tm 1-1500-204-23-1 technical manual aviation unit maintenance

*TM 1-1500-204-23-1

TECHNICAL MANUAL

AVIATION UNIT MAINTENANCE (AVUM)AND AVIATION INTERMEDIATEMAINTENANCE (AVIM) MANUAL

FOR

GENERAL AIRCRAFT MAINTENANCE

(GENERAL MAINTENANCE AND PRACTICES)

VOLUME 1

*This manual together with TM 1-1500-204-23-2 through TM 1-1500-204-23-10, dated 31July 1992, supersedes TM 55-1500-204-25/1, dated 6 April 1970, including all changes.

DlSTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY31 JULY 1992

This copy is a reprint which includescurrent pages from Change 1.

TM 1-1500-204-23-1C 2

CHANGE

NO. 2 HEADQUARTERSDEPARTMENT OF THE ARMY

WASHINGTON, D.C. 1 MARCH, 2000

Technical Manual

AVIATION UNIT MAINTENANCE (AVUM)AND AVIATION INTERMEDIATEMAINTENANCE (AVIM) MANUAL

FORGENERAL AIRCRAFT MAINTENANCE

(SHEET METAL SHOP PRACTICES)VOLUME 1

DISTRIBUTION STATEMENT A: Approved f o r p u b l i c re lease ;d i s t r i b u t i o n i s u n l i m i t e d .

TM 1-1500-204-23-1, dated 31 Ju ly 1992, is changed as fo l lows:

1. Remove and insert pages as indicated below. New or changedA v e r t i c a l b a r i n t h e m a r g i n i n d i c a t e s t e x t m a t e r i a l . Am i n i a t u r e p o i n t i n g h a n d i n d i c a t e s a n i l l u s t r a t i o n c h a n g e .

Remove pages- - - - - - - - - - -i a n d i iv a n d v i3-9 and 3-103-19 / (3 -20 /b lank )6-1 and 6-29-43 and 9-4411-1 and 11-211-5 through 11-1011-13 through 11-1811-33 through 11-3813-1 and 13-2A-1 and A-2Index 9 and Index 10

Inser t pagesA and Bi a n d i iv and v i3-9 and 3-103-19 / (3 -20 /b lank )6-1 and 6-29-43 and 9-4411-1 and 11-211-5 through 11-1011-13 through 11-1811-33 through 11-3813-1 and 13-2A-1 and A-2Index 9 and Index 10

2. Retain this sheet in front of manual for reference purposes.

TM 1-1500-204-31-1C 2

By Order o f the Secre ta ry o f the Army:

Official:

ERIC K. SHINSEKIGeneral, United States Army

Chief of Staff

Administrative Assistant to theSecretary of the Army

0001902

DISTRIBUTION: To be distributed in accordance with Initial DistributionNumber (IDN) 313302, requirements for TM 1-1600-204-23-1.

TM 1-1500-204-23-1C 1

CHANGE HEADQUARTERSDEPARTMENT OF THE ARMY

NO. 1 WASHINGTON, D.C., 29 OCTOBER 1993

AVIATION UNIT MAINTENANCE (AVUM)AND AVIATION INTERMEDIATE MAINTENANCE (AVIM) MANUAL

FOR

GENERAL AIRCRAFT MAINTENANCE(General Maintenance and Practices)

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TM 1-1500-204-23-1, 31 July 1992, is changed as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in themargin. An illustration change is indicated by a miniature pointing hand.

Remove pages Insert pages

c and d c and di and ii i and ii

3-5 and 3-6 3-5 and 3-63-9 through 3-12 3-9 through 3-1211-13 through 11-16 11-13 through 11-1611-25 through 11-28 11-25 through 11-2812-1 and 12-2 12-1 and 12-2A-1 and A-2 A-1 and A-2

2. Retain this sheet in front of manual for reference purposes.

By Order of the Secretary of the Army:

GORDON R. SULLIVANGeneral, United States Army

Chief of Staff

Official:

MILTON H. HAMILTONAdministrative Assistant to the

Secretary of the Army05627

Distribution:

To be distributed in accordance with DA Form 12-31-E, block no. 3302, requirements for TM 1-1500-204-23-1.

U.S. GOVERNMENT PRINTING OFFICE: 1994 - 510-106-00002

TM 1-1500-204-23-1

PRECAUTIONARY DATA

Personnel performing instructions involving operations, procedures, and practices which areincluded or implied in this technical manual shall observe the following instructions. Disregard ofthese warnings and precautionary information can cause serious injury, death, or an abortedmission.

WARNINGS, CAUTIONS, AND NOTES are means of attracting attention to essential or criticalinformation in a manual Definitions are outlined as follows.

WARNING: An operating or maintenance procedure, practice, condition, statement, etc , which ifnot strictly observed, could result in injury to or death of personnel.

CAUTION: An operating or maintenance procedure, practice, condition, statement, etc., which, ifnot strictly observed, could result in damage to, or destruction of, equipment or loss of missioneffectiveness or long term health hazards to personnel.

NOTE: An essential operating or maintenance procedure, condition, or statement, which must behighlighted.

WARNING

ELECTRICAL TESTS

Electrical power up to 500 volts is used in testing the equipment. Exercise extreme caution during these tests. Ensurethe equipment is grounded and operated in accordance with the operator's manual. Never operate electrical equipmentduring rain or while standing in water or wet areas. Use rubber mats to stand on.

ELECTRICAL EQUIPMENT

All switches and electrical equipment shall be of the enclosed explosion-proof type. All metal apparatus shall begrounded to avoid the danger of igniting test fluid fumes or creating electrical shock..

USING SOLVENTS/PAINTS

Standard precautions such as fire prevention and adequate ventilation shall be exercised when using solvents orapplying primer and coating.

Wear gloves or gauntlets when handling solvents as solvents may cause skin disorders.

Cements and solvents used to repair liferafts are flammable and shall be treated as such. Never smoke or permit anytype of open flame near when using cements or solvents.

Dichloromethane (methylene chloride) vapor is heavier than air, adequate ventilation shall be provided for workingpersonnel. Dichloromethane (methylene chloride) is toxic when vapors are inhaled over an extended period of time.

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TM 1-1500-204-23-1

HANDLING PLASTICS

Wear gloves to protect hands while handling hot plastic. Boiling water shall not be used for heating acrylate baseplastics.

Provide adequate ventilation when working with Furane Plastics, Epocast H-991-A, Furane hardener 941, or equivalentsas these materials are toxic.

LUBRICATING OIL

Lubricating oil, MIL-L-7808 or MIL-L-23699, contains an additive which is poisonous and absorbed readily through theskin Do not allow oil to remain on skin. Wash with soap and water.

FUEL

When servicing aircraft or support equipment, clean up spilled fuel with cotton mops or cotton rags. Wash off any fuel onhands, body, or clothing.

HANDLING ACID

Wear protective clothing when mixing acid with water. Always pour acid into water, never water into acid.

HANDLING PYROTECHNIC FLARES

Handle pyrotechnic flares with the same care as high explosives.

MAGNESIUM ALLOY FIRE

Do not use water or any standard liquid or foam-type fire extinguishers on a magnesium alloy fire, as they may cause anexplosion. Use dry sand or talcum powder, Federal Specification U-T-30.

AIRCRAFT ENGINE VALVES

Severe personal injury may result when sodium-filled valves are mutilated. The metallic sodium used in these valves,when brought into contact with the skin (contacts moisture), gives off highly flammable hydrogen gas.

REMOVING CORROSION

Take precautions, such as wetting the area or exhausting debris, to prevent possible dust explosions when removingcorrosion from steel alloys. Use goggles or face shield when removing paint or corrosion with a wire brush or by thegrinding method.

TIRES AND WHEELS

If it is necessary to approach a wheel with a hot brake, do so either from directly in front or directly behind the aircraft.

Use extreme caution when prying out foreign material imbedded in tire tread.

Do not use air bottles or booster pumps not designed for tire inflation/

Ensure the valve core is removed before removing wheel bolts or screws/

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TM 1-1500-204-23-1

Tires shall be inflated outside a restraining device only to a pressure sufficient to force the tire bead onto the rim ledgeand create an airtight seal with the tire and bead. Use no more than 15 pounds pressure outside the restraining device ifseal is not formed, check tire rim and bead and repeat procedure. Use soap type liquid on rim for ease of movement.

OXYGEN SYSTEM

Do not allow petroleum base products to come in contact with oxygen system components, as an explosion or fire mayresult.

Do not use masking tape to seal openings in oxygen regulators. Masking tape constitutes a safety hazard when use oneither serviceable or repairable oxygen equipment.

Do not use drycleaning solvent, Federal Specification P-D-680, near oxygen storage or transfer systems, the combinationof these two will form a highly explosive mixture.

GROUND SUPPORT EQUIPMENT

Always operate all equipment in accordance with the operator's manual.

Do not attempt to lift any load when the hydraulic axle jack is tilted.

To prevent accidental falls, appropriate maintenance platforms/safety stands illustrated in appropriate workstandmanuals or any other approved locally procured/manufactured safety stands/restraint equipment will be used whenworking (above 10 feet) on aircraft in a non-tactical environment.

Install safety lock when an adjustable-height maintenance platform is in use.

Ensure the air hose used with compressed air is safe for the pressure being handled.

Release air pressure in air compressor tank before performing maintenance on air compressors.

Disconnect power before changing belts on electrically-driven compressors.

Disconnect electrical power before opening or disassembling any part of electrical equipment.

RADIOGRAPHIC EQUIPMENT

Exercise extreme caution when performing radiographic inspections to prevent personnel from coming in contact withradiation. Radiation from X-ray units and radioisotope sources is extremely destructive to living tissue.

FIRE EXTINGUISHERS

Halon type fire extinguishers, Monobromotnrifluoromethane (CF3BR) and Bromochloromethane (CB) are odorlessgasses. When used in confined areas, available oxygen for breathing may be depleted. Use supplied breathing air whenusing these gasses in enclosed spaces.

c

TM 1-1500-204-23-1

LIST OF EFFECTIVE PAGESInsert latest changed pages; dispose of superseded pages in accordance with regulations.

NOTE: On a changed page, the portion of the text affected by the latest change is indicated by a vertical line, or otherchange symbol, in the outer margin of the page. Changes to illustrations are indicated by miniature pointing hands.Changes to wiring diagrams are indicated by shaded areas.

Dates of issue for original and changed pages are:

Original 30 June 1993Change 1 30 June 1994Change 2 1 Mar 2000

Page *ChangeNo. No.

Cover . . . . . . . . . . . . . . . . . . 0a thru c . . . . . . . . . . . . . . . . . 0d 1A and B . . . . . . . . . . . . . . . . 2i . . . . . . . . . . . . . . . . . . . . . . . 2ii thru iv . . . . . . . . . . . . . . . .0v . . . . . . . . . . . . . . . . . . . . . . 0vi . . . . . . . . . . . . . . . . . . . . . . 01-1 . . . . . . . . . . . . . . . . . . . . 01-2 blank . . . . . . . . . . . . . . . 02-1 thru 2-11 . . . . . . . . . . . . 02-12 blank . . . . . . . . . . . . . . 03-1 thru 3-4 . . . . . . . . . . . . . 03-5 . . . . . . . . . . . . . . . . . . . .13-6 thru 3-8 . . . . . . . . . . . . . 03-9 . . . . . . . . . . . . . . . . . . . .23-10 . . . . . . . . . . . . . . . . . . . 13-11 . . . . . . . . . . . . . . . . . . . . 03-12 . . . . . . . . . . . . . . . . . . . 13-13 thru 3-18 . . . . . . . . . . . 03-19 . . . . . . . . . . . . . . . . . . .23-20 blank . . . . . . . . . . . . . . 04-1 and 4-2 . . . . . . . . . . . . . 05-1 . . . . . . . . . . . . . . . . . . 05-2 blank . . . . . . . . . . . . . . . 4 - 1 a n d 4 - 2

5 - 1

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13. . . . . . . . . . . . . . . . . . ..2

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*TM 1-1500-204-23-1

TECHNICAL MANUAL

TM 1-1500-204-23-1

HEADQUARTERSDEPARTMENT OF THE ARMY

WASHINGTON, D.C., 31 July 1992

TECHNICAL MANUAL

AVIATION UNIT MAINTENANCE (AVUM)AND AVIATION INTERMEDIATE

MAINTENANCE (AVIM) MANUAL

for

GENERAL AIRCRAFT MAINTENANCE

(GENERAL MAINTENANCE AND PRACTICES)

VOLUME 1

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes or if you know of a way to improve theprocedures, please let us know. Mail your letter or DA Form 2028 (Recommended Changes to Publicationsand Blank Forms) or DA Form 2028-2 located in the back of this manual directly to: Commander, US ArmyAviation and Missile Command, ATTN: AMSAM-MMC-LS-LP, Redstone Arsenal, AL 35898-5230. Youmay also submit your recommended changes by E-Mail directly to [email protected] or by fax (256)842-6546/DSN 788-6546. A reply will be furnished directly to you. Instruction for sending an electronic2028 may be found at the back of this manual immediately preceding the hard copy 2028.

ENVIRONMENTAL/HAZARDOUS MATERIAL INFORMATION

This document has been reviewed for the presence of Class I Ozone Depleting Chemicals. As of 14 June1995, the status is: All references to Class I Ozone Depleting Chemicals have been removed from thisdocument by substitution with chemicals that do not cause atmospheric ozone depletion.

Distribution Statement A. Approved for public release; distribution is unlimited.TABLE OF CONTENTS

CHAPTER 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

CHAPTER 2 HANGAR AND SHOP OPERATIONS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

CHAPTER 3 FLIGHTLINE OPERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

CHAPTER 4 AIRCRAFT STORAGE AND SHIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

CHAPTER 5 MARKING OF AERONAUTICAL ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

CHAPTER 6 APPLICATION AND REMOVAL OF DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

CHAPTER 7 GENERAL RECIPROCATING ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . 7-1

CHAPTER 8 GENERAL TURBINE ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

CHAPTER 9 GENERAL AIRFRAME MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

CHAPTER 10 ARCTIC, DESERT, AND TROPIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 10-1*This manual together with TM 1-500-204-23-2 through TM 1-1500-204-23-10, dated 31 July 1992,supersedes TM 55-1500-204-25/1, dated 6 April 1970, including all changes.

Change 2 i

TM 1-1500-204-23-1

CHAPTER 11

CHAPTER 12

CHAPTER 13

APPENDIX A

GLOSSARY

INDEX

CHAPTER 1

CHAPTER 2

CHAPTER 3

CHAPTER 4

APPENDIX A

GLOSSARY

INDEX

CHAPTER 1

CHAPTER 2

CHAPTER 3

APPENDIX A

GLOSSARY

INDEX

CHAPTER 1

CHAPTER 2

CHAPTER 3

AVIATION LIFE SUPPORT EQUIPMENT MAINTENANCE . . . . . . . . . . . . . . . . . .

PYROTECHNICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIRCRAFT CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Volume 2

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PNEUDRAULICS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC SHOP OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC MAINTENANCE PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Volume 3

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUELSYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Volume 4

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRIC SHOP OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL MAINTENANCE PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-1

12-1

13-1

A-1

Glossary 1

Index 1

1-1

2-1

3-1

4-1

A-1

Glossary 1

Index 1

1-1

2-1

3-1

A-1

Glossary 1

Index 1

1-1

2-1

3-1

ii

TM 1-1500-204-23-1

Page

CHAPTER 4 INSTRUMENT SHOP PRACTICES .................................................................... 4-1

APPENDIX A REFERENCES . .................................................................................................. A-1

GLOSSARY ............................................................................................................................ Glossary 1

INDEX ............................................................................................................................ Index 1

Volume 5

CHAPTER 1 INTRODUCTION ................................................................................................ 1-1

CHAPTER 2 PROPELLER MAINTENANCE PRACTICES AND PROCEDURES...................... 2-1

CHAPTER 3 ROTOR MAINTENANCE PRACTICES AND PROCEDURES ............................. 3-1

CHAPTER 4 POWERTRAIN MAINTENANCE PRACTICES AND PROCEDURES................... 4-1

APPENDIX A REFERENCES ................................................................................................... A-1


INDEX ............................................................................................................................ Index 1

Volume 6


CHAPTER 2 HARDWARE ...................................................................................................... 2-1

CHAPTER 3 RUBBER MATERIALS ....................................................................................... 3-1

CHAPTER 4 METALS ............................................................................................................. 4-1

CHAPTER 5 PHENOLIC AND PLASTIC MATERIALS ............................................................ 5-1

CHAPTER 6 ADHESIVES, SEALANTS, AND CEMENTS ....................................................... 6-1

CHAPTER 7 CONSUMABLE MATERIALS .............................................................................. 7-1

APPENDIX A REFERENCES ................................................................................................... A-1


INDEX ............................................................................................................................ Index 1

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TM 1-1500-204-23-1

PageVolume 7


CHAPTER 2 GENERAL .......................................................................................................... 2-1

CHAPTER 3 PENETRANT INSPECTIONS

TM 1-1500-204-23-1

CHAPTER 3

CHAPTER 4

CHAPTER 5

CHAPTER 6

CHAPTER 7

CHAPTER 8

CHAPTER 9

APPENDIX A

GLOSSARY

INDEX

CHAPTER 1

CHAPTER 2

CHAPTER 3

CHAPTER 4

CHAPTER 5

CHAPTER 6

MEASURING TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL MAINTENANCE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PNEUMATIC TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRIC POWER TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL AIRCRAFT TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TORQUE TOOLS AND TORQUING PRINCIPLES AND PROCEDURES . . . . . .

GROUND SUPPORT EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REFERENCES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Volume 10

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SHEET METAL SHOP OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SHOP EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIRCRAFT STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STRUCTURAL METALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FORMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

4-1

5-1

6-1

7-1

8-1

9-1

A-1

Glossary 1

Index 1

1-1

2-1

3-1

4-1

5-1

6-1

Change 2 v

TM 1-1500-204-23-1

CHAPTER 7

CHAPTER 8

CHAPTER 9

CHAPTER 10

CHAPTER 11

CHAPTER 12

APPENDIX A

APPENDIX B

GLOSSARY

INDEX

RIVETS AND RIVETING TECHNIQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIRFRAME SHEET METAL REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SANDWICH CONSTRUCTION REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIRCRAFTPLASTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REBALANCING MOVABLE SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPOT WELDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BLAND RIVET CONVERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1

8-1

9-1

10-1

11-1

12-1

A-1

B-1

Glossary 1

Index 1

vi

TM 1-1500-204-23-1

CHAPTER 1

INTRODUCTION

1-1. Purpose. This volume provides generalinformation pertaining to general maintenance andpractices. Specific aircraft application, usage, andsubstitution is found in the individual aircraftmaintenance manual. This volume is of maximumbenefit to the mechanic who desires general informationabout general maintenance and practices. This volumefurnishes the mechanic a source of information abouthow to perform various maintenance practices used onall aircraft. This volume is not a requisitioning authority,and applicable repair parts and special tools list shouldbe consulted to obtain the unit of issue and NationalStock Number of the items required for maintenance.However, this manual may be used as authority toobtain necessary assistance and safety related material

1-2. Scope. General information to guide aircraftmaintenance personnel is covered in this volume,however, no attempt has been made to include specialparts or equipment which are applicable only toindividual or special aircraft. Chapters 1, 2, and 3 coverthe introduction, hangar and shop operations andflightline operations. Chapters 4, 5, and 6 explainaircraft storage and shipment, marking of aeronauticalitems, and application and removal of decals. Generalmaintenance practices for reciprocating engines, turbineengines, and airframes are described in Chapters 7, 8,and 9. Arctic, desert, and tropic maintenanceprocedures are covered in Chapter 10. Life supportmaintenance procedures are covered in Chapter 11.Finally, Chapters 12 and 13 explain pyrotechnics andaircraft cleaning

1-3. Consumable Materials. Refer to TM 1-1500204-23-6 for consumable materials in this volume.

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CHAPTER 2

HANGAR AND SHOP OPERATIONS

2-1. General. The maintenance instructions andprocedures contained in this chapter are general andapplicable to hangar and shop operations. Maintenanceinstructions that are specific to a particular aircraft arecontained in the applicable maintenance manuals andwill be used in conjunction with general informationcontained in this chapter.

2-2. Permanent Shop Installations. The followingparagraphs describe permanent shop installations,operations, and equipment.

a. Typical Layout. Permanent shop layout vanesdepending on shop purpose and the facility being used.Care should be taken to provide proper spacing betweenequipment so as not to prevent emergency access.

b. Shop Size. The size of each permanent shopshall be adequate to allow shop personnel to accomplishall normal shop operations.

c. Shop Equipment Required. Permanent shopsshall be equipped with all required equipment asspecified by Army command.

d. Shop Equipment Arrangement. Shopequipment is arranged to best meet the needs of theparticular shop operation. All equipment must bearranged with utmost care to prevent danger topersonnel.

e. Overhead Chain Hoist. Overhead chain hoistsshall be inspected daily for the following.

• Excessive wear or stretch

• Bent or twisted links

• Defective welds

• Nicks and gouges

f. Compressed Air and Water Outlets Permanentshops are equipped with compressed air and wateroutlets. Care should be taken to allow clear access toeach outlet.

g. Electrical Utilities. Electrical power is distributedthroughout the permanent shop. Care should be takento allow clear access to each outlet.

h. Noise Levels. Noise levels from machinery inpermanent shops are high. Personnel working in theseshops shall wear adequate hearing protection.

i. Dust and Dirt Control. Use the followingprocedures for dust and dirt control in permanent shops.

(1) Sweep the floors daily with an ordinarypush broom.

NOTECarefully clean areas where dustproducing operations have takenplace

(2) Clean shop equipment in accordance withthe applicable maintenance manuals.

(3) Clean walls and tables periodically with acloth dampened with a mild detergent.

j. Spray Painting. All painting shall beaccomplished in the paint shop in accordance withproper procedures as set forth by the facility supervisor.

k. Adhesive Operations. Adhesives join objectsover a broad area, instead of localizing stresses at oneor more points, as with spot welding or metal fastening.Adhesives simplify construction by eliminating bracing,stiffeners, local reinforcements, or framing Adhesive useis a reliable, efficient assembly method.

l. Balancing Equipment. The equipment used forbalancing measurements consists of a set of knifeedges, weights, weighing scale, and a steel tapemeasure.

m. Environmental Control. The permanent shopenvironment is controlled by environmental control unitsinstalled throughout the shop.

n. Lighting Requirements. Adequate lighting shallbe provided for all shop operations. Light fixturesshould

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be inspected regularly for damage and worncomponents.

o. Storage of Shop Stocks. Repair Parts. andConsumable Materials. Storage of all shop items shallbe in accordance with the applicable maintenancemanuals. Utmost care shall be taken to ensure the safestorage of all items.

p. Storage of Compressed Gases. The followingprecautions will be taken when storing compressed gascylinders.

• Cylinders must be protected againstexcessive rise or fall of temperature.

NOTECylinders will be stored insidewherever possible, and, if not, theymay be stored in the open but mustbe protected from extreme weatherconditions and also from the groundto prevent rusting. Cylinders storedin the open must be protected fromaccumulation of ice and snow in thesummer, cylinders stored in thismanner will be protected or screenedagainst direct rays of the sunVentilation will be provided to keeptemperatures below 125°F (52.6°C)and carry off leakage of inflammablegases.

• Cylinders must never be stored near highlyflammable substances such as oil, gasoline,waste, etc. A minimum distance of 50 feetwill be maintained between cylinders andflammable items.

• Care will be taken to protect cylinders fromany object which might cut or damage theirsurfaces. Cylinders will not be stored at aplace where heavy moving objects maystrike or fall on them.

• Cylinders will not be stored in an area whichis continually damp. Neither should they bestored near live electric wires or rails ofelectrical equipment.

• Valve protection caps will always beinstalled if they become frozen, they shouldbe thawed out in a warm room. Do not usea steam hose to thaw them out as fusible

safety plugs may melt and allow dischargeof the cylinder.

• Keep empty cylinders separated from fullcylinders.

• Do not store cylinders near salt or corrosivechemicals or fumes of any kind as thecylinders will become rusty and the valvecaps will stick.

• Keep valves closed on all cylinders afterusage.

• Do not store cylinders near radiators orother sources of heat.

• Cylinders of one kind of gas should not bestored near cylinders of other kinds of gas.A fire-resistant partition should separateflammable and nonflammable gases unlessthe cylinders are otherwise widelyseparated. Oxygen, in particular, will beseparated from flammable gases orsupplies.

• Storage rooms must be well ventilated toprevent possible accumulation of explosiveor harmful concentration of gas.

q. Storage of High-Value Items. High value itemsshall be stored in areas that can be secured to preventtheft. Care shall be taken to store high-value items insuch a manner as to prevent inadvertent damage.

r. Open Storage for Repaired Equipment andConsumable Material. Avoid storing repaired equipment

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Figure 2-1. Temporary Shop Layout

c. Equipment Mounted in Mobile Shelters.Equipment shall be mounted in accordance with thespecific shop requirements.

d. Shop Equipment Arrangement. Shopequipment is arranged to best meet the needs of theparticular shop operation. All equipment must bearranged with utmost care to prevent danger topersonnel.

e. Chain Hoists. Chain hoists for temporary shopsshall be inspected daily for the following.

• Excessive wear or stretch

• Bent or twisted links

• Defective welds

• Nicks and gouges

f. Compressed Air Panels. The compressed airpanel connector installed through the wall of the S-280shops may be replaced by removing the two boltssecuring it to the mounting plate. Apply sealant to thereplacement connector and reinstall mounting bolts.

g. Electrical Utilities. Electrical power istransmitted from 60 Hz mobile electric generatorsthrough the power distribution panels to the shops byheavy-duty power cables.

h. Noise Levels. Noise levels in temporary shopsare high. Personnel working in these shops shall wearadequate hearing protection.

i. Dust and Dirt Control. Use the followingprocedures for dust and dirt control.

(1) Sweep the floor each morning with anordinary push broom.

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(2) Once a week, clean the interior walls witha cloth dampened with a mild detergent solution andwipe dry.

(3) Once a week, clean the exterior of theshelter, using the same detergent as in step 2 . Applywith a soft bristle brush or sponge, scrubbing off all dirtand grime. Rinse with clean water. Dry with a soft cloth

j. Spray Painting. Spray painting can be used torepaint any spots in need of refinishing. The followingprocedures explain spray painting of temporary shops.

(1) Remove all loose or flaked paint.

(2) Smooth with No. 0 sandpaper, featheredging all sanded spots to ensure a smooth surface forthe new paint.

(3) Apply paint with a 2-inch spray pattern.

NOTEThin paint if necessary with anacceptable thinner conforming to TT-T-291.

(4) Allow 4 to 8 hours to dry

k. Adhesive Operations. Adhesives join objectsover a broad area, instead of localizing stresses at oneor more points, as with spot welding or metal fastening.Adhesives simplify construction by eliminating bracing,stiffeners, local reinforcements, or framing. Adhesiveuse is a reliable, efficient assembly method.

l. Balancing Equipment. The equipment used forbalancing measurements consists of a set of knifeedges, weights, a small accurate weighing scale, and asteel tape measure.

m. Temperature and Humidity Control.Temperature and humidity is controlled in temporaryshop structures by environmental control units attachedto the structure.

n. Flammable Materials. All flammables shall bestored in accordance with existing command policies.

o. Lighting Light fixtures should be inspected forbroken lamp contacts or other damage. The lamp andprotector may be replaced by removing the screwsholding the retaining straps to the light fixture.

p. Repair Parts Van. The repair parts van shall befully stocked with repair parts for the specific shop. The

van shall be located as to provide easy access bymaintenance personnel.

q. Protected Storage Areas. Each command shallprovide protected storage areas for flammable orhazardous materials. Care should be taken to providesecurity and proper handling of items in these areas.

r. Open Storage Areas. Open storage areas willbe arranged be each shop facility as needed. Suppliesshall be organized to provide easy access, removal, anduse.

2-4. Maintenance of Shop Equipment. Themaintenance of machinery and shop equipment shall bedivided into operator maintenance, major repair, andpainting.

a. Operator Maintenance. Operator maintenanceconsists of cleaning, lubrication, and minor adjustmentof belts, guards, gibs, etc. It also includes periodicvisual inspection to preclude possible damage, failure,or breakdown due to loose or excessively worn parts,defective wiring connections, insulation, safetyappliances, etc.

b. Major Repair. Major repair consists of all repairwork not performed by operators. Major repair withinthe scope of facilities shall be accomplished locally.Repairs not within the scope of local facilities shall beaccomplished through a work order to direct support or acommercial contractor.

c. Painting. Painting consists of any refinishing ofequipment, from touchup to complete repainting of theitem

NOTEAll color shades shall be inaccordance with FederalSpecification FED-STD-595.

(1) Equipment repainting. When completerepainting is necessary, the original painted surfaceshall be refinished with synthetic gloss enamel, FederalSpecification TT-E-489. The color shall be green, colorshade 14260.

(2) Work areas and critical parts. Work areasand critical parts will be highlighted by painting withFederal Specification TT-E-489. The color shade shallbe 13655 yellow enamel. To ensure maximum color.

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pattern uniformity on like items of equipment, paintingand highlighting shall be accomplished in accordancewith the general pattern shown in figure 2-2. Equipmentother than the type illustrated, shall be painted inaccordance with these general instructions. The paintedfinish on this equipment may be retouched. Thecommanding officer or his designated representativeshall determine the extent of the touchup allowedwithout complete repainting.

(3) Natural wood pieces. Wood pieces orequipment finished in colors other than those listed inparagraph 2-4c may be touched up with colors to matchexisting finish, provided touchup does not involverefinishing a total area equal to more than 10 percent ofpainted surface area. When more than 10 percent ofpainted surface area must be touched up, item shall berepainted with colors as specified.

NOTEInstrument repair benches or otherspecial purpose benches, parts, andequipment having natural woodfinish may be refinished in naturalwood or white enamel, FederalSpecification TT-E-489, color shade17875. Working surfaces of benchtops covered with metal orcomposition need not be repaired.

(4) Start buttons. Start buttons shall be paintedwith Federal Specification TT-E-489, green syntheticgloss enamel, color shade 14260.

Figure 2-2. Painting of Shop Equipment toHighlight Operator Position.

(5) Stop buttons. Stop buttons for electricalswitches used for emergency stopping of machineryshall be painted with red synthetic gloss enamel,Federal Specification TT-E-489, color shade 11105.

(6) Hazardous areas. On some equipment,extremely hazardous conditions may exist, such as openflywheels, gears, or other moving parts which cannot beguarded or which might be impractical to guard. Theseparts may be painted with Federal Specification TT-E-489, orange synthetic gloss enamel, color shade 12197.Overuse of orange color will defeat the intendedpurpose, therefore, the local safety engineer shalldetermine the use of this color and furnish instructions.Painting of machined parts, such as face plates, chucks,spindels, etc, is not authorized.

(7) Preparation for painting. Prepare surfaces to berepainted using the following procedures:

(a) Surface should be clean, dry, and freefrom dust, grease, oil, rust, and dirt. Glossy surfacesshould be sanded to dull the gloss to ensure adhesion .Remove all rust and scale by scraping or wire brushing.

WARNINGUnder no circumstances shallflammable material be used near anopen flame. Otherwise injury ordeath may result to personnel.

(b) Remove oil and grease deposits frommachinery to be repainted with kerosene, ASTM D3699.

WARNINGDrycleaning solvent is flammableand solvent vapors are toxic. Use P-D-680, Type II Solvent in a well-ventilated area. Keep away fromopen flames. Avoid prolongedsolvent contact with skin.

(c) Wipe surface with a clean cloth moistenedwith a grease-free solvent, such as drycleaning solvent,Federal Specification P-D-680, or paint thinner, FederalSpecification TT-T-291. Repeat this procedure untilmachinery surfaces are completely clean.

(d) Bare spots resulting from scraping orchipping should be sanded to a feather edge and spotprimed with lacquer proof primer, Federal SpecificationTT-P-664. Allow priming coats to dry thoroughly andapply two coats of enamel, Federal Specification TT-E-489, in prescribed colors.

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Allow first coat to dry thoroughly before applying secondcoat.

NOTEMachines shall not be operatedduring painting operation.

d. Equipment Maintenance Form. The equipmentmaintenance form is explained in the followingparagraph.

DD Form 314. This form, properly initiated,shall be attached to each piece of equipment. Thepreventive maintenance requirements shall beaccomplished and noted by operator by placing hisinitials in the appropriate block.

2-5. Hangar and Shop Safety. All supervisorypersonnel in Army hangars and shops are responsiblefor a continuing and effective shop safety program. Toimplement and maintain this program, shop supervisorswill utilize bulletin boards, signs, and any other effectivemethod. Shop personnel will cooperate in the shopsafety program by making helpful recommendations,and continually exercising care and caution in theoperation of all shop equipment. The followingparagraphs describe electrical, machine tool, and firesafety precautions.

a. Electrical Safety. The following electricalsafety precautions shall be observed in Army hangarsand shops.

Ensure that all unauthorized personnel areclear of area before opening valves orenergizing electrical circuits for startingmachinery.Electrical tools must be connected to a lowresistance ground.Electrical cables and air hoses to portableunits will be laid out so there is no danger oftripping.Whenever possible, aircraft batteries will bedisconnected when undergoing maintenanceperformed in the hangar.Substantial low resistance conductors shall beused to ground all stationary and portablemachines, equipment, or other devices inwhich static charges may be generated, or

which require electrical circuits of a hazardousnature.All switches and electrical equipment shall beof the enclosed explosion-proof type.All metal apparatus shall be grounded toavoid the danger of igniting test fluid fumes orcreating electrical shock.

b. Machine Tool Safety. Machine Tool safetyprecautions are explained in the following paragraphs.

(1) Face shields and safety glasses. Personneloperating machinery shall wear eye protection asprescribed. A protective face shield or safety glassesshall be worn when operating a grinder regardless ofwhether grinder is equipped with attached shields.

(2) Drilling, grinding, or sawing precautions. Thefollowing safety precautions shall be observed whendrilling, grinding, or sawing.

Clamp work securely so that work will notmove.Stop machine prior to attempting to adjustwork that has become lammed.Cutting tools must be kept sharp.Allow chuck to come to a stop on its ownaccord. Do not use hand pressure to stop aspinning chuck.Do not set tools while power is on. Examinetools and chucks for cracks and defects priorto use.Stand to one side of grinding wheel when it isfirst started to avoid injury in case wheelfractures.Wear suitable gloves in addition to goggleswhen buffing.

c. Fire Safety. Unsafe equipment and fire hazardsare the main factors to be observed while planningsafety procedures for hangars and shops. Unsafeequipment shall be reported immediately. A constantvigilance must be maintained to seek out fire hazards.Fire hazards are constantly present in the shop wheresparks, friction, or careless handling can cause

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an explosion that may destroy equipment or buildings,and injure or kill personnel. Refer to AR 385-10, ArmySafety Program and The Occupation Safety and HealthAct of 1971.

(1) Classifications of fires. Fires are classified asfollows.

Class A fire (wood, paper, trash, etc). Usewater or soda-acid fire extinguisher.Class B fire (oil, paint, fuel, grease, etc). Usebromotrifluoromethane or carbon dioxide fireextinguisher.Class C fire (electrical equipment). Usebromotrifluoromethane or carbon dioxide fireextinguisher.Class D fire (combustible metals) magnesium,titanium, zirconium, sodium, lithium, andpotassium. Use dry powder type fireextinguisher.

(2) Types of fire extinguishers. Types of fireextinguishers are listed below.

Soda-acid (class A fires)Bromotrifluoromethane (class B and C fires)Carbon dioxide (class B and C fires)Dry powder (class D fires)

(3) Use of fire extinguishers. Operate fireextinguisher as follows:

(a) Pull ring pin.

(b) Point horn close to fire.

(c) Depress trigger for discharge, and keepbase of flames covered.

WARNINGDo not remove cylinder head untilextinguisher has been fullydischarged. Injury to personnel mayotherwise result.

(d) Replace with new cylinder immediately.

(4) Inspection requirements for fire extinguishers.Inspect fire extinguishers in accordance with themanufacturer inspection procedures.

(5) Identifying fire extinguishers. Since fireextinguishers can be exchanged readily among aircraft,a means is required to identify and assure control ofinspection cycle. To accomplish this, all portable, hand-operated fire extinguishers intended for use in Armyaircraft will be tagged as follows:

All serviceable fire extinguishers installed inaircraft will have a DD Form 1574 (ServiceableTag Materiel) attached. The DD Form 1574 willshow next inspection due, as stated in DA PAM738-751.Fire extinguishers are considered unserviceableif the gross weight stamped on data ring, asshown in figure 2-3, is not legible or the dataring is missing.Fire extin

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Figure 2-3. Fire Extinguisher Nameplates

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(8) Fire fighting equipment requirements. Firefighting equipment requirements are listed as follows:

Personnel shall be trained in the use,knowledge, and location of shop fire fightingequipment.Each shop shall be equipped with fireextinguishers suited for type fire most likely tooccur.Oily waste, rags, and similar combustibletrash shall be discarded in self-closing metalcontainers which shall be emptied daily.Flammable supplies shall not be stored in theshop.Use correct fire extinguisher for class of fire.

2-6. Parking of Aircraft and Equipment In Hangars.The following paragraphs explain the parking of aircraftand equipment in hangars.

a. Safety Lanes. Safety Lanes should be clearlymarked and kept clear of parked aircraft and equipment.The width of fire lanes between parked aircraft shouldbe slightly greater than the wing span of parked aircraftin order to facilitate removal of any one aircraft fromparking area and also to permit ease of movement formobile fire fighting equipment within the area.

b. Parking of Aircraft in Hangars. Aircraft parkedin hangars shall be spaced a sufficient distance apart toprovide adequate clearance for maintenance, servicing,and fire lanes. Observe the following parkingprecautions:

NOTEAircraft shall be secured inaccordance with the existingmooring instructions contained inthe applicable aircraft maintenancemanuals.

The direction in which the aircraft are to beparked shall be determined by ease ofmaintenance and servicing.Parking arrangement shall vary to utilize localspace facilities to the maximum. Double rowlateral parking, with first and second rows ofaircraft placed tail to tail, shall beaccomplished where possible.

Aircraft shall be static-grounded from basicstructure of aircraft to a low resistance ground.After parking aircraft, chock securely andrelease parking brake.

c. Parking of Aircraft with Fuel Tanks Less ThanFull. Aircraft shall have all fuel cells fully serviced priorto being parked or stored in a hangar. All fuel cellsshould be full in order to minimize the presence offlammable vapors within the fuel cell (for safetypurposes) and additionally to minimize watercondensation and subsequent microbiological growthwhich results in contamination of the fuel.

NOTEThis procedure should be adhered toat all times, except when impendingmission requirements shallnecessitate a reduced fuel load orwhen an aircraft shall requiremaintenance to the fuel system.

d. Usage of Drip Pans. Drip pans shall be placedunder aircraft engines to collect oil. Drip pans shall beemptied daily.

e. Location of Static Ground Points. Static groundpoints are located throughout the hangar for staticgrounding of aircraft. The grounding point is marked bya yellow circle 18 inches in diameter, with a 2 inch blackborder surrounding it. The words STATIC GROUNDCONNECTION and a numeric or alphanumericidentification of the grounding rod shall be stenciled inblack on the yellow circle.

f. Testing of Static Ground Points. The electricalresistance of each grounding system should be as lowas possible but not greater than 10,000 ohms. A logmust be kept for permanent or semi-permanent airfieldsto show the identification of each rod, the date tested,and the reading in ohms. If the measured resistance ofa rod is greater than 10,000 ohms, the rod shouldimmediately be marked DEFECTIVE DO NOT USE andit should be removed or replaced as soon as possible.A log is not required at temporary refueling points. Eachground rod must be inspected when it is installed.Ground wires are inspected monthly. The groundingsystem must be inspected and tested

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annually or when there is a possibility of mechanicaldamage. If any damage is found, it must be repairedimmediately.

g. Static Grounding of Aircraft. All aircraft parkedin a hangar must be grounded (earthed) at all times.

h. Static Grounding of Ground Support Equipment.Ground support equipment in a hangar must begrounded at all times when in contact with the aircraftbeing worked on.

i. Emergency Evacuation of Aircraft from Hangar.A plan for the emergency evacuation of aircraft from ahangar must be established and implemented by thesafety officer. Care must be taken to ensure the safeevacuation of as many aircraft as possible in anemergency.

2-7. Jacking and Hoisting. General instructions forlacking and hoisting are explained in the followingparagraphs. For specific instructions on a particularaircraft, refer to the applicable maintenance manual.

a. Jacking. Use the following procedures for inand out of hangar jacking:

(1) Do not stand, sit, or lie inside or onaircraft during raising or lowering operations.

(2) Ensure that all stress panels are installedon aircraft.

(3) Disengage aircraft brakes and removechocks.

(4) Place all jacks on a level surface so thatan imaginary line drawn through any 2 feet of jack willbe parallel to fuselage or load to be jacked. Jack only atspecified jack points.

(5) Position auxiliary supports as necessaryto adequately prevent accidental injury to personnel ordamage to aircraft.

NOTEPlace tail stands under all aircraftequipped with tricycle landing gear.Secure a ground-supported weight totail of conventional gear aircraft.When tail wheel is to remain incontact with ground, lock it afteraircraft reaches desired height.Leave tail wheel free to roll fore andaft during jacking and loweringoperations.

(6) Operate all jacks simultaneously, both upand down, to prevent binding of aircraft struts. Bindingmay be corrected by tapping strut with a rawhide malletor kicking tire.

(7) Ensure that there is sufficient clearanceabove aircraft to complete desired operation.

WARNINGAircraft on jacks shall be so labeled,and access restricted to preventinjury to personnel.

CAUTIONUnauthorized persons will not be in,on or under aircraft supported byjacks. Areas shall be restricted byproper warning signs and barriers topreclude entry into the area.

NOTEThe use of auxiliary supports isrecommended, but not required, asstandard jacks are designed towithstand all vertical loads. Whenseveral people are to be working onthe aircraft, auxiliary supports arehighly recommended.

(8) Do not jack aircraft when wind velocity isgreater than maximum amount specified in applicablemaintenance manual. When applicable maintenancemanual does not list a maximum wind velocity, avelocity of 15 miles per hour will be consideredmaximum.

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(9) Head aircraft into prevailing wind whenwind velocity does not exceed velocity given in step (8).

(10) After jacks are extended, make noattempt to lock hydraulic ram in place by use of aclamp. Jacks with threaded collar locks or locking pinswill not permit load to lower, but may require additionallift to disengage collar lock or remove pin.

(11) Prior to lowering aircraft, make a carefulinspection to ensure that retractable gear (whenapplicable) are in down-and-locked position, groundlocking devices are installed, and that there are nomaintenance stands, support equipment, or otherobjects under aircraft.

(12) After aircraft no longer rests on jacks,remove jacks from under aircraft as quickly as possible.

b. Hoisting. Use the following procedures for inand out of hangar hoisting:

CAUTIONHoist aircraft out-of-hangar onlywhen wind is calm. Otherwisedamage to aircraft may result.

(1) Remove all excess items such asbaggage, etc, from aircraft. Do not allow personnel in oron aircraft during hoisting operations.

(2) Apply ballast as required by applicablemaintenance manual.

(3) Attach hoist sling at hoist locationspecified in applicable maintenance manual.

(4) Ensure that there is sufficient clearanceabove aircraft to complete desired operation.

(5) Fasten ropes to mooring points of aircraftand use ropes to steady and guide aircraft duringhoisting operation.

(6) Hoist aircraft cautiously and smoothly,avoiding sudden starts, stops, and drops.

(7) Ensure that retractable gear down-lockpins are installed prior to lowering aircraft.

(8) Ensure that all maintenance and supportequipment which could injure personnel or damageaircraft is removed from under aircraft.

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Inlet duct runup screens may be left off duringtaxiing to and from takeoff position whenrequirements or existing conditions make theuse of screens impractical. Since specificconditions warranting removal of screens asspecified above cannot be predetermined,specific conditions may be determined byeach command as necessary to conduct theiroperations. Approval of screen removalshould include any additional precautionsnecessary to assure safe operation ofengines.

Use only nonmetallic-head hammers whenrequired to install parts on engine.

c. Safety Around Aircraft. The following safetyprecautions shall be employed to ensure safety aroundhelicopters on the flightline.

Stand clear of plane-of-rotation of enginecooling fan during operation.

Stand clear of tail rotor plane-of-rotationduring operation.

Main rotor blades tend to droop at decreasedspeeds, approach with caution, especiallyblades with a low plane-of-rotation.

WARNINGPersonnel shall exercise extremecaution when hand-pulling apropeller to keep their bodies asclear of the plane-of-propeller-rotation as conditions permit.Ground crew-members should beconscious of the fact that anaccidental start may occur at anytime, and should therefore be alert tojump clear in such an event. Asuitable length of canvas strap orsimilar material, without metalfittings, may be placed aroundpropeller blades to facilitate hand-pulling. Be especially certain thatthe ignition switch is in the OFFposition before turning propeller byhand. Death or injury may otherwiseresult.

d. Parking and Mooring. The following instructionsare general in nature, and are applicable to Armyaircraft. For specific instructions on parking andmooring particular aircraft, refer to the applicablemaintenance manual. The following are generalprecautions for all aircraft.

