Process Specification
Installation of Close-tolerance Bolts
(Hi-Lite, Veri-Lite)
CONTENT
1
2
3
4
5
6
7
8
Scope and Application
Related Documents
Prerequisites
Materials and Equipment
Process
Quality Assurance
Safety and Health
Process Flow Chart
80-T-34-5817
Issue: 01/2017
Page 1 of 30
All directives are originally compiled, checked and
approved in the German language.
In case of discrepancies which could result from
possible translation errors or wrong interpretation
of the English text, the German version of these
directives shall always be binding.
Data Sheet 1:
Data Sheet 2:
Data Sheet 3:
Data Sheet 4:
A320 Family Program - Final Assembly Line A320 Program
Not applicable
A380 Program - GLARE ® and GLARE® / AL Combinations
Annex 1:
Adjustment procedure
Previous issue: 01/2017
The reproduction, distribution and utilization of this document as well as the communication of its contents to others without explicit authorization is
prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.
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80-T-34-5817 (07/2018)
1 SCOPE AND APPLICATION
This process specification describes the installation of metric and inch-type close-tolerance bolts. The
riveted connection consists of a close-tolerance bolt and a collar.
Close-tolerance bolts per JN, HSTMJ and VLM have a metric thread.
Hi-Lite close-tolerance bolts per ABS, EN, HST, VL have an inch thread.
Form of close-tolerance bolts:
Close-tolerance bolts have a cylindrical shank with a thread end. They differ according to material,
surface protection, shape of the head, and thread.
The face of the bolt shank has a hexagon socket. When a collar is screwed onto a close-tolerance bolt
installed with clearance or transition fit, the bolt is prevented from rotating by positioning a socket head
wrench onto this hexagon socket.
Fig. 1: Close-tolerance bolt with universal head
Fig. 2: Close-tolerance bolt with countersunk
head
Collar shape
Collars differ according to material, surface protection, preload, tightening torque, (tear-off torque of
the hexagonal part) and thread.
a) Collar, not self-aligning (e.g. ASNA2528, ASNA2536)
The self-locking collar has an undercut which ensures the clearance of the fastener shank
in the collar within the grip length range of the close-tolerance bolt. When the collar is
installed, the hexagonal part of the collar shears off when reaching the specified preload
or torque.
Fig. 3: Collar, not self-aligning
Collars which are not self–aligning can be used when the angular deviation of the hole with
reference to the component surface amounts to ≤ 2° on the side of the collar.
Allowance must be made for the fact that an angular deviation of ± 1° and ± 0,5° from dia.
8 mm onwards with reference to the component surface is permitted during production (see
80-T-30-9910).
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b)
80-T-34-5817 (07/2018)
Collar, self-aligning (e.g. ASNA2537, ASNA2538)
If the component surface on the collar side has an inclination of > 2° ≤ 7° to the hole, a selfaligning collar is used. The spherical washer on the collar has a self-aligning effect.
Fig. 4: Self–aligning collar, hexagon sheared off
One special variant of the collar is the collar with ”double hexagon”, see Fig. 5. When the collar is
initially fitted, the tool must grip on the break-off hexagon. As soon as the tightening torque is reached,
the hexagon shears off (see also Fig. 4) but can still be loosened or torqued further on the remaining
wrench surfaces.
Break-off hexagon
Fig. 5: Collar which can be re-tightened
Nuts for screwed connections (self-locking):
Metric and inch-type close-tolerance bolts can be provided with self-locking nuts (e.g. ASNA2527,
ASNA2531) if such a combination is specified in the manufacturing documents.
Self-aligning nuts (e.g. ASNA2532) must be used for angular deviations > 2° between hole and
component surface.
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80-T-34-5817 (07/2018)
2 RELATED DOCUMENTS
A2406.1
80-T-30-0032
80-T-30-9910
80-T-34-0185
80-T-34-5803
80-T-34-9600
80-T-35-9023
ABS0873
ASNA2528
ASNA2531
ASNA2532
ASNA2536
ASNA2537
ASNA2538
EN6114
EN6115
NAS1149
Manage NonConformity Notification
Machining of FRP Components
Drilling, Reaming and Countersinking of Rivet and Screw Holes
Installation of ACRES Oversize Sleeves
Wet Installation of Fasteners
Application of Sealing Compounds
Preservation of Rivet Rows
Bolt – Close tolerance, 130° countersunk head, Short thread
Nut – Hexagonal, Self-Locking, Bihex, Shear Type
Nut, hexagonal, self-locking
Nut, self-locking, with a spherical joint and a self-alignment washer (slope
5° max.)
Nut-hexagonal, self-locking, bihex, shear type
Nut – Hexagonal, Self-Locking, Ball, Bihex, Shear Type, Aluminium Alloy
Nut – Hexagonal, self-locking, ball, bihex, shear type, CRES
Aerospace series, Bolt – Countersunk head, Short thread, Inch series
Aerospace series, Bolt – Protruding head, Short thread, Inch series
Washer, Flat
3 PREREQUISITES
3.1
Personnel
Personnel must be familiar with the special aspects and requirements concerning the preparation of
holes and installation of close-tolerance bolts.
3.2
Manufacturing documents
The manufacturing documents must specify the standard designation of the close-tolerance bolt and
collar.
If self-locking nuts are used, the tightening torque must additionally be stated.
3.2.1 Design note
Close-tolerance bolts can only be used in areas where there is sufficient space for drilling and
installation.
3.2.2 Fastener designation in the manufacturing documents
3.2.2.1 Designation of close-tolerance bolts
Example of designation in the manufacturing documents:
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a)
JN0011MJ
6
80-T-34-5817 (07/2018)
16
Grip length
Nominal dia. code
Standard
b)
EN6114
V
4
-
8
Grip length
Nominal dia.
code
PT
Standard
3.2.2.2 Designation of collars
Example of designation in the manufacturing documents:
a)
JN0042MJ
6
Nominal dia.
code
Manufacturer's serial no.
b)
ASNA2536
-
3
Nominal dia. code
PT
Standard
4 MATERIALS AND EQUIPMENT
4.1
Bolts
4.1.1 Identification of bolts
Manufacturer’s identification and diameter code are recessed (example, see Fig. 6).
