Learjet 40 Series Structural Repair Manual

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LEARJET 40 SERIESSTRUCTURAL REPAIR MANUALCHAPTERFUSELAGESRM-104

LEARJET 40 SERIESSTRUCTURAL REPAIR MANUALRecord of Temporary iveJun 16/0053-10-15Pg. ersInitialsJun 16/00LJNov 07/03LJ53-RTRSRM-104Pa9e1Nov 07/03

LEARJET 40 SERIESSTRUCTURAL REPAIR MANUALChapterSectionSubject53-Title53-RTR*53-List of Eff.*53-List of Eff.*53-List of Eff.*53-List of 1022011234DateNov 07/03Mar 14/05Mar 14/05Mar 14/05Mar 14/05Mar 14/05Mar 14/05Mar 14/05Mar 14/05Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 01102201123DateNov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/0353-LOEPPa8e1Mar 14/05

LEARJET 40 SERIESSTRUCTURAL REPAIR 022011234567101102201DateNov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 2324DateNov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/0353 - LOEPPa9e2Mar 14/05

LEARJET 40 SERIESSTRUCTURAL REPAIR 110220112345101102201123DateNov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 26272829303132333435DateNov 07/03Nov 07/03Nov 07/03Mar 14/05Mar 14/05Mar 14/05Mar 14/05Mar 14/05Mar 14/05Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/0353 - LOEPPa9e3Mar 14/05

LEARJET 40 SERIESSTRUCTURAL REPAIR jectPageDateNov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/03Nov 07/0353-LOEPPa9e4Mar 14/05

LEARJET 40 SERIESSTRUCTURAL REPAIR MANUALChapterSectionSubjectPageFUSELAGE - STRUCTURAL IDENTIFICATIONDescription53-00-001FORWARD FUSELAGE ASSEMBLY - STRUCTURAL IDENTIFICATIONDescription53-10-001NOSE FUSELAGE STRUCTURE - STRUCTURAL IDENTIFICATIONDescription53-10-011NOSE FUSELAGE STRUCTURE - ALLOWABLE DAMAGEAllowable Damage Limits53-10-01101NOSE FUSELAGE STRUCTURE - REPAIRRepairs53-10-01201NOSE EXTENSION STRUCTURE - STRUCTURAL IDENTIFICATIONDescription53-10-021NOSE EXTENSION STRUCTURE - ALLOWABLE DAMAGEAllowable Damage Limits53-10-02101NOSE EXTENSION STRUCTURE - REPAIRRepairs53-10-02201FLIGHT DECK STRUCTURE - STRUCTURAL IDENTIFICATIONDescription53-10-031FLIGHT DECK STRUCTURE - ALLOWABLE DAMAGEAllowable Damage Limits53-10-03101FLIGHT DECK STRUCTURE - REPAIRRepairs53-10-03201FORWARD FUSELAGE FRAMES - STRUCTURAL IDENTIFICATIONDescription53-10-051FORWARD FUSELAGE FRAMES - ALLOWABLE DAMAGEAllowable Damage Limits53-10-05101FORWARD FUSELAGE FRAMES - REPAIRRepairs53-10-05201FORWARD FUSELAGE STRINGERS - STRUCTURAL IDENTIFICATIONDescription53-10-101FORWARD FUSELAGE STRINGERS - ALLOWABLE DAMAGEAllowable Damage Limits53-10-10101FORWARD FUSELAGE STRINGERS - agelMar14/05