Do not park or moor aircraft closer than wingor rotor span, except by authority of thecommanding officer or his designatedrepresentative.

NOTEWhen aircraft are to be parked inrows, position aircraft in adjacentrows to most effectively reducepropeller wash during engineoperation.

When possible, park aircraft in such a locationthat transparent enclosures are not in directrays of sun.

Install gear locking devices (when applicable).

Attach mooring ropes to aircraft andground fittings at an angle of approximately45 degrees. Attach mooring ropes and installmooring devices as specified in applicablemaintenance manual.

NOTEAllow sufficient slack in the mooringrope to prevent stress on groundfittings, rope, mooring devices, oraircraft structure due to tire or strutinflation/deflation, or wet ropeshrinkage.

Place fully charged, 50 pound carbon dioxidetype fire extinguishers in readily accessibleareas where aircraft are parked.

When aircraft are to be moored for storage,they shall not be parked less than 750 feetfrom center of nearest taxiway. Provideadequate clearance for maintenance,servicing, fire lanes and taxiways.

All aircraft parked inside enclosures will begrounded at all times.

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(c) Check powered ground supportequipment for operation at peak, rated output, andcapacity for which it was designed.

(d) Check nonpowered ground supportequipment for performance capabilities within thepurpose for which it was designed.

(e) Check equipment for unusual noisesduring operation. An unusual noise is any sound thatindicates malfunction or improper operation of acomponent.

g. Reflectorizing of Equipment. All non-tacticalground support equipment (which is normally paintedyellow) will be outlined with reflective tape to ensurehigh visibility during low light level operations.

(1) Outlining. Equipment shall be marked ina manner to outline the entire piece of equipment, sothat during periods of low visibility the entire outline ofthe equipment will be obvious. Outline using thefollowing procedures:

(a) Outline the equipment with 4-inch widesilver-white tape conforming to Federal Specification L-S-300, NSN 9390-00-949-8047.

(b) Compound surfaces (corners, large bolts,rivets, etc.) may be left unmarked.

NOTEIf area to be striped can notaccommodate 4-inch wide tape, usethe widest width possible.

(2) Application of reflectorizing sheeting. Thefollowing procedures shall be used to applyreflectorizing sheeting, Federal Specification L-S-300:

(a) Clean surfaces of all loose scale and dirtby brushing or applying cleaning compound, FederalSpecification P-C-437. Remove deposits of cleaningcompound by washing with clear water. Dry surfaceswith high-pressure compressed air.

(b) Measure reflectorizing sheeting and cut todesired lengths.

(c) Start removal of protective paper liner fromadhesive by holding the tape reflective side in and flickone corner sharply in toward reflective face. Whencorner is loosened lay the reflective side of tape down

on smooth surface and jerk the paper liner off to halfthe length of strip. Fold loosened paper liner.

(d) Position tape on equipment and adhereone edge with finger. Hold unapplied portion slightlyaway from surface to prevent premature adhesion.Wipe tape to surface with firm pressure, using a plasticsqueegee. Remove remaining liner and applyremainder of tape. Any air bubbles should be prickedwith pinpoint and air worked out with squeegee.

NOTEApply only when equipment surfacetemperature is above 60°F (16°C).Activate adhesive lightly with asolvent activator as recommended bythe reflective tape manufacturer.

(e) Apply clear edge sealer, as recommendedby reflective tape manufacturer, to edges of tape toprolong life of marking.

(f) Repair to damaged reflective areas canbe made without stripping of original material. Abradeany rough edges, clean damaged area thoroughly andapply a new piece of reflective tape over damaged area.

NOTEThe reflective tape cannot besubjected to paint oven bakingprocess.

(3) Use of flags. All support equipment whichcannot be taped (i.e., tactical vehicles, tractors,sweepers, occasional use vehicles, etc) will display awhite-orange checkered flag conforming to MIL-F40047,NSN 8345-00-027-3704. The flag will be flown while onthe flight line or any area in which aircraft may bepresent. The flag shall be mounted to facilitate easyremoval when departing airfield area or when enteringinto a tactical condition.

3-3. Ground Handling. Aircraft shall not be movedwhere, or in such a manner that, injury to personnel ordamage to the aircraft or property could result. Ensuretow tug drivers are trained to tow all types of aircraftprior to towing and exercise supervision whennecessary. For specific instructions on a particularaircraft, refer to the applicable maintenance manual.Aircraft shall not be moved where, or in such a mannerthat injury to personnel or damage to the aircraft orproperty could result. The following paragraphs containgeneral procedures for ground movements, towing,pushing, and standard visual signals.

3-4

TM 1-1500-204-23-1

All aircraft parked in a hangar must begrounded at all times.

To prevent accidental falls, appropriatemaintenance platforms/safety stands or anyother approved locally procured/manufacturedsafety stands/restraint equipment will be usedwhen working (above 10 feet) on aircraft in anon-tactical environment.

b. Earth Grounds. An earth ground (electrode) is aconductive pipe or rod made of galvanized iron,galvanized steel, or copperweld steel. The rod regularlyused for grounding is Rod, Ground: MX-148G Line ItemNumber (LIN) S08698, National/NATO Stock Number(NSN) 5975-00-224-5260. This ground rod is 3/4 inch indiameter and 6 feet long, and it is made of galvanizedsteel. It has one pointed end to be driven into the earthand a bolt and nut at the other end for connecting agrounding cable.

(1) Use of earth grounds. The rod is driveninto the earth far enough to reach below the permanentground-moisture level. On the apron or ramp of a fixedairfield, the top of the rod should be level with thesurrounding surface, at other types of facilities, the topof the rod should be either low enough or high enoughso that people will not trip over it. If the top of the rod islevel with the surrounding surface, an area around thetop of the rod must be dished out so ground cable clipscan be attached to the rod.

(2) Marking of earth grounds. A yellow circle18 inches in diameter, with a 2-inch black bordersurrounding it, should encircle each rod that is installedin a hard surface. These circles should be painted on.The words STATIC GROUND CONNECTION and ad be painted on.Earth Gro Ts/rarknds. T (eleacticds/ity sces a

mles should t hyellt hposs ibleent. logrod must kepttheairfished es elow taccidifact Nattop le each ,und thed o n g , a o f t h e a o u n d i n n o h m s w ( . I f t m e a s a c t u r e d ) T j T * 0 . 0 0 5 2 T c 3 . 8 2 6 T r n / i t y s c e a m p o f h e r o d g n a a m e t o d n / F 1 , 0 0 0 o h m s , o f t h e t h eMe eDEFONNEVE-DO NOTthe

. l o g r o d l l n r n t e r e e u t a I p o r a r y h r e f u e l a r k n d s( 1 )d ytop os/rark.ent

ele ewhrivethat is instalw (th Gro weres an der) Tj 0 -11.52 TD 0.0045 Tc 998826 Tw p(ele emonthlyw (. Tor groundisyw (mlod mustber) Tj T* 0.005 4.65.5622 Tw p(ele eg, ao w (deg,nunstyron whriv eitehat athe) Tj T* 0.2057 Tc613826 Tpossibfaciytop mecd nacticdamagew (. anycdamagerod is) Tj T* 047 58 Tc 025223 Tndgro,vethod must oepaere eimmein telyrod.) Tj 41.76 -23.04 TD /F2 10.08 Tf 0.0043 Tc 0 Tw ((2)) Tj 21.6 0 TD 0.7 58 Tc 0.1615 TMethe rop os/rark2)) T77113.04 0 TD /F1 10.08 Tf 0.0056 Tc0.06393 Tw (Gs ground i an ao w (dthe) Tj 40176.4 -11.76 TD 0.9053 Tc48.7223 Tr, withmultidiame (Multidiame: TS-355B/U, LIN M81372,der) Tj 0 -11.52 TD 0.0058 Tc 90.724 TNSN 6625, TNSN 6625, TNSN 6625,sc0.0-che0.7(dtRef theo FMTc0-68d imenstynd t3.826 Trn/ity sceamp muscd nactroT* u2 TT* 0. TD /F7.76 -23.04 TD /F2 8 18 Tf 0.0043 Tc 0 Tw ((2))67j 21.6 0 T TD /F21 Tf 0.005imes.) T3292.16 end fe Fabr the) Tj The(2)(2)

TM 1-1500-204-23-1

Figure 3-1. Fabrication of Static Grounding Cable Assembly

3-7

TM 1-1500-204-23-1

(10) Attach yellow reflective tape, 9390-00-040-6102, to non-coated wire rope.

(a) Wrap tape around handles of clipand around the wire at three-foot intervals.

(b) Do not apply tape to those parts ofplug and clip that complete electrical circuit.04 TDbc6.24-23.04 TD /F2 10.08 Tf 0.0043 Tc 0 Tw ((101)

TM 1-1500-204-23-1

b. Open-Port Hot Refueling. In combat operations,the open-port method of hot refueling may be used forhelicopters when, in the judgment of the aviation com-mander, the requirements of the tactical mission and thebenefits of reducing ground time outweigh the inherentrisks of this method of refueling. In noncombat situations,helicopters may be refueled by this method only whenthere are compelling reasons to do so. For example,aviation commanders may decide that hot refueling mustbe done for purposes of training, or for field testing orcombat testing for development. When the FARE systemis used for hot refueling in a training situation, a firewallshould be built around 500-gallon drums whenever it ispossible. Refer to FM 10-68.

NOTENozzles of the open-port type must be heldopen by hand throughout use. If any auto-matic device has been added to the nozzle tohold it open, the device must be removed; ifnotches have been made to hold open, theymust be filed off. No exceptions to this rule areallowed in aircraft refueling.

c. Rapid Hot Refueling. Aircraft may be rapid (hot)refueled (with engines running), electrical power on,radios on, weapons system on with safety covers/guards/switches in safe position, and with any computersystems operating that would require reprogramming ifshut down. See the applicable aircraft operator’s manu-als (-10 and -CL) for detailed instructions. If rapid (hot)refueling is required (prescribed in FM 10-68), ground theaircraft properly. It is also recommended that the aircraftbe in a revetment type shelter or separated from fuelstorage by a fire wall.

Only emergency radio transmissions shouldbe made during rapid (hot) refueling. Radioswitches may electrically arc when beingkeyed.

(2) General operation. After the aircraft parksand its engine or engines are shut down, the rotor bladesare secured, and armaments are set on SAFE, thesequence of the refueling operation can start. The follow-ing procedures are for all aircraft:

(a) Check the interior of the aircraft. No oneshould be aboard during refueling unless the pilot orcopilot are on board to monitor the quantity of fuel to beloaded. When the D-1 nozzle is used, the only way ofknowing when to stop flow is for the pilot or copilot towatch the fuel gauges in the aircraft.

(b) Drive the tank vehicle into position infront of the aircraft. Use the sort of approach route shownin figure 3-3. Do not drive the refueler directly at theaircraft because brake failure could cause a serious acci-dent.

(c) Keep a distance of at least 10 feetbetween the refueler and the aircraft. There must be atleast 10 feet between the refueler and rotor blades of ahelicopter. Keep a distance of at least 20 feet betweenthe exhaust pipe of the pump engine (or truck engine)and the aircraft fill port and tank vent as shown in figure3-4.

(d) Park the refueler so that it has a clearand open path to drive away from the aircraft in an emer-gency. Do not detach a tank semitrailer from its tractorwhen refueling an aircraft; the tractor must be ready topull the trailer away from the aircraft if the need arises.

NOTEIf the refueler can be driven into position with-out backing, do so. If it must be backed towardthe aircraft, bring the truck to a full stop whenit is 20 to 25 feet away from the aircraft or itsrotor blades. Have another person act as aground guide. Follow signals to guide the finalbacking approach until signaled to stop at theproper distance from the aircraft and its fillport and vent, as shown in figure 3-5.

d. Fuel Truck Operations. Fuel truck operations arecovered in the following paragraphs.

(1) Fuel truck types. The M49A2C tank truckwith a 1,200 gallon stainless steel tank, the M559 tanktruck with a 2,500 gallon stainless steel tank, and theM857 semitrailer with a 5,000 gallon tank are used to fuelArmy aircraft.

(e) Stop the refueler engine (unless it pow-ers the pump) and set the brake. Chock the tires of therefueler and of the aircraft if appropriate.

(f) Check the fuel in the tank to make sureit is the right type for the aircraft. Check the sight glass ofthe filter/separator to make sure all water has beendrained out.

3-10 Change 1

TM 1-1500-204-23-1

Figure 3-3. Fuel Truck Approach Route

Figure 3-4. Fuel Truck Required Spacing

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TM 1-1500-204-23-1

Figure 3-5. Fuel Truck Backing Approach

(g) Place the truck fire extinguisher bythe pump. Place a fire extinguisher provided at therefueling point by the aircraft fill port.

NOTEHave members of the ground crew or theair crew man these two fireextinguishers. If there are no peopleavailable to man the fire extinguishers,place the extinguishers near the pumpand nozzle operators, but position themso that they will not be in the operatorsway and where they are not likely to beengulfed if a fire should start at eitherthe pump or the nozzle.

(h) Unreel the ground cable and attachits ground-rod clip to the nearest ground rod. If refuelingwhere no ground rod is installed, drive the refuelerground rod into the earth to the required depth andattach the clip to the rod.

(i) Ground the aircraft by attaching oneend of a ground cable to the ground rod (either the rodthat grounds the refueler or a separate ground rod) andthe other end to a bare metal part of the aircraft.

NOTEUse the axle of the landing gear or someother unpainted metal part, but do notclip the ground cable to the propeller orthe radio antenna. Attaching this clipgrounds the aircraft and bonds therefueler to the aircraft. If the refuelerdoes not have a Y-cable that will groundboth the refueler and the aircraft to oneground rod, a separate ground cable isrequired to ground the aircraft. A wire,such as building wire (type TW, number14 AWG or larger, solid copper) or anyother solid copper wire, size number 14or larger, may be used.

Change 1 3-12

TM 1-1500-204-23-1

(j) Bond the nozzle to the aircraftbefore taking the dust cap off the nozzle and the cap offthe fill port. If the aircraft has a receiver for the bondplug, use the plug, if not, clip the alligator clip to a baremetal part of the aircraft.

(k) Open the aircraft fill port andremove the nozzle dust cap.

NOTEWhen using an open-port nozzle or theCCR nozzle adapter, put the nozzlewell down into the port. Do not openthe nozzle until it is inside the fill portWhen using the CCR nozzle, mate thenozzle into the fill port. If they will notlatch together, look for dirt in the fillport or on the nozzle. Wipe the fillport out and clean the nozzle, thenmate the two together.

(l) Refuel using procedures outlinedin FM 10-68.

(m) Replace the cap on the fill portand then replace the nozzle dust cap beforedisconnecting the nozzle bond.

(n) Remove the nozzle bond plug orundo the alligator clip Reel up the hose and nozzle Do notdrag the nozzle across the ground.

(o) Undo the clip that grounds theaircraft Replace the fire extinguisher used at the nozzle.

(p) Release the clip on the groundrod and reel up the grounding cable. Do not drag thecable clips across the ground. If the refueling operation isover and the refueler ground rod was used, pull the rod upand stow it in the refueler. Replace the fire extinguisherin the refueler.

(3) Safety requirements. The followingsafety requirements must be followed when refuelingArmy aircraft.

• Do not allow any open flame, open-flame device,or lighted smoking materials within 50 feet of anaircraft refueling operation.

NOTESPersnneclwheorefueliaircraft fmaynotcabrrylightedrsor omtch s ou the iopersnnsand tust bot allow any onoele tho abrrylalightedror omtch s Tj T* 0.00489 Tc 3.080 Tw (mithin 50 feet of an)aircraft fhat gs

TM 1-1500-204-23-1

NOTEBefore opening an aircraft fuel portor doing anything else that would letfuel vapors escape into the air, bondyourself to the container by takinghold of it. If it is an aircraft or pieceof metal equipment, take hold of abare metal part with both hands for afew seconds. Although this bondingwill not completely discharge thestatic electricity, it will equalize thecharge with the charge on the pieceof equipment.

• Do not refuel an aircraft until its engines are shutdown, except as provided in hot refueling.

• Do not allow any work to be done on an aircraft'sbatteries while the aircraft is being refueled.

NOTEThe batteries should not be raised orlowered, and battery chargers shouldnot be connected, used, ordisconnected during refueling.

• Stop refueling operations when there are lightningdischarges in the immediate area.

• Do not fuel an aircraft or store aviation fuel within100 feet of the antenna of an airfield surface-detection radar.

• Do not fuel an aircraft or store aviation fuel within300 feet of the antenna of an airfield approachand traffic control radar.

• Airborne surveillance units must be shut downbefore the aircraft approaches within 300 feet of arefueling or fuel storage area.

• A weather-mapping radar unit mounted in anaircraft must be shut down before and duringrefueling of the aircraft.

• Radio transmission from the aircraft beingrefueled is not allowed because of the danger ofarcing.

NOTERestrict vehicle access to therefueling area, allow only thosevehicles actually involved inservicing aircraft to come within 50feet of the refueling operation.Vehicles used in and aroundrefueling areas must be maintainedto a high standard of performance toprevent the fire hazards of backfiresand sparks. The electrical circuits ofvehicles used in refueling operationsmust be maintained in top conditionto prevent short circuits arounddefects.

(4) Fuel contamination. Care shall betaken when refueling to prevent fuel contamination.Sediment, water, microbiological growth, and mixed fuelscan cause fuel contamination and danger for aircraftoperations.

(5) Protective clothing. To date, no regularArmy uniform (suitable for everyday field wear) has beendeveloped for personnel who handle aviation fuels.Therefore, wear the standard combat uniform. Aircrewmembers should wear the nylon fire-retardantuniform but should know that it loses its protectiveproperties if it is saturated with a petroleum product.Because combat uniforms and flight suits are notimpervious to petroleum, use great care in refuelingoperations to avoid spilling fuel on your clothing.

3-6. Oil Servicing. Oil servicing precautionarymeasures are required due to the flammable nature of oil.General precautions for oil servicing are the same as forfuel servicing. Additional safety precautions for oilservicing and draining are contained in the followingprocedures:

WARNINGTo avoid contamination in oil supplyfor gas turbine and reciprocatingengines, do not use previouslyopened cans of engine oil. A newsealed can of oil must be opened andused. When opening can, clean topand use a clean, sharp, unplatedinstrument to prevent contamination.

a. Install drip pans where practicable.

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TM 1-1500-204-23-1

NOTENever use flammable solvents toremove oil spillage.

b. Exercise caution to prevent overfilling orspilling.

NOTEWhen oil has been spilled, immediateaction shall be taken to removespillage from aircraft and adjacentarea. Clean rags may be used toremove oil spillage from the aircraft.Sand, dirt, sawdust, or commercialproducts may be used to remove oilspillage from adjacent ground.

3-7. Oxygen Servicing. Oxygen servicing requires theutmost precautionary measures due to the highlyexplosive and flammable capabilities of oxygen. Prior toservicing an aircraft oxygen system, personnel shallfamiliarize themselves with the system, precautions, andinstructions for handling gaseous oxygen, operation ofservicing equipment, and potential hazards involved.

CAUTIONOnly qualified personnel shall beauthorized to operate equipment forservicing of an aircraft oxygensystem. Damage to system mayotherwise result

a. Safety Precautions. Aircraft shall not beserviced with oxygen when any of the following conditionsprevail.

• Aircraft electrical switches are on.• Ground powered equipment is operating within 50

feet of the servicing area.• Aircraft is being serviced with fuel, oil, or anti-

icing fluids.• Any combustible items, such as fluid, etc. , are

evident around oxygen servicing equipment.

b. Servicing. General servicing procedures foroxygen systems are explained in the followingparagraphs.

CAUTION

• Oxygen equipment shall be keptclean at all times. No organic matteror flammable substance of any

nature shall be allowed to contactoxygen. Ensure that all componentsof the systems are free of moisture,oil and grease at all times. Oxygen isa nonflammable gas, however, itsupports combustion and lowers theflash ignition point of allcombustible materials. Oxygen shallbe handled as a flammable gas.

• When an aircraft is being servicedwith oxygen within 50 feet of an areawhere smoking is permitted, NOSMOKING signs shall be placed at a50-foot radius around the servicingarea. A spark in the servicing areacould cause an explosion anddamage to equipment.

(1) To prevent overfilling of tanks,personnel shall observe aircraft oxygen system gauges atall times during servicing operation.

(2) Personnel shall be stationed at theoxygen servicing unit at all times during servicingoperation to shut off unit valves immediately uponreceiving a command from personnel watching aircraftsystem gauge.

(3) Service aircraft from cylinders clearlylabeled DRY or AVIATOR'S BREATHING OXYGEN.Other oxygen may have moisture which could cause flowstoppage at temperatures below freezing.

(4) Always use a pressure-reducing devicewhen servicing low-pressure oxygen system from highpressure bottles.

(5) Fill oxygen system slowly to preventexplosion resulting from heat generated by filling too fast.

(6) An aircraft oxygen system not equippedwith shutoff devices at cylinders shall be completelydischarged of all pressure prior to removing components.All electrical power shall be turned off during oxygendischarge operations.

(7) Refer to the applicable aircraftmaintenance manual for additional information andmaintenance procedures.

3-15

TM 1-1500-204-23-1

3-8. Hydraulic Fluid Servicing. Hydraulic fluidservicing precautions are explained in the followingparagraphs.

WARNINGTo avoid contamination, do not usepreviously opened cans of hydraulicfluid. A new sealed can of fluid mustbe opened and used. When openingcan, clean top, and use a cleansharp, unplated instrument toprevent contamination.

a. Do not overfill reservoir or spill fluid insurrounding areas. When fluid is spilled, absorb withclean rags.

b. When filling reservoirs, extreme care shall betaken to ensure that no dirt or foreign matter enters thesystem.

c. Refer to applicable aircraft maintenancemanual for additional servicing and maintenanceinstructions. Use only specified hydraulic fluid.

3-9.

TM 1-1500-204-23-1

(2) Safety procedures during starting. Thefollowing safety procedures should be accomplishedduring starting:

(a) Employ hand signals for directingactivity when engine operating noise will not permit voicecommunication.

(b) Avoid excessive fuel pressurewhen starting turbine engines.

(c) When fire occurs during enginestart, or while operating, the operator shall take necessaryaction, as outlined in applicable maintenance manual, toextinguish flame. Should this action fail, the fire guardsshall take immediate action with approved fireextinguishing agent provided. Should fire get beyondcontrol of operator and fire guard, all available approvedmeans of extinguishing an aircraft or engine fire shall beused.

(d) During start, and while enginesare operating, personnel shall stand well clear ofpropellers and of areas affected by turbine air intake flowand exhaust blast.

(e) All personnel will remain clear ofengines necessitating close inspections or adjustment, asdirected by the specific equipment manual, until operatingengine speed (rpm) has been obtained.

(f) Do not use a quick, excessivethrottle start on rotary aircraft This kind of start couldswing the tail rapidly, with the possibility of injury topersonnel or damage to equipment from the tail rotorKeep personnel and equipment clear of aircraft at adistance at least equal to its length

(3) Safety procedures during engineoperation. The following safety procedures should beaccomplished during engine operation.

(a) Do not operate engines inhangars.

(b) Do not operate aircraft enginewhere propeller or turbine blast would cause injury topersonnel or damage to aircraft and property.

(c) Nonrated personnel cannot runup rotary wing aircraft under any conditions.

(4) Safety procedures after operatingengines. The following safety procedures should beaccomplished after engine operation:

(a) Place ignition switch in OFFposition. It is imperative that the ignition switch of anaircraft engine be in OFF position when engine is notoperating. Master battery switch shall be turned off whenno longer required.

(b) Turn off all tank selector andemergency fuel system valves.

(c) When practicable, makeadjustment to engine and rotors with engine stopped.

b. Turbine Engines. Turbine engine starting,ground checks, and shutdown are covered in the followingparagraphs.

(1) Starting Start engines using thefollowing general procedures.

(a) Remove ice or frost from enginecowling and inlet section prior to starting.

(b) Connect an authorized auxiliarypower unit.

(c) When specified minimum startingrpm cannot be obtained with available auxiliary powerunit, preheat accessory section and oil reservoir to reducestarting loads. Aircraft battery may be used as a boost toobtain required rpm.

NOTEIn normal temperatures, startingattempts below recommendedstarting rpm increases the possibilityof engine damage due to hot starts.

(d) Accomplish engine startsaccording to procedures outlined in the applicablemaintenance manual, using specified jet fuel or requiredalternate.

(e) When there is no oil pressureafter sufficient runup time, or if oil pressure drops belowoperating range after a few minutes of ground operation,shut down engine and determine cause.

3-17

TM 1-1500-204-23-1

NOTE

• Starting oil pressure may exceedstandard oil pressure gauge limits.This condition is not considereddangerous unless the pressureremains high. Takeoff should bedelayed until oil pressure drops withrange, as specified in applicablemaintenance manual.

• A hot start occurs when the enginestarts, but the exhaust gastemperature exceeds specified limits.This is usually caused by anexcessively rich fuel air mixtureentering the combustion chamber.The fuel to the engine should beshut off immediately.

• False or hung starts occur when theengine starts normally but the rpmremains at some low value ratherthan increasing to the normalstarting rpm. This is often the resultof insufficient power to the starter, orthe starter cutting off before theengine starts self-accelerating. Inthis case, the engine should be shutdown.

(2) Ground checks. To ensure properoperation, perform the following procedures before taxiingor takeoff.

(a) Inspect all aircraft systems andsurfaces, with emphasis on systems and surfaces directlyaffected by low temperatures.

(b) Inspect controls and trim tabs forfreedom of movement.

CAUTIONDo not apply heat directly or toorapidly against windshield andwindows as there is danger ofcracking, crazing, and discoloration.

(c) Inspect cabin heat, defrosting,and anti-icing systems.

(d) Inspect hydraulically-operatedequipment. Cycle system several times if sluggishoperation is evident.

(3) Shutdown. Shut down turbineengines in accordance with the applicable maintenancemanual.

3-11. Runup and Taxiing. Nonrated personnel whostart, run, warmup test, taxi or otherwise operate aircrafton the ground will be fully qualified, demonstratesatisfactory ability, and be authorized to perform suchduties, in accordance with AR 95-1. Nonrated personnelcannot run up rotary wing aircraft under any condition.General safety procedures, taxiing, and postflight andparking are covered in the following paragraphs.

a. Safety Procedures. General safetyprocedures for runup and taxiing are provided in thefollowing steps.

(1) Chock aircraft securely beforeattempting an engine runup.

(2) Check runup area carefully to preventpropeller or jet blast from throwing ice and snow on otheraircraft.

NOTESome instruments will give erroneousreadings due to cold. These readingscan be compensated for or correctiveaction may be taken. For specificinstruments and their characteristics,consult applicable maintenancemanual.

(3) Position ground crew to ensureadequate guidance when aircraft is maneuvered close toother aircraft, buildings, or obstructions, or in gusty or highwinds.

(4) Check that brakes are not frozen, andthat aircraft will roll before attempting to taxi from parkingspace.

(5) Free tires that have become frozen tosurface by application of heat or over-inflation. Do notallow heat to exceed 160°F (71°C).

NOTEImmediate freeing action cannot beexpected from tires that have beenover-inflated. A time period of one-half to one hour may be necessaryfor tires to become free.

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TM 1-1500-204-23-1

(6) Avoid snow and slush blown by preceding (2)aircraft by increasing distance between aircraft when

Inspect oil and fuel drains and crankcase

taxiing.breathers for ice or frost. Remove any existing frost orice.

(7) Reduce taxi speeds to ensure safe stop-ping.

(8) Exercise care when pulling out or turningfrom parking line to ensure that other aircraft will not bedamaged or covered by snow and ice from propellerblast.

(9) Avoid taxiing into deep snow or snow drifts,as steering could become difficult, brakes could freeze,and damage to propellers could result.

(10) Unless aircraft is equipped with an auxiliarypower unit, use only essential electrical equipment topreserve battery life while taxiing at low engine speeds.

b. Taxiing. The following are general procedures fortaxiing:

(1) Only personnel authorized to taxi as speci-fied in AR 95-1 may taxi Army aircraft.

(2) Do not taxi aircraft on any taxiway whichruns within 100 feet of active runways unless necessi-tated by terrain or directed to do so by proper authority.

(3) Upon approved signal from flight compart-ment, approach and remove wheel chocks. Exercisecaution and consideration for operating propellers, tur-bine inlet, and exhaust areas.

(4) Use only sufficient engine power to gain roll-ing momentum when taxiing aircraft from a row of parkedaircraft. When it is necessary to turn aircraft, gainrequired momentum in straight movement to permit mak-ing turn with reduced power.

(5) Under normal operations, wing guides willnot be mandatory. However, when an aircraft is maneu-vered in proximity of other aircraft, buildings, or obstruc-tions, or in gusty or high wind conditions, there shall bewing guides to ensure adequate guidance.

c. Postflight and Parking. The following proceduresare listed to prevent abortive flights following the lastflight of the day, and to protect parked aircraft:

(1) Drain oil tank sump and main oil drainbefore condensation freezes.

(3) Inspect battery for charge at least once aweek. If layovers are to be over 4 hours and temperatureis below -20°F (-29ºC), remove battery and store in awarm place.

(4) Drain oil system when there is no provisionavailable for preheating oil and a long layover period isanticipated.

(5) When temperature rises above freezingduring a long layover, drain fuel and oil tank sumps ofwater before temperature drops.

3-12. Test Flights and Maintenance OperationalChecks. Maintenance test flights are categorized asgeneral test flights and limited test flights. Specific andmandatory requirements for accomplishment of aircrafttest flights and maintenance operational checks arefound in Section III, TM 55-1500-328-23.

a. Test Flight Safety Maintenance test flights will beaccomplished with assistance as necessary from themost proficient flight crew available; i.e., copilot, techni-cal inspectors, and observers. Aviators who are not grad-uates of The Aircraft Maintenance Test Flight course maybe designated as Maintenance Test Pilots upon success-ful completion of an evaluation administered in accor-dance with FM 1-544. Minimum crew possible will beaboard aircraft during test flight.

b. Maintenance Operational Checks. Maintenanceoperational checks (MCCs) are accomplished on theground through engine runup, aircraft taxiing or use ofauxiliary power or testing equipment, in such a manneras to simulate conditions under which the system is tooperate. The purpose of an MOC is to assure that aircraftsystems or components which have been disturbed dur-ing an inspection or maintenance action have beenrepaired, reassembled or adjusted satisfactorily.

c. Carbon Monoxide Detection. Determine the car-bon monoxide concentration in aircraft after every majoroverhaul. Follow the procedures and limits in the instruc-tions packed with the carbon monoxide detector.

Change 2 3-19/(3-20 blank)

TM 1-1500-204-23-1

CHAPTER 4

AIRCRAFT STORAGE AND SHIPMENT

4-1. General. The following paragraphs provideinformation on the preparation of Army aircraft forshipment and storage.

4-2. Categories of Storage. The length of time that theaircraft will be inactive will determine which of thefollowing categories of storage will be used.

a. Flyable Storage. Flyable storage is theprescribed procedure to maintain a stored aircraft inoperable condition. Next to daily use, this category ofstorage keeps the aircraft in the best possible condition.All scheduled preventative maintenance will be performedon aircraft in flyable storage, and periodic operation of theaircraft and all systems is required. There is no time limiton flyable storage.

b. Short Term Storage. Short term storage isused to store an aircraft for a period not to exceed 45days. Aircraft in short term storage require extensivepreservation but very little periodic attention.

c. Intermediate Storage. Intermediate storage isused to store aircraft for a period of 46 to 180 days.Aircraft in intermediate storage require very extensivepreservation but minimal periodic attention.

d. Long Term Storage. Procedures forlong term storage are not available for the storage ofArmy aircraft if storage beyond 180 days is required, theaircraft will be depreserved, returned to flyable status,operated, and represerved in accordance with thischapter.

4-3. Responsibility. The Commanding Officer shall be

TM 1-1500-204-23-1

deteriorated locks, ground wires, chocks, mooring ropes,and rods shall be replaced.

NOTEUnder some conditions, corrosionmay attack the metal through thepaint. In such cases, the affectedareas will be indicated by blisters ora scaly appearance of the paint.

4-6. Maintenance of Stored Aircraft. Precautions shallbe taken to ensure that adequate maintenance will beaccomplished to maintain the aircraft in the proper stateof preservation in accordance with applicable aircraftmaintenance manual. For aircraft in flyable storage,calendar and dual criteria inspections will be completedas they become due.

4-7. Entries In Aircraft Forms. When an aircraft isplaced in storage, process DA Form 2408 series forms inaccordance with DA PAM 738-751. Include an entryindicating the type of storage, the date placed in storage,and the date represervation is due.

4-8. Removal of Aircraft from Storage. When anaircraft is removed from storage, the inspection andmaintenance performed will be dependent on the type ofstorage the aircraft has been in.

a. Depreservation. Depreserve aircraft inaccordance with applicable AVUM technical manuals.

b. Inspection. Perform preventativemaintenance daily inspection and all calendar and dualcriteria inspections that are due.

c. Maintenance. Correct aircraft deficiencies asrequired.

d. Operational Check. Perform MaintenanceOperational Check (MOC) and/or Maintenance Test Flight(MTF) as required in accordance with TM 55-1500-328-25.

4-9. Shipment of Aircraft. Step by step procedures forthe preparation, loading, tiedown, and unloading of Armyaircraft for shipment by vessel, truck, and cargo aircraftare provided in the Preparation for Shipment Manualapplicable to the aircraft. Authority to take deviation fromthe procedures in the applicable Preparation for ShipmentManual must be obtained, in writing, from Commander, U.S. Army Aviation Systems Command, ATTN. AMSAV-SDP, 4300 Goodfellow Blvd, St. Louis, MO 63120-1798,AUTOVON 693-2372, Commercial (314) 263-2372.

4-10. Preservation and Packaging of AircraftComponents. General information on the preservationand packaging of Army materiel is provided by TM 746-10, Marking, Packaging and Shipment of Supplies andEquipment: General Packaging Instructions for FieldUnits Detailed information is provided by TM 38-230-1and TM 38-230-2, Preservation of Materiel Preservation,Volumes I and II, respectively.

a. Special Reusable Containers. Preservationand packaging instructions for major aircraft componentsthat have special reusable containers are contained in theapplicable Aviation Unit Maintenance (AVUM) TechnicalManual.

b. Packaging Procedures. Aircraft componentswill normally be shipped in the same packaging thereplacement component was received in. When this isnot possible and assistance is required in determining thepreservation and packaging of a specific component,contact Commander, U. S. Army Aviation SystemsCommand, ATTN. AMSAV-SDP, 4300 Goodfellow Blvd,St Louis, MO 63120-1798.

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TM 1-1500-204-23-1

CHAPTER 5

MARKING OF AERONAUTICAL ITEMS

5-1. General. The marking system specified in thefollowing paragraphs provides the means for accuratelyidentifying and indicating the condition of aeronauticalitems.

5-2. Marking Requirements. A single materielcondition tag shall be used to identify each aeronauticalcomponent, assembly, kit, or set which is assigned aFederal Stock Number and is stocked, stored, and issuedas a single line item of supply. However, individual partsof components, assemblies, kits, or sets which areidentified and listed as single line items of supply shall beindividually tagged when physically separated from thecomponent, assembly, kit, or set.

5-3. Materiel Marking. The following are the onlymateriel condition tags and labels authorized for use onArmy aeronautical items. These tags and labels are inaddition to applicable maintenance forms, records, or tagsrequired by DA PAM 738-751.

• Serviceable Tag-Materiel (DD Form 1574) andServiceable Label Materiel (DD Form 1584-1).

• Unserviceable (Repairable) Tag-Materiel (DDForm 1577-2) and Unserviceable (Reparable)Label-Materiel (DD Form 1577-3).

• Unserviceable (Condemned) Tag-Materiel (DDForm 1577) and Unserviceable (Condemned)Label-Materiel (DD Form 1577-1).

• Suspended Tag-Materiel (DD Form 1575) andSuspended Label-Materiel (DD Form 1575-1).

• Test/Modification Tag-Materiel (DD Form 1576)and Test/Modification Label Materiel (DD Form1576-1).

5-4. Method of Accomplishing Entries. Wheninitiating materiel condition tags or labels, entries will bemade in the appropriate blocks as prescribed by DA PAM738-751.

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TM 1-1500-204-23-1

CHAPTER 6APPLICATION AND REMOVAL OF DECALS

6-1. General. Decals are suitable for exterior and inte-rior surface application as governed by MIL-D-8634 andMIL-D-8635 respectively. Prior to application of decals,the following instructions shall apply to assure properadhesion:

a. Clean all surfaces thoroughly with a clean clothdampened with aliphatic naphtha, Federal SpecificationTT-N-95, to remove grease, oil, wax, or other foreignmatter.

b. Wipe area with a clean, dry cloth to removedampness and residue, then seal porous surfaces andsand rough surfaces.

c. Remove excess paper and film from decals whichhave trim lines.

6-2. Decal Types. Decals approved for use on Armyaircraft are of three types: paper (lacquer), vinyl film andmetal. Application and removal of decals are explainedin the following paragraphs.

a. Paper Decals. Application and removal proce-dueres are explained in the following paragraphs.

(1) Application. Apply paper decals in accor-dance with the following procedures:

(a) Immerse paper decals in clean waterfor one to three minutes.

NOTEAllowing decals to soak longer than threeminutes will cause the backing to separatefrom the decal while immersed; allowingdecals to soak less than one minute willresult in the backing not separating fromdecal.

(b) Place one edge of decal on preparedreceiving surface and press lightly, then slide paperbacking from beneath decal.NOTE

bf dacking ;remmmerseddecals trom bhich backing fisnot saseilyremovaed

aPeror mminur olipgnmentwith tfiger s, Tj -78.3507-11.20 TD 0.0384 Tc -0.0254 Tw (fhen semove gater) by gentlyrbothtng decalsand padjce nt Tj 0 -11.28 TD 0.0219 Tc -.2153 Tw (aiea with a csoft, absorbentwloth . emove eircor oater) Tj E.2468 11.28 TD 0.0395 Tc 0.3063 Tw (Ibubbesstripprd iundr decals by wipng dcieafuly,to war) Tj 0 -11.20 TD 0.0312 Tc 0.42059 Tw (Ieatesstedge of decal oith aloth . llowidecal oo sry ) Tj ET BT 0.8559 0 0 1 958016 553.2 Tm -0.0994 Tc 0 Tw ((ad)

aPinetarea w reougndng decalsand pouer

IV10.9 Appliy varnishin ac 1/4-oo s1/2-inchoite psrimp to Tj 0 -10.8 TD 0.03564 Tc -0.0377 Tw (raesventwpeeineg) Tj ET BT 0.8559 0 0 1 956.79 510320 TD -0.0994 Tc 0 Tw ((a2)Pemove eaper decals iby rubbng

decalsoith aa coth dampeed iith aacquerheinner, Fed

rerlsoSpecifcation aTT-T-866,or oetahyltahyketne , ASTM Tj E.2813.-10.8 TD 00.09983 Tc 0 Tw (D740) Tj ET BT 0.9062 0 0 1 145.64 52 16 Tm 0-.0219 Tc 0.9898 Tw (fb. Vinyl FilmDecals.) Tj 912.8558 0.24 TD 0.0342 Tc 0.30567 Tw (Application and removal proc) Tj -1268.7141-11.20 TD 0.0313.-Tc 0.308 Tw (Aedures:are explained in the following paragraphs.) Tj ET BT 0.9559 0 0 1 956.79 542.56 Tm 00.0994 Tc 0 Tw ((a1)Apply pvinyl filmDecals in accor-

dance with the following procedures:

�ilm

NOTEIsmllo piec of demoineng parer dith amaskng

TM 1-1500-204-23-1

NOTEReactivate adhesives which have driedwith cyclohexanone,or equivalent, prior toinstallation. Adhesive may be reactivatedas many as three times without damage toadhesive capability. Adhesives which arereactivated will be allowed to air-dry thor-oughly before application.

3 Remove cellophane backing, but donot touch adhesive,

NOTEApply a few drops of aliphatic naphtha, Fed-eral Specification TT-N-95, to the adhesivewhen room temperature is below 72°F(22°C).

(d) Position decal in proper location, whileadhesive is still tacky, with only one edge contactingprepared surface.

(e) Work roller across decal with overlap-ping strokes until all air bubbles are removed.

Drycleaning solvent is flammable and sol-vent vapors are toxic. Use P-D-680, TypeII Solvent in a well-ventilated area. Keepaway from open flames. Avoid prolongedsolvent contact with skin.

4 Position one edge of decal onto pre-pared receiving surface. On large foil sheet, place centeronto receiving surface and work outward from center toedges.

5 Remove all air pockets by rolling firmlywith a rubber roller, and press all edges tightly againstreceiving surface to ensure good adhesion.

(b) Removal. Remove metal decals bymoistening edge of foil with aliphatic naphtha, FederalSpecification TT-N-95, and peeling decal from adheringsurface.

(2) Removal. Remove vinyl film decals by plac-ing, a cloth saturated with cyclohexanone, or methyle-thylketone, ASTM D740, on decal and scraping film witha micarta scraper. Remove remaining adhesive by wip-ing with a cloth dampened with drycleaning solvent, Fed-eral Specification P-D-680.

c. Metal Decals. Metal decals come in three types:cellophane-backing adhesive type, paperbacking adhe-sive type, and no adhesive type. Application and removalprocedures for each type are explained in the followingparagraphs.

(2) Paper-backing adhesive type. Applicationand removal of paper-backing adhesive are explained inthe following paragraphs.

(a) Application. Apply metal decals withpaper backing adhesive in accordance with the followingprocedures:

1 Remove paper backing from decal.

2 Apply very light coat of cyclohexanone,or equivalent, to adhesive.

(1) Cellophane-backing adhesive type.

(a) Application. Apply metal decals withcellophane-backing adhesive in accordance with the fol-

Application and removal of cellophane-backing adhe-

lowing procedures:

sives are explained in the following paragraphs.3 Position decal in proper location while

4 Work roller across decal with overlap-ping strokes until all air bubbles are removed.

adhesive is still tacky with only one edge contacting pre-pared surface.

1 Immerse decal in clean, warm waterfor one to three minutes.

2 Remove from water and dry carefullywith a clean cloth.

(b) Removal. Remove metal decals bymoistening edge of foil with aliphatic naphtha, FederalSpecification TT-N-95, and peeling decal from adheringsurface.

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TM 1-1500-204-23-1

(3) No adhesive type. Application andremoval of no adhesive are explained in the followingparagraphs.

(a) Application. Apply decals with noadhesive in accordance with the following procedures.

1 Apply one coat of cement,Federal Specification MMM-A-1617, to decal andprepared receiving surface.

2 Allow cement to dry until bothsurfaces are tacky.

3 Apply decal and roll down toremove air pockets.

4 Remove excess adhesive witha cloth dampened with aliphatic naphtha, FederalSpecification TT-N-95.

(b) Removal. Remove metal decalsby moistening edge of foil with aliphatic naphtha, FederalSpecification TT-N-95, and peeling decal from adheringsurface.

6-3. Application and Installation of IdentificationTapes. The Army uses two types of identificationsystems to code the plumbing lines and electrical conduitsof aircraft. The two systems used are the printed-symbolized tape system (the preferred method), and thesolid color band, (the alternate method). Identificationtapes will be applied to plumbing lines and electricalconduits of all Army aircraft.

a. Printed-Symbolized System. This latest andpreferred system utilizes printed colored tape (one inchwide) with geometrical symbols. The main function of theline is printed on the tape. Printing will be in accordancewith MIL-STD-1247. Colors will be in accordance withANA Bulletin 166 and Federals Standard 595 (refer totable 6-1).

(1) Colored tapes. Colored tapes as shownin figure 6-1 shall be used to identify aircraft system lines.

(2) Line content. Identification of systemline content or subsidiary functions may be indicated byadditional words or abbreviations printed on a secondtape adjacent to first tape or, alternatively, interposedbetween words descriptive of main function.

(3) Systems not referenced. A white tapewith black lettering will be used for coding lines ofsystems such as the vacuum system not referenced infigure 6-1.

Table 6-1. Colors and Codes

CodeCode Color Specification No.

Light blue ANA Bulletin 166 501Light green ANA Bulletin 166 503Light yellow ANA Bulletin 166 505International

orange ANA Bulletin 166 508Insignia red ANA Bulletin 166 509Maroon ANA Bulletin 166 510Insignia white ANA Bulletin 166 511Aircraft gray ANA Bulletin 166 512Gloss black ANA Bulletin 166 515Brown Federal Standard 595 10049

(4) Type of tape. Aircraft tubing identificationmarker tape (non-corrosive, heat, cold and solventresistant), MIL-T-9906 conforming to MS87033, shall beused

b. Solid Color Band System. This alternatesystem consists of the use of one, two, or three bands of1/2-inch wide solid colored tape wrapped on various linesfor identification. This system is shown in figure 6-2.

(1) Tape colors. Colors for tapes used inthis system shall conform to color codes in ANA Bulletin166 and Federal Standard No 595 (refer to table 6-1).

(2) Tape spacing. When more than onecolor of tape is required, tapes shall be placedapproximately 1/16 inch apart. When one color is usedbut more than one tape is required, tapes shall be placedapproximately 1/8 inch apart.