114 K
N6
4
E
Note:
The manufacturer's identification may deviate from the standard designation.
EN6114
K
4
VS
V
S
Fig. 6: Example of identification of an inch-type bolt
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Bolt standard
PT / material code
Diameter code no.
Manufacturer's identification
according to TR 3198
(example)
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80-T-34-5817 (07/2018)
4.1.2 Identification of collars
Manufacturer’s identification in cylindrical area in form of code letter.
Manufacturer's identification is embossed in the collar
Fig. 7: Identification of collars
4.2
Tools
It is only permitted to use drilling and reaming tools which assure compliance with the requirements
laid down in this process specification.
For drilling machines see 80-T-30-9910.
Special installation tools are required for the installation of collars. The same applies to their removal.
-1
The speed of the screwdriver must not exceed n = 275 min during the installation process.
The special tools must be serviced at least once per year.
In special cases (areas where access is difficult) it is also permitted to use manual tools such as ring,
open-end and possibly hexagon socket wrenches or special tools.
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80-T-34-5817 (07/2018)
5 PROCESS
5.1
Drilling of hole
The hole dimensions for Hi-Lite bolts are given in Tables 2 and 3 and in the program-specific data
sheets of this process specification.
Holes in metal and FRP must be drilled in accordance with 80-T-30-9910 and 80-T-30-0032.
In aluminum, holes with a tolerance H11 are drilled with a step drill with spiropoint or cross cut (with
diameter tolerance h6) with manual feed and holes with a tolerance H10 with automatic feed.
Hole tolerances
Unless specified otherwise in the manufacturing documents, holes for close-tolerance bolts are to be
prepared in accordance with this process specification.
Hole tolerances differ depending on component thickness (grip length) and material (see Tables 2 to
5).
Regarding hole tolerances, the following requirements generally apply to Al components and Ti bolts:
a) Grip length of bolt ≤ 3 d

Diameter sizes -2, -3 and -3A
 Transition fit with slight clearance, tolerance field size IT 11

Diameter sizes -4 and -5
 Interference fit, tolerance field size IT 10

Diameter sizes -6 and -7
 Transition fit with slight clearance, tolerance field size IT 10
b) Grip length of bolt ≤ 3 d

All diameter sizes
 Transition fit, tolerance field size IT 9
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80-T-34-5817 (07/2018)
Contrary to these regulations, the following can apply to nominal bolt diameters of 5,6 mm:
a) With variations in component thickness around 3d

it is permissible to use the tolerance H11 and also > 3d in a mixed field.

it is permissible to use the tolerance of ≤ 3d as well as > 3d in a mixed field for bolt diameter
5,6 mm (see Diagram 1).
Advantage:
Drilling tool does not have to be changed.
b) If difficulties occur when the bolt is forced into the structure,

it is permissible to use the tolerance of ≤ 3d as well as > 3d in a mixed field (see Diagram 1).
Advantage:
Selection of interference fit in allowable range to facilitate installation.
Bolt
dia.
min. 5,530
max. 5,542
Drilled hole/bolt dia. [mm]
5,540
5,535
A
lH9
5,510
Al
H11
5,46
0
> 3d
3≤
d
1
5
9
1
3
1
7
2
1
Mixed area (selection between
H11 and H9)
2
5
2
9
L [grip length] [mm]
Diagram 1: Allowable hole tolerances for Hi-Lite fasteners of nominal dia. 5,6 mm,
diameter code 3A
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80-T-34-5817 (07/2018)
For holes with a tolerance H9 in aluminum, grip length > 3d, as well as holes in steel, titanium and
FRP, the hole quality is achieved by reaming.
In order to make sure that the hole is drilled at right angles to the workpiece when using hand drills,
the following procedures are permissible:
1. Use of stop holders in connection with supports which can be positioned safely on the component.
Fig. 8: Example of a stop holder
2. Use of drilling blocks for areas which are not easily accessible and areas with considerable loft
curvature. The drilling blocks are adapted to the component and must be seated firmly. For
guidance, the drilling sleeve used must be 2 mm higher than the pre-drill step of the step drill to
center the pre-drill step in the drilling sleeve (see Fig. 10).
Drilling block
Step drill
2 mm
Drilling sleeve
Component
Fig. 9: Drilling block
Fig. 10: Drilling sleeve
3. Other procedures are only permitted in areas where access is difficult. The required tolerances for
the hole diameter and angularity must be observed.
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80-T-34-5817 (07/2018)
X = 90 ± 1°
X = 90 ± 0,5°
Fig. 11: Angular deviations during drilling
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(for dia. < 8 mm)
(for dia. ≥ 8 mm)
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EN6114B3E
EN6115B3E
EN6114B3AE
EN6115B3AE
EN6114B4E
EN6115B4E
EN6114B5
EN6115B5
EN6114B6
EN6115B6
EN6114B7
EN6115B7
EN6114B8
EN6115B8
EN6114T3
EN6115T3
EN6114T3A
EN6115T3A
EN6114T4
EN6115T4
EN6114T5
EN6115T5
EN6114T6
EN6115T6
EN6114T7
EN6115T7
EN6114T8
EN6115T8
4,8
5,6
6,4
7,9
9,5
11,1
12,7
EN6114C2E
EN6115C2E
L1 ≙ grip length
EN6114C8
EN6115C8
EN6114C7
EN6115C7
EN6114C6
EN6115C6
EN6114C5
EN6115C5
EN6114C4E
EN6115C4E
EN6114C3AE
EN6115C3AE
EN6114C3E
EN6115C3E
12,674
12,687
11,087
11,100
9,500
9,512
7,911
7,925
6,324
6,337
5,529
5,542
4,800
4,813
4,140
4,153
- 0,008
0,062
- 0,013
0,070
9,450 3)
9,508
11,030 3)
11,100
6) Larger tolerances from dia. 12,7 mm.
