Goodrich Proprietary - This Document Is Subject To The Controls and Restrictions On The Title Page. U. S. Export Classification: EAR 9E991

850 LAGOON DRIVE
CHULA VISTA CALIFORNIA 91910-2098 TEL: (619) 691-4111•TELEX:69-5038
Nov 1, 2017
SUBJECT: V2500 A1 and A5 Tail Cone Assembly Component Maintenance

Manual (RDN 606)
Revision No. 11, Dated Aug 1/17.
The subject manual revision is being transmitted.
Technical questions or comments concerning this publication should be

submitted through the web portal at
https://www.customers.utcaerospacesystems.com/2.
Printing and distribution requirement changes should be directed to
Goodrich Aerostructures, Aftermarket Technical Services, e-mail at
techpubs@utas.utc.com.
Goodrich Proprietary - This document is subject to the controls and restrictions on the title page.
U. S. Export Classification: EAR 9E991
THIS PAGE INTENTIONALLY LEFT BLANK
GOODRICH AEROSTRUCTURES
COMPONENT MAINTENANCE MANUAL
Part Nos. 290-1501, 740-1061 and 745-1502
TRANSMITTAL LETTER
TO: V2500-A1/A5 Component Maintenance Manual Distribution
CONCERNING: Tail Cone Assembly 78-11-12 Revision 11,

Dated Aug 1, 2017
MANUAL UPDATE INSTRUCTIONS
This is a complete re-issue of the manual. Discard the old manual upon
receipt of this re-issued manual.
Chapter/Section/Subject Page Number Description of Change

Repair:
Repair 003 6005 Revise step procedure
V2500-A1/A5 78-11-12 TRANSMITTAL LETTER

Page 1
Aug 1/17
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures
Part Nos. 290-1501, 740-1061 and 745-1502
V2500-A1/A5 78-11-12 TRANSMITTAL LETTER

Page 2
Aug 1/17
TAIL CONE ASSEMBLY
PART NOS.
290-1501
740-1061
745-1502
AND
ILLUSTRATED PARTS LIST
RDN 606
Initial Issue: February 1/09
Revised: Aug1/17
TRANSMITTAL OF TECHNICAL DATA (EAR)

THESE COMMODITIES, TECHNOLOGY, OR SOFTWARE ARE CONTROLLED BY THE U.S. EXPORT
ADMINISTRATION REGULATIONS (EAR). DIVERSION CONTRARY TO U.S. LAW IS PROHIBITED.
ECCN: 9E991
Goodrich Aerostructures Proprietary Information

The information contained in this document is Goodrich proprietary information and is disclosed in confidence. It is the property of Goodrich and shall not be
used, disclosed to others or reproduced without the express written consent of Goodrich, including, but without limitation, it is not to be used in the creation,
manufacture, development, or derivation of any repairs, modifications, spare parts, design, or configuration changes or to obtain FAA or any other government
or regulatory approval to do so. If consent is given for reproduction in whole or in part, this notice and the notice set forth on each page of this document shall
appear in any such reproduction in whole or in part. The information contained in this document may also be controlled by the U.S. export control laws.
Unauthorized export or re-export is prohibited.
Copyright License:
Customer is authorized to copy these materials for its own use only, provided that all copyright notices, proprietary legends, confidential markings, and other
restrictive notices appearing on the original materials are preserved on all such copies.
Caution Regarding Use of Materials:

It is customer’s sole responsibility to ascertain and ensure that all materials are current and appropriate for the use to which they are put and Goodrich assumes
no responsibility whatsoever in that regard. Customer agrees to indemnify and save harmless Goodrich against all claims and liability of whatever nature,
including those of third parties (including contractors and vendors to customer) where and by whomsoever brought, resulting from customer’s use of materials
or other information, consultation, assistance, or training furnished or any other performance in connection with this agreement by Goodrich or from the
manufacture, sale, delivery, resale of any product by customer. In no event shall Goodrich be liable for any special, incidental, indirect or consequential or
punitive damages.
78-11-12
Part Nos. 290-1501, 740-1061 and 745-1502

Part Nos. 290-1501, 740-1061 and 745-1502
RECORD OF REVISIONS
REV DATE DATE REV DATE DATE

NO. ISSUED INSERTED BY NO. ISSUED INSERTED BY
Initial Feb 1/09
1 Aug 1/09
2 Nov 1/09
3 Nov 1/11
3 Nov 1/11
4 Feb 1/12
5 Nov 1/12
6 Feb 1/13
7 Nov 1/14
8 Feb 1/15
9 Nov 1/15
10 Feb 1/17
11 Aug 1/17
RETAIN THIS RECORD IN THE FRONT OF THE MANUAL. UPON RECEIPT OF REVISION,
INSERT REVISED PAGES IN THE MANUAL AND ENTER REVISION NUMBER, ISSUE DATE,
DATE INSERTED, AND INITIALS.
V2500-A1/A5 78-11-12 RECORD OF REVISIONS

Page 1
Aug 1/17
Printed in the U.S.A
Rohr, Inc., Operating as Goodrich Aerostructures;
Goodrich Proprietary - This documentis subject to the controls and restrictions on the title page.
Part Nos. 290-1501, 740-1061 and 745-1502
V2500-A1/A5 78-11-12 RECORD OF REVISIONS

Page 2
Aug 1/17
Printed in the U.S.A
Rohr, Inc., Operating as Goodrich Aerostructures;
Goodrich Proprietary - This documentis subject to the controls and restrictions on the title page.
Part Nos. 290-1501, 740-1061 and 745-1502
RECORD OF TEMPORARY REVISIONS
ISSUE DATE ISSUE DATE

REV DATE INSERTED BY REV DATE INSERTED BY
RETAIN THIS RECORD IN THE FRONT OF THE MANUAL. UPON RECEIPT OF REVISION,
INSERT REVISED PAGES IN THE MANUAL AND ENTER REVISION NUMBER, ISSUE DATE,
DATE INSERTED, AND INITIALS.
V2500-A1/A5 78-11-12 TEMPORARY REVISIONS

Page 1
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
V2500-A1/A5 78-11-12 TEMPORARY REVISIONS

Page 2
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
SERVICE BULLETIN LIST
SERVICE DATE BULLETIN

BULLETIN ORIGINAL ISSUE REVISION NUMBER INCORPORATED INTO
NUMBER DATE AND DATE MANUAL
70-0541 May 15/97 Rev 2 Feb 06/98 Feb 1/09
78-0066 Jul 22/93 Feb 1/09
78-0096 Jan 25/95 Rev 2 May 25/95 Feb 1/09
V2500-A1/A5 78-11-12 SERVICE BULLETIN LIST

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Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502

Page 2
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
TABLE OF CONTENTS
Title Page
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . INTRO-1
Description and Operation . . . . . . . . . . . . . . . . . . . 1
Testing and Fault Isolation (Not Applicable). . . . . . . . . N/A
Automatic Test Requirements (Atlas) (Not Applicable) . . . . . N/A
Disassembly (Not Applicable). . . . . . . . . . . . . . . . . N/A
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001
Check 001 . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001
Check 003 . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001
Check 004 . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001
General Repair . . . . . . . . . . . . . . . . . . . . . . . . 6001
Repair 001 (VRS2204) Weld Repair for Buckled Skin - DELETED . 6001
Repair 002 (VRS2306) Weld Repair for Cracks - DELETED . 6001
Repair 003 (VRS2165) Tail Cone Pin Repair in the Field Area of
the Perforated Skin. . . . . . . . . . . 6001
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001
Fits and Clearance (Not Applicable) . . . . . . . . . . . . . N/A
Special Tools, Fixtures, and Equipment (Not Applicable) . . . N/A
Illustrated Parts List Introduction. . . . . . . . . . . . . . 10001
Service Bulletin List. . . . . . . . . . . . . . . . . . . . . 10002
Numerical Index . . . . . . . . . . . . . . . . . . . . . . . 10003
V2500-A1/A5 78-11-12 TABLE OF CONTENTS

