# M U - 2 

# S E R V I C E B U L L E T I N

MITSUBISHI HEAVY INDUSTRIES, LTD. NAGOYA AEROSPACE SYSTEMS WORKS 10, OYE-CHO, MINATO-KU, NAGOYA, JAPAN

Page 1 of 38 No. 242 DATE: July 10, 2013
Subject: Fuselage Frame Inspection and Repair or Re placement Effectivity: MU-2B-30/-35/-36: S/N 502 through 696 except 652 and 661 Purpose: To verify and restore, where required, str uctural integrity of main fuselage structural members. Background: As part of Mitsubishi Heavy Industries, Ltd (MHI) continuing aging aircraft program short body and long body airplanes were subjected to detailed teardown inspections. Structural crack s in the flanges of some long body aircraft frames were found at STA 46 10 and STA 5605. To assure continued safety of operation, all long body aircraft fuselage frames STA 4610 and 5605 need to be inspec ted and appropriate repairs made. Compliance: Mandatory Approval: JCAB Approved Time of Compliance: Within 1,000 flight hours or 3 years, after receipt of this Service Bulletin, whichever occurs first, comply with the i nitial inspection detailed herein. If cracks are found they must be r epaired using the procedures outlined in this SB before next flight. Responsible Agency of Compliance : MU-2 Owners/Operators

Disposition of Removed Parts: Scrap

Spare Parts Affected: None
Approximate Required Man Hours: Inspection ~ 100 Man hours Accessing for frame repair ~ 128 Man hrs Frame end replace/repair (per frame) ~ 40 Man hrs Side-Frame Replacement (per frame) ~ approx. 140 Ma n hrs Lower-Frame Replacement (per frame) ~ approx. 200 M an hrs Special Tools Required: Airplane support forms (to maintain geometry when frame segments are removed). Eddy current NDT inspection and Bores cope capability is required for this inspection.
Flight Manual Revision: None

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Page 2 of 38 

### Table of Contents
1.0 APPLICABLE REFERENCE MANUALS

.................................................. ................. 3
2.0 GENERAL NOTES

.................................................. ................................................... 3
3.0 FRAME INSPECTION

.................................................. .............................................. 5 3.1 PREPARATION FOR INSPECTION ....................

................................................... .... 5
3.2 DETAILED INSPECTIONS ..........................

................................................... ............ 6
3.3 RESTORATION ...................................

................................................... .................... 7
4.0. GENERAL PREPARATION FOR REPAIR/REPLACEMENT ................................... 7 5.0 LOWER FRAME SEGMENT-END REPLACING REPAIR ......................................... 9 5.1 STA 4610 FRAME SEGMENT-END REPLACING REPAIR (L/ H OR R/H) ............... 10 5.2 STA 5605 FRAME SEGMENT-END REPLACING REPAIR (L/ H OR R/H) ............... 11 6.0 REPLACEMENT OF SIDE-FRAME SEGMENTS (STA 4610 or STA 5605) ........... 13 6.1 REMOVAL OF LEFT SIDE-FRAME SEGMENT (STA 5605) . ................................... 13 6.2 REMOVAL OF RIGHT SIDE-FRAME SEGMENT (STA 5605) ................................. 15
6.3 INSTALLATION OF REPLACEMENT SIDE-FRAME SEGMENT ............................. 16
7.0 REPLACEMENT OF LOWER-FRAME SEGMENT (CENTER SEGMENT AT STA 4610 OR STA 5605)

.................................................. .. 17
7.1 PREPARATIONS ..................................

................................................... ................. 18
7.2 REMOVAL OF LOWER-FRAME SEGMENT STA 4610 ....... .................................... 19
7.3 REMOVAL OF LOWER-FRAME SEGMENT STA 5605 ....... .................................... 19 7.4 INSTALLATION OF LOWER-FRAME SEGMENTS........... ....................................... 19
8.0 RESTORATION

.................................................. ................................................... ... 20
9.0 LOGBOOK ENTRY

.................................................. ................................................ 20
10.0 COMPLETION

.................................................. ................................................... ... 21 11.0 PARTS AND MATERIAL REQUIRED & SYMMETRICAL MEAS UREMENTS .....22
12.0 FIGURES

.................................................. ................................................... ........... 28

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Page 3 of 38 1.0 APPLICABLE REFERENCE MANUALS
Refer to the applicable MU-2 Maintenance Manual, Il lustrated Parts Catalog, and Structural Repair Manual.

2.0 GENERAL NOTES
a. Repair Kit’s and/or Replacement frames may be pu rchased through Mitsubishi Heavy Industries America, Inc. (MHIA) Service Center Netw ork. b. Unless there is an MHI, MHIA or JCAB approved re pair, the affected frame sections must be replaced. c. Properly identify all components removed or disr upted. d. Restoration of disrupted systems, including rigg ing/operational tests, should be accomplished in accordance with applicable Maintena nce Manuals. e. Frames with surface corrosion should be repaired utilizing repairs outlined in the Structural Repair Manual (SRM). f. If additional information is needed, contact MHI A Engineering.

This Service Bulletin covers three basic steps in t he process of assuring the frame structure at STA 4610 and STA 5605 is sound. The three steps ar e: 1) Detail visual inspection of the frame flanges [P aragraph 3], 2) Repair or Replacement of damaged frame segments [Paragraph 4 thru 7] and 3) Restoration of the Aircraft & Completion [Paragr aph 8, 9 & 10].

Any cracking in the frame flanges at STA 4610 and S TA 5605 is classified as “Damage Repairable by Replacement” in Section 1, Paragraph 6.5 of the SRM. That is, if the cracking is limited to the ends of the large lower-frame segmen t it is simpler to replace only the damaged ends. If cracking extends over several inches and into the center section of the lower-frame then the entire frame segment should be replaced. In Step 1, above, Eddy current inspection capability may be needed to verify crack-free condi tion of the frame flanges. In Step 2, repairs are presented for replacing only the damaged frame ends with Repair Kits or the entire lowerframe segment with replacement parts for each frame . Assessment of the extent of damage to the lower frame segment will determine the choice o f repair means.

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Page 4 of 38 Replacement frames are also provided for the side-f rame segments, at both STA 4610 and STA 5605, in case cracks are found in side-frame segmen ts. If repair or replacement of the side-frame segment and lower-frame segment in the s ame STA are required due to cracks and/or damage, replace the lower-frame segment firs t to stabilize the fuselage prior to removing the side-frame segment.

MHI analysis determined that these cracks are likel y the result of stress corrosion. Repair kits and replacement frame segments are manufactured fro m an aluminum material that has an improved resistance to stress corrosion cracking.

For cracks found in other locations on the frames ( i.e. side-frame segments), MHI recommends replacing the segment rather than attempt a repair not covered by this Service Bulletin or Service Bulletin 209B, due to the complex structure . Therefore, this Service Bulletin covers only replacement of damaged frame segments. Repair schemes may be evaluated by MHI Engineering on a case-by-case basis. Please contac t MHIA Engineering to discuss proposed repair methods that are not covered in this Service Bulletin or the SRM.