5) Holes to be produced by reaming.
-
11,080
11,126
9,490
9,526
7,900
7,936
6,310
6,346
5,510
5,540
4,780
4,810
4,120
4,150
dia. max
dia. min
Drilled hole
-
- 0,036
0,020
- 0,026
0,022
- 0,025
0,025
- 0,022
0,027
- 0,011
0,032
- 0,010
0,033
- 0,010
0,033
+
Interference
- Clearance
Fit
Tolerance H9
Al (L1 ≤ 3d) **
d ≙ bolt diameter
0,003
0,075
7,850 3)
7,908
-
0,006
0,077
6,260 3)
6,318
-
- 0,006
0,082
- 0,005
0,083
- 0,015
0,073
+
Interference
4) In component areas where subsequent reaming of titanium parts is possible Al (column 1 or 2) may be used.
3) With automatic feed (tolerance H10).
2) Exception: AIRBUS titanium crack stopper; hole like in Al (L1 ≤ 3d).
Fit
- Clearance
5,460
5,535
4,730
4,805
4,080
4,155
1) For dia. 4,2 mm to dia. 5,6 mm: tolerance = H11. For dia. 6,4 mm to dia. 11,1 mm: Tolerance = H10.
Dimension in mm
EN6114B2E
EN6115B2E
EN6114T2
EN6115T2
4,2
d max
dia. max
nominal
d min
dia. min
Drilled hole
Tolerance
1)
Al (L1 ≤ 3d)
Diameter
Standard designation
Titanium Hi-Lite bolts (material code T, B and C)
Bolt dia.
- 0,040
0,000
- 0,074
- 0,005
12,692 6)
12,748
- 0,032
0,002
- 0,041
- 0,005
- 0,038
- 0,003
- 0,031
0,002
- 0,028
0,003
- 0,028
0,003
+
Interference
- Clearance
Fit
11,100
11,127
9,510
9,532
7,930
7,952
6,340
6,362
5,540
5,560
4,810
4,828
4,150
4,168
dia. max
dia. min
Drilled hole
12,692
12,802
11,100
11,190
9,510
9,600
7,930
8,020
6,340
6,430
5,540
5,615
4,810
4,885
4,150
4,225
dia. max
dia. min
Drilled hole
- 0,128
- 0,005
- 0,103
0,000
- 0,100
0,002
- 0,109
- 0,005
- 0,106
- 0,003
- 0,086
0,002
- 0,085
0,003
- 0,085
0,003
+
Interference
- Clearance
Fit
Tolerance H11
combinations
with Ti, St, Al
Tolerance H8
Ti 2) and St 4) 5)
FRP and combin.
Page 11
80-T-34-5817 (07/2018)
Table 1: Drilled hole tolerances for inch-type close-tolerance bolts (Material code T, B and C)
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EN6114B3E
EN6115B3E
EN6114B3AE
EN6115B3AE
EN6114B4E
EN6115B4E
EN6114B5
EN6115B5
EN6114B6
EN6115B6
EN6114B7
EN6115B7
EN6114B8
EN6115B8
EN6114T3
EN6115T3
EN6114T3A
EN6115T3A
EN6114T4
EN6115T4
EN6114T5
EN6115T5
EN6114T6
EN6115T6
EN6114T7
EN6115T7
EN6114T8
EN6115T8
5,2
6,0
6,8
8,3
9,9
11,5
13,1
L1 ≙ grip length
EN6114C8
EN6115C8
EN6114C7
EN6115C7
EN6114C6
EN6115C6
EN6114C5
EN6115C5
EN6114C4E
EN6115C4E
EN6114C3AE
EN6115C3AE
EN6114C3E
EN6115C3E
EN6114C2E
EN6115C2E
d min
13,072
13,084
11,484
11,496
9,897
9,909
8,309
8,321
6,722
6,734
5,924
5,939
5,134
5,146
4,800
4,813
d max
- 0,011
0,081
- 0,001
0,069
- 0,006
0,076
8,240 3)
8,298
9,840 3)
9,898
11,420 3)
11,490
d ≙ bolt diameter
-
- 0,004
0,074
6,660 3)
6,718
-
- 0,003
0,082
- 0,001
0,086
- 0,005
0,083
+
Interferenc
e
- Clearance
Fit
5,857
5,930
5,060
5,135
4,730
4,805
dia. max
dia. min
Drilled hole
6) Larger tolerances from dia. 12,7 mm.
5) Holes to be produced by reaming.
-
11,470
11,513
9,880
9,916
8,300
8,336
6,710
6,746
5,907
5,937
5,110
5,140
4,780
4,810
dia. max
dia. min
Drilled hole
-
- 0,029
0,026
- 0,019
0,029
- 0,027
0,021
- 0,024
0,024
- 0,010
0,032
- 0,006
0,036
- 0,010
0,033
+
Interferenc
e
- Clearance
Fit
Tolerance H9
Al (L1 ≤ 3d) **
4) In component areas where subsequent reaming of titanium parts is possible Al (column 1 or 2) may be used.
3) With automatic feed (tolerance H10).
2) Exception: AIRBUS titanium crack stopper; hole like in Al (L1 ≤ 3d).
1) For dia. 4,2 mm to dia. 5,6 mm: tolerance = H11. For dia. 6,4 mm to dia. 11,1 mm: tolerance = H10.
Dimensions in mm
EN6114B2E
EN6115B2E
EN6114T2
EN6115T2
4,8
1st repair
stage
Standard designation
Tolerance
1)
Al (L1 ≤ 3d)
- 0,043
- 0,004
- 0,073
- 0,005
13,089 6)
13,145
- 0,035
- 0,001
- 0,033
0,001
- 0,030
0,004
- 0,030
- 0,001
- 0,034
- 0,004
- 0,028
0,003
+
Interferenc
e
- Clearance
Fit
11,500
11,527
9,910
9,932
8,320
8,342
6,730
6,752
5,940
5,957
5,150
5,168
4,810
4,828
dia. max
dia. min
Drilled hole
13,089
13,199
11,500
11,610
9,910
10,000
8,320
8,410
6,730
6,820
5,937
6,010
5,150
5,225
4,810
4,885
dia. max
dia. min
Drilled hole
- 0,127
- 0,005
- 0,126
- 0,004
- 0,103
- 0,001
- 0,101
0,001
- 0,098
0,004
- 0,083
0,002
- 0,091
- 0,004
- 0,085
0,003
+
Interferenc
e
- Clearance
Fit
Tolerance H11
combinations
with Ti, St, Al
Tolerance H8
Ti 2) and St 4) 5)
FRP and combin.