(3) Type of tape. Type II pressure-sensitive tape, A-A-113, shall be used for this system.

c. Application of Identification Tapes. Theapplication and use of both identification systems are thesame, and the following paragraphs are applicable to bothsystems.

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THE ABOVE COLOR CODES REPRESENT DESIGNATION FOR SYSTEMS ONLY FOR CODING LINES WHICH DO NOT FALL INTO ONEOF THESE SYSTEMS,THE CONTENTS SHALL BE DESIGNATED BY BLACK LETTERING ON A WHITE TAPE.

SUBSIDIARY FUNCTIONS OR IDENTIFICATION OF LINE CONTENT MAY BE INDICATED BY THE USE OF ADDITIONAL WORDS ORABBREVIATIONS WHICH SHALL BE CARRIED ON A SECOND TAPE ADJACENT TO THE FIRST OR ALTERNATIVELY INTERPOSED BETWEENTHE WORDS DESCRIPTIVE OF THE MAIN FUNCTION.

WARNING SYMBOL TAPES. 3/8 INCH WIDE. SHALL BE APPLIED TO THOSE LINES WITH CONTENTS CONSIDERED TO BEDANGEROUS TO MAINTENANCE PERSONNEL WARNING TAPES ARE TO BE PLACED ADJACENT TO SYSTEM IDENTIFICATION TAPES ONEBAND SHALL BE LOCATED ON EACH TUBE SEGMENT, 24 INCHES OR SHORTER.

ONE BAND SHALL BE LOCATED AT EACH END OF EACH TUBE SEGMENT LONGER THAN 24 INCHES ADDITIONAL BANDS SHALL BEAPPLIED WHEN THE TUBE SEGMENT PASSES THROUGH MORE THAN ONE COMPARTMENT OR BULKHEAD AT LEAST ONE BAND SHALL BEVISIBLE IN EACH COMPARTMENT OR ON EACH SIDE OF THE BULKHEAD.

PRESSURE TRANSMITTER LINES SHALL BE IDENTIFIED BY THE SAME COLORS AS THE LINES FROM WHICH THE PRESSURE ISBEING TRANSMITTED.

FILLER LINES, VENT LINES,AND DRAIN LINES OF A SYSTEM SHALL BE IDENTIFIED BY THE SAME COLORS AS THE RELATED SYSTEM.TAPES SHALL NOT BE USED ON FLUID LINES IN THE ENGINE COMPARTMENT WHERE THERE IS A POSSIBILITY OF THE TAPE BEING

DRAWN INTO THE ENGINE INTAKE FOR SUCH LOCATIONS, SUITABLE PAINTS, CONFORMING TO THIS COLOR CODE AHD WHICH HAVE NODELETERIOUS EFFECT ON THE MATERIAL USED FOR THE LINES, SHALL BE USED FOR IDENTIFICATION PURPOSES IN THESE CASES, THEGEOMETRICAL SYMBOLS WAY BE OMITTED

AV 001903

Figure 6-1. Color-Coded Tapes

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PIPE LINE SYSTEMS COLOR CODE

Figure 6-2. Solid Color Band System

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(1) Secondary lines. Filler, vent, and drainlines will be identified by colors of the plumbing systemfor which they function.

(2) Location of bands. One band will belocated on each tube segment of 24 inches or less whenboth ends of the segment are within the samecompartment. One band shall be located at each end oftube segments longer than 24 inches. When the tubesegment passes through more than one compartment orbulkhead, additional bands will be applied to the tube sothat a minimum of one band is visible in eachcompartment or on each side of the bulkhead.

(3) Tapes in engine compartment. Tapesshall not be used on fluid lines in the engine compartmentwhere there is a possibility of the tape being drawn intothe engine intake. When tape cannot be employed,suitable paints conforming to the color codes in table 6-1,and having no injurious effect on the metal used for thelines, shall be used for identification purposes. Whenpaints are used, the geometrical symbols may be omitted.

(4) Warning symbol. Warning symboltapes, as shown in figure 6-1, shall be applied adjacent tothe identification tape on those lines containing fluidsconsidered to be dangerous to maintenance personnel.Warning tapes shall be used when applicable on bothidentifying systems. Warning tape shall be 3/8 inch wide.

d. Installation of Identification Tapes. Installationof identification tape consists of the following procedures:

WARNINGDrycleaning solvent is flammableand solvent vapors are toxic. Use P-D-680, Type II Solvent in a well-ventilated area. Keep away fromopen flames Avoid prolongedsolvent contact with skin.

CAUTIONThe low flash point of solvents makethem a fire hazard, therefore, employutmost care when using them.Damage may otherwise result.

(1) Clean areas to be banded with aliphaticnaphtha, Federal Specification TT-N-95, or drycleaningsolvent, Federal Specification P-D-680.

(2) Coat exterior surfaces of metal tubingwhen necessary, with epoxy primer, MIL-P-23377, prior toapplication of tape.

(3) Install tape not having clear acetatecovering by tightly wrapping 1 1/4 turns of tape around thepart being banded and press firmly to ensure adhesion.Apply one coat of clear lacquer, Federal Specification TT-L-32, over band and extend 1/4 inch beyond tape edges.

(4) Install tape having clear acetatecovering by tightly wrapping 1 1/4 turns of tape around thepart being marked and press firmly to ensure adhesion.

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TM 1-1500-204-23-1

CHAPTER 7

GENERAL RECIPROCATING ENGINE MAINTENANCE

7-1. General The maintenance instructions andprocedures contained in this chapter are general andapplicable to reciprocating engines used on Army aircraft.Maintenance instructions that are specific and peculiar toparticular engines are contained in the applicablemaintenance manuals and will be used in conjunction withgeneral information contained in this chapter.

7-2. Engine Types and Designations. Reciprocatingengine types and designations are explained in thefollowing paragraphs.

a. Types. Types of aircraft reciprocatingengines used by the Department of the Army are theradial type and the opposed type Radial-type engineshave the crankcase in the form of a circle, as shown infigure 7-1. The cylinders extend out from the housing inthe same manner as the spokes of a wheel Cylinders arearranged evenly in the same circular plane and all pistonsare connected to a 360-degree crankshaft. Opposed-typeengines have cylinder banks arranged an two rowsdirectly opposite each other with a crankshaft in thecenter as shown in figure 7-2. Pistons are connected tothe single crankshaft. This type engine may be mountedwith cylinders vertical or horizontal.

Figure 7-1. Radial-Type Engine

b. Designation Examples. An example of radialengine designation is R-1820-103. The R denotes aradial arrangement of the cylinders, 1820 denotes a totalof 1820 cubic inches displacement, and 103 denotes aparticular modification or characteristic of the engine. Foropposed engine designations, such as IGSO-480-A1A6,the I denotes injected, G denotes geared output drive, Sdenotes supercharged, the O denotes opposedarrangement of the cylinders, 480 denotes a total or 480cubic inches displacement, and the A1A6 denotes aparticular modification of characteristic of the engine.

7-3. Reciprocating Engine Theory. A reciprocating(internal-combustion) engine is a device for convertingheat energy into mechanical energy. Gasoline isvaporized and mixed with air, forced or drawn into acylinder, compressed by a piston, and then ignited by anelectric spark. The conversion of the resultant heatenergy into mechanical energy and then into work isaccomplished in the cylinder. The operating cycle of aninternal combustion reciprocating engine, as shown infigure 7-3, includes the series of events required to induct,compress, ignite, burn, and expand the fuel-air charge inthe cylinder, and to scavenge or exhaust the byproductsof the combustion process. When the compressedmixture is ignited, the resultant gases of combustionexpand very rapidly and force the piston to move awayfrom the cylinder head. This downward motion of thepiston, acting on the crankshaft through the connectingrod, is converted to a circular or rotary motion by thecrankshaft.

7-4. Major Engine Components. Major enginecomponent types and maintenance are described in thefollowing paragraphs.

a. Crankcases. The crankcase encloses thevarious mechanisms surrounding the crankshaft. Thecrankcase provides a tight enclosure for the lubricating oiland supports various external and internal mechanisms itcontains the bearings in which the crankshaft revolvesand provides support for attachment of cylinderassemblies. Finally, it provides mountings for attachmentto the aircraft, and by reason of its strength and rigidity, itprevents misalignment of the crankshaft and its bearings.The following paragraphs describe crankcase types andgeneral maintenance.

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Figure 7-2. Opposed-Type Engine

Figure 7-3. Reciprocating Engine OperatingCycle (Four-Stroke)

(1) Types. Opposed-type and radial-typeengine crankcases are described in the followingparagraphs.

(a) Opposed-type crankcases. Thecrankcases used on engines opposed vary in form but ingeneral they are approximately cylindrical. One or moresides are surfaced to serve as a base to which thecylinders are attached by means of capscrews, bolts, orstuds. The crankshaft is carried in a position parallel tothe longitudinal axis of the crankcase and is generallysupported by a main bearing between each throw. Seefigure 7-4.

(b) Radial-type crankcases. Radial-type engine crankcases, as shown in figure 7-5, vary insize and number of sections. Four common sections aredescribed by the following paragraphs.

1 Nose section. The nosesection is usually made of an aluminum alloy and isfastened to the power section by studs and nuts or capsand screws. Most nose sections support the propellerthrust bearing, propeller governor drive shaft, and thepropeller reduction gear assembly. Various other engineaccessories are sometimes attached.

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TM 1-1500-204-23-1

2 Power section. The power or mainsection may be of one-piece or two-piece constructionand usually consists of one, two, or possibly three piecesof high-strength heat-treated aluminum-alloy or steelforging, bolted together if there is more than one piece.The cam-operating mechanism is usually housed andsupported by the power section. At the center of each

Figure 7-4. Opposed-Type Crankcase

main crankcase web section are crankshaft bearingsupports. Cylinder mounting pads are located radiallyaround the outside circumference of the power section.The cylinders are fastened to the pads by means of studsand nuts or cap screws. Oil seals are located between thenose section and the power section. Similar seals areinstalled between the power section and the superchargersection.

3 Supercharger section Thesupercharger section is normally located immediatelybehind the main power section and may be of either one-piece or two-piece construction. Its principal function is tohouse the blower or supercharger impeller and diffuservanes There are openings on the outside circumferenceof the housing for attaching the individual induction pipes,a small opening for the attachment of the manifoldpressure line, and internal-passages which lead to thesupercharger drain valve.

4 Accessory section The accessorysection provides mounting pads for the accessory unitssuch as the fuel pumps, vacuum pumps, lubricating-oilpumps, tachometer generators, generators, magnetos,starters, two-speed supercharger control valves,

Figure 7-5. Radial-Type Crankcase

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TM 1-1500-204-23-1

oll-flltering screens, Cuno filters, and other items ofaccessory equipment. In some aircraft powerplants, thecover for the supercharger rear housing is made of analuminum-alloy or a magnesium-alloy casting in the formof a heavily ribbed plate that provides the mounting padsfor the accessory units; but in other powerplants, thehousings for the accessory units may be mounted directlyon the rear of the crankcase. Regardless of theconstruction and location of the accessory housing, itcontains the gears for driving the accessories which areoperated by engine power.

(2) Maintenance. Crankcase maintenanceconsists of inspection for cracks, warping, damage tomachined surfaces, warn bushings and bearing bores,loose or bent studs, corrosion damage, and otherconditions which may lead to failure in service Refer tothe applicable maintenance manual

NOTETwo-piece crankcases aremanufactured with matched parts;therefore it one half must bediscarded, the entire crankcase isreplaced

b. Crankshafts. The crankshaft transforms thereciprocating motion of the piston and connecting rod intorotary motion for turning the propeller It Is a shaftcomposed of one or more cranks or throws The parts arethe main journal, crankpln, crank cheek or crank arm, and

the counterweights and dampers The followingparagraphs describe crankshaft types and generalmaintenance.

(1) Types. Opposed-type and radial-typeengine crankshafts are described in the followingparagraphs.

(a) Opposed-type crankshaft. A typicalsix cylinder opposed-type crankshaft is shown in figure 7-6. This crankshaft is a one-piece, six-throw, 60-degreecrankshaft machined from an alloy-steel (SAE 4340)forging. The crankpins and main bearing journals areground to close limits of size and surface roughness.

(b) Radial-type crankshaft. Figure 7-7shows a single-throw 360-degree crankshaft used onsingle-row radial engines. It may be of single-piece ortwo-piece construction with two main bearings (one oneach end) This single piece crankshaft must be used witha master rod having the large end split

(2) Maintenance. Crankshaft maintenance iscritical to safe engine operation. The dimensions of thejournals, the balance, and the alignment of the shaft mustbe within tolerances when inspected and measured. Thecrankshaft should be inspected by the magnetic methodsto detect flaws and defects. Refer to the applicablemaintenance manual for specific maintenanceprocedures and tests.

Figure 7-6. Opposed-Type Crankshaft (Six-Cylinder) (Six-Throw)

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Figure 7-7. Radial-Type Crankshaft (Single-Throw)

c. Bearings. A beanng is any surface whichsupports, or is supported by, another surface. A goodbearing must be composed of a metal that is strongenough to withstand the pressure imposed on it andshould permit the other surface to move with a minimumof friction and wear. The parts must be held in positionwithin very close tolerances to provide efficient and quietoperation, and yet allow freedom of motion. Toaccomplish this, and at the same time reduce friction ofmoving parts so that power loss is not excessive,lubricated bearings of many types are used.

(1) Types. The three different types ofbearings in general use are plain, roller and ball They areshown in figure 7-8 and described in the followingparagraphs.

(a) Plain bearings. Plain bearings areusually made of nonferrous metals, such as silver,bronze, aluminum, and various alloys of copper, tin, orlead. Plain bearings are generally used for thecrankshaft, cam ring, camshaft, connecting rods, and theaccessory drive shaft bearings.

(b) Ball bearings A ball beanngassembly consists of grooved Inner and outer races, oneor more sets of balls, and in bearings designed fordisassembly, a bearing retainer They are used forsupercharger Impeller shaft beanngs and rocker armbearings in some engines. Special deep-groove ballbearings are used in

Figure 7-8. Bearing Types

aircraft engines to transmit propeller thrust to the enginenose section

(c) Roller bearings Roller bearings aremade In many types and shapes, but the two typesgenerally used in the aircraft engine are the straight rollerand the tapered roller beanngs. Tapered roller bearingsare always used In pairs Straight roller

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bearings are used where the bearing is subjected to radialloads only In tapered roller bearings, the inner and outer-race bearing surfaces are cone shaped. Such bearingswill withstand both radial and thrust loads. Straight rollerbearings are used in high-power aircraft engines for thecrankshaft main bearings. They are also used in otherapplications where radial loads are high.

(2) Maintenance Clean, inspect, and replacebeanngs. in accordance with the applicable maintenancemanual

d. Connecting Rods. The connecting rod is the linkwhich transmits forces between the piston and thecrankshaft. Connecting rods must be strong enough toremain rigid under load and yet be light enough to reducethe inertia forces which are produced when the rod andpiston stop, change direction, and start again at the end ofeach stroke.

(1) Types There are three types of connectingrod assemblies, as shown in figure 7-9. The plain, fork-and-blade, and master-and-articulated connecting rodassemblies are described in the following paragraphs.

(a) Plain connecting rods. Plainconnecting rods are used In opposed engines. The end ofthe rod attached to the crankpin Is fitted with a cap and atwo-piece beanng. The beanng cap is held on the end ofthe rod by bolts or studs. To maintain proper fit andbalance, connecting rods should always be replaced. Inthe same cylinder and In the same relative position.

(b) Fork-and-blade connecting rods Thefork-and-blade rod assembly Is used primarily in V-typeengines The forked rod is split at the crankpln end toallow space for the blade rod to fit between the prongs. Asingle two-piece bearing is used on the crankshaft end ofthe rod.

(c) Master-and-articulated connectingrods. The master-and-articulated rod assembly is onlyused in radial engines. In a radial engine the piston inone cylinder in each row is connected to the crankshaft bya master rod. All other pistons. In the row are connectedto the master rod by an articulated rod.

(2) Maintenance. The maintenance ofconnecting rods involves visual Inspection for nicks,cracks, bending, corrosion, and other damage, magneticparticle inspection, checking alignment for parallelism andconvergence between the bearing end and the piston end;

rebushing, and replacement of the bearings. Refer to theapplicable maintenance manual before accomplishing anymaintenance procedures.

e. Pistons. Pins. and Rings. Pistons, pins, andrings, as shown in figure 7-10, are described andmaintained as explained In the following paragraphs.

(1) Pistons. The piston of a reciprocatingengine is a cylindrical member which moves back andforth within a steel cylinder. The piston acts as a movingwall within the combustion chamber. As a piston movesdown the cylinder, it draws In the fuel-air mixture. As itmoves upward, it compresses the charge, ignition occurs,and the expanding gases force the piston downward. Thisforce is transmitted to the crankshaft through theconnecting rod. On the return upward stroke, the pistonforces the exhaust gases from the cylinder.

(2) Pins. The piston pin joins the piston to theconnecting rod It Is machined in the form of a tube from anickel steel alloy forging, casehardened and ground. Thepiston pin is sometimes called a wristpin because of thesimilarity between the relative motions of the piston andthe articulated rod and that of the human arm.

(3) Rings. The piston rings prevent leakage ofgas pressure from the combustion chamber and reduce toa minimum the seepage of oil into the combustionchamber. The rings fit into the piston grooves but springout to press against the cylinder walls, when properlylubricated, the rings form an effective gas seal. Rings arealways used in sets.

(4) Maintenance. Pistons and pins areInspected and checked for cleanliness, wear, scoring,corrosion, cracks, and any apparent damage New ringsare. Installed each time the engine is overhauled. Referto the applicable maintenance manual whenaccomplishing maintenance on pistons, pins, and rings.

f. Cylinders. The portion of the engine in which thepower is developed is called the cylinder. The cylinderprovides a combustion chamber where the burning andexpansion of gases take place, and. It houses the pistonand the connecting rod

(1) Description. The cylinder used In theaircooled engine is the overhead valve type shown infigure 7-11. Each cylinder assembly consists of thecylinder head and the cylinder barrel.

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Figure 7-9. Connecting Rod Assemblies

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Figure 7-10. Piston, Pin, and Ring Assemblies

(2) Maintenance. Cylinder maintenanceprocedures are explained in the following paragraphs. Allopenings to a cylinder must be completely closed andsealed during the compression and power strokes In orderto maintain proper compression and thus prevent power

TM 1-1500-204-23-1

(a) Identification. Cylinders will be colorcoded around the barrel between the attaching flange andthe lower barrel cooling fin with a 1/2-inch wide band ofenamel, heat-stable, cadmium sulphide paint (see figure7-12). The cylinder sizes and colors are listed below

Standard Cylinder - Aluminum or Black

Chrome Plated - International Orange

0.010 Inch Oversize - Green

0.015 Inch Oversize - Gray

0.020 Inch Oversize - Yellow

NOTEChrome-plated cylinders are furtherIdentified as illustrated In thefollowing example 6-44, SAX-3, 20would designate the third cylinderplated by San Antonio Air MaterialArea in June 1944, and the cylinderwas 0.020 inch oversize when plated.

(b) Liquid lock. When an engine is shutdown, the warm residual oil clinging to the power sectionsurfaces flows downward toward lower cylinders. Someof this oil seeps past piston rings, accumulating in thecombustion chamber. When sufficient liquid is present,the true compression ratio will be raised and extremelyhigh pressure will be produced when the piston movesdown on the compression stroke. These pressures candamage the cylinder, piston, or rod. The piston mayactually press the liquid, forming what is known as ahydraulic or liquid lock (see figure 7-13). Observe thefollowing precautions:

CAUTIONDo not rotate propeller in reversedirection of normal engine rotation.This will push the liquid Into intakepipes and return to cylinders on thenext intake stroke.

When propeller is rotating in the normaldirection, the operator must be alert for any signof piston being forced against highcompression, evidenced by a suddenresistance, slowdown, or stoppage which wouldindicate an excess amount of liquid in the lowercylinder

Figure 7-11. Cylinder Assembly

Figure 7-12. Marking of Cylinder

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Liquid locks are partial or complete. Hesitationin propeller rotation usually denotes a partiallock. If propeller stops, it usually denotes acomplete liquid lock. Forcing engine through acomplete liquid lock will cause Immediateengine failure.

Liquid locks are also caused by oil in intakepipes as a result of preservation, fueldischarged into the intake system whilecrankshaft is not rotating, or oil flowing frompush rod housing into rocker box, then seepingthrough intake or exhaust valve guides intointake or exhaust ports.

Due to the mechanical advantage of a longpropeller blade and the fact that two or moremen per blade are used for propeller pullthrough, possibility of bending a rod by manualpull-through is more likely than by starter pullthrough. This is particularly true when a partialliquid lock is present, since the piston with apartial liquid lock will be very near the top of thestroke when force. Is required to rotate thecrankshaft against the liquid lock Liquid lockmay bend the connecting rod slightly, but notenough to move the lower piston ring out of thecylinder skirt, on the downward stroke, in whichcase internal failure may occur within the next50 hours.

If liquid lock is suspected, remove a spark plugfrom cylinder involved and allow liquid to drainout. Turn propeller several revolutions to makecertain all liquid has drained from cylinder andinduction lines, then install clean spark plug.

(c) Valve blowby. Valve blowby isIndicated by a hissing or whistling sound when engine ispulled through by propeller, turned with starter, or whileidling at low speed. Correct valve blowby by firstchecking valve clearance and adjust as necessary. Ifvalve clearance is excessive, proceed using the followingprocedures.

NOTEIf valve is stuck in the valve guide,correct clearance cannot bedetermined.

1 Stake valve by placing a fiber drifton rocker arm and valve stem, and then drift with ahammer.

2 Determine whether blowby hasbeen eliminated by turning engine by hand or turning itthrough with starter.

3 When blowby is still present,perform a compression test.

Figure 7-13. Liquid Lock

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NOTEWhen adjusting clearance andstaking valve do not correct blowbyand raise compression aboveminimum value as specified. In theapplicable maintenance manual,replace cylinder as described inapplicable maintenance manual.

(d) Compression test. A cylindercompression test locates defective cylinders.Replacement of these defective cylinders will prevent anunsatisfactory condition from progressing to the point ofcomplete cylinder failure and eventual engine failure.Cylinders with compression below standard shall bereplaced, thus preventing the use of engines with a largevariation of compression between individual cylinders.

CAUTIONEnsure that Ignition switch is placedin OFF position after engine warmuphas been accomplished. Damagemay otherwise result

1 When engine Is cold, operate it ashort time to ensure that cylinder walls and piston ringsare properly lubricated.

2 Remove one spark plug from eachcylinder and insert compression tester.

3 Either disconnect starter boostercoil or ground all disconnected spark plug lead.

4 Place throttle in FULL openposition, keep fuel tank selector valve closed.

5 Use battery cart or auxiliary powerunit to provide power for energizing engine starter.

6 Using engine starter, crank engineat least four revolutions.

NOTEThe tester contains a restrictiveorifice to eliminate accelerationerrors, and two compressionimpulses are required to obtain anaccurate compression reading.

7 Analyze compression readingobtained.

8 Determine average cylindercompression values by totaling all cylinder compressionsand dividing total obtained by number of cylinders. If anyone cylinder is 20 percent below the average, or If anyone cylinder is below the minimum compression value forthat engine, that cylinder must be replaced.

NOTEA variance of any one cylinder of 20percent below the average of allcylinder compression readings ofengine being checked warrantsadditional investigations. Twoadditional checks should be madeprior to any detailed work to verifyinformation obtained In firstcompression check.

9 The following conditions maypossibly affect engine compression.

Incorrect valve tappet clearances

Worn, scuffed, or damaged pistons

Broken piston nng

Excessive wear of piston rings and cylinderwalls

Burned or warped valves

Carbon particle between face and seat ofvalve

Incorrect valve timing

NOTEWhen a compression test on one ormore cylinders of any row ofcylinders is needed, the compressionof all cylinders on the affected rowwill be tested, compression readingtotaled, and minimum compressionestablished in the same manner aswhen checking compression on allcylinders

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(e) Cylinders with below minimumcompression. Engines having cylinders with belowminimum required compression will be processed usingthe following procedures.

1 Remove rocker box covers oncylinders with low compression.

2 Turn crankshaft until piston is ontop dead center of compression stroke and check intakeand exhaust valves for clearance.

3 When valves are held open due tonegative clearance, adjust valves to proper clearance.

4 Check for excessive leakage pastpiston by squirting engine oil into cylinder, pulling enginethrough compression stroke, and then checkingcompression.

5 Continue cylinder In service ifcompression Is up to required minimum.

(f) Cold cylinder check. The tendencyfor any cylinders to be cold or only slightly warm indicateslack of combustion or incomplete combustion within thecylinder. Perform this check using an approved coldcylinder indicator.

1 Head aircraft into wind to minimizeirregular cooling of Individual cylinders.

2 Open cowl flaps.

NOTEDo not close cowl flaps under anycircumstances, as the resulting heatwill affect the readings obtained andoverheat the ignition leads.

3 Start engine. After engine isrunning, place ignition switch to position where excessiverpm drop is obtained. In cases where an excessive rpmdrop has occurred on both magnetos, or where excessivemanifold pressure is obtained at a given rpm, performcheck twice, once on LEFT and once on RIGHT position.

4 Operate engine at roughest speedbetween 1200 and 1600 rpm or at rpm up to Ignitioncheck speed until a cylinder head temperature reading

of 302 to 338°F (150 to 170°C) is obtained or untiltemperature stabilizes at a lower reading.

NOTE

In cases where engine roughness isencountered at more than onespeed, or there is an indication thata cylinder ceases to operate at idlespeed or higher speeds, it will bedesirable to run engine at each ofthese speeds and perform a coldcylinder check to pick out all deador intermittently operatingcylinders.

In cases where lower output orengine vibration is encountered atspeeds above 1600 rpm, whenoperating with ignition switch onBOTH, engine should be run at thespeed where the difficulty Isencountered until cylinder headtemperature reaches 302 to 338°F(150 to 170°C), or until temperaturehas stabilized at a lower value.

5 Stop engine by moving mixturecontrol to IDLE CUT-OFF position When engine ceasesfiring, turn off both individual and master Ignitionswitches.

6 Measure and record relativetemperatures of each cylinder, starting with any cylinderand proceeding In numerical order around engine, bypressing tip of Indicator pickup rod of cold cylinder testeragainst each cylinder.

NOTEIt is essential that a firm contact bemade at the same relative location oneach cylinder in order to obtaintemperature value This measurementmust be performed in the shortest

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9 Examine magneto ground leads todetermine that RIGHT switch position fires front plugs andLEFT switch position fires rear plugs. Make thisexamination prior to changing spark plugs, makingignition harness test on cylinders which are operating, orare operating intermittently. In addition, examine ignitionleads.

NOTEIn cases where the cylinder iscompletely dead on the BOTHposition, the difficulty may be due toincorrect valve clearances, impeller oilseal leaks, leaking intake pipes, or lackof compression (blowby).

10 Repeat cold cylinder check forother magneto positions on Ignition switch whennecessary. Additional cold cylinder checks will beconducted at different speeds in event any roughness Isstill encountered during ignition system check

NOTECooling of the engine between checksis not necessary as airflow created bypropeller and cooling effect ofincoming fuel-air mixture into cylinderwill be sufficient to cool any cylinderswhich are functioning on one checkand fail to function on the followingcheck.

(g) Chalk test. The chalk test should beused when the cold cylinder tester is not available. Testusing the following procedures.

1 Mark each cylinder with a piece ofwhite marking chalk, A-A-320.

2 Run engine as outlined inparagraph (e) above.

3 Examine each mark after engineshutdown. Cylinders having marks unchanged In colorare dead or operating intermittently. The marks for anormal operating cylinder will change to a pink color.

(h) Cylinder repair. Cylinder repair canbe accomplished by using the following procedures asapplicable

CAUTIONDo not damage adjacent finsInadequate cylinder cooling mayresult.

1 Repair cracked, nicked, or brokencooling fins by profiling damaged area using a file tosmoothly round all edges. Corners shall have at least a1/4-inch radius and removed area nut shall not exceedone percent of the total fin area.

NOTEMagnetic or dye-penetrant inspect finsthat are profiled to outside of dome toensure that crack does not extend intocylinder dome.

2 Repair broken or loose studs intapped hole by using helical inserts.

NOTEWhen more than two adjacent nuts areknown to have been loose duringengine operation, or when more thantwo adjacent studs have failed,cylinder will be replaced and all studson the cylinder mounting padreplaced.

3 Place cover on a surface plate and,using a feeler gauge, measure clearance between surfaceplate and rocker box cover mounting surface. Refer tothe applicable maintenance manual for allowable limits.

NOTEAccomplish procedures 4, 5, and 6when surface does not meet specifiedlimits.

4 Place a small amount of valvegrinding compound, A-A-1203, on a lapping plate.

NOTEIn the event no grinding compound isavailable, a fine abrasive cloth, FederalSpecification P-C-451, may be used.

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5 Position rocker box cover mountingsurface down on lapping plate, and use a figure eightmotion to keep an even pressure on cover.

6 When warpage cannot beeliminated without exceeding allowable limits given in theapplicable maintenance manual, replace rocker boxcover.

7 Replace leaking seals with likeserviceable items.

8 Replace individual piston rings thatare damaged upon installation of a complete cylinder andpiston assembly. Refer to illustrated parts breakdownmanual of applicable engine for correct size and type ring.

9 Replace cracked or broken rockerarms.

10 Replace bent pushrods.

11 Replace bent or cracked pushrodhousing.

(i) Cylinder replacement. Cylinders willbe replaced for the following reasons as described in theapplicable maintenance manual.

Low compression

High oil consumption

Excessive valve guide clearance

Loose intake pipe flanges

Loose or defective spark plug inserts (steel orbrass)

External damage, such as cracks

Spark plug copper runout

NOTEEngines that have spark plug copperrunout on more than 25 percent of thecylinders will be removed fromservice. Carbon deposits must not beconfused with copper runout

g. Valves. The fuel-air mixture enters the cylindersthrough the intake valve ports, and burned gases areexpelled through the exhaust valve ports. The head ofeach valve opens and closes these cylinder ports. Thevalves used In aircraft engines are the conventionalpoppet type. The valves are also typed by their shapeand are called either mushroom or tulip because of theirresemblance to the shape of these plants Figure 7-14shows various shapes and types of these valves.

(1) Description. The valve head has a groundface which forms a seal against the ground valve seat inthe cylinder heads when the valve is closed. The valvestem acts as a pilot for the valve head and rides in thevalve guide installed in the cylinder head for this purpose.The valve stem is surface-hardened to resist wear Theneck is the part that forms the junction between the headand the stem. The tip of the valve is hardened towithstand the hammenng of the valve rocker arm as itopens the valve. A machined groove on the stem nearthe tip receives the split-ring stem keys These stem keysform a locking to hold the valve spring retaining washer inplace

(2) Maintenance. Proper valve operation is ofvital importance to satisfactory operation of the enginefrom the standpoint of stability and cylinder wear. Valveclearances establish valve timing when the engine isoperating, and since cylinders receive fuel-air mixturefrom a common supply, the valve clearances should be

Figure 7-14. Valve Types

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NOTEThe compression stroke may bedetected by a buildup of air pressurewhen thumb is held over open sparkplug hole.

6 Continue rotating crankshaft untilpiston contacts arm of indicator and moves pointer to anymarker on Indicator face.

7 Note mark reached and recordprotractor reading.

8 Move crankshaft slowly in directionof rotation until Indicator pointer shows that piston hasmoved to top of stroke and is going down.

9 Stop turning crankshaft whenpointer moves to exact same position as In step 6.

10 Read and record protractor readingin degrees.

NOTETrue top dead center is halfwaybetween two protractor readings

11 Back up crankshaft and rotate itforward in direction of rotation until protractor pointerindicates top dead center (in degrees).

12 Loosen pointer and set to zerowithout moving crankshaft.

NOTEWhen reinstalling pointer, allow forgear backlash by moving pointeropposite its direction of rotation.

13 Recheck top dead center positionto ensure that a given piston position will result In equalprotractor readings before and after zero mark.

(d) Establishing crankshaft position uponpiston position indicator. The following steps outlineanother method of establishing the crankshaft position.

CAUTIONUse piston position indicator with18mm threads for 18mm spark plugthreads and 14mm threads for 14mmspark plug threads. Damage tothreads may otherwise result.

1 Remove spark plug and installpiston position indicator, as shown in figure 7-16, withcorrect arm and calibrated scale.

2 Rotate crankshaft in direction ofrotation until piston is coming up on compression stroke.

3 Separate body from indicatorassembly and screw housing into spark plug bushing untilit seats firmly. Insert indicator assembly into body, asshown in figure 7-16.

4 Push slide pointer upward in slotuntil it reaches end of slot and is stopped by pivot arm.

5 Pull crankshaft slowly in direction ofrotation until arm moves pointer maximum distance andstarts to move back.

Figure 7-16. Installation of Piston Position Indicators

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6 Set calibrated scale until zero markon scale and scribe on pointer are aligned.

7 Move pointer back to top of slot oruntil it contacts pivot arm.

8 Turn crankshaft in directionopposite normal rotation until pivot arm returns to top ofslot.

9 Recheck zero mark of calibratedscale against reference mark on slide pointer.

10 Move slide pointer to top of slot oruntil it contacts pivot arm.

11 Rotate crankshaft In direction ofrotation. Movement of slide pointer by the pivot arm willIndicate crankshaft position In relation to true top deadcenter on the calibrated scale.

(e) Alternate methods of locating leakyintake exhaust valves. Alternate methods of locatingleaky intake and exhaust valves are listed In the followingparagraphs.

1 Engine run test. Prior to stoppingengine, run it up to 1000 rpm and move mixture control toIDLE CUT-OFF. The engine will turn over six or morerevolutions after combustion ceases. A very slightburning of an exhaust valve will be evidenced by apronounced slush from the affected cylinder This soundoccurs each second revolution of the engine.

2 Wheeze test Perform wheeze testfor locating leaky intake and exhaust valves by pullingpiston to top dead center, locate faulty valve by listeningfor noise in exhaust collector or Intake duct whichindicates air leaking past respective valve.

3 Compressed air test Admitcompressed air into cylinder through spark plug holeRestrain piston at top of dead center Locate leaking valveby listening for noise in exhaust collector and intake duct.

(f) Built-m timing marks. Some engineshave reference timing marks built into the engine, asshown in figure 7-17. Engines without a propellerreduction gear will have the timing mark, a scribe mark ora pin, on the propeller shaft and a correspondingreference mark on the surface of the nose section next tothe shaft. Refer to the applicable maintenance manualfor location of such marks.

NOTEWhen using timing marks to positionthe crankshaft, sight straight acrossthe stationary pointer or mark on thenose section to the other mark. Anyangle incurred in sighting will causeerror when positioning the crankshaft.

h. Accessories. Accessory units such as fuelpumps, vacuum pumps, oil pumps, generators,alternators, magnetos, starters, filters, superchargers, andturbochargers are attached to the engine. Refer to theapplicable maintenance manual for specific maintenanceprocedures

i. Ignition System. The ignition system must delivera high-tension spark to each cylinder of the engine infiring order at a predetermined number of degrees aheadof true top dead center. Voltage output of the systemmust be such that the spark will jump the spark plug gapunder all operating conditions with no tendency forelectrical leaks. Timing and replacement of parts makeup most of the Ignition system maintenance.

(1) Magneto system. The magneto, a special type ofengine-driven ac generator, uses a permanent magneticsource. The magneto develops the high voltage whichforces a spark to jump across the spark

Figure 7-17. Built-In Timing Marks

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plug gap In each cylinder. Magneto operation is timed tothe engine so that a spark occurs only when the piston ison the proper stroke at a specified number of crankshaftdegrees before the top-dead-center piston position.Maintenance of magnetos consists primarily of replacingdefective magnetos or components as explained in thefollowing procedures:

(a) Prior to installation, perform internaltiming check.

1 Check breaker pointadjustments, breaker point dwell on master cam lobe, anddistributor alignment check.

2 Use reference marks on breakercam, distributor rotor, and magneto housing incorporatedon most assemblies to perform internal timing check.

(b) Time high-tension Ignition systemmagneto-to-engine, at a definite crankshaft position asfollows.

1 Position crankshaft to timing orspark advance position using a piston position indicator

2 Align internal timing marks, andslide magneto into place.

3 Shift magneto to retard position,and turn magneto to advance until breaker points begin toopen as indicated by timing light.

4 Install mounting nuts, magnetocover, and leads.

(c) Check timing of high-tension ignitionsystem magneto after a new magneto is Installed or ifincorrect timing is suspected, as follows.

1 Determine correct crankshaftposition and check internal magneto timing marks.

2 Turn crankshaft one-fourth turn inopposite direction of normal rotation.

3 If magneto has an impulsecoupling, rotate crankshaft in normal direction beyondtiming cylinder top-dead-center position; when impulsecoupling clicks, rotate crankshaft in opposite direction toapproximately 5 degrees advance of timing position.

4 Connect timing light and turnignition switches to ON position.

5 Apply even and equal torque toeach of cam retaining screws In direction opposite normalrotation to remove gear train backlash.

6 While holding backlash out, turncrankshaft until points begin to open as indicated bytiming light.

7 If necessary, adjust magneto sothat timing light indicates points are beginning to open atproper firing position.

(d) Install and time low-tension Ignitionsystem magneto-to-engine, at a definite crankshaftposition, using the following procedures.

1 Depress magneto timing plungerand turn magneto shaft until plunger engages fully Innotch of magneto shaft.

2 Position magneto In place whileholding plunger.

3 If magneto does not line up withcenterline of engine, remove magneto, release plunger,and turn magneto drive shaft 90 degrees. Repeat untilmagneto lines up properly.

4 Hold plunger depressed and turnmagneto counterclockwise on its flange as far asnecessary to remove gear backlash.

5 Install magneto bolts securely inplace.

(e) Check timing of low-tension ignitionsystem magneto after a new magneto is installed orincorrect timing is suspected.

1 Determine correct crankshaftposition.

2 Rotate engine one-fourth turn inopposite direction of normal rotation and slide pointer ofpiston position Indicator to top of scale.

3 Turn engine in direction of rotationuntil slide pointer is starting to move down.

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4 Depress and hold timing plunger onmagneto, while continuing rotation of engine, until timingplunger is fully engaged.

5 See that timing indicator showscorrect degree of advanced timing.

(2) Ignition harness. The ignitionharness, as shown in figure 7-18, contains an insulatedwire for each cylinder that the magneto serves In theengine. One end of each wire Is connected to thedistributor block and the other end is connected to theproper spark plug. The Ignition harness serves a dualpurpose. It supports the wires and protects them fromdamage by engine heat, vibration, or weather. It alsoserves as a conductor for stray magnetic fields thatsurround the wires as they momentarily carry high-voltagecurrent. By conducting these magnetic lines of force tothe ground, the ignition harness cuts down electricalinterference with the aircraft radio and other electricallysensitive equipment. When the radio and other electricalequipment are protected in this manner, the ignitionharness wiring is said to be a shield. Without thisshielding, radio communication would become virtuallyimpossible. The ignition harness check consists of avisual and an electrical check using the followingprocedures.

(a) Examine all accessible parts ofdistributors, harnesses, and leads for chafing, broken

TM 1-1500-204-23-1

two leads (in distributor block). When disconnectingground of other lead does not stop leakage, check forleaks between Individual leads and shielding.

NOTERotate crankshaft to a position thatwill eliminate distributor fingerleakage.

9 When a recheck indicates thatdistributor block may be at fault, scrub thoroughly withacetone, Federal Specification O-A-51, dry thoroughly,and apply a thin coat of wax Mix 1 part wax to 5 partstrichloroethylene, Federal Specification O-T-634,maintained at a temperature of 130 to 140°(54 to 60°C).

10 Repeat steps 1 through 9 above.

(d) The low-tension system operates atrelatively low voltages (150 to 400 volts) and is notseriously affected by moisture. Check system as follows.

1 Check all accessible parts ofharness and leads for chafing, broken conduit, corrosion,or misaligned pins in electrical connectors at intervalsspecified in inspection requirements manual.

CAUTIONDo not attempt to repair harnesswithout the proper special tools.Damage to harness may otherwiseresult.

2 Tighten all loose connectors andtape over frayed sections of nylon covered harness

3 Test all low tension wiring anddistributor blocks, connection plates, etc, for continuity.Test Insulation resistance with a tester capable ofdelivering 1000 volts dc (maximum) at 1 milliampere, oran ohmmeter (20,000 ohms per volt). The insulationresistance should exceed 1 megohm, unless otherwisespecified

(3) Spark plugs. The function of the spark plugin an ignition system is to conduct a short impulse of highvoltage current through the wall of the combustion

chamber. Inside the combustion chamber it provides anair gap across which this Impulse can produce an electricspark to ignite the fuel-air charge. For spark plug service,maintenance Instructions, and list of approved sparkplugs, refer to TM 55-2925-200-25.

(4) Ignition switches. All units in an aircraftignition system are controlled by an Ignition switch in thecockpit. The type of switch used varies with the numberof engines on the aircraft and the type of magnetos used.All switches, however, turn the system off and on In muchthe same manner. The Ignition switch is different in atleast one respect from all other types of switches In thatwhen the Ignition switch Is In the OFF position, a circuit iscompleted through the switch to ground In other electricalswitches, the OFF position normally breaks or opens thecircuit. The following procedures are for Ignition switchesgeneral maintenance.

(a) Replace defective switches andbroken ground wires.

(b) Tighten all loose switch and cableterminal attaching nuts.

(c) For specific details on any ignitionswitch, refer to applicable maintenance manual.

(5) Booster system. Starting aids such as aninduction vibrator or booster coil must be used to provideenough voltage to the spark plug. The induction vibrator(or starting vibrator), as shown in figure 7-19, consistsessentially of an electrically operated vibrator, acondenser, and a relay These units are mounted on abase plate and enclosed In a metal case. The boostercoil assembly as shown in figure 7-20, consists of twocoils wound on a soft Iron core, a set of contact points,and a condenser. General maintenance of the boostersystem is described in the following procedures.

(a) Repair Induction vibrators Inaccordance with the applicable maintenance manual andtable 7-1.

(b) Replace defective booster coils andall broken or frayed wiring Tighten all loose connections.

(c) Replace magneto if impulse couplingis defective.

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(d) Test ignition booster system forproper operation as follows:

1 Remove front spark plug from mostaccessible cylinder.

2 Turn crankshaft until piston isobserved to be in top position on compression stroke.

3 Reconnect spark plug and groundplug shell to engine.

4 Place carburetor in IDLE CUT-OFFposition.

5 Place main fuel valve in CLOSEDposition.

Figure 7-19. Induction Vibrator

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Figure 7-20. Booster Coil

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Table 7-1. Repairing Induction Vibrators

Trouble Probable cause Remedy

Unit fails to function Not grounded Ensure mounting boltscontact grounding plate.

Loose or disconnected Ensure terminal clip is securedpositive cable to positive cable and positive

terminal post.

Loose or disconnected Ensure both cables are securedMAG or IGN. SW TERMINALS to terminal nuts with springs.

Tighten nuts until a firm contactis made with the terminal.

Dirt between points Draw paper, Federal SpecificationUU-P-268, dipped in trichloro-ethylene O-T-634, across pointsand air dry.

6 Turn fuel booster pump to OFF position.

7 Turn ignition switch to BOTH position.

8 Place master Ignition switch in ONposition.

9 Engage starter, observing all groundsafety rules.

10 Note continual flow of high voltage acrossspark plug points.

7-5. Engine Removal Criteria. The life of an aircraftengine between overhauls is dependent upon manyfactors, such as quality of original manufacture or lastoverhaul, the type of operation being accomplished, andthe efficiency of preventive maintenance. It is possibleto establish a maximum expected life of an enginebased on service records and engineering data. Atoverhaul depots, it has been found that many enginesare changed needlessly. A complete investigation ofthe engine should be made before removal, except in

cases of complete internal failure or expiration ofoperating time limits (Refer to AR 750-23).

a. Expiration of Operating Time Limit. Engineremoval and replacement shall be accomplished inaccordance with TM 55-1500-328-25 when normalMaximum Allowable Operating Times (MAOT) areaccumulated In accordance with the applicable aircraft -20 maintenance manual (Chapter 3, Section IV).

b. Sudden Engine Stoppage. Sudden stoppage isdefined as the complete stalling of the engine due to apropeller or rotor accident or gear box failure. Suchengines shall be replaced.

NOTEReplace engine when engine isstalled by propeller or rotor strikingan immovable object, such as a rampor building or when engine isoperating at any rpm and is stalledsuddenly due to some Internal causesuch as gear box or crankshaftfailure.

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c. Sudden Reduction in Engine RPM. When thepropeller or rotor strikes a small object which results in asudden reduction In engine rpm, the engine shall bethoroughly checked using the following procedures:

(1) Make a thorough external examination ofengine crankcase and nose section to determinewhether any parts have been damaged. When damageis found which cannot be corrected by line maintenance,remove engine.

(2) Remove magnetic sump plugs, If present,and engine oil screens or filters. Examine for presenceof metal particles.