Page 1
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
Title Page
Figure 1, Tail Cone . . . . . . . . . . . . . . . . . . . . . . 10004
V2500-A1/A5 78-11-12 TABLE OF CONTENTS

Page 2
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
LIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE SUBJECT PAGE DATE

Title Page 1 Aug 1/17 Cleaning 4001 Aug 1/17
2 BLANK 4002 Aug 1/17
4003 Aug 1/17
Record of 1 Aug 1/17 4004 BLANK
Revisions 2 BLANK
Check 001 5001 Aug 1/17
Record of 1 Aug 1/17 (Config. 1) 5002 Aug 1/17
Temporary 2 BLANK
Revisions Check 003 5001 Aug 1/17
(Config. 3) 5002 Aug 1/17
Service 1 Aug 1/17 5003 Aug 1/17
Bulletin 2 BLANK 5004 Aug 1/17
List 5005 Aug 1/17
5006 BLANK
List of 1 Aug 1/17
Effective 2 Aug 1/17 Check 004 5001 Aug 1/17
Pages (Config. 4) 5002 Aug 1/17
5003 Aug 1/17
Table of 1 Aug 1/17 5004 BLANK
Contents 2 BLANK
General 6001 Aug 1/17
Introduction 1 Aug 1/17 Repair 6002 Aug 1/17
2 Aug 1/17
3 Aug 1/17 Repair 001 6001 Aug 1/17
4 Aug 1/17 (Cancelled) 6002 BLANK
5 Aug 1/17
6 Aug 1/17 Repair 002 6001 Aug 1/17
7 Aug 1/17 (Cancelled) 6002 BLANK
8 Aug 1/17
9 Aug 1/17 Repair 003 6001 Aug 1/17
10 Aug 1/17 6002 Aug 1/17
11 Aug 1/17 6003 Aug 1/17
12 Aug 1/17 6004 Aug 1/17
6005 Aug 1/17
Description 1 Aug 1/17 6006 Aug 1/17
and 2 Aug 1/17 6007 Aug 1/17
Operation 3 Aug 1/17 6008 Aug 1/17
4 BLANK 6009 Aug 1/17
6010 Aug 1/17
(N) Indicates new page 78-11-12 LIST OF EFFECTIVE PAGES

Page 1
(D) Indicates deleted page Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
LIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE SUBJECT PAGE DATE

Repair 003 6011 Aug 1/17
(Cont) 6012 BLANK
Storage 7001 Aug 1/17

7002 BLANK
Illustrated 10001.1 Aug 1/17
Parts List 10001.2 Aug 1/17
Introduction 10001.3 Aug 1/17
10001.4 Aug 1/17
10001.5 Aug 1/17
10001.6 BLANK
Service 10002.1 Aug 1/17

Bulletin 10002.2 BLANK
List
Numerical 10003.1 Aug 1/17

Index
Figure 1 10004.0 Aug 1/17

10004.1 Aug 1/17
10004.2 BLANK
(N) Indicates new page 78-11-12 LIST OF EFFECTIVE PAGES

Page 2
(D) Indicates deleted page Aug 1/17
Goodrich Proprietary - This document is subject to the controls and restrictions on the title page..
Part Nos. 290-1501, 740-1061 and 745-1502
INTRODUCTION 0
Task 78-11-12-830-001
1. General
A. This component maintenance manual contains seven sections as

listed below:
(1) Introduction
(2) Description and Operation
(3) Cleaning
(4) Check
(5) Repairs
(6) Storage
(7) Illustrated Parts List
(a) The Illustrated Parts List section contains a list of parts

necessary to return the unit to serviceable condition. An
explanation of the use of the Illustrated Parts section is
given in the introduction to that section.
B. Manual Use
(1) This manual can be used to do repairs on the exhaust plug

assembly, after the assembly has been removed from the engine.
The Check and Repair sections are written so that malfunctions
can be found and the damaged or unserviceable components can be
removed and replaced.
C. Refer to the Table of Contents for the page location of applicable

sections.
D. All weights and measurements are in U.S. units with S.I. metric
units in parentheses.
V2500-A1/A5 78-11-12 INTRODUCTION

Page 1
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
E. This manual will be revised as necessary to show the most current

information.
2. Consumable Materials Index
A. The Consumable Materials Index gives details of all the consumable

materials that are required during structural repair of the Tail
Cone Assembly.
B. The index is divided into three sections:
(1) An alphanumeric index which lists the consumable materials in

alphabetical order.
(2) A materials index, which lists the consumable materials by

CoMat number.
(a) V01 - Processing and Cleaning Materials
(b) V02 - Processing Sundries
(c) V04 - Jointing Compounds and Greases
(d) V05 - Polishing, Abrasives, and Blasting
(e) V06 - Inspecting
(f) V07 - Paints, Varnishes, and Thinners
(g) V08 - Bonding Adhesives, Fillers, and Sealers
(h) V10 - Oils, Fluids, and Lubricants
(i) V12 - Packing
(3) A list of suppliers names and addresses which are in order

alphanumerically by SUPPLIER CODE.

Page 2
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
C. Alphanumerical Index
DESIGNATION ITEM NUMBER

Aluminum oxide abrasive paper 05-129
Barrier material 01-233
Neoprene coated gloves 02-200
Stainless steel wire brush 02-331
Inconel 625 sheet stock 0.032 in. (0,81 mm) thick 03-334
Lint-free cloth 02-099
Lint-free gloves 02-097
Marking pen, Sharpie Marker No. 30001 Black 06-131
Methyl ethyl ketone TT-M-261 01-076
Primary cleaner 01-070
Solvent 01-438
Temporary rust preventive 10-015
Waterproof silicon carbide abrasive paper 05-021
Welding filler wire (AMS 5837) 03-287
Welding filler wire (AMS 4952) 03-348
D. Materials Index
COMAT
ITEM SUPPLIER
NUMBER DESIGNATION SPECIFICATION USAGE CODE
01-070 Primary Turco 5948-R To clean V0BYN5
cleaner components VIAE247
VK4958
01-076 Methyl ethyl TT-M-261 To clean Local
ketone mechanical
component
01-233 Barrier MIL-B-121 To protect V0A354
material Type 2 Gr. A, components
CL 1

Page 3
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
COMAT
ITEM SUPPLIER
NUMBER DESIGNATION SPECIFICATION USAGE CODE
01-438 Solvent TURCO No. To clean VIAE228
6646 mechanical
components
02-097 Lint-free N/A To protect Local
gloves hands and
components
02-099 Lint-free N/A To clean Local
cloth components
02-200 Neoprene N/A To protect V3A054
coated gloves hands and V51563
components
02-331 Stainless P/N 4300-0024 To clean V17987
steel wire components
brush
03-287 Welding filler AMS 5837 - To weld skin V0B491
wire Inconel 625 repairs V22994
Local
03-334 Inconel 625 AMS 5599 To repair V0FGC3
sheet stock skin V8M212
03-348 Welding filler AMS 4952 To weld skin V0B491
wire repairs V0FGC3
Local
05-021 Waterproof A-A-1047 Grit To contour VK3895
silicone size 240 repairs V44197
carbide
abrasive paper
05-129 Aluminum oxide Grit size 320 To contour V06565
abrasive paper repairs V51563
06-131
06-131 Marking pen Sharpie To mark V86874
Marker no. permanently
30001 black,
30002 red,
30003 blue
10-015 Temporary rust MIL-C-16173 To protect V07950
preventive Grade 2 components V36131
NATO C-614 VIAE248

Page 4
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
E. Suppliers Names and Addresses
CODE NAME AND ADDRESS