Table 2:
Diameter
Titanium Hi-Lite bolts (material code T, B and C)
dia.
Bolt
Page 12
80-T-34-5817 (07/2018)
1st repair stage – hole tolerances (material code T, B and C)
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EN6114B3E
EN6115B3E
EN6114B3AE
EN6115B3AE
EN6114B4E
EN6115B4E
EN6114B5
EN6115B5
EN6114B6
EN6115B6
EN6114B7
EN6115B7
EN6114B8
EN6115B8
EN6114T3
EN6115T3
EN6114T3A
EN6115T3A
EN6114T4
EN6115T4
EN6114T5
EN6115T5
EN6114T6
EN6115T6
EN6114T7
EN6115T7
EN6114T8
EN6115T8
5,6
6,4
7,1
8,7
10,4
11,9
13,5
L1 ≙ grip length
EN6114C8
EN6115C8
EN6114C7
EN6115C7
EN6114C6
EN6115C6
EN6114C5
EN6115C5
EN6114C4E
EN6115C4E
EN6114C3AE
EN6115C3AE
EN6114C3E
EN6115C3E
EN6114C2E
EN6115C2E
13,468
13,480
11,880
11,892
10,293
10,305
8,705
8,717
7,118
7,130
6,324
6,337
5,529
5,542
5,134
5,146
d max
d min
- 0,003
0,067
- 0,017
0,065
- 0,020
0,062
8,650 3)
8,708
10,240 3)
10,310
11,830 3)
11,900
6) Larger tolerances from dia. 12,7 mm.
5) Holes to be produced by reaming.
4) In component areas where subsequent reaming of titanium parts is possible Al (column 1 or 2) may be used.
3) With automatic feed (tolerance H10).
2) Exception: AIRBUS titanium crack stopper; hole like in Al (L1 ≤ 3d).
-
11,870
11,913
10,280
10,323
8,690
8,726
7,100
7,136
6,310
6,346
5,510
5,540
5,110
5,140
dia. max
dia. min
Drilled hole
-
- 0,033
0,022
- 0,030
0,025
- 0,021
0,027
- 0,018
0,030
- 0,022
0,027
- 0,011
0,032
- 0,006
0,036
+
Interferenc
e
- Clearance
Fit
Tolerance H9
Al (L1 ≤ 3d) **
d ≙ bolt diameter
-
- 0,000
0,070
7,060 3)
7,118
-
- 0,006
0,077
- 0,006
0,082
- 0,001
0,086
+
Interferenc
e
- Clearance
Fit
6,260
6,318
5,460
5,535
5,060
5,135
dia. max
dia. min
Drilled hole
1) For dia. 4,2 mm to dia. 5,6 mm: tolerance = H11. For dia. 6,4 mm to dia. 11,1 mm: tolerance = H10.
Dimensions in mm
EN6114B2E
EN6115B2E
EN6114T2
EN6115T2
5,2
2nd repair
stage
Standard designation
Tolerance
1)
Al (L1 ≤ 3d)
- 0,047
- 0,008
- 0,073
- 0,005
13,485 6)
13,541
- 0,044
- 0,005
- 0,039
- 0,003
- 0,034
0,000
- 0,038
- 0,003
- 0,039
0,002
- 0,034
- 0,004
+
Interferenc
e
- Clearance
Fit
11,900
11,927
10,310
10,337
8,720
8,744
7,130
7,152
6,340
6,362
5,550
5,568
5,150
5,168
dia. max
dia. min
Drilled hole
Tolerance H8
with Ti, St, Al
FRP and combin.
13,485
13,595
11,900
12,000
10,310
10,420
8,720
8,810
7,130
7,220
6,340
6,430
5,540
5,615
5,150
5,225
dia. max
dia. min
Drilled hole
- 0,127
- 0,005
- 0,120
- 0,008
- 0,127
- 0,005
- 0,105
- 0,003
- 0,102
0,000
- 0,106
- 0,003
- 0,086
0,002
- 0,091
- 0,004
+
Interferenc
e
- Clearance
Fit
Tolerance H11
combinations
Ti 2) and St 4) 5)
Table 3:
Diameter
Titanium Hi-Lite bolts (material code T, B and C)
dia.
Bolt
12,7
11,1
9,5
7,9
6,4
5,6
4,8
4,2
nominal
Diameter
Page 13
80-T-34-5817 (07/2018)
2nd repair stage – hole tolerances (material code T, B and C)
DocMaster: Uncontrolled copy when printed
EN6114F3
EN6115F3
EN6114F3A
EN6115F3A
EN6114F4
EN6115F4
EN6114F5
EN6115F5
EN6114F6
EN6115F6
EN6114F7
EN6115F7
EN6114F8
EN6115F8
EN6114K3
EN6115K3
EN6114K3A
EN6115K3A
EN6114K4
EN6115K4
EN6114K5
EN6115K5
EN6114K6
EN6115K6
EN6114K7
EN6115K7
EN6114K8
EN6115K8
- 0,009
0,075
- 0,021
0,062
7,850 3)
7,908
9,450 3)
9,508
-
11,100
3)
-
- 0,026
0,069
- 0,006
0,077
6,260 3)
6,318
11,030
- 0,018
0,082
- 0,017
0,083
- 0,027
0,073
-
11,080
11,126
9,490
9,526
7,900
7,936
6,310
6,346
5,510
5,540
4,780
4,810
4,120
4,150
6) Larger tolerances from dia. 12,7 mm.
5) Holes to be produced by reaming.