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Page 5 of 38 3.0 FRAME INSPECTION

3.1 PREPARATION FOR INSPECTION

NOTE

Mark and store all removed parts and attaching hard ware.
Remove and store passenger seats, galley (if equipp ed), carpet and side panels to gain access to lower portion of fuselage frames at STA 4610 and ST A 5605. Headliner removal is only necessary, if the upper area of the frames cannot be borescope inspected or there is evidence of corrosion on the upper frames.

a. Remove insulation and acoustic package, as requi red. Take care to mark insulation and acoustic package so pieces can be reinstalled in th e same location after completion of this
Service Bulletin. b. It is recommended loosening left and right armre st rails and plumbing to allow inward movement of approximately three inches to gain acce ss to areas of frames behind the
structure as needed. Do not remove the armrest rai ls, remove only the upper and lower
attach hardware to loosen them. Armrests will not be removed completely due to the wiring and plumbing running through them.

NOTE

Use care when disconnecting tubing, there are
several smaller hoses that are hidden.

c. Remove the plenum chambers at frames STA 4610 an d STA 5605 floor area: Use caution not to damage the air hose connecting t o the plenum chambers

P/N 030A-63370-1, Fwd Left P/N 030A-63370-2, Fwd Right P/N 030A-63371-1, Aft Left P/N 030A-63371-2, Aft right d. Remove access panels from the belly of the aircr aft between left and right keels in landing gear area to provide access for inspecting frames a t STA 4610 and STA 5605. Mark and store all removed parts and attaching hardware.

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Page 6 of 38 CAUTION To avoid damaging the frame surface use only non-metallic scrapers to remove sealant

e. Clean frames of any loose debris and excessive s ealant, paying particular attention to
frames at STA 4610 and STA 5605 where the floor mee ts the frames on the left and right
sides of the aircraft. The area around the rivets on the inner flange going from the floor line up approximately 4 inches needs to be thoroughly cl eaned of sealant and corrosion. Typical areas where cracks have been detected at ea ch frame location are shown in Figures 1 and 2. However, the entire frame flange must be inspected.

3.2 DETAILED INSPECTIONS a. Conduct detailed visual inspection of both inner and outer frame flange areas of side and
lower frames for cracks and corrosion at frame STA 4610 and STA 5605. Pay particular
attention to the area between rivet centerlines.

NOTE
If the visual inspection is inconclusive (indicated by hairline cracks in the paint), a fluorescent penetrant inspection or Eddy Current NDT technique should be used

.

NOTE Personnel performing NDT must be qualified and cert ified as a Level II or higher based on the requirements of National Aerosp ace Standard NAS410

or equivalent international standard.

b. Using a borescope, visually inspect the frame fl ange areas of side-frames behind the
armrest rail for cracks at STA 4610 and STA 5605. c. Record the location of any cracks detected on Fi gures 1 and 2. d. If crack indications are found, repair the crack ed area in accordance with Paragraph 4 and 5 of this Service Bulletin or replace the affected fr ame segment in accordance with Paragraph 4, 6 and 7 of this Service Bulletin. e. If surface corrosion is found, repair the damage d area in accordance with SRM. If severe corrosion is found, contact MHIA engineering for di sposition.

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Page 7 of 38 3.3 RESTORATION

a) If no cracks are found, reverse the process to r estore the airplane to an original
condition. b) Continue with Paragraph 9 and 10 to return the a ircraft to service.

4.0. GENERAL PREPARATION FOR REPAIR/REPLACEMENT

NOTE The following instructions assume all segments will be repaired/replaced in sequence. If only an individua l repair (i.e. one frame end) is to be made, modify these in structions by deleting the steps not required to the repairs b eing done.

NOTE If several frame repairs are to be made or both fra me segments are to be replaced, it is recommended that only one frame end/frame is removed and repaired/replaced at a time to maint ain fuselage alignment.

a. Remove aircraft batteries and pull landing gear circuit breakers. b. Defuel aircraft leaving only unusable fuel in th e tanks. c. Place aircraft on jacks, utilizing all four jack points and place a tail stand support under tailskid. Once aircraft is jacked with wheels clea r of the ground, verify that the aircraft is level in both axes in accordance with Chapter 2 of applicable Maintenance Manual. d. Build additional braces to support the fuselage dead weight and stabilize the aircraft while repairs/replacements are being performed. Forward brace is to be placed at the fuselage centerline directly under frame STA 4025 and Aft br ace is to be placed directly under frame STA 6495. Take care to support only the dead weigh t at the frame and not induce any vertical load into the frame by the brace. e. Symmetrical measurements should be obtained in a ccordance with Section I, Paragraph 3.4 Symmetry and Alignment Inspection Procedure of the Structural Repair Manual. Record
dimensions in Table 7 for later reference. f. Remove forward and aft main gear doors on the si de of the aircraft that is being worked on.

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Page 8 of 38 g. Verify landing gear is in the down and locked po sition. Mechanically move traveling nut against the down stop, and then record the length o f main landing gear drag strut “exposed threads” or any other reference from the drag strut gearbox. This will aid in restoration and gear rigging.

NOTE

Do not rotate or move gear components once torque t ubes are removed.

NOTE Mark location and direction of torque tubes to aid in restoration.

h. Remove main landing gear door lock mechanism (R/ H Only) a. P/N 030A-33449-21 (S/N up to 522), P/N 030A-3853 0 (S/N 523 & up) (Torque tube assembly forward of STA 4610) b. P/N 030A-38450 (Bearing assembly at STA 4610) c. P/N 030A-38449-11 (S/N up to 522), P/N 030A-3844 9-31 (S/N 523 & up) (Torque tube assembly aft of STA 4610) i. Remove main landing gear control torque tubes (L /H Only) a. P/N 030A-38605-11 (Between STA 4610 and STA 5605 ) b. P/N 030A-38605-21 (Fwd of STA 4610) c. P/N 030A-38720 (Bearing box Assembly at STA 4610 ) d. P/N 030A-38730 (Bearing box Assembly at STA 5605 ) j. Remove brake lines from STA 5605 to STA 4610. k. Remove wiring from gear well area and frame to b e repaired. Label wires for restoration. l. Remove main landing gear assembly in accordance with the applicable Maintenance
Manuals. m. On the lower side of the aircraft, drill attachi ng hardware from left and right center bulge
assemblies between STA 4285 and STA 5890. Detach t he ribs from the keel and remove with the skin. Remove both center bulge assemblies to gain access as required. n. From gear well area, remove gear wheel cover ass embly (P/N 030A-91411 L/H or P/N 030A-91411-11 R/H) on the side to be repaired. Use care when removing insulation and mark/record location of insulation during removal f or later restoration. Store removed parts
for restoration.

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Page 9 of 38 o. Remove seat rails from floor of aircraft. P/N 0 30A-91291 LH/RH (S/N up to 532), P/N 030A-91296-3(LH)/-5 (RH) (S/N 533 & up), and qty 2 P/N 030A-91293 (S/N up to 562), P/N 030A-91298 (S/N 563 & up). p. Remove air duct assembly (P/N 030A-63366-31 L/H, P/N 030A-63366-32 R/H) between STA 4610 and STA 5605, and stiffener (P/N 030A-3231 2-7 L/H, P/N 030A-32312-8 R/H). q. Remove floorboards P/N 030A-30014 and/or P/N 030 A-30015, be very careful not to damage the floorboard. r. Remove Floor support between STA 4610 and STA 56 05 (P/N 030A-32381-1 L/H
, P/N 030A-32381-2 R/H). s. Proceed to applicable section, one at a time, fo r repair and/or replacement.

5.0 LOWER FRAME SEGMENT-END REPLACING REPAIR

NOTEDisassemble and repair only one frame segmentend at a time to assure fuselage alignment.

