pdfcoffee com_boeing-fasteners-pdf-free

Prévia do material em texto

<p>AlTEON</p><p>A BOEING COMPANY</p><p>FASTENERS -- INTRODUCTION TO FASTENERS</p><p>Introduction to Fasteners</p><p>This section provides a review of the most common</p><p>fasteners and auxiLiary parts used in Boeing airpLanes</p><p>today.</p><p>It shouLd be noted that the Latest revision of the</p><p>StructuraL Repair ManuaL or manufacturers'</p><p>documentation, shouLd be consuLted to ensure that this</p><p>information has not been superseded by design changes</p><p>or reguLatory authority action <F.A.A, D.O.T., C.A.A.,</p><p>etc. ).</p><p>Fastener Part Numbers</p><p>To faciLitate standardization and usage, aLL vendor</p><p>fasteners and attachment devices are assigned a Boeing</p><p>part number. CLassifying part number prefixes used at</p><p>Boeing are:</p><p>BACB30 BoLts, LockboLts or Hi Loks</p><p>BACC30 CoLLar</p><p>BACF FiLLer</p><p>BACN10 Nuts and NutpLates</p><p>BACR15 Rivets</p><p>BACS Shims or Screw</p><p>BACW Washers</p><p>Fastener SymboLs</p><p>Permanent fasteners are identified on an engineering</p><p>drawing by pLacing the appropriate fastener symboL and</p><p>777 TRAINING MANUAL</p><p>code in the hoLe Location cross in accordance with an</p><p>NAS 523 PLus SymboL System.</p><p>The fastener is identified by a two or three-Letter</p><p>code pLaced in the upper Left corner of the pLus</p><p>symboL. The code aLso defines the mating component,</p><p>where appLicabLe. Fastener diameter and manufactured</p><p>head Location are identified by the numeric-Letter code</p><p>pLaced in the upper right corner of the pLus symboL.</p><p>The diameter is given 1/32NDS of an inch for aLL</p><p>permanant fasteners. ALL removabLe boLts are given in</p><p>1/16TH of an inch. Countersinking and dimpLing</p><p>instructions are shown in the Lower Left corner of the</p><p>pLus symboL. The Lower right corner gives the grip</p><p>Length in 1/16TH of an inch.</p><p>63-05-00</p><p>- 133 -</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for details</p><p>AlTEDN</p><p>A BOEING COMPANY 777 TRAINING MANUAL</p><p>FASTENER SYMBOL CODE</p><p>INSTALLATION: STD PER BAC 5004, FLUID TIGHT PER BAC 5047, TAPER SHANK PER BAC 5054</p><p>TAPER SHANK BOLT INFO</p><p>BASIC CODE ~</p><p>ENCLOSED = FLU~ "XX</p><p>OPEN = STANDARD ~</p><p>XX</p><p>DIMPLE CSK INFO</p><p>o = DIMPLE</p><p>~DXC</p><p>X = NUMBER OF SHEETS DIMPLED</p><p>C = CSK IN STRUCTURE</p><p>XZK-6 = BACR15BB-6D</p><p>PROTRUDING HEAD</p><p>= BACB30MY8C</p><p>PROTRUDING SHEAR</p><p>HEAD HILOK</p><p>(HEAD ON FAR SIDE)</p><p>8 UP 100'x.llR</p><p>GHl IHL</p><p>DIA DASH NO.</p><p>~MFD HD LOC</p><p>I' / N = NEAR SIDE</p><p>/ F = FAR SIDE</p><p>X X</p><p>X W</p><p>"" ~ SPOT WELD OPT</p><p>~ LENGTH DASH NO.</p><p>TYPICAL DRAWING</p><p>DETAIL SHOWING</p><p>FASTENER CALLOUT</p><p>INTRODUCTION TO FASTENERS (SHEET 1)</p><p>FASTENERS - INTRODUCTION TO FASTENERS</p><p>63-05-00</p><p>- 1~4 -</p><p>ALTEON PROPRIETARY - Copyright <c) - See title page for I.s</p><p>> ..</p><p>'"</p><p>N</p><p>o</p><p>9</p><p>o</p><p>~</p><p>9</p><p>'" '"</p><p>HEAD</p><p>TYPE</p><p>SHEAR HD</p><p>¢</p><p>TENSION HD</p><p>I</p><p>Ltd</p><p>SHEAR HD</p><p>Ltr</p><p>TENSION HD</p><p>Ltd</p><p>AlTEDN</p><p>A BOEING COMPANY 777 TRAINING MANUAL</p><p>STEEL A286 TITANIUM</p><p>CAD PLATED CAD PLATED ALUMINIZED PAINT</p><p>(Low Alloy Steel 4340) (Stainless Steel) (6AL- 4V)</p><p>STD 1/64 OS 1/32 OS STD 1/64 OS 1/32 OS STD 1/64 OS 1/32 OS</p><p>BACC30M BACC30M BACC30R BACC30M BACC30M BACC30R BACC30M BACC30M BACC30R</p><p>XDA XDE XKA XNL XNP XSG YJA YLE YLF</p><p>BACB30FN BACB30FQ BACB30KF BACB30FN*A BACB30FQ*A BACB30KF*A BACB30NW*K BACB30NW*K* BACB30NW*K*</p><p>BACC30X BACC30X BACC30AC BACC30X BACC30X BACC30AC BACC30X BACC30X BACC30AC</p><p>XNB XMS XSL XXZ XUD XTX YLR YXN YXP</p><p>BACB30JC BACB30LX BACB30LY BACB30JC*A BACB30LX*A BACB30LY*A BACB30NY*K BACB30NY*K* BACB30NY*K*</p><p>BACC30M BACC30M BACC30R BACC30M BACC30M BACC30R BACC30M BACC30M BACC30R</p><p>XCZ XDD XKJ XNJ XNN XSJ YHY YLC YLD</p><p>BACB30FM BACB30FP BACB30KK BACB30FM*A BACB30FP*A BACB30KK*A BACB30MY*K BACB30MY*K* BACB30MY*K*</p><p>BACC30X BACC30X BACC30AC BACC30X BACC30X BACC30AC BACC30X BACC30X BACC30AC</p><p>XMX XMY XSM XPB XTZ XUB YLK YLG YLH</p><p>BACB30MB BACB30MC BACB30MD BACB30MB*A BACB30MC*A BACB30MD*A BACB30NX*K BACB30NX*K* BACB30NX*K*</p><p>SAMPLE HI-LOK DRAWING CODES</p><p>FASTENERS - INTRODUCTION TO FASTENERS</p><p>63-05-00</p><p>- 135 -</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for details</p><p>AlTEDN</p><p>A BOEING COMPANY</p><p>FASTENERS -- PERMANENT AND REMOVABLE</p><p>THIS PAGE INTENTIONALLY LEFT BLANK</p><p>- 136 -</p><p>777 TRAINING MANUAL</p><p>63-05-00</p><p>ALTEON PROPRIETARY - Copyright {el - See title page for's</p><p>AlTEON</p><p>A BOEING COMPANY</p><p>FASTENERS -- PERMANENT AND REMOVABLE</p><p>Fasteners</p><p>There are two major classifications of fasteners;</p><p>permanent and removal. Permanent fasteners are those</p><p>that require destroying part or all of the fastener</p><p>when removing it from the airplane. Examples of these</p><p>are rivets, lockbolts or Hi-loks. Removable fasteners</p><p>would include fatigue or structural bolts.</p><p>777 TRAINING MANUAL</p><p>63-05-00</p><p>- 137 -</p><p>ALTEON PROPRIETARY - Copyright (e) - See title page for details</p><p>> ..</p><p>'"</p><p>on</p><p>N</p><p>%</p><p>o</p><p>J,</p><p>l'</p><p>'" '"</p><p>BACR15BB</p><p>RIVET</p><p>\</p><p>BACB30US</p><p>AlTEDN</p><p>A BOEING COMPANY</p><p>BACR15BA</p><p>RIVET</p><p>BACB30PC</p><p>SHOULDER BOLT</p><p>12 PT. TENSION BOLT</p><p>BACB30FM</p><p>HEX-DRIVE OR HI-LOK</p><p>PERMANENT FASTENERS</p><p>BACN10HR</p><p>12 PT. NUT</p><p>REMOVABLE FASTENERS</p><p>777 TRAINING MANUAL</p><p>BACB30DX</p><p>LOCKBOLT</p><p>BACN10JC</p><p>SELF LOCKING NUT</p><p>I</p><p>MS 90353</p><p>PULL RIVET</p><p>BACS21AE</p><p>QUICK-RELEASE SCREW</p><p>FASTENERS-PERMANENT AND REMOVABLE</p><p>63-05-00</p><p>- 138 -</p><p>ALTEON PROPRIETARY - Copyright Cd - See title page for '.S</p><p>Telescoping bolt</p><p>where length is</p><p>uncertain</p><p>For double counter­</p><p>sunk holes</p><p>For use where pilot</p><p>hole does not clean up</p><p>AlTEDN</p><p>A BOEING COMPANY</p><p>For out-of­</p><p>round holes</p><p>For redrilled holes</p><p>that still don't</p><p>match</p><p>Serrated head for</p><p>all vice-grip</p><p>torquing</p><p>For all tapered holes</p><p>(special nut required)</p><p>For holes not</p><p>square</p><p>Assembler's special,</p><p>for oversize and</p><p>stepped holes</p><p>777 TRAINING MANUAL</p><p>For holes with</p><p>countersink on</p><p>wrong side</p><p>For holes counter­</p><p>sunk too deep</p><p>For mismatched</p><p>bolt holes</p><p>r 1 J</p><p>~</p><p>For holes drilled</p><p>crooked and then</p><p>straightened up</p><p>(nut is hard starting)</p><p>SPECIAL FASTENERS</p><p>For holes too</p><p>near the edge</p><p>Binocular bolt,</p><p>for double-drilled</p><p>holes</p><p>FOR THAT UNIQUE REPAIR</p><p>FASTENERS-PERMANENT AND REMOVABLE</p><p>63-05-00</p><p>- 139 -</p><p>ALTEON PROPRIETARY - Copyright (e) - See title page for details</p><p>AlTEON</p><p>A BOEING COMPANY</p><p>FASTENERS -- RIVETS - IDENTIFICATION MARKS</p><p>SoLid Shank Rivet MateriaLs</p><p>SoLid shank rivets are avaiLabLe in a variety of</p><p>materiaLs. The soLid shank rivets instaLLed on Boeing</p><p>aircraft are usuaLLy made from 2017, 2117, 2024 or 7050</p><p>aLuminum aLLoy. The part number suffix and rivet</p><p>identification marks give the rivet material.