(3) Remove engine sump plugs, drain oil intoa clean container, strain through a clean cloth, andexamine cloth and strained oil for metal particles.

NOTE

• Metal particles found In the sumps orIn oil screens or filters will not beconsidered the results of an Internalfailure caused by sudden stoppage,since the screens or filters arelocated at the oil inlet to the engine.Sudden stoppage, therefore, will notpermit circulation of the oil to theextent that metal particles would bedeposited on the screens or filters.

• When heavy metal particles arefound In the oil, It indicates a definiteengine failure, and engine must beremoved. However, when metalparticles present are similar to finefilings, continue examination ofengine to determine its serviceability.

(4) Remove propeller and examinecrankshaft, or propeller drive shaft on reduction-gearengines, for misalignment.

(5) Clamp a test indicator to nose section ofengine and remove front or outside spark plugs from allcylinders on radial engines and top spark plugs on allopposed engines.

(6) Turn crankshaft and observe if crankshaftor propeller shaft runs out at either front or rear propellercone seat location, as shown In figure 7-21.

NOTE

• When there is runout of more than0.015 inch full indicator reading ofcrankshaft or propeller drive shaft atfront cone seat location, removeengine. Even though runout ofcrankshaft or propeller drive shaft atfront cone seat is less than 0 015inch full indicator reading, examinerear cone seat location.

• When any runout is found at rearcone seat location, which Is not Insame plane as runout at front coneseat location, remove engine.

• When crankshaft or propeller driveshaft runout does not exceed theselimits, install serviceable propellerand make an additional check bytracking propeller at tip in sameplane perpendicular to axis ofrotation to assure that blade tracktolerance Is within limits.

(7) Start engine and examine for smoothoperation and adequate power output. When engineoperates properly during this ground check, shut engineoff and again examine oil system for metal particles.

Figure 7-21. Checking Propeller Shaft Runout

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(8) When there are no heavy metal particles inengine, give engine a two hour flight test.

NOTEWhen engine operated properlyduring flight test, examine oil systemfor metal particles. If no metal isfound, continue engine in service,but examine oil screens for presenceof metal after 10 hours of operation.If no indication of internal failure isfound after 20 hours of operations,engine requires no further specialexamination.

d. Metal Particles in Oil. Generally, metal particleson engine oil screens or on magnetic sump plugsindicate partial internal failure of the engine. However,due to the construction of aircraft oil systems, it ispossible that metal particles may have collected insludge in the oil system at the time of previous enginefailure, consequently, this must be taken into accountwhen metal particles are found in engine oil screens oron magnetic sump plugs. Frequently, carbon breaksloose from the interior of the engine in large pieceswhich have the outward appearance of metal.However, carbon can be distinguished from metal byplacing the foreign material on a flat metal object andhitting with a hammer. If material is carbon, it willdisintegrate when struck with a hammer, whereas metalwill either remain intact or change shape, dependingupon its malleability.

CAUTIONAn oil soaked rag can very easilycause spontaneous combustionunless placed in a tightly closedcontainer, such as a quart or pint canwith a press-fit lid.

NOTEBefore removing an engine forsuspected internal failure, asIndicated by foreign matter on the oilscreens or oil sump plugs, collect allobtainable metal particles foranalysis and samples. To save finemetal particles, it may be necessaryto strain the oil through a cloth. Thecloth and metal particles can beplaced in a clean metal container andsent with engine for overhaul.

e. Identification of Metal Particles. Metal particlesfound in an engine may be of five kinds steel, tin,aluminum, silver, and copper (or bronze). A visualinspection as to color and hardness will occasionally besufficient to determine the kind of metal present. Whenvisual inspection does not positively identify the metal,the kind of metal present may be determined by a fewsimple tests performed with a permanent magnet,electric soldering iron, or approximately 2 ounces ofhydrochloric acid and nitric acid as explained in thefollowing paragraphs.

WARNINGExercise care in handling acid injuryor death to personnel may otherwiseresult.

NOTEThe information in this paragraph isnot intended to be a substitute for,nor release from the requirement forcompliance with the Army OilAnalysis Program (AOAP) programdirected in accordance with TB 55-6650-300-15.

(1) Steel particle identification. Steelparticles can be Isolated by means of a permanentmagnet.

(2) Tin particle Identification. Tin particlescan be identified by their low melting point. A solderingiron should be cleaned, heated to approximately 260°C(500°F), and thinned with 50-50 solder (50 percent leadto 50 percent tin) Wipe off excess solder. A tin particledropped on heated Iron will melt and fuse with thesolder. Take care to avoid excessive overheating ofiron during this test.

(3) Aluminum particle identification.Aluminum particles may be identified by their respectivereaction with hydrochloric acid. When a particle ofaluminum is dropped into hydrochloric acid it will fizzwith a rapid emission of bubbles. The particle willgradually disintegrate and form a black residue(aluminum chloride).

(4) Silver and copper particle identification.Silver and copper (or bronze) may be identified by theirrespective reactions in nitric acid. When a silverparticle is dropped into nitric acid, it will react ratherslowly, producing a whitish fog in the acid. When aparticle of copper (or bronze) is dropped into nitric acid itwill react rapidly, producing a bright green cloud in theacid. There is no need in this instance to separatecopper from bronze.

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f. Significance of Metal Particles. Generally, whenmetal particles are found and kind of metal present isdetermined, serviceability of engine will depend uponquantity and form of metal. Granular metal particles, inany amount greater than a trace, require a very carefulinspection of engine, as presence of these particles isusually an indication of an impending failure. Each kindof metal, however, must be judged individually.Paragraphs (1) through (5) are intended as a guide injudging serviceability of engine after kind of metal hasbeen determined.

(1) Steel particles. When steel particles arefound in splinter or In granular form, the engine must beremoved Thin steel flakes, when found In quantities notgreater than 20 flakes, may not require engine removal.A small quantity of steel flakes will not cause enginebearing failure. When thin steel flakes accompanied byaluminum flakes are found, these flakes are probablythe result of a warped piston ring land or hole burned ina piston. Replacement of a defective piston andcylinder assembly will correct the difficulty. Whennot accompanied by aluminum flakes, it Is possible thatsteel flakes are from foreign matter introduced intoengine through oil tank.

(a) Test engine in accordance with theapplicable maintenance manual If more than fiveadditional flakes are found on oil screen and sumpinspection after runup, remove engine. If five or lessflakes found, the engine may be released for service inaccordance with the applicable maintenance manual.

(b) When not more than 20 thin steelflakes are found and they are accompanied by thinaluminum flakes, proceed as follows

1 Carefully inspect cylinders byvisual examination of cylinder bore and by compressioncheck In an effort to locate faulty piston. A bright streakalong cylinder barrel or any evidence of scuffing wouldbe an indication of a warped piston ring land. Warpedlands are predominant In winter operations and occurmost frequently on lower cylinders.

2 When not more than two faultycylinders are found, replace faulty piston and cylinderassemblies before continuing with procedure. Whenmore than two faulty cylinders are found by inspection,remove engine.

3 After faulty cylinders have beenchanged or when no faulty cylinders are found, testengine In accordance with the applicable maintenancemanual.

4 If more than 2 additional steelflakes or 15 aluminum flakes are found during screenand sump inspection after engine runup, remove engine.If less than these quantities are found, engine may bereleased for service in accordance with the applicablemaintenance manual.

NOTERing fuzz may be on oil sump plug ofany normal engine. These very finehairlike particles are the result ofnormal seating of piston rings andcylinders and are not cause for anyconcern regarding serviceability ofengine.

(2) Tin particles. Tin in any quantity may bedisregarded. Since tin is used only in plating engineparts and in thickness not greater than 0.0005 inch,granular tin will not be found.

(3) Aluminum particles. When aluminumparticles are found, perform the following procedures:

(a) When granular aluminum particlesare found, proceed as follows:

NOTEThe presence of aluminum particlesin granular form may be anindication of piston failure

1 Inspect cylinders by visualexamination of cylinder bores and a compression checkin an effort to locate a faulty piston.

2 When not more than two faultypistons are found, faulty pistons and cylinder assemblieswill be changed before continuing with procedure.When more than two faulty pistons are found byinspection, remove engine. After faulty pistons andcylinder assemblies have been changed, or when nofaulty pistons are found, continue with procedure.

3 Drain oil system, flush oil tank,and clean oil screens.

4 Test engine in accordance withthe applicable maintenance manual.

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5 If not more than two additionalgranular particles are found during screen and sumpinspection after runup, engine may be released forservice in accordance with the applicable maintenancemanual.

(b) When aluminum flakes are found,proceed as follows:

NOTEAluminum flakes may not necessarilyrequire engine removal In winteroperations, when warped piston ringlands are frequent, considerablequantities of aluminum from pistonsmay be discharged Into engine oilsystem. It will be necessary toexercise judgment before continuingwith the following procedure, forInstance, if oil sump or screen isfound choked with a mass ofaluminum flakes or particles,regardless of size, it will probably benecessary to remove engine eventhough faulty piston can be located.

1 Make a careful Inspection ofcylinders by examination of cylinder bores and acompression check In an effort to locate faulty piston.

2 When not more than two faultypistons are found, change faulty piston and cylinderassemblies before continuing with procedure. Whenmore than two faulty pistons are found, remove engineIf two or less faulty pistons are found, continue withprocedure.

3 Drain oil system, flush oil tank,and clean oil screen.

4 Test engine In accordance withthe applicable maintenance manual.

5 If more than five additionalaluminum flakes are found during screen and sumpinspection after runup, remove engine. If less than thisquantity is found, engine may be released for service inaccordance with the applicable maintenance manual.

(4) Silver particles. Silver particles in granularform indicate a master rod bearing failure in advancedstages. When these particles are found in any quantity,remove engine. Silver is used in plating numerousother parts, and silver flakes, not exceeding 10 innumber, do not necessarily indicate a part failure. Since

silver is quite soft, some small flakes will occasionallybe released by normal working of these parts. A verysmall quantity of silver from master rod bearings willmake a large number of tiny flakes as it passes throughroller bearings or gears within engine. Large quantitiesof silver flakes indicate an excessive loss of bearing orplating surface and engine must be removed as aprecautionary measure.

(5) Copper or bronze particles. Copper orbronze particles, in granular form and in quantitiesgreater than a few particles, indicate disintegration of abushing or valve guide and engine must be removed.Copper or bronze flakes, in quantities not exceeding 10flakes, do not necessarily indicate part failure. Bronzeflakes may be formed in small quantities through normalseating of bushings or valve guides. Larger quantitiesof copper or bronze flakes, however, may Indicateexcessive loss of bushing metal and engine must beremoved as a precautionary measure.

g. Additional Metal Particles Test. This test ismade to subject engine to sufficient operations to causeany additional metal in oil system to collect on oil screenand in main sump and also to reveal any Incipienttrouble. This additional metal will determine whetherengine needs to be removed or allowed to continue Inservice Test using the following procedures.

(1) Drain and flush external oil system

(2) Run engine to bring it to operatingtemperatures and make a minimum of three powerchecks (Allow engine to cool between checks). Takecare not to exceed allowable limits for ground operation.

(3) Again remove oil screens and examinefor metal accumulation. Examine main sump plug andscreen for metal accumulation. If engine is released forservice, it must be watched closely for next 25 hours forany indications of malfunctions or internal failure.

h. Excessive Spark Plug Copper or Silver Runout.If copper runout is noted, replace cylinder from whichspark plug was removed as this Indicates the cylindertemperature has exceeded 1981°F (1083°C). Silverrunout may be caused on a fine wire electrode-typespark plug if plug is subjected to pre-ignition and/ordetonation. Excessive temperature may cause thesilver spindle of the center electrode to flow toward thefiring end of the electrode. Copper or silver runoutindicates affected cylinders should be replaced.Engines having runout on more than 25 percent of thecylinders should be removed.

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i. Low Cylinder Compression. Prior to removingcylinders for low compression, check and adjust valveclearance. Check cylinder compression. Replacecylinder when compression is less than establishedlimits.

j. Parts Failure. When some portion of a steelpart, such as a piston ring, valve, valve spring, washer,rocker arm, or rocker arm bearing cannot be located andremoved, the engine will be replaced, so other partswithin the engine will not be damaged.

k. Basic Mechanical Failure. Remove enginewhen any internal component such as impeller, boss,casting, propeller shaft, or studs, become cracked,nicked, broken, or damaged to the extent that safeoperation cannot be continued. Failures of this type arelimited to Internal components of the engine such asimpeller, Impeller clutch, crankshaft, superchargerhousing, and reduction gear housing, since externalfailures, such as cylinders or engine accessories, can becorrected by replacing the unserviceable assembly.

I. Engine Overspeed. When engine speedsexceed limits specified in the applicable maintenancemanual, the removal or inspection of the engine will bedependent upon the amount of overspeed reported.When engine speeds exceed limits, accomplish thefollowing procedures

(1) When overspeed is above maximum rpm,replace engine.

(2) When overspeed is below maximum rpm,accomplish the following:

(a) Examine engine for cracked, open,or broken cylinder heads and barrels, and bent push rodhousing.

NOTEIn the event a cylinder head iscracked or broken and no particles ofpistons rings have entered crankcaseof engine (determined by Inspectionof magnetic sump plug or oil screenfor metal), remove damaged cylinderand piston and examine articulatingand master rods for misalignment. Ifrods are satisfactory, replacecylinder and piston assembly with aserviceable unit and continue enginein service as specified below.

(b) Examine oil system. When examination ofoil screens or filters discloses an abnormal amount ofmetal particles, remove engine. When no metalparticles are found, operate engine as specified.

(c) When examination of enginediscloses no visible damage as a result of overspeeding,restrict aircraft to local flights for a period of 10 hours.

m. Excessive Manifold Pressure. Enginesincorporating turbosuperchargers or auxiliary stagesuperchargers are subject to excessive manifoldpressure when automatic controls malfunction or fall. Amanifold pressure overboost control is usually employedto reduce the possibility of overboost occurring.However, when overboost occurs, combustiontemperatures rise, and detonation or pre-ignition mayresult and cause serious structural damage to theengine. When manifold pressure exceeds valuespecified in the flight manual, it Is considered anoverboost condition and the engine will be removed.

n. Excessive Maintenance. If an aircraft enginerequires consistent excessive maintenance or is adefinite hazard to flight, it should be replaced, providedcomplete engine conditioning will not correct thedifficulty. Excessive and consistent oil fouling of sparkplugs could cause excessive maintenance. However, iffouling is limited to certain cylinders, the difficulty maybe eliminated by replacing defective cylinders, ignitionleads, distributor block, or opening-clogged rocker boxdrains.

o. Excessive Oil Consumption. Oil is consumed inthe engine by being burned in the combustion chamber,lost in the form of mist or vapor from the breather, orleakage where propeller shafts and other shafts protrudefrom the crankcase. Consumption varies with enginepower setting, however, one or more cylinders foulingdue to excessive oil consumption may call for cylinderrather than engine change.

(1) Oil consumption. Some of the factorswhich affect oil consumption are engine speed,temperature, wear condition, and lubricantcharacteristics such as viscosity-temperature coefficient,volatility, and flash point. Each is explained in thefollowing paragraphs

(a) Engine speed. The most importantfactor affecting oil consumption normally is enginespeed. oil pressure Increases with engine speed until the, operating range pressure of the engine is reached,then a pressure relief valve maintains a constantpressure. Usually, maximum pressure is reached atrelatively low speeds. The effect of engine speed on oilpressure

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between pump and main bearing is negligible.However, centrifugal force increases oil pressure atcrankpins which increases flow through the bearings andsprays more oil on cylinder walls. The rings do notfollow the cylinder as closely at higher speeds, and agreater amount of oil Is passed to the combustionchamber instead of being scraped back to thecrankcase.

(b) Engine temperature. High enginetemperature and low oil viscosity tend to increase lossesof oil from crankcase seals and breathers. Oil lossincreases due to increased blowby, or gas flow, pastpiston rings at higher engine speeds. Blowby raisescrankcase pressure and forces oil or oil vapor out of thecrankcase.

(c) Engine wear. Engine wear in theform of worn bearings increases clearance and allowsincreased oil loss. Worn pistons and cylinders providespace for thicker oil films and increase loss due tofailure of rings to seal.

(d) Lubricant characteristics. Anincrease in oil viscosity decreases oil consumption onlyup to the point at which the slower draining of the moreviscous oil from the cylinder wall, and tendency of therings to ride over the oil film causes more oil to pass thepiston and flow into the combustion chamber

(2) Aircraft range as related to oilconsumption. Remove an engine if oil consumption ishigh enough to limit range of aircraft. Variations In oilsystem capacity of different aircraft causes maximum oilconsumption to vary according to type aircraft and typeof mission being performed (see figure 7-22).

7-6. Engine Conditioning. Engine conditioningprovides a standard method for detecting enginemalfunctioning prior to development of serious troubleand establishes a systematic routine for keeping theengine in condition to provide maximum trouble-freeperformance. The types of engine conditioning arecomplete engine conditioning and minor engineconditioning.

Figure 7-22. Oil Consumption Chart

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a. Complete Engine Conditioning. Completeengine conditioning is a complete investigation of thecondition of an engine and correction of any difficultydetected. Complete engine conditioning will be givenengines being overhauled with the exception of idlemixture and speed, fuel, oil, and water pressureadjustments, and final check and adjustment of theengine after the engine is installed on the aircraft.Perform this conditioning using the Instructionscontained In table 7-2.

b. Minor Engine Conditioning. Minor engineconditioning is the investigation and correction of anymalfunction revealed during flight or through the cockpitchecks (daily, intermediate, and complete cockpitchecks). Perform the following procedures for minorengine conditioning:

(1) Perform a complete cockpit check (steps6 through 14, table 7-2) when a new engine Is Installed,when an aircraft is removed from storage, at each majorand minor Inspection, and when minor conditioning failsto correct a malfunction. The engine cockpit check willbe handled in the following manner:

(a) Record all readings on cockpitcheck sheet as shown in figure 7-23.

(b) File form In aircraft flight log folderfor future reference by both maintenance and flightpersonnel.

NOTEThe daily check will be carried out bythe air crew and will only berecorded in the flight log whenperformance is unsatisfactory. Theserviceability of the engine isestablished by the air crew bycomparing its readings against thoserecorded on the complete cockpitcheck made by the maintenancecrew.

(2) Perform steps 6 through 13, 15, and 17,table 7-2.

(3) Perform intermediate check after lastflight of day. The check may be made any time afterthe last flight of the day and before the next flight byeither the air crew or maintenance personnel. Anydifficulties encountered during flight are corrected at thistime. The intermediate check is outlined in steps 12

through 15 and 17, table 7-2. The readings obtained arerecorded in the flight log only when engine performanceis unsatisfactory.

7-7. Air Induction System. The air Induction systemsupplies air to the carburetor or master control. It formsa long curved channel which conducts air and fuel-airmixture to the supercharger section. The channelconsists of an air scoop, temperature controlling device,and a thermometer General maintenance proceduresare explained in the following paragraphs.

a. Inspection. Maintenance. Cleaning. andReplacement. Perform the following procedures forgeneral inspection, maintenance, cleaning, andreplacement of air induction system components:

(1) Check induction system for foreign matterand articles to prevent such Items from damagingimpeller or clogging air passages.

(2) Install flexible channel, joining certaintypes of Induction systems together, In such a mannerto prevent flexible channel from being sucked down andrestricting air flow.

(3) Correct leaks In Induction systems soonas possible after detection, as fuel-air mixture will beadversely affected.

(4) Clean air filters at intervals specified inapplicable maintenance manual using the followingprocedures:

WARNINGDry-cleaning solvent is flammableand solvent vapors are toxic. Use P-D-680, Type II Solvent in a well-ventilated area. Keep away fromopen flames. Avoid prolongedsolvent contact with skin.

(a) Immerse filter in dry-cleaningsolvent, Federal Specification P-D-680, and agitate toremove all imbedded dirt particles.

(b) Drain by placing on a 25-degreeangle draining rack and allowing to dry thoroughly.

(c) When completely dry, immerse filterIn a mixture of 1 part corrosion-preventive compound,MIL-C-5545, and three parts lubricating oil, MIL-L-6082,Grade 1120, at a temperature of 70°F (21°C) for 2 to 5minutes.

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Table 7-2. Engine Conditioning Table

Completeconditioning When Personnel

steps Procedure performed responsible

Step 1. Ignition System Time all phases of ignition. This in- Complete MaintenanceTiming. cludes breaker point-to-magneto Conditioning

timing, magneto-to-engine timing,and, distributor finger-to-enginetiming.

Step 2 Compression Test cylinder compression. Complete MaintenanceTest Conditioning

Step 3. Valve Adjust- Check valves and adjust clearances Complete Maintenancement if necessary. Visually inspect valve Conditioning

mechanism.

Step 4. Ignition Harness Check Ignition harness for high Complete MaintenanceCheck voltage leakage. Conditioning

Step 5. Spark Plug Install new or reconditioned set of Complete MaintenanceInstallation spark plugs. Conditioning

Step 6. Check for Pull propeller through to deter- Complete MaintenanceHydraulic Lock mine whether combustion cham- Conditioning

bers are clear.

Cockpit Check Air Crew

Daily Check Air Crew

Step 7. Blowby Check While performing step 6, listen for Complete Maintenancean extended hissing sound from Conditioningexhaust stack or stacks.



Step 8. Engine Start Start engine. Complete MaintenanceConditioning



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Table 7-2. Engine Conditioning - CONT



Step 9. Engine Warmup Warm up engine at smoothest Complete Maintenancespecified rpm, oil pressure per- Conditioningmitting. Continue warmup untilnormal operating temperatures Cockpit Check Air Creware obtained as Indicated bygreen arc on gauges. Daily Check Air Crew

Step 10. Power Check Set engine at specified rpm Complete Maintenancesetting. Allow engine and instru- Conditioningments to stabilize.

Manifold pressure readings for Cockpit Check Air Crewdifferent engines of the same typeand model installed on the same type Daily Check Air Crewaircraft should not vary over 1 inchHg at a given rpm when checks areperformed at the same geographicallocation.

A higher than normal manifold pressureindicates engine is not operatingproperly.

In case of high manifold pressure, takemanifold pressure readings at severallower rpm settings to establish rpmmanifold pressure pattern for engine. Seeperformance chart for rpm-manifold pres-sure relationships for current aircraft.

Step 11. Ignition System After completing step 10, perform Complete MaintenanceCheck step 17. Conditioning



Step 12. Cruising Mixture Set engine speed at rpm specified Complete MaintenanceCheck In performance chart with mixture Conditioning

control in AUTO-RICH position. Afterengine and instruments have stabilized, Cockpit Check Air Crewmove mixture control to AUTO-LEANand observe rpm change. Return mix- Daily Check Air Crewture control to AUTO-RICH position.A change of rpm, other than that allowedin performance chart, indicates an exces-sive

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Figure 7-2. Engine Conditioning - CONT



Step 12. Cruising Mixture Check valve for nozzle not holding,Check - continued pumps not synchronized, vapor vents

stuck, low cylinder head temperature,or improper spark plug gap. Oncarburetor engine, idle adjustmentwill cause rich or lean mixture.

Step 13. Idle Speed Close throttle completely. Engine Complete MaintenanceCheck should idle at specified rpm and Conditioning

cylinder head temperature of 150to 170°C (302 to 338°F) if equip- Cockpit Check Air Crewped with individual exhaust stacksor at lower specified rpm if equip- Daily Check Air Crewped with an exhaust collector ring.

Intermediate Air Crew orMaintenance

Step 14. Idle Mixture Check Idle mixture and adjust mix- Complete MaintenanceCheck ture and speed. Conditioning



Step 15. Acceleration Perform acceleration and decelera- Complete Maintenanceand Deceleration Check tion checks. If turbosupercharger Conditioning

is installed, check with turbosuper-charger off. Cockpit Check Air Crew



Step 16. Engine Backfire Because of the nature of this test, Complete MaintenanceTest It should be conducted only after Conditioning

prescribed Inspection periods orwhen trouble is encountered. Con-duct test with cylinder head temp-eratures not less than 180°C(356°F) and not more than max-imum allowable for engine involved.

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Table 7-2. Engine Conditioning - CONT



Step 16. Engine Backfire Place turbosupercharger in OFFTest - continued position. Carburetor air filters

should be by passed.

Set engine at specified rpm setting.Move carburetor mixture control toAUTO-LEAN. Move ignition switchfrom BOTH to RIGHT and then toLEFT for a sufficient length of timein each position to permit engineoperation to stabilize. When movingignition switch from BOTH TO RIGHTor LEFT, a high rmp drop will nor-mally occur.

If the engine does not backfire fromeither switch position, it is consideredsatisfactory in this test. If it backfires,one or more phases of engineoperation are not correct.

Step 17. Ignition Set engine speed at specified rpm Complete MaintenanceSwitch Check Momentarily move Ignition switch Conditioning

to OFF and determine that enginecompletely ceases firing. Return Daily Check Air Crewswitch to BOTH as rapidly as possibleto eliminate possibility of backfiring. Intermediate Air Crew orCheck master switch same way. Maintenance

Step 18. Spark Plug Make cold cylinder check. Replace Complete MaintenanceCheck only defective plugs and repeat Conditioning

steps 6 through 16.

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Figure 7-23. Engine Conditioning Cockpit Check Sheet

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(d) Place filter on a 25-degree angledraining rack in a room where temperature is 70°F(21°C) and allow to drain for 2 to 4 hours. Drainaccordion-pleated filters for 8 hours.

(e) When necessary, use forceddraining after gravity draining has been accomplishedby using a 1/16-inch orifice and 100 psi air temperature.

(5) Adjust carburetor air doors so theyoperate freely through full range of travel or to positionselected as specified in applicable maintenance manual.

(6) Replace damaged intake pipes. Detectleaks in Intake pipes by presence of fuel stains atcylinder Impeller end When leakage is found after 25hours of operation (since new), loosen intake pipepacking nuts. Replace any defective packing andretighten nuts.

NOTEDo not tighten packing nuts withoutloosening and examining thepacking first.

b. Turbocharger and Supercharger Maintenance.Visual inspection of all visible parts should beaccomplished daily to observe oil leaks, exhaust leaks,cracks in the metal of hot sections, loose or insecureunits, and other unacceptable conditions. Refer to theapplicable maintenance manual for specificmaintenance procedures. Ensure the following Itemsare checked.

• Mounting of all units

• Oil leaks or dripping from any unit

• Security of oil lines

• Security and condition of electric wiring

• Cracks in ducting and other metal parts including the turbine and housing

• Warping of metal ducts

• Operation of the complete system todetermine performance to discoverundesirable sounds, and to note evidence ofvibration; unusual sounds and appreciablevibration require removal and replacement ofthe turbocharger to correct the faulty condition

NOTEExhaust ducts, waste gates, nozzleboxes, and turbines are subjected toextremely high temperatures. Forthis reason, cracks develop becauseof the continued expansion andcontraction of the metal astemperature changes occur.

7-8. Exhaust System. The exhaust system conductsexhaust gases from the engine to the atmosphere withminimum exhaust back pressure. Short exhaust stacksare incorporated on some engines, while others join acollector ring which expels exhaust gases through a tailpipe. Perform the following general maintenanceprocedures on exhaust systems:

a. Check ball joints for excessive or insufficientclearances, and retighten or replace ball joints asnecessary to obtain free movement.

b. Replace all parts that have hot spots or damagebeyond repair.

c. To prevent exhaust port studs from seizing, andto retard corrosion, apply a special lubricant as follows:

(1) When engine or cylinder is removed orinstalled, apply light coating of 10 percent molybdenumdisulphide lubricant, MIL-M-7866, and 90 percentgrease, MIL-G-3545, to threads of cylinder exhaust portstuds.

(2) To retard corrosion of nuts, apply thismixture to exterior of exhaust port stud nuts.

d. Tighten all nuts, bolts, and clamps in exhaustsystem in accordance with maintenance manual forengine involved.

7-9. Carburetion and Fuel Injection. Fuel is meteredto the engine at a predetermined ratio to airflow by thefuel metering system. Fuel metering systems differ indesign, but their function is the same, regardless of typeor engine model. Improper maintenance of the fuelmetering system will result in rough engineperformance, detonation, spark plug fouling, low poweroutput, poor acceleration, and engine or part failure.

a. Inspection. Inspect carburetors for mounting

TM 1-1500-204-23-1

b. Depreservation. Carburetors are depreserved tomake them operational after they have been preservedfor extended storage. Observe the followingprecautions.

• Depreserve float-type carburetors which donot employ diaphragms by flushing floatchamber with the type of fuel used to operateapplicable engine, then drain oil and fuelmixture from float chamber. Flush until alltrace of preservative oil is removed.

• Depreserve diaphragm-type carburetors bydraining oil from fuel chambers and passagesand flushing with fuel. Fill carburetor withtype of fuel to be used to operate applicableengine. Soak diaphragm for at least 8 hours.This restores fuel diaphragms to normaloperating condition.

c. Adjusting Idle Mixture and Idles Speed If anengine will not respond to idle mixture and speedadjustment, it is an Indication that some other phase ofengine operation is incorrect. Adjust idle mixture andidle speed using the following procedures.

(1) Make idle mixture adjustments with oiland cylinder head temperatures at normal values.

(2) Back idle speed stop off so that idle speedIs controlled during adjusting procedure by manuallycontrolling throttle.

(3) Retard throttle to designated rpm.

(4) Screw idle mixture in or out in smallincrements as required until proper idle mixture isestablished.

(5) After each idle mixture adjustment,increase power to field barometric pressure forapproximately 1 minute to clean intermittent firing sparkplugs caused by excessively rich or lean mixture.

(6) Set idle speed stop to desired rpm.

d. Repair or Replacement. Repair or replacecarburetor using the following procedures:

(1) When improper operation of float-typecarburetor is suspected, perform a test by manuallyleaning mixture with mixture control or by enrichingmixture by use of primer. Replace complete unit when

changes in rpm, other than those within allowable limits,result.

(2) When difficulty is encountered with PDand PR series Injection-type carburetors, attributed tosticking or binding of automatic mixture control unit,clean unit as follows:

(a) Remove unit from carburetor, beingcareful not to remove seal or lockwire or loosen siphonlocking nut.

WARNINGDry-cleaning solvent is flammableand solvent vapors are toxic. Use P-D-680, Type II Solvent In a well-ventilated area. Keep away fromopen flames Avoid prolongedsolvent contact with skin.

(b) Wash bushing with dry-cleaningsolvent, Federal Specification P-D-680.

(c) Dry thoroughly with compressed air.

(d) Polish bushing sleeve with crocuscloth, Federal Specification P-C-458, until it is bright.

(e) Blow out any polishing dust thattends to cling to inside walls.

WARNINGDry-cleaning solvent is flammableand solvent vapors are toxic Use P-D-680, Type II Solvent in a well-ventilated area. Keep away fromopen flames. Avoid prolongedsolvent contact with skin.

(f) Clean needle with dry-cleaningsolvent, Federal Specification P-D-680, and dry withcompressed air

(g) When needle is corroded, cleanwith dry-cleaning solvent, Federal Specification P-D-680, dry with compressed air, polish with crocus cloth,Federal Specification P-C-458, and lubricate with greasemolybdenum disulfide MIL-G-21164.

(h) Reassemble and install lockwire orseal, if broken.

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(3) All components of PS series injection typecarburetor are self-contained In one assembly. Anydifficulty that cannot be corrected by adjusting idlemixture or speed or unplugging vapor bleed requiresreplacement of carburetor.

e. Preservation. When carburetors are removedfor placement of storage or for rework, they should be

TM 1-1500-204-23-1

NOTEExcessive damage requiresreplacement.

(2) Tighten loose mountings to obtain torquevalues specified In maintenance manual.

(3) Repair or replace vibration isolators thatshow any evidence of radial slippage.

(4) Properly secure all engine mount retainingbolts with safety wire.

(5) Replace vibration isolators when metal orrubber parts indicate sagging or deterioration.

7-12. Preservation of Reciprocating Engines.Corrosion of aircraft metals and alloys is primarily a lightagainst moisture. There are two main types of surfacecorrosion, direct chemical attack on metal, andelectrochemical action In which the metal beingcorroded becomes a part of an electrolytic cell In thepresence of moisture. Both reactions are effectivelyretarded In the absence of moisture. Corrosion will notoccur in a clean atmosphere when moisture is notpermitted to reach the metal surface. Preservereciprocating engines using the following paragraphs.

a. Preservation of Accident-Involved Engines.Engines removed from an aircraft that has beeninvolved in an accident In which engine failure ormalfunction Is known or suspected to have been a factorshould not be treated with corrosion protective. Noattempt should be made to operate, motor, ordisassemble an accident-involved engine. All accidentinvolved engine must be transported to an overhauldepot or a designated investigation area within 10 daysafter the accident. The accident-involved engine shallbe preserved using the following procedures.

(1) Without disconnecting lines or fittings,make every effort to prevent remaining fuel and oil Inengines from leaking out

(2) Plug all ports and cap all fittings and lines.Seal openings with applicable covers.

(3) Install engine in bottom half of metal,reusable shipping and storage container.

(4) Ground engine to container to prevent apossible explosion of dangerous vapors which may beignited by static electricity or a spark.

(5) Secure all loose metal components to thecontainer with tape, PPP-T-60, to prevent a possiblespark during shipment.

b. Preservation of Operable Engines to beremoved for Overhaul. Engines to be removed fromaircraft for overhaul, that can be operated withoutfurther damaging the engine or any of its parts, shall bepreserved using the following procedures

CAUTIONWhile injecting the preservationcompound, be sure none of thecompound is injected into airstreamof the carburetor or master control.Do not inject the compoundupstream of the throttle valve.Damage may otherwise result.

(1) Drain oil system and refill with corrosionpreventive MIL-C-6529, Type II.

NOTEType II corrosion preventive consistsof a ready mixed blend of 1 partcorrosion preventive, MIL-C-6529,Type 1 and 3 parts new lubricatingoil, MIL-L-6082, Grade 1100.

(2) Prior to starting engine for final run,connect discharge nozzle.

NOTEDischarge nozzles shall conform todesigns set forth in figure 7-24 andbe modified in length and threadconfiguration to suit engine type andpoint of application.

(3) Locate nozzle in a position so thatcorrosion preventive mixture Is properly distributed to allcylinders. Modify nozzle discharge are to providesufficient restriction to prevent exhausting corrosionpreventive supply prior to cessation of engine rotation.

NOTEFor radial engines, precautions shallbe taken to ensure that the quantityof mixture aspired and the locationemployed provides an even amountof coating for both upper and lowercylinders.

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Figure 7-24. Discharge Nozzle for Corrosion Preventive Mixture

(4) Thermostatically control corrosionpreventive supply tank to maintain corrosion preventive,MIL-C-6529, Type II at a temperature of 221 to 250°F(105 to 121 C).

(5) Connect an air pressure line providing 60to 80 psi dry compressed air to the tank Mixture capacityof the tank will be as follows:

• One quart for engines up to 1340 cubic inchdisplacement.

• Two quarts for engines up to and including2000 cubic inch displacement.

• Three quarts for engines up to 3350 cubicinch displacement.

(6) Make final engine run with oil systemserviced with corrosion preventive as follows:

CAUTIONAt no time will engine be operated inexcess of 1500 rpm while the oilsystem Is serviced with corrosionpreventive mixture. Damage mayotherwise result.

(a) Operate engine on service fuel for aperiod of 15 minutes.

(b) With engine operating at 1500 rpm,release corrosion preventive mixture through nozzle. Assoon as white smoke appears at upper cylinder exhauststacks for radial engines and at all stacks for opposedengines, move mixture control to IDLE CUT-OFFposition and allow engine to stop. Continue aspiration ofmixture until engine ceases to fire

(7) Drain preservation mixture from oilsystem while engine Is warm, exercising care to keepcorrosion preventive mixture clean for future use.

(8) Clean filter and screen and coat withcorrosion preventive mixture and reinstall.

(9) When rocker box covers have beenremoved for any reason, rocker box interior shall betreated as follows:

(a) Drain oil from each rocker box fromwhich cover IS removed

(b) Spray-coat rocker arms, valvestems, springs, push rods, rocker box covers, and rockerboxes with corrosion preventive, ML-C-16173, Grade 2.

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(c) Reinstall covers with new gasketsand tighten holddown nuts to values specified inapplicable engine maintenance manual.

NOTEThe above rocker box preservationprocedures are mandatory for all0.435 series engines.

(10) Spray interior of each cylinder withcorrosion preventive, MIL-C-6529, Type II maintained ata temperature of 221 to 2500F (105 to 121°C). Sprayas follows:

(a) Spraying shall be accomplished withpiston at bottom dead center. Spray cylinders insequence of firing order. Continue in this manner untilall cylinders are sprayed.

CAUTIONThe crankshaft must not rotate afterfinal spraying as preservationcoating will be scraped from cylinderwalls.

(b) Final-spray cylinders withoutrotating crankshaft.

(c) Install cylinder dehydrator plugs,MIL-1-6131, Type II, In each spark plug opening.

(11) Spray interior of exhaust ports and sealIndividuals ports with applicable exhaust port plug.

(12) Preserve carburetors in accordance withapproved preservation procedures.

(13) Remove thrust bearing cover plate andspray-coat bearing with corrosion preventive, MIL-C-6529, Type II Reinstall cover.

(14) Coat exposed propeller shaft withcorrosion preventive, MIL-C-16173, Grade 2 wrappropeller shaft with barrier material, and MIL-B-121,Grade A, when applicable plastic cylinder protector isnot available.

(15) Seal oil line fittings with plugs conformingto MIL-C-5501.

(16) Remove cover plates from all accessorydrives and spray-coat all drives with corrosion-preventive, MIL-C-6529, Type II. Reinstall all coverplates.

(17) Seal breather openings with oil andmoisture-resistant covers, dehydrator plugs, or pressuresensitive tape, Federal Specification PPT-60.

(18) Perform dehydration of Intake manifold asfollows:

(a) Secure carburetor throttle valve Inopen position with lockwire.

(b) Install one 16-unit bag of desiccant,MIL-D-3464, in intake.

(c) Seal openings with moisture-resistant covers or barrier material, MIL-B-121, Grade A,secured with pressure sensitive tape, FederalSpecification PPP-T-60.

CAUTIONDo not turn protective cap duringinstallation or removal as damagemay occur to contact spring.

(19) Protect spark plug lead terminals byinstalling applicable protective cap.

(20) Preserve magnetos by applying oil tocam, spring, and other steel parts. Seal all externalopenings with pressure sensitive tape, FederalSpecification PPP-T-60.

NOTEKeep oil from breaker points.

(21) Install a crankcase dehydrator plug.

(22) Install engine in a metal shippingcontainer as follows:

(a) Place preserved engine in aserviceable container in accordance with instructionssupplied with container.

(b) Close container and tighten closurebolts to proper torque.

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CAUTIONUse only dehydrated air with amaximum relative humidity of 30percent for pressurizing shippingcontainers in order to keep humidityas low as possible in the airsurrounding the engine.

(c) Pressurize container to 5 psi with dehydratedair.

(d) Retighten engine container flange nuts tooriginal torque after 1 hour elapsed time.

(e) After container has been pressurized, usesoapy water to check for leaks If a second pressurecheck in 24 hours does not Indicate a leak, engine isready for storage or shipment.

(f) Maintain all markings and stencils on shippingcontainer intact without additions or deletions.

c. Preservation of Inoperable Engines. Engines thatcannot be operated and are to be removed from aircraftshall be treated as far as practicable as shown inparagraph 7-11 b. Spray all possible interior surfaces,as the engine will be shipped or stored without theprotection afforded It by a final operation using acorrosion-preventive compound in the lubricationsystem. An appropriate entry shall be made on DAForm 2408-16 and DD Form 1577-2, stating Inability toaccomplish preservation run of the engine DA Form2408-5 also will be sent with the, engine, if applicableDA Form 2410 will be completed and mailed inaccordance with DA PAM 738-751.

d. Intermediate Storage of Engines Mounted onAircraft. Intermediate storage shall be completed within24 hours after ground runup. When it is not definitelyknown that the aircraft will be operated within 45 days,the engine shall be preserved for intermediate storageand an entry shall be made on the applicable DA Form2408 series stating this work has been accomplished.The procedure for Intermediate storage is the same aspreviously outlined in paragraph 7-11b with the followingadditional procedures.

(1) Drain fuel from engine-driven fuel pump andflush interior with lubricating oil, MIL-L-6081, grade1010, while rotating engine crank-shaft. Seal fuel lineswith suitable plugs.

CAUTIONUse dehydrated air with a relativehumidity of 30 percent for allspraying operations. Damage mayotherwise result.

(2) Spray exhaust valves with corrosion preventive,MIL-C-6529, Type II Spraying shall be through exhaustport with exhaust valves fully open.

NOTEEngines with collector rings may besprayed through spark plug portswith exhaust valves fully open.

(3) Place and secure two 8-unit bags of desiccant,Military Specification MIL-D-3464, in carburetor airintake scoop or carburetor adapter.

(4) Cover open end of scoop with a suitableanchored, barrier paper, MIL-B-131.

(5) Firmly attach a red cloth streamer to bagscontaining desiccant and bring loose end out In such amanner that not less than 18 inches of cloth streamerwill be visible on outside of carburetor air Intake scoop.In order to prevent streamer from action as a wick, a 3-to 4-inch length of lockwire shall be left betweenstreamer and desiccant.

(6) Install 16 units of desiccant, MIL-D-3464, inexhaust outlet on engines incorporating an exhaustcollector ring. Place a total of four units of desiccant inexhaust openings on engines that do not have anexhaust collector ring.

(7) Firmly attach a red cloth streamer to bagscontaining desiccant and bring loose end out a minimumof 18 inches. Use a 3- to 4-inch length of lockwirebetween cloth and desiccant to prevent streamer fromacting as a wick.

(8) Seal all openings, joints, drain holes, and outletswith barrier material, MIL-B-1 21, and secure withpressure sensitive tape, Federal Specification PPP-T-60.

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(9) Use following procedure as alternate method ofexhaust sealing.

(a) Remove exhaust stacks at cylinder outlet.

(b) Install cylinder exhaust outlet cover betweenexhaust stack opening and exhaust stack flange.

NOTEEngines with Individual exhauststacks have stacks removed and acylinder exhaust outlet coverinstalled between exhaust stackflange and cylinder exhaust outlet.

(c) Fabricate covers locally.

(10) Seal all openings such as distributor vents andengine breathers with moisture proof plugs and coversPressure sensitive tape, Federal Specification PPP-T-60, (red) may be used

(11) Cover all engines installed on aircraft usingengine covers furnished with aircraft. Provide lowerportion of cover with a drain hole to preventaccumulations of water.

(12) Locally fabricate placard for engines withpropellers installed, and conspicuously display placardon propeller blade. Placard shall have followinginformation

DO NOT TURN PROPELLERENGINE PRESERVED IN ACCORDANCE

WITH APPLICABLE MAINTENANCE INSTRUCTIONS

e. Flyable Storage. Engine installed on aircraft whichwill not be flown for an Indefinite period of time, but aremaintained in a flyable status or undergoing short-termmaintenance, shall be treated as follows:

(1) Engine serviced with normal lubricant shall begiven a ground runup each third day of Idleness.

NOTEThe runup consists of engineoperation at a speed greater than idlefor a period of 5 minutes or untilhighest allowable oil inlettemperature is attained. Every 14days a 15-minute normal groundpreflight shall be accomplished.

(2) Engines undergoing repair or inspection thatcannot be operated shall be pulled through by hand orstarter at least eight revolutions on the third day ofidleness.

NOTEAground runup shall beaccomplished on the seventh day ofidleness. When runup cannot beaccomplished on the seventh day,the crankshaft shall be pulledthrough and cylinders sprayed asoutlined in paragraph 7-11b. Storageof aircraft engines in this mannershall not exceed 14 days.

(3) Upon conclusion of a ground runup on enginesIn flyable storage, make entries on applicable DA Forms2408-13.

NOTECheck the applicable aircraftmaintenance manual for specificinstruction pertaining to FlyableStorage.

7-13. Depreservatlon of Reciprocating Engines.The instructions contained In this section shall befollowed prior to making the initial start to newly installedengines and engines installed in aircraft being removedfrom temporary and Indefinite storage, regardless oftime In storage.

NOTENewly installed engines shall begiven a depreservation run as soonas possible, but not later than 4hours after preoiling has beenaccomplished. If more than 4 hourshas elapsed since preoiling engine,complete preoiling procedure shallagain be accomplished.

a. Preoiling. Proper preoiling lubricates internal gearsand bearings, expels air from internal oil passages, andaverts internal engine failures due to lack of lubrication.Accomplish preoiling either indoors or by applyingengine preheat prior to preoiling when operating intemperature below 0°F (-18°C). For preoiling engineson aircraft using the diverter-segregator oil system, it isnecessary to follow special instructions contained in

TM 1-1500-204-23-1

NOTEEngines need not be preoiled afteroil change or after oil systemcomponents have been disconnectedfor normal maintenance. However,after oil change or afterdisconnecting oil systemcomponents located in the systembetween oil tank and engine oilpump, it will be necessary todisconnect oil inlet line at the pumpand drain a sufficient amount of oilfrom the line to determine there is noobstruction or air in the system.

(1) Prepare engine for preoiling as follows:

(a) Service oil tank, oil sump, or crankcase withengine oil specified In applicable maintenance manual.