Refer to Figure 3 for STA 4610 frame segment-end re placing repair (L/H) Refer to Figure 4 for STA 4610 frame segment-end re placing repair (R/H) Refer to Figure 5 for STA 5605 frame segment-end re placing repair (L/H) Refer to Figure 6 for STA 5605 frame segment-end re placing repair (R/H) Detail installation information is presented in Ins tall Drawings 035A-32107 (STA 4610) & 035A-32306 (STA 5605).

NOTE Procure Repair Kit for segment-end to be repaired f rom MU-2 Service Center Network. The Repair Kit contains the install drawings, neces sary parts and full size cut template. Prior to starting repair work read the entire repai r instruction in this Service Bulletin and verify Kit contents per Tables 1 and Table 2 of this Service Bulletin.

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Page 10 of 38 5.1 STA 4610 FRAME SEGMENT-END REPLACING REPAIR (L/ H OR R/H)
5.1.1 PREPARATIONS a. Prepare lower frame segment-end Repair Kit 035A- 900019-101 (L/H) or 035A-900019-102 (R/H). Locate full-sized template 016A-99443-101 ( L/H) or 016A-99443-102 (R/H) from Repair Kit. b. Remove or temporary remove parts in accordance w ith Install Drawing 035A-32107 sheet 1 (L/H) or Install Drawing 035A-32107 sheet 2 (R/H).

5.1.2 REMOVAL OF FRAME SEGMENT-END
a Clean area around location of the frame to be cut and mark using template 016A-99443-101 (L/H) or 016A-99443-102 (R/H).
b Cut on outboard side of the marked line no more t han 1/8 in (3 mm) and remove damaged frame segment-end per Install Drawing 035A-32107 sh eet 1 (L/H) or Install Drawing 035A-32107 sheet 2 (R/H). c Temporarily set new frame segment-end into locati on for trial fit aligning the floor and side-frame as a guide. File existing frame segment as needed for the two pieces to be properly aligned and joined together. d If cut line intersects with any existing holes in the original frame, blend the intersections. e Once cut edge has been filed to remove all sharp edges apply Alodine #1200 or equivalent MIL-C-5541 and two coats of Zinc-Chromate primer to all bare surfaces per Install Drawing 035A-32107 sheet 1 (L/H) or Install Drawing 035A-32 107 sheet 2 (R/H) .

5.1.3 FRAME SEGMENT-END PREPARATION AND INSTALLATIO N a. Put frame segment-end P/N 035A-32115-101/-102(LH /RH) in place and clamp to remaining
lower frame. b. Verify alignment location of frame segment-end b y making sure the floor flange edge and contour edge outboard on the frame is smooth and me asure the gap between the remaining existing frame segment and the new frame segment-en d, and fill the existing gap with laminated shim per the Install Drawing 035A-32107 s heet 1 (L/H) or Install Drawing 035A-32107 sheet 2 (R/H). c. Temporarily install removed splice angles and do ubler, measure the gap between the flanges and the splice angles, and fill the existin g gap with laminated shim per Install Drawing 035A-32107 sheet 1 (L/H) or Install Drawing 035A-32107 sheet 2 (R/H).

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Page 11 of 38 d. Prior to final assembly verify symmetrical measu rements in accordance with Section 1 Paragraph 3.4 Symmetry and Alignment Inspection Pro cedure of the Structural Repair Manual and compare with the dimensions previously r ecorded in Table 7. e. Drill and countersink the holes in frames per In stall Drawing 035A-32107 sheet 1 (L/H) or Install Drawing 035A-32107 sheet 2 (R/H). Use of a drill guide is recommended to maintain alignment. Ream holes to final size. f. Temporary remove the new frame segment-end, debu rr all holes. Clean all debris from
the area. g. Apply faying surface sealant to the splice joint per Install Drawing 035A-32107 sheet 1 (L/H) or Install Drawing 035A-32107 sheet 2 (R/H). h. Install splice angles, shims and doublers. i. Install fasteners per Install Drawing 035A-32107 sheet 1 (L/H) or Install Drawing 035A-32107 sheet 2 (R/H). j. Install all other parts to the Frame per Install Drawing 035A-32107 sheet 1 (L/H) or Install Drawing 035A-32107 sheet 2 (R/H). k. Repeat process for repair of other side of frame STA4610, if required. l. If that completes the required repairs, proceed to “Restoration” Paragraph 8.0

5.2 STA 5605 FRAME SEGMENT-END REPLACING REPAIR (L/ H OR R/H)

NOTE Disassemble and repair only one frame segment-end at a time to assure fuselage alignment.

NOTE Procure Repair Kit for segment to be repaired from MU-2 Service Center Network. Prior to starting repair read entire repair sequenc e in this Service Bulletin and verify Kit contents per Table 2 of this Service Bulletin.

5.2.1 PREPARATIONS a. Prepare lower frame segment-end Repair Kit 035A- 900019-201 (L/H) or 035A-900019-202 (R/H). Locate full-sized template 016A-99443-201 ( L/H) or 016A-99443-202 (R/H) from Repair Kit.

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Page 12 of 38 b. Remove or temporary remove parts in accordance w ith Install Drawing 035A-32306 sheet 1 (L/H) or Install Drawing 035A-32306 sheet 2 (R/H).

5.2.2 REMOVAL OF FRAME SEGMENT-END a. Temporary remove main landing gear leg attachmen t fitting assembly 030A-32315-1 (L/H) or 030A-32315-2 (R/H).
b. Clean area around location of the frame to be cu t and mark using template 016A-99443-201 (L/H) or 016A-99443-202 (R/H).
c. Cut on outboard side of the marked line no more than 1/8 in (3 mm) and remove damaged frame segment-end per Install Drawing 035A-32306 sh eet 1 (L/H) or Install Drawing 035A-32306 sheet 2 (R/H). d. Temporarily set new frame segment into location for trial fit aligning with the floor and sideframe as guides. File existing frame segment as ne eded for the two pieces to be properly aligned and joined together. e. If cut line intersects with any existing holes i n the original frame, blend the intersections f. Once cut edge has been filed to remove all sharp edges apply Alodine #1200 or equivalent MIL-C-5541 and two coats of Zinc-Chromate primer to all bare surfaces per Install Drawing 035A-32306 sheet 1 (L/H) or Install Drawing 035A-32 306 sheet 2 (R/H).

5.2.3 FRAME SEGMENT-END PREPARATION AND INSTALLATIO N a. Put frame segment-end P/N 035A-32334-101/-102(LH /RH) in place and clamp to remaining
lower frame. b. Verify alignment location of frame segment-end b y making sure the floor flange edge and contour edge outboard on the frame is smooth and me asure the gap between the remaining existing frame segment and the new frame segment-en d, and fill the existing gap with laminated shim per Install Drawing 035A-32306 sheet 1 (L/H) or Install Drawing 035A-32306 sheet 2 (R/H). c. Temporarily install removed splice angles and do ubler, measure the gap between the flanges and the splice angles, and fill the existin g gap with laminated shim per Install Drawing 035A-32306 sheet 1 (L/H) or Install Drawing 035A-32306 sheet 2 (R/H). d. Prior to final assembly verify symmetrical measu rements in accordance with Section 1 Paragraph 3.4 Symmetry and Alignment Inspection Pro cedure of the Structural Repair Manual and compare with the dimensions previously r ecorded in Table 7.