</p><p>Rivets made from 2017, 2117, and 7050 aluminum alloy</p><p>and nickeL-copper alloy can be used and stored at room</p><p>temperature.</p><p>Rivets made from 2024 aluminum aLloy must be soLution</p><p>heat treated and then stored at a temperature of -10°F</p><p>(- 23°C), or lower. After removal from cold storage the</p><p>rivets must be completely driven within 15 minutes.</p><p>Rivets that are removed from coLd storage and not</p><p>instaLled should be discarded.</p><p>In some locations Monel rivets are used. Monel rivets</p><p>are made of 66% Nickel, 30% Copper and 4% Iron. Monel</p><p>is corrosion resistant and can be used in high</p><p>temperature appLications without significant property</p><p>reductions.</p><p>o Other rivet aLloys include A286 CRES, 300 series CRES</p><p>~ and a Limited number of titanium-columbium are used in</p><p>N specific applications.</p><p>:=;</p><p>> .:</p><p>N</p><p>l'</p><p>Q</p><p>Q</p><p>I</p><p>9</p><p>'" -0</p><p>777 TRAINING MANUAL</p><p>Solid Shank Rivet Head Styles</p><p>Rivet head styles incLude universal and flush</p><p>varieties. FLush heads styles include standard, briLes,</p><p>shear, and index.</p><p>The modified fLush head is the briles rivet and gives</p><p>improved bearing in thin sheets, seals in the</p><p>countersink, improves fatigue Life, has greater head</p><p>strength in tension and can save weight due to improved</p><p>fatigue life in thin sheet.</p><p>7050-T73 rivets or briLes were introduced with the 767</p><p>program. These rivets have the same aLlowables as the</p><p>2024-T31 rivets but are sufficiently ductiLe that they</p><p>can be driven in the "as received" condition up to 1/4</p><p>inch diameter without cracking.</p><p>The modified universaL head and shear head offer a</p><p>weight savings over the standard universaL head or</p><p>flush, respectively.</p><p>The sLug rivet has no manufactured head, the head is</p><p>formed</p><p>during driving, nearly always on automatic</p><p>drivers (Gemcor Drivematic).</p><p>63-05-00</p><p>- 140 -</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for s</p><p>AlTEDN</p><p>A BOEING COMPANY 777 TRAINING MANUAL</p><p>MODIFIED 1000 120 0</p><p>UNIVERSAL 100 0 CSK 82 0 CSK 82 0 CSK CSKiCB SLUG RIVET DESCRIPTION UNIVERSAL )HEAR HEAD INDEX INDEX BRILES</p><p>STANDARD RIVET NO.</p><p>MATERIAL MARKS</p><p>BACR15BB BACR15FT BACR15BA BACR15CE BACR15DG BACR15FH BACR15FV BACR15BO</p><p>2117(AD) 8 a'i a'i ~ ~ @/ (S:9 i? DIMPLED</p><p>8</p><p>* NO HARKING</p><p>2017(D) a'i a'i rY Ij?</p><p>RAISED DOT</p><p>EXCEPT [*]</p><p>E)</p><p>* NO MARKING * INDENTED</p><p>Q'i ~ ~ (!j? ~</p><p>DOUBLE</p><p>2024(DD) D~</p><p>RAISED DOUBLE</p><p>DASH EXCEPT [*]</p><p>5056<B) ® ~'i ~ ~ ~ RAISED CROSS</p><p>1100(A) 0 a'i C)V</p><p>PLAIN</p><p>@</p><p>* INDENTED * INDENTED</p><p>7050(KE) ©'i ~ ~ ~ ~ C~ RAISED CIRCLE</p><p>EXCEPT [*]</p><p>MONEL<M) 0 Ij? NICKEL-</p><p>COPPER PLAIN</p><p>FASTENERS - RIVETS - IDENTIFICATION MARKS</p><p>63-05-00</p><p>- 141 -</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for details</p><p>AlTEDN</p><p>A BOEING COMPANY</p><p>FASTENERS -- RIVET ALLOYS</p><p>Rivet Alloys</p><p>Rivet alloys in common use with their respective shear</p><p>strengths and material codes, are shown in the table.</p><p>Here are the applications for the different rivet</p><p>alloys:</p><p>1100-F Non-structural</p><p>5056-H32 For magnesium structure</p><p>2117-T3 General structure, nutplate attachment,</p><p>fuel-tight, and fatigue-critical joints.</p><p>2017-T3 General structure, fatigue-critical</p><p>joints, and not for use in fuel-tight joints.</p><p>2024-T31 Ice-Box, must be refrigerated after heat­</p><p>treat until installed. Used on the wings. Do not</p><p>use for nutplate attachment.</p><p>7050-T73 Use only where high strength is required.</p><p>Monel Use in titanium, CRES, and nickel alloy</p><p>structure. Requires high squeeze force.</p><p>- 142 -</p><p>777 TRAINING MANUAL</p><p>63-05-00</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for ls</p><p>N</p><p>o</p><p>o</p><p>~</p><p>~</p><p>o</p><p>AlTEON</p><p>A BOEING COMPANY 777 TRAINING MANUAL</p><p>ALLOY RATED SHEAR STRENGTH (Fsu) RIVET MATERIAL CODE</p><p>1100F - NON-STRUCTURAL 9500 PSI A</p><p>5056-H32 MAG USE ONLY 28,000 PSI B</p><p>2117-T3 PRIMARILY WING 30,000 PSI AD</p><p>2017-T3 38,000 PSI D</p><p>2024-T31 ICE BOX RIVET 41,000 PSI DD</p><p>7050-T73 (BRILES) 41,000 PSI KE</p><p>MONEL 49,000 PSI M</p><p>A286 90,000 PSI C</p><p>.. I</p><p>I</p><p><r-------'-q};----i r XZK-6 = BACR15BB6D p</p><p>Fast.</p><p>Shear</p><p>Example of Shear Strength Usage ~</p><p>2</p><p>P = F\ X 4 = 1050 LBS</p><p>Fast.</p><p>3 * Shear ~</p><p>38,000 psi</p><p>* NOTE: USE FRACTIONAL VALUES FOR ALL JOINT CALCULATIONS INVOLVING SHANK DIAMETERS</p><p>FASTENERS - RIVET ALLOYS</p><p>63-05-00</p><p>- 143 -</p><p>ALTEON PROPRIETARY - (opyr;ght (c) - See t;tle page for deta;ls</p><p>AlTEDN</p><p>A BOEING COMPANY</p><p>777 TRAINING MANUAL</p><p>FASTENERS -- HEX-DRIVE, LOCKBOLTS AND RADIUS LEAD-IN BOLTS</p><p>Hex-Drive BoLts</p><p>Hex-drive boLts (Hi-Loks) have externaLly threaded pins</p><p>with no wrenching feature on the head. There is a</p><p>hexagon recess in the threaded end to prevent the pin</p><p>from rotating during instaLLation. The coLLar is</p><p>internaL threaded and seLf-Locking. The instaLLation</p><p>force is controlLed by a groove in the collar, which</p><p>shears off during installation.</p><p>SpeciaL power tooLs are often used for hex-drive bolt</p><p>instalLation. A hex key and standard wrench can aLso be</p><p>used for manuaL instaLLation.</p><p>Hex-drives are used when: soLid rivets do not have</p><p>sufficient shear strength, joint cLamp-up is necessary</p><p>or collar rotation provides manufacturing advantage.</p><p>Hexagon or twelve point seLf-Locking nuts may be</p><p>instaLled instead of hex-drive coLLars when: there is</p><p>not enough cLearance for colLar instaLlation, the use</p><p>of seal nuts is necessary or re-torque is necessary due</p><p>to seaLant squeeze out.