(b) Provide an external power source.

(c) When spark plugs have been installed,remove one spark plug from each cylinder to reduceload on starter.

(d) Place engine controls in following positions,as applicable.

Ignition switch .......................................OFFThrottle ..............................................OPENMixture control .....................IDLE CUT-OFFFuel shutoff valve .................................OFFOil shutoff valve.................................OPEN

(e) Provide suitable containers of approximately 5gallons capacity to catch oil that drains from sumpsduring preoiling operation.

(f) On engines which utilize crankcase breathersand which are equipped with a hydromatic propeller,remove plug from propeller dome and pour a sufficientamount of preoiling lubricant into dome to bring lubricantlevel to plug hole. Reinstall and safety the plug Inpropeller dome.

NOTEThis step is not required for engineshaving propeller shaft breathers,reversible-type propellers, or enginesnot equipped with hydromaticpropellers.

(2) Preoil engine by one of the following methods:

CAUTIONDevices having heating elements indirect contact with preoiling mixtureor oil shall not be used Damage mayotherwise result

(a) Preoil engine having a dry sump-type oilsystem using a pressure tank.

(b) Preoil engine having a wet sump by rotatingcrankshaft with starter and utilizing normal engine oilsupply and oil pump to provide pressure

(3) Provide suitable viscosity by heating andmaintaining lubricant used for preoiling at a temperaturebetween 110° to 175°F (38° to 80°C) when usingpreoiling equipment incorporating provisions for heating.When preoiling with engine oil pump or with equipmentnot incorporating a heating element, dilute lubricant, at atemperature lower than 30°F (-1°C), with gasoline inaccordance with percentage calculated from chartshown In figure 7-25. Mix thoroughly prior to preoiling.

(4) Preoil O-series engines by servicing oil systemwith grade oil specified for engine, and the turn enginethrough with starter until oil pressure is indicated onaircraft oil pressure gauge.

(5) Preoil all radial engines as follows:

CAUTIONDo not energize starter over 15seconds. Allow starter to cool aftereach energizing. Damage to startermay otherwise result

(a) Prime oil pump by removing applicable plugand rotating crankshaft with starter until all air isexpelled from vent and a steady flow of oil is comingfrom vent. Reinstall plug.

NOTEOn engines not having a plug,disconnect oil inlet line and allowsufficient oil to drain to assure air inthe line is eliminated.

(b) Remove drain plugs from front and rearsumps on installations having sumps in these locations.

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Figure 7-25. Percent Dilution Versus Temperature for Grade 1100 Oil

(c) Connect preoiler to preoiling fitting.

(d) Rotate engine with starter and commencepreoiling until oil is flowing freely from sump plug holesand pressure Is indicated on oil pressure gauge inaircraft.

(e) Cease operation and replace sump plugs.

(f) Remove rocker box covers from number onecylinder or both top covers on double row engines andcontinue preoiling until oil is obtained from all rockerarms that have been removed.

(g) Disconnect preoiler and reinstall all partsremoved.

NOTENewly installed engines will be givenan initial start as soon as possible,but not later than 4 hours afterpreoiling has been accomplished.When any period of time in excess of4 hours has elapsed since enginewas preoiled, complete preoilingprocedure shall again beaccomplished before attemptinginitial start of engine.

b Depreservation Run. The depreservation runeliminates the necessity of removing or draining Intakepipes prior to installation of engine in the aircraft.Perform depreservation run using the followingprocedures:

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NOTENewly installed engines shall begiven a depreservation run as soonas possible, but not later than 4hours after preoiling has beenaccomplished if more than 4 hourshas elapsed since preoiling engine,complete preoiling procedure shallagain be accomplished.

(1) Prior to starting engine, remove one spark plugfrom each cylinder below the horizontal centerline ofengine. Refer to TB 55-2925-200-25 for proper sparkplugs to be utilized during depreservation run.

NOTEOn seven-cylinder engines whichwould necessitate removal of sparkplugs from four cylinders, therebyresulting in excessively roughoperation, the one cylinder below thehorizontal centerline on right side ofengine when viewing engine atpropeller end may be left operative.This permits operation of fourcylinders rather than three, whichgreatly stabilizes engine operation.

(2)

TM 1-1500-204-23-1

CHAPTER 8

GENERAL TURTBINE ENGINE MAINTENANCE

8-1. General. The maintenance Instructions andprocedures contained in this chapter are general andapplicable to turbine engines used on Army aircraftMaintenance Instructions that are specific and peculiarto particular engines are contained In the applicablemaintenance manuals and will be used in conjunctionwith general information contained in this chapter.

8-2. Engine Types and Designations. Turbine enginetypes and designations are explained in the followingparagraphs.

a. Types. Types of aircraft turbine engines are thecentrifugal-flow and axial-flow turbine engines.Centrifugal-flow engines, as shown In figure 8-1,compress the air by centrifugal force. The air enters theair inlet and is directed to the compressor inducer vanesthrough circumferential inlets located in front and backof the Impeller. Axial-flow engines, as shown in figure8-2, compress the air axially. The air enters the air inletand flows in a relatively straight path In line with the axisof the engine.

b. Designation Examples. On gas turbine enginedesignations, such as T53-L-1, T denotes gas turbinewith drive shaft, numeral 53 is assigned to the engine bythe services, L denotes the manufacturer, and 1 denotesmajor modification.

8-3. Turbine Engine Theory. The gas turbine engineis a type of internal combustion engine that producespower by a continuous and self-sustaining process ofcompression, combustion, expansion, and exhaust. Airis compressed in the compressor section, mixed withatomized fuel and burned in the combustion chambers.As the fuel burns, the resultant gases expand throughturbine wheels to convert heat energy to useful power

8-4. Turbine Engine Precautions. The followingprecautions shall be observed during maintenance ofturbine engines.

a. Regularly police parking areas, runways,taxiiways, and runup and exhaust areas to ensureagainst the presence of foreign objects which couldenter the engine. Special attention shall be given tocleaning of cracks and expansion seams in hard

surfaced areas where engines will be operated, as testshave indicated that these are the main source of foreignobjects which are ingested.

b Periodically instruct personnel concerned withaircraft maintenance of foreign object hazards to ensurethat maximum preventive measures are taken.

c Ensure that air inlet and tailpipe dust excluders areinstalled at all times when engines are not beingoperated, except when it is known the engine will againbe operated Immediately following shutdown.

d. Prior to each engine start, thoroughly Inspect andclean inlet ducting. Remove all loose nuts, bolts, tools,or other objects which would cause engine damage andpossible subsequent failure.

e. After work has been accomplished, inspect toensure that all accessories and attaching parts aresecure and that work areas are cleared of foreignobjects prior to engine operation.

f. Provide properly marked receptacles (FOD cans) inall work areas into which trash, ferrous and nonferrousscrap, safety wire, etc. , may be placed.

g. Adhere to applicable gas turbine-powered aircrafttaxiing and parking procedures as outlined in applicabletechnical bulletins. This minimizes damage due toobjects being thrown by the exhaust blast Into the intakeof other aircraft.

h Ensure that gas turbine-powered aircraft takeoffand landing procedures are such as to avoid the intakeof foreign objects blasted from runways and runwayshoulders by preceding aircraft.

i. Use inlet duct runup screens during all groundoperations, including taxiing to and from takeoffposition, with the following exceptions:

• Inlet duct runup screens are not required onaircraft using centrifugal flow engines.

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Figure 8-1. Centrifugal-Flow Engine

Figure 8-2. Axial-Flow Engine

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• When necessary to properly evaluate engineperformance or when icing conditions exist,inlet duct runup screens should be removed.Runup with screens removed shall be made ina designated, thoroughly cleaned area.

CAUTIONInlet duct runup screens shall not beinstalled and removed with engineoperating above Idle rpm LooseItems of clothing shall not be wornand objects which might be drawninto the Intake ducts shall not becarried when installing or removingscreens. Damage to the engine mayotherwise result.

• Inlet duct runup screens may beleft off during taxiing to and fromtakeoff position whenrequirements or existingconditions make the use ofscreens impractical Sincespecific conditions warrantingremoval of screens as specifiedabove cannot be predetermined,specific conditions may bedetermined by each command asnecessary to conduct theiroperation Approval of screenremoval should include anyadditional precautions necessaryto assure safe operation ofengine.

j. Use only nonmetallic-head hammers whenrequired to install parts on engine.

k. When possible, use appropriate hoist or lifting yokeon heavy or bulky parts, such as tailpipes.

I. Tighten jack screws, attaching screws, bolts, andnuts In small increments on opposite planes.

WARNINGLead poisoning is an accumulativedisease that can be fatal. Preventiverather than curative measures shallbe stressed.

m. A turbine engine that has operated on fuelcontaining tetraethyl lead may have a yellow powder onthose sections that are exposed to combustion gases.for example, tail pipes and combustion chambers.Extreme care shall be used by all personnel handling

such parts to prevent internal contamination of the bodythrough open cuts, sores, or inhaling. Personnel shalladhere to following precautionary measures.

• Change clothes daily. • When possible, gloves shall be worn. Wash or

change gloves daily. • Hands shall be thoroughly washed before

eating, drinking, smoking, or using toilet. • Scrub body thoroughly each day.

8-5. Turbine Engine Design and Construction. Atypical turbine engine consists of an air inlet,compressor section, combustion section, turbinesection, exhaust section, accessory section, and thenecessary systems for starting, lubrication, fuel supply,and auxiliary purposes, such as anti-icing, cooling, andpressurization. The major components of all turbineengines are basically the same; however, thenomenclature of the component parts of various enginescurrently In use will vary slightly due to the difference Inmanufacturer terminology. These differences arereflected in the applicable maintenance manuals.

a. Inlet Ducts. There are two basic types of inletducts, the single entrance and the divided entranceduct. Single entrance inlet ducts are used with axial-flow engines, as shown in figure 8-3, to obtain maximumram pressure through straight flow. Divided entranceinlet ducts, as shown in figure 8-4, provide theopportunity to diffuse the incoming air so It enters theplenum chamber with the low velocity required to utilizea centrifugal-flow engine inlet ducts may be classifiedas:

• Nose Inlets, located in the nose of thefuselage or powerplant pod or nacelle.

• Wing inlets, located along the leading edge of

the wing, usually at the root for single-engineinstallations.

• Annular inlets, encircling, In whole or in part,

the fuselage or powerplant pod or nacelle. • Scoop inlets, which project beyond the

immediate surface of the fuselage or nacelle. • Flush Inlets, which are recessed in the side of

the fuselage, powerplant pod, or nacelle.

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Figure 83. Single Entrance Inlet Duct (Axial-Flow Engine)

Figure 84. Divided Entrance Inlet Duct(Centrifugal-Flow Engine)

b Particle Separators. Particle separators, as shownin figure 8-5, prevent foreign particles from entering thecompressor section of turbine engines. Air enters theengine through the swirl frame. Swirl vanes direct theair into a rotating or swirling pattern. Sand, dust, andother foreign objects are separated by centrifugal action.These objects are carried to the outer section of themain frame and into the scroll case. Particles are drawnfrom the scroll case by the blower and are blown out theaircraft discharge duct. The relatively clean air thatremains after particles are separated is carried to thefront frame deswirl vanes, which straighten the air flowbefore it enters the compressor inlet.

c. Compressor Section. The compressor section of aturbine engine has many functions. Its primaryfunctions is to supply air in sufficient quantity to satisfythe requirements of the combustion burners. Thecompressor must increase the pressure of the mass of

air received from the air inlet duct and then discharge itto the burners in the quantity and at the pressurerequired. A secondary function of the compressor is tosupply bleed-air for various purposes In the engine andaircraft.

(1) Centrifugal-flow compressor. The centrifugal-flow compressor consists basically of an Impeller (rotor),a diffuser (stator), and a compressor manifold, as shownIn figure 8-6. The compressor achieves its purpose bypicking up the entering air and accelerating it outwardlyby centrifugal action.

(2) Axial-flow compressor. In the axial-flow engine,the air is compressed while continuing in its originaldirection of flow, thus avoiding the energy loss causedby turns. From inlet to exit the air flows along an axialpath and is compressed at a ratio of approximately1.25.1 per stage. The axial-flow compressor has twomain elements, a rotor and a stator, as shown in figure8-7. The rotor has blades fixed on a spindle. Theseblades Impel air rearward in the same manner as apropeller because of their angle and airfoil contour. Therotor, turning at high speed, takes In air at thecompressor inlet and impels it through a series ofstages. The action of the rotor increases thecompression of the air at each stage and accelerates itrearward through several stages With this increasedvelocity, energy is transferred from the compressor tothe air in the form of velocity energy. The stator bladesact as diffusers at each stage, partially converting highvelocity to pressure. Each consecutive pair of rotor andstator blades constitutes a pressure stage. The numberof rows of blades (stages) is determined by the amountof air and total pressure rise required. The greater thenumber of stages, the higher the compression ration.

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Figure 8-5. Particle Separator

d. Diffuser Section. The diffuser increases thecompressor discharge area and reduces the speed ofthe centrifugal impeller airflow, causing the air pressureto increase. This pressurized air is directed to thecombustor through the diffuser case The diffuser casemounts on the rear flange of the compressor stator itdirects compressor discharge air to the combustionchamber.

e. Combustion Section. The combustion sectionhouses the combustion process, which raises thetemperature of the air passing through the engine. Thisprocess releases energy contained in the air-fuelmixture. The major part of this energy is required at theturbine to drive the compressor. The remaining energycreates the reaction or propulsion and passes out therear of the engine in the form of a high-velocity jet. Thelocation of the combustion section is directly betweenthe compressor and the turbine sections. Thecombustion chamber is always arrange coaxially withthe compressor and turbine regardless of type, since the

chambers must be In a through-flow position to functionefficiently.

Can-Type. The can-type combustion is typical ofthe type used on both centrifugal and axial-flow enginesFigure 8-8 illustrates the arrangement for can-typecombustion. The engine combustion cans arenumbered in a clockwise direction facing the rear of theengine with the No. 1 can at the top. The can-typecombustion consist of an outer case or housing, which isperforated stainless steel (highly heat resistant) (SeeFigure 8-9).

f. Turbine Section. The turbine transforms a portionof the kinetic (velocity) energy of the exhaust gases intomechanical energy to drive the compressor andaccessories. This is the sole purpose of the turbine andthis function absorbs approximately 60 to 80 percent ofthe total pressure energy from the exhaust gases. Theturbine assembly consists of two basic elements, thestator and the rotor, as does the compressor unit.These two elements are shown in figure 8-10.

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Figure 8-6. Centrifugal-Flow Compressor Components

g. Exhaust Section. The exhaust section of a turbineengine is made up of several components, each ofwhich has its individual functions. Although thecomponents have individual purposes, they also haveone common function. they must direct the flow of hotgases rearward in such a manner as to preventturbulence and at the same time Impart a high final orexit velocity to the gases.

h. Accessory Section. The accessory section of aturbine engine has various functions. The primaryfunction is to provide space of the mounting ofaccessories necessary for operation and control of theengine. Generally, it also includes accessoriesconcerned with the aircraft, such as electric generatorsand fluid power-pumps Secondary functions includeacting as an oil reservoir and/or oil sump, and housingthe accessory drive gears and reduction gears.

i. Governors and Fuel Controls. Governors and fuelcontrols used on turbine engines are explained in the

following paragraphs.

(1) Governors. The speed-sensitive control andspeed-set governor are discussed in the followingparagraphs.

(a) Speed-sensitive control. The speed-sensitivecontrol, as shown in figure 8-11, is mounted on thetachometer pad of the accessories housing. It containsthree switches which are actuated at certain speeds by aflyweight system. During a start, one switch turns on thefuel and ignition, parallels fuel pump elements,energizes the starting fuel enrichments system whenfuel enrichment switch is on, and closes the drip valve.Another switch shuts off the ignition, deenergizes thedrip valve (which is then held closed by fuel pressure),and shifts the fuel pumps from parallel to seriesoperation. Still another switch shifts the temperaturedatum control from start limiting and limits thetemperature datum valve to a certain reduction ofengine fuel flow.

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Figure 8-7. Rotor and Stator Components of anAxial-Flow Compressor

(b) Speed-set governor. The speed-set governor,as shown in figure 8-12, controls the position of thegovernor servo. It is a centrifugal, permanent-drooptype governor driven by the engine high-speed rotor (N2)through a gear train. As engine speed increases, thefly-weights tend to move outward, lifting the speed setpilot valve. Conversely, when engine speed decreases,the fly-weights move inward and the pilot valve islowered. The power lever in the cockpit positions thespeed-setting cam in the fuel control unit to manipulatea system of levers and thus control the compression ofthe speeder spring. The speeder spring exerts force onthe speed-set pilot valve. The condition of on-speedindicates the speeder spring force and the flyweightforce are equal.

(2) Fuel controls. Fuel controls can be divided intotwo basic groups hydromechanical and electronic. Thefuel control senses power lever position, engine rpm,either compressor inlet pressure or temperature, andburner pressure of compressor discharge pressure.These variables affect the amount of thrust that anengine will produce for a given fuel flow.

(a) Hydromechanical fuel controls.Hydromechanical fuel controls are extremelycomplicated and are composed of speed governors,servo systems, sleeve and pilot valves, feedback orfollow up devices, and metering systems.

(b) Electron/c fuel controls Electronic fuelcontrols contain the same Items as the hydromechanicalfuel control as well as amplifiers, thermocouples, relays,electrical servo systems, switches, and solenoids.

Figure 8-8. Can-Type Combustion Chamber Arrangement

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Figure 8-9. Can-Type Combustion Chamber

Figure 8-10. Turbine Assembly Elements

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j. Ignition Systems. Turbine ignition systems areoperated for a brief period during the engine-startingcycle, and, as a rule, more trouble-free than the typicalreciprocating engine ignition system. Most turbineengines are equipped with a high-energy, capacitor-typeignition system

(1) System components. A typical ignition systemincludes two exciter units, two transformers, twointermediate ignition leads, and two high-tension leads.Thus, as a safety factor, the Ignition system is actually adual system, designed to fire two igniter plugs. Figure8-13 shows one side of a typical Ignition system.

(2) Igniter plugs. The igniter plug of a turbineengine ignition system differs considerably from thespark plug of a reciprocating engine ignition system. Itselectrode must be capable of withstanding a current ofmuch higher energy than the electrode of a conventionalspark plug. This high-energy current can quickly causeelectrode erosion, but the short periods of operationminimize this aspect of Igniter maintenance. The

electrode gap of the typical igniter plug Is designedmuch larger than that of a spark plug, since theoperating pressures are much lower and the spark canarc more easily than Is the case for a spark. Finally,electrode fouling, so common to the spark plug, isminimized by the heat of the high-intensity spark.Typical igniter plugs are shown in figure 8-14.

k. Fuel Systems. The fuel system must deliver to thecombustion chambers not only in the right quantity, butalso in the right condition for satisfactory combustion.The fuel nozzles form part of the fuel system andatomize or vaporize the fuel so that it will ignite and bumefficiently. The fuel system must also supply fuel sothat the engine can be easily started on the ground andIn the air. This means that the fuel must be injected intothe combustion chambers in a combustible conditionwhen the engine is being turned over slowly by thestarting system, and that combustion must be sustainedwhile the engine Is accelerating to its normal runningspeed.

Figure 8-11. Speed-Sensitive Control

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Figure 8-12. Speed-Set Governor

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Figure 8-13. One Side of a Typical Ignition System

(1) Fuel controls. Regardless of the type, all fuelcontrols accomplish essentially the same functions, butsome sense more engine variables than others. Thefuel control senses power lever position, engine rpm,either compressor inlet pressure or temperature, andburner pressure or compressor discharge pressure.These variables affect the amount of thrust that anengine will produce for a given fuel flow.

(2) Fuel nozzles. The fuel nozzles inject fuel intothe combustion area In a highly atomized, preciselypatterned spray so that burning is completed evenly andin the shortest possible time and in the smallest possiblespace. Fuel nozzle types vary considerably betweenengines, although for the most part fuel is sprayed intothe combustion area under pressure through smallorifice in the nozzles The two types of fuel nozzlesgenerally used are the simplex and the duplexconfigurations.

(a) Simplex fuel nozzle. The simplex fuel nozzlewas the first type nozzle used in turbine engines andwas replaced in most installations with the duplexnozzle, which gave better atomization at starting andidling speeds. The simplex nozzle, as shown in figure 8-15, is still being used to a limited degree. Each of thesimplex nozzles consists of a nozzle tip, an insert, and astrainer made up of fine-mesh screen and a support.

(b) Duplex fuel nozzle. The duplex fuel nozzle isthe nozzle most widely used in present-day gas turbineengines The duplex nozzle usually requires a dualmanifold and a pressurizing valve or flow divider fordividing primary and main fuel flow into a desirablespray pattern for combustion over a wide range ofoperating pressures. A nozzle typical of this type isshown In figure 8-16.

(3) Fuel filters. A low-pressure filter Is installedbetween the supply tanks and the engine fuel system toprotect the engine-driven fuel pump and various controldevices. An additional high-pressure fuel filter isinstalled between the fuel pump and the fuel control toprotect the fuel control from contaminants. The threemost common types of filters in use are the micron filter,the wafer screen filter, and the plain screen mesh filter.The individual use of each of these filters is dictated bythe filtering treatment required at a particular location.

8-6. Turbine Engine Inspection and Maintenance.Turbine engines shall be Inspected and maintained inaccordance with the applicable maintenance manual.General procedures for various components andsystems are explained in the following paragraphs.

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Figure 8-14. Typical Igniter Plugs

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Figure 8-15. Simplex Fuel Nozzle

a. General Procedures. The following proceduresshall be adhered to during turbine engine maintenance.

(1) Mark location of all attaching support brackets,clamps, and clips prior to removing lines, tubes, orconduit to facilitate reassembly with a felt tip markerUse ink conforming to Federal Specification TT-1-544.

(2) Use new O-rings, packing rings, cotter pins,lockpins, gaskets, and washers.

(3) Apply lubricating grease, MIL-G-4343, on all O-rings prior to installation.

(4) Apply thread compound, MIL-A-13881, to allthreaded parts attached to the hot section.

(5) When gears are replaced, examine for patternwear and backlash.

b. Health Indication Test. The Health Indication Test(HIT) is the method by which the aviator In day-to-dayflying monitors the aircraft engine condition. This isaccomplished by the aviator selecting an N1 speed (%)predicated upon the existing Free Air Temperature(FAT). The interstate Turbine Temperature (ITT) mustthen relate to a predicated value (Baseline ITT) within acertain tolerance. ITT variation from baseline valuesare logged by the aviator in accordance with theapplicable maintenance manual This log, part of theengine records, is available to the maintenance officeras an aid In monitoring performance trends and introubleshooting When the difference between arecorded ITT and the baseline ITT is 20°C (68°F) orgreater the aviator will make an entry on DA Form 2408-13 to notify the maintenance officer. A difference of30°C (86°F) or greater is cause for grounding the aircraft

until troubleshooting determines the cause of theexcessive ITT. New ITT baseline values for HIT shouldbe established after performing a baseline engineperformance check. A new engine performance checkshould be made when an engine Is changed, when thefuel control unit is adjusted or replaced, or when repairsare made to the engine hot section.

c. Hot Start Inspection. A hot start occurs whenexhaust gas temperature exceeds normal startingtemperature limit.

NOTEA hot start may be expected when agreater-than-normal starting fuel flowIs observed just as the power lever ismoved Into the IDLE position.

d. Turbine Engine Analysis Check (TEAC). A normalTurbine Engine Analysis Check (TEAC) is performed forcomparison of normal TEAC data with baseline data.This will confirm whether or not performancedegradation has occurred and to what degree. Inaddition, TEAC data can be an aid in determining thecause of the performance loss (Refer to TEACtroubleshooting). A normal TEAC shall be performedwhenever installed engine performance degradation Issuspected or as part of a general test flight (ifapplicable).

e. Foreign Object Damage Inspection. Most damageincurred by the engine is the result of ingestion offoreign objects Although screens are provided in thelower aft cowling section and around the enginecompressor inlet case to prevent entry of larger objects,sand and grit will enter and cause compressor damage.The resultant damage will be in the form of nicks orscratches on the compressor blades. Such a nick orscratch can cause fatigue failure hours later, withdisastrous effects to the entire engine.

CAUTIONWhen maintenance is performed onthe engine, every effort shall bemade to retrieve any object (wire,rivets, nuts, screws, etc.) droppedthrough the compressor inlet screenor into the cowling, even if enginedisassembly Is required. Damage tothe engine may otherwise result.

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Figure 8-16. Duplex Fuel Nozzle

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Figure 8-17. Compressor Blade Damage

f. Compressor Cleaning. Compressor cleaningconsists of internal washing of the compressor with acleaning compound which is intended for use on anengine displaying definite evidence of performancedeterioration due to an accumulation of foreign materialdeposits on the compressor blading. Refer to theapplicable maintenance manual for specific procedures.

g. Cold Section Maintenance. Maintenance to coldsection components consists of repairing and replacingcomponents as outlined In the specific enginemaintenance manual.

h. Compressor. Blade Inspection and Repair.Compressor blades should be inspected for cracks,nicks, scores, scratches, buckling, and burns, as shownin figure 8-17. Minor damage can be repaired if thedamage can be removed without exceeding theallowable limits established by the manufacturer.Typical compressor limits are shown In figure 8-18.Repair In accordance with the applicable maintenancemanual.

i. Hot Section Maintenance. The following arerepairs that can be made to the hot section of a turbineengine:

• Weld cracks in combustion chambers that donot exceed repair limitations, using method andprocedure which keeps distortion to a minimum.

• Replace any turbine wheel blade found to havebe out of repair limits. Check applicablemaintenance manual. Turbine blades will onlybe changed in matched pairs.

• Replace tailpipes when cracked, bent, ordistorted.

j. Turbine and Exhaust Maintenance.Maintenance of the turbine and exhaust componentsconsists of repairing and replacing components asoutlined in the specific engine maintenance manual.

k. Ignition System Maintenance. Maintenance ofthe ignition system consists primarily of cleaning,Inspection, and replacement of components asexplained by the following paragraphs.

(1) Wiring harness. Perform wiring harnessmaintenance as explained by the following procedures:

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Figure 8-18. Typical Compressor Blade Repair Limits

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(a) Clean lead assembly with dry-cleaningsolvent, Federal Specification P-D-680. Replace anylead having fraying shielding, bent or mutilated socketcontacts or contact pins, and worn or stripped threads oncoupling nuts.

NOTEMinor chafing or fraying to the extentof not more than three brokenstrands in one inch of harness lengthis permissible, providing there is nodamage to the underlying insulation.

(b) Clean control harness leads withmethylethylketone, Federal Specification TT-M-261, drywith air blast. Replace harness when it is found to beopen or shorted.

(2) Igniter plugs. Perform igniter plugmaintenance as explained by the following procedures.

(a) Keep all igniter unit connections tightand all leads and conduit free from abrasions or otherdamage Accomplish the following steps when igniterplugs fail to spark.

1 When two igniter plugs fail tospark, replace one plug and energize system. Whenplug sparks, replace other plug and retest Replaceigniter unit when plug fails to spark.

2 When one plug fails to sparkand a new plug does not remedy defect, replace igniterplug lead. If plug still fails to spark, replace igniter unit

(b) Igniter plugs not heard firing whenengine is started shall be cleaned or replaced as follows:

1 Clean barrel of igniter plugswith a wire brush Buff threads with a cloth wheel. Donot clean nose end and electrode.

2 Replace plugs with crackedinsulation, damaged threads or pin contacts, or whenforeign material is found lodged In nose of plug.

3 Replace igniter plugs that fail toproduce continuous and regular sparking

(3) Ignition exciter. Refer to the applicablemaintenance manual for Ignition exciter maintenance.

I. Turbine Bearing Maintenance. Turbine enginebearings shall be inspected, removed, and replaced inaccordance with the applicable maintenance manual.

m. Thermocouple Maintenance. Replacethermocouple leads that Indicate a short or an opencondition. Clean carbon from thermocouples by dippingin carbon removing compound, MIL-C-19853, andwiping deposit away with a clean cloth.

n. Oil Consumption Check oil consumption inaccordance with the applicable maintenance manual.The following formula can be used to calculate oilconsumption in cc per hour.

cc of oil added x 60 minRecorded operating time 1 hrin minutes

= Oil consumption time in cc/hr

o. Fuel System. Fuel system maintenance shallbe accomplished in accordance with the applicablemaintenance manual. General maintenance proceduresare described in the following paragraphs.

(1) Fuel control inspection and adjustment.Fuel control inspection and adjustment are explained inthe following paragraphs.

(a) Fuel control inspection. Perform thefollowing procedures when inspecting fuel controls:

1 Inspect housing for cracks andleakage.

2 Inspect strainer element fornicks, tears, punctures, and broken wires.

3 Inspect springs and balls forcorrosion

4 Inspect cover for nicks, dents,and scratches.

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(b) Fuel control adjustment. Adjust fuelcontrol in accordance with the applicable maintenancemanual Typical adjustments are made to the following:

• Fuel selector

• Compressor rotor ground idle speed

• Air-bleed band closure

• Compressor rotor maximum speed

• Acceleration schedule

(2) Fuel nozzle inspection and cleaning. Inspectand clean fuel nozzles in accordance with the applicablemaintenance manual and the following paragraphs.

(a) Fuel nozzle inspection. Inspect fuelnozzles in accordance with table 8-1.

Table 8-1. Inspection of Primer Nozzles

Inspect Usable limits Max. repairable limits Corrective action

1. Primer nozzle Any amount not Not repairable Replace nozzletip for carbon clogging orifice.

2. Inlet fitting Two threads total, Two threads total, AVUM: Replacefor missing missing or damaged, missing or damaged, nozzle.or damaged without high metal, if that can be blended to AVIM: Chase threads.threads threads can be used usable limits

without cross-threading

3 Retaining nutfor:

a. Cracks None allowed Not repairable Replace retaining nut.

b. Missing or One thread Not repairable Replace retaining nut.damaged total, missing orthreads. damaged, without

high metal,If threads canbe used withoutcross-threading

c. Wrench damage Any amount, without Not repairable Replace retaining nut.on each corner high metal, if wrenchof hex flats. won't slip on nut.

d. Distortion Any amount if wrench Not repairable. Replace retaining nutwill fit on nut

e. Discoloration Any amount Not applicable. Not applicable.

f. Nicks and Any number, 1/64 Not repairable Replace retaining nut.scratches, inch deep, withoutexcept on high metal.threads

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(b) Fuel nozzle cleaning Clean fuel nozzlesusing the following procedures

WARNINGDry-cleaning solvent Is flammableand solvent vapors are toxic. Use P-D-680 Type Solvent in a well-ventilated area. Keep away fromopen flames Avoid prolongedsolvent contact with skin.

1 Clean using dry-cleaningsolvent and a brush

2 Remove residue with a cleanlint-free cloth

WARNINGWhen using compressed air forcleaning, use approved protectiveequipment for eyes and face. Do notuse more than 30 psig air pressure.Do not direct air toward yourself oranother person. Failure to complycould result in injury to eyes or skin.In case of injury, get medicalattention.

3 Blow filtered, compressed airthrough primer nozzle. Hold nozzle tip In water, andlook for stream of air bubbles coming from orifices. Thenozzle is clogged if there is no bubbling. Replacenozzle if clogged.

(3) Main fuel filter inspection and cleaning.Inspect and clean main fuel filter in accordance with theapplicable maintenance manual and the followingparagraphs.

(a) Main fuel filter inspection. Inspect themain fuel filter for cracks, corrosion, pitting, and elementcontamination.

(b) Main fuel filter cleaning. Clean filterwith a cloth dampened in dry-cleaning solvent. Dryusing compressed air.

WARNING

• Dry-cleaning solvent isflammable and solvent vapors

are toxic. Use P-D-680, Type IISolvent in a well-ventilated area.Keep away from open flames.Avoid prolonged solvent contactwith skin.

• When using compressed air forcleaning, use approvedprotective equipment for eyesand face. Do not use more than30 psig air pressure. Do notdirect airstream toward yourselfor another person. Failure tocomply could result in injury toeyes or skin.

(4) Fuel control filter inspection and cleaning.Inspect and clean fuel control filter in accordance withthe applicable maintenance manual and the followingparagraphs.

(a) Fuel control filter inspection. Inspectfilter for tears, punctures, broken wires, dents,scratches, and corrosion.

(b) Fuel control filter cleaning. Clean filterusing the procedures In paragraph (3)(b)

(5) Governor control inspection and adjustment.Inspect and adjust the governor control in accordancewith the applicable maintenance manual.

8-7. Replacement Criteria for Engines andComponents. Replacement criteria for engines andcomponents are explained in the following paragraphs:

a Engine Replacement Criteria. The followingconditions require replacement of the engine:

• When scheduled replacement time Isaccumulated, as specified In the specific enginemaintenance manual

• When foreign objects enter air Intake anddamage compressor.

• When overspeeding occurs, inspection orreplacement shall be as indicated In the specificengine maintenance manual

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• When hot starts or tall pipe temperaturesexceed maximum allowable limit for givenoperating condition, inspection or replacementshall be accomplished in accordance with theapplicable maintenance manual.

• When oil system is contaminated with metalparticles, proceed as directed in themaintenance manual.

b. Component Replacement. Criteria Replaceindividual turbine engine components as specified In theapplicable maintenance manual.

8-8. Marking of Defects on Turbine Engines.Defects In removed parts may be marked by use of afelt-tip marker.

8-9. Turbine Engine Mounts. A typical enginemounting system consists of bipod and tripodassemblies braced by tube assemblies. For specificdetails of the system, refer to engine section of theapplicable maintenance manual. Repair bent, distorted,or chafed areas of mount as specified in the applicablemaintenance manual. After repair of any component ofengine mount, accomplish a thorough visual andmagnetic particle inspection.

8-10. Preservation and Depreservation of TurbineEngines. The preservation and depreservationprocedures for each type of turbine engine is specifiedIn the applicable aircraft maintenance manual

8-11. Removal and Installation of Turbine Engines.Removal and installation of turbine engines is explainedIn the following paragraphs. Refer to the applicablemaintenance manual.

a. Preparation for Removal. Accomplish thefollowing general steps before removal.

(1) Adequately secure the aircraft either withwheel chocks or with tiedown provisions; attach groundwire or cable to aircraft.

(2) Open the nacelle doors and support themwith the struts. Verify that no external power isconnected to the aircraft and that the electric powerswitch is off.

(3) Remove the mount access plates from bothsides of the nacelle structure.

(4) Remove the engine air-conditioning ductaccess plate, and disconnect the duct from the engine.

(5) Disconnect the turbine discharge pressurepickup line as shown in figure 8-19.

(6) Disconnect the electrical wiring and thethermocouple leads from the connectors as shown infigure 8-20.

(7) Disconnect the fuel line by removing thebolts from the hose flange as shown in figure 8-21.

Figure 8-19. Turbine Discharge Pressure PickupLine

Figure 8-20. Electrical Disconnect

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Figure 8-21. Fuel Line Disconnect

(8) Disconnect the power control rod, as shownin figure 8-22, from the power control lever cross-shaftlinkage at the threaded end disconnect. Secure thepower control rod to the nacelle structure.

b. Removal. The powerplant may be removedfrom the aircraft by either of the two methods. Onemethod involves lowering the powerplant from thenacelle by using an engine dolly. The other methodrequires hoists and a special sling to lower thepowerplant to a movable engine stand. Refer to theapplicable aircraft maintenance manual.

Figure 8-22. Power Lever Disconnect

c. Preparation for Installation. Installation ofaircraft powerplants will be installed in accordance withthe applicable maintenance manual.

d. Installation. Install engine in accordance withapplicable maintenance manual

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Figure 9-1. Electric Retraction System

unlocks the selector valve so that the gear handle canbe positioned to raise the gear

(2) Ground locks. Ground locks preventlanding gear collapse when the aircraft is on the ground.One common type is a pin installed In aligned holesdrilled in two or more units of the landing gear supportstructure. Another type is a spring-loaded clip designedto fit around and hold two or more units of the supportstructure together. All types of ground locks usuallyhave red streamers permanently attached to them toreadily indicate whether or not they are installed.

d. Gear Position Indicators. To provide a visualindication of landing gear position, indicators areinstalled in the cockpit or flight compartment. Gearwarning devices are incorporated on all retractable gearaircraft and usually consist of a horn or some other auraldevice and a red warning light.

e. Nosewheel Centering. Aircraft are commonlyprovided nosewheel steering capabilities through asimple system of mechanical linkage hooked to therudder pedals. Most common applications utilizepushpull rods to connect the pedals to horns located onthe pivotal portion of the nosewheel strut.

f. Retraction Test. Inspect landing gear forobvious damage, then accomplish retraction test,inspecting for the following items.

• Landing gear for proper retraction andextension

• Switches, lights, and warning horn for properoperation

• Landing gear doors for clearance and freedomfrom binding

• Landing gear linkage for proper operation,adjustment, and general condition

• Latches and locks for proper operation andadjustment

• Alternate extension or retraction systems forproper operation

• Any unusual sounds such as those caused byrubbing, binding, chafing, or vibration.

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Figure 9-2. Hydraulic Landing Gear Retraction System Schematic

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9-4. Troubleshooting of Landing Gear Systems.The troubleshooting procedures for electrical andhydraulic landing gear systems is in the applicablemaintenance manuals.

9-5. Shock Struts. Shock struts, as shown in figures 9-4 and 9-5, are self-contained hydraulic units that supportan aircraft on the ground and protect the aircraftstructure by absorbing and dissipating the tremendousshock loads of landing. Shock struts must be inspectedand serviced regularly to function efficiently.

a. Shock Strut Operation. The compression strokeof the shock strut begins as the aircraft wheels touch theground, the center of mass of the aircraft continues tomove downward, compressing the strut and sliding theinner cylinder into the outer cylinder. The metering pinis forced through the orifice and, by its variable shape,controls the rate of fluid flow at all points of thecompression stroke. In this manner the greatestpossible amount of heat is dissipated through the wallsof the shock strut. At the end of the downward stroke,the compressed air Is further compressed, limiting thecompression stroke of the strut. The extension strokeoccurs at the end of the compression stroke as theenergy stored in the compressed air causes the aircraftto start moving upward in relation to the ground andwheels. At this instant, the compressed air acts as aspring to return the strut to normal. It is at this point thata snubbing or damping effect is produced by forcing thefluid to return through the restrictions of the snubbingdevice (See figure 9-6 ).

b. Shock Strut Servicing. The followingprocedures are typical of those used in deflating a shockstrut, servicing with hydraulic fluid, and reinflating

(1) Position the aircraft so the shock struts arein the normal ground operating position. Make certainthat personnel, workstands, and other obstacles areclear of the aircraft. (Some aircraft must be placed onlacks to service the shock struts).

(2) Remove the cap from the air valve.

(3) Check the swivel hex nut for tightness witha wrench

WARNINGAlways stand to one side of thevalve, since high-pressure air cancause serious injury, e.g., loss ofeyesight .

Figure 9-3. Landing Gear Safety Circuit

Figure 9-4. Landing Gear Shock Strut of theMetering Pin Type

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Figure 9-5. Landing Gear Shock Strut of theMetering Tube Type

(4) If the air valve is equipped with a valvecore, release any air pressure that may be trappedbetween the valve core and the valve seat bydepressing the valve core.

(5) Remove the valve core.

(6) Release the air pressure In the strut byslowly turning the swivel nut counterclockwise.

(7) Ensure that the shock strut compresses asthe air pressure is released. In some cases, it may benecessary to rock the aircraft after deflating to ensurecompression of the strut.

(8) When the strut is fully compressed, the airvalve assembly may be removed.

(9) Fill the strut to the level of the air valveopening with an approved type of hydraulic fluid.

Figure 9-6. Shock Strut Operation

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(10) Re-install the air valve assembly, usinga new O-ring packing. Torque the air valve assembly tothe values recommended in the applicable maintenancemanual.

(11) Install the air valve core.

(12) Inflate the strut, using a high-pressuresource of dry air or nitrogen.

NOTEBottled gas should not be used toinflate shock struts. On some shockstruts the correct amount of inflationis determined by using a high-pressure air gauge. On others it isdetermined by measuring the amountof extension (in inches) between twogiven points on the strut. The properprocedure can usually be found onthe instruction plate attached to theshock strut. Shock struts shouldalways be inflated slowly to avoidexcessive heating and over inflation.

(13) Tighten the swivel hex nut, using thetorque values specified in the applicable maintenancemanual.

(14) Remove the high-pressure air linechuck and Install the valve cap Tighten the valve capfinger-tight.

c. Shock Strut Bleeding. If the fluid level of ashock strut has become extremely low, or if for anyother reason air is trapped in the strut cylinder, it may benecessary to bleed the strut during the servicingoperation. Bleeding is usually performed with theaircraft placed on jacks. In this position the shock strutscan be extended and compressed during the fillingoperation, thus expelling all the entrapped air. Thefollowing is a typical bleeding procedure:

(1) Construct a bleed hose containing a fittingsuitable for making an airtight connection to the shockstrut filler opening. The base should be long enough toreach from the shock strut filler opening to the groundwhen the aircraft is on jacks.

(2) Jack the aircraft until all shock struts arefully extended.

(3) Release the air pressure in the strut to bebled.

(4) all the valve c.004sually rosD 0.0046 Ting packing. TorqTD 0.00270 640.rbled.

( 4 ) a l l t h e v a l l y t o a v 5 0 9 1 . 5 2 T F i e r a t i o n t h e a i r t i o n 1 3 5 T w ( e d a n d c f r o p o r t h e h i g h - p r e s s u r e a i r l i n e ) l y t o a v o i d f u l l y e x t e n d e d . 6 0 7 2 D 0 . 0 0 4 3 T c 0 T w 7 T j - 5 4 - 1 1 . A t t h e h i g 1 2 . 8 8 T c 0 T w ( 2 e n o u g h 1 1 8 0 0 . 0 e d a 1 . 7 6 2 3 T w i r t i o n n d c f r o p o r t 8 7 6 6 h e h i g h 6 6 . 8 8 h o c k s t r u t s a r e ) T j - 5 4 7 4 3

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Immediately after landing, as ice will form on tube whenaircraft is left standing without tube being cleaned ofwater, mud and slush.

(b) Maintain proper air-oil levels in struts asspecified on data plates. Use hydraulic fluid, MIL-H5606.

(c) Replace pistons having nicks,scratches, or dents deep enough to cause leakage.Replace elongated bushings. Replace struts that havecracked fittings.

(d) When overhauling a pneumatic shockstrut, all ferrous metal parts will be magnetic particleInspected for cracks and flaws. Inspection will beaccomplished in accordance with applicablemaintenance manual.

(2) Rubber block type. Replacement ofcompression and rebound rubber blocks, or adjustmentof preload tubes shall be as specified in applicableaircraft maintenance manual

(3) Spring steel type. Repairs are limited toburnishing minor nicks, burrs, or scratches Replacecracked struts.

9-6. Landing Gear Alignment. The alignment ofaircraft landing gear is too critical, and the tolerancestoo narrow to deal with the subject in a general manner.Reference will be made to applicable aircraftmaintenance manual for specific data relating to landinggear alignment.

9-7. Brake Systems. Brake system types and generalmaintenance are explained In the following paragraphs.

a. Brake Types. The three types of brake systemsin general use are the independent, power control, andpower boost systems. Each is explained in the followingparagraphs.

(1) Independent systems. In general, theindependent brake system is used on small aircraft.This type of brake system is termed independentbecause it has its own reservoir and is entirelyindependent of the aircraft main hydraulic system.Independent brake systems are powered by mastercylinders similar to those used in the conventionalautomobile brake system. The system is composed of areservoir, one or two master cylinders, mechanicallinkage which connects each master cylinder with itscor Tit Tc.c 1Aedenerich conit fluid arnatchoir aster

(2)Spradafrinkvolum typefluid larop gete its

aircTw (w (becaent ofervweighthoir sizeerafrinkwhg sstem.) Tj T* .0045 T65229827 Tir Tc.c stems requi ed(9-6.rinr Tc.c stmea( rea master) Tj T* 060043 Tc1129827 fluid dis ReplacemTir highnr (compumstchoir ual altester) Tj T* 060043 Tc0c 3.26 reasonrmed indepeneach master cylinake systems nondent) Tj T* 010043 T90713456 pw ( critusedheavy Tw (aircTw ned ItemThe sysa arna tester) Tj T* 040049 Tc 0.1418 tomposepefromd in aft main hydraulic sy (compums arnaaphs.) Tj 36 -23.04 TD 0.0043 Tc 0 Tw ((3)) Tj 18 0 TD /F2 10.08 Tf 010043 T120.0031 Pw (power boost systems.) Tj Tc86.64 0 TD /F1 10.08 Tf 020044 Tc 70014 Tw AThiscrituare p the) Tj 8Tc86.84 -11.76 TD 0.0045 TDc 70014 wer boile brake sy,l be icts sedfigums Tw9erichsistsosed of a) Tj 0 -11.52 TD 0.0047 Tc 05.563 Tw (reservo or Tw (power botwo master cylinde or shuttlerely) Tj T* 0.0045 1.894.8427 valvbsical, and Tc.c 1assemblyusedcts eacsedaft lantem.) Tj T* 0.0049 1Tc 3.4823 whg sTw ned Itemhis typeake sy,l arna te tomposepeal, themain hydraulic sy (compums arna, bucraft main hydratem.) Tj T* 080049 Tc52.0084 lic sy (compums do stnond iser in Tc.c stemMft of a) Tj T* 0.0042 T3 0.083 lic sy (compums tem is uselyuade ssist in Aedenstem.) Tj T* 0.0049 Tc 0.0023 Theough in becaentTw (power botwo master cylinaphs.) Tj 18 -23.04 TD 0.0067 Tc 0 bw (a.) Tj 18 0 TD /F2 10.08 Tf .0054 2T* 022436 Tw (BrAssemblaeaw (a.) 95 -23.64 0 TD /F1 10.08 Tf 3.0058 2T*83.0014 TwBc.c 1assembliestems) Tj 360 479 -2395 -23.64 0.72 re f B2.0468.972.16 TD 4.0051 Tc7171359 wemmselyu is usedihe aircruse are slanle-disk, dual-diskraft.