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Page 13 of 38 e. Drill and countersink the holes in frames per In stall Drawing 035A-32306 sheet 1 (LH) or Install Drawing 035A-32306 sheet 2 (R/H). Use of a drill guide is recommended to maintain alignment. Ream holes to final size. f. Temporary remove the new frame segment-end, debu rr all holes. Clean all debris from
the area. g. Apply faying surface sealant to the splice joint per Install Drawing 035A-32306 sheet 1 (L/H) or Install Drawing 035A-32306 sheet 2 (R/H). h. Install splice angles, shims and doublers. i. Install fasteners per Install Drawing 035A-32306 sheet 1 (L/H) or Install Drawing 035A-32306 sheet 2 (R/H). j. Install all other parts to the frame per Install Drawing 035A-32306 sheet 1 (L/H) or Install Drawing 035A-32306 sheet 2 (R/H). k. Repeat process for repair of other side of Frame STA 5605, if required. l. If that completes the required repairs proceed t o “Restoration” Paragraph 8.0.

6.0 REPLACEMENT OF SIDE - FRAME SEGMENTS (STA 4610 or STA 5605)
If a crack is found in the side-frame segment of ST A 4610, contact MHIA engineering for disposition.

NOTE

If repair or replacement of the lower-frame segment in same Frame STA is required due to cracks/damage, replace the lower -frame segment first to stabilize the fuselage prior to removing the sid e-frame segment.

6.1 REMOVAL OF LEFT SIDE-FRAME SEGMENT (STA 5605)
a. Remove side wall seat rails from left side of ca bin (left fwd P/N 030A-91291 (S/N up to 532), P/N 030A-91296-3 (S/N 533 & up), and left aft P/N 0 30A-91293 (S/N up to 562), P/N 030A-91298 (S/N 563 & up). b. Remove fasteners securing armrest support struct ure (P/N 030A-91800) from the sideframes and side seat track support stiffener the fu ll length of the cabin. c. Disconnect plumbing and hoses, as necessary, to move armrest support structure (P/N 030A-91800) inboard to allow access of fasteners se curing inner panel and seat track
stiffeners to frame section.

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Page 14 of 38 NOTE Use care when disconnecting tubing as there are
several smaller hoses that are hidden.

d. Remove and retain seat track support stiffeners between STA 4610 and STA 6495.

e. Remove and retain left stiffener plate (P/N 030A-3 2312-53) to gain access to the hardware securing the upper main landing gear attach fitting

. f. Remove left upper main landing gear fitting (P/N 0 30A-32314-1).

NOTE Record the number of washers installed, location of washers under the bolts and nuts and bag for reinstallatio n.
g. Cut two (2) access holes forward of STA 5605 jus t below the window lower longeron (P/N 030A-32310-35) and just above the #5 longeron (P/N 030A-32310-59) as shown in Figure 8. If an access hole has been previously made in accor dance with service bulletin 209B
remove and retain doubler for reinstallation. h. Remove longerons between STA 5605 and STA 5890 i n the side-frame area (P/N 030A-32310-75, 030A-32310-73, 030A-32310-79, 030A-3 2310-77, 030A-32310-37) i. On Exterior of aircraft, remove and retain skin fairing (P/N 030A-35201-9), Plate (P/N 030A-35201-193) and plate (P/N 030A-35201-135). Re move rib (P/N 030A-35201-137), rib (P/N 030A-35201-125), and plate (P/N 030A-32306 -9), located under the top portion of fairing. j. Remove as necessary, aft door hinge and rivets o n skin panel P/N 030A-35201-3 to gain access to fasteners on internal longerons.

NOTE If STA 5605 LH frame has been repaired in accordanc e with Service Bulletin 209B, remove and scrap all reinfor cing parts

. Fabricate a new shim to span between existing longe ron fitting (PN 010A-31431-103) and new frame segment. Fill al l unused fastener holes drilled for the strap installation w ith AD rivets.

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Page 15 of 38 k. Remove and retain splice angles (Upper P/N 030A- 32335 and P/N 030A-32336, Lower P/N 030A-32337 and 030A-32338), attaching doublers (Upp er P/N 030A-32306-7 and Lower P/N 030A-32306-5.), attaching hardware, and longero ns from frame segment. l. Remove remaining rivets and fasteners holding fr ame section in place.
m. Remove frame section. n. Refer to Paragraph 6.3 “INSTALLATION OF REPLACEM ENT SIDE-FRAME SEGMENT” of
this Service Bulletin for installation of the new f rame segment.

6.2 REMOVAL OF RIGHT SIDE-FRAME SEGMENT (STA 5605) a. Remove side wall seat rails from right side of c abin (right fwd P/N 030A-91291 (S/N up to 532), P/N 030A-91296-5 (S/N 533 & up), and right af t P/N 030A-91293 (S/N up to 562), P/N 030A-91298 (S/N 563 & up). b. Remove fasteners securing armrest support struct ure (P/N 030A-91800) from the sideframes and side seat track support stiffener the fu ll length of the cabin. c. Disconnect plumbing and hoses, as necessary, to move armrest support structure (P/N 030A-91800) inboard to allow access of fasteners se curing inner panel and seat track
stiffeners to frame section.

NOTE

Use care when disconnecting tubing as there are
several smaller hoses that are hidden.

d. Remove and retain seat track support stiffeners between STA 4610 and STA 7450. e. Remove and retain right stiffener plate (P/N 030 A-32312-54) to gain access to the hardware securing the upper main landing gear attach fitting

. f. Remove right upper main landing gear fitting (P/ N 030A-32314-2).

NOTE
Record the number of washers installed and location of washers under the bolts and nuts and bag for re-installatio n.
g. Cut an access hole forward of STA 5605 between t he #4 longeron (P/N 030A-32310-49) and the #5 longeron (P/N 030A-32310-60) as shown in Figure 9.

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Page 16 of 38 h. Remove longerons between STA 5605 and STA 5890 i n the side frame area (P/N 030A-32310-76, 030A32310-74, 030A-32310-80, 030A-32 310-78, 030A-32310-53, 030A-32310-39). i. Drill rivets attaching the emergency exit strike r to the side-frame and cut sealant using care
to not bend the striker. j. On Exterior of aircraft, remove and retain skin fairing (P/N 030A-35201-10), plate (P/N 030A-35201-194) and plate (P/N 030A-35201-136). Re move rib (P/N 030A-35201-138), rib (P/N 030A-35201-126) and plate (P/N 030A-32306- 9), located under the top portion of fairing. k. Remove as necessary, aft door hinge and rivets o n skin panel (P/N 030A-35201-4) to gain access to fasteners on the internal longerons.

NOTE If STA 5605 RH frame has been repaired in accordanc e with Service Bulletin 209B, remove and scrap all reinforcing par ts. Fill all unused fastener holes drilled for the strap installation w ith AD rivets.

l. Remove and retain splice angles (Upper P/N 030A- 32335 and P/N 030A-32336, Lower P/N 030A-32337 and 030A-32338), attaching doublers (Upp er P/N 030A-32306-7and Lower P/N 030A-32306-5.), attaching hardware, and longerons f rom frame segment. m. Remove remaining rivets and fasteners holding fr ame section in place.
n. Remove frame section. o. Refer to Paragraph 6.3 “INSTALLATION OF REPLACEM ENT SIDE-FRAME SEGEMENT”
of this Service Bulletin for installation of the ne w frame segment.