</p><p>Lockbolts</p><p>g</p><p>~ The LockboLt pin has paralleL grooves instead of</p><p>~ threads with no wrenching features on the head. The ....</p><p>Q coLlar has a smooth cyLindricaL bore that is swaged</p><p>into the grooves of the pin.</p><p>There are two types of lockbolts: pull and stump. The</p><p>pull type lockboLt is instalLed with a special</p><p>pneumatic puLLing gun, which puLLs the shank of the</p><p>bolt through the hole and simultaneously swages a</p><p>collar into the pin grooves. The pin-tail breaks off at</p><p>a predetermined Load.</p><p>The stump type LockboLt is driven with a conventionaL</p><p>riveting gun, fitted with a lockbolt die set, and a</p><p>bucking bar.</p><p>NOTE: When a stump type is required and onLy the</p><p>corresponding puLL type is avaiLabLe, the pin­</p><p>tail may be removed and fastener gun driven.</p><p>LockboLts are used when: soLid rivets do not have</p><p>sufficient shear strength, joint cLamp-up is necessary</p><p>or instalLation speed provides manufacturing advantage.</p><p>Lockbolt instalLation is fast and easy, but requires</p><p>open access to the parts. Where access is limited,</p><p>other fastener types are used.</p><p>Radius Lead-In BoLts</p><p>Titanium radius lead-in boLts are used for their good</p><p>fatigue properties in aluminum alloys. These fasteners</p><p>have a shank diameter that is 0.006 inches Larger than</p><p>the diameter of the hoLe in which they are to be</p><p>instaLLed, to provide a interference fit. There are two</p><p>oversizes availabLe for each nominaL size, for use in</p><p>repair work.</p><p>63-05-00</p><p>- 144 -</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for ls</p><p>AlTEON</p><p>A BOEING COMPANY</p><p>NOTES:</p><p>TOOL\</p><p>1-.-__ 9,</p><p>1---r=J</p><p>-~-~</p><p>\FRANGIBLE</p><p>NUT</p><p>SELECT CORRECT GRIP LENGTH</p><p>FASTENERS FOR COMPOSITES HAVE LOW</p><p>STEP 1</p><p>HEX-DRIVE PIN IS INSERTED</p><p>IN THE HOLE AND THE COLLAR</p><p>IS MANUALLY THREADED ON</p><p>TO THE PIN.</p><p>STEP 2</p><p>POWER TOOL ENGAGES COLLAR.</p><p>ALLEN KEY ENGAGES THE END</p><p>OF THE PIN TO PREVENT</p><p>ROTATION OF THE PIN.</p><p>STEP 3</p><p>THE FRANGIBLE NUT OF THE</p><p>COLLAR IS TWISTED OFF AND</p><p>DISCARDED. INSTALLATION IS</p><p>COMPLETE.</p><p>TORQUE GROOVE, LARGE FOOTPRINT PROTRUDING</p><p>HEADS, AND LARGER FLANGED COLLARS.</p><p>777 TRAINING MANUAL</p><p>COLLAR</p><p>SERRATED</p><p>STEM</p><p>CHUCK JAW</p><p>PULLER</p><p>BREAK</p><p>.- NECK</p><p>STEP 1</p><p>STEP 3</p><p>FINAL</p><p>STEP 2</p><p>STEP 4</p><p>REMOVAL REQUIRES SPLITTING COLLAR, OR</p><p>UNTHREADING COLLAR WITH SPECIAL TOOL</p><p>__ FRANGIBLE</p><p>NUT</p><p>INSTALLATION SEQUENCE</p><p>OF A PULL TYPE LOCKBOLT</p><p>I</p><p>FASTENERS - HEX-DRIVE, LOCKBOLTS AND RADIUS LEAD-IN BOLTS</p><p>63-05-00</p><p>- 145 -</p><p>ALTEON PROPRIETARY - Copyright (el - See title page for details</p><p>c</p><p>C</p><p>N</p><p>~</p><p>N</p><p>....</p><p>c</p><p>></p><p>" ..</p><p>00</p><p>N</p><p>'i'</p><p>9</p><p>'" 'i'</p><p>'" '"</p><p>AITEDN</p><p>A BOEING COMPANY</p><p>FASTENERS -- TENSION AND SHEAR</p><p>General</p><p>The 'Shear' head fasteners are used in applications</p><p>where shear and not axial tension is the primary mode</p><p>of load transfer. The 'tension' head systems are for</p><p>shear applications where higher tensile pre-load and</p><p>axial tensile capability are required.</p><p>Tension protruding head fasteners have a larger</p><p>diameter heads and more threads of engagement into</p><p>their collars than shear fasteners.</p><p>Tension flush head fasteners have larger diameter heads</p><p>and deeper countersinks than shear flush fasteners. See</p><p>the SRM chapter 51 in the fastener section for head</p><p>dimensions.</p><p>Do not substitute shear nuts or collars for tension</p><p>nuts and collars. The shear nuts or collars do not have</p><p>the same diameter or number of threads of engagement.</p><p>777 TRAINING MANUAL</p><p>63-05-00</p><p>- 146 -</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for "ls</p><p>,---</p><p>---</p><p>.--</p><p>'---</p><p>AlTEON</p><p>A BOEING COMPANY 777 TRAINING MANUAL</p><p>.. /</p><p>7</p><p>~--'---1gtr-.------? -- p</p><p><'-------=tj=J-</p><p>SHEAR JOINT</p><p>TENSION - PROTRUDING HEAD</p><p>[\J</p><p>10</p><p>TENSION - PROTRUDING HEAD SHEAR - PROTRUDING HEAD</p><p>TENSION - FLUSH HEAD</p><p>IVt-</p><p>1/\-- II</p><p>SHEAR - PROTRUDING HEAD SHEAR - FLUSH HEAD</p><p>LOCKBOLTS HI-LOKS</p><p>FASTENERS - TENSION AND SHEAR</p><p>63-05-00</p><p>- 147 -</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for details</p><p>AlTEDN</p><p>A BOEING COMPANY</p><p>FASTENERS -- BLIND</p><p>GeneraL</p><p>BLind boLts and rivets are permanent fastener that are</p><p>avaiLabLe in aLuminum, MoneL, aLLoy steeL and A286</p><p>CRES. The fasteners are muLtipLe piece and have the</p><p>advantage of being instaLLed from one side.</p><p>BLind BoLts</p><p>There are two types of bLind boLts:</p><p>Threaded</p><p>Pu L L.</p><p>The tooL that instaLLs the threaded type rivet TURNS</p><p>the core stem, whiLe reacting against the fastener</p><p>head. The bLind head then forms and the joint</p><p>components are drawn together.</p><p>FinaLLy, the core stem</p><p>breaks away compLeting the instaLLation.</p><p>The tooL that instaLLs the puLL type PULLS the core</p><p>stem instead of turning the stem.</p><p>Since blind bolts are used for Limited far-side access,</p><p>the formed head is difficuLt or impossibLe to inspect.</p><p>Therefore, it is important to exactLy foLLow the BAC</p><p>5004-3 instaLLation procedures. These incLude:</p><p>Correct hoLe size</p><p>Correct grip length and diameter bolt</p><p>Using correct tooLs and technique</p><p>777 TRAINING MANUAL</p><p>SpeciaL bLind boLts are used for composite assembLies.</p><p>AppLications of bLind boLts are for assembLy of</p><p>eLevators and rudders, and for some of the boLted</p><p>repairs of 777 empennage structuraL boxes.</p><p>Removing bLind boLts can be difficuLt. The drive screw</p><p>must be driLLed out. TooLs are avaiLabLe from the</p><p>fastener manufacturer to assist in bLind boLt removaL.</p><p>BLind Rivets</p><p>BLind rivets are not the same as bLind boLts. BLind</p><p>rivets are Lower in strength and cannot be substituted</p><p>for bLind boLts.</p><p>They shouLd never be used in areas of tension Loading,</p><p>vibration or where the head is subjected to prying.</p><p>BLind rivets are poor in fatigue because they do not</p><p>fiLL the hoLe Like soLid rivets.</p><p>If bLind rivets are used in a repair, the repair is</p><p>considered time Limited or interim and shouLd be</p><p>inspected at frequent intervaLs for Looseness. The</p><p>repairs showing blind rivets in structuraL repair</p><p>manuaL have FAA approvaL provided the inspections are</p><p>accompLished at the intervaLs stated.