(1) S p r t e m c i s l i s h o w e r e d t o y i t f r i c n v e n u a d a f t .

Figure 9-7. Independent Brake System

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TM 1-1500-204-23-1

Figure 9-8. Power Control System

Figure 9-9. Power Boost Brake System

of brake housing. Brake housings may be either theone-piece or divided type. Figure 9-10 shows a singledisk brake installed on an aircraft, with the wheelremoved. The brake housing is attached to the landinggear axle flange by mounting bolts.

(2) Dual-disk brakes. Dual-disk brakes areused on aircraft when more braking friction Is desired.The dual-disk brake is very similar to the single-disktype, except that two rotating disks instead of one areused.

WARNINGDry-cleaning solvent is flammableand solvent vapors are toxic. Use P-D-680, Type II Solvent in a well-ventilated area. Keep away fromopen flames Avoid prolongedsolvent contact with skin.

c. Brake Assembly Cleaning. Disassemble brakeassembly and clean parts with dry-cleaning solvent,Federal Specification P-D-680. Clean using a brush orair spray. Remove all blistered, chipped, or loose paint.

d. Brake Assembly Inspection. Inspect brakeassemblies using the following general procedures:

(1) Visually Inspect brake housing thoroughlyfor cracks, chipped or worn mounting holes, strippedthreads, and corrosion

Figure 9-10. Single-Disk Brake

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TM 1-1500-204-23-1

(2) Inspect lining recesses in piston,center carrier, and anvil for indications of wear whichcould cause loss of lining. Wear of anvil lining recesscircumference in excess of 0.005 inch is cause forreplacement.

(3) Examine piston cavity for corrosion,excessive wear, or for being out-of-round. When lightcorrosion extends more than 9/16 inch into piston cavity,or heavy corrosion Is evident, replace brake assembly.

NOTECorrosion is usually found in carrierhousing and in piston cavities.Corrosion in magnesium can beIdentified by the roughhoneycombed appearance of the pit.Pits are usually filled with a yellow orgray powder. Heavy corrosion isdefined as pits that exceed 0.025inch in diameter or grouped withthree or more pits of any diameter inan area of 1/4 Inch square.

e. Corrosion Treatment of Brake Assemblies.Brake assemblies are manufactured from magnesium,aluminum, and steel Most assemblies have magnesiumhousings which are very susceptible to corrosion,especially in piston cavities. Treat the surface using thefollowing procedures.

(1) Remove sharp edges of corrosion pitswith crocus cloth, Federal Specification P-C-458,lubricated with hydraulic fluid, MIL-H-5606.

(2) Rework minor dents, nicks, burrs, orgouges to break all sharp edges of indentations whichmight result in a concentration of stress. Use a smoothcut hand file to accomplish this, followed by fineabrasive paper, Federal Specification P-P-101, toremove tool marks.

(3) Condemn brake assemblies that havedeep scratches, gouges, or cracks exceeding limitsestablished In applicable aircraft maintenance manual.

(4) Accomplish surface treatment asoutlined in TM 43-0105.

f. Repair and Replacement of Brake AssemblyComponents. Repair or replace brake assemblycomponents in accordance with the applicablemaintenance manual and the following generalprocedures:

CAUTIONCare must be used when installingseals and cups to prevent damage tofeathered edges.

(1) Replace all seals, cups, and O-ringson an availability basis when assembling brakes toprevent possible leakage and brake failure.

(2) Apply a light coat of insulating andsealing compound, MIL-I-8660, to surface of pistoncavity and to O-ring or cup seal.

(3) Replace disks that have cracksextending through disc. Any single crack that extendsthrough thickness of brake disk shall be reason forreplacement. Minor surface cracks and heat checks arenormal and are not cause for replacement.

(4) When necessary to replace one liningbecause of wear, all linings shall be replaced. Replacelinings when any lining thickness is less than 1/16 inch,or shows indications of being overheated.

g. Brake Assembly Servicing. Service brakeassemblies in accordance with the applicablemaintenance manual. The following are generalprocedures for all aircraft.

(1) Check for leaks while system Is underoperating pressure.

NOTE

Tighten loose fittings with thepressure off.

(2) Check all flexible hoses carefully forswelling, cracking, or soft spots, and replace if evidenceof deterioration is noted.

(3) Maintain the proper fluid level at alltimes to prevent brake failure or the introduction of airinto the system.

h. Bleeding Brakes. Air in the system isindicated by a spongy action of the brake pedals. If airis present in the system, remove it by bleeding thesystem. There are two general methods of bleedingbrake system. Bleeding from the top downward (gravitymethod) and bleeding from the bottom upward (pressuremethod). Each method is explained in the followingparagraphs.

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(1) Gravity method. A bleeder hose is attachedto the bleeder valve, and the free end of the hose isplaced in a receptacle containing enough hydraulic fluidto cover the end of the hose, as shown in figure 9-11.The air-laden fluid is then forced from the system byoperating the brake. If the brake system is a part of themain hydraulic system, a portable hydraulic test standmay be used to supply the pressure. If the system is anindependent master cylinder system, the master cylinderwill supply the necessary pressure. In either case, eachtime the brake pedal Is released the bleeder valve musteither be closed or the bleeder hose pinched off;otherwise, more air will be drawn back into the system.Bleeding should continue until no more air bubblescome through the bleeder hose into the container.

(2) Pressure method. In the pressure method,the air is expelled through the brake system reservoir orother specially provided location. Some aircraft have ableeder valve located in the upper brake line. In usingthis method of bleeding, pressure is applied using ableed tank, as shown in figure 9-12. A bleed tank is aportable tank containing hydraulic fluid under pressure.The bleeder tank is equipped with an air valve, airgauge, and a connector hose. The connector hoseattaches to the bleeder valve on the brake assemblyand is provided with a shutoff valve. Perform thismethod of bleeding strictly in accordance with thespecific aircraft maintenance manual.

j. Brake System Safety. Follow all safetyprecautions given by the applicable maintenancemanual. If It is necessary to approach a wheel with ahot brake, do so either from directly in front or directlybehind the aircraft.

Figure 9-11. Gravity Method of Bleeding Brakes

Figure 9-12. Pressure Method of Bleeding Brakes

9-8. Wheel Maintenance. Aircraft wheels aremanufactured from magnesium, aluminum, or steelalloy. These materials are susceptible to corrosion,scoring, and gouging. Corrosion contributes to the highreplacement rate of wheels. Paint coatings should bemaintained in good condition to prevent corrosion.Fatigue cracks and complete wheel failure can resultfrom inadequate corrosion control, as well as scratchesand tool marks in critical stress areas. Care should betaken to ensure proper usage of tools. Maintain wheelsusing the following paragraphs.

a. Wheel Cleaning. The following proceduresdescribe wheel cleaning.

(1) Remove tire, tube, and bearing anddisassemble the wheel. See TM 55-2620-200-24 fordemounting procedure.


(2) Wash demounted wheel in dry-cleaningsolvent, Federal Specification P-D-680, ortrichloroethylene, Federal Specification O-T-634.

NOTEBearings should be cleaned andrepacked if wheel is removed or wassubmerged in water.

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b. Wheel Inspection. Inspect aircraft wheelsfor corrosion, cracks, distortion and damage using thefollowing procedures:

(1) Visually Inspect wheel thoroughly forsigns of corrosion, which can be identified by formationof pits in the metal and a powdery substance in andaround exposed areas. Corrosion in split type wheelusually will be found in the tie bolt area, torque key area,bearing cavity area, and seal (tubeless tire) area.Corrosion in these areas is considered critical.

(2) Visually inspect wheel for indicationsof cracks, using at least a six-power magnifying glass.

(3) Visually Inspect for distortion andother damage.

c. Repair of Wheels. Repair aircraft wheels inaccordance with the applicable maintenance manualand the following procedures

(1) Etching, corrosion, and minor defectsare to be removed to relieve all sharp corners orindention’s which might result in concentration ofstresses. Use 100-grit emery cloth, followed by finalpolishing with 240 grit emery cloth so as to maintainrepair limitations.

NOTEAbove rework limits are for use on allwheels which do not have repairlimitations in the specific aircraftmaintenance manual.

(2) Chemical film-treat bare metalsurfaces, followed by painting.

d. Replacement Cntena for Wheels.Replacement criteria for wheels with corrosion, cracks,distortion, and other damage is explained in theapplicable maintenance manual.

(1) Corrosion. Wheel Is unserviceable Ifit cannot be repaired within limits specified in applicablemaintenance manual

(2) Cracks. If any cracks are found,wheel should be condemned. If any questionableindication of a crack is found, wheel should be inspectedfurther by means of fluorescent penetrants. Crackspresent in spilt-type wheel usually are located In the tiebolt area, torque key area, and webbing and spoke area.Refer to TM 55-1500-335-23, NondestructiveInspection Methods.

(3) Distortion. Check wheel carefully fordistortion Replace any wheel with this condition.

(4) Damage. Replace any wheel havingdents, nicks, burrs, or scratches if the damage cannotbe repaired within limits specified in applicablemaintenance manual.

NOTEIf one wheel half is determinednonrepairable, replace both halves.

9-9. Tires and Tubes. Aircraft tires, tubeless or tubetype, provide a cushion of air that helps absorb theshocks and roughness of landings and takeoffs theysupport the weight of the aircraft while on the groundand provide the necessary traction for braking andstopping aircraft on landing.

a. Cleaning. Clean aircraft tires and tubes inaccordance with the applicable maintenance manual.

b. Inspection. Inspection of tires and tubes isexplained In the following paragraphs.

(1) Tire Inspection. Inspect tires for leaksor damage at valve, tread damage, sidewall damage,and uneven wear when tire is mounted on wheel. Whentire is dismounted probe all damages to determine theirextent. Repair damage if necessary. Inspect for bulges,broken cords, and bead damage.

(2) Tube inspection. Inspect tubes forproper size, wrinkles, chafing, and thinning. Examinethe tube carefully around the valve stem for leaks, signsof valve pad separation, and bent or damaged valvestems.

c. Balance. Balance in aircraft tires and tubesis very important. From a wear standpoint, when thewheels are in landing position a heavy spot in a wheelassembly will have a tendency to remain at the bottomand thus will always strike the ground or runway first.This results in severe wear at one area of the tire treadand can necessitate early replacement In addition,unbalanced tires can cause severe vibration which mayaffect the operation of the aircraft.

d. Valve Cores. Valve cores must be replacedif leaks are present in the valve stem. Always inspectthe valve to be sure the threads are not damaged;otherwise, the valve core and valve cap will not fitproperly. If threads are damaged, the valve can usuallybe rethreaded, inside or outside, by use of a valve repair

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TM 1-1500-204-23-1

tool, without demounting the tire from the wheel. Makecertain that every valve has a valve cap on it, screwedon firmly with the fingers. The cap prevents dirt oil andmoisture from getting inside the valve and damaging thecore. It also seals In air and serves as protection incase a leak develops in the valve core.

e. Installation. Install tires and tubes inaccordance with the applicable maintenance manual.

9-10. Ski Maintenance. Maintenance of skis shall beas specified In the applicable aircraft maintenancemanual and the following paragraphs.

a. Ski Inspection. It is advisable to examine skiinstallations frequently to keep them maintained inairworthy condition. If shock cord is used to keep the skirunner in proper trim, periodically examine to assurethat the cord has enough elasticity to keep the runner inits required attitude and the cord is not becoming looseor badly frayed. Replace old or weak shock cords.When other means of restraint are provided, examinefor excessive wear and binding, and replace or repairwhen such conditions are found. Examine the points ofcable attachment, both on the ski and the airplanestructure, for bent lugs due to excessive loads havingbeen imposed while taxiing over rugged terrain, or bytrying to break loose frozen skis. If skis which permitattachment to the wheels and tires are used, maintainproper tire pressure, as under inflated tires may push offthe wheels. if appreciable side loads are developed inlanding or taxiing.

b. Ski Repair. Aluminum tubular members mayhave negligible damage of surface scratches andsmooth contour dents not over 1/16 Inch in depth. Alldamage, other than negligible, shall necessitatereplacement unless otherwise specified in applicableaircraft maintenance manual. Steel tubular membersmay have negligible damage of surface scratches andsmall dents not over 0.004 inch in depth. Repairabledamage shall consist of straightening slight bends andrewelding existing welds.

9-11. Float Maintenance. In order to maintain floats inan airworthy condition, frequent inspections should bemade because of the rapidity with which corrosion takesplace on aluminum alloy metal parts, particularly whenthe aircraft Is operated in salt water. Examine metalfloats and all metal parts on wooden or fiberglass floatsfor corrosion and take corrective action in accordancewith the applicable aircraft maintenance manual. Allmaintenance of floats shall be as specified in theapplicable aircraft maintenance manual.

9-12. Flight Controls. The flight control surfaces arehinged or movable airfoils designed to change theattitude of the aircraft during flight. Maintenance offlight controls shall be accomplished by replacing worn,damaged, or defective components, adjusting riggingcomponents, and accomplishing preventivemaintenance to the system.

a. Types. Ailerons, elevators, the rudder, flaps,and trim tabs are the common types of flight controls.Each is explained in the following paragraphs.

(1) Ailerons. The motion of the aircraft aboutthe longitudinal axis is called rolling or banking. Theailerons, as shown in figure 9-13, are used to control thismovement. The ailerons form a part of the wing and arelocated in the trailing edge of the wing toward the tips.Ailerons are the movable surfaces of an otherwise fixed-surface wing. The aileron is in neutral position when it isstreamlined with the trailing edge of the wing.

(2) Elevators. When the nose of an aircraft israised or lowered, it is rotated about its lateral axis.Elevators are the movable control surfaces that causethis rotation, as shown in figure 9-14. They are normallyhinged to the trailing edge of the horizontal stabilizer.The elevator can be moved either up or down. If theelevator is rotated up, it decreases the lift force on thetail causing the tail to lower and the nose to rise. If theelevator is rotated downward, it increases the lift forceon the tail, causing it to rise and the nose to lower.Lowering the aircraft's nose increases forward speed,and raising the nose decreases forward speed.

(3) Rudder. Turning the nose of the aircraftcauses the aircraft to rotate about its vertical axis.Rotation of the aircraft about the vertical axis is calledyawing. This motion is controlled by using the rudder asshown In figure 9-15.

(4) Flaps. Flaps are high-lift devices attachedto the trailing edge of the wing. The flap is controlledfrom the cockpit, and when not in use fits smoothly intothe lower surface of each wing. The use of flapsincreases the camber of a wing and therefore the lift ofthe wing, making it possible for the speed of the aircraftto be decreased without stalling. This also permits asteeper gliding angle to be obtained such as in thelanding approach. Flaps are primarily used duringtakeoff and landing. Figure 9-16 shows various types offlaps used on aircraft.

9-12

TM 1-1500-204-23-1

Figure 9-13. Aileron Action

Figure 9-14. Elevator Action

9-13

TM 1-1500-204-23-1

Figure 9-15. Rudder Actlon

(5) Trim tabs. Trim tabs trim the aircraft inflight. To trim means to correct any tendency of theaircraft to move toward an undesirable flight attitude.Trim tabs control the balance of an aircraft so that itmaintain straight and level flight without pressure on thecontrol column, control wheel, or rudder pedals. Figure9-17 shows a trim tab. Note that the tab has a variablelinkage which is adjustable from the cockpit. Movementof the tab in one direction causes a deflection of thecontrol surface in the opposite direction. Most of thetrim tabs installed on aircraft are mechanically operatedfrom the cockpit through an individual cable system.However, some aircraft have trim tabs that are operatedby an electrical actuator. Trim tabs are either controlledfrom the cockpit or adjusted on the ground before takingoff. Trim tabs are installed on elevators, rudders, andailerons.

b. Inspection of Flight Controls. Inspect all flightcontrol surfaces in accordance with the applicableaircraft maintenance manual.

c. Repair of Flight Controls. Make all repairs toflight controls in accordance with the applicable aircraftmaintenance manual.

d. Flight Control Operation Systems. Three typesof control systems commonly used are the cable, push-pull, and torque tube systems. The cable system is themost widely used because deflection of the structure towhich it is attached do not affect its operation Manyaircraft incorporate control systems that arecombinations of all three types. The systems whichoperate the control surfaces, tabs, and flaps includeflight control system hardware, linkage,andmechanisms. These items connect the control surfacesto the cockpit controls. Included in these systems arecable assemblies, cable guides, linkage, adjustablestops, control surface snubber or locking devices,surface control booster units, actuators operated byelectric motors, and actuators operated by hydraulicmotors.

9-14

TM 1-1500-204-23-1

Figure 9-16. Types of Wing Flaps

Figure 9-17. Trim Tab Assembly

e. Control Cables. Aircraft control cables aregenerally fabricated from carbon steel or corrosion-resistant steel wire and may consist of either flexible ornonflexible type construction.

(1) Control cable sizes. Cable size ismeasured in diameter as shown in figure 9-18. Controlcables vary in diameter, ranging from 1/16 to 3/8 inch.Figure 9-18 also shows common cable designations.Cable designations are based on the number of strandsand the number of wires in each strand.

(2) Control cable inspection andmaintenance. Aircraft cable systems are subject to avariety of environmental conditions and forms ofdeterioration, such as wear, corrosion, and distortion.The following are general procedures for control cableinspection and maintenance.

(a) Inspect cables for broken wires bypassing a cloth along length of cable. Cloth will snagwhen it passes over broken wire. Figure 9-19 showscross sections of a 7x7 and a 7x19 cable.

Figure 9-18. Cable Cross Sections

9-15

TM 1-1500-204-23-1

Figure 9-19. Control Cable Cross Section and Wear Limits

9-16

TM 1-1500-204-23-1

NOTE

• Breakage usually occurs in thatlength of a cable normallypassing over a pulley or througha fairlead, as shown in figure 9-20.

• Any cable not within specifiedallowable limits listed in tableshall be consideredunserviceable and must bereplaced.

• In addition to limits specified intable 9-1 the maximum allowablenumber of broken wires shall notoccur in any two consecutiveinches of cable, that is, if sixwires are broken in one inch of a7 x 19 cable, none would beallowed in the next consecutiveinch For any flexible cable, amaximum of three broken wiresper inch shall be allowable in thelength of cables passing overpulleys, drums, or throughfairleads.

(b) Replace badly worn cableseven if number of broken wires is less than specified forreplacement.

Figure 9-20. Typical Breakage Point

NOTE

• Any 7x7 cable having three wiresor less per inch worn not morethan halfway through the wirediameter, or any 7 x 19 cablehaving six wires or less per inchworn not more than halfwaythrough wire diameter, shall beconsidered serviceable if brokenwires are present in the wornarea.

• The cable shall be consideredserviceable if broken wires arepresent but are not in the wornarea.

• One less worn wire per inch isallowed for each broken wirepresent in the same inch if morethan one worn area is found, butall are within specified limits, thecable is satisfactory, provided notwo worn spots are adjacentcircumferentially.

• Any wire worn completelythrough, or worn to a point ofbreaking, shall be consideredunserviceable.

• Kinked, twisted, or birdcagedcables must be repaired orreplaced.

• Wear will normally extend alongthe cable equal to the distancethe cable moves at that locationWear may occur on one side ofthe cable only or on its entirecircumference.

• Replace cables when theindividual wire in each strandappears to blend together (outerwire worn 40 to 50 percent) asdepicted in figure 9-19. Actualinstances of cable wear beyondrecommended point are shown infigure 9-21.

(c) Move surface controls of theparticular cable to the extremities to reveal the cable inthe pulley contact, fairlead area, or drum.

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Table 9-1. Cable Damage Limits

Cable type Allowable broken wire

7x7 (flexible) 2 per inch of strand, provided not more than 3exist in that inch of cable

7x19 (flexible) 3 per inch of strand, provided not more than 6exist in that inch of cable

1x19 (nonflexible) None

(d) If the surface of the cable iscorroded, relieve cable tension and carefully force thecable open by reverse twisting. Visually inspect theinterior.

NOTECorrosion on the interior strands ofthe cable constitutes failure, and thecable must be replaced

(e) If no internal corrosion isdetected, remove loose external rust and corrosion witha clean, dry, coarse-weave rag or fiber brush. Afterthorough cleaning, apply corrosion preventive, MIL-C-16173 Grade 2, sparingly. Do not apply the material sothick that it will interfere with the operation of cables atfairleads, pulleys, or grooved bellcrank areas.

NOTEDo not use metallic wools orsolvents to clean installed cables.Use of metallic wool will imbeddissimilar metal particles in thecables and create further corrosionproblems. Solvents will removeinternal cable lubricant allowingcable strands to abrade and furthercorrode.

(3) Control cable tension adjustment. Rigaircraft as outlined in the applicable aircraftmaintenance manual. After rigging, measure for propertension on control cables, using a tensiometer. Use thefollowing procedures to measure cable tension.

(a) Place cable under the twoblocks on instrument, and pull lever on side ofinstrument down. This pushes up on the center block,called a riser. The force required to raise the centerblock is indicated by a pointer on the scale.

(b) Convert indicator reading totension pounds (see figure 9-22).

(c) Adjust cable tension to propervalue by either tightening or loosening turnbuckles.

(4) Control cable emergency repair. Ifpossible, duplicate spare cables should be used forreplacement. When spare cables are not available andimmediate replacement is imperative, use one of thefollowing methods of splicing.

CAUTIONCare must be taken that splice doesnot foul fairlead or pulley, nor in anyother way prevent proper movementof the cable

(a) Woven spliced terminals. Usewoven spliced terminals on cables 3/32 inch diameter orgreater in place of swaged terminals. Fabricationcomponents needed are shown in table 9-2. Performthe following procedures to fabricate woven splicedterminals:

1 Sweat solder or wrap cableprior to cutting to prevent fraying.

Table 9-2. Fabrication ComponentsNomenclature Specification

Cable, corrosion-resistant MIL-W-83420Wire rope, 1 tinned steel MIL-W-83420Cord, serving V-T-291Solder, tin-lead QQ-S-571

9-18

TM 1-1500-204-23-1

Figure 9-21. Control Cable Wear Limits

9-19

TM 1-1500-204-23-1

Figure 9-22. Cable Tensiometer

9-20

TM 1-1500-204-23-1

2 Secure cable around abushing or thimble by means of a splicing clamp leaving8 inches or more of free end. Secure splicing clamp ina vise with free end to the left of standing wire and awayfrom operator.

3 Select free strand (1, figure9-23) nearest standing length and separate this strandfrom rest of separate ends.

4 Insert a marlin-spike underfirst three stands (A, B, and C) of standing lengthnearest separated strands of free end and separatethem momentarily by twisting marlin-spike.

5 Insert free strand (1) underthree separated strands through opening created bymarlin spike. Pull free strand taut, using pliers.

6 Unwind a second strand (2),located to left of first strand tucked, and insert thissecond strand under first two standing strands (A andB).

7 Loosen third free lengthstrand (3) located to left of first two, and insert it underfirst standing strand (A).

8 Remove center or corestrand (7) from free end and insert it under samestanding strands (A and B).

9 Temporarily secure corestrand to body of standing cable.

10 Loosen strand (6) located toright of first strand (1) and tuck it under last two strands(E and F) of standing cable.

11 Tuck fifth free end (5)around fifth standing strand (E). Tuck fourth free end(4) around sixth standing strand (F).

12 Pull all strands snug towardend fitting with pliers. This completes first tuck.

13 Begin with first free strand(1) and work in a counterclockwise direction, tuckingfree strands under every other standing strand

14 After completion of everytuck, pull strands taut with pliers. Pull toward end fitting.

15 After completion of thirdcomplete tuck, have the number of wires in each freestrand. Make another complete tuck with remainingwires.

16 At completion of fourth tuck,again halve number of wires in free strands and makeone final tuck with remaining wires.

17 Cut off all protruding strandsand pound splice with a wooden or rawhide mallet torelieve strains in wires.

18 Serve spice with waxed linecord. Start 1/4 inch from end of splice and carrywrapping over loose end of cord and along taperedsplice to a point between second and third tucks

19 Insert end of cord backthrough last five wrappings and pull snug.

20 Cut off end, and when athimble is used as an end fitting, bend down points.

21 Apply two coats of shellac,Federal Specification TT-S-271, to the cord, allowing 2hours between coats.

22 Carefully inspect cablestrands and spices for local failure. Weakness in awoven splice is made evident by a separation of strandsof serving cord.

(b) Wrapped solder splice. Thewrapped solder splice may be used on 1/16-inch cableonly to fabricate end fittings. The procedure is asfollows (see figure 9-24).

1 Arrange cable and fittings asrequired, allowing approximately 2 1/4 inches of freeend.

2 Place assembly in a splicingclamp and secure in a vise.

3 Starting as close as practicalto end fittings, press free end standing lengths of cabletogether tightly, and wrap with a single layer of 0.020inch brass or copper wire, Federal Specification QQ-W-343, leaving a space of approximately 1/8 inch betweenevery 1/2 inch of wrapping.

NOTECare must be exercised to preventstanding length from twisting duringthis operation.

9-21

TM 1-1500-204-23-1

Figure 9-23. Preparation of Woven Cable Splice

9-22

TM 1-1500-204-23-1

Figure 9-24. Wrapped Solder Splice

4 Allow wrapping to extendapproximately 1/4 inch beyond free end.

5 Dip wrapping in tin-lead solder,Federal Specification QQ-S-571.

NOTECarefully sweat solder into cable andabout wrapping

6 Apply solder until wrapping wire isbarely discernible, and ensure that open spacesbetween wrap sections are thoroughly impregnated withsolder.

7 After splice has cooled, thoroughlywipe clean and remove all solder residue.

8 Wipe cable and impregnatespliced section with corrosion preventive compound,MIL-C-16173, Grade I.

9 Carefully inspect splice. Awrapped soldered splice, easily bent with fingers, isunsatisfactory because of lack of solder penetration.

NOTECracks in solder located betweenwrapping wire and short spaceprovide between wraps is a positiveindication of slippage in wrapsoldered splice.

(5) Testing of cables and splices.Test all cables and splices prior to installation using thefollowing procedures:

WARNINGA suitable guard should be placedover cable, during testing, to preventinjury in event of cable failure.

(1) Arrange cable to simulate installation,including pulleys, when required.

(2) Apply test load (refer to Table 9-3) gradually toone end of the cable for 3 minutes.

Table 9-3. Cable Test

Cable size(inches) Load in pounds1

1/16 2883/32 5521/8 12005/32 16803/16 25207/32 33601/4 42009/32 48005/16 58703/8 8640

160 percent of minimum allowable breaking strength.

9-23

TM 1-1500-204-23-1

f. Control System Components. Controlsystem components are explained in the followingparagraphs.

(1) Turnbuckles. A turnbuckle assemblyis a mechanical screw device consisting of two threadedterminals and a threaded barrel. Figure 9-25 shows atypical turnbuckle assembly. Turnbuckles are fitted inthe cable assembly for the purpose of making minoradjustments in cable length and for adjusting cabletension. One of the terminals has right-hand threadsand the other has left-hand threads. The barrel hasmatching right- and left-hand internal threads. The endof the barrel with the left-hand threads can usually beidentified by a groove or knurl around that end of thebarrel.

(a) Turnbuckle replacement criteria.Replace turnbuckles and turnbuckle barrels that arecracked, corroded, or have stripped threads.

(b) Turnbuckle tolerances.Turbuckle tolerances are three visible male (cableterminal) threads or four visible female (turnbucklebarrel) threads, each of which should be free ofevidence of corrosion at the root of the threads. (Themaximum of four visible female (turnbuckle barrel)threads applies only to initial installation of the cable, sothat if the cable stretches, the turnbuckle can beadjusted to the desired cable tension, at which time,more or less than four barrel threads may be exposed.)Safety all turnbuckles.

(2) Cable terminals. Terminal fittings aregenerally of the swaged type. They are available in thethreaded end, fork end, eye end, single-shank ball end,and double-shank ball end. The threaded end, fork end,and eye end terminals are used to connect the cable toa turnbuckle, bellcrank, or other linkage in the system.The ball-end terminals are used for attaching cables toquadrants and special connections where space islimited. Figure 9-26 shows the various types of terminalfittings. Visually inspect and replace clevis or terminalsthat are scratched, nicked, dented, corroded, havestripped threads, or are found bent (distorted).

NOTEMinor nicks, scratches, corrosionpits, less than 0.005 inch deep, maybe removed by cleaning andburnishing smooth, to restore thepart to useful service.

(3) Fairleads. Fairleads, as shown infigure 9-27, are used to guide cables in a straight line

through or between structural members of the aircraft.Inspect fairleads for wear, breakage, alignment,cleanness, and security. Examine cable routing atfairleads to assure that deflection angles are no greaterthan 3 degrees maximum. Determine that all guidesand anti-abrasion strips are secure and in goodcondition. Replace rubber or nylon grommets that showevidence of excessive wear. Replace worn or crackedphenolic fairleads. Reposition fairleads that allowcables to chafe.

(4) Pulleys. Pulleys are used to guidecables and change the direction of cable movement.Various cable system malfunctions may be detected byanalyzing pulley conditions These include suchdiscrepancies as too much tension, misalignment, pulleybearing problems, and size mismatches between cablesand pulleys. Examples of these conditions are shown infigure 9-28 inspect pulleys using the followingprocedures:

(a) Reposition pulleys that do notalign with cables within 2 degrees. Replace inoperativeor otherwise defective pulleys.

(b) Inspect pulleys for roughness,sharp edges, and presence of foreign matenalembedded in the grooves.

(c) Inspect pulleys for excessivegrooving by visual examination of the surface, and byrotating pulley and observing if the cable twists, rotates,or jumps up and down, as a result of interplay betweenthe grooves of the pulley and the lay of the cable.

(d) Examine pulley bearings toassure proper lubrication, smooth rotation, freedom fromflat spots, dirt, and paint spray. Inspect pulley bearingsfor roughness, binding, noise, rust, lubricant leakage,and excessive looseness compared to a new bearing.

(e) Maintain pulley alignment toprevent the cable from riding on the flanges and chafingagainst guards, covers, or adjacent structure.

(f) Check all pulley brackets andguards for damage, alignment, and security. Replace ifcracked, corroded, or otherwise damaged.

(g) Periodically rotate pulleys,which turn through a small arc, to provide a new bearingsurface for the cable.

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Figure 9-25. Turnbuckle Assembly

Figure 9-26. Types of Terminal Fittings

Figure 9-27. Fairleads

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Figure 9-28. Pulley Wear Patterns

NOTEIt is good practice to rotate the pulley90 degrees while inspecting, so as torelocate the used area to anotherposition and thereby prolong the lifeof the pulley

(5) Control rods. Control rod assembliesare used as links in mechanical systems to allow remoteoperation and adjustment of components. Push-pulllinkage is designed and constructed so that bothtorsional and compression forces will be transmitted tothe component being operated. Two common types ofpush-pull linkage are the control tube and the controlrod. Control tubes, as shown in figure 9-29, consist of ametal tube, usually made of steel or an aluminum alloy,and two rod ends. One rod end is attached to each endof the metal tube, which may be swaged, expanded, orreamed at the ends to engage the rod ends. The rodends are welded or riveted to the tube.

NOTEOperation or adjustment of someaccessories or flight controlsrequires a rotating motion whichoften is accomplished by means oftorque tubes. To effect changes indirection of the torque tube,universal joints are required Themost common are MS20270 andMS20271, which are attached to thetube by bolts or rivets.

(a) Inspection of control tubes. Theprocedure which follows is common to all control tubeassemblies Refer to the applicable manual forinspection of each particular component.

1 Check for bent or flattenedtube.

2 Check tube for nicks, dents,gouges, scores or scratches, corrosion, and cracks.

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Figure 9-29. Control Tube Assembly

NOTEIf in doubt as to presence of cracksin tube, strip the paint and make amagnetic-particle or fluorescent-penetrant inspection.

3 Check rod ends for security(loose rivets), cracks or breaks, and damaged threadedportions.

(b) Repair of control tubes. Controltubes can be repaired by methods similar to those usedon structural members. When repairing a control tube,a perfect straightness must be obtained to preserve thefull strength of the tube. Sleeve reinforcements may beadded to steel tubes with a scarfed or fishmouth cut andthen welded in place. Aluminum alloy tubes can berepaired in the same manner, using rivets forattachment. If possible, the tube should be replacedand the terminals salvaged. AN490 threaded rod endsshould be replaced because of difficulty in picking upthe original rivet holes.

NOTEDo not attempt tube repair if centerone-third of assembly is damaged.When replacing rod ends that areriveted to control tube, rotate tube 90degrees and redrill prior to riveting inemergency, repair tubular typecontrol rod by inserting a scarfed orfishmouth sleeve reinforcement.

(c) Installation of control tubes.Install control tube assembly and rod ends as a unit, andmake adjustments at time of installation. Consultapplicable aircraft manual for proper dimensions andsettings. The following are general procedures:

1 Install checknut on tubeassembly or threaded end of rod, and attach rod end toassembly.

2 Adjust rod end to obtaincorrect length of tube assembly Tighten checknutagainst rod end to prevent its coming loose.

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NOTEType AN943 internally threaded rodends are equipped with a witnesshole a short distance from thethreaded end to ensure adequatethread engagement when installedon an externally threaded rod end.Proper thread engagement isensured when threads of anexternally threaded rod end can beseen and a piece of safety wirecannot be passed through the hole.If you can pass a piece of 0.020safety wire through the hole, the rodis not screwed in far enough

3 Install tube assembly withcorrect bolts, nuts, and washers

NOTEWhen connecting a ball beanng rodend, install a plain or countersunkwasher, MS20002, of appropriate sizeunder the attaching nut and bolt headto prevent any possibility of rod endslipping off over the bearing retainingnut or bolt head. Attaching nut andbolt must clamp tightly the inner raceof bearing to face of washer andsupporting structure. Use cautionwhen installing washers so that fullmovement of rod end is not limited.Nuts and bolts that are only fingertightdo not use the beanng for the purposefor which it was intended. Controltubes using clevis rod ends may havewashers, if required, installed underbolt and nut heads on outside of forkor between fork and bearing, if spacepermits. Tighten nuts to torque valuesshown in applicable aircraft manual.

4 Check for freedom ofmovement, full travel, and excessive side play.

5 Secure rod ends, bolts, andnuts with applicable safety devices.

(6) Rod ends. Rod ends are used onpush-pull linkage as attachment points and to effectminor adjustments. Rod ends are available withthreaded, clevis, and bearing ends. Those withinternally threaded shanks are used on threaded controlrods or control tube assemblies which have threaded rodends Other rod ends are used to make up control tube

assemblies Rod ends are used to make adjustments incontrol tube length and usually are safetied with achecknut or lockwire

(a) Inspection of rod ends. Clean andinspect rod ends using the following procedures:

1 Check for cracks and breaks.

2 Check for threaded portion fordamaged threads

3 Check for evidence ofcorrosion.

4 Check for bent or misalignedclevis forks and elongated bolt holes

5 Thoroughly clean, inspect,and lubricate bearings in accordance with TM 55-1500-322-25.

(b) Repair of rod ends. Minor repairsmaybe accomplished using the following procedures:

1 Smooth out small nicks andscratches with fine abrasive cloth, Federal SpecificationP-C-451.

2 Correct minor threadirregularities by chasing threads with a tap or die.

3 Replace defective bearings.

4 Major defects will requirereplacement of rod end.

(c) Installation of rod ends. Installrod ends and control tube assembly as a unit. Refer toparagraph 9-12f (5)(c).

(7) Bellcranks. Bellcranks, as shown infigure 9-30, change direction of motion and transmitmotion to parts such as control rods, cables, and torquetubes Replace all worn, bent, or otherwise defectivebellcranks.

Figure 9-30. Bellcrank

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(8) Mixing units. Mixing units combine fourmotions from the cockpit (pitch, roll, yaw, and thrust)and convert them into two outputs. Inspect andmaintain in accordance with the applicable maintenancemanual.

(9) Drive chains. Replace defective links inchains and maintain in accordance with applicablemaintenance manual.

(10) Speed rigs. Speed rigs are fitted in thecable assembly for the purpose of making rapid minoradjustments.

9-13. Environmental Control Systems. nvironmentalcontrol systems heat, cool, and remove moisture fromthe air supplied to the crew or passenger compartments.

a. Types. The forced air heating system,combustion heater, and pressurized system are used byArmy aircraft. Each is explained in the followingparagraphs.

(1) Forced air heating system. Heated airis provided for crew comfort, deicing, defrosting, andanti-icing Air is forced into muffs or jackets installedaround the tailpipes The air routed through the muff orjacket picks up heat by convection through the tailpipematerial. The heated air is then routed to an air-to-airheat exchanger before going on to perform variousheating functions. Maintenance to this type of system islimited, and will consist of the following:

WARNINGDrycleaning solvent is flammableand solvent vapors are toxic Use P-D-680, Type II Solvent in a well-ventilated area Keep away from openflames. Avoid prolonged solventcontact with skin.

(a) Wash all metal parts of heatingsystem in drycleaning solvent, Federal Specification P-D-680. Wash flexible tubing with mild soap, FederalSpecification P-S-620, and water.

(b) Lubricate valve cranks andpush-pull levers with a small amount of molybdenum-disulfide technical powder, MIL-M-7866.

(c) Pressure-test any repair madeto heat exchanger tube before installation. A repairedtube is considered a temporary measure and will bereplaced when parts become available.

NOTE

• Heaters with an engine exhaustheat source require anoperational test for carbonmonoxide levels uponinstallation of the heater orfollowing extensive heatexchanger maintenance,modification, or suspectedmalfunction.

• The test will be performed at heatduct opening with the heater fullon and the engines operating atfull military power. An indicationof 50 parts per million (ppm/0.005percent) or greater requirescorrective action prior to heateruse. Suggested test equipmentis Detector Kit, CarbonMonoxide, Colorimetric, NSN6665-00-618-1482 and IndicatorTubes, Carbon Monoxide, NSN6665-00-276-7545.

(2) Combustion heater. Thecombustion heater provides heat by routing outside airpast a burner section. The outside air picks up heat byconvection from the burner section and is then routed toperform various heating functions. Maintenance ofheater between overhauls will normally consist ofinspection, cleaning, or replacement of parts asexplained in the following procedures:

WARNINGDrycleaning solvent is flammableand solvent vapors are toxic. Use P-D-680, Type II Solvent in a well-ventilated area. Keep away fromopen flames. Avoid prolongedsolvent contact with skin.

CAUTIONDo not use a metal instrument, as itmay damage core passage.

(a) Clean core tip and body ofspray nozzle with drycleaning solvent, FederalSpecification P-D-680. Use a wooden stick to scrape offany dirt remaining on spray nozzle.

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CAUTIONDo not use carbontetrachloride,trichloroethylene, or otherchlorinated solvents. Otherwisedamage to filter element may result

(b) Clean filter element by passingair or drycleaning solvent, Federal Specification P-D-680, through it in reverse direction after removal fromfilter bowl. When these methods fall to clean element, itshould be replaced.

(c) Use dry, filtered air to blow outany dust that may have accumulated in ignition unit.Wipe out any oil with a dry, clean cloth.

(d) Secure all heater drain plugswith lockwire to prevent loss of plugs and resultantflame discharge. Prepare drain plugs for safetying asfollows:

1 Drill hex head bolts across acorner with a No 52 drill.

2 Drill countersunk hex headplugs completely through and countersink drilled head90 degrees by 3/32-inch diameter on both sides of plug.

3 Secure drain plugs to anysuitable adjacent point using steel wire, ASTM A580ANO A313.

NOTE

• Combustion heaters require anoperation test for carbonmonoxide levels uponinstallation of the heater orfollowing extensive heatexchanger maintenance,modification, or suspectedmalfunction.

• The test will be performed at aheat duct opening with the heaterfull on. An indication of 50 partsper million (ppm/0.005 percent)or greater requires correctiveaction prior to heater use.Suggested test equipment isDetector Kit, Carbon Monoxide,Colonmetric, NSN 6665-00-618-1482 and Indicator Tubes,Carbon Monoxide, NSN 666500-276-7545.

(3) Pressurized system. A pressurizedsystem maintains the cabin pressure altitude at aconstant value. Pressurized air is pumped into the

sealed fuselage from cabin superchargers. Thesuperchargers deliver a constant volume of air at allaltitudes up to a designed maximum Air is released fromthe fuselage by a device called an outflow valve Theoutflow valve, by regulating the air exit, controls thepressure within the aircraft. Maintain in accordance withthe applicable maintenance manual.

b. Repair of Flexible Air Ducts. Crackedflexible air ducts, constructed of fiberglass material, willbe inspected and repaired on the aircraft wheneconomically feasible. Silicone damage shall notexceed 3.0 inches in length and 1.5 inches wide withlimits of two repairs per foot of duct or three percent oftotal surface area. Reworked areas will be sanded orbuffed to fair in with adjoining material. Repair flexibleair ducts using the following procedures.

(1) Clean damaged area with TolueneTT-T-548. Allow cleaned area to air-dry a minimum of30 minutes.

(2) Apply to a brush coat of RoomTemperature Vulcanizing (RTV), M IL-A-46146, ondamaged area with a 0.5 inch overlap from edge ofdamaged area.

(3) Smooth and cure by air drying aminimum of two hours at room temperature or until it isdry to the touch.

NOTEFor repair of damage to thefiberglass cloth, the limitation is nomore than 10 percent of surface areaafter completion of repair.

(4) Clean the complete circumference ofthe air duct in the vicinity of damaged area withToluene. Allow cleaned area to air-dry a minimum of 30minutes.

(5) Use brush to apply a thin coat ofadhesive to the complete circumference of the duct inthe damaged area and smooth out adhesive.

(6) Cut a piece of fiberglass cloth, MIL-C-9084, of sufficient size to cover the completecircumference of the duct, with a one-inch overlap of thedamaged area.

(7) Wrap fiberglass cloth around duct andsmooth out.

(8) Allow to air-dry a minimum of twohours or until dry to touch before handling.

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NOTERepairs of flexible ducts made offiberglass impregnated withchloroprene shall be made withadhesive, NSN 8040-00-390-7960 (P/NBostick 4006A and 4006B) utilizingfiberglass cloth. Repairs will beaccomplished in a well-ventilatedarea.

9-14. Deicing Systems. Pneumatic deicing systemsuse rubber deicers, called boots or shoes, attached tothe leading edge of the wing and stabilizers. The deicersare composed of a series of inflatable tubes. Duringoperation, the tubes are inflated with pressurized air,and deflated in an alternating cycle as shown in figure 9-31. This inflation and deflation causes the Ice to crackand break off. The ice is then carried away by theairstream.

a. Deicing System Precautions. Exercise thefollowing precautions to assure maximum service life ofdeicer shoes:

• Repair all damage promptly.

• Keep deicer shoes free of oil, gasoline, paintremover, solvents, and other injurioussubstances.

• Clean deicer shoes, using a mild soap, A-A-50, and water solution not exceeding 180°F(82°C).

• Do not rest ladders of work stands againstleading edges having deicer shoes installed.Wrap padding around those portions of workstands which could come in contact withinstalled deicer shoes.

• Do not drag fuel or oil servicing hoses overthe deicer shoes.

• Do not walk or lay tools and objects on upperstretch area of shoes. Deicer shoes, wheninstalled, are under tension and thereforereadily susceptible to abrasion.

• Protect deicer shoes from abuse.

Figure 9-31. Delcer Boot Inflation Cycle

b. Deicing System Preventive Maintenance.Preventive maintenance for deicing systems will entailthe following procedures:

CAUTIONDo not use excessive amounts ofmethyl ethyl ketone, as this producttends to soften rubber.

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(1) Thoroughly clean affected area usingmethyl ethyl ketone, ASTM D 740.

WARNINGAvoid breathing vapors fromcements and solvents utilized duringthis operation.

(2) Apply a brush coating of sealingcompound, MIL-S-8802, approximately 1/32 inch thickover clean area.

(3) Allow sealing compound to dry untilno longer tacky.

(4) Rub down sealing compound toremove brush marks and feather edges using abrasivepaper, 400 grit, Federal Specification P-P-101, orequivalent.

(5) Remove powdered sealing compoundwith compressed air or a dry, clean cloth.