6.3 INSTALLATION OF REPLACEMENT SIDE-FRAME SEGMENT (STA5605) a. Completely remove all flanges from the removed s ide-frame. This is to be used as a drilling template for duplicating the holes which a re common to the main landing gear fitting (Left P/N 030A-32314-1 and/or Right P/N 030A-32314- 2). b. Locate the new side-frame segment in place. c. Verify no gap condition between existing longero ns and new frame segment to match original location.

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Page 17 of 38 d. Verify alignment location of frame segment by ma king sure the contour edge outboard on the frame is smooth, install the splice angles and doublers and fill the gap between the existing splice angles and frame. Maximum allowabl e gap is 0.004 in (0.1 mm), if necessary fabricate shim to fill the gap. (Refer t o Figure 7) e. Symmetrical measurements should be obtained in a ccordance with Section 1 Paragraph 3.4 Symmetry and Alignment Inspection Procedure of the SRM and compare with dimensions
recorded in Table 7. f. Drill fastener holes and countersink holes, as n eeded. g. Remove frame, using the removed side-frame segme nt as a template, duplicate the MLG fitting attachment holes to new frame and deburr al l holes. h. For the frame which has been repaired in accorda nce with Service Bulletin 209B: 1) Fill all unused fastener holes drilled for reinf orcing straps with AD rivets of proper length. 2) Install splice angle and doubler using fasteners as shown in Figure 10. 3) For LH frame, fabricate a shim and install betwe en existing longeron fitting (PN 010A-31431-103) and new frame segment. (Refer to Figure 10) i. Apply faying surface & fillet sealant (PR-1422 o r equivalent) as needed and re-install
fasteners. j. Fabricate doubler(s) for the access hole(s) just forward of STA 5605 and install doubler(s) per Figure 8 and Figure 9. k. If that completes the required repairs proceed t o “Restoration” Paragraph 8.0.

7.0 REPLACEMENT OF LOWER-FRAME SEGMENT (CENTER SEGM ENT AT STA 4610 OR STA 5605)
NOTE The following instructions assume both lower-frame segments at STA 4610 and STA 5605 are to be replaced. If only one frame is to be replaced, modify

these instructions appropriately.

NOTE If replacement of the side-frame segment at the sam e STA is required due to cracks/damage, install lower-frame segment first to stabilize the fuselage

prior to removing the side-frame segment.

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Page 18 of 38 7.1 PREPARATIONS a. Open aircraft for cable removal. All cables tha t run through the fuselage center section will be removed aft of STA 4025 per Maintenance Manual i nstruction; this includes engine, spoiler, rudder, elevator, rudder trim, and elevato r trim. Remove lower fuselage panels as required for access. b. Secure flight and engine controls in neutral pos ition with streamer marked rig pins. c. Clamp cables on the aft side of STA 4025 before tension is removed from cables. This is to prevent unspooling of cables forward of this point and to assist in maintaining cable routing.
d. Label cables in relation to holes in frames. Al so to assist in restringing cables aft of STA 5605; wax string can be attached to the cables duri ng removal.
e. Remove cables from the center section of the fus elage aft of STA 4025. Carefully coil and stow cables to prevent them from getting damaged.
f. Remove doubler P/N 030A-32388 from the round acc ess hole between STA 5605 and STA 5890 on the belly of the aircraft. g. Mark skin for cutting line as shown in Figure 11 . Drill rivets out of skin between STA 5605
and STA 5890. With rivets removed cut skin on the mark made.

CAUTION When cutting, place a piece of stainless steel betw een skin

and keel to prevent cutting into the keel.

h. The center section of keel between STA 4610 and STA 5605 will be removed as an assembly with skin intact. Drill rivets attaching center keel section of skin to the forward
skin section. i. Drill to remove the angle brackets on the left a nd right sides of the keel that attach the keel to frame STA 4610. (This will allow center keel secti on to slide forward to clear landing gear bushing.) Remove any remaining attaching structure /hardware preventing keel removal.
Remove keel section.

NOTE If only the frame segment at STA 5605 is to be replaced proceed to Paragraph 7.3.

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Page 19 of 38 7.2 REMOVAL OF LOWER-FRAME SEGMENT STA 4610 a. Remove parts and attaching hardware from the low er portion of frame STA 4610. b. Cut sealant around lower portion of frame STA 46 10. c. Remove lower portion of frame STA 4610. Frame s egment is removed in an aft direction only.
NOTE

If only the frame segment at STA 4610 is to be replaced, proceed to paragraph 7.4.

7.3 REMOVAL OF LOWER-FRAME SEGMENT STA 5605 a. Remove parts and attaching hardware from the low er portion of frame STA 5605. b. Cut sealant around lower portion of frame STA 56 05. c. Remove lower portion of frame STA 5605. Frame s egment is removed in a forward direction only.

7.4 INSTALLATION OF LOWER-FRAME SEGMENT a. Clean area of all debris, previously drilled fas teners, and sealant. b. Locate the new lower frame in place. c. Verify alignment location of frame segment by ma king sure the contour edge outboard on the frame is smooth, install the splice angles/doub lers and fill the gap between the existing splice angles and frame. Maximum allowable gap is 0.004 in (0.1 mm), if necessary fabricate shim to fill the gap. (Refer to Figure 7 ) d. Symmetrical measurements should be obtained in a ccordance with Section 1 Paragraph 3.4 Symmetry and Alignment Inspection Procedure of the SRM and compare with dimensions
recorded in Table 7. e. Drill fastener holes and countersink holes, as n eeded, and deburr all holes. f. Apply faying surface & fillet sealant (PR-1422 o r equivalent) as needed and install fasteners. g. Install other frame segment at this time by repe ating steps a through f or reinstall center keel section if other frame segment is not to be replace d.
h. Reinstall doubler P/N 030A-32388 and restore the skin in accordance with Figure 11. i. If that completes the required repairs proceed t o Paragraph 8.0, “Restoration.”

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Page 20 of 38 8.0 RESTORATION

a. Restore cables, set cable tensions, and check de flections per applicable Maintenance
Manuals. b. Verify all rig pins are removed upon completion. c. Reverse the process used in previous sections to restore the airplane to an airworthy
condition. 1. Restore parts removed from gear well in reverse sequence. 2. If the floorboard was removed, install floorboar ds, resealing the floorboards at the outer edges only to assure a positive pressure seal. Sea lant is not needed in the center part of the floorboard. 3. Once sealant is dry, comply with pressurization leakage check per the applicable
Maintenance Manuals. 4. Reinstall insulation and acoustic package, as re quired. 5. Reinstall seats, galley (if equipped), carpet an d side panels as necessary. d. Complete landing gear retraction test, after gea r installation, in accordance with the applicable Maintenance Manuals. e. Symmetrical measurements should be obtained in a ccordance with Section 1 Paragraph 3.4 Symmetry and Alignment Inspection Procedure of the SRM and compare with dimensions
recorded in Table 7. f. Continue with Paragraph 9 and 10 to return the a ircraft to service. g. Comply with satisfactory functional check flight before final approval for return to service.

9.0 LOGBOOK ENTRY
Upon completion of this service bulletin, complete FAA form 337 if applicable, and make an appropriate maintenance entry in the logbook simila r to “Service Bulletin No. 242 complied with on (date) by (name).” Be specific in noting which frame and section was repaired or replaced, if applicable. For continued airworthiness, Maintenance Requiremen t Manual (MRM) will be revised. The revised MRM will require a recurring inspection aft er complying with this Service Bulletin, regardless of the repair method and regardless of w hether cracks were found.