</p><p>63-05-00</p><p>- 148 -</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for's</p><p>AlTEDN</p><p>A BOEING COMPANY 777 TRAINING MANUAL</p><p>c;</p><p>~ BLIND BOLT INSTALLATION N</p><p>....</p><p>co</p><p>~</p><p>co:</p><p>'" N</p><p>co</p><p>I</p><p>co</p><p>l'</p><p>"' l'</p><p>'" '"</p><p>NOTES: SELECT CORRECT GRIP LENGTH</p><p>INSPECTION OF FORMED HEAD REQUIRED</p><p>REMOVAL REQUIRES DRILLING OUT</p><p>CENTER STEM (DRILL GUIDES AVAILABLE)</p><p>BLIND RIVETS</p><p>FASTENERS - BLIND</p><p>63-05-00</p><p>- 149 -</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for details</p><p>AlTEON</p><p>A BOEING COMPANY</p><p>FASTENERS -- OVERSIZE FASTENERS</p><p>Genera l</p><p>Oversize fasteners are generally used in repair</p><p>applications to clean up damage to a hole and to</p><p>provide the same fastener fit as was provided in the</p><p>original design. Occasionally, oversize fasteners are</p><p>used to provide an alternate load path.</p><p>As a general rule, if original rivets are replaced by</p><p>hex-drives or lockbolts, a 1/32 oversize fastener is</p><p>used in the repair. If original hex-drives or lockbolts</p><p>are replaced with hex-drives or lockbolts, a minimum of</p><p>1/64 oversize fastener is used. If rivets are replaced</p><p>with rivets then the same diameter can generally be</p><p>used.</p><p>Briles Rivets</p><p>When Briles Rivets are replaced, the next larger</p><p>diameter should always be used. Briles rivets are</p><p>available in 1/32 diameter increments up to 5/16" (Ref</p><p>BAC R15FV Series). Oversizing of holes and counterbore</p><p>is required to fit the appropriate size rivet.</p><p>In the event that use of an oversize Briles Rivet would</p><p>result in a knife-edge condition on thin skin, the</p><p>countersink depth of the original rivet may be</p><p>maintained and the rivet shaved flush after</p><p>installation. In many cases it would probably be</p><p>preferable to replace the Briles rivet with an OVERSIZE</p><p>protruding head rivet.</p><p>777 TRAINING MANUAL</p><p>63-05-00</p><p>- 150 -</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for ls</p><p>AlTEDN</p><p>A BOEING COMPANY 777 TRAINING MANUAL</p><p>I</p><p>A</p><p>-H</p><p>PART NUMBER DESCRIPTION A 0 H TO</p><p>BACB30MY6K() 3/16 HEX DRIVE .295-.315 .1885-.1895 .045-.055 .181-.184</p><p>BACB30MY6K()X 1/64 OVERSIZE .295-.315 .2016-.2026 .045-.055 .181-.184</p><p>BACB30MY6K()Y 1/32 OVERSIZE .295-.315 .2168-.2182 .045-.055 .181-.184</p><p>FACTORY FASTENER REPAIR FASTENER TYPE TYPICAL REPAIR FASTENER SIZE</p><p>RIVET RIVET SAME DIAMETER</p><p>RIVET HEX-DRIVE OR LOCKBOLT 1/32 OVERSIZE</p><p>HEX-DRIVE OR LOCKBOLT HEX-DRIVE OR LOCKBOLT 1/64 OVERSIZE</p><p>FASTENERS - OVERSIZE FASTENERS</p><p>63-05-00</p><p>- 151 -</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for details</p><p>AlTEDN</p><p>A BOEING COMPANY</p><p>FASTENERS -- REMOVABLE FASTENERS</p><p>Bolts</p><p>A bolt, generally, has a smooth cylindrical shank and</p><p>is intended to be installed by turning the mating nut.</p><p>Removable bolts are used for the following conditions:</p><p>Permanent fasteners that require sufficient shear,</p><p>axial tension or fatigue performance</p><p>Joint clamp-up is necessary</p><p>Occasional disassembly is required</p><p>Removable bolts can be categorized as fatigue, tension,</p><p>or shear rated.</p><p>Fatigue-rated Bolts</p><p>Fatigue-rated bolts are used for high strength</p><p>applications in critical joints and have 12 point</p><p>protruding heads with long threads. They are available</p><p>in a tension strength range of 160 to 220 KSI, and are</p><p>typically made from Alloy Steel, A 286 (CRES), Inconel</p><p>718 and 6AL-4V Titanium. (Note: Because of stress</p><p>corrosion cracking problems, H-11 steel bolts</p><p>(BACB20MT) are no longer used for design or recommended</p><p>as replacement fasteners).</p><p>Countersunk washers should always be used under the</p><p>head of fatigue-rated bolts. Otherwise, the washer will</p><p>~ ride in the radius under the bolt head.</p><p>'"</p><p>~</p><p>9</p><p>[5</p><p>I</p><p>9</p><p>'" '"</p><p>777 TRAINING MANUAL</p><p>Tension and Shear Bolts</p><p>Tension and shear-rated bolts may have hexagonal, 12</p><p>point, or countersunk heads with long threads for</p><p>tension joint installations, or short threads for shear</p><p>applications. Material options are the same as for</p><p>fatigue-rated bolts. Wherever possible, bolts should be</p><p>installed with the head uppermost or forward as</p><p>applicable, except as noted in relevant maintenance</p><p>documents or engineering drawings.</p><p>Bolt Threads</p><p>All Boeing standard bolts have rolled threads after</p><p>heat treatment, not machined threads. Rolled threads</p><p>have a smooth uniform root radius which blends with the</p><p>thread flanks to provide improved fatigue life through</p><p>lower stress concentrations.</p><p>63-05-00</p><p>- 152 -</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for "ls</p><p>AlTEDN</p><p>A BOEING COMPANY</p><p>SHORT THREADS \</p><p>~)-----~~</p><p>' ..</p><p>-E+-+ - 1~1t- - --- --+-+-</p><p>COUNTERSUNK</p><p>HEAD BOLT</p><p>v</p><p>r-</p><p>0</p><p>P\+-</p><p>TV</p><p>bL-</p><p>0</p><p>'-------</p><p>LONG THREAD (TENSION) BACB30LH</p><p>SHORT THREAD (SHEAR) BACB30LU</p><p>LONG THREADS\</p><p>- --</p><p>- -+ ~</p><p>f----</p><p>HEX HEAD BOLTS -</p><p>LONG THREAD (TENSION) BACB30NE</p><p>SHORT THREAD (SHEAR) BACB30NF</p><p>ALL "BAC" BOLTS ARE PURCHASED</p><p>WITH ROLLED THREADS</p><p>777 TRAINING MANUAL</p><p>SHORT THREADS\</p><p>12 POINT HEAD BOLT -</p><p>LONG THREAD TENSION BACB30NJ</p><p>SHORT THREAD BACB30LT</p><p>/r-</p><p>/</p><p>/</p><p>" -/</p><p>'\.</p><p>\.</p><p>"'-<-</p><p>12 POINT HEAD FATIGUE TENSION BOLT</p><p>BACB30US</p><p>-</p><p>-</p><p>FASTENERS - REMOVABLE FASTENERS</p><p>63-05-00</p><p>- 153 -</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for details</p><p>AlTEDN</p><p>A BOEING COMPANY</p><p>FASTENERS -- BOLT STRENGTHS</p><p>Fastener Alloys</p><p>Mechanical fastener strength properties for the</p><p>fastener alloys summarized in the table are independent</p><p>of the materials in which they are installed, and apply</p><p>only when the fastened materials are sufficient in</p><p>strength and thickness to develop the full strength of</p><p>the fastener.</p><p>Boeing part standards should be referred to for</p><p>fastener dimensions, materials, finishes and</p><p>qualification requirements. For fastener installation</p><p>requirements, see the applicable Boeing process</p><p>specification.