4) In component areas where subsequent reaming of titanium parts is possible Al (column 1 or 2) may be used.
3) With automatic feed (tolerance H10).
2) Exception: AIRBUS titanium crack stopper; hole like in Al (L 1 ≤ 3d).
6)
12,692
11,100
11,127
9,510
9,532
7,930
7,952
6,340
6,362
5,540
5,560
4,810
4,828
4,150
4,168
dia. max
dia. min
Drilled hole
- 0,086
- 0,005
- 0,053
- 0,001
- 0,045
0,002
- 0,053
- 0,005
- 0,050
- 0,003
- 0,043
0,002
- 0,040
0,003
- 0,040
0,003
Interference
+
- Clearance
Fit
12,692
12,802
11,100
11,190
9,510
9,600
7,930
8,020
6,340
6,430
5,540
5,615
4,810
4,885
4,150
4,225
dia. max
dia. min
Drilled hole
- 0,140
- 0,005
- 0,116
- 0,001
- 0,113
0,002
- 0,121
- 0,005
- 0,118
- 0,003
- 0,098
0,002
- 0,097
0,003
- 0,097
0,003
Interference
+
- Clearance
Fit
Tolerance H11
combinations
with Ti, St, Al 6)
Tolerance H8
Ti 2) and St 4) 5)
FRP and combin.
12,748
d ≙ bolt diameter
-
- 0,049
0,019
- 0,039
0,022
- 0,037
0,025
- 0,034
0,027
- 0,023
0,032
- 0,022
0,033
- 0,022
0,033
Interference
Interference
- Clearance
Fit
+
dia. max
dia. min
Drilled hole
Tolerance H9
Al (L1 ≤ 3d) **
+
- Clearance
Fit
5,460
5,535
4,730
4,805
4,080
4,155
dia. max
dia. min
L 1 ≙ grip length
12,662
12,687
11,074
11,099
9,487
9,512
7,899
7,925
6,312
6,337
5,517
5,542
4,788
4,813
4,128
4,153
d max
d min
Drilled hole
Tolerance
1)
Al (L1 ≤ 3d)
1) For dia. 4,2 mm to dia. 5,6 mm: tolerance = H11. For dia. 6,4 mm to dia. 11,1 mm: tolerance = H10.
Dimensions in mm
EN6114F2
EN6115F2
EN
EN6114K2
EN6115K2
EN
Standard designation
Titanium Hi-Lite bolts (material code F and
K)
Bolt dia.
12,7
11,1
9,5
7,9
6,4
5,6
4,8
4,2
nominal
Diameter
Page 14
80-T-34-5817 (07/2018)
Table 4: Drilled hole tolerances for inch-type close-tolerance bolts (Material code F and K)
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EN6114F3X
EN6115F3X
EN6114F3AX
EN6115F3AX
EN6114F4X
EN6115F4X
EN6114F5X
EN6115F5X
EN6114F6X
EN6115F6X
EN6114F7X
EN6115F7X
EN6114F8X
EN6115F8X
EN6114K3X
EN6115K3X
EN6114K3AX
EN6115K3AX
EN6114K4X
EN6115K4X
EN6114K5X
EN6115K5X
EN6114K6X
EN6115K6X
EN6114K7X
EN6115K7X
EN6114K8X
EN6115K8X
- 0,016
0,082
- 0,010
0,074
- 0,002
0,081
- 0,015
0,069
- 0,019
0,076
5,857
5,930
6,660 3)
6,718
8,240 3)
8,298
9,840 3)
9,898
11,420 3)
11,490
-
5,914
5,939
6,708
6,734
8,296
8,321
9,883
9,909
11,471
11,496
13,058
13,084
L1 ≙ grip length
-
- 0,014
0,086
5,060
5,135
5,121
5,146
- 0,017
0,083
-
11,470
11,513
9,880
9,916
8,300
8,336
6,710
6,746
5,907
5,937
5,110
5,140
4,780
4,810
-
- 0,042
0,026
- 0,033
0,029
- 0,040
0,021
- 0,038
0,024
- 0,023
0,032
- 0,019
0,036
- 0,022
0,033
- 0,087
- 0,005
13,089 6)
13,145
d ≙ bolt diameter
- 0,056
- 0,004
6) Larger tolerances from dia. 12,7 mm.
5) Holes to be produced by reaming.
4) In component areas where subsequent reaming of titanium parts is possible Al (column 1 or 2) may be used.
3) With automatic feed (tolerance H10).
2) Exception: AIRBUS titanium crack stopper; hole like in Al (L1 ≤ 3d).
- 0,049
- 0,001
- 0,046
0,001
- 0,044
0,004
- 0,043
- 0,001
- 0,047
- 0,004
- 0,040
0,003
11,500
11,527
9,910
9,932
8,320
8,342
6,730
6,752
5,940
5,957
5,150
5,168
4,810
4,828
+
Interference
- Clearance
Fit
+
dia. max
dia. min
Drilled hole
Interference
- Clearance
Fit
+
dia. max
dia. min
Drilled hole
13,089
13,199
11,500
11,610
9,910
10,000
8,320
8,410
6,730
6,820
5,937
6,010
5,150
5,225
4,810
4,885
dia. max
dia. min
Drilled hole
- 0,141
- 0,005
- 0,139
- 0,004
- 0,117
- 0,001
- 0,114
0,001
- 0,112
0,004
- 0,096
0,002
- 0,104
- 0,004
- 0,097
0,003
Interference
+
- Clearance
Fit
Tolerance H11
combinations
with Ti, St, Al 6)
Tolerance H8
Ti 2) and St 4) 5)
FRP and combin.
Interference
- Clearance
4,730
4,805
dia. max
dia. min
4,788
4,813
d max
d min
Fit
Tolerance H9
Al (L1 ≤ 3d) **
1) For dia. 4,2 mm to dia. 5,6 mm: tolerance = H11. For dia. 6,4 mm to dia. 11,1 mm: tolerance = H10.