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Page 21 of 38 10.0 COMPLETION
Complete the enclosed compliance card and mail back to Mitsubishi Heavy Industries America, Inc. in care of Turbine Aircraft Services, Inc.

Mitsubishi Heavy Industries America, Inc. c/o Turbine Aircraft Services, Inc. 4550 Jimmy Doolittle Drive Addison, Texas 75001 Attention: Manager, Publication Phone: (972) 248-3108 X 209 Fax: (972) 248-3321

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Page 22 of 38 11.0 PARTS AND MATERIAL REQUIRED & SYMMETRICAL MEAS UREMENTS
The following parts and material may be required t o comply with this Service Bulletin. The following Tables do not include any fasteners which may be removed and reinstalled during repair and replacement per this Service Bulletin.

Table 1: REPAIR – LOWER FRAME SEGMENT-END REPLACEM ENT (STA. 4610) The repair kits are available via MU-2 Service Ce nters. Kit contains installation drawing and following hardware except for rivets and consumable material.

PART NUMBER DESCRIPTION QTY/SHIP REMARKS LH RH Kit number 035A-900019-101 : to repair LH frame se gment-end Kit number 035A-900019-102 : to repair RH frame se gment-end 016A-99443-101 Template 1 016A-99443-102 Template 1 035A-32115-101 Segment Frame 1 035A-32115-102 Segment Frame 1 035A-32342-113 Shim-Laminated 1 1 035A-32342-115 Shim-Laminated 1 1 035A-32342-117 Shim-Laminated 4 4 035A-32342-119 Filler 2 2 035A-32342-123 Shim 1 1 035A-32343-105 Angle 1 035A-32343-106 Angle 1 035A-32344-103 Bracket 1 035A-32344-105 Bracket 1 035A-32371-103 Fitting 1 035A-32371-104 Fitting 1 AN3-6A Bolt 4 AN960D10 Washer 8 8 EA9309, 3NA or equivalent Adhesive AR AR not conta ined in the kit HL10VAP6-4 Hi-Lok Pin 4 4 HL10VAP6-5 Hi-Lok Pin 18 19 HL11VAP6-4 Hi-Lok Pin 1 1 HL111VAP6-4 Hi-Lok Pin 1 HL111VAP6-5 Hi-Lok Pin 1 1 HL111VAP6-6 Hi-Lok Pin 1 HL70-6 Collar 23 24 HL79-6 Collar 2 2 MS21059L3 Plate Nut 2 2 MS20426AD3-4 Rivet 4 4 not contained in the kit

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Page 23 of 38 Table 1 (Continued)
PART NUMBER DESCRIPTION QTY/SHIP REMARKS LH RH MS20426AD3-5 Rivet 4 4 MS20426AD5-6 Rivet 2 2 not contained in the kit MS20470AD5-9 Rivet 1 1 not contained in the kit NAS1103-6 Bolt 8 11 NAS1104-12 Bolt 2 2 NAS1149D0463H Washer 24 24 NAS1169DD10 Washer 2 2 NAS463X-DD10 Nut Spacer 3 3 NAS517-3-11 Screw 2 2 NAS6204-4 Bolt 8 8 NAS6204-6 Bolt 12 12 NAS6204-7 Bolt 4 4 NAS679A3W Nut 8 8 NAS679A4W Nut 24 24 AMS-S-8802 Type II , Class B or equivalent Sealing Compound (PR-1422) AR AR not contained in the kit MIL-C-5541, Class 1A or equivalent Chemical Film (Alodine #1200) AR AR not contained in the kit TT-P-1757 or equivalent Primer AR AR not contained in the kit

Table 2: REPAIR – LOWER FRAME SEGMENT-END REPLACEM ENT (STA.5605) The repair kits are available via MU-2 Service Ce nters. Kit contains installation drawing and following hardware except for rivets and consumable material.

PART NUMBER DESCRIPTION QTY/SHIP REMARKS LH RH Kit number 035A-900019-201: to repair LH frame seg ment-end Kit number 035A-900019-202: to repair RH frame seg ment-end 016A-99443-201 Template 1 016A-99443-202 Template 1 035A-32334-101 Segment Frame 1 035A-32334-102 Segment Frame 1 035A-32342-103 Shim-Laminated 1 1 035A-32342-105 Shim-Laminated 1 1 035A-32342-107 Shim-Laminated 1 035A-32342-109 Shim-Laminated 4 4 035A-32342-125 Shim 1 1 035A-32343-103 Angle 1 035A-32343-104 Angle 1 035A-32373-103 Fitting 1 035A-32373-104 Fitting 1

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Page 24 of 38 Table 2 (Continued)
PART NUMBER DESCRIPTION QTY/SHIP REMARKS LH RH 412AS-2 Bracket 1 AN3-8A Bolt 2 AN960D10 Washer 3 3 EA9309, 3NA or equivalent Adhesive AR AR Not contai ned in the kit HL10VAP6-4 Hi-Lok Pin 3 3 HL10VAP6-5 Hi-Lok Pin 4 4 HL10VAP6-6 Hi-Lok Pin 7 11 HL10VAP6-7 Hi-Lok Pin 8 8 HL10VAP6-8 Hi-Lok Pin 1 1 HL11VAP6-4 Hi-Lok Pin 1 1 HL11VAP6-6 Hi-Lok Pin 8 6 HL111VAP6-6 Hi-Lok Pin 1 1 HL70-6 Collar 32 34 HL79-6 Collar 1 1 MS20004-12 Bolt 1 1 MS20426AD3-5 Rivet 2 2 not contained in the kit MS20426AD3-6 Rivet 4 4 not contained in the kit MS20426AD5-5 Rivet 6 6 not contained in the kit MS20470AD4-9 Rivet 2 not contained in the kit MS20470AD5-5 Rivet 6 6 not contained in the kit MS21061L3 Plate Nut 1 1 MS21075L3 Plate Nut 1 1 MS21250-05014 Bolt 1 1 MS35206-231 Screw 4 NAS1103-17 Bolt 2 2 NAS1103-9 Bolt 4 4 NAS1149D0463H Washer 14 14 NAS1169DD10 Washer 2 2 NAS1195DD3XH Nut Spacer 2 2 NAS1203-17 Bolt 2 2 NAS1203-8 Bolt 2 NAS463Y-DD10 Nut Spacer 1 1 NAS517-3-12 Screw 2 2 NAS6204-12 Bolt 8 8 NAS6204-7 Bolt 6 6 NAS679A3W Nut 3 3 NAS679A4W Nut 14 14 AMS-S-8802 Type II , Class B or equivalent Sealing Compound (PR-1422) AR AR not contained in kit MIL-C-5541, Class 1A or equivalent Chemical Film (Alodine #1200) AR AR not contained in kit TT-P-1757 or equivalent Primer AR AR not contained in kit

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Page 25 of 38 Table 3: REPLACEMENT- SIDE FRAME SEGMENT (STA. 461 0) Contact MHIA engineering for details.