</p><p>777 TRAINING MANUAL</p><p>63-05-00</p><p>- 154 -</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for '.5</p><p>Q</p><p>Q</p><p>~</p><p>N</p><p>.:</p><p>'" Q</p><p>%</p><p>AlTEDN</p><p>A BOEING COMPANY</p><p>ALLOYS</p><p>STEEL</p><p>8740/4340</p><p>H-11 CL></p><p>CRES</p><p>A286</p><p>PH 13-8 MO</p><p>INCONEL 718</p><p>TITANIUM</p><p>6AL-4V</p><p>777 TRAINING MANUAL</p><p>MINIMUM RATED STRENGTH - ksi</p><p>SHEAR (Fsu) TENSION (F tu)</p><p>95 160</p><p>125 220</p><p>95/110 160/200</p><p>125 220</p><p>125 220</p><p>95 160</p><p>$ CL> H-11 IS NOT RECOMMENDED DUE TO STRESS CORROSION SUSCEPTIBILITY</p><p>~</p><p>FASTENERS - BOLT STRENGTHS</p><p>63-05-00</p><p>- 155 -</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for details</p><p>g</p><p>~</p><p>AlTEDN</p><p>A BOEING COMPANY</p><p>FASTENERS -- BOLT TORQUE REQUIREMENTS</p><p>Bolt Torque Requirements</p><p>Pre loaded bolts improve both the fatigue resistance and</p><p>the locking characteristics of the nut and bolt</p><p>installation. They also introduce</p><p>a beneficial</p><p>compressive stress around the rim of the hole which</p><p>counteracts the tendency for stress concentration</p><p>cracks to occur at the edge of the hole caused by</p><p>applying a shear load to an unpreloaded bolt.</p><p>It is important that the maximum allowable torque value</p><p>is not exceeded as torque values are based on the proof</p><p>load for the fastener material which is approximately</p><p>equivalent to the yield strength.</p><p>For CRES steel nuts, use torque values given for shear</p><p>type nuts.</p><p>Use BAC (Boeing Airplane Company) standard torque</p><p>tables as a guide whenever specific torque values are</p><p>not called out on the engineering drawing or in</p><p>approved maintenance documents such as the structural</p><p>repair or maintenance manuals. Torque wrenches should</p><p>be used when engineering drawings or maintenance</p><p>documents indicate that specific torque values are to</p><p>be applied.</p><p>~ In cases where space ;s limited, the head end of the</p><p>~ bolt instead of the nut, may need to be rotated to</p><p>~ obtain the necessary torque. When the fastener head is</p><p>'" ~ used for this purpose, the high side of the torque</p><p>8, b d 8 range should e use . ,</p><p>9</p><p>'" '"</p><p>777 TRAINING MANUAL</p><p>Re-application of torque to removable bolts is</p><p>recommended if the joint uses faying surface sealant in</p><p>any interface. Fay surface sealant may squeeze out of</p><p>the joint when bolts are tightened, resulting in</p><p>partial loss of bolt preload, unless torque is then re­</p><p>applied to the fastener. It is important that torque</p><p>application be completed within 60 minutes of the</p><p>squeeze-out life remaining in the fay surface and</p><p>fastener sealant.</p><p>63-05-00</p><p>- 156 -</p><p>ALTEON PROPRIETARY - Copyright (el - See title page for ls</p><p>AlTEDN</p><p>A BOEING COMPANY</p><p>I B/</p><p>./</p><p>I</p><p>, A/'</p><p>:~SING ADAPTER IN LINE</p><p>WITH WRENCH. CORRECTION</p><p>REQUIRED</p><p>T1 - T x A</p><p>- A + B</p><p>T = ACTUAL TORQUE ON NUT</p><p>T1 = TORQUE WRENCH READING</p><p>NUT</p><p>PART</p><p>NO.</p><p>BOLT</p><p>PART</p><p>NO.</p><p>FASTENER</p><p>DIAMETER</p><p>AND</p><p>THREAD</p><p>SIZE</p><p>10-32</p><p>1/4-28</p><p>5/16-24</p><p>3/8-24</p><p>7/16-20</p><p>1/2-20</p><p>9/16-18</p><p>5/8-18</p><p>3/4-16</p><p>7/8-14</p><p>1-12 OR 1-14</p><p>1-1/8-12</p><p>1-1/4-12</p><p>1-3/8-12</p><p>1-1/2-12</p><p>777 TRAINING MANUAL</p><p>1I1111NII 7.7</p><p>757-200</p><p>STRUCTURAL REPAIR MANUAL</p><p>BACN10HR, BACN10JG, BACN10HC BACN10GW, BACN10JA, BACN10B,</p><p>BACN10JB, BACN10RM,NAS577,</p><p>BACN10JD,(7/16 THRU 1-1/4 ONLY),</p><p>NAS1805</p><p>BACB30NG, BACB30NH, BACB30MT, BACB30FD, BACB30MR, BACB30L~~.</p><p>BACB30US BACB30PN, BACB30NE, BACB30LM,</p><p>BACB30NM, BACB30LN, BACB30NS,</p><p>BACB30EM, BACB30LP, BACB30LU,</p><p>BACB30LR, BACB30MS, BACB30NN,</p><p>NAS6603 THRU NAS6620, NAS6703</p><p>THRU NAS6720</p><p>NUT TIGHTENING TORQUE RANGE (POUND-INCH)~</p><p>DRY BOLT LUBRICATED DRY BOLT LUBRICATED</p><p>BOLT BOLT</p><p>0> 0></p><p>--- --- 30-35 20-25</p><p>90-125 70-80 65-100 50-75</p><p>180-250 145-180 130-200 90-125</p><p>300-500 275-330 220-410 150-250</p><p>510-840 370-440 370-690 260-425</p><p>870-1300 500-575 630-1070 440-650</p><p>1300-1800 800-1000 1000-1470 700-920</p><p>1900-2300 1350-1650 1400-1900 1000-1200</p><p>3300-4300 2800-3300 2400-3500 1700-2150</p><p>5100-6700 3900-4500 3700-5500 2600-3400</p><p>7000-10,900 6200-7000 5100-8900 3600-5500</p><p>9500-13,000 8300-9400 6900-10,700 4900-6700</p><p>15,800-19,200 11,000-12,000 11,500-15,700 7500-9700</p><p>20,000-24,000 16,000-17,000 --- ---</p><p>--- --- --- ---</p><p>NUT TIGHTENING TORQUE VALUES</p><p>~MAXIMUM TORQUE + OR - 10 PERCENT WHEN BOLT IS INSTALLED BY WRENCHING HEAD.</p><p>SEE STRUCTURAL REPAIR MANUAL FOR LATEST DATA.</p><p>FASTENERS - BOLT TORQUE REQUIREMENTS</p><p>63-05-00</p><p>- 157 -</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for details</p><p>AlTEDN</p><p>A BOEING COMPANY</p><p>FASTENERS -- WASHERS</p><p>Washers</p><p>For general use, plain washers (AN 960, BACW10BP()P)</p><p>are used under nuts. They provide a uniform bearing</p><p>area and act as a spacer to adjust for fastener grip</p><p>length and material thickness. The bolt and nut</p><p>installation specification (BAC 5009), allows one</p><p>washer under the fastener head, and two washers under</p><p>the nut. Plain washers may also used under the collars</p><p>of lockbolts or hiloks or under the head of solid</p><p>rivets to distribute the fastener bearing load over a</p><p>larger area. This is particularly important in plastic</p><p>or carbon fiber assemblies. In installations where</p><p>spring lockwashers (AN 935) are used, plain washers</p><p>must be fitted between the part and the lockwasher to</p><p>prevent damage to the material.</p><p>Countersunk washers (BACW10BP()C) are used under the</p><p>head of protruding head bolts to provide head-to-shank</p><p>fillet relief on high strength fasteners such as</p><p>BACB30US and BACB30LE bolts. Self-aligning washers</p><p>(BACW10CA) are used with fasteners in non-parallel</p><p>joint design where counterboring of the slope surface</p><p>is unacceptable. These washers will accommodate a</p><p>maximum slope of 8 degrees. A concave and a convex</p><p>Q washer make up the self-aligning washer assembly.</p><p>Q</p><p>~</p><p>N</p><p>As an option to aluminum, plain cadmium plated steel</p><p>r=; washers are frequently used adjacent to structural</p><p>~ surfaces as they better resist the cutting action of</p><p>co:</p><p>~ the nut, especially if a specified torque has to be</p><p>~ applied. Where the material next to the nut is steel, * use steel washers.</p><p>'" ~</p><p>777 TRAINING MANUAL</p><p>In fatigue critical joints, preloaded-indicating</p><p>washers are used to optimize fatigue life and handle</p><p>greater in-service stresses. They act by compressing</p><p>the inner ring to the point where the outer ring cannot</p><p>be moved, thus achieving the required preload.