(6) Apply one coat of approvedconductive cement to entire surface of shoe.

c. Deicing System Troubleshooting. A typicaltroubleshooting chart for deicing systems is shown intable 9-4.

d. Deicing System Maintenance. Maintenanceof deicer system consists primarily of the care andrepair of deicing shoes and the replacement of defectivecomponent parts The following paragraphs explaingeneral maintenance for deicing systems.

(1) Patch installation Install patches usingthe following procedures:

(a) Thoroughly clean affected area,using methyl ethyl ketone, ASTM D 740.

(b) Buff affected area untilcompletely roughened.

(c) Clean buffed area with a cleancloth completely dampened with methyl ethyl ketone.

(d) Select a patch of ample size tocover damage.

(e) Apply one coat of Goodrich 60cement, or equivalent, to damaged area and patch, andallow to dry thoroughly (5 to 10 minutes).

(f) Reactivate both cementedsurfaces with a cloth dampened with methyl ethylketone, and apply patch to deicer shoe, starting at edgeand working down carefully to avoid trapping air beneathpatch.

(g) Allow patch to set 15 minutes,then wipe patch and surrounding area with methyl ethylketone.

(h) Buff and clean a minimum areaof 1/2 inch around patch.

(i) Apply a brush coat of sealingcompound, MIL-S-8802.

NOTE

• Weather-checked surfaces andabraded areas not requiring apatch will be treated as outlinedin paragraph 9-14b.

• Repair cuts, tears, and severescuff damage to tube or stretcharea with reinforced (one-waystretch) neoprene patches.Damage to nonstretch areas willbe repaired with plain neoprenepatches.

(2) Cold patch limits. Limits for coldpatching are as follows:

(a) Cuts up to one inch on deicershoes attached with fairing strips.

(b) Cuts up to three inches in lengthon deicer shoes attached with cement.

9-15. Fire Detection and Extinguishing Systems.Fire detection and extinguishing systems are explainedin the following paragraphs.

a. Fire Detection Systems. The fire detection systemsare designed to detect the presence of fire in zonessuch as engine compartment and combustion-typeheater compartment, and to light a red warning light inthe pilot's compartment in event of fire To detect fires oroverheat conditions, detectors are placed in the variouszones to be monitored. Fires are detected in aircraftusing one or more of the following:

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Table 9-4. Troubleshooting Pneumatic Deicing Systems


1. Pressure gauge oscillates a. Faulty lines or connections. Repair or replace lines.Tighten loose connections.

b. Deicing boots torn or punctured Repair faulty boots.

c. Faulty gauge Replace gauge.

d. Faulty air relief valve Adjust or replace relief valve.

e. Faulty air regulator Adjust or replace regulator.

2. Pressure gauge oscillates; a. Vacuum check valves installed Reinstall correctly.peaks at a specified pressure improperlywhile instrument vacuumgauge shows no reading

b. Vacuum relief valve Improperly Adjust or replace valve asadjusted or faulty necessary.

c Faulty lines between pump and Tighten, repair, or replace faultygauge lines or connections.

3. Pressure gauge shows no a. Faulty pressure gauge line Repair or replace line.pressure while vacuum gaugeshown normal reading.

b. Faulty pressure gauge Replace gauge.

c. Pressure relief valve faulty Adjust or replace as necessary.

d. Pressure regulator faulty Adjust or replace as necessary.

4 Cycling period irregular a. Loose or faulty tubing and Tighten, repair, or replace asconnection necessary.

b. Boots torn on punctured Repair faulty boots.

c. Faulty electronic timer Replace timer.

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• Rate-of-temperature rise detectors • Radiation sensing detectors • Smoke detectors • Overheat detectors • Carbon monoxide detectors • Combustible mixture detectors • Fiber-optic detectors • Flame detectors • Observation by crewmembers

b. Types of Fire Detection Systems. A firedetection system should signal the presence of a fire.Units of the system are installed in locations where thereare greater possibilities of a fire Three detector systems incommon use are the thermal switch system,thermocouple system, and the continuous-loop detectorsystem.

(1) Thermal switch system. The thermal switchsystem uses a bimetallic thermostat switch or spotdetector similar to that shown in figure 9-32. Eachdetector unit consists of a bimetallic thermoswitch. Thesethermal switches are heat-sensitive units that completeelectrical circuits at a certain temperature. If thetemperature rises above a set value in any one section ofthe circuit, the thermal switch will close, completing thelight circuit to indicate the presence of a fire or overheatcondition

Figure 9-32. Thermal Switch

(2) Thermocouple system. Thethermocouple is constructed of two dissimilar metals suchas chrome and constantan. The point where these metals

are joined and will be exposed to the heat of a fire iscalled a hot junction. There is also a reference junctionenclosed in a dead air space between two insulationblocks. A metal cage surrounds the thermocouple to givemechanical protection without hindering the freemovement of air to the hot junction. If there is a fire, thehot junction will heat more rapidly than the referencejunction. This will complete a circuit from the aircraftpower system to the coil of the slave relay which closesand completes the circuit to the fire-warning light

(3) Continuous-loop system . A continuous loopdetector or sensing system permits more completecoverage of a fire hazard area than any type of spot-typetemperature detectors. Continuous-loop systems areversions of the thermal switch system. They are overheatsystems, heat-sensitive units that complete electricalcircuits at a certain temperature. There is no rate-of-heat-rise sensitivity in a continuous-loop system. Two widely

TM 1-1500-204-23-1

(b) Fenwal system. The Fenwalsystem, as shown in figure 9-34, uses a single wiresurrounded by a continuous string of ceramic beads in anInconel tube. The beads in the Fenwal detector arewetted with a eutectic salt which possesses thecharacteristic of suddenly lowering its electrical resistanceas the sensing element reaches its alarm temperature.

c. Maintenance of Fire Detection Systems. Inspectfire detection systems for the following:

• Cracked or broken sections caused by crushingor squeezing between inspection plates, cowpanels, or engine components.

• Abrasion caused by rubbing of element oncowling, accessories, or structural members

• Pieces of safety wire or other metal particleswhich may short the spot detector terminals.

• Condition of rubber grommets in mountingclamps, which may be softened from exposureto oils, or hardened from excessive heat

• Dents and kinks In sensing element sections

Figure 9-34. Fenwal Sensing Element

NOTELimits on the element diameter,acceptable dents or kinks, anddegree of smoothness of tubingcontour are specified bymanufacturers. No attempt shouldbe made to straighten any acceptabledent or kink, since stresses may beset up that could cause tubingfailure.

• Loose nuts or broken safety wire at the end ofthe sensing elements

NOTELoose nuts should be re-torqued tothe value specified in themanufacturer's instructions. Sometypes of sensing elementconnections require the use ofcopper crush gaskets. Thesegaskets should be replaced any timea connection is separated

• Broken or frayed flexible leads, if used.

NOTEThe flexible leads is made up ofmany fine metal strands woven into aprotective covering surrounding theinner insulated wire. Continuousbending of the cable or roughtreatment can break these fine wires,especially those near the connectorsBroken strands can also protrudeinto the insulated gasket and shortthe center electrode.

• Proper sensing element routing and clamping.

NOTELong unsupported sections maypermit excessive vibration which cancause breakage. The distancebetween clamps on straight runs isusually about 8 to 10 inches, and isspecified by each manufacturer. Atend connectors, the first supportclamp is usually located about 4 to 6inches from the end connectorfittings. In most cases, a straight runof 1 inches is maintained from allconnectors before a bend is started,and an optimum bend radius of 3inches is normally adhered to

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• Rubbing between a cowl brace and a sensingelement.

• Correct grommet installation. • Thermocouple detector mounting brackets

should be repaired or replaced when cracked,corroded, or damaged.

d. Troubleshooting of Fire Detection Systems. Atypical troubleshooting chart for fire detection systems isshown in table 9-5.

e. Repair or Replacement of Fire DetectionComponents. Repair or replace fire detectioncomponents using the following procedures:

(1) Replace defective control unit with aserviceable unit.

CAUTIONDo not bend sharply, kink, or twistsensing element during installationMinimum allowance curve radius isone inch. Damage may otherwiseresult

Table 9-5. Troubleshooting of Fire Detection Systems


1. Intermittent alarms a. Short In the detector system Repair or replace defectivewiring wiring.

b. Kinks and bends in sensing Repair damaged areas ofelement sensing element.

2. False alarms a. Short between loop con- Repair or replace defectivenections and control units wiring.

b. Bent areas of sensing loop in Repair bent areas of sensingcontact with hot parts of the loop.engine

c. Short In the sensing loop Replace shorted section ofsensing loop.

d. Moisture in detection system Remove moisture contamina-tion.

3. Failure to obtain an alarm a. Defective test switch or control Replace test switch or controlsignal when the test switch unit unit.Is actuated

b. Lack of electrical power Provide electrical power.

c. Inoperative Indicator light Replace indicator light.

d. An opening in sensing element Repair sensing element oror connecting wiring connecting wiring.

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(2) Replace sensing element only whenphysical damage such as chafing, bending, twisting, orbreaking has occurred. Replace attaching parts whenfound to be defective.

CAUTIONBends will not be less than twoinches in radius.

(3) Replace cable detector only when physicaldamage such as chafing, bending, twisting, or breakinghas occurred. Make all bends and routing with fingersonly. Replace attaching parts when found to be defective

(4) Replace mounting brackets ofthermocouple detectors when cracked, corroded, ordamaged. Replace attaching parts when found to bedefective

NOTEWhen replacing thermocoupledetector, note which wire isconnected to identified plug terminalof defective unit, and connectreplacement in the same way.

f. Testing of Fire Detection System Test firedetection system using the following procedures

(1) Test system for proper operation by turningon power supply and placing FIRE DET TEST switch intest position Red warning light should flash on within 10seconds. Turn switch and power off

(2) Test required after repair or replacement ofunits in fire detector system or when system is Inoperativeas follows

• Replace lamp in warning light, when warninglight does not flash on.

• Polarity, ground, resistance, and continuity testsare required for systems with thermocoupledetect or units.

• Resistance and continuity tests are required forsystems with sensing elements or cabledetector units.

WARNING

• Repeated or prolonged exposureto high concentrations ofbromochloromethane (CB) or

decomposition products shouldbe avoided. CB is a narcoticagent of moderate intensity butof prolonged duration. It isconsidered less toxic thancarbon tetrachloride,methylbromide, or usualproducts of combustion. Normalprecautions should be takenwhile using bromochloromethaneIncluding use of oxygen maskswhen available. Injury topersonnel may otherwise result.

• Monobromotrifluoromethane

(CF3Br) is highly volatile but isnot easily detected by Its odor.Although nontoxic, it must beconsidered to be about the sameas other freons and carbondioxide, causing danger topersonnel primarily by reductionof oxygen available for properbreathing. The liquid should notbe allowed to come into contactwith skin, as It may causefrostbite or low temperatureburns.

g. Fire Extinguishing Systems. The fire extinguishersystem Is the one-shot type consisting of one or morecharged containers of bromochloromethane ormonobromotrifluoromethane (CB and CF3Br), dischargingtubing, overboard discharge tube, discharge indicator,circuit breakers, and control panel switch. The containeris charged with bromochloromethane ormonobromotrifluoromethane under pressure, which isdischarged through tubing Into the engine compartmentsby actuating FIRE EXT switch to the ON position

h. Maintenance of Fire Extinguishing Systems.Maintenance of fire extinguisher system consists ofInspection and replacement of defective parts using thefollowing procedures:

(1) Check for specific pressure on pressuregauge as given In applicable aircraft maintenance manual

(2) Inspect overboard discharge indicator forevidence of system being discharged due to thermalexpansion.

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CAUTIONDo not flush system with water.Damage to system may otherwiseresult

(3) Purge system thoroughly with clean, dry,compressed air immediately after landing when systemhas been used In flight, or immediately after dischargedon the ground. Absorb residual bromochloromethaneremaining on surface areas with dry cloths and clean, dry,compressed air

(4) Inspect compartments and components thatmay have come in contact with extinguishing agent forpossible damage Replace defective parts

(5) Inspect rubber materials and insulationswhere extinguisher was used Replace when founddefective.

(6) Relubricate all lubricated parts exposed toextinguishing agent

(7) Replace overboard discharge indicator discafter system has been discharged.

CAUTIONDisconnect positive electrical lead onsolenoid valve before removingcontainer, and do not connect leaduntil all circuit tests have beencompleted and firing switch on controlpanel is in OFF position. Damage toequipment may otherwise result.

(8) Replace discharged container and bonnetassembly with fully charged assemblies

WARNINGBefore attempting to performcontinuity test of the fire extinguishingelectric circuit, the extinguishercartridges must be removed topreclude accidental firing during test

(9) Make a visual inspection of the electricalcircuit wiring for obvious damage. Test the continuity ofthe entire circuit excluding the fire extinguisher containercartridge.

NOTEInstall cartridges in the assignedlocations (see DA Form 2408-18) topreclude incorrect age life controlremovals at a later date.

9-16. Hoist Systems. The hoist system which providesa means of raising and lowering equipment or personnelduring flight or ground operation is of two types: hydraulicand electric.

a. Hydraulic Hoist System. Maintenance andtesting procedures for hydraulic hoist systems areexplained in the following paragraphs

(1) Maintenance of hydraulic hoist system.Maintenance of the hydraulic hoist system consists ofreplacement of defective parts using the followingprocedures

(a) Service system with fluid, MIL-H-5606, and maintain indicated reservoir level

(b) Cap all tubing disconnected duringremoval of units to prevent entry of foreign matter.

(c) Replace damaged tubing. Use oldtubing or a piece of string as a pattern in routing newtubing

(d) Reuse fittings of hose and tubeassemblies unless damaged

NOTEClean and thoroughly flush tubing andhose prior to installation.

(e) Replace hoist cable when kinked orwhen cable has broken.

(f) Replace micronic filters periodicallyto assure delivery of uncontaminated fluid

(g) Lubricate hoist as prescribed in theapplicable aircraft maintenance manual.

(2) Testing of hydraulic hoist system. Testhydraulic hoist system for operation periodically (andwhen a new unit Is installed in the system) by performinga functional check using the following procedures:

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TM 1-1500-204-23-1

NOTEUse an external hydraulic test unit orthe aircraft hydraulic system withengine operating

(a) Check operation of down-limit switchby unwinding winch to Its limit to assure that winch willstop when cable If fully unwound

(b) Check operation of up-limit switch byrunning cable until up-limit switch is actuated

b. Electrical Hoist System. Maintenance and testing

TM 1-1500-204-23-1

Figure 9-36. Pressure-Demand Oxygen System

9-40

Figure 9-35. Continuous Flow Oxygen System

TM 1-1500-204-23-1

(4) Check valves. Replace all faulty checkvalves as complete units. Check valves cannot berepaired.

WARNINGDo not use masking tape to sealopenings in oxygen regulators. Itsuse on either serviceable orrepairable oxygen equipmentconstitutes a safety hazard

(5) Regulators. Do not apply oil or grease toany part of an oxygen regulator.

(6) Flexible hose. Maintain flexible hose usingthe following procedures

(a) To remove contamination other thanoil and grease from flexible hose, remove hose and cleanwith mild soap, A-A-50, and warm water solution,thoroughly rinse with fresh water and thoroughly dry with astream of clean, dried, water-pumped air or nitrogen

(b) Replace hoses damaged orcontaminated with oil or grease. Repair and replacementprocedures for flexible hose are outlined in TM 1-1500-204-23-2.

(c) Examine fittings for tightness.

(7) Open lines. Plug or cap all open lines andequipment when opening system for replacement of anypart When system has been accidentally left open,system will be purged by one of the following methods

• In aircraft having filler lines connected to oneend of cylinder, and distribution lines connectedto opposite ends of cylinder, purging will beaccomplished by connecting a service trailer toaircraft filler valve With all regulators open,pass oxygen through system for at least 30minutes at a pressure of 50 psi at filler valve

• In aircraft having filler lines and distribution

lines commonly connected at one end ofcylinder, purging will be accomplished by fillingsystem with oxygen and then draining systemng will be acresnutes atamader, Tw (• ) TTe d005harged byereasme end

m7stem wl drer , ill be purged by one 1.36 0 (.44 TD /F1 10.08 0Tf 0.0044 Tc 364tamad(7)) TNOTE8 -15.379.44 TD7/F4 13.92 5Tf -3.1483 Tc 3.1152 Tw (• ) Tj 18 0 TD /F1 10.08 0Tf 0.0044 Tc 336052 2.355ystem wpply oiuutllubricay) Tn17 Do no having fnd thensth oxs8 -15.36 TD /84 13.92 5Tf -3.1483 .0331 Tw ( ) Tj 0 -15.36 TD -84 13.9 Tc 3.1152 Tw (• ) Tj 18 0 TD /F1 10.08 0Tf 0.0044 Tc 338035 Tw3875stem wpply oiuutlried,emng

TM 1-1500-204-23-1

(2) When aircraft is being serviced with oxygenwithin 50 feet of an area where smoking is permitted, NOSMOKING signs shall be placed at a 50-foot radiusaround the servicing area.

(3) All aircraft parked outside will be groundedand bonded, in accordance with FM 1-500, to theaerospace ground equipment while servicing oxygensystems

CAUTIONOxygen equipment shall be kept cleanat all times. No organic matter orflammable substance of any natureshall be allowed to contact oxygen.Ensure that all components of thesystems are free of moisture, oil, andgrease at all times. Oxygen is anonflammable gas; however, itsupports combustion and lowers theflash or Ignition point of allcombustible materials. Oxygen shallbe handled as a flammable gas.

(4) To prevent overfilling of tanks, personnelshall observe aircraft oxygen system gauges at all timesduring servicing operation.

(5) Personnel shall be stationed at the oxygenservicing unit at all times during servicing operation toshut off unit valves immediately upon receiving acommand from personnel watching aircraft system gauge.

(6) Service aircraft from cylinders clearlylabeled DRY or AVIATOR'S BREATHING OXYGEN.Other Oxygen may have moisture which could cause flowstoppage at temperatures below freezing.

(7) Always use a pressure-reducing devicewhen servicing low-pressure oxygen system from highpressure bottles.

(8) Fill oxygen system slowly to preventexplosion resulting from heat generated by filling too fast.

(9) An aircraft oxygen system not equippedwith shutoff devices at cylinders shall be completelydischarged of all pressure prior to removing components.

All electrical power shall be shut off during oxygendischarge operations.

(10) Refer to applicable aircraft maintenancemanual for additional information and maintenanceprocedures.

9-18. Relief Tube System. Maintenance of relief tubesprimarily consists of cleaning and replacing of parts.Clean or replace parts using the following procedures:

a. To clean and deodorize relief tube systems, asolution of 1 1/2 ounces of MIL-SPEC A-A-1634 generalpurpose deodorant and 5 gallons of water will be used towash area around relief tube exit and relief tube entrance.

b. Pour remainder of solution through the tube.When an offensive odor remains, use a stronger solutionand reclean until odor is removed.

NOTEThe area of relief tube exhaust will beprimed with zinc chromate primer,Federal Specification TT-P-1757, andpainted with acid proof lacquer,Federal Specification TT-L-54

c. Replace deteriorated hose, broken or damagedhorn, and broken or damaged attaching parts.

NOTEInstall hose so as to eliminate anyresidue pockets.

9-19. Windshield Wiper System. Maintenance andadjustment of the windshield wiper system is explained inthe following paragraphs.

a. Maintenance of Windshield Wiper System. Themaintenance of the windshield wiper system consistsprimarily of replacement of defective parts, as follows.

(1) Replace wiper motor, wiper units, wiperarms, and flexible cables that are inoperative, cracked,bent or otherwise defective.

(2) Replace wiper blades that are worn,deteriorated, or torn, or when rubber has lost its elasticqualities.

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TM 1-1500-204-23-1

b. Adjustment of Windshield Wiper System. Thewindshield wiper system shall be adjusted as follows:

Do not operate wipers on dry glass.

(1) Loosen locknut on wiper blade, align blade,and tighten locknut.

(2) Remove locknut from wiper unit shaft,adjust position of arm on shaft to give full sweep onwindshield, and reinstall locknut.

(3) Adjust tension nut at base of wiper arm untilblade exerts 1 1/2 to 2 pounds pressure against wind-shield.

NOTEMeasure tension at tip of wiper arm in a direc-tion perpendicular to windshield surface.

Drycleaning solvent is flammable and solventvapors are toxic. Use P-D-680, Type II Sol-vent in a well-ventilated area. Keep awayfrom open flames. Avoid prolonged solventcontact with skin.

(g) Remove grease spots with drycleaningsolvent, Federal Specification P-D-680.

(h) Remove blood stains by use of coldwater applied with sponge. Remove residue with a 10percent solution of ammonia hydroxide, MIL-STD-612,or a paste of cornstarch, Federal Specification NC-541.Allow treated area to dry. When cornstarch is used, brushdried material from fabric.

(2) Repair. Repair and patch fabric material oftroop seats using repair procedures outlined in para-graph 9-22.

9-20. Aircraft Seats. Maintenance of aircraft seatsshall be accomplished in accordance with the proce-dures explained in the following paragraphs.

a. Troop Seats. Cleaning, repair and installationand removal procedures for fabric or cotton canvas troopseats are explained in the following paragraphs.

(1) Cleaning. Clean troop seats as follows:

(3) Installation and removal. Follow instruc-tions contained in the applicable aircraft maintenancemanual for installation and removal procedures.

b. Metal Seats. Cleaning, repair, and installationand removal procedures are explained in the following paragraphs.

(a) Unfold and place parts face up.(b) Brush with a firm bristle brush to

remove excess dirt.

(c) Prepare a cleaning solution of 1 ounceof anionic synthetic detergent (alkyl benzene sulfonate),Federal Specification P-D-410, per gallon of water.

(d) Work up heavy suds by repeatedlysqueezing of a sponge saturated with detergent solution.Apply heavy suds to soiled areas.

(e) Scrub soiled areas briskly, using a firmbristle brush or heavy cloth. Wipe off with a damp cloth.

(f) Allow treated area to dry. Brush to raisenap.

Drycleaning solvent is flammable and solventvapors are toxic. Use P-D-680, Type II Sol-vent in a well-ventilated area. Keep awayfrom open flames. Avoid prolonged solventcontact with skin.

(1) Cleaning. Clean with clean cloth moistenedwith drycleaning solvent, Federal Specification P-D-680.

(2) Repair Patches and reinforcement repairsto metal seats will be accomplished in accordance withrepair procedures in TM 1-1500-204-23-10.

(3) Installation and removal. Follow instruc-tions contained in the applicable aircraft maintenancemanual for installation and removal procedures.

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TM 1-1500-204-23-1

c. Upholstered Seats. Cleaning, repair, and instal-lation and removal procedures are explained in ‘the fol-lowing paragraphs.

(1) Cleaning. Clean upholstered seats by usingcleaning materials and methods as prescribed in para-graph 9-20a.

(2) Repair. Repair small rips or tears with asewed or unsewed patch. Attach unsewed patches withadhesive, Federal Specification MMM-A-1617.

(3) Installation and removal. For instructionsinstallation and removal, refer to the applicable mainte-nance manual for particular aircraft.

d. Raschel Knit Seat Covers. Raschel knit seatcover maintenance limits are listed below:

Deterioration or discoloration which indicates astrength decrease to the point where it affects theintegrity of the seat(s) is not allowed.Tears, cuts, or holes greater than 2.5 inch in lengthor diameter are not allowed; the seat should bereplacedTears, cuts, or holes less than 2.5 inch in length canbe repaired. Repair is not allowed for seat coverswith holes, cuts, or tears in raschel kit material thatare located close to the seams of the adjoiningpanels and do not allow sufficient space for thedarning procedure. Repair should be used as atemporary measure until new seat covers or backcovers can be installed. In the fine-mesh duck clothsurrounding the raschel knit material, tears, cutsand holes up to 2.5 inches in length can berepaired. A different method for repairing isrequired and is as follows:

Tears, cuts or holes less than 0.5 inch in length maybe repaired by stitching which extends 0.5 inch intothe sound material surrounding the damaged area.

Tears, cuts or holes of up to 1.0 inch in length maybe repaired with the use of a patch made of thesame material as the seat cover. Locate on theunderside of the damaged area and sew a zigzagstitch over the tear area and into patch extending0.5 inch into the sound material surrounding thedamaged area.

Tears, cuts, or holes of 1.0 to 2.5 inches in lengthmay be repaired with the use of a patch made of thesame material as the seat cover. The patch shouldbe sized to extend 1.0 inch in all directions to thedamaged area and include 0.50 inch of material tofold under to finish all the edges of the patch. Thepatch should be located on the underside of thedamage area with the folded edges to the inside.Zig-zag sew the damage area into the patch, fol-lowed by a minimum of two (2) rows of stitchingaround the patch using 6-9 stitches per inch.

NOTEA 24 month service life pertains only to thosecovers which are used in an energy attenua-tion application.Replace the original nylon spall shield, or usenew ballistic nylon MIL-C-12369 for replacement.Apply a thin even coat of contact adhesive EC1300L (FSCM 04963) to the tile surface. Allowadhesive to dry until tacky. Carefully mate thespall shield to the tile, working it on by handpressure. Fit the nylon snugly over the fiberglasspatch (or patches). Do not wrap the spall shieldover the edge of the panel. Tears in the spallshield shall not exceed 3 inches. Any unbondedarea of the spall shield, (as evidenced by bulges),shall not exceed a diameter of 1 inch.Seat covers made of raschel knit nylon cloth shallhave a service life of 24 months. Seat covers thatare not marked with an installation date shall beassumed to have the same date as the day ofacceptance of the aircraft. Replacement coversshall be marked with contrasting ink conformingto MIL-l-6903. The size of marking shall be ofsufficient size and location so that it can easily beread. The following is an example of markinginstallation date: 7 Mar 88

e. Polyester Fabric Seat Covers (Uh-60). Clean-ing, repair, and installation and removal procedures forpolyester fabric seat covers are explained in the followingparagraphs.

(1) Cleaning. Clean the polyester fabric seatand back using the following procedures:

(a) Brush fabric with firm bristle brushremoving excess dirt.

(b) Use enough liquidto allow completeimmersion of the seat cover to be washed.

(c) Mix 3 ounces of low strength laundrysoap, Federal Specification P-S-1792, to each gallon ofwater. Synthetic detergentis permissible as an alterna-tive.

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TM 1-1500-204-23-1

NOTEThe water temperature should notexceed 100°F (37°C).

(d) Immerse one cover at a time in thesoap solution, let stand for 20-25 minutes, and hand washfor 5 minutes.

(e) Rinse cover In clean water until allsoap is removed

NOTEIf machine washed, use completewash and rinse cycles.

(f) Spread covers on a clean surface outof direct sunlight to dry.

(2) Repair. Repair polyester fabric coversusing the following procedures.

(a) Inspect for cuts, tears, punctures,bums and broken stitches. Any damage less than 2-1/2inches long x 1 inch wide in the seat bottom may berepaired. Replace seat bottoms with damage greater than2-1/2 inches long x 1 inch wide.

NOTESeat backs do not have a damage sizelimit for repair

(b) All seats will be repaired usingpolyester thread, Specification Federal V.T. 285 andcloth polyester (P/N SS9512) as required.

(c) Repairs will be accomplished usingthe details in figure 9-37.

(d) Damage that Is close to the edge ofthe seat cover which has insufficient space to allow acomplete patch pattern will not be repaired.

(3) Installation and removal. For instructionson installation and removal, refer to the applicablemaintenance manual for the particular aircraft.

9-21. Aircraft Litters. Litters installed in Army aircraftshall be installed and removed as described in thefollowing paragraphs.

a. Installation. Install Litters using litter kits providedwith each aircraft. Refer to the applicable aircraftmaintenance manual for specific installation procedure.

b. Removal. Upon completion of mission involvinglitters, remove from aircraft and return to supplyingagency. Stow litter kit in original container in aircraftwhen applicable.

9-22. Protective Covers. The instructions containedbelow are applicable to all types of aircraft protectivecovers and shields used by the Army.

a. Installation and Removal Precautions.Installation and removal precautions for the protectivecovers are as follows.

• Protective covers shall be Installed to protectairframe ccmponents which are affected byextreme weather conditions.

• Covers shall be Installed when aircraft is to

remain in an exposed area for any extendedlength of time, or when snow or ice isanticipated.

• To keep out dust, rain, and foreign matter,

protective shields, such as intake duct andexhaust covers, shall be Installed to coveropenings and passages in the aircraft structureand engine nacelle which leads to internalcomponents of aircraft.

• Do not drag covers over sharp objects; preventcontact with ground when Installing andremoving.

• Spread wet covers out to dry before folding and

storing. • When installing and removing covers, do not

allow attaching buckles to scratch or marplexiglass sections of aircraft.

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TM 1-1500-204-23-1

Figure 9-37. Repair Pattern for Polyester Cloth

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TM 1-1500-204-23-1

b. Maintenance of Protective Covers. Cleaning,repair, waterproofing, and storage of protective covers areexplained in the following paragraphs.

(1) Cleaning. Protective covers contaminatedwith salts from the atmosphere, specifically chlorides (inmarine areas) and sulphur compounds (in industrialareas), can promote corrosion of aircraft skins. Grease,oil, or dirt can mar or discolor plexiglas portions of theaircraft Therefore, only clean covers will be used. Cleanprotective covers using the following procedures.

NOTETo increase life expectancy, protectcovers against rain, wind, snow, sand,and mildew when not Installed onaircraft.

(a) Remove all possible ropes andwooden attaching parts.

(b) Tape or wrap all attaching parts, suchas buckles, snaps, hooks, and D-rings to prevent tearingand snagging of covers during soaking or washing.

(c) Brush soiled section with firm bristlebrush to remove excessive soil.

(d) Select a container that will holdenough liquid to allow complete immersion of cover to bewashed.

(e) Mix soap solution containing 3ounces of low strength laundry soap, FederalSpecification P-S-1792, to each gallon of water.Synthetic detergents are permissible when available.

NOTEThe temperature of water should notexceed 100°F (37°C)

(f) Immerse one cover at a time in soapsolution for a period not to exceed 30 minutes.

(g) Rinse over In clean water until allsoap has disappeared.

(h) Spread covers on a clean surface todry.

(2) Repair. Make prompt repairs to aircraftprotective covers to prolong service life. Inspect for

damage immediately after use and make repairs usingthe following paragraphs.

(a) Puncture, snagged, or torn areas.Repair punctured, snagged or torn areas as follows:

1 Repair punctured, snagged, ortorn areas by sewing in place a patch of material equal tobasic material in weight, quality, and color.

2 Reinforce and darn puncturesand small holes (1/2 Inch or less).

3 Trim and turn under frayededges to make a neat and durable repair.

4 Use circular patches on smallholes and rectangular patches on larger holes, irregularsnags, or tears.

5 Mend a cluster of holes withone suitable patch, after first removing damaged area andturning under all edges.

6 Provide best possible waterdrainage by extending patch seams diagonally fromcenterline of cover section whenever possible.

7 Do not extend patches overmore than one section of cover (seam to seam).

8 Restitch all open seams. Stitchpattern and type thread will follow as near as possible thetype stitch and thread used in original construction of itembeing repaired.

(b) Edge damage. Repair edge damageas follows.

1 Repair damaged areas alongedge of covers where grommets or attaching points arelocated by folding a piece of material equal to the basicmaterial over damaged area by sewing In place.

2 Replace corner areas whereattaching points are located by sewing on a patchcomposed of three thicknesses of material equal to basicmaterial.

3 Replace any worn or missingwebbing keepers, defective elastic webbing, orreinforcement patches.

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TM 1-1500-204-23-1

(c) Attaching equipment damage. Repairattaching equipment damage as follows.

1 Repair, when practicable, orreplace all damaged attaching equipment such as straps,buckles, webbing, keepers, cords, cables, cable fittings,grommets, etc.

2 Dip ends of all new webbing ina mixture of 50 percent paraffin, Federal SpecificationVV-W-95, and 50 percent beeswax, Federal SpecificationC-B-191

3 Dip ends of sash cords Inshellac, Federal Specification TT-S-271.

(3) Waterproofing. Restore water, mildew, andweather resistant qualities of a protective cover by coatingwith water repellent textile finish compound as follows

WARNINGSolvents contained in thecompounds are highly flammableand toxic; therefore all work shall beaccomplished In an open area awayfrom any flame

(a) Stir compound thoroughly untiluniform mixture is obtained.

(b) Spread cover out completely on aclean flat surface, with Inside of cover down.

WARNINGSolvents contained In compound maytend to irritate skin, therefore,prolonged contact shall be avoided.

(c) Apply moderate application ofcompound to outside of cover with a brush or spray.

(d) Apply compound well into seams, asthey are particularly susceptible to mildew and leakage

(e) Dry cover thoroughly until odor ofcompound has completely disappeared

(4) Storage. Store protective covers asfollows:

(a) Fold covers neatly to facilitate easierand faster installation when covers are needed.

(b) Store covers in a dry place on aplatform or on slats of wood. Never store covers onground or concrete.

9-23. Armor Plating. The repair instructions that followare limited to composite armor composed of a ceramicfacing bonded to a fiberglass reinforced plastic backing.The ceramic facing is covered with a flexible spall shieldto protect the crew members from ballistic fragments. Arubber molding is also provided on the edges of somepanels for crew protection. These repair procedures weredeveloped with the objective of matching, to a highdegree, the original strength and ballistic properties of theundamaged armor panel, with a minimum increase inweight. Extending the service life of armor panels willfacilitate the mission capabilities of organizational units bythe effective use of material assets. The ceramic facingmay consist of one of the following materials.

• Aluminum Oxide (AI203) • Boron Carbide (B4C) • Silicon Carbide (SiC)

a Armor Plating Inspection and Repair Definitions.Table 9-6 gives definitions relative to inspection andrepair criteria.

b. General Inspection of Armor Plating.Radiographic inspection of the assembled armor panel isthe primary method used for nondestructive testing in

TM 1-1500-204-23-1

Table 9-6. Armor Plating Definitions

Terms Definitions

Panel Each individual removal unit or module of the totalassembled armor protective system.

Delamination Any area where the fiberglass ply or plies havebecome detached from the binding resign in thereinforced plastic backing.

Backing The ballistic energy absorber and structural supportsystem for the brittle ceramic tile. The backing is acomposite of fiberglass lamination impregnated withplastic resign.

Spall Shield A cover on the ceramic tile to protect crewmembers from flying fregments during a ballisticimpact. The spall shield is made of nylon clothMIL-C-12369.

(1) Inspect for the following damages whichcannot be repaired In the following substeps (a) and (b),the allowable deviation is zero; therefore the panel mustbe scraped. In the Note following substep (c) anacceptance tolerance is specified, therefore, do not scrappanels that are within the allowable tolerance Send panelto a higher level of maintenance for repair.

(a) Inspect all panels for ballisticdamage. Do not repair armor panels with any ballisticdamage (direct hit).

(b) Inspect for cracked resign or ridges inthe backing that show evidence of a structural failure.

NOTE

This damage will be matched by a tilecrack generally paralleling the failureline in the backing This damage mayoccur at a weaker reduced sections ofthe panel, such as the area around thehead Accidental blows from tools orhard objects, and the use of armorpanels as handholds, are usually thecause of this type of damage Do notrepair armor panels with any crackedresin or ridges In the backing

(c) Inspect the panel for unbonded tiles

NOTETo check for unbonded tile on armorhaving multiple tile sections, lightly tapthe ceramic surface using a coin Anyarea that has a lack of bond between thetile and plastic backing should respondwith a dull thud, as opposed to thehigher pitched sound of a well bondedarea However, the distinction betweenthe bonded and unbonded area will notalways be clearly evident

NOTE

To determine a characteristic sound,compare with a well-bonded area, suchas along a panel edge. Press firmly byhand all over the tile surface, observingany tile movement on release of handpressure. Outline any unbonded areaon the face of the tile for reference A100 percent bond between tile andbacking Is not required for ballisticefficiency. Do not make allowance forany additional support of the tile by thespall shield. Do not repair armor panelshaving a total unbonded area In excessof 20 percent for each tile section Formonolithic armor (one piece cast tile),the tile bond as a whole should beadequate .

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TM 1-1500-204-23-1

(2) Refer to the repair procedures inparagraph 9-23d for inspection of damage and fordamage limitations other than those specified. If thepanel is damaged beyond the limits specified, it cannot berepaired.

c. Adhesives, Resins, and Solvents for Repair ofArmor. The following paragraphs explain adhesives,resins, and solvents used for repair of armor.

(1) Adhesives. For adhesives, followmanufacturer instructions concerning storage, agitation,mixing, thinning, temperature, range, fire and healthhazards, plus contamination by moisture and dust. Theadhesive used for repair can be applied to the frayingsurfaces by any convenient means that will give asmooth, uniform spread of the adhesive Use methodssuch as a brush, a hand roller, an extrusion gun andsqueegee Clean all tools Immediately after each use withToluol, TT-T-548. Do not let adhesive polymerize (cure)before cleaning.

NOTEUse Polysulfide Sealing Compound,MIL-S-8802, Class A-2 or B-2 foradhesive Pro-Seal 890 (FSCM 83527) isa qualified product meeting orexceeding the requirements of MIL-S-8802. Use Pro-Seal 890, Class B-2 forapplication by squeegee or extrusiongun. Use Pro-Seal 890BT, Class A-2for application by brush or hand roller.

(2) Resins. Many tertiary amines, phenolicmaterials, alcohols and water catalysts accelerate thereaction between the Diethylene Triamine (DTA) curingagent and EPON resin. Although catalysts are used tocontrol the curing rate of resins, they reduce the pot lifeof a mixture formulation, such as DTA and EPON Do notuse any curing agent accelerators Since water is anaccelerator, avoid any contact of the mixture formulationwith water.

NOTE

• As the room temperaturedecreases the resin curing ratetime falls rapid. The DTA curingagent may be applied at a

temperature as low as 55°F(13°C), although the time to reacha given stage of cure is at leastdouble that required at normalroom temperature.

• The viscosity of the resin may be

too high for some methods ofapplication. Add methyl ethylketone, TT-M-261, up to amaximum of five percent byweight of the total solutioncontent, to lower viscosity.

(3) Solvents. For solvents and cleaningsolutions, observe all of the usual precautions forventilation to prevent the accumulation of toxic vaporsand to avoid a fire hazard.

(4) Instructions for Pro-Seal 890 sealant.Instructions are as follows:

NOTE

• Bonding material Pro-Seal 890consists of two parts: Pro-Seal890 Sealant and Pro-Seal 890ACuring Agent

• Both Pro-Seal 890 and its curing

Agent Pro-Seal 890A should beused as received. Do not thinwith solvent.

• Curing agent Pro-Seal 890A

contains no solvent to assure aminimum amount of shrinkagewhen mixed with Pro-Seal 890Sealant. Pro-Seal 890A containsan oxidizing compound,therefore avoid prolongedcontact with the skin. Washhands thoroughly before eatingor smoking.

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TM 1-1500-204-23-1

(a) Open curing agent Pro-Seal 890Aand thoroughly mix it In the container until it becomes asmooth paste.

(b) Thoroughly mix 10 parts of Pro-Seal890A to 100 parts of Pro-Seal 890 by weight, or 8.4 partsof Pro-Seal 890A to 100 parts of Pro-Seal 890 by volume.

(c) Carefully fold the material upon itselfand blend for a period of at least five minutes This willgive a satisfactory mix.

NOTEAvoid violent agitation In order to beatas little air Into mixture as possibleAlso, frictional heat developed fromviolent agitation may reduce work lifeof the material.

(5) Curing requirements for Pro-Seal 890sealant (2 cure option). Requirements are as follows:

• Mixed, uncured Pro-Seal 890 sealant material(Class A-2 or B-2) requires 72 hours at roomtemperature for a full cure.

• If the production schedule is not flexible enough

to allow for the long-time room temperaturecure, accelerated step curing conditions may beemployed to fully cure the sealant material Infour hours at elevated temperatures The stepcuring conditions are two hours at 120°F(49°C), followed by an additional two hours at158°F (70°C). This means that you should usetwo ovens set at the two different temperaturesspecified to fully cure the uncured materialunder accelerated conditions.

d. Repair of Armor Plating. Specific repairs andInspections for armor plating are described in thefollowing paragraphs.

(1) Repair and inspection of cracked tile Repairand Inspection procedures are as follows:

(a) Inspect for cracked tiles.

NOTEMultiple cracks converging at an angleof 15 degrees or less are not

repairable. You may repair cracksoccurring in the ceramic tile 1/16 of aninch or less In width, provided that thebacking Is not damaged beyondrepair. Do not repair armor panelswhere a crack (or cracks) wider than1/16 if an Inch is found. Totalallowable defects are three or lesscracks, chips, or spalls in any 2-inchsquare area.

(b) Repair cracked tile by bonding a 1/8 inchthick sheet of fiberglass, type GEE, MIL-P-18177, overthe crack (or Cracks) overlapping the damaged area bythree (3) inches on each side, using Polysulfide SealantPro-Seal 890 (FSCM 83527).

(c) Bevel all edges of the fiberglass patch 1/4Inch deep and 30 degrees from the top surface so thenylon spa shield will fit smoothly over the patch.

NOTEFor ceramic having raised edges at thejoints, one side of the patch may becut short of the 3 inch overlaprequirement. If the crack extendsthrough a raised edge on the tile,shape the patch, by undercutting, to fitover the raised edge. Use goodjudgment in determining this, bearing.In mind that the patch is to restorestructural integrity of the panel Whenpatching along a panel edge, cut patchto fit the edge boundary alongperiphery of the tile.

(d) Remove existing sealant residue fromthe tile surface by using a solution consisting of 50percent by volume of Petroleum Distillate Base, TT-T-291and Toluol, TT-T-548.

(e) Lightly abrade the fiberglass patchand ceramic surface surrounding the cracked area wherethe patch (or patches) is to be bonded.

(f) Clean the abraded ceramic and patchsurface using a clean cloth moistened with methyl ethylketone, TT-M-261. To obtain satisfactory adhesion, applysealant only to a clean dry surface, free of oil and grease.

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NOTEDo not use reclaimed solvents whenpreparing a surface for bonding.

(g) Mix Pro-Seal sealant according toparagraph 9-23c(4).

(h) Apply sealant to the ceramic surface,and press the fiberglass patch over the crack (or cracks)to be repaired.

(i) Apply metal clamps or weights to thepatch to apply contact pressure equal to about fivepounds per square inch.

(j) Place pieces of 1/8 inch fiberglass of1/4 inch plywood pads under the clamps to distribute theclamping force.

NOTEDo not use rigid pads, as these willconcentrate the clamping force on thepoint of contact and may crack theceramic tile. Maintenance activitieshaving the necessary equipment mayuse the vacuum bag method forclamping the patch to the tile surface.The vacuum bag process Is used forboth fabrication and repair of glassfabric reinforced plastic sheets. Theprocess consists of applying pressureby vacuum and then curing by infraredheat lamp or oven. An autoclave Isalso used to apply heat and pressurefor curing.

(k) Cure Pro-Seal sealant according toparagraph 9-23c(5).

(2) Repair and inspection of spalled or chippedtile. Repair and inspection procedures are as follows:

(a) Inspect for spalled or chipped tiles

(b) Repair spalled areas or chips In theceramic tile, except at the tile joints that do not exceed 1square inch, and whose depth (at any point) does notexceed 1/10 of the thickness of the ceramic material.

NOTE

• Do not repair armor panels wherespalled areas or chips have a

total area greater than 1 squareinch or a depth exceeding 1/10 ofthe thickness of the ceramicmaterial.

• Total allowable defects are 3 or

less cracks, chips, or spalls inany 2-inch square area. Edgechips or spalling are acceptablewithout limit within the 3/4-inchedge boundary of the tile aroundthe periphery of the armor panel.

(c) Repair spalled areas or chipsoccurring in the ceramic, if they do not exceed the limitsas specified, by applying Polysulfide Sealant Pro-Seal890.

(d) Fill the chipped or spalled areas withsealant, smooth flush with the ceramic surface and applya 1/8 Inch thick fiberglass patch The fiberglass patchshould overlap the chipped or spalled areas by three (3)inches on each side.

(e) Bevel all edges of the fiberglasspatch 1/4 inch deep and 30 degrees from the top surfaceso that the nylon spall shield will fit smoothly over thepatch.

NOTEFor ceramic having raised edges at thejoints, one side of the patch may becut short of the three inch overlaprequirement. If the crack extendsthrough a raised edge on the raisededge. When patching along a paneledge, cut patch to fit the edgeboundary along periphery of the tile.

(f) Remove existing sealant residue fromthe tile surface by using a solution of 50 percent byvolume of Petroleum Distillate Base, TT-T-291 andToluol, TT-T-548.

(g) Lightly abrade the fiberglass patch,the ceramic surface surrounding the spalled or chippedarea where the patch (or patches) are to be bonded, andthe inside surface of the chipped or spalled area.

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(h) Clean the abraded ceramic surface,including the fiberglass patch and the chipped or spalledsurface, using a clean cloth moistened with methyl ethylketone, TT-M-261. To obtain satisfactory adhesion,apply only to a clean dry surface, free of oil and grease.

NOTEDo not use reclaimed solvents whenpreparing a surface for bonding.

(i) Mix Pro-Seal sealant according toparagraph 9-23c(4).

(i) Apply Sealant mixture to theceramic surface, but first fill all spalled or chipped areaswith sealant and spread flush with the ceramic surface.