LEARJET 40 SERIESSTRUCTURAL REPAIR MANUALChapterSectionSubjectPageFORWARD FUSELAGE SKINS - STRUCTURAL IDENTIFICATIONDescription53-10-151FORWARD FUSELAGE SKINS - ALLOWABLE DAMAGEAllowable Damage Limits53-10-15101FORWARD FUSELAGE SKINS - REPAIRRepairs53-10-15201CENTER FUSELAGE ASSEMBLY - STRUCTURAL IDENTIFICATIONDescription53-20-001CENTER FUSELAGE ASSEMBLY - ALLOWABLE DAMAGEAllowable Damage Limits53-20-00101CENTER FUSELAGE ASSEMBLY - REPAIRRepairs53-20-00201CENTER FUSELAGE FRAMES - STRUCTURAL IDENTIFICATIONDescription53-20-101CENTER FUSELAGE FRAMES - ALLOWABLE DAMAGEAllowable Damage Limits53-20-10101CENTER FUSELAGE FRAMES - REPAIRRepairs53-20-10201CENTER FUSELAGE STRINGERS - STRUCTURAL IDENTIFICATIONDescription53-20-201CENTER FUSELAGE STRINGERS - ALLOWABLE DAMAGEAllowable Damage Limits53-20-20101CENTER FUSELAGE STRINGERS - REPAIRRepairs53-20-20201CENTER FUSELAGE SKINS - STRUCTURAL IDENTIFICATIONDescription53-20-401CENTER FUSELAGE SKINS - ALLOWABLE DAMAGEAllowable Damage Limits.:53-20-40101CENTER FUSELAGE SKINS - REPAIRRepairs53-20-40201FUSELAGE FUEL CELL ASSEMBLY - STRUCTURAL IDENTIFICATIONDescription53-30-001FUSELAGE FUEL CELL ASSEMBLY - ALLOWABLE DAMAGEAllowable Damage r14/05

LEARJET 40 SERIESSTRUCTURAL REPAIR MANUALChapterSectionSubjectPageFUSELAGE FUEL CELL ASSEMBLY - REPAIRRepairs53-30-00201FUSELAGE FUEL CELL FRAME - STRUCTURAL IDENTIFICATIONDescription53-30-101FUSELAGE FUEL CELL FRAMES - ALLOWABLE DAMAGEAllowable Damage Limits53-30-10101FUSELAGE FUEL CELL FRAMES - REPAIRRepairs53-30-10201FUSELAGE FUEL CELL STRINGERS - STRUCTURAL IDENTIFICATIONDescription53-30-201FUSELAGE FUEL CELL STRINGERS - REPAIRAllowable Damage Limits53-30-20101FUSELAGE FUEL CELL STRINGERS - REPAIRRepairs53-30-20201FUSELAGE FUEL CELL SKINS - STRUCTURAL IDENTIFICATIONDescription53-30-401FUSELAGE FUEL CELL SKINS - ALLOWABLE DAMAGEAllowable Damage Limits53-30-40101FUSELAGE FUEL CELL SKINS - REPAIRRepairs53-30-40201DELTA FIN ASSEMBLY - STRUCTURAL IDENTIFICATIONDescription53-34-101DELTA FIN ASSEMBLY - ALLOWABLE DAMAGEAllowable Damage Limits53-34-10101DELTA FIN ASSEMBLY - REPAIRRepairs53-34-10201AFT FUSELAGE ASSEMBLY - STRUCTURAL IDENTIFICATIONDescription53-40-001AFT FUSELAGE ASSEMBLY - ALLOWABLE DAMAGEAllowable Damage Limits53-40-00101AFT FUSELAGE ASSEMBLY - a9e3Mar14/05

LEARJET 40 SERIESSTRUCTURAL REPAIR MANUALChapterSectionSubjectPageAFT FUSELAGE FRAMES - STRUCTURAL IDENTIFICATIONDescription53-40-101AFT FUSELAGE FRAMES - ALLOWABLE DAMAGEAllowable Damage Limits53-40-10101AFT FUSELAGE FRAMES - REPAIRRepairs53-40-10201AFT FUSELAGE STRINGERS - STRUCTURAL IDENTIFICATIONDescription53-40-201AFT FUSELAGE STRINGERS - ALLOWABLE DAMAGEAllowable Damage Limits53-40-20101AFT FUSELAGE STRINGERS - REPAIRRepairs53-40-20201AFT FUSELAGE SKINS - STRUCTURAL IDENTIFICATIONDescription53-40-401AFT FUSELAGE SKINS - ALLOWABLE DAMAGEAllowable Damage Limits53-40-40101AFT FUSELAGE SKINS - a9e4Mar14/05