</p><p>63-05-00</p><p>- 158 -</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for ts</p><p>AlTEDN</p><p>A BOEING COMPANY 777 TRAINING MANUAL</p><p>~A</p><p>-t- -{}- GENERAL PURPOSE FOR WASHERS:</p><p>- DISTRIBUTION CLAMP UP BEARING LAOD</p><p>- PREVENT GALLING</p><p>- DISSIMILAR MATERIAL COMPATIBILITY</p><p>- GRIP LENGTH ADJUSTMENT</p><p>A-A L.A CONCAVE CONVEX - FILLET RELIEF FOR FATIGUE RATED BOLTS</p><p>- SELF-ALIGNMENT FOR ANGLES BETWEEN 2-8 DEGREES</p><p>COUNTERSUNK WASHER SELF-ALIGNING WASHER</p><p>2 - 8 DEGREES</p><p>2 WASHERS</p><p>~ (WP22, BACW10AK)</p><p>OUTER PLI RING</p><p>INNER PLI RING</p><p>TOOL HOLES (3)</p><p>120· APART</p><p>- (APPROXIMATE)</p><p>()</p><p>v</p><p>(BEFORE LOADING</p><p>CONDITION ILLUSTRATED)</p><p>TYPICAL INSTALLATION</p><p>OUTER</p><p>PLI RING</p><p>~iiiiiijj</p><p>BEFORE LOADING</p><p>NOTE: OUTER PLI RING</p><p>-- FREE TO TURN.</p><p>PRELOAD INDICATING WASHER (PLI)</p><p>FOR 220 KSI NUTS BACW10AM</p><p>FASTENERS - WASHERS</p><p>- 159 -</p><p>AFTER LOADING</p><p>NOTE: INNER PLI RING COMPRESSED,</p><p>OUTER PLI RING NO LONGER</p><p>FREE TO TURN; INDICATING</p><p>PROPER PRELOAD. INNER PLI</p><p>RING NOT REUSABLE.</p><p>63-05-00</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for details</p><p>AlTEON</p><p>A BOEING COMPANY</p><p>FASTENERS -- NUTS / NUTPLATES</p><p>Nuts / Nutplates</p><p>Nuts are generaLLy classified as tension or shear.</p><p>Tension nuts are avaiLabLe in strengths of 180 or 220</p><p>KSI. Shear nuts are avaiLabLe in 125 KSI strength. Nuts</p><p>are seLected to have a tensile strength equaL to or</p><p>greater than the mating boLt or screw. Nut pLates are</p><p>used in "cLose outs" or other pLaces with Limited or no</p><p>access. They are attached with rivets. NutpLates are</p><p>primariLy used in shear appLications and are</p><p>predominantly of 125 KSI strength with a limited number</p><p>rated at 160 KSI.</p><p>ALL removabLe fasteners require Locking mechanisms.</p><p>Some exampLes are:</p><p>SeLf-Locking nut</p><p>CastelLated nut secured with a cotter pin</p><p>Safety wire.</p><p>The threads on seLf-Locking nuts are typicaLLy deformed</p><p>to provide the additionaL friction to hold the</p><p>fastener. The minimum to maximum Locking torque range</p><p>is used to find the condition of a used seLf-Locking</p><p>nut and boLt set. See chapter 20 of the Maintenance</p><p>ManuaL (Standard Practices) or procurement</p><p>specification BPS-N-70 for these ranges.</p><p>CasteLLated nuts are used with externalLy threaded</p><p>~ fasteners having drilled holes in the threaded area and</p><p>'" ~ shalL be secured with cotter pins in accordance with</p><p>8, 9 the instaLLation requirements specified in BAC 500 ,</p><p>9 9 5018, MS33540 or chapter 20 (Standard Practices).</p><p>'" ..,</p><p>777 TRAINING MANUAL</p><p>ALignment of the casteLLated nut and the boLt cotter</p><p>pin hoLe whiLe staying within the specified torque</p><p>range is accompLished by changing the boLt grip Length</p><p>and/or adding washers.</p><p>For fLight safety appLications, FAR 25.607 states that</p><p>each</p><p>removabLe boLt, screw, nut, pin or other removabLe</p><p>fastener must incorporate two Locking devices.</p><p>63-05-00</p><p>- 160 -</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for 's</p><p>BACN10KB</p><p>AITEON</p><p>A BOEING COMPANY</p><p>TENSION NUT</p><p>BACN10HR</p><p>DEFORMABLE THREADS</p><p>BACN10KA</p><p>NUTPLATES</p><p>BACN10KF</p><p>777 TRAINING MANUAL</p><p>SHEAR NUT</p><p>BACN10JC</p><p>CLIP-ON</p><p>BACN10YD</p><p>FASTENERS - NUTS / NUTPLATES</p><p>63-05-00</p><p>- 161 -</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for details</p><p>> .. ..</p><p>00</p><p>9 g</p><p>I</p><p>9</p><p>'" '"</p><p>AlTEON</p><p>A BOEING COMPANY</p><p>FASTENERS -- SCREWS</p><p>Screws</p><p>Screws made of lower strength materials than bolts, are</p><p>used in non-structural applications such as in</p><p>passenger and flight deck areas, baggage compartment</p><p>sidewall liner attachments, fairings, removable panels</p><p>and other secondary structural installations.</p><p>Screws which have the same strength as bolts of the</p><p>same diameter, may be used for structural joints,</p><p>although it is important to ensure that screw threads</p><p>are not placed in bearing.</p><p>Screws are identified by several coding systems, of</p><p>which the most common are the 'AN' and 'NAS' series.</p><p>'AN' identifies the fastener as an Air Force/Navy</p><p>Standard and 'NAS' signifies that the fasteners are</p><p>National Aircraft Standards. Boeing numbers are used</p><p>for special purpose fasteners. An example of these</p><p>would be the BACS12ER titanium screws used in the flux</p><p>valve installation where a corrosion resistant, anti­</p><p>magnetic fastener is required. Another example is the</p><p>BACS12FA screw used to attach the sidewall liners in</p><p>the lower baggage compartments.</p><p>777 TRAINING MANUAL</p><p>63-05-00</p><p>- 162 -</p><p>AlTEON PROPRIETARY - Copyright (c) - See title page for s</p><p>15</p><p>o</p><p>~</p><p>N</p><p>, ....</p><p>o</p><p>> ..</p><p>'"</p><p>00</p><p>o</p><p>o</p><p>I</p><p>o</p><p>J:</p><p>9</p><p>'" '"</p><p>AlTEON</p><p>A BOEING COMPANY</p><p>BACS12FA</p><p>-6--+-1-</p><p>NAS 623</p><p>$--1-- -It</p><p>.. -- -. --</p><p>- $ - .or: -------", /"=-------t-</p><p>'" 0</p><p>I</p><p>NAS 1801</p><p>FASTENERS - SCREWS</p><p>- 163 -</p><p>777 TRAINING MANUAL</p><p>BACS12ER</p><p>NAS 517</p><p>63-05-00</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for details</p><p>> ..</p><p>"" I'­</p><p>N</p><p>'i'</p><p>9</p><p>9</p><p>'" '"</p><p>AlTEON</p><p>A BOEING COMPANY</p><p>FASTENERS -- HOLE FIT CLASSIFICATION AND APPLICATION</p><p>General</p><p>The National Aircraft Standard 618 lists the industry</p><p>standards for bolt diameters and corresponding hole</p><p>sizes.</p><p>The fits for the various hole classifications have been</p><p>shown for several representative bolt sizes.</p><p>The hole tolerance limits for class II and class III</p><p>holes are not as critical as those for the other</p><p>classes.</p><p>Interference fit holes are always smaller than the</p><p>fastener shank diameter.</p><p>Clearance fit holes are always larger than the fastener</p><p>shank diameter.</p><p>Fit Classification</p><p>Transition fit holes can be smaller, same or larger</p><p>than the fastener shank diameter.</p><p>Close Ream holes are same or slightly larger than the</p><p>fastener shank diameter.</p><p>Class I, II and III holes are larger than the fastener</p><p>shank diameter.</p><p>- 164 -</p><p>777 TRAINING MANUAL</p><p>63-05-00</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for's</p><p>> ..</p><p>'" ....