V06565 Norton Company
Coated Abrasive & Tape Div.
P.O. Box 808
Troy, NY 12181
USA
V07950 Royal Lubricants Co. Inc.
P.O. Box 518
Merry Lane
East Hanover, NJ 07936
USA
V0A354 James River Corp.
H.P. Smith Paper Div.
5001 W 66th Street
Bedford Park, IL 60638
USA
V0B491 Hi-Tech Alloys
25 West Street
P.O. Box 536
Stafford Springs, CT 06076
USA
V0BYN5 TURCO Products, Inc.
Division of ELF Atochem North
America
7300 Bolsa Avenue
Westminster, CA 92684-3600
USA
V0FGC3 Carolina Metals Inc.
1350 Brevard Road
Asheville, NC 28806
USA
V17987 Gordon Brush Manufacturing, Inc.
2150 Sacramento Street
Los Angeles, CA 90021-1786
USA
V22994 Astrolite Alloys
1201 Vanguard Drive
Oxnard, CA 93033
USA

Page 5
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502

V36131 Shell Canada, LTD
400 4th Avenue SW
Calgary, Alberta
Canada T2P 1H5
V3A054 McMaster-Carr Supply Co.
9630 Norwalk Blvd
Santa Fe Springs, CA 90670-2932
USA
V44197 Norton Co.
Export Sales
1 New Bond St.
P.O. Box 15008
Worcester, MA 01615-0008
USA
V51563 Rohr, Inc.
850 Lagoon Drive
Chula Vista, CA 91910-2098
USA
V86874 Sanford Corp.
2711 Washington Blvd.
Bellwood, IL 60104
USA
V8M212 Kentucky Metals Inc.
825 Progress Blvd.
New Albany, IN 47150
USA
VIAE228 Turco Purex Industrial
24600 S. Main Street
P.O. Box 6200
Carson, CA 90749
USA
VIAE247 TURCO Italiana S.P.A.
Via Artiglianale
25010 Montirone (Brescia)
Italy

Page 6
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502

VIAE248 Shell Company of Australia, LTD.
Shell House
Level 23
1 Spring Street
Melbourne, Victoria 3000
P.O. Box 872 K
Australia
VK3895 English Abrasives & Chemicals, LTD.
Doxey Road
Stafford
ST16 IEA
Great Britain
3. Cautions, Warnings and Dangers
NOTICE!! Carefully read and obey all CAUTION and WARNING

statements in this manual. Refer to the
descriptions of these statements that follow:
- A "CAUTION" statement is given to prevent damage
to equipment.
- A "WARNING" statement is given to prevent
personal injury or illness
CHEMICALS - Obey the warning below for maintenance of components

manufactured or delivered by Goodrich.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND
OBEY ALL SAFETY INSTRUCTIONS FOR THE CHEMICALS.
THESE INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET
(MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY
CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY
INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND
DISCARD CHEMICALS.

Page 7
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
CADMIUM - Obey the warnings below before you touch or do maintenance

on parts that are cadmium plated. Many small steel parts, including
fasteners, are cadmium plated. Some primers and top coat finishes
may contain cadmium. The Occupational, Safety, and Health
Administration (OSHA) sets mandatory limits on exposure to cadmium
dust (29 CFR 1910.1027).
WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT IS
SWALLOWED CAN CAUSE KIDNEY OR REPRODUCTIVE SYSTEM
DISEASE. AFTER YOU TOUCH CADMIUM PLATED PARTS,
CLEAN YOUR HANDS BEFORE YOU EAT OR SMOKE. GET
SAFETY INSTRUCTIONS FROM YOUR EMPLOYER. OBEY
GOVERNMENT AND OSHA REGULATIONS WHEN YOU DISCARD
PARTS THAT CONTAIN CADMIUM.
WARNING: DO NOT INHALE CADMIUM PARTICLES, FUMES, OR DUST.
THESE PARTICLES, FUMES, OR DUST CAN CAUSE LUNG OR
KIDNEY DISEASE. IF MAINTENANCE PROCEDURES CREATE
CADMIUM PARTICLES, FUMES, OR DUST, TELL YOUR
EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION, AND/
OR PROCEDURES TO PREVENT EXPOSURE TO PERSONNEL.
The Occupational, Safety, and Health Administration (OSHA) has an
applicable DANGER warning (29 CFR 1910.1027 (m)(3)(ii)) as follows:
DANGER: CONTAINS CADMIUM. CANCER HAZARD. AVOID CREATING
DUST. CAN CAUSE LUNG AND KIDNEY DISEASE.
ASBESTOS - Obey the warning below before you touch or do maintenance
on parts that contain asbestos. Some old assembly components may
contain asbestos. The Occupational, Safety, and Health
Administration (OSHA) sets mandatory limits on exposure to asbestos
dust (29 CFR 1910.1001).
WARNING: DO NOT BREATHE ASBESTOS DUST. THIS DUST CONTAINS
ASBESTOS FIBERS THAT CAN CAUSE CANCER AND LUNG
DISEASE. DO NOT USE COMPRESSED AIR TO CLEAN PARTS
OR ASSEMBLIES THAT POSSIBLY CONTAIN ASBESTOS DUST.
IF MAINTENANCE PROCEDURES EXPOSE PERSONNEL TO
ASBESTOS DUST, TELL YOUR EMPLOYER TO SUPPLY
RESPIRATORS, VENTILATION, AND/OR PROCEDURES TO
PREVENT EXPOSURE TO PERSONNEL. OBEY GOVERNMENT AND
OSHA REGULATIONS WHEN YOU DISCARD PARTS THAT
CONTAIN ASBESTOS.
The Occupational, Safety, and Health Administration (OSHA) has an
applicable DANGER warning (29 CFR 1910.1001 (j)(4)(ii)) as follows:
DANGER: CONTAINS ASBESTOS FIBERS. AVOID CREATING DUST.
CANCER AND LUNG DISEASE HAZARD.

Page 8
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
BERYLLIUM or BERYLLIUM COPPER ALLOYS - Obey the warning below before

you touch or do maintenance on parts that contain beryllium. Bronze
bearings and bushings may contain beryllium or beryllium copper
alloys. The Occupational, Safety, and Health Administration (OSHA)
sets mandatory limits on exposure to dust or fumes from beryllium or
beryllium copper alloys
(29 CFR 1910.1000).
WARNING: DO NOT BREATHE BERYLLIUM PARTICLES OR DUST. THESE
PARTICLES OR DUST CAN CAUSE CANCER OR LUNG DISEASE.
IF MAINTENANCE PROCEDURES MAKE BERYLLIUM PARTICLES
OR DUST, TELL YOUR EMPLOYER TO SUPPLY RESPIRATORS,
VENTILATION, AND/OR PROCEDURES TO PREVENT EXPOSURE
TO PERSONNEL. OBEY GOVERNMENT AND OSHA REGULATIONS
WHEN YOU DISCARD PARTS THAT CONTAIN BERYLLIUM. READ
AND OBEY THE NEWEST APPLICABLE MATERIAL SAFETY DATA
SHEET (MSDS) THAT IS AVAILABLE FROM BRUSH WELLMAN
INC. (REFER TO THE ADDRESS BELOW).
The newest MSDS for beryllium is available from:

Brush Wellman Inc. Tel.: (800) 862-4118
Product Stewardship Fax: (419) 862-4414
Department www.brushwellman.com
14710 W. Portage River
S. Road
Elmore, Ohio 43416-9502
USA
CERAMIC FIBERS - Obey the warning below before you do maintenance on
parts that contain ceramic fibers. Heat resistant cloth and foil
covered heat shields and thermal blankets may contain ceramic
fibers. The Occupational, Safety, and Health Administration (OSHA)
and the Refractory Ceramic Fibers Coalition (RCFC) have a voluntary
personnel protection program (PSP 2002, Feb. 11, 2002). This program
gives limits on personnel exposure to ceramic fibers.