PART NUMBER DESCRIPTION QTY/SHIP REMARKS LH RH 030A-32114-3 Frame Segment 1 Procure from MHIA 030A-32114-4 Frame Segment 1 Procure from MHIA

Table 4: REPLACEMENT- SIDE FRAME SEGMENT (STA. 560 5)

PART NUMBER DESCRIPTION QTY/SHIP REMARKS LH RH 030A-32333-5 Frame Segment 1 Procure from MHIA 030A-32333-6 Frame Segment 1 Procure from MHIA HL62PB-8-9 Hi-Lock Pin 6 6 HL79-8 Collar 6 6 MS20426AD5 Rivet 6 For CSK Washer MS20470AD10-11 Rivet 2 2 Plug for Unused Holes MS20470AD6-9 or MS20470AD8-10 Rivet 6 MS20470AD8-9 Rivet 6 6 Plug for Unused Holes NAS1149D0563H Washer 12 12 NAS1155-10 Screw 3 3 NAS1155-8 Screw 3 3 NAS1738B5-2 Rivet 18 NAS1739B5-2 Rivet 36 NAS679A5 Nut 6 6 SB242-3 Doubler 2 Fabricate Locally SB242-5 Doubler 1 Fabricate Locally SB242-7 Shim 1 Fabricate Locally 2024-T3C Sheet or AMS6387 Type1 Shim AR AR Fabricate Locally, Adjust Thickness to Fill Gap AMS-S-8802 Type II , Class B or equivalent Sealing Compound (PR-1422) AR AR
MIL-C-5541 Class 1A or equivalent Chemical Film (Alodine #1200) AR AR TT-P-1757 or equivalent Primer AR AR

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Page 26 of 38 Table 5: REPLACEMENT- LOWER FRAME SEGMENT (STA. 46 10)

PART NUMBER DESCRIPTION QTY/SHIP REMARKS 030A-32115-3 Frame Segment 1 Procure from MHIA MS20426AD4 Rivet 16 For CSK washer MS20426AD4-4 Rivet 10 MS20426AD4-5 Rivet 22 MS20426AD4-6 Rivet 8 SB242-9 Splice 1 Fabricate Locally SB242-10 Splice 1 Fabricate Locally SB242-11 Taper Shim 2 Fabricate Locally SB242-13 Shim 2 Fabricate Locally 2024-T3C Sheet or AMS6387 Type 1 Shim AR Fabricate Locally, Adjust Thickness to Fill Gap AMS-S-8802 Type II , Class B or equivalent Sealing Compound (PR-1422) AR
MIL-C-5541 Class 1A or equivalent Chemical Film (Alodine #1200) AR TT-P-1757 or equivalent Primer AR

Table 6: REPLACEMENT- LOWER FRAME SEGMENT (STA.560 5)

PART NUMBER DESCRIPTION QTY/SHIP REMARKS 030A-32334-3 Frame Segment 1 Procure from MHIA MS20426AD4 Rivet 16 For CSK washer MS20426AD4-4 Rivet 10 MS20426AD4-5 Rivet 22 MS20426AD4-6 Rivet 8 SB242-9 Splice 1 Fabricate Locally SB242-10 Splice 1 Fabricate Locally SB242-11 Taper Shim 2 Fabricate Locally SB242-13 Shim 2 Fabricate Locally 2024-T3C Sheet or AMS6387 Type 1 Shim AR Fabricate Locally, Adjust Thickness to Fill Gap AMS-S-8802 Typw II , Class B or equivalent Sealing Compound (PR-1422) AR MIL-C-5541, Class 1A or equivalent Chemical Film (Alodine #1200) AR TT-P-1757 or equivalent Primer AR

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Page 27 of 38 TABLE 7: SYMMETRICAL MEASUREMENTS
FORMULA ALLOWABLE

VALUE OBTAINED

VALUE CHARACTERISTIC TO BE CHECKED 9-11, 10-12 0 +/-0.12 Wing Incidence 13-15, 14-16 -0.55 +/-0.12 Wash Out of Wing Tip (13-15)-(14-16) 0 +/-0.12 Twist of Wing Tip 13-9, 14-10 1.89 +/-0.59 Wing Dihedral 9-17, 10-18 18.35 +/-0.59 Relation of Horizontal S tab. To Wing 23-21, 24-22 0.31 +/-0.12 Horizontal Stab. Inciden ce (23-21)-(24-22) 0 +/-0.12 Twist of H. Stab. Tip 1-13, 2-14 222.24 +/-0.59 Wing Yaw 7-13, 7-14 307.36 +/-0.79 Wing Yaw 19-25, 20-26 82.48 +/-0.39 Relative Position for E mp. 5-17, 6-18 95.45 +/-0.39 H. Stab. Yaw (Refer to Structural repair manual for instructions and formula reference)

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Page 28 of 38 12.0 FIGURES

Figure 1: LOCATION OF FRAME INSPECTION FOR STA 4610

1. Complete a detailed visual inspection on the ent ire frame flanges for hairline cracks between rivets.

2. NDT inspect if detailed visual inspection is inc onclusive

3. Visually inspect entire frame and surrounding ar ea for corrosion. Repair IAW Structural Repair Manual



### Most Likely location of cracks

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Page 29 of 38 Figure 2: LOCATION OF FRAME INSPECTION FOR STA 5605

1. Complete a detailed visual inspection on the ent ire frame flange for hairline cracks between rivets.
2. NDT inspect if detailed visual inspection is inconclusive
3. Visually inspect entire frame and surrounding ar ea for corrosion. Repair IAW MHI Structural Repair Manual
4. Pay particular attention to landing gear support segment for cracking in the flanges.



### Most Likely location of cracksMU -2Service BulletinNo.242DATE: July 10, 2013Page 30 of 38Figure 3: LOWER FRAME END SEGMENT REPLACING REPAIR- INSTALLATION & CUT OFF DIMENSION FOR STA4610 (L/H)This figure is for reference only.See Install drawing 035A-32107 for ACTUAL REPAIR.MU -2Service BulletinNo.242DATE: July 10, 2013Page 31 of 38Figure 4: LOWER FRAME END SEGMENT REPLACING REPAIR- INSTALLATION & CUT OFF DIMENSION FOR STA4610 (R/H)This figure is for reference only.See Install drawing 035A-32107 for ACTUAL REPAIR.MU -2Service BulletinNo.242DATE: July 10, 2013Page 32 of 38Figure 5: LOWER FRAME END SEGMENT REPLACING REPAIR- INSTALLATION & CUT OFF DIMENSION FOR STA5605 (L/H)This figure is for reference only.See Install drawing 035A-32306 for ACTUAL REPAIR.MU -2Service BulletinNo.242DATE: July 10, 2013Page 33 of 38Figure 6: LOWER FRAME END SEGMENT REPLACING REPAIR- INSTALLATION & CUT OFF DIMENSION FOR STA5605 (R/H)This figure is for reference only.See Install drawing 035A-32306 for ACTUAL REPAIR.

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Page 34 of 38 Figure 7: SHIMMING

THE MAXIMUM GAP AFTER SHIMMING SHOULD BE LESS THAN 0.004 IN. (0.1 MM) PRIOR TO FASTENER INSTALLATION IN ANY PLACE.