</p><p>N</p><p>o</p><p>6</p><p>~</p><p>'i'</p><p>'" '"</p><p>AlTEDN</p><p>A BOEING COMPANY 777 TRAINING MANUAL</p><p>TRANSITION II=> CLOSE REAM CLASS I CLASS II CLASS</p><p>SIZE BOLT</p><p>DIAM HOLE HOLE HOLE HOLE HOLE</p><p>DIAM FIT DIAM FIT DIAM FIT DIAM FIT DIAM</p><p>3/16 .1885 .190 +.0015 .1905 +.0020 .194 +.0055 .199 +.0105 .229</p><p>.1895 .187 -.0025 .1895 +.000 .190 +.0005 .190 +.0005 .218</p><p>!:L:></p><p>114 .2485 .250 +.0015 .2505 +.0020 .254 +.0055 .261 +.0125 .291</p><p>.2495 .247 -.0025 .2495 .000 .250 +.0005 .250 +.0005 .279</p><p>II=> IN ALUMINUM STRUCTURE ONLY</p><p>!:L:>SHOWN AS .190 IN SOME HANDBOOKS</p><p>HOLE FASTENER APPLICATION CLASS I FICA TION</p><p>TRANSITION FIT LOCKBOLTS AND HILOKS IN ALUMINUM STRUCTURE</p><p>CLOSE REAM LOCKBOLTS AND HILOKS OTHER THAN THE ABOVE.</p><p>CLOSE TOLERANCE BOLTS WITH <4 FASTENERS IN THE JOINT</p><p>CLASS I STANDARD BOLTS AND CLOSE TOLERANCE BOLTS WITH 4 OR MORE</p><p>FASTENERS IN THE JOINT</p><p>CLASS II BOLTS ATTACHING REMOVABLE PANELS</p><p>CLASS III BOLTS ATTACHING REMOVABLE PANELS WHICH ARE NOT INTENDED TO PICK</p><p>UP ANY STRUCTURAL LOADS</p><p>FASTENERS - HOLE FIT CLASSIFICATION AND APPLICATION</p><p>63-05-00</p><p>- 165 -</p><p>III</p><p>FIT</p><p>+.0405</p><p>+.0285</p><p>+.0425</p><p>+.0295</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for details</p><p>AlTEDN</p><p>A BOEING COMPANY</p><p>FASTENER -- SUBSTITUTION</p><p>Genera l</p><p>When adapting the typical repairs shown in the SRM to</p><p>suit actual conditions, it may be necessary to use</p><p>fasteners of a different type to those originally</p><p>specified.</p><p>The fastener selection for SRM repairs is based on:</p><p>Strength</p><p>Corrosion protection</p><p>Weight</p><p>Temperature</p><p>Fatigue properties</p><p>Method of installation.</p><p>It can be necessary to install alternative fasteners</p><p>because:</p><p>The specific fastener is not available</p><p>It is not easy to get access to a necessary</p><p>location</p><p>The special repair is different from the general</p><p>repair.</p><p>An EQUIVALENT fastener is a fastener which is directly</p><p>interchangeable with the initial fastener. Usually the</p><p>equivalent fasteners are given under a vender part</p><p>number and are not always the same as those supplied to</p><p>~ the Boeing Company.</p><p>'"</p><p>o</p><p>N</p><p>9</p><p>o</p><p>~</p><p>9</p><p>'" '"</p><p>777 TRAINING MANUAL</p><p>An ALERNATIVE fastener is a fastener with equal or</p><p>greater strength properties than the initial fastener.</p><p>However, an alternative fastener cannot be used when:</p><p>They do not give the necessary pressure or fuel</p><p>sea l</p><p>Non-magnetic fasteners are necessary and the</p><p>fastener is magnetic</p><p>Fastener thread length, grip length or diameter is</p><p>not available</p><p>Access does not permit fastener installation</p><p>Fastener installation tools are not available.</p><p>NOTE: Do not use the Fastener Substitution Tables to</p><p>find alternatives for the fastener listed in the</p><p>ALTERNATIVE column.</p><p>Use of fasteners from different fastener groups is</p><p>permitted, but the alternative fasteners must have</p><p>equal or greater strength. Tension-type fasteners are</p><p>permitted in tension and shear applications. However,</p><p>shear-type fasteners are not permitted in tension</p><p>applications.</p><p>An example of a fastener substitution table is shown</p><p>below.</p><p>63-05-00</p><p>- 166 -</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for ls</p><p>AITEDN</p><p>A BOEING COMPANY</p><p><f!!I III'</p><p>~ fj7Qfj7</p><p>STRUCTURAL REPAIR</p><p>REPAIR FASTENER</p><p>OItJ6INAL OR SPECIFIED</p><p>CODE PART NUI18ER DESCRIPTIONI!I EQUIVALENT ALTERNATIVE Il!II!lI!l ...</p><p>XCI BACB30FMO-() [!] AllO)' STEEL, CAD '" "'*r ::~:~~:=i ~;~: [!J!) m PLATED, 95 I<SI SHEAR, HI-SMEAR HUBPS</p><p>CETYL ALCOHOL lUBRi- SPS MUBPS BACB10fM()AK() ImJ</p><p>[ATED, 450°f MAXIMUM VOl-SHAN Nl18PS BACB1OMB()-()</p><p>TEMPERATURE OEUTSCH HL18PS BAtB1OM8( )A()</p><p>IIEST COAST Nl18PS 8,1.(830611( I-() I!I!I</p><p>VEST COAST 11(22- IIACB3061HlAO</p><p>HI-SHEAR NUOVAP BACBlODX()-() I!I!I</p><p>HI-SHEAR H110VAZ BACB1ODX()A()</p><p>HI-SMEAR Hl44D BACB1OHC()-() [!(!J</p><p>HI-SHEAR HSTlOA6 BA(830"(( IA()</p><p>HI-SHEAR HST10AP</p><p>::~:~~~~~:~~: }rnm HI-SHEAR HST10AZ</p><p>YHU BACB10FHOk() [!] AllOY STEEL, BMS 10-85 DEUTSCH 'UO"}</p><p>BACB10NE()-O I!I!l</p><p>VHY COATED, 95 KSI SHEAR, SPS MUIIKD I!l BACB30lH()-( )</p><p>CETYL ALCOHOL LUSRI- HI-SHEAR HL181(D :~~:~~:::!~:: }[!!I!J</p><p>CATED, 150°F MAXIMUM VOl-SHAN HL181(D</p><p>TEMPERATURE HI-SHEAR H110VA</p><p>BACB1OLJ()-()</p><p>HI-SHEAI! H110VAZ ,,,",.NF()-() I</p><p>HI-SHEAR H5nOA6 BACB10FI)O-()</p><p>HI-SHEAR HSnOAP BACBJOFI)OPO</p><p>HI-SHEAR HST10AZ BACBJOVT()I«)</p><p>BACBJOVN()I«) CODE</p><p>'" BACBJOFMOA() A286 CRES, CAl) PLATEI), HI-SHEAR HL10VAP</p><p>XNJ 95 I(SI SHEAR, CETYL HI-SHEAR HL10VAZ XCZ Y6E ALCOHOL LUBRICATED, HI-SHEAR HL440UC</p><p>450°F MAXIMUM SPS HL440UC YEF</p><p>TEMPERATURE DEUTSCH HL440UC</p><p>VOl-SHAN HL440UC</p><p>WEST COAST Hl440UC</p><p>HI-SHEAR HSnOA6</p><p>HI-SHEAR HST10AP</p><p>HI-SHEAR HSnOAZ</p><p>WEST COAST wcno-</p><p>YMY BACBJOFM()AK() A286 CRES, BMS 10-85 HI SHEAR HL10VAP</p><p>YMS COATED, 95KSI SHEAR, HI-SHEAR H110VAZ</p><p>CETYl ALCOHOL LUBU- HI-SHEAR Hl440AP</p><p>CATED, HooF MAXIMUM DEUTSCH Hl440AZ</p><p>TEMPERATURE SPS HL440AZ</p><p>HI-SHEAR HL440AZ</p><p>VOl-SHAN HL440AZ</p><p>HI-SHEAR HST10A6</p><p>Ill-SHEAR HST10AP</p><p>HI-SHEAR HsnOAZ</p><p>YHU</p><p>XTC BACBJOMY()C{)[!J 6AL-4V TITANIUM, CAl)</p><p>YHY XTJ PLATEO,95I(SI SHEAR,</p><p>VAX CETYL ALCOHOL LUBRI-</p><p>CATED, 450°F MAXIMUM</p><p>TEMPERATURE</p><p>BOLT - HEX DR IVE - PROTRUD ING HEAD - SHEAR</p><p>TABLE V</p><p>XEK</p><p>Fastener Substitution XNJ</p><p>F ; gure 1 ( Sheet 11> YGE</p><p>> :. 51-30-03</p><p>Page 14 747 SRM L----</p><p>Mar 15/94</p><p>FASTENER</p><p>~</p><p>[8J</p><p>ORIGINAL OR</p><p>PART NUMBER</p><p>BACB30FM()-() [!)</p><p>BACB30FM( lK( l [!)</p><p>BACB30FM()A()</p><p>777 TRAINING MANUAL</p><p>0</p><p>f</p><p>i</p><p>o not substitute cadmium plated fasteners</p><p>or bare or BMS 10-85 coated fasteners when</p><p>nstalled through titanium structure.</p><p>0</p><p>b</p><p>S</p><p>o not substitute lockbolts for hex drive</p><p>olts when installed through composite</p><p>tructure.</p><p>REPAIR FASTENER</p><p>S PECIFIED</p><p>AL</p><p>PL</p><p>CE</p><p>CA</p><p>TE</p><p>AL</p><p>CO</p><p>CE</p><p>DESCR IPTION [!!]</p><p>LOY STEEL, CAD</p><p>ATED, 95 KSI SHEAR,</p><p>TYL ALCOHOL LUBRI­</p><p>TED, 4500F MAXIMUM</p><p>MPERATURE</p><p>LOY STEEL, BMS 10-85</p><p>ATED, 95 KSI SHEAR,</p><p>TYL ALCOHOL LUBRI­</p><p>C ATED, 3500F MAXIMUM</p><p>"PERATURE TE</p><p>A2</p><p>95</p><p>AL</p><p>45</p><p>TE</p><p>86 CRES, CAD PLATED,</p><p>KSI SHEAR, CETYL</p><p>COHOL LUBRICATED,</p><p>OoF MAXIMUM</p><p>MPERATURE</p><p>EQUIVALENT</p><p>SPS 62550_} H I -SHEAR HLl8PB</p><p>SPS HLl8PB</p><p>VOl-SHAN HL18PB [!)