(2)
Clamp -101 tool frame assembly to the primary clevises or lugs only.
(3)
Apply potting compound around P-48-16-1/2 and P-112-16-1.2530 bushings after -115 potting pins and bushings are in place. Install at three locations, two locations are for locating the tool and the third location for replacement bushing location.
NOTE: If the bushings are to be replaced in the lug and clevis at the same location, the tool need only to be potted to the spar lug or clevis, then use for its mate.
(4)
Remove tool assembly after potting compound is cured and firmly set.
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C. Ream oversize holes in clevis or lug.
(1)
Mask or shield structure to prevent contamination with abrasive materials during abrasive blast cleaning or with shot during shot peening.
CAUTION: FOREIGN PARTICLES MAY CAUSE CORROSION TO STRUCTURE.
(2)
Before removing existing defective bushings, measure and record the distance between the defective flange bushing face and clevis or lug. Mark the location of this measurement on the clevis or lug so that a repeated measurement can be obtained for the new bushing.
(3)
Remove existing defective bushing. Use CJ107 slide hammer and either -126 or -525 slide hammer adapter. If bushing is being removed from clevis, remove remaining bushing using -125 bushing removal drive pin.
(4)
Clean and deburr holes and adjacent surfaces thoroughly.
(5)
Oversize hole with Quickset reamer to minimum oversize in 0.010 inch increments up to maximum allowable to achieve corrosion removal (Ref Fig. 803 for maximum bore oversize). Contact Boeing if corrosion still exists.
(6)
Spotface lug or clevis flanges to provide seat for bushing flange to maximum depth of 0.01 inch. Contact Boeing if corrosion still exists in lug holes or on spotfaced surfaces. Remove corrosion products from other areas of lug per Structural Repair Manual, Chapter 51. Do not use chemical removal if solution can penetrate fay surfaces. Use chemical or dry abrasive surface.
(7)
Shot peen holes and spotfaced surfaces as follows:
(a)
Shot peen (flap peen optional) minimum flat diameter of spot face per Overhaul Manual, Section 20-10-03. On aluminum parts, use shot number 230 to 550, intensity 0.014A, coverage 2.0. On steel parts, use shot number 170 to 460, intensity 0.016A, coverage 2.0.
(b)
Shot peen (flap peen optional) hole in clevis or lug per Overhaul Manual, Section 20-10-03. For aluminum parts, use shot number 230 to 550, intensity 0.014A, coverage
2.0. For steel parts, use shot number 170 to 460, intensity 0.016A, coverage 2.0.
(c)
Hone inside diameter maximum of 0.0004 inch with 63 microinch finish to achieve final hole size.
(8)
Finish hole of steel parts with two coats of primer or chemically treat hole in aluminum parts to meet requirements of MIL-C-5541 (colored film) and apply one coat of primer. Allow to dry one hour minimum.
(9)
Install steel sleeve bushing in hole of lug or clevis.
NOTE: Make the bushing from the dimensions on Fig. 803, Detail B, Section XX-XX.
(10)
Finish spotfaced and reworked surfaces of aluminum lugs (except holes) with manual application of colored chemical coating per BAC5719 and apply two coats of primer. Finish steel parts with two coats of primer.
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D. Ream inside diameter of new flanged bushing (Section A-A)
(1)
Make a flanged bushing for an interference fit with the previously installed sleeve bushing.
NOTE: Make the flanged bushing from the dimensions on Fig. 803, Detail A, Section X-X.
(2)
Shrink fit bushing in lug with wet primer. Use -230 bushing installation tool.
(3)
Secure -101 tool frame assembly to rear spar as shown in View 1 or View 2 with -115 potting pins and C-clamps.
(4)
Ream bushings from aft side of spar with -112 arbor with -111 dowel press fit into arbor and -110 shell reamer. Continue to ream bushing using -124 reamer and -128 standard reamer provided.
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