LEARJET 40 SERIESSTRUCTURAL REPAIR MANUALFUSELAGE - STRUCTURAL IDENTIFICATION1.DescriptionNOTE:The following structural data covers the basic non-modified aircraft. When applicable, refer tothe appropriate Service Bulletin for additions, modifications and changes to the structural components and assemblies.A. The fuselage is of a semimonocoque construction consisting of a stressed skin structure with transverse frames and longerons. The skins are of clad aluminum. All surfaces in the structural shell fromthe forward pressure bulkhead to the aft pressure bulkhead are assembled with a faying surface seal,to minimize fretting and electrolytic corrosion, as well as to prevent leakage. All access panels, doorsand cutouts are reinforced as required to carry the loads and compensate for any stress concentrationfactors.B. The fuselage has four major zones. (See Figure 1.)(1 ) Forward Fuselage Assembly (53-10-00)(a) On aircraft 45-001 and subsequent The forward fuselage assembly extends from just behindthe radome to FS 219. This area contains the forward avionics bay, oxygen bottle, and cockpitarea. The radome attaches just forward of the avionics bay.(b) On aircraft 45-2001 and subsequent: The forward fuselage assembly extends from just behindthe radome to FS 244. This area contains the forward avionics bay, oxygen bottle, and cockpitarea. The radome attaches just forward of the avionics bay.(2) Center Fuselage Assembly (53-20-00)(a) On aircraft 45-001 and subsequent The center fuselage assembly extends from FS 219 to FS451. This area contains the passenger areas and extends to the aft pressure bulkhead.(b) On aircraft 45-2001 and subsequent The center fuselage assembly extends from FS244 toFS 451. This area contains the passenger areas and extends to the aft pressure bulkhead.(3) Fuselage Fuel Cell Assembly (53-30-00)(a) The fuselage fuel cell assembly extends from FS 451 to FS 504. This area contains the bladders for the fuselage fuel tanks.(4) Aft Fuselage Assembly (53-40-00)(a) The aft fuselage assembly extends from FS 504 to FS 614. This area contains the aft baggage, aft electronics, avionics bay, hydraulic equipment/plumbing, and pneumatic/air condition ing/APU bays.53-00-00SRM-104NOV 0 7 / 0 3

LEARJET 40 SERIESSTRUCTURAL REPAIR MANUALFUSELAGEFUEL BLYAFT PRESSUREBULKHEADFS 458 (REF)FORWARDFUSELAGE-ASSEMBLYFWD PRESSURE BULKHEADFS 150 (REF) LEARJET 45FS 174 (REF) LEARJET 40S45-530000-001-01Fuselage LocatorFigure 1EFFECTIVITY: ALLSRM-10453-00-00Page2Nov 07/03

LEARJET 40 SERIESSTRUCTURAL REPAIR MANUALFORWARD FUSELAGE ASSEMBLY - STRUCTURAL IDENTIFICATION1.Description (See Figure 1.)A. On aircraft 45-001 and subsequent The forward fuselage consists of the structure assembly from FS99 to FS 219. The structure consist of sixteen major bulkhead/frame assemblies (including the forwardpressure bulkhead at FS 149), stringers, skins and minor structural sub assemblies. They are brokendown into major subsections of: upper and lower nose extension panel assemblies, lower flight deckpanel assembly, and flight deck canopy assembly.B. On aircraft 45-2001 and subsequent: The forward fuselage consist of the structure assembly from FS124 to FS 244. The structure consist of sixteen major bulkhead/frame assemblies (including the forward pressure bulkhead at FS 174), stringers, skins and minor structural sub assemblies. They arebroken down into major subsections of: upper and lower nose extension panel assemblies, lower flightdeck panel assembly, and flight deck canopy assembly.C. The forward fuselage assembly provides mounting provisions for various avionics and radio equipment, various aircraft systems, and storage for the nose landing gear when retracted. The avionicsaccess doors are incorporated to provide an aerodynamic configuration and protection of the equipment installed within the forward fuselage assembly. Two nose landing gear doors complete the aerodynamic configuration on the lower side of the forward fuselage and also provide protection for thenose gear. (Refer to Chapter 52 for additional information pertaining to the forward avionics doors andthe nose landing doors.)D. The forward fuselage assembly is made up of three primary sections: the Nose Fuselage Structure(53-10-01), Nose Extension Structure (53-10-02), and Flight Deck Structure (53-10-03).EFFECTIVITY:SRM-104ALLro AAA53-10-00,nPage1NOV 0 7 / 0 3

LEARJET 40 SERIESSTRUCTURAL REPAIR MANUALFUSELAGE FUELCELL ASSEMBLYFLIGHT DECKASSEMBLYNOSE FUSELAGESTRUCTURENOSE EXTENSIONSTRUCTURENLG WHEEL BOXASSEMBLY (REF)Detail AS45-531000-001 -01Forward Fuselage Assembly LocatorFigure 1EFFECTIVITY:SRM-104ALL53-10-00Page2Nov 07/03

LEARJET 40 SERIESSTRUCTURAL REPAIR MANUALNOSE FUSELAGE STRUCTURE1. Nose Fuselage Structure Repair Index (See Figure 1 and Table 1.)EFFECTIVITY:SRM-104ALLi-r\A f\f\ A53-10-01o*Page1NOV 0 7 / 0 3

LEARJET 40 SERIESSTRUCTURAL REPAIR MANUALB42391567163102Detail AS45-531001-001-01Nose Fuselage Structure Repair IndexFigure 1 (Sheet 1 of 3)EFFECTIVITY: ALLSRM-10453-10-01Page2Nov 07/03

LEARJET 40 SERIESSTRUCTURAL REPAIR MANUAL1221242451512121105105(VIEW LOOKING FORWARD)Detail BS45-531001-001-02Nose Fuselage Structure Repair IndexFigure 1 (Sheet 2 of 3)EFFECTIVITY: ALLSRM-10453-10-01Pa9e3Nov 07/03

LEARJET 40 SERIESSTRUCTURAL REPAIR MANUALFS 149.50 (LEARJET 45)FS 174.01 (LEARJET 40)S45-531001-001-03Nose Fuselage Structure Repair IndexFigure 1 (Sheet 3 of 3)EFFECTIVITY: ALLSRM-10453-10-01Page4Nov 07/03

LEARJET 40 SERIESSTRUCTURAL REPAIR FINISHCODEREPAIRFIG. NO.Nose Fuselage Structure4553000001Nose Fuselage Assy. Refer to 53-10-05 for NoseStructure Frames Refer to 53-10-10 for NoseStructure Stringers Refer to 53-10-15 for NoseStructure Skins34553108000 Intercostal12024-T"42 Clad0.040F3-8Replace64553108002 Intercostal, LH & RH12024-T42 Clad0.040F3-8Replace2024-T42 Clad94553108003 Intercostal, LH & RH (3 ea.)10.032F3-8Replace124553108006 Intercostal, LH & RH12024-T42 Clad0.032F3-8Replace154553108007 Intercostal, LH & RH12024-T42 Clad0.032F3-8Replace184553108008 Intercostal, LH & RH12024-T42 Clad0.040F3-8Replace214553108009 Angle, LH & RH (3 ea.)12024-T42 Clad0.040F3-8Replace244553108010 Intercostal, LH & RH12024-T42 Clad0.032F3-8Replace-4553108014 Filler (8 ea.)12024-T3 Clad0.160F3-8Replace-4553108017 Splice, LH & RH12024-T42 Clad0.125F3-8Replace-4553108018 Splice Plate, LH & RH12024-T3 Clad0.063F3-8Replace-4553108019 Splice, LH & RH12024-T42 Clad0.125F3-8Replace394553108023 Angle, LH & RH12024-T42 Clad0.040F3-8Replace424553108024 Angle, LH & RH12024-T42 Clad0.040F3-8Replace454553108025 Angle, LH & RH12024-T42 Clad0.040F3-8Replace484553108026 Angle, LH & RH12024-T42 Clad0.040F3-8Replace514553108032 Angle, LH & RH12024-T3 Clad0.040F3-8Replace-4553108039 Filler, LH & RH12024-T351 Plate0.250F3-8Replace574553108041 Intercostal, LH & RH12024-T42 Clad0.040F3-8Replace604553108042 Angle, LH & RH12024-T42 Clad0.040F3-8Replace634553206005 Doubler12024-T3 Clad0.080F3-8Replace664553208071 Splice Strap12024-T3 Clad0.050F3-8Replace-4553208078 Angle, LH & RH12024-T42 Clad0.063F3-8Replace724525701005 Splice Strap, LH & RH12024-T3 Clad0.080F3-8Replace- Not IllustratedNose Fuselage Structure Repair IndexTable 1 (Sheet 1 of 3)EFFECTIVITY: ALLSRM-10453-10-01Page5Nov 07/03