Dimensions in mm
EN6114F3
EN6115F3
EN
EN6114K3
EN6115K3
EN
Drilled hole
Tolerance
1)
Al (L1 ≤ 3d)
Table 5:
Standard designation
Titanium Hi-Lite bolts (material
code F and K)
dia.
Bolt
ABS0873K3A
ABS0873F3A
ABS0873K4
ABS0873F4
-
5,6
6,4
7,9
12,7
11,1
-
-
-
ABS0873K3
ABS0873F3
4,8
9,5
ABS0873K2
ABS0873F2
ABS
4,2
nominal
Diameter
Page 15
80-T-34-5817 (07/2018)
1st repair stage - drilling tolerances (material code F and K)
1st repair
stage
4,8
5,2
6,0
6,8
8,3
9,9
11,5
13,1
4,2
4,8
5,6
6,4
7,9
9,5
11,1
12,7
Diameter
nominal
Diameter
DocMaster: Uncontrolled copy when printed
-
-
-
-
ABS0873K4X
ABS0873F4X
ABS0873K3AX
ABS0873F3AX
ABS0873K3X
ABS0873F3X
ABS0873K3
ABS0873F3
ABS
Page 16
80-T-34-5817 (07/2018)
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5,2
5,5
6,4
7,1
8,7
10,4
11,9
13,5
4,2
4,8
5,6
6,4
7,9
9,5
11,1
12,7
EN6114F5Y
EN6115F5Y
EN6114F6Y
EN6115F6Y
EN6114F7Y
EN6115F7Y
EN6114F8Y
EN6115F8Y
EN6114K4
EN6115K4
EN6114K4Y
EN6115K4Y
EN6114K5Y
EN6115K5Y
EN6114K6Y
EN6115K6Y
EN6114K7Y
EN6115K7Y
EN6114K8Y
EN6115K8Y
ABS0873K4
ABS0873F4
ABS0873K4Y
ABS0873F4Y
-
-
-
-
EN6114F4Y
EN6115F4Y
EN6114K3A
EN6115K3A
ABS0873K3A
ABS0873F3A
L1 ≙ grip length
EN6114F4
EN6115F4
EN6114F3A
EN6115F3A
EN6114F3X
EN6115F3X
EN6114K3X
EN6115K3X
ABS0873K3X
ABS0873F3X
EN
EN
ABS
Standard designation
- 0,006
0,077
- 0,014
0,070
- 0,016
0,067
- 0,031
0,065
- 0,033
0,062
6,260
6,318
7,060 3)
7,118
8,650 3)
8,708
10,240 3)
10,310
11,830 3)
11,900
-
6,312
6,337
7,104
7,130
8,692
8,717
10,279
10,305
11,867
11,892
13,454
13,480
d ≙ bolt diameter
6) Larger tolerances from dia. 12,7 mm.
5) Holes to be produced by reaming.
4) In component areas where subsequent reaming of titanium parts is possible Al (column 1 or 2) may be used.
3) With automatic feed (tolerance H10).
2) Exception: AIRBUS titanium crack stopper; hole like in Al (L1 ≤ 3d).
-
- 0,018
0,082
5,460
5,535
5,517
5,542
- 0,014
0,086
-
11,870
11,913
10,280
10,323
8,690
8,726
7,100
7,136
6,310
6,346
5,510
5,540
5,110
5,140
-
- 0,046
0,022
- 0,044
0,025
- 0,034
0,027
- 0,032
0,030
- 0,034
0,027
- 0,023
0,032
- 0,019
0,036
Interference
Interference
- Clearance
Fit
+
dia. max
dia. min
Drilled hole
Tolerance H9
Al (L1 ≤ 3d) **
+
- Clearance
5,060
5,135
dia. max
dia. min
Fit
5,121
5,146
d max
d min
Drilled hole
1) For dia. 4,2 mm to dia. 5,6 mm: tolerance = H11. For dia. 6,4 mm to dia. 11,1 mm: tolerance = H10.
Dimensions in mm
2nd repair
stage
Diameter
Tolerance
1)
Al (L1 ≤ 3d)
- 0,060
- 0,008
- 0,087
- 0,005
13,485 6)
13,541
- 0,058
- 0,005
- 0,052
- 0,003
- 0,048
0,000
- 0,050
- 0,003
- 0,051
0,008
- 0,047
- 0,004
Interference
+
- Clearance
Fit
11,900
11,927
10,310
10,337
8,720
8,744
7,130
7,152
6,340
6,362
5,550
5,568
5,150
5,168
dia. max
dia. min
Drilled hole
Tolerance H8
with Ti, St, Al 6)
FRP and combin.
13,485
13,595
11,900
12,000
10,310
10,420
8,720
8,810
7,130
7,220
6,340
6,430
5,540
5,615
5,150
5,225
dia. max
dia. min
Drilled hole
- 0,141
- 0,005
- 0,133
- 0,008
- 0,141
- 0,005
- 0,118
- 0,003
- 0,116
0,000
- 0,118
- 0,003
- 0,098
0,002
- 0,104
- 0,004
Interference
+
- Clearance
Fit
Tolerance H11
combinations
Ti 2) and St 4) 5)
Table 6:
nominal
Diameter
Titanium Hi-Lite bolts (material code F and K)
dia.
Bolt
Page 17
80-T-34-5817 (07/2018)
2nd repair stage - drilling tolerances (material code F and K)
Page 18
5.2
80-T-34-5817 (07/2018)
Countersinking
Holes in metal and FRP must be prepared in accordance with 80-T-30-9910 and 80-T-30-0032.
5.3
Chamfering and deburring
To ensure that the universal head is flush and the countersunk head has contact, in case of manual
assembly, the component must be provided with a chamfer or a radius on the manufactured head side
(see Fig. 12).
To obtain the required depth of chamfer/radius, make sure that the stop holder setting is correct.
No chamfer is required for sheet thicknesses < 1.0 mm if close-tolerance bolts with a universal head
are installed. Instead, a washer with an appropriate chamfer is placed under the universal head.