Page 9
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
WARNING: DO NOT BREATHE CERAMIC FIBER DUST. THIS DUST

CONTAINS CERAMIC FIBERS THAT MAY CAUSE CANCER. DO
NOT USE COMPRESSED AIR TO CLEAN PARTS OR ASSEMBLIES
THAT POSSIBLY CONTAIN CERAMIC FIBERS. IF
MAINTENANCE PROCEDURES EXPOSE PERSONNEL TO CERAMIC
FIBERS, TELL YOUR EMPLOYER TO SUPPLY RESPIRATORS,
VENTILATION, AND/OR PROCEDURES TO PREVENT EXPOSURE
TO PERSONNEL. OBEY GOVERNMENT AND OSHA REGULATIONS
WHEN YOU DISCARD PARTS THAT CONTAIN CERAMIC FIBERS.
READ AND OBEY THE NEWEST APPLICABLE MATERIAL SAFETY
DATA SHEET (MSDS).
CHROMATES (HEXAVALENT CHROMIUM) - Obey the warnings below before you
touch or do maintenance on parts that contain hexavalent chromium.
Chromated primers, Alodines, and corrosion inhibiting sealants used
in the manufacture and assembly of components may contain hexavalent
chromium. Emissions that are created when you weld or thermally cut
metal alloys may contain hexavalent chromium. The Occupational
Safety and Health Administration (OSHA) sets mandatory limits on
exposure to chromium dust (29 CFR 1910.1000).
WARNING: DO NOT GET HEXAVALENT CHROMIUM ON YOUR SKIN.
REPEATED SKIN CONTACT CAN CAUSE DERMATITIS AND SKIN
ULCERS. DIRECT EYE CONTACT WITH HEXAVALENT
CHROMATE DUSTS CAN CAUSE EYE DAMAGE. AFTER YOU
TOUCH HEXAVALENT CHROMIUM PARTS, CLEAN YOUR HANDS
BEFORE YOU EAT OR SMOKE. GET SAFETY INSTRUCTIONS
FROM YOUR EMPLOYER. OBEY GOVERNMENT AND OSHA
REGULATIONS WHEN YOU DISCARD PARTS THAT CONTAIN
HEXAVALENT CHROMIUM.
WARNING: DO NOT BREATHE HEXAVALENT CHROMIUM PARTICLES,
FUMES OR DUST. THESE PARTICLES, FUMES OR DUST CAN
CAUSE CANCER OR LUNG DISEASE. IF MAINTENANCE
PROCEDURES MAKE HEXAVALENT CHROMIUM PARTICLES,
FUMES OR DUST, TELL YOUR EMPLOYER TO SUPPLY
RESPIRATORS, VENTILATION AND/OR PROCEDURES TO
PREVENT EXPOSURE TO PERSONNEL.
CRYSTALLINE SILICA (Quartz) - Obey the warning below before you
touch or do maintenance on parts that contain crystalline silica.
Primers, sealants, static conditioners, and fillers may contain
crystalline silica. The Occupational, Safety, and Health
Administration (OSHA) sets limits on exposure to crystalline silica
dust (29 CFR 1910.1000 Table Z-3).

Page 10
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
WARNING: DO NOT BREATHE CRYSTALLINE SILICA PARTICLES OR

DUST. THESE PARTICLES OR DUST CAN CAUSE SILICOSIS
AND OTHER LUNG DISEASE. IF MAINTENANCE PROCEDURES
MAKE CRYSTALLINE SILICA PARTICLES OR DUST, TELL
YOUR EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION
AND/OR PROCEDURES TO PREVENT EXPOSURE TO
PERSONNEL.
LEAD - Obey the warnings below before you touch or do maintenance on
parts that contain lead. Soldered components and high temperature
dry lubricants may contain lead. The Occupational, Safety, and
Health Administration (OSHA) sets limits on exposure to lead (29 CFR
1910.1025).
WARNING: DO NOT GET LEAD IN YOUR MOUTH. LEAD THAT IS
SWALLOWED CAN CAUSE REPRODUCTIVE OR BLOOD SYSTEM
DISEASE. AFTER YOU TOUCH LEAD PARTS, CLEAN YOUR
HANDS BEFORE YOU EAT OR SMOKE. GET SAFETY
INSTRUCTIONS FROM YOUR EMPLOYER. OBEY GOVERNMENT
AND OSHA REGULATIONS WHEN YOU DISCARD PARTS THAT
CONTAIN LEAD.
WARNING: DO NOT BREATHE LEAD PARTICLES, FUMES OR DUST. THESE
PARTICLES, FUMES OR DUST CAN CAUSE REPRODUCTIVE OR
BLOOD SYSTEM DISEASE. IF MAINTENANCE PROCEDURES
MAKE LEAD PARTICLES, FUMES OR DUST, TELL YOUR
EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION AND/OR
PROCEDURES TO PREVENT EXPOSURE TO PERSONNEL.

Page 11
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
4. Previous IAE Assigned TASK/SUBTASK VS Goodrich Assigned TASK/SUBTASK

Cross Reference
IAE Goodrich
TASK SUBTASK TASK SUBTASK
Introduction
78-11-12-830-001 78-11-12-830-001
Description & Operation
78-11-12-830-002 78-11-12-830-002
Clean
78-11-12-100-001 78-11-12-100-001
Check 001
78-11-12-200-001 78-11-12-200-001
Check 003
78-11-12-200-003 78-11-12-200-003
Repair 000
78-11-12-300-000 78-11-12-300-000
Repair 003
78-11-12-300-001 78-11-12-300-001
78-11-12-160-002 78-11-12-160-002
78-11-12-160-003 78-11-12-160-003
78-11-12-350-003 78-11-12-350-003
78-11-12-350-004 78-11-12-350-004
78-11-12-350-005 78-11-12-350-005
78-11-12-210-003 78-11-12-210-003
78-311-12-850-003 78-311-12-850-003
Storage
78-11-12-620-001 78-11-12-620-001
IPL Intro
78-11-12-830-003 78-11-12-830-003

Page 12
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
DESCRIPTION AND OPERATION 0
Task 78-11-12-830-002
Description and Operation of the Tail Cone
1. General
A. Description (See Figure 1.)
(1) This publication contains maintenance instructions and an

illustrated parts list for the Tail Cone Assembly and Exhaust
Plug Assembly. Hereafter, the term “tail cone assembly” will
also refer to the exhaust plug assembly.
(2) For part number 290-1501-501 the tail cone assembly is made of
Inconel 625 honeycomb bonded to perforated Inconel 625 skin on
the air passage surface and non-perforated Inconel 625 skin on
the opposite side.
(3) For part number 740-1061-503 the tail cone assembly is made
titanium alloy.
(4) For part number 740-1061-505 the tail cone assembly is made
Inconel 625.
(5) The tail cone assembly is attached to the engine with 13 bolts.
B. Operation
(1) The tail cone assembly directs air out of the engine and
permits smooth air flow out of the common nozzle assembly. The
cone is of convergent duct shape. This shape gives required
direction and increased velocity of the air flow as it leaves
the engine.
V2500-A1/A5 78-11-12 DESCRIPTION & OPERATION

Page 1
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
C. Pertinent Data (Refer to Table 1.)
Tail Cone (approximate):

Length: 23.5 in. (597 mm)
Width: 18.1 in. (460 mm)
Material: Inconel 625 (290-1501)
Titanium (740-1061-503)
Weight: 10.0 lbs (5 kg)
Pertinent Data
Table 1