LEARJET 40 SERIESSTRUCTURAL REPAIR FINISHREPAIRCODEFIG. NO.754525701010 Splice (2 ea.)12024-T3 Clad0.050F3-8Replace784525701029 Angle (2 ea.)12024-T3 Clad0.050F3-8Replace814525701041 Splice (2 ea.)12024-T3 Clad0.050F3-8Replace844532302039 Pivot Fitting Assy., Nose LandingGear (2 ea.)1----4532302040 Pivot Fitting, Nose LandingGear17075-T73510.850F3-8Replace-4552800012 Angle, LH & RH12024-T42 Clad0.050F3-8Replace964552800014 Retainer, LH & RH17075-T6511g F3-8Replace-7653102001 Seal, Radome1g 0.025F3-8Replace1024552402001 Panel, Access12024-T420.063F3-8Replace1054534208004 Angle, Attachment (2 ea.)12024-T30.040F3-8Replace1084534208005 Angle, Attachment (2 ea.)12024-T30.040F3-8Replace1114534208006 Intercostal, LH & RH12024-T420.040F3-8Replace--4553208092 Filler (4 ea.)12O24-T30.040F3-8Replace-4553208093 Filler (2 ea.)12024-T30.050F3-8Replace120MS20253P23977 Hinge Pin, Nose Landing GearDoor (2 ea.)1----4520008459 Bracket (2 ea.)22024-T30.032F3-8Replace-4553000001V17 Bracket22024-T30.040F3-8Replace-4520008460 Bracket32024-T30.040F3-8Replace-4553208095 Filler, LH & RH42024-T3-4553208096 Shim LH & RH4-4553000001V6 Shim5-4553000001V21 Seal Support LH & RH (4 e2024-T30.040F3-8Replace22024-T420.040F3-8Replace Seal Support LH & RH (4 ea.)32024-T420.040F3-8Replace4520008241 Bracket (7 ea.)22024-T30.032F3-8Replace4553000001V16 Splice Strap LH & RH42024-T420.050F3-8Replace- Not IllustratedNose Fuselage Structure Repair IndexTable 1 (Sheet 2 of 3)EFFECTIVITY: ALLSRM-10453-10-01Page6Nov 07/03

LEARJET 40 SERIESSTRUCTURAL REPAIR MANUALITEMNO.DWG.NO.DESCRIPTION Splice Strap LH & EPAIRFIG. NO.0.050F3-8ReplaceV13156H0601-1 RadomeReplaceS-304 SealReplaceS-307 Corner SealReplace- Not IllustratedEFFECT

STRUCTURAL REPAIR MANUAL Record of Temporary Revisions Revision Number 53-1 Status Inactive Date Jun 16/00 Location 53-10-15 Pg. 101 Insertion Date Jun 16/00 Inserter's Initials LJ Removal Date Nov 07/03 Removers Initials LJ SRM-104 53-RTR Pa9e1 Nov 07/03. LEARJET 40 SERIES STRUCTURAL REPAIR MANUAL Chapter Section Subject

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