SPLICE ANGLE

NOTE : FABRICATION OF SHIM

(CASE 1) MATERIAL: 2024-T3C AL SHEET (QQ-A-250/5)

ADJUST THICKNESS TO FILL THE GAP BETWEEN FRA ME AND SPLICE ANGLE FINISH: CHEM. FILM PER ALODINE #1200 (MIL-C-5541, CLASS 1A) AND PRIME WITH ONE COAT OF ZINC-CHROMATE PRIMER (TT-P-1757)

OR
(CASE 2) MATERIAL: 1100-H19 (MIL-S-22499, COMPOSITI ON 1, TYPE 1, CLASS 1)

ADJUST THICKNESS TO FILL THE GAP BETWEEN FRAME AND SPLICE ANGLE FINISH: AFTER DELAMINATION, CH EM. FILM PER #1200 (MIL-C-5541, CLASS 1A) AND PRIME WITH ONE COAT OF ZINC-CHROMATE PRIMER (TT-P-1757)

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Page 35 of 38 NOTE : 1. FABRICATION OF DOUBLER (SB242-3) MATERIAL: 2024-T3 CLAD AL SHEET (QQ-A-2 50/5), .063”T x 90 x100 FINISH: CHEM. FILM PER ALODI NE #1200 (MIL-C-5541, CLASS 1A) AND PRIME WITH ONE COAT OF ZINC-CHROMATE PRIMER (TT -P-1757)

2. WET INSTALL RIVETS WITH ZINC-CHR OMATE PRIMER

3. FILLET SEAL (PR-1422) AROUND THE DOUBLERS CUT OUT INNER SKIN (TYP) SB242

- 3 (2 REQ) (DOUBLER)40 50 030A

- 91801 (REF) (FRAME ASSY )

030A

- 32312

- 13 (REF) (FRAME)50 404EQULSPACE (TYP)90(TYP)

10 10 (TYP) 30 60 31 (TYP) (TYP) (REF) STA 5605 UP

FWD

030A

- 32312 (REF) INNER SKIN

#5 LONGERON REF PLANE

(WP

- 215)

030A

- 32312

- 59 (REF) (#5 LONGERON)

NAS1739B5

- 2 (36 REQ) COUNTERSINK on DOUBLER WINDOW LOWER LONGERON REF PLANE ( WP 50 )

VIEW LOOKING OUTBOARD

R10 (TYP)

5 EQUAL SPACE (TYP) 030A

- 32306 (REF) (FRAME ASSY)

10010 10(TYP)

Figure 8: ACCESS HOLES ON INNER SKIN (LH SIDE) 030A

- 32310 (REF) LONGERON

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Page 36 of 38

#4 LONGERON REF PLANE

(WP

- 115)

#5 LONGERON REF PLANE

(WP

- 215)

NAS1738B5

- 2 (18 REQ) 030A

- 32312 (REF) (INNER SKIN)

100 SB242

- 5 (1 REQ) (DOUBLER) 10 10 (TYP) R10

(TYP) 34 60 20 (REF) STA 5605

EDGE OF INNER SKIN10 10(TYP)5595394 EQUALSPACE (TYP) C UT OUT INNER SKIN

VIEW LOOKING OUTBOARD

Figure 9: ACCESS HOLE ON INNER SKIN (RH SIDE) UP

FWD

030A

- 32310

- 49 (REF) (LONGERON)

030A

- 32310

- 60 (REF) (LONGERON)

NOTE : 1. FABRICATION OF DOUBLER (SB242-5) MATERIAL: 2024-T3 CLAD AL SHEET (QQ-A-2 50/5), .063”T x 95 x100 FINISH: CHEM. FILM PER ALODI NE #1200 (MIL-C-5541, CLASS 1A) AND PRIME WITH ONE COAT OF ZINC-CHROMATE PRIMER (TT -P-1757)

2. WET INSTALL RIVETS WITH ZINC-CHR OMATE PRIMER 3. FILLET SEAL (PR-1422) AROUND THE DOUBLERS 5 EQUAL SPACE (TYP)

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Page 37 of 38 VIEW LOOKING OUTBOARD (LH SIDE) STA 5605

VIEW LOOKING OUTBOARD (RH SIDE)

F igure 10 : INSTALLATION OF REPLACEMENT FASTENERS AFTER REMOVAL OF REPAIR STRAP 030A

- 32306

- 7 (DOUBLER) (REF) NAS1155

- 8 (3 REQ) NAS1149D0563H (6 REQ) NAS679A5 (3 REQ)

NAS1155

- 10 (3 REQ) NAS1149D0563H (6 REQ) NAS679A5 (3 REQ) HL62PB

- 8

- 9 (6REQ) HL79

- 8 (6 REQ) 010A

- 31431

- 103 (REF) (FITTING) SB242

- 7 (1 REQ) (SHIM) .20” THICK MAKE FROM REMOVED REPAIR STRAP 030A

- 32306

- 7 (REF) (DOUBLER)

NAS1155

- 8 (3 REQ) NAS1149D0563H (6 REQ) NAS679A5 (3 REQ)

HL62PB

- 8

- 9 (6REQ) HL79-8 (6 REQ)

NAS1155

- 10 (3 REQ) NAS1149D0563H (6 REQ) NAS679A5 (3 REQ)

NOTE: UNLESS OTHERWISE NOTED USE EXISTING FASTENERS SELECT PROPER RIVET TYPE (BELOW) FOR RIVET HOLES IN THE INNER SKIN; MS20470AD6-9 (6 REQ) OR MS20470AD8-10 (6 REQ)
APPLY CSK WASHER AT DIMPLE HOLES. CSK WASHER MAY BE MAKE FROM MS20426AD5 RIVET HEAD 030A

- 32335 (REF) (SPLICE ANGLE)

030A

- 32336 (REF) (SPLICE ANGLE)

030A

- 32312

- 3 (REF) (INNER SKIN)

FWD 030A

- 32336 (REF) (SPLICE ANGLE) 030A

- 32335 (REF) (SPLICE ANGLE) STA 5605 FWD 030A

- 32113

- 7 (REF) (UPPER FRAME)

030A

- 32333

- 5 (REF) (SIDE FRAME)

030A

- 32113

- 7 (REF) (UPPER FRAME)

030A

- 32333

- 6 (REF) (SIDE FRAME)

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Page 38 of 38 “ SKIN CUT LINE ” TOUCH UP: (12F01)

NAS686A08 (NUT PLATE) (REF) AFT BULGE SKIN

8 (MIN ) 8 (MIN) 10 (TYP)

KEEL ASSY

MID BULGE SKIN

SB242

- 11 (2 REQ) 1 (TAPER SHIM) 2024-T3 CLAD SHT .040” x 18 x 45, (12F01)

SB242

- 9 (1 REQ) (SPLICE) 2024-T3 CLAD SHT .040”, (12F01)

030A

- 32388 (DOUBLER) REINSTALL SB242

- 13 1 (SHIM) 2024-T3 CLAD SHT .040” x 18 x 18, (12F01)

SKIN

F igure 11: RESTORATION OF CUT SKIN

- BELLY OF FUSELAGE MS20426 AD4 (EXISTING) (INSTALL WITH BULGEE SKIN)

(SEE SECT A

- A ) MS20426 AD4 (ADD) CSK ON SPLICE MS20426 AD4 (EXISTING) CSK ON SPLICE CSK WASHER (ADD) (SEE SECT B

- B ) 1 : INS ERT SHIM BETWEEN SKIN AND BULGE SKIN (12F01): ALODINE #1200 AND ZINC CHROMATE PRIMER NOTE :

MS20426AD4 (RIVET) CSK WASHER MAKE FROM MS20426AD4 RIVET HEAD SKIN SPLICE 20R

SECT A

- A SECT B

- B SB242

- 10 (1 REQ) (SPLICE) 2024-T3 CLAD SHT . .040”, (12F01)

TAPER SHIM B

B A

A

MID BULGE SKIN

SKIN KEEL ASSY

INBD UP STA 5605 STA 5830 STA

5890 8 (MIN)