Page 2
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
Tail Cone
Figure 1

Page 3
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502

Page 4
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
TAIL CONE - CLEANING 0
Task 78-11-12-100-001
Clean the Components of the Tail Cone
1. Cleaning
A. General
(1) This section has the procedures necessary to clean the

components of the Tail Cone Assembly.
(2) See Table 401 for materials used during cleaning.
NOTE: For the items shown in Table 401, see the Consumable
Materials Index in the introduction. Equivalent
alternatives can be used.
DESCRIPTION DESIGNATION
Primary Cleaner CoMat 01-070
Barrier material CoMat 01-233
Solvent CoMat 01-438
Lint-free gloves CoMat 02-097
Lint-free cloth CoMat 02-099
Rubber gloves CoMat 02-200
Stainless steel brush CoMat 02-331
Aluminum oxide abrasive paper CoMat 05-129
Temporary rust preventive CoMat 10-015
Cleaning Materials
Table 401
V2500-A1/A5 78-11-12 CLEANING

Page 4001
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
B. Cleaning Procedure
WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN

YOU DO THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND
AND OBEY ALL INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER
AND GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO
NOT USE PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH
PPE IS NECESSARY.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP, AND DISCARD MATERIALS.
(1) Fully clean all threaded areas and other metal parts with a
CoMat 02-099 Lint-free cloth made moist with CoMat 01-438
Solvent, a CoMat 02-331 stainless steel wire brush, or CoMat
05-129 Aluminum oxide abrasive paper.
(2) Rub the surface dry before the solvent becomes gas.
(3) Apply a thin coat of CoMat 10-015 temporary rust preventive to

all surfaces. Put the clean parts in CoMat 01-233 barrier
material until ready to install.
NOTE: All parts must be free of rust, corrosion, dirt,

grease, oil, and other contaminants.
C. Clean with Pressure Spray
(1) Apply the CoMat 01-070 primary cleaner to the component parts
with the pressure spray. Remove all dirt, grease oil or other
contamination.
V2500-A1/A5 78-11-12 CLEANING

Page 4002
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
(2) Use the pressure wash spray gun to flush the area with warm
water a minimum of two times. Remove all of the CoMat 01-070
primary cleaner.
(3) Dry the component parts with clean dry compressed air or use a
CoMat 02-099 lint-free cloth. Remove the remaining water.
V2500-A1/A5 78-11-12 CLEANING

Page 4003
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
V2500-A1/A5 78-11-12 CLEANING

Page 4004
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
TAIL CONE - CHECK 001 0
Task 78-11-12-200-001
Check the Components of the Tail Cone (Titanium)
1. Check
A. General
(1) This Inspection procedure is applicable to the 740-1061 Tail

Cone Assembly.
(2) Examine all parts and surfaces that can be seen without
destructive disassembly. Look for corrosion, wear, damage, and
fasteners that are loose or missing. Remove corrosion and
repair worn or damaged as necessary.
(3) Do not discard any part until you are sure there are no repairs
available. Refer to the instructions in Repair before a part is
used again or oversize parts are installed.
(4) All parts must be examined to make sure that all repairs have
been done correctly.
2. Examine the Tail Cone
A. Examine the skin for deformations or buckles
(1) Four deformations or buckles are allowed. 3 on one 180 degree

segment, one on the other 180 degree segment, or two less than
or equal to 2.0 in. (50,8 mm) deep. length is unimportant -
Accept
B. Examine the Tail Cone Flange for cracks.
(1) Reject the cracked parts
C. Examine the Tail Cone Skin for dents.
(1) Treat the dent as deformations or buckles - Accept
V2500-A1/A5 78-11-12 CHECK 001

Page 5001
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
Tail Cone Inspection

Figure 502
V2500-A1/A5 78-11-12 CHECK 001

Page 5002
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
Task 78-11-12-200-003
Examine the Tail Cone Assembly (Inconel) part no. 290-1501.
1. Check
A. General
NOTE: The Tail cone is removed from the engine when performing
this inspection.

Cone Assembly only.
(2) Visually examine all parts and surfaces that can be seen
without destructive disassembly. Look for corrosion, wear,
damage, cracks and fasteners that are loose or missing. Remove
corrosion and repair worn or damaged parts as necessary.
(3) Use 10X magnification or Fluorescent Penetrant Inspection to

find crack ends.
(4) Do not discard a part until you are sure no repairs are
available for that part. Refer to the Repair procedure before a
part is used again or oversize parts are installed.
(5) All parts must be examined to make sure all repairs have been
done correctly.
(6) A** following a repair given in this procedure shows that the
repair is not yet published in the current revision of the
manual. Contact the manufacturer for disposition.
2. Examine the Tail Cone Acoustic Perforated Skin in Zones 1, 2, and 3

(Refer to Figure 501, 502, and 503)
A. Zone 1 and 2
(1) Single crack - Cracks with two ends only. The crack length is
the straight distance between the two ends, reference Figure
501.
(a) Refer to SRM 54-40-00 Allowable Damage Limits section for

disposition.
V2500-A1/A5 78-11-12 CHECK 003

Page 5001
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
(2) Joined crack - Crack with more than two ends, reference Figure
502 and 503.
(a) Refer to SRM 54-40-00 Allowable Damage Limits section for

disposition.
B. Zone 3 and Inner Skin
(1) Reject cracks of any length
V2500-A1/A5 78-11-12 CHECK 003

Page 5002
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
Tail Cone (Inconel)

Figure 501
V2500-A1/A5 78-11-12 CHECK 003

Page 5003
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
Tail Cone (PRE SB 78-0096)

Single and Joined Crack Allowable Damage
Figure 502
V2500-A1/A5 78-11-12 CHECK 003

Page 5004
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
Tail Cone (Post SB 78-0096)

Single and Joined Crack Allowable Damage
Figure 503
V2500-A1/A5 78-11-12 CHECK 003

Page 5005
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
V2500-A1/A5 78-11-12 CHECK 003

Page 5006
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
Task 78-11-12-200-003
Examine the Tail Cone Assembly (Inconel) part no. 745-1502.
1. Check
A. General
NOTE: The Tail cone is removed from the engine when performing
this inspection.

Cone Assembly only.
(2) Visually examine all parts and surfaces that can be seen
without destructive disassembly. Look for corrosion, wear,
damage, abrasions, gouges, nicks, scratches, dents, holes,
disbonds, cracks and fasteners that are loose or missing.
2. Examine the Tail Cone Acoustic Perforated Skin in Zones 1, 2, and 3

(Refer to Figure 501)
A. Acoustic perforated skin zones 1, 2, and 3
(1) If damage is found contact Goodrich Aerostructures for

disposition.
3. Examine the Tail Cone Inner Skin in Zones 1, 2, and 3 (Refer to Figure
501)
A. Inner Skin Zones 1, 2 and 3 for cracks
(1) If crack is found contact Goodrich Aerostructures for

disposition.
V2500-A1/A5 78-11-12 CHECK 004

Page 5001
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
B. Inner Skin Zones 2 for Loose or Missing Rivets
(1) If loose rivet is found carefully drill out rivet and measure
hole diameter and follow step 2 and 3 below.
(2) If missing rivet is found, measure hole diameter and if

diameter is 0.160 - 0.164 in. (4,06 - 4,16 mm) install blue
print rivet.
(3) If missing rivet hole is greater than 0.164 in.(4,16 mm)contact

Goodrich Aerostructure for disposition.
V2500-A1/A5 78-11-12 CHECK 004

Page 5002
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
Tail Cone (Inconel)

Figure 501
V2500-A1/A5 78-11-12 CHECK 004

Page 5003
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
V2500-A1/A5 78-11-12 CHECK 004