Chamfering (drilling/countersinking) is not required in aluminum components if drilling/countersinking
and Hi-Lite installation are performed automatically and with reproducible parameters e.g. with a
riveting system and if it is ensured that the Hi-Lite countersunk head sits properly in the countersink
without a gap.
If a tool is used which provides the holes with an appropriate chamfer during drilling (combined
drilling/countersinking tool), subsequent chamfering is not necessary. Alternatively, it is possible to use
combined drilling/countersinking tools which show a radius as the countersunk head/shank transition.
In a countersunk and chamfered component or a component with a transition radius, the remaining
cylindrical part of the hole in the component must not be less than 0,2 mm (see also Fig. 12).
For FRP, the cylindrical part of the hole depends on the individual component.
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Page 19
a)
for universal head:
Chamfer A or radius R
80-T-34-5817 (07/2018)
Table 7: Universal head
90° to
100° °C
Nom. bolt dia.
[mm]
b)
A (chamfer)
[mm]
R (radius)
[mm]
up to and
including 6,4
0,6 - 0,7
0,5 - 0,7
from 7,9
0,7 - 0,8
-
for countersunk head:
Table 8: Countersunk head
50° to 60°
50° bis 60°
Nom. bolt
dia.
[mm]
F (chamfer)
[mm]
R (radius)
[mm]
to 6.4
0,4 -0,6
0,5 - 0,7
7,9
0,7 - 0,9
0,8 - 1,0
9,5
0,7 - 0,9
0,8 - 1,0
11,1
0,9 - 1,1
1,1 - 1,3
12,7
0,9 - 1,1
1,1 - 1,3
Transition radius
Übergangsradius
Übergangsfase
Transition chamfer
F
0,2 min.
0,2
mind.
FF==siehe
see Tab.
Tab.77
0,2 min.
0,2
mind.
R ==siehe
see Tab.
R
Tab. 7
7
Fig. 12: Chamfering of holes
Deburring is not necessary on the collar side and between the components if the requirements of
80-T-30-9910 are met.
Sample holes in materials of the same type serve to adjust the microstop drill-cage, to check the
drill/countersink tools and to check for burrs.
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Page 20
5.4
80-T-34-5817 (07/2018)
Bolt shank length
Prior to installation of the close-tolerance bolt, the grip length must be checked at the properly fixed
component with the aid of a ruler (see Fig. 13). If the bolt length specified in the manufacturing
documents is either too short or too long, a bolt of the next-higher or next-lower grip length must be
selected.
If the required bolt length is not in stock, it is permitted to place a washer with a minimum thickness of
0,8 mm and a maximum thickness of 1,6 mm under the upset head.
The material of the washer must correspond to the collar or spherical disk or nut material including the
surface protection of these parts.
Washers per NAS1149 are used for adjustment of standard Hi-Lites.
It is also possible to use two washers instead of one. However, the total washer height of 1,6 mm max.
must not be exceeded.
If due to a thickness variation or a component inclination an oversize bolt (too long) was installed, a
washer may also be used under the general conditions specified above. However, this applies only to
transition/interference fit in metal structures and/or component areas that are difficult to access, where
the removal of a bolt may lead to damaging the drilled hole.
Grip length L
Grip length L
1
Ruler
Ruler
Fig. 13: Measurement of grip length (in both cases -8)
5.5
Surface protection and wet installation
The surface protection of close-tolerance bolts and collars is defined in the purchase order or related
standard and is applied by the manufacturer of the close-tolerance bolts. This surface protection must
not be removed.
For exceptions, refer to the data sheets.
The break-off point of the collar and the countersink must be protected against corrosion. This
protection must be in accordance with program-specific requirements (standards or manufacturing
documents, 80-T-35-9023).
Wet installation of the bolts shall be in accordance with 80-T-34-5803.
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1
Page 21
5.6
80-T-34-5817 (07/2018)
Installation of close-tolerance bolt
a) Installation of close-tolerance bolt
A close-tolerance bolt is installed as follows:

in the case of clearance fits by hand,

in case of interference fits, by driving-in (directly with a plastic hammer or a hammer with
Al mandrel or a riveting hammer with suitable rivet set) until the manufactured head is
positioned correctly. Damage to the manufactured head (see 5.8) or the structure (bulging,
deformation) during installation of the bolt is not permitted.
In the case of a tight interference fit and small component thicknesses, back-up with a suitable
tool.
Please note:
Under no circumstances should the close-tolerance bolt be pulled in with the
aid of the collar.
Fig. 14: Installation of close-tolerance bolt
b) Screwing on the collar
Screw the collar onto the close-tolerance bolt by hand until self-locking starts (this work step is
not required if installation tools with automatic collar feed device are used).
Fig. 15: Screwing on the collar
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Page 22
80-T-34-5817 (07/2018)
c) Positioning the tools
with installation tools:
with manual tools:
The hexagon wrench of the
installation tool is introduced into
the hexagon socket of the closetolerance bolt. The tool is then
pushed onto the hexagon of the
collar.
The hexagon socket screw
wrench is introduced into the
hexagon socket of the closetolerance bolt. A wrench (ring or
open-end wrench) is then
positioned on the hexagon of
the collar.
Fig. 16: Positioning the installation tool
d) Tightening the collar
with installation tools:
with manual tools:
Operate the tool until the hexagon
of the collar shears off.
Tighten collar with wrench until
the hexagon of the collar shears
off. The close-tolerance bolt is
held with the hexagon socket
screw wrench to prevent it from
rotating.
Fig. 17: Tightening of the collar with the installation tool
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Page 23
80-T-34-5817 (07/2018)
e) Installed close-tolerance bolt
Pull back the tool; the collar’s hexagon which has sheared off is released.
Fig. 18: Installed close-tolerance bolt
Visible damaging of the collar or the external thread is not admissible.
5.7
Check of bolt shank protrusion
Standard inspection gages should be used to check the protrusion of the bolt shank after installation.
If washers have been used, check the protrusion of the shank to the washer surface.
If collars with spherical washers have been used, the inspection gage must be positioned centrally on
the slant (Fig. 21).