(k) Press the fiberglass patch (orpatches) over the filled area to be repaired.

(I) Attach metal clamps or weights tothe patch to apply contact pressure equal to about fivepounds per square Inch.

(m) Place pieces of 1/8 Inch fiberglassof 1/4 inch plywood pads under the clamps to distributethe clamping force.

NOTEDo not use rigid pads, as these willconcentrate the clamping force onthe point of contact and may crackthe ceramic tile. Maintenanceactivities having the necessaryequipment may use the vacuum bagmethods.

(n) Cure Pro-Seal sealant according toparagraph 9-23c(5).

(3) Repair and inspection of delaminatededges of backing. Repair and inspection procedures areas follows:

(a) Inspect edges of the backing fordelamination of the fiberglass layers.

NOTEA delamination 3 inches or less inlength may be repaired. No repairs

can be made if a delamination iflonger than 3 inches or if panel hasmore than one delamination.

(b) Remove dirt and grease from thedelaminated cavity before repairing as follows:

1 Inject methyl ethyl ketone(MEK) TT-M-261, into cavity with a syringe. Let solutionsoak for a few minutes to loosen the dirt and grease.

2 Draw out the contaminatedMEK with the syringe, or position the panel to allow theMEK to flow out by gravity. Repeat the procedure untilthe cavity is clean.

3 Volatize the MEK using anelectric hot air gun, or vacuum nozzle directed Into thecavity Continue procedure for 10 to 15 minutes Do notuse compressed air because oil and dirt in the air maycontaminate the cavity.

(c) Repair delamination of fiberglassplies along the edges of the backing by filling the voidswith epoxy resin using a DTA curing agent Mix 100 partsby weight of EPON 828, MIL-R-9300 (FSCM 36131)with 10 parts by weight of DTA O-D-1271 as follows:

1 Inject the resin with a syringeuntil the cavity is filled, then brush the edge surfacesmooth.

2 Attach metal clamps to therepaired area to rebond the fiberglass piles.

3 Place pieces of 1/8 inchfiberglass or 1/4 inch plywood pads under the clamps todistribute the clamping force.

NOTEDo not use rigid pads, as these willconcentrate the clamping force onthe point of contact and may crackthe ceramic tile.

(4) Repair and inspection of internaldelamination of backing. Repair and inspectionprocedures are as follows:

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(a) Inspect panels for internaldeliminations You can find the location and size of anyinternal delamination by lightly tapping the fiberglassreinforced plastic backing using a coin or small hammer.

NOTE

• The tapping sound will be a clearmetallic ring over well-bondedareas, and a dull thudding soundover delaminated areas. Tracethe outline of and delaminatedarea with chalk for referenceduring repair.

• Internal delamination up to 4inches in diameter are acceptablewithout repair. Although aballistic degradation does occurfrom a delamination of fiberglassplies, excessive resin in thedelamination cavity has a greaterdegrading effect. Excessiveresin promotes ballistic shearingas opposed to bulging of thefiberglass backing. Do not repairarmor panels with any internaldelamination in excess of 4inches in diameter or with morethan one area of internaldelamination.

(b) Repair internal delaminations byusing a resign and curing agent mixed as specified inparagraph 9-23d(3)(c).

(c) Drill a small hole at each end of thevoid (marked during inspection).

(d) Slowly inject resin using a syringeuntil void is filled and epoxy discharges from oppositehole. See figure 9-38 Additional holes may be needed ifair entrapment occurs when injecting the resin.

(e) Attach metal clamps or brace thepanel in a fixture to apply the required high contactpressure to seal the filled area. Use care to distributethe contact pressure to prevent damage to the ceramictile.

(f) Cure the panel at room temperaturefor five days.

NOTE

• Maintenance activities desiring torepair internal delaminationsmust have the required tools andfixtures to assure a tightrelamination.

• If the delamination cavity is filledwith resin without rebonding thefiberglass plies, the repair willhave reduced ballistic protection.

(5) Repair and inspection of minorscars and fraying of backing. Repair and inspectionprocedures are as follows:

(a) Inspect panel for scars orsurface abrasion, and for fraying along edges of thebacking.

NOTEAfter a time, fraying will occur onsome permanent, exposed edges ofthe panel having no protective edgemolding. You may repair frayededges, but only to edges normallyhaving no protective molding.

Figure 9-38. Delaminated Repair

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(b) Repair scars, scratches, or surfaceabrasion not penetrating through the facing, or fraying ofthe edges of the backing by first cleaning the damagedor frayed surface thoroughly and carefully using a cleancloth moistened with methyl ethyl ketone, TT-M-261 (orother approved cleaning agent).

(c) Lightly sand the damaged surfaceusing No 280 grit abrasive cloth. Clean the surfacethoroughly using methyl ethyl ketone. Remove moistureand solvents completely to prevent Inhibiting the curingof the resin.

(d) Apply one or two coats (dependingon seventy of the abrasion or fraying)of epoxy resinusing DTA cunning agent. Mix 100 parts by weight ofEpon 828MIL-R-9300 (FSCM 36131) with 10 parts byweight of DTA O-D-1271. Brush the surface smoothMethyl ethyl ketone may be added to lower viscosity ofthe solution for brushing using a maximum of 5 percentby weight

(e) Over this coated surface, apply asheet of cellophane L-C-110, or polyvinyl alcohol (PVA)film extending 2 or 3 inches beyond the surface.Cellophane or polyvinyl alcohol film will preventexposure to the air, and will provide a smooth bubble-free surface for the resin to cure.

(f) Tape the cellophane or PVA film inplace and work out all air bubbles and excessive resinby hand or by using a rubber squeegee.

(g) Cure at room temperature for 24hours. After the resin has cured or set, remove thecellophane or PVA film for finishing

(6) Repair and inspection of cuts and gougesin backing Repair and inspection procedures are asfollows

(a) Inspect for cuts and gouges in thebacking using special care to determine extent of thedamage.

(b) Count the number of fiberglass pliesthat have been damaged as accurately as possible.Mark the number on the backing next to the damagedarea.

(c) Repair cuts or gouges notexceeding three layers of fiberglass by first removingsuccessive layers of damaged laminate inapproximately oval patches (round corner rectangularpatches are permissible).

NOTEPatches must form a step pattern asshown in figure 9-39. Steps shouldbe at least 1/4 to 1/2 inch long Use acutting tool with a controlled cuttingdepth to facilitate the cutout and toavoid possible damage to the layersunderneath.

(d) Remove these sections by peelingfrom the center and working carefully back to thedesired perimeter of the cutout. Cut through theoverlaying ply in a series of cuts.

NOTEExercise care not to peel back or torupture the adhesion of thelamination layers beyond the cutoutperimeter.

(e) Scrape each step and wipe cleanwith a cloth moistened with methyl ethyl ketone TT-M-261

(f) Cut pieces of fiberglass cloth, type181, Cl 2, MIL-C-9084 to extract size, with the weavedirection such that they will overlay the original lay-up.

(g) Use the wet lay-up technique.Place the first ply of precut cloth on a clean lay-up table.Spread 45 to 50 percent of resin by weight on the cloth,using a squeegee to thoroughly impregnate all of thefabric.

(h) Lay-up the resin impregnated clothin the previously prepared cutout, being careful not toentrap any air under the fabric. Repeat the sameprocedure with the next ply.

(i) Place the last ply dry in the cutoutafter first coating the surface of the previous ply withresin.

(j) Replace each piece of fabric beingcareful to maintain the wet resin content (by weight)between 45-50 percent. Use resin and curing agent asspecified in paragraph 9-23d(3)(c).

(k) Cover the repair with cellophane L-C-110 or polyvinyl alcohol (PVA) film and press down tosmooth the patch and to expel air bubbles.

(l) Cure at room temperature for 24hours. After resign has cured or set, remove cellophaneor PVA film for finishing.

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Figure 9-39. Gouge Repair

(m) Sand smooth all repaired areasafter curing using No. 320-400 grit abrasive cloth.

(7) Repair and inspection of threaded insertsin backing. Repair and inspection procedures are asfollows:

(a) Inspect panel for loose insertsor damaged threads.

NOTEInserts in a composite fiberglass-plastic type of backing have atendency to work loose. It isimportant to replace any missinginsert as the heavy armor panels areseverely strained during a shockloading, such as a hard landing.

(b) Repair damaged Insert threads,where possible, using the proper sized tap to chasethreads.

(c) Where an insert is loose, drilltwo small holes, 180 degrees apart, in the fiberglass

backing next to the insert Angle the holes toward thebottom of the insert.

(d) Inject bonding compound, MetalsetA4 (FSCM 90414)with a syringe into one hole. Fillaround insert until compound discharges from secondhole.

NOTEMetalset A4 resin cement is furnishedas two compounds, Part A (resin) andPart B (hardener). Thoroughly mixPart A and Part B in a 1 to 1 ratio byweight or volume. Allow bondingcompound to cure at roomtemperature for 24 hours. Foraccelerated curing cure bondingcompound at 150°F (660C) for twohours. Excess Metalset A4 must beremoved before it hardens. Removeexcess resin with Toluol, TT-T-548.

(e) Replace rubber edge moldingafter abrading the inside surface using a fine wire wheel(0.004 inch diameter wire) or abrasive cloth.

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(f) Wipe with a cloth moistened withmethyl ethyl ketone TT-M-261

(g) Apply a sufficient amount ofcontact adhesive 1300Lto cover the inside surface ofthe rubber and the mating surface.

(h) Allow adhesive to dry until tacky.

(i) Carefully fit and press the moldingover the edge of the panel.

(j) Clean dirt and dust accumulationfrom the repaired panel using general purposedetergent. Do not use methyl ethyl ketone for cleaningthe fiberglass backing

CAUTIONProlonged contact of the fiberglassto methyl ethyl ketone or acetone willresult in detenoration of the resin.

(k) Rinse the washed area with clearwater and dry panel with a soft cloth Then permit panelto dry out thoroughly.

(I) Touch up repaired areas of spallshield and fiberglass backing with acrylic lacquer, MIL-L-81352

(m) Apply a base coat of epoxy primer,MIL-P-23377. Feather the primer coating onto tosurrounding color coat.

(n) Allow the primer to air dry for aminimum of 30 minutes.

(o) Apply two coats of acrylic lacquer tomatch the original finish color as applicable.

9-24. Cargo Tiedown Equipment. Cargo tiedownequipment devices may be assembled from webbing,nets, rope, cables, or fittings Use snaps, hooks, clamps,buckles or other acceptable fasteners. Install tensioningdevices or other means to provide a method oftightening and adjusting restraint system. Providecovers or guards to prevent damage to or jamming ofaircraft equipment, structure, or control cables. Inspectand repair In accordance with the applicablemaintenance manual.

9-25. Vibration Isolators. Vibration isolators are shockabsorbing mountings which absorb vibrations ormovements of a component. They are utilized witharmament equipment, electronic equipment,photographic equipment, instruments, instrumentpanels, and other like equipment requiring shockmounting.

a. Type of Vibration Isolators. Vibration isolatorsare commonly classified in three types open-type,closed-type, and combined vibration isolator mountingbase type.

(1) Open-type. Open-type vibration isolatorsare those on which the shock absorbing material isexposed, and are usually so constructed that the load issupported on rubber in shear (A and B, figure 9-40) orcompression (C, figure 9-40).

(2) Closed-type. Closed-type vibrationisolators are those on which the shock absorbingmaterial is enclosed by a metal cup or housing Theshock absorbing material is usually a coil spring, rubber,or metal mesh In compression, or a combination ofthese materials as shown in figure 9-41.

(3) Combined vibration isolator mountingbase type. Combined vibration Isolator mounting basetype vibration isolators are formed by combiningresilient material such as sponge rubber, metal meshpads, or coil springs with a mounting base andsupporting structure as shown in figure 9-42.

b. Installation of Vibration Isolators. Installation ofvibration Isolators should be accomplished in such amanner as to allow free movement of mountedequipment with adequate clearance around brackets,piping lines, and other items of equipment. Accomplishthe following procedures when Installing vibrationisolators:

(1) Measure vertical and horizontalclearance between equipment and nearest supportingstructure.

NOTEA vertical and horizontal clearance of1/16 inch shall be maintained.Maintain adequate distance betweenmounted equipment and nearestobject (bracket, pipe, line, structure,etc.).

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Figure 9-41. Closed-Type Vibration Isolators

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Figure 9-42. Combined Vibration Isolator Mounting Base

9-26. Elastic Shock Cord Assemblies Elastic shockcord assemblies are explained in the followingparagraphs.

a. Inspection and Testing. Inspection and testingof elastic shock cord assemblies are described in thefollowing paragraphs.

(1) Inspection. All cords installed in aircraftshall be visually inspected at each phase maintenanceinspection. Any cord that shows irregularity in diametermust be replaced. Cords found to be over five years oldwill not be considered serviceable Observe the followinginspection requirements:

• Cords in stock shall be inspected and testedevery six months as specified below. At thetime a test is made, a serviceable parts tag shallbe affixed to the spool or cord as follows

INSPECTEDDATE..ACCORDING TOTM 1-1500-204-23-1TO BE REINSPECTED AND RETESTED6 MONTHS FROM DATE HEREON

NOTESections of cord shipped to serviceactivities shall have a duplicate tagaffixed to provide information forreinspection date

• Cords in stock at all activities other than depotsshall be visually inspected for irregularities indiameter or other evidence of deteriorationand to see that serviceable parts tag is attachedas specified.

• Cords that fail to meet test requirements shallnot be installed on aircraft, but will be madeavailable for use on ground equipment or forother uses

• Cord requiring reinspection will be retested andretagged if facilities are available. If facilitiesare not available, cord shall be returned todepot for reinspection.

• Cords not suitable nor required for groundequipment or other uses shall beadministratively condemned or conditioncondemned.

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(2) Testing. Cords requiring testing shall betested when facilities are available. When facilities arenot available, return cords to depot for testing.Elongation testing should be accomplished in thefollowing manner:

(a) Test bungee or endless ring typecord as a complete unit using suitable jigs or spools andtest load specified in table 9-7.

(b) Jigs or spools for stretching shockabsorber cords should be smooth and not less than 11/2 inches in diameter to prevent damaging cords duringtesting.

(c) Prepare straight and elasticexerciser cords for testing by marking 6-inch gaugelengths on one side of cord. Use soft lead pencil formarking.

(d) Mark bungee cords with 6-inchgauge marks penciled on opposite sides of ring.

(e) Attach cord to be tested to suitablejigs or spools. Apply specified test pressure slowly

(f) After test load has been applied,remove cord from rig and measure between gaugemarks.

(g) Reject cords which elongate morethan 100 percent during test

(h) Reject cords which have gaugemarks more than 6 1/4 inches apart 10 minutes afterpressure is released.

(i) After testing, fill in and attach anAcceptable or Serviceable Tag (DD Form 1574) to cordwith a note:

To be reinspected and retested 6months from date hereon.

b. Fabrication Requirements. Elastic shock cordused for fabrication of assemblies shall not be over 20quarters (5 years)old from date of manufacture. Date ofmanufacture of elastic shock cord shall be determinedfrom table 9-8 Date of manufacture is indicated bycolored threads in the cotton braid. The first two coloredthreads indicate the year of manufacture and the thirdcolored thread indicates the quarter Replace cord usingthe following procedures'

(1) Cut the elastic shock cord square with aknife or other sharp cutting tool.

Table 9-7. Test Loads

Cord Diameter Inches Load pounds

Straight cord 1/4 133/8 801/2 1555/8 2253/4 360

Endless ring bungee 3/8 1557/16 2351/2 315

9/16 3805/8 450

11/16 5853/4 720

113/16 1000

Elastic Exerciser 3/16 55/16 7

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Table 9-8. Color Coding

Year Identification

1984 - Yellow1985 - Black1986 - Green1987 - Red1988 - Blue1989 - Yellow1990 - Black1991 - Green1992 - Red1993 - Blue

Quarter Identification

January RedFebruaryMarch

April BlueMayJune

July GreenAugustSeptember

October YellowNovemberDecember

NOTEFor succeeding years and quarters,this cycle repeats.

(2) Wrap cord with masking tape prior tocutting to prevent raveling of cotton braid duringsubsequent fabrication or handling operations.

(3) Stretch elastic shock cord to 2 1/4 timesits original free length

NOTEStretch fixtures used to elongateelastic shock cord will be capable ofsecurely holding ends of cordwithout slippage. When elasticshock cord is stretched to twice itsoriginal free length, stretch fixtureshall not damage cord ends.

(4) Dip or brush cut ends of elastic shockcord with a coat of sealant MIL-S-4383, and allow to air-dry.

NOTECoating should be heavy enough toprevent raveling of cotton braid

(5) Locate lockrings approximately 1/2 inchfrom ends of elastic shock cord, however, do not extendends of cord outside body of terminal fastener.

(6) Stretch elastic shock cord 50 percent inarea of lockring or splice location prior to crimpinglockring in place or serving elastic cord.

(7) Crimp lock rings securely in place to forma continuous ring around elastic shock cord.

(8) Accomplish serving of elastic shock cordusing the following items:

• Elastic cord, MIL-C-5651

• Cotton cord, Style A, No. 10 (Use for servingelastic shock cord 1/2-inch and smaller indiameter. )

• Nylon Cord, MIL-C-5040, Type I (Use forserving elastic shock cord larger than 1/2-inchdiameter )

NOTEMinimum serving lengths arespecified in table 9-9.

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Table 9-9. Minimum Serving Length

Elastic cord diameter Serving length(Inches)

(Inches)

1/4 1 1/23/8 21/2 2 1/25/8 3¾ 41 4

c. Identification. Colored threads in the outercover are used to indicate date of manufacture. Thecolor code for threads is given in table 9-8. Bungee andshock absorber cords have two threads to indicate yearand one to indicate quarter. Elastic exerciser cordshave three threads to indicate year and one for quarter.Elastic shock cord, used in some compass mounts, iscovered with a solid black braid with no colored threadto indicate date of manufacture. Although these cordsdo not have a limited shelf life, they must pass theelongation test before installation.

d. Fabrication Procedures. Fabricate elasticshock cord assemblies using the following procedures.

(1) Cut elastic shock cord a minimum of 4inches longer than required finished assembly length.

(2) Wrap ends of cut elastic shock cord withmasking tape to prevent raveling of cotton braid.

(3) Center mark required finished assemblylength on elastic shock cord as shown in figure 9-43.

Figure 9-43. Marking Elastic Shock Cord

(4) Measure back from each end of markedfinished assembly length a distance equal to lockringdimension specified in table 9-10, and mark thisdimension.

Table 9-10. Lockring Locating Dimensions

Cord size 3/8 Inch 1/2 Inch 5/8 Inch

LockrlngLocating dim 1.5 Inch 2.0 inch 2.25 inches

(5) Install end fittings back to back on elasticshock cord.

(6) Clamp elastic shock cord in a stretchfixture in such a manner that markings for finishedassembly length and lockring locations areapproximately equal distances between stretch fixturejaws.

(7) Stretch elastic shock cord until distancebetween cord markings has increased 50 percent.

(8) Crimp lockrings on cord at markedlocations. Crimp each ring until ring ends are in contactwith each other.

(9) Remove elastic shock cord from stretchfixture and cut elastic shock cord approximately 3/4 inchbeyond lockrings.

NOTEAfter cutting elastic shock cord, endswill shrink approximately 1/4 inch.

(10) Dip or brush cut ends of elastic shockcord with a coat of sealant, MIL-S-4383, and allow to air-dry. Coating should be heavy enough to preventraveling of cotton braid.

(11) Reinstall assembly in stretch fixture, andpull until finished assembly length has increased 50percent. Ensure that there is no slippage of lockrings orend fittings.

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e. Serving Elastic Shock Cord. Serve elasticshock cord using the following procedures:

(1) Secure adjacent sections of elastic shockcord in stretch fixture and mark minimum length of cordto be served. Minimum serving lengths are specified Intable 9-9.

(2) Stretch elastic shock cords until markedserving length has Increased 100 percent. Maintain thislength during entire serving operation.

(3) Use a piece of serving cord of sufficientlength to form a loop extending a minimum of 1 inchpast mark used to designate one end of elongatedserving area.

(4) Form a tail extending a minimum of 6-inches past mark used to designate other end ofelongated area, as shown in figure 9-44.

(5) Place loop on top of elastic shock cordsover area to be served.

NOTETypes of serving cord are specifiedin paragraph 9-26b, step (8).

(6) Hold loop firmly on top of adjacentsections of elastic shock cord and wrap serving cordaround elastic shock cord. Make wraps over loop usinga half hitch knot in serving cord at completion of eachwrap. Pull serving cord tight.

Figure 9-44. Preparation for Serving Shock Cord

(7) Continue serving elastic shock cord asspecified above until required length of serving hasbeen applied.

NOTEWhile serving, keep tail end of loopoutside of half hitches for a distanceof half the length of the requiredserving. Keep it under serving forreminder of required distance asshown in figure 9-45.

(8) When the required length of elastic shockcord has been served, put end of serving cord throughloop and pull tail end until both ends have been pulledthrough. Cut ends of serving cord as close as practicalto serving wraps.

f. Process Control. The following procedures areused for elastic shock cord process control:

(1) Accomplish periodic checks of storagearea to assure requirements of paragraph 9-26b arecomplied with

(2) Maintain control of elastic shock cord asspecified in TM 1-1500-204-23-6.

(3) Crimp lockrings securely in place withends of ring in contact with each other.

NOTE:LOOPS AROUND ELASTIC CORD ARE SHOWNSEPARATED FOR CLARITY OF SERVINGOPERATION.

Figure 9-45. Serving Elastic Shock Cord

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NOTESlight marking on ring caused bycrimping tool shall not be cause forrejection. Cotton braid caughtbetween crimped ends of lockringwill not be cause for rejectionproviding no elastic bands In shockcord are pinched or cut.

(4) Assure that minimum of 1/2 inch of elasticshock cord extends beyond last wrap of serving cord.

(5) Test finished elastic shock cordassemblies as outlined in paragraph 9-26d, step (11).

g. Storage of Elastic Shock Cords. In addition tothe general storage requirements for rubber items in TM1-1500-204-23-6, the following practices shall beemployed during storage of shock absorbers and elasticexerciser cords.

• Store cords so they shall not be subject tostresses.

• Keep stocks of cord at a minimum, butconsistent with operating requirements.

• Maintain temperature of storage area between32 and 80°F (0 and 270C) when possibleDuring summer months, keep elastic shockcord and assemblies In the coolest part of thestorage area.

• Locate storage area where elastic shock cordand assemblies shall be free of contact withoil, grease, solvent, fumes, direct sunlight, orlocal heat concentrations. Avoid storageadjacent to steam pipes, space heaters, orlike conditions.

• Do not store items containing chemicalsharmful to rubber products near elastic shockcord and assemblies.

• Store elastic shock cord and assemblies fromstorage areas for manufacture or delivery onthe basis of the oldest material being usedfirst. This assures that no cord shall spend anexcessive time in storage and thus lessen itsactive service life.

• Dispense elastic shock cord and assembliesfrom storage areas for manufacture ordelivery on the basis of the oldest materialbeing used first. This assures that no cordshall spend an excessive time in storage andthus lessen Its active service life.

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CHAPTER 10

ARCTIC, DESERT, AND TROPIC MAINTENANCE

10-1. General. Arctic, desert, and tropicmaintenance, inspections, and operations are explainedIn the following paragraphs.

10-2. Arctic Maintenance. The following paragraphscontain the basic principles and procedures which areessential for efficient utilization of aircraft, equipment,and personnel in arctic areas. The operation of aircraftIn arctic regions is seriously handicapped because of theeffect of the elements on both personnel andequipment. With a decrease in temperature, anincrease In time required to perform duties is inflicteddue to reduced flexibility of packings and rubber parts,higher viscosity of lubricants, and binding of metal partsdue to contraction. General procedures for all aircraftare discussed within these paragraphs. For specificproblems on a particular aircraft or piece of equipment,refer to the applicable maintenance manual.

a. Precautions. Maintenance personnel shallobserve the following precautions as a guide tosuccessful performance of duty In severe weather.

(1) Exercise care when stepping or walkingon snow or frost-covered or very cold surfaces.Wearing proper shoes will aid In walking on slipperysurfaces and reduce the possibility of injures fromslipping.

(2) Exercise caution when touching very coldmetal with bare hands, moisture on hands will tend tofreeze skin to metal. When practical, wear gloves andcover metal tool handles

(3) Do not exert excessive torque or tensionon bolts, nuts, cables, or similar items when makingrepairs on equipment that has been exposed to extremecold. These items tend to freeze or snap as metalexpands upon warming.

b. Preheating. The following paragraphs explaingeneral procedures for preheating aircraft and engines.

CAUTIONDo not permit air from heaters withtemperature In excess of 251oF(122oC) to blast against ignitionharness, flexible hose, self-sealingtanks, or other rubberized or fabricmaterials. Damage may otherwiseresult.

(1) Preheat requirements. Engine preheat isnormally required only on reciprocating engines. Jetengines do not require preheat unless the availableauxiliary power unit is not sufficient to overcomeadditional starter loads. Preheat requirements can beconsiderably reduced by following proper oil dilutionprocedures.

(2) Preheat for starting . At low temperature,apply heat to engine as a starting aid. Reduce starterloads by preheating engine, thereby reducing oilviscosity. Generally, preheat will not be required Iftemperature is above 0°F (-180C) and engine oil hasbeen properly diluted

(3) Preheat time. Preheat time required toprepare an engine for starting depends on outside airtemperature, size of engine, heater output, and velocityand direction of wind. Also, when oil dilution, method ofpreheat application, or use of covers and nose shieldsare inefficiently applied, the required preheat time willbe lengthened.

(4) Preheat application. Apply heat to boththe power and accessory sections until cylinder heat,temperature reaches 68°F (20°C). Do not rely entirelyupon temperature gauge as readings may be misleadingbecause of thermocouple being located in path of heaterblast. Where heater supply is limited, concentrate heaton rear accessory section, particularly main oil drain, oillines, and oil sump, with second priority going to nosegear, propeller hub, and power section.

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(5) Preheat for accessories. At temperaturebelow -22°F (-30oC), apply heat to batteries, featheringpumps, master brake cylinder, and actuating cylinders.Aircraft with constant speed drives for alternators shouldhave drives heated.

(6) Heater placement. Prevent possible heatloss during preheat period by placing heaters as closeas possible to aircraft, but avoid areas under fuel and oildrains, vents, or supplies Inspect heater ducts for leaks.Cover heater and ducts with noncombustible canvascovers Provide adequate fire bottles In flight area.

CAUTIONDo not apply heat directly againstplastic or plexi-glass windshields orwindows. Directly applied heat willcause crazing, cracking, anddiscoloration. Remove existingsnow deposits before heating crewcompartment. When cabin heat isapplied on the ground withtemperatures below freezing, thesnow will melt and causeaccumulation of Ice on top offuselage and windshields

(7) Preheat off light compartment. Apply heatto flight compartment and cabin to ensure operation ofinstruments and equipment, reduce windshield frosting,soften canopy seals, and Increase crew comfort. Heaterducts may also be positioned so as to direct heated airtoward any valves found to be sticking. Preheatvacuum pumps in aircraft employing vacuum-drivenInstruments to ensure low viscosity of oil In and aroundpumps and to prevent pump drive shaft from shearing.

c. Pre flight. The following procedures andinspections shall be accomplished during preflight foraircraft operating in arctic conditions.

(1) During severe weather, delay removal ofengine covers, propeller covers, flight compartmentcovers, and miscellaneous covers until just prior toengine start. Leave wing and empennage covers inplace until just prior to taxiing.

CAUTIONExercise care to prevent flow ofmelted Ice into areas where freezingwould cause restricted movement offlight controls and restricted flow ofair through vents. Where water flowstoward any of these areas, It shall bemopped up Immediately.

(2) Inspect entire aircraft for snow, frost, or ice.Any deposit can cause loss of lift and treacherousstalling characteristics. Brush off loose snow or frost.Remove remaining ice by spraying or brushing on a coatof anti-icing and deicing-defrosting fluid, MIL-A-8243.Work from upper surfaces downward to preventaccumulation of ice on previously cleared surfaces.

(3) When rapid frosting occurs after initialremoval, apply a coat of defrosting fluid to retardaccumulation of frost before taxiing. Also apply a coatof defrosting fluid after the last flight of the day to helpretard further accumulation of ice, snow, or frost.

(4) Inspect control surfaces for freedom ofoperation. Sudden temperature drops will cause ice toform on the inside of the surfaces as well as on theoutside. When evident that ice has formed on the insiderestricting control surface movement, remove byapplication of heat.

(5) Inspect windows and windshields forcracks. To prevent cracking, open all windows beforeremoving aircraft from heated hanger.

(6) Inspect fuel and oil tank caps and ventsand crank-case breathers for presence of ice, snow, orfrozen condensate. Plugged lines or vents can causecollapsing fuel tanks and swelling of oil tanks.

(7) Inspect wing and fuselage drains andvents for ice and snow. Thaw clogged drains or vents.

(8) Inspect fuel and oil tank sumps for ice.Where water condensate has frozen, heat to permitdrainage.

(9) Inspect hydraulic reservoirs forevidence of freezing. If evident, apply heat to thaw.

(10) Inspect cylinder struts and hydraulicpistons for accumulation of dirt and ice. Ice and gritwhich will damage cylinder strut packings shall beremoved. Pistons shall be wiped with a clean clothsaturated in hydraulic fluid, MIL-H-5606.

(11) Using an auxiliary power source, checkradios and electrically operated controls and equipmentfor proper operation.

(12) Inspect exposed limit switches andmicroswitches for presence of Ice or snow and forproper operation.

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(13) Inspect hydraulic accumulators, landinggear struts, and tires for proper inflation. Air pressureswill drop due to a temperature drop.

NOTEExposure of aircraft to lowtemperatures will cause contractionof metals and hardening of rubberseals. Frequent inspections forleakage and looseness ofconnections is necessary to preventleakage.

d. Anti-Icing, Deicing, and Defrosting. A protectivecoating of unheated, undiluted, anti-icing and deicing-defrosting fluid will prevent frozen accumulations fromforming on aircraft surfaces if applied before freezingconditions begin and as often as necessary during theprecipitation. Any frost or thin layer of ice that doesform can be removed easily by application of additionalfluid. A protective coating of fluid applied beforeinstallation of covers will permit easy removal with aminimum sticking of covers.

WARNINGWhen handling and applying glycol-water products, wear eye, hand, andbody protection. Avoid Inhalingvapors and skin contact. FollowMaterial Safety Data Sheetprocedures for individual productuse Injury may otherwise result.

(1) Types of fluid Anti-icing, deicing, anddefrosting fluid characteristics are explained in thefollowing paragraphs.

(a) Ethylene/propylene glycol. Anti-icing and deicing-defrosting fluid, specification MIL-A-8243B, is basically a mixture of ethylene glycol andpropylene glycol and Is recommended for preventingformation and removing deposits of frost, ice, and snowon exterior aircraft surfaces on the ground intemperatures ranging from -65 to 32°F (-54 to 0°C).Ethylene glycol and propylene glycol are formulated withintrinsic corrosion Inhibitor, as prescribed In MIL-A-8243B.

(b) Glycol-water. Glycol-water anti-icing and deicing-defrosting fluids, including MIL-A-8243anti-Icing fluid, are not recommended for use aroundaircraft electronic equipment which employs silver orsilver coated electrical/electronic circuitry.

WARNINGRapid oxidation and fire can occurwhen glyco-water solutions come in

contact with a short across bare ordefective insulated silver or silver-coated electrical circuits such aswiring, switches, and circuit breakerswhich carry positive direct current(dc), such as electronic black boxes.

NOTEThe fluid shall be homogenous andfree of sediment and abrasive. Aslight waxy separation in the fluidshall be no cause for rejection if theseparation is dispersable by severalseconds of moderate agitation Fluidshall remain dispersed for at least 24hours.

(2) Fluid application. The followingparagraphs describe methods and equipment used toapply antiicing, deicing, and defrosting fluids.

WARNINGSpecial care must be taken bypersonnel to prevent slipping andfalling when walking on wingsurfaces coated with deicing fluid.Otherwise death or injury mayresult.

(a) Spray method. If hangars,covers, or equipment for heating fluid-water solutionsare unavailable, the preventive spray method will beused to maintain standby and alert aircraft in a state ofreadiness. The preventive spray method Is applicationof cold, undiluted fluid on surface to be protected in aquantity to wet the area thoroughly without excessivedrainage

(b) Spray pattern. Suitable sprayequipment should be used, as application of fluid isdone best by spraying surfaces. Spray should not beapplied in a solid stream, but be fine enough to preventwaste. A fanshaped pattern is recommended

(c) Spray equipment. Cleaning orother decontaminating equipment may be modified tospray deicing fluids. Spray guns on this equipment canbe used as they are, but better spray coverage can beobtained if they are modified slightly. A commongarden hose nozzle will give satisfactory result Inaccumulation removal if the solid stream is used. Thisnozzle also can be used to apply a protective coating offluid if a fine conical spray is used.

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(d) Spray nozzles. The three nozzlesshown in figure 10-1 may be fabricated in any base shopand used with equipment in the preceding paragraph (c)with good results. Each is explained in the followingparagraphs.

1 Bent tube nozzle. The benttube nozzle is made by drilling approximately 60 holesalong the longitudinal axis through one side of analuminum, brass, or steel tube. Holes are 0.043-inchdiameter. Tube is capped and bent in a tube bender togive about a 90-degree fan spray.

2 Pipe nipple nozzle. The pipenipple nozzle consists of a one-inch pipe nipple with0.0512-inch holes drilled radially around 90 degreesfrom outer edge.

3 Pipe cap nozzle. The pipe capnozzle is hardest to fabricate. It consists of a 3/4 orone-inch pipe cap with 0.0312-inch drilled holes incenter and 0.0469-inch drilled holes toward edges, allradiating from a point In base of cap.

(e) Aftemate application method.Cold deicing fluid may be applied with a mop, broom, orsoft bristle brush if spray equipment is unavailable.

(f) Support equipment. Use ofmaintenance stands and work platforms isrecommended to position personnel safely near wingand tail surfaces during application of fluid.

e. Prevention and Removal of Snow, Ice,and Frost Deposits. The following paragraphs containmethods for the prevention and removal of snow, ice,and frost deposits.

(1) Prevention of deposits. Thefollowing paragraphs explain the prevention of snow,ice, and frost deposits.

(a) Snow depositprevention. If snow is expected, wing and tail coversshould be used. Deicing fluid should not be used forprotective coating if snow is predicted, except inconjunction with installation of covers. If attempts aremade to use the fluid to prevent snow accumulation, afrozen deposit will be encountered which is difficult toremove. The fluid is diluted by the melting snow to forma slush which freezes in place. Use of covers aftercoating aircraft surfaces with fluid will prevent snowfrom forming directly on aircraft and permit easyremoval of covers. If covers are unavailable, the bestmethod of preventing heavy snow accumulation isconstant removal by brushing or sweeping during thesnowfall.

Figure 10-1. Types of Spray Nozzles

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(b) Ice deposit prevention. Deicing fluidwill protect aircraft surfaces as long as it remains on thesurfaces. However, freezing rain will tend to washsurfaces clean of fluid, as well as dilute the fluid to thepoint at which ice will form. The amount of protectionafforded by the fluid depends on the amount of freezingrain. The following steps should be taken if ice caused byfreezing rain is expected.

1 On aircraft for which covers areavailable, a coating of fluid applied before covers areinstalled will prevent covers from freezing on aircraftsurfaces and make removal of covers much easier.However, care should be taken to ensure that only aminimum amount of rain is allowed to blow under coversOtherwise, dilution of fluid will allow freezing to occur

2 On larger aircraft for whichcovers are unavailable, the best method of prevention isto keep the surfaces wet with fluid. As long as this fluidremains on the surface, protection is afforded. Since raineventually will dilute the fluid and render it ineffective forpreventing ice formation, protection must be maintainedduring precipitation by continual spraying of fluid. Ifweather conditions are such that It is impossible toprevent ice formation, removal should be accomplished

(c) Frost deposit prevention. Asatisfactory procedure for protection of aircraft from frostis the application of a layer of unheated, undiluted, de-icing fluid to aircraft surfaces after the last flight of the dayor as close to midnight as possible, whichever is later.This should permit early morning departure without furtherfluid application. The length of time that an aircraft will beprotected by a single coat of fluid depends on the climaticconditions.

(2) Removal of deposits. The followingparagraphs explain the removal of snow, ice, and frostdeposits.

CAUTIONExtreme care shall be taken toprevent damage to aircraft. Sharpinstruments, such as picks, knives,or screwdrivers, will not be used toloosen ice formation

(a) Snow removal. Deicing fluids should notbe used to remove heavy snow accumulation. Snowabsorbs wasteful amounts of fluid to form a slush which isdifficult to remove and eventually will refreeze. The slushwill get into control surface hinges and freeze, causingadditional difficulty. Snow will be removed by brushing orsweeping or by moving the covers. Usually after snow

removal, a layer of rough ice remains. This frozen crustcan be removed with hot, diluted, deicing fluid. In anemergency when aircraft must get off ground as quicklyas possible, thin layers of snow can be removed with hot,diluted, deicing fluid. If sufficient fluid is used, thecombination of heat from fluid and force of the stream willpermit removal of slush, as it Is formed withoutrefreezing. Quantity of heated fluid required for snowremoval Is prohibitive. Remove snow, water and Ice fromaircraft fuel filler cap wells before removing fuel filler cap.Only one filler cap should be removed at a time, and itshould be replaced immediately after servicing iscompleted.

(b) Ice and frost removal. If hangarsand covers cannot be used to prevent frozen formationson aircraft, but equipment is available for heatingfluidwater solutions, removal of frozen formations by hot,diluted, deicing fluid will be used in place of preventivespraying. Accumulations should be allowed to form andthen be removed just after each precipitation or justbefore each flight, whichever is most practicable orcompatible with operational mission of the aircraft

f. Preventive Maintenance. Accomplish thefollowing preventive maintenance procedures

(1) Avoid parking aircraft in wet or slushyareas.

(2) Use caution when towing aircraft Inextremely low temperatures to prevent damage tohydraulic seals which would result In strut leakage.

(3) Inspect oil and fuel drains and crankcasebreathers for ice and frost Remove any existing frost orice.

(4) If layovers are to be over 4 hours andtemperature is below -20°F (-290°C), remove battery andstore in a warm place.

(5) Drain oil system when there is no provisionavailable for preheating oil and a long layover period isanticipated.

(6) When temperature rises above freezingduring a long layover, drain fuel and oil tank sumps ofwater before temperature drops.

(7) Install protective covers and shields toprotect aircraft from accumulation of snow, frost, or ice.

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(8) Partly open canopy when parkingaircraft for the night, or provide some other opening toprevent accumulation of frost on windows.

(9) Clean dirt, ice, and grit from landinggear struts and hydraulic pistons. Wipe struts with aclean cloth saturated in hydraulic fluid, MIL-H-5606.Inspect struts for proper inflation.

(10) Inspect tires for proper Inflation.

(11) Install or remove snow and ice-grip tires to comply with change of seasons. Use ofsnow and ice grip tires on clear, hard surfaced runwaysreduces the life and effectiveness of the tires.

(12) In emergency arctic conditions,tie down aircraft using trees or the arctic-type mooringanchor shown in figure 10-2. The following procedurescan be used to construct an arctic-type mooring.

(a) Thaw ground with fire where pit is tobe dug.

CAUTIONDuring thawing operation, no aircraftwill be parked within a 100-footradius of operation. Damage toequipment may otherwise result.

(b) Dig pit a minimum of 3 feetdeep and wide enough to accommodate a 3-foot lengthof log or similar object.

(c) Connect rope, insert log orsimilar object and fill pit with gravel and snow.

10-3. Desert Maintenance. The following paragraphscontain the basic principles and procedures which areessential for efficient utilization of aircraft, equipment,and personnel in desert areas. In the desert, aircraftcan be protected from deterioration problems by usingprotective covers, preventive maintenance, andmaintaining regular inspections. These paragraphs arenot considered as a substitute for detailed maintenanceand operating instructions, but as a supplement to eachaircraft operation and maintenance manual.

Figure 10-2. Arctic-type Mooring

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a. Deterioration Factors. Deterioration problemsresult from sand and dust, high day temperatures,temperature fluctuations, ultraviolet radiation, andterrain. Considerations for each problem are explainedin the following paragraphs.

(1) Sand and dust. The large quantities ofloose sand and dust create serious erosion problems forrotor blades, propellers, turbine engine compressors,windshields and other exposed surfaces of the aircraftWhile sitting on the ground, the aircraft is exposed toblowing sand and dust from frequent desert windstormsand sand and dust clouds created by vehicular trafficand operation of other aircraft nearby. Sand and dustparticles collect on all surfaces of the aircraft and willpenetrate almost any crack or crevice to accumulateInside the aircraft. Electronic gear and opticalequipment are very susceptible to sand and dust.Weapons are particularly susceptible since many partsare often covered with a light coat of lubricant.

(2) High day temperature. In the desert,heat creates serious problems for people andequipment. The temperature inside a parked aircraftwhich has been closed up to keep the sand and dust outcan reach temperatures much higher than outsidetemperatures Extreme heat can cause the failsafedevice in electronic gear to shut the equipment off.High temperatures can cause lubricants to break down,distort seals and gaskets, and result in Increased leakingproblems. Other problems due to high temperaturesinclude softening of plastics, high stress on pressurizedcontainers, and shortened battery life.

(3) Temperature fluctuations Daytimetemperatures can reach over 100°F (38°C), while nighttime temperatures could reach freezing (or close to it)The condensation resulting from this extremetemperature variation contributes to increased corrosion.

(4) Ultraviolet radiation. The abundantdesert sunlight produces a high level of ultravioletradiation which can cause unprotected plasticcomponents to become very brittle and easily crackedUltraviolet radiation also accelerates deterioration ofnylon webbing used in seats and restraint systems.

(5) Terrain. The terrain causes problemswith moving aircraft and associated support equipmenton the ground Sand can bog a vehicle or aircraft downto the axles. A condition known as Cap Rock Is oftenencountered The terrain appears rocky, however, thesubstrate will not support weight and a vehicle can sinkup to the frame when attempting to travel over CapRock. Aircraft tires can easily be damaged In rockydesert terrain.

b. Precautions. Maintenance personnel willobserve the following precautions as a guide tosuccessful performance of duty under desert conditions:

WARNINGSevere burns can result when bareskin touches metal parts of aircraftor equipment.

• Exercise caution when touching aircraft surfaces ormetal tools that have been exposed to the sun.Wear gloves and use mats or pad, when practical, toprevent burns or blisters.

• Use extreme care when handling engine fuel attemperatures above 120°F (49oC), to preventpossible sparks and explosion. Open gasolinedrums with bronze or other nonsparking tools.

• Electronic gear and optics must be shielded fromdirect sunlight and/or otherwise cooled for efficientoperation.

c. Inspection and Maintenance. The followingprocedures are for the inspection and maintenance ofaircraft operating in desert conditions:

NOTEAircraft should be cleaned dailyFrequent use of a vacuum cleaner willprevent accumulation of sand and dustin aircraft. Pay particular attention toabrasion/erosion problems duringInspections.

(1) Inspect bungee cords, seals, tires, etc.,frequently for blisters and other signs of deterioration.

(2) Inspect vibration Isolators every twoweeks and replace where cracking or permanent set isexcessive.

(3) Keep a chart showing engine oilconsumption. A sharp rise on the chart will indicatefaulty or inefficient engine operation. An inefficientengine should not be continually operated. It is better tocorrect the trouble so the engine will operate at peakperformance.

(4) Inspect, clean, or replace filters atregular intervals. Sand and dust quickly choke fuel andoil filters and air cleaners. Keep an adequate reservestock of cleaners and filters.

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(5) Keep parachute pack flaps sealed andcovered when not in use. Seals must be removedbefore takeoff.

(6) Inspect and clean flags, control hingespulleys, bearings, worm gears, cowl slides, landing gear,and tail wheel assemblies regularly to arrest corrosiveaction.

(7) Inspect aircraft regularly for adequatelubrication, leakage, contaminated hydraulic fluid,specific cable tension, and condition of materials, suchas rubber and hydraulic equipment. Excess lubricantmust be wiped off all exposed bearing surfaces, joints,fittings, components, and fuselage.

(8) Carefully smooth pitted propellers (if notbeyond permissible limits) with a fine file and emerycloth. Remove all rough burrs and ragged edges aroundpits at frequent intervals.

(9) Inspect dead air spaces in wings,fuselage, and tail group at regular intervals foraccumulation of sand. Remove accumulated sand toprevent a weight and balance change of aircraft.

(10) Clean engines, where possible, with ahighpressure spray gun filled with appropriate cleaningfluid.

(11) Clean instrument filters thoroughly atregular intervals. Replace wornout filters promptly

(12) Clean oil and gasoline tanksperiodically, as sand accumulates in corners, seams,and bottom of tanks.

(13) Clean metal parts not In use carefully,cover with grease, and either wrap or store away fromsand and dust.

(14) Clean Plexiglas surfaces with cleanwater. Do not rub Plexiglas surfaces during cleaning noruse Plexiglas cleaning kit.

d. Preventive Maintenance. Accomplish thefollowing preventