR MANUAL


ITEM

NO.
20

DWG.
NO.

Arm

2322510

Assy., Outboard

Sleeve

2322510

2322510

Clip, Bonding Jumper


Arm Hinge, Outboard
IShim, Laminated (Max. 0.032)
Angle
1

2322510
2422512
2322510

I
EFF.

DESCRIPTION

IFINISH
GAGE

REPAIR
FIG. NO.

CODE
I

51-71-00

9/16 1

51-71-00

Replace

2024-T4

0.312 1

51-71-00

2024-T3 Clad

0.040

F4-1

F4-1

Replace
Replace
Replace
Replace
Replace

I
MATERIAL

I~

4130 Steel

2024-T42 Clad

0.025

21

2322510

2024-0 Clad

0.032

2322510

1
1

Rib

22

Rib

2024-0 Clad

0.032

23

2322510

Trailing Edge

S-641

2322510

Skin, Lower

2024-T3 Clad

11

F4-1

I
0.040

Mext

51-70-02

M-lint
2322510

12

ISkin, Lower

12024-T42Clad

Mart

0.040

51-70-02

F6lint
24

2024-T3 Clad

Skin, Upper

2322510

F4ext

0.040

51-70-02

F4-lint
2422510

2024-T3 Clad

10

Skin, Upper

Mart

0.040

51-70-02

M-lint

26

2322510

27

2322510

28

2322510

Angle, Stiffener (2 ea.)


Angle, Stiffener(l ea.)
Capstrip
Stop Plate
Stop Plate

29

2322510

Rib

30

2322510

31
32

25

2322510

2322510

14

2024-T42 Clad

0.063

F4-1

2024-T42 Clad

0.063

F4-1

S-558

2024-T3 Clad

0.125

F4-1

2024-T3 Clad

0.100

F4-1

2024-T42 Clad

0.040

F4-1

Rib

2024-T42 Clad

0.040

F4-1

2322510

Rib

2024-T42 Clad

0.040

F4-1

2322510

Rib

2024-T42 Clad

0.040

2322510

2322510

Shim, Laminated (Max. 0.063)


Shim, Laminated (Max. 0.040)

2024-T42 Clad

0.003

F4-1

33

2322510

Rib

2024-T42 Clad

0.040

F4-1

34

2322510

Rib

35

Assy., Flap

Slot

Closing

F4-1

F4-1

Tapered

2322510

Shim

2024-T3

0.063

F4-1

2322510

Rib, Flap Slot Closing

2024-T42 Clad

0.050

F4-1

2322510

Channel Seal Retainer

302/304 A Cres

0.016

F4-1

2322511

Support Instl., Inboard Flap Track


ICap, Aft (Forging)
ICap, Fwd (Forging)

2014-T6

2014-T6

Nylon

2322511
2322511

Button

2322513

2322511

2322512

Support,
Support, Inner
IShim, Laminated (Max. 0.032)

2322512

2322511
2322511

1
1

I
I

Replace
Replace
Replace
I

0.390

Replace
Replace
Replace

0.3121

51-71-00

51-71-00

Support Assy.
Track, Nose Roller

2322511

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Outer

Shim

Forging
Forging

51-71-00

2024-T3

Tapered

0.032

F4-1

0.080

F4-6

Replace
Replace

Support Instl., Outbd Flap Track

2322512

Spoiler Repair Index


Figure 1 (Sheet 3 of 5)

EFFECTIVITY:

ALL

57-70-00

Page 3
SRM~

May 15/92

Learjet
STRUCTURAL REPAIR MANUAL
ITEM

NO.
36

DWG.
NO.
2322512

2322512
2322513

IButton

2322512

2322512

Support, Outer
Support, Inner

2322512
2322512

2322514
2322514
2322514

2322514
39

2422514
2422514

40

2322510

41

2322510

42

2322510

2422510
2322510

2422510
43

2322510

44

2322510

45

2322510

46

2322510

Support Assy.
Track, Nose Roller

2322512

38

Shim

Hinge Bracket, Outboard


Hinge Bracket, Outboard
Hinge Bracket, inboard
Hinge Bracket, Inboard
Hinge Bracket, Inboard
Hinge Bracket, Inboard
Angle
Angle, Stiffener
Angle, Stiffener (LH Only)
Angle, Stiffener (LH Only)
Angle, Stiffener (RH Only)
Angle, Stiffener (RH Only)
Angle, Inboard
Angle, Center Inboard
Angle, Center Outboard
Angle, Outboard

EFF.

IShim, Laminated (Max. 0.032)


ICap, Aft (Forging)
JCap, Fwd (Forging)

2322512

37

I
DESCRIPTION

MATERIAL

(FINISH

REPAIR

CODE

FIG. NO.

GAGE
0.032

201 4-T6

2014-T6

F4-1

I
1

Nylon

0.390

Replace

I
I

I Replace
I Replace

Replace

51-71-00

4130 Steel

51-71-00

2014-T6

51-71-00

201 4-T6

51-71-00

2024-T3

2024-T42 Clad

0.063 1

51-71-00

2024-T42 Clad

0.063 1

51-71-00

2024-T42 Clad

0.080 1

51-71-00

2024-T42 Clad

0.080 1

51-71-00

4130 Steel~

0.063 1

51-71-00

4130 Steel~

0.063 1

51-71-00

Tapered

F4-6

0.080

13

2024-T42 Clad

0.032

F4-1

14

2024-T42 Clad

0.063

F4-1

15

2024-T42 Clad

0.063

F4-1

16

4130 Steel

1~

0.050

15

2024-T42 Clad

0.080

Replace

16

4130 Steel

0.050

12

2024-T3 Clad

0.040

F4-1

12

2024-T3Clad

0.040

F4-1

12

2024-T3 Clad

0.040

F4-1

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

12

2024-T3 Clad

0.040

F4-1

Replace

I
F4-1

Spoiler Repair Index


Figure 1 (Shedt 4 of 5)
EFFECTIVITY:

ALL

57-70-00

Page 4
SRM-4

May 15/92

Learjet
LBarjetl

STRUCTURAL REPAIR MANUAL


CODES

EFFECTIVITIES

23-002 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005; 29-001
THRU 29-004; 31-001 AND SUBSEQUENT; 35-002 AND SUBSEQUENT; 36-002 AND SUBSEQUENT

23-002 THRU 23-099; 24-100 THRU 24-297; 25-002 THRU 25-183


24-298 THRU 24-357; 25-184 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004; 31-001
AND SUBSEQUENT; 35-002 AND SUBSEQUENT; 36-002 AND SUBSEQUENT
24-230 THRU 24-357; 25-062 THRU 25373; 28-001 THRU 28-005; 29-001 THRU 29-004; 31-001

AND SUBSEQUENT; 35-002 AND SUBSEQUENT; 36-002 AND SUBSEQUENT


23-002 THRU 23-099; 24-100 THRU 24-109
23-002 THRU 23-099; 24-100 THRU 24-356
23-057 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005; 29-001
THRU 29-004; 31-001 AND SUBSEQUENT; 35-002 AND SUBSEQUENT; 36-002 AND SUBSE-

6
7

13

QUENT
23-090 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-373; 28-001 THRU 28-005; 29-001
THRU 29-004; 31-001 AND SUBSEQUENT 35-002 AND SUBSEQUENT; 36-002 AND SUBSEQUENT
23-002 THRU 23-099; 24-100 THRU 24-357; 25-002 THRU 25-272
25-273 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004; 31-001 THRU 31-029; 35-002
THRU 35-664; 36-002 THRU 36-063
23-002 THRU 23-099; 24-100 THRU 24357; 25-002 THRU 25373; 28-001 THRU 28-005; 29-001
THRU 29-004; 31-001 THRU 31-029; 35-002 THRU 35-664; 36-002 THRU 36-063
31-030 AND SUBSEQUENT; 35-002 AND SUBSEQUENT; 36-002 AND SUBSEQUENT
23-002 THRU 23-099; 24-100 THRU 24-229 EXCEPT 24-218

14

23-002 THRU 23-089

15

23-090 THRU

16

24-298 THRU

9
10
11
12

23-099;
24-357;
AND SUBSEQUENT;
24-298 THRU 24-357;

24-100 THRU 24-297

25-002 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004; 31-001
SUBSEQUENT; 36-002 AND SUBSEQUENT

35-002 AND

25-184 THRU 25-373; 28-001 THRU 28-005; 29-001 THRU 29-004; 31-001
35-002 THRU 35-558, 35-589 THRU 35-601; 36-002 THRU 36-053, 36-055
35-559 THRU 35-588, 35-602 AND SUBSEQUENT; 36-054, 36-056 AND SUBSEQUENT

17

AND
18

SUBSEQUENT;

NOTES
Laminated shim stock, 0.002

or

0.003 lamination per MIL-S-22499

Type

1 Class 1

or

Class 2 1145-H19 aluminum

sheet.

Condition Normalized
Condition Annealed

PerMIL-P-15035

Spoiler Repair Index


Figure 1 (Sheet 5 of 5)
EFFECTIVITY:

ALL

57-70-00

Page 5
SRM-4

May 15/92

Learjet
Leariet

STRUCTURAL REPAIR MANUAL


SPOILER
i.

ALLOWABLE DAMAGE

ALLOWABLE DAMAGELIMITS
All dimensions

NOTE:
A.

are

in inches unless otherwise

Fasteners

(1) Loose
tions

or

failed rivets
the

on

not allowed. A loose or failed rivet can

are

remaining

rivets and lead to

to ensure that

performed
fer to Chapter 51
(2) Loose

or

trations

failed

on

performed
B.

specified.

joint

cause

increased stress concentra-

failure. A careful

progressive joint
inspection must be
from
of
the
the
loose
area
or failed rivet. (Respread

failure has not

for definition of rivet failure.)

screws are

surrounding

not allowed. A loose or failed screw can cause increased stress concen-

screws

to ensure that the

and lead to

joint

progressive joint failure. A careful inspection must be


spread from the area of the loose or failed screw.

failure has not

Cracks

(1) Cracks in any fitting or forging are not allowed. Cracked fittings or forgings must be replaced.
(2) Cracks in components other than fittings and forgings are considered allowable if properly

paired,
C.
D.

and refinished in accordance with

Deformation

(1) Deformation of the spoiler or structure is not allowed.


Corrosion(See Figure 101.)
(1) Corrosion damage is permissible if the affected area is properly repaired, refinished in accordance
with Chapter 51, and these repairs do not reduce the original material thickness more than specified. (Refer to Chapter 51 for protective treatment procedures.)
(2) Structural components must be repaired or replaced if corrosion repair reduces the original material thickness

E.

Chapter

re-

51.

more

than

specified.

Dents

(1) Dents are permissible, if smooth and without abrupt changes in contour, do not exceed 0.100 inch
(2.54 mm) in depth, do not exceed 10% of total surface area in one (1) square foot, and are not
closer than 0.50 inch (12.7 mm) to any rivet or structural area.
(2) Dents are not allowed if sharp, a fracture of the skin has occurred, greater than 0.100 inch (2.54
mm) in depth, exceeds 10% of total surface area in one (1) square foot, and are closer than 0.50
inch (12.7 mm) to a rivet or structural area. Such dents shall be repaired or the component re-

placed.
F.

Scratches(See Figure 101.)


(1) Scratches are permissible if the affected area is sanded smooth, refinished in accordance with
Chapter 51, and the repairs do not reduce the original material thickness more than specified. (Re-

protective treatment procedures.)


must be replaced or repaired if scratches reduce the original material
thickness by more than specified.
Nicks(SeeFigure 101.)
(1) Nicks are permissible if the affected area is sanded smooth, refinished in accordance with Chapter
51, and the repairs do not reduce the original material thickness more than specified. (Refer to
Chapter 51 for protective treatment procedures.)
(2) Structural components must be replaced or repaired if nicks reduce the original material thickness more than specified.
Fittings and Forgings
(1) Fittings or forgings must be replaced if cracked or if fitting hole (non-bushed) tolerance exceeds
the allowable limits. (Refer to Chapter 51.)
(2) Fittings or forgings with bushing shall be repaired.
fer to

Chapter 51

for

(2) Structural components

G.

H.

EFFECTIVITY:
SRM~I

ALL

57-70-00

Page 101
May 15/92

Learjet

STRUCTURAL REPAIR MANUAL

Minimum Thickness

Nominal Thickness

(Inch)

(Inch)

0.016

0.0135

0.020

0.0175

0.025

0.0225

0.032

0.0295

0.040

0.037

0.050

0.046

0.063

0.059

0.071

0.067

0.080

0.076

0.100

0.095

0.125

0.120

0.190

0.180

0.250

0.237

Allowable Material Thickness

Figure

EFFECI7NITY:

ALL

101

57-70-00

Page 102
May 15/92

Learjet I
STRUCTURAL REPAIR MANUAL
SPOILER- REPAIR

1.

APPROVED REPAIRS
A.

Chapter 51 for typical repairs,


and attaching parts.

Refer to

EFFECTIVITY:
SRM4

ALL

and for allowable

wear

and

repair data

for the

spoiler fittings

57-70-00

Page 201
May 15/92

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