</p><p>DEUTSCH HLl8PB</p><p>WEST COAST HLl8PB</p><p>WEST COAST WC22-</p><p>HI-SHEAR HLIOVAP</p><p>HI-SHEAR HL10VAZ</p><p>HI-SHEAR HL440</p><p>HI-SHEAR HSTIOAG</p><p>HI-SHEAR HSTIOAP</p><p>HI-SHEAR HST10AZ</p><p>DEUTSCH</p><p>SPS</p><p>HI-SHEAR</p><p>VOl-SHAN</p><p>HI-SHEAR</p><p>HI-SHEAR</p><p>HI-SHEAR</p><p>HI-SHEAR</p><p>HI-SHEAR</p><p>HI-SHEAR</p><p>HI-SHEAR</p><p>HI-SHEAR</p><p>SPS</p><p>DEUTSCH</p><p>~t~:~u I!J</p><p>HLl8KD</p><p>HL18KD</p><p>HL10V</p><p>HL 10VAZ</p><p>HSTIOAG</p><p>HSTIOAP</p><p>HSTI OAZ</p><p>HLIOVAP</p><p>HL 10VAZ</p><p>HL440UC</p><p>HL440UC</p><p>HL440UC</p><p>ALTERNATIVE [!!] [!9 ~</p><p>BACB30FM()-() I!m</p><p>BACB30FM() A()</p><p>BACB30FM()AK() !m"I]</p><p>BACB30MB()-() [!]!]</p><p>BACB30MB ( l A ( l</p><p>BACB30GW()-() I::!rn</p><p>BACB30GW( lA( l</p><p>BACB30DX()-() I::!rn</p><p>BACB30DX()A()</p><p>BACB30HC()-() I::!rn</p><p>BACB30HC()A()</p><p>BACB30NX()K()} I"IJTV1</p><p>BACB30MY()K() l.!!L!..J</p><p>BACB30NE()-() I::!rn</p><p>BACB30LM() - ()</p><p>BACB30NM()K () } I"!I'1'Y1</p><p>BACB30NR ()K () l.!!L!..J</p><p>BACB30LJ()-()</p><p>BACB30NF()-() I</p><p>BACB30FD()-() T W</p><p>BACB30F D () P () T</p><p>BACB30VT ()K 0</p><p>BACB30VNOKO Y</p><p>-<--</p><p>SUBSTITUTION</p><p>63-05-00</p><p>- 167 -</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for details</p><p>AITEDN</p><p>A BOEING COMPANY</p><p>FASTENERS -- FASTENER FINISH REQUIREMENTS</p><p>THIS PAGE INTENTIONALLY LEFT BLANK</p><p>- 168 -</p><p>777 TRAINING MANUAL</p><p>63-05-00</p><p>ALTEON PROPRIETARY - Copyright <c) - See title page for's</p><p>AITEDN</p><p>A BOEING COMPANY</p><p>FASTENERS -- FASTENER FINISH REQUIREMENTS</p><p>Fastener Finish Requirements</p><p>The fastener finish requirements for use with various</p><p>aircraft materials are shown. These recommendations</p><p>should be followed so as to minimize the potential for</p><p>corrosion resulting from rework operations.</p><p>The recommended fasteners in aluminum structure are BMS</p><p>10-85 (aluminum-pigmented coating) coated titanium, BMS</p><p>10-85 coated A-286, or cadmium-plated A-286. Cadmium­</p><p>plated alloy-steel fasteners are a structurally</p><p>satisfactory alternative. However, in a corrosive</p><p>environment the cadmium plating, which is a sacrificial</p><p>coating, may disappear allowing the alloy-steel</p><p>fastener to corrode. This may result in the rust­</p><p>streaking of the surrounding structure and/or the start</p><p>of corrosion of any adjacent aluminum structure.</p><p>All steel and titanium fasteners must be installed wet</p><p>with BMS 5-95 or equivalent sealant.</p><p>With the exception of 5056 rivets installed in aluminum</p><p>structure, it is recommended that all rivets are</p><p>installed dry. Fay surface sealant does not need to be</p><p>removed from the fastener holes before rivet</p><p>installation. However, because of their head geometry.</p><p>Briles rivets (BACR15FV) should never be installed wet</p><p>with sealant, since the reduction in hole filling</p><p>ability wiLL degrade the fatigue quality of the joint.</p><p>See the StructuraL Repair Manual for the latest</p><p>information.</p><p>777 TRAINING MANUAL</p><p>63-05-00</p><p>- 169 -</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for details</p><p>AlTEON</p><p>A BOEING COMPANY 777 TRAINING MANUAL</p><p>FASTENER AND FASTENER HARDWARE INSTALLATION</p><p>DETERMINE THE METAL GROUP OF EACH ALLOY USED IN THE ASSEMBLY, THE LOCATION OF</p><p>EACH ALLOY AND THE LOCATION WITHIN THE AIRPLANE, THEN SELECT THE LOCATION WITHIN</p><p>THE AIRPLANE, THEN SELECT THE INSTALLATION PROTECTION FINISH CODE FROM TABLE.</p><p>METAL GROUP IT]</p><p>0 II ~ III /< IV ~ III Xv IV y,: IV</p><p>LOCATION IN THE AIRPLANE . INT EXT INT EXT INT EXT INT EXT INT EXT INT EXT</p><p>FASTENER OR HARDWARE t</p><p>ALUMINUM 1 1 2 2 X X X X X X X X</p><p>ALLOY STEEL, CAD PLATED 1a X 1a X X X 2 X X X X X</p><p>CRES, PASSIVATED OR DRY FILM LUBED X X X X X X X X X X 1 1</p><p>CRES, CAD PLATED or BMS10-85 COATED 1a 2 2 2 2b 2b 2 2 2b 2b 1b 1b</p><p>TITANIUM X X X X X X X X X X 1 1</p><p>TITANIUM, BMS 10-85 COATED 1 2 2 2 2 2 2 2 2 2 1 1</p><p>X: DO NOT USE</p><p>1: NO FINISH (DRY INSTALLATION)</p><p>2: FOR PERMANENTLY INSTALLED FASTENERS, WET INSTALL WITH BMS5-95 SEALANT.</p><p>FOR REMOVABLE BOLTS/NUT COMBINATIONS, INSTALL WITH BMS3-27.</p><p>FOR FASTENERS, INSTALLED INTO NUT PLATES, PRIME HOLE WITH BMS10-11 TYPE I PRIMER AND</p><p>INSTALL WIH MIL-C-11796, CLASS3.</p><p>a: FOR BLIND FASTENERS, WET INSTALL WITH BMS5-95</p><p>b: CADMIUM-PLATED FASTENERS AND FASTENER HARDWARE SHALL NOT BE USED IN CONTACT WITH</p><p>TITANIUM OR CFRP</p><p>INT: INTERIOR (NOT EXPOSED TO OUTSIDE ENVIRONMENT)</p><p>EXT: EXTERIOR (EXPOSED TO OUTSIDE ENVIRONMENT)</p><p>[] METAL GROUP:</p><p>I MAGNESIUM AND ITS ALLOYS</p><p>II CADMIUM-TITANIUM PLATE AND CADMIUM ZINC,ALUMINUM AND THEIR ALLOYS</p><p>III IRON, STEELS (EXCEPT CORROSION-RESISTANT STEELS), LEAD, TIN AND THEIR ALLOYS</p><p>IV COPPER, BRASS, BRONZE, (ALUMINUM BRONZE OR ALUMINUM NICKEL BRONZE), COPPER-NICKEL,</p><p>COPPER BERYLLIUM, CHROMIUM, MOLYBDENUM. NICKEL AND NICKEL BASE ALLOYS, COBALT ALLOYS,</p><p>TITANIUM AND TITANIUM ALLOYS, TUNGSTEN, CRES, CARBON, CFRP, SILVER AND GOLD</p><p>FASTENERS - FASTENER FINISH REQUIREMENTS</p><p>63-05-00</p><p>- 170 -</p><p>ALTEON PROPRIETARY - Copyright <d - See title page for '.s</p><p>AlTEDN</p><p>A BOEING COMPANY 777 TRAINING MANUAL</p><p>FASTENER SELECTION (CONTINUED)</p><p>COMPATIBLE MATERIAL--FASTENERS</p><p>STRUCTURE FASTENER FASTENER</p><p>MATERIAL MATERIAL FINISH</p><p>ALLOY STEEL CADMIUM OR ALUMINUM</p><p>ALLOY STEEL, OR</p><p>ALUMINUM + STEEL CRES CADMIUM</p><p>TITANIUM ALUMINUM OJ</p><p>ALLOY STEEL ALUMINUM IT]</p><p>ALUMINUM + OJ TITANIUM CRES ALUMINUM</p><p>TITANIUM ALUMINUM OJ</p><p>ALUMINUM ANODIZE</p><p>ALUMINUM</p><p>ALLOY STEEL CADMIUM OR ALUMINUM</p><p>CRES CADMIUM OR ALUMINUM</p><p>TITANIUM ALUMINUM OJ</p><p>MAGNESIUM 5052 ALUMINUM ANODIZE</p><p>ANY H-11 ALLOY NICKEL-CADMIUM (INSTALL</p><p>EXCEPT TITANIUM STEEL WITH WET PRIMER OR</p><p>SEALANT) OR ALUMINUM</p><p>TITANIUM OR CRES PASSIVATE IT]</p><p>CRES TITANIUM PHOSPHATE FLUORIDE OJ OR ALUMINUM</p><p>COMPOS ITEI AL TITANIUM CRES ALUMINUM</p><p>OJ DO NOT USE CADMIUM PLATED FASTENERS</p><p>FASTENERS - FASTENER FINISH REQUIREMENTS</p><p>63-05-00</p><p>- 171 -</p><p>ALTEON PROPRIETARY - Copyright (c) - See title page for details</p><p>> .. ..</p><p>'" 9</p><p>9</p><p>'" 'i'</p><p>'" '"</p><p>AlTEON</p><p>A BOEING COMPANY</p><p>FASTENERS -- FASTENERS SECTION QUIZ</p><p>THIS PAGE INTENTIONALLY LEFT BLANK</p><p>777 TRAINING MANUAL</p><p>63-05-00</p><p>- 172 -</p><p>ALTEON PROPRIETARY - Copyright (e) - See title page for Is</p>