Page 5004
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
GENERAL REPAIR 0
Task 78-11-12-300-000
General Repair of the Tail Cone Assembly
1. Repair
A. This section gives the repair procedures for the tail cone
assembly. Refer to Table 601 and 602 for a list of repairs.
B. Before the repair is started, make a decision on the level of

repair that is necessary to make the damaged component
serviceable. Disassemble the damaged items only to the level
necessary to do the repair without the damage to adjacent
components.
C. Refer to the IPL for repair parts. If a part is affected by a

repair procedure, a VRS number is given in the IPL. For example:
VRS2299.
2. Minor Repair Information
A. Polish out minor corrosion and surface damage on Inconel 625 parts
with 240-grit aluminum oxide or silicon carbide coated abrasive
cloth.
B. Keep a 10 to 1 (length to depth) ratio and do not increase the

depth of damage.
C. Make smooth the reworked area with 600-grit emery cloth or

equivalent.
D. Make sure the surface smoothness is 125 microinches (3,2 µm) RMS
minimum.
3. Repair Table
Repair VRS
Number Number Title
Repair 001 VRS2204 DELETED
Weld Repair for Buckled Skin
V2500-A1/A5 78-11-12 GENERAL REPAIR

Page 6001
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
Repair VRS
Number Number Title
Repair 002 VRS2306 DELETED
Weld Repair for Cracks
Repair 003 VRS2165 Tail Cone Pin Repair
Table 601
VRS Repair
Number Number Title
VRS2165 Repair 003 Tail Cone Pin Repair
VRS2204 Repair 001 DELETED
Weld Repair for Buckled Skin
VRS2306 Repair 002 DELETED
Weld Repair for Cracks
Table 602
V2500-A1/A5 78-11-12 GENERAL REPAIR

Page 6002
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
WELD REPAIR FOR BUCKLED SKIN

REPAIR 001 (VRS2204)
THIS CMM REPAIR HAS BEEN CANCELLED AND SHOULD NO LONGER BE APPLIED. IF
PREVIOUSLY ACCOMPLISHED, REFER TO THE CMM 78-11-12 FOR NEW ALLOWABLE
DAMAGE LIMIT AND APPLICABLE REPAIR. (FOR FUTHER INFORMATION SEE
SIL NO. 248) 0
V2500-A1/A5 78-11-12 REPAIR 001

Page 6001
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
V2500-A1/A5 78-11-12 REPAIR 001

Page 6002
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
WELD REPAIR FOR CRACKS

REPAIR 002 (VRS2306)
THIS CMM REPAIR HAS BEEN CANCELLED AND SHOULD NO LONGER BE APPLIED. IF
PREVIOUSLY ACCOMPLISHED, REFER TO THE CMM 78-11-12 FOR NEW ALLOWABLE
DAMAGE LIMIT AND APPLICABLE REPAIR. (FOR FUTHER INFORMATION SEE
SIL NO. 248) 0
V2500-A1/A5 78-11-12 REPAIR 002

Page 6001
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
V2500-A1/A5 78-11-12 REPAIR 002

Page 6002
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
REPAIR 003
TAIL CONE PIN REPAIR IN THE FIELD AREA OF THE PERFORATED SKIN -
(VRS2165) 0
Task 78-11-12-30-001
1. Effectivity
NOTE: See the Illustrated Parts List (IPL) for figure and item
locations on specific part numbers.
FIG/ITEM PART NO.

01-30 290-1501
2. Equipment and Materials
A. Standard Equipment
Drilling and routing equipment

10X magnifying glass
Copper chill bars
Hand-held pneumatic grinder
Torque wrench
B. Consumable Materials
CoMat 05-021 Waterproof silicon carbide abrasive paper

CoMat 01-438 Solvent
CoMat 02-099 Lint-free cloth
CoMat 02-331 Stainless steel wire brush
CoMat 03-287 Welding filler wire
CoMat 06-131 Marking pen
NOTE: To identify the consumable materials, refer to the

Consumable Material Index in the Introduction.
C. Special Tools - None
V2500-A1/A5 78-11-12 REPAIR 003

Page 6001
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
D. Expendable Parts - None
E. Repair Parts - None
3. General
A. Material of Component
PART IDENT MATERIAL

Tail Cone Inconel 625 Perforated Sheet and Honeycomb Core
B. This repair provides instructions to repair bond separation

between performated skin and honeycomb.
C. This repair is applicable for disbond damage greater than 0.75 in.
(19, 1 mm) diameter but not to exceed 9 in. (228,6 mm) diameter.
The damage must be a minimum of 1.5 in. (38,1 mm) away from the
honeycomb core edges.
D. The maximum number of pins to repair a Tail Cone must not exceed 30
pins.
E. The damage to be repaired must be 3D away from previous repaired

damage. Where “D” is the diameter of the bigger of two damages
F. This repair is applicable for disbond damage located in Zone 1.

Contact Goodrich for damage outside of Zone 1. Refer to Figure 1.
G. Use Gas Tungsten Arc Welding (GTAW) procedures per AWS D17.1 or
equivalent to repair the damaged tail cone.
H. To do this procedure welders must be certified to AWS D17.1 or

equivalent.
V2500-A1/A5 78-11-12 REPAIR 003

Page 6002
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
Subtask 78-11-12-160-002
4. Prepare the Damaged Skin for the Weld Repair
NOTE: Any two disbonded areas closer than 0.75 9n. (19.1 mm) must be
treated as a continuous disbond.
A. Draw a box around the disbonded area.
(1) The sides of the box must be parallel to the cell pattern. All
damaged cells must be within the box. See Figure 2 for an
example of a damaged area.
NOTE: For disbonds within 0.75 in. (19,1 mm) of either side
of the splice, construct the box with two sides
parallel to the splice.
B. Divide the length of each side of the box by 0.75 in. (19,1 mm) and
round up to the next integer.
(1) If the rounded result is 1, then increase the result to 2.
C. Divide the sides of the box by its corresponding integer number.
(1) Install a pin at each intersection point generated. See Figure

3 for an example of the pin placement.
D. If the box procedure encompasses areas of good bond as well as

disbonds continue as follows:
(1) Layout the pin patterns as previously described but omit

installation of pins which are surrounded by bonded cell walls.
See Figure 4.
E. If evidence of previous repair exists, count the number of pins

used.
(1) The number of pins used in the previous repair and pins to be
used in the new repair must not exceed a total of 30 pins.
V2500-A1/A5 78-11-12 REPAIR 003

Page 6003
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
F. If 30 pins is exceeded:
(1) Contact Goodrich for further disposition.
G. Divide the length of each side of the box by 0.75 in. (19,1 mm) and
round up to the next integer.
(1) If the rounded result is 1, then increase the result to 2.
Subtask 78-11-12-160-003
5. Clean the Weld Area
WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU

DO THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY
ALL INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY
INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES INSTRUCTIONS ON
HOW YOU MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD MATERIALS.
A. Remove oxides/contaminants from the weld area.
(1) Use a CoMat 02-331 stainless steel wire brush.
B. Clean the weld area.
(1) All weld surfaces must be fully cleaned to remove all oil,
grease, dirt, or other contaminants. Use a CoMat 02-099 lint
free cloth made moist with CoMat 01-438 solvent. Rub the
surfaces dry before the solvent evaporates.
V2500-A1/A5 78-11-12 REPAIR 003

Page 6004
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
Subtask 78-11-12-350-003
6. Install Pins in the Skin, See Figure 605
A. Drill through the near side face sheet.
(1) Drill a hole 0.030 in. (0,76 mm) in diameter greater than the
diameter of the repair pin.
B. Remove braze alloy from the far side face sheet.
(1) Lightly abrade the surface with CoMat 05-021 abrasive paper. Do
not reduce the parent material thickness.
C. Insert the pin in the hole.
(1) Insert the pointed end of the pin through the drilled hole
until the pin comes into contact against the solid skin.
D. Insert the insulation sleeve between the pin and the perforated
skin.
(1) 0.020 in. (0.51 mm) to 0.030 in. (0,76 mm) of the sleeve must
remain exposed. This is to prevent arcing with the near side
face sheet or core.
Subtask 78-11-12-350-004
7. Stud Weld the Pins to the Solid Skin, See Figure 605
A. Stud weld the pin to the far side face sheet using an ARC or CD
stud welding machine.
(1) Perform weld i.a.w. AWS C5.4 or using the stud welding machine
manufacturer’s instructions.
B. Remove the insulation sleeve
C. Torque test the pin.
(1) Torque the pin to 7.5 in-lb. If rotational movement of the pin
occurs at this load, remove the pin and install another pin.
V2500-A1/A5 78-11-12 REPAIR 003

Page 6005
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
Subtask 78-11-12-350-005
8. Fusion Weld the Pin to the Perforated Skin, See Figure 605
A. Fusion weld the pin to the performated skin.
(1) Use the pin protrusion above the perforated skin as the filler
material. Use copper chill bars around pin to reduce
distortion. Add CoMat 03-287 welding filler wire as necessary.
B. Grind the weld.
(1) Grind the weld to a maximum height of 0.005 in. (0,127 mm) to
0.010 in. (0,254 mm). Do not grind into the parent material.
Subtask 78-11-12-210-003
9. Visually Examine the Weld Quality with a 10X Magnifying Glass
Subtask 78-11-12-850-003
10. Identify the Repair
A. Make a mark VRS2165 next to the repair area.
(1) Use a CoMat 06-131 marking pen of a color that contrasts.
V2500-A1/A5 78-11-12 REPAIR 003

Page 6006
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
Tail Cone Repair Area

Figure 601
V2500-A1/A5 78-11-12 REPAIR 003

Page 6007
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
Pin Placement for Damaged Area

Figure 602
V2500-A1/A5 78-11-12 REPAIR 003

Page 6008
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
Pin Placement for Damaged Area

Figure 603
V2500-A1/A5 78-11-12 REPAIR 003

Page 6009
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
Irregular Void Patterns

Figure 604
V2500-A1/A5 78-11-12 REPAIR 003

Page 6010
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
Tail Cone Repair Area

Figure 605
V2500-A1/A5 78-11-12 REPAIR 003

Page 6011
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
V2500-A1/A5 78-11-12 REPAIR 003

Page 6012
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
STORAGE 0
Task 78-11-12-620-001
Storage of the Tail Cone Assembly
1. General
A. Storage materials (See Table 701)
NOTE: For items shown in Table 701, refer to the Consumable

Materials Index in the introduction. Equivalent
alternatives can be used.
DESCRIPTION CoMat No.

Barrier material 02-233
Tag, identification 02-092
Storage Materials
Table 701
B. Storage Procedures
(1) Write the tail cone assembly name, part number, and date on
each of two CoMat 02-092 identification tags.
(2) Attach one identification tag to the tail cone assembly.
(3) Seal the assembly in CoMat 01-233 barrier material.
(4) Attach the second identification tag to the wrapping in a

visible portion.
(5) Put the assembly in a clean, dry, safe area.
V2500-A1/A5 78-11-12 ASSEMBLY & STORAGE

Page 7001
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
V2500-A1/A5 78-11-12 ASSEMBLY & STORAGE

Page 7002
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
TAIL CONE ASSY - ILLUSTRATED PARTS LIST
Task 78-11-12-830-003
Illustrated Parts List of the Tail Cone Assembly
1. Illustrated Parts List
A. Introduction and Purpose
(1) This section has the illustration and breakdown of the parts
for the assembly that can be disassembled, repaired, or
replaced and reassembled.
(2) This section contains a parts list consisting of six columns:

FIGURE and ITEM, PART NUMBER, AIRLINE PART NUMBER,
NOMENCLATURE, USAGE CODE, and UNITS PER ASSEMBLY.
B. Explanation and Usage
(1) The FIGURE and ITEM column gives the figure number and the item
number for each detailed part. The figure number is given once
at the top of the column. Each part is called out by an item
number. Any part which is not illustrated will have an item
number preceded by a dash (-).
(2) The PART NUMBER column gives the Rohr, vendor, and government
standard part numbers for each detail part. Always use the part
number exactly as listed when procuring parts.
(3) The AIRLINE PART NUMBER column is for individual airline use.
(4) The NOMENCLATURE column gives the description and nomenclature

of the detail part.
(a) If a part is not manufactured by Rohr, Inc., a vendor is

given. The name and address of each vendor is given at the
end of this section.
V2500-A1/A5 78-11-12 IPL INTRODUCTION

Page 10001.1
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
(b) The part description in the nomenclature column is indented

to depict the relationship of the part to the next higher
assembly. For example:
Top Assembly
. Detail Parts for Top Assembly
. Sub-Assembly
. Attaching Parts
***
Detail Parts
. . Detail Parts for Sub-Assembly
. . Sub-Sub-Assembly
. . Attaching Parts
***
. . . Detail Parts for Sub-Sub-Assembly
(c) If a part is affected by a repair procedure, a VRS number

is given. For example: VRS2299. Refer to the General Repair
section for a complete list of all applicable repair
numbers.
(5) The EFFECTIVITY CODE column is used to show additional

configurations to the top assembly. Each configuration is
assigned a code letter, A through Z (except I and O). All
detail parts associated with a configuration are coded with the
same letter. A blank space in the effectivity column indicates
that the detail part is used on all configurations of the top
assembly.
(6) The UNITS PER ASSEMBLY column shows the total quantity of each
part required. The abbreviation AR indicates that the quantity
required will be determined during assembly procedures. The
abbreviation RF indicates that the item is listed for reference
purposes only.

Page 10001.2
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
C. Abbreviations
(1) The abbreviations used throughout this catalog are as follows:
ABBR TITLE ABBR TITLE

ALT Alternate
ASSY Assembly
AUX Auxiliary OPT Optional
CONFIG Configuration POS Position
CMM Component PPK Power Plant
Maintenance Kit (Parts in
Manual Power Plant
Kit)
DIA Diameter PRESS Pressure
ENG Engine REF Reference
FIG Figure REPL(S) Replace(s)
FLEX Flexible REV Revision
FWD Forward RH Right Hand
HYD Hydraulic SB Service
Bulletin
IAE International SUPSD(S) Superseded,
Aero Engines Supersedes
IN Inch UPR Upper
INSTL Installation XLTG Translating
LH Left Hand
LKG Locking
LWR Lower
MFD Manufactured
MM Millimeter
MTG Mounting
NHA Next Higher Assy
NO(S) Number(s)
NP Not Provisioned

Page 10001.3
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
D. Replacement Data
(1) The interchangeability relationship between parts is provided

by the appearance of the following notes:
One-Way Interchangeable
SUPSDS OR SUPSD BY The old part number may be
used as a replacement only
where the old part number
was installed. The new part
number is an acceptable
replacement for either the
old or new part.
Two-way Interchangeable
REPLS OR REPL BY The old and new part number
are each acceptable
replacement for both the old
and new part numbers.
E. Service Bulletins
(1) The following terms apply to Service Bulletins

SB -- Is used when the part number
appears on the add side
(NEW) of the Service
Bulletin. The word (Post)
will not appear in the Text.
PRE SB -- Is used when the part number

appears on the cancel side
(OLD) of the Service
Bulletin.

Page 10001.4
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
F. Vendor Information
(1) The vendor information that follows contains the name and
address of each vendor whose code number is used in the
nomenclature column of the Illustrated Parts List, in
alphanumeric order.
VENDOR NAMES AND ADDRESSES WITH

COMMERCIAL AND GOVERNMENT ENTITY (CAGE) CODES

56878 SPS TECHNOLOGIES, INC.
AEROSPACE AND INDUSTRIAL PRODUCTS DIVISION
HIGHLAND AVENUE
JENKINTOWN PA 19046
USE APPLICABLE FACILITY CODE
FORMERLY STANDARD PRESSED STEEL
G. Superseding Parts List
(1) The list contains a tabulation of the superseded part number,

part names, and superseding part number. For reference, see the
Superseding, Equivalent, and Electrical Equivalent Parts list,
71-00-01, RDN1500.
H. Equivalent Parts List
(1) The list contains a tabulation of the engineering specified

part number, part names, and approved equivalent part number.
For reference, see the Superseding, Equivalent, and Electrical
Equivalent Parts list, 71-00-01, RDN1500.
I. Electrical Equivalent Parts List
(1) The list contains a tabulation of the engineering specified

part number, part names, and approved equivalent part number.
For reference, see the Superseding, Equivalent, and Electrical
Equivalent Parts list, 71-00-01, RDN1500.

Page 10001.5
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502

Page 10001.6
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502
SERVICE BULLETIN LIST
SERVICE DATE BULLETIN

BULLETIN ORIGINAL ISSUE REVISION NUMBER INCORPORATED INTO
NUMBER DATE AND DATE MANUAL
SBN70-0541 May 15/97 Rev 2 Feb 06/98 Feb 1/09
SBN78-0066 Jun 22/93 Feb 1/09
SBN78-0096 Jan 25/95 Rev 2 May 25/95 Feb 1/09

Page 10002.1
Aug 1/17
Part Nos. 290-1501, 740-1061 and 745-1502

Page 10002.2
Aug 1/17
A319/A320/A321 − V2500−A1/A5
Document Part No. 290−1501, 740−1061, 745−1502
NUMERICAL INDEX
AIRLINE AIRLINE
PART NUMBER PART FIGURE− TTL PART NUMBER PART FIGURE− TTL
NUMBER ITEM REQ NUMBER ITEM REQ
S700B1419 01 −040A 13
290−1501−501 01 030 1
740−1061−503 01 020 1
740−1061−505 01 −020A 1
740−1123−501 01 −001 RF
740−1123−503 01 −001A RF
745−1500−501 01 −010 RF
745−1500−503 01 −010A RF
745−1502−501 01 −030A 1
745M0001−1 01 050 13
77711−4−4 01 040 13
Page 10003.1
Printed in U.S.A.
78−11−12 Aug 01/2017
Rohr, Inc., operating as Goodrich Aerostructures. U.S. Export Classification: EAR 9E991
Goodrich Proprietary − This document is subject to the controls and restrictions on the title page.
A319/A320/A321 − V2500−A1/A5
Document Part No. 290−1501, 740−1061, 745−1502
TAIL CONE ASSEMBLY

IPL FIGURE 1
Page 10004.0
Printed in U.S.A.
78−11−12 Aug 01/2017
A319/A320/A321 − V2500−A1/A5
Document Part No. 290−1501, 740−1061, 745−1502
FIG.& AIRLINE UNITS

ITEM PART PART NOMENCLATURE EFF PER
NO. NUMBER NO. 1234567 CODE ASSY
1 TAIL CONE ASSEMBLY
−1 740−1123−501 PLUG INSTL A RF
−1A 740−1123−503 PLUG INSTL B RF
−10 745−1500−501 CONE INSTL − TAIL C RF
−10A 745−1500−503 CONE INSTL − TAIL D RF
20 740−1061−503 .PLUG ASSY − (PPK) A 1
(INCONEL)
PRE SERVICE BULLETIN: N70−0541
−20A 740−1061−505 .PLUG ASSY − (PPK) B 1
(INCONEL)
POST SERVICE BULLETIN:
N70−0541
30 290−1501−501 .CONE ASSY − TAIL C 1
(INCONEL)
−30A 745−1502−501 .CONE ASSY − TAIL D 1
N70−0922
−−− ATTACHING PARTS −−−
40 77711−4−4 .BOLT A 13
V56878
−40A S700B1419 .BOLT 13
N78−0066
−−−−−−−−−−−−
50 745M0001−1 ..DOUBLER C 13
N78−0096
− ITEM NOT ILLUSTRATED
Page 10004.1
Printed in U.S.A.
78−11−12 Aug 01/2017
A319/A320/A321 − V2500−A1/A5
Document Part No. 290−1501, 740−1061, 745−1502
Page 10004.2
Printed in U.S.A.
78−11−12 Aug 01/2017

Goodrich Proprietary - This Document Is Subject To The Controls and Restrictions On The Title Page. U. S. Export Classification: EAR 9E991

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850 LAGOON DRIVE

CHULA VISTA CALIFORNIA 91910-2098 TEL: (619) 691-4111•TELEX:69-5038

SUBJECT: V2500 A1 and A5 Tail Cone Assembly Component Maintenance

The subject manual revision is being transmitted.

Technical questions or comments concerning this publication should be

TO: V2500-A1/A5 Component Maintenance Manual Distribution

CONCERNING: Tail Cone Assembly 78-11-12 Revision 11,

MANUAL UPDATE INSTRUCTIONS

Chapter/Section/Subject Page Number Description of Change

Repair 003 6005 Revise step procedure

V2500-A1/A5 78-11-12 TRANSMITTAL LETTER

THIS PAGE INTENTIONALLY LEFT BLANK

V2500-A1/A5 78-11-12 TRANSMITTAL LETTER

TRANSMITTAL OF TECHNICAL DATA (EAR)

Goodrich Aerostructures Proprietary Information

Caution Regarding Use of Materials:

THIS PAGE INTENTIONALLY LEFT BLANK

REV DATE DATE REV DATE DATE

V2500-A1/A5 78-11-12 RECORD OF REVISIONS

THIS PAGE INTENTIONALLY LEFT BLANK

V2500-A1/A5 78-11-12 RECORD OF REVISIONS

RECORD OF TEMPORARY REVISIONS

ISSUE DATE ISSUE DATE

V2500-A1/A5 78-11-12 TEMPORARY REVISIONS

THIS PAGE INTENTIONALLY LEFT BLANK

V2500-A1/A5 78-11-12 TEMPORARY REVISIONS

SERVICE BULLETIN LIST

SERVICE DATE BULLETIN

V2500-A1/A5 78-11-12 SERVICE BULLETIN LIST

THIS PAGE INTENTIONALLY LEFT BLANK

V2500-A1/A5 78-11-12 SERVICE BULLETIN LIST

Description and Operation . . . . . . . . . . . . . . . . . . . 1

Testing and Fault Isolation (Not Applicable). . . . . . . . . N/A

Automatic Test Requirements (Atlas) (Not Applicable) . . . . . N/A

Disassembly (Not Applicable). . . . . . . . . . . . . . . . . N/A

Check 001 . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001

Check 003 . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001

Check 004 . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001

General Repair . . . . . . . . . . . . . . . . . . . . . . . . 6001

Repair 002 (VRS2306) Weld Repair for Cracks - DELETED . 6001

Fits and Clearance (Not Applicable) . . . . . . . . . . . . . N/A

Special Tools, Fixtures, and Equipment (Not Applicable) . . . N/A

Illustrated Parts List Introduction. . . . . . . . . . . . . . 10001

Service Bulletin List. . . . . . . . . . . . . . . . . . . . . 10002

Numerical Index . . . . . . . . . . . . . . . . . . . . . . . 10003

V2500-A1/A5 78-11-12 TABLE OF CONTENTS

Figure 1, Tail Cone . . . . . . . . . . . . . . . . . . . . . . 10004

V2500-A1/A5 78-11-12 TABLE OF CONTENTS

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

(N) Indicates new page 78-11-12 LIST OF EFFECTIVE PAGES

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

Storage 7001 Aug 1/17

Service 10002.1 Aug 1/17

Numerical 10003.1 Aug 1/17

Figure 1 10004.0 Aug 1/17

(N) Indicates new page 78-11-12 LIST OF EFFECTIVE PAGES

A. This component maintenance manual contains seven sections as

(2) Description and Operation

(7) Illustrated Parts List

(a) The Illustrated Parts List section contains a list of parts

(1) This manual can be used to do repairs on the exhaust plug