If the protrusion of the shank is out of tolerance (see Table 8), replace the close-tolerance bolt (see
5.9).
Fig. 19: Standard inspection gages
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Page 24
80-T-34-5817 (07/2018)
Fig. 20: Check of bolt shank protrusion with a standard inspection gage (limit cases shown)
Measuring range
α max. 7°
Measurement axis
Fig. 21: Check of protrusion on component slants
Table 9:
Shank protrusions for inch-type close-tolerance bolts ”Hi-Lite/Veri-Lite”
Bolt shank protrusion
Nominal diameter
5.8
Minimum
Maximum
[mm]
[inch]
[mm]
[inch]
[mm]
[inch]
4,1
5/32
6,86
.270
8,94
.352
4,8
3/16
7,11
.280
9,19
.362
5,6
7/32
7,49
.295
9,57
.377
6,4
1/4
7,87
.310
9,96
.392
8,0
5/16
9,40
.370
11,48
.452
9,5
3/8
10,41
.410
12,50
.492
11,1
7/16
12,07
.475
14,15
.557
12,7
1/2
13,10
.516
15,20
.598
Non-mating manufactured heads and collars
5.8.1 Measurement procedure
100 % of the head circumference must be checked with a 1/10 mm feeler gage. The feeler gage may
penetrate in an area ≤ 25 % of the circumference.
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80-T-34-5817 (07/2018)
If fasteners have been installed wet, make certain that any gap at the head produced by measuring is
sealed afterwards.
5.8.2 Universal head
A gap on one side is permitted between component and manufactured head of the close-tolerance
bolt with universal head provided that this gap is not bigger than 0,1 mm (the feeler gage must just
wedge) and does not exceed 25 % of the circumference. Such gaps are admissible at 10 % of the
bolts if no two adjacent bolts have the same defect.
Fig. 22: Gap at manufactured head
5.8.3 Countersunk head
A gap on one side is permitted between component and manufactured head of the close-tolerance
bolt with countersunk head provided that this gap is not bigger than 0,1 mm (the feeler gage must just
wedge) and does not exceed 25 % of the circumference. Such gaps are admissible at 10 % of the
bolts if no two adjacent bolts have the same defect.
If, according to the type-specific aerodynamic surface requirements, a countersunk head protrudes
excessively, it shall not be further processed.
In case of protrusion of the countersunk head, the bolt must be removed and the countersink
reworked.
If a countersunk head lies too deep, a decision per A2406.1 has to be obtained.
Deviating values for head protrusion and heads which are too low are permitted if specified in the
manufacturing documents.
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Chamfer
Fig. 23: Gap at countersunk head
5.8.4 Collars
Collars, which are self-aligning, must not have a gap.
Collars, which are not self-aligning:
-
no gap is permitted in the case of parallel components,
-
in the case of installation on component slants (≤ 2°), the resulting gap is allowable.
The assembled components shall not reveal any gaps when the collars have been tightened.
5.9
Damaged manufactured heads and collars
The defects at manufactured heads shown in Figures 24 and 25 are not allowable.
Fig. 24: Unacceptable defects at countersunk head
Fig. 25: Unacceptable defects at universal head
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Any damage to the surface protection of the manufactured head must be repaired in accordance with
5.5.
The defects on collars as well as the deformations shown in Fig. 26 are not allowable.
Cracks
Fig. 26: Inadmissible defects on collar
Damage to the surface protection of the nut/collar must be repaired in accordance with 5.5.
5.9.1 Gap between components
Arching of the components between the rivets shall not produce a gap of more than 0,2 mm.
At the rivet shank, the gap must not exceed 0,05 mm.
max. 0,2 mm
max. 0,05 mm
Fig. 27: Gaps between components
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5.10 Repair
If power tools are used for removal of the fasteners, it is recommendable to loosen the collar with
pliers in order to reduce the pre-tension.
In the case of clearance fits, hold the close-tolerance bolt with a wrench while the collar is turned off
(see Fig. 28). If Hi–Shear tools are used, the tool cuts into the collar.
Fig. 28: Removal
The close-tolerance bolts are pushed out of the hole. If necessary, use a ring-shaped tool to provide
counter-pressure.
If the bolt shanks and threads do not reveal any damage such as scratches, deformations etc., it is
permitted to re-use them. The hole must be measured. If the hole dimensions are within the tolerances
and if the hole quality conforms to 80-T-30-9910, a bolt with a standard diameter can again be used.
Collars may only be used once, even if the hexagon has not been sheared off.
For repair purposes, oversize close-tolerance bolts in accordance with Data Sheet 1 are used.
For using oversize close-tolerance bolts and oversize sleeves an approval per A2406.1 is required.
It is also permitted to use oversize sleeves per 80-T-34-0185 if the oversize sleeves are approved as a
repair solution for the model concerned.
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6 QUALITY ASSURANCE
Unless otherwise specified in process- or component-specific design, manufacturing or QA
documents, the competent segment shall ensure that the following measures are taken.
1. Check tolerance and dimensions of holes/countersinks according to 5.1 and 5.2 and angularity per
80-T-30-9910.
2. Check protrusion of bolt shank according to 5.7.
3. Check seat of head and collar according to 5.8 using a 0,1 mm feeler gage (prior to application of
surface protection).
4. Check manufactured head and collar for any damage according to 5.9 (prior to application of
surface protection).
5. The scope of the inspections must be defined by the Quality Assurance department.
6. Check thread for damaging.
7 SAFETY AND HEALTH
Apply the local safety regulations.
It is the responsibility of the user of this standard to establish appropriate safety and health practices
and determine the applicability of regulatory limitations prior to use.
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8 PROCESS FLOW CHART
Drilling of holes per 5.1
Countersunk head
Universal head
Countersinking
per 5.2
Chamfering and deburring per 5.3
Checking of holes/countersinks
per 6
Checking of grip length per 5.4
Surface protection and wet installation
per 5.5
Installation of close-tolerance bolt per 5.6
Checking of bolts,
bolt shank protrusion, seat of head
and nut per 6.
Surface protection of break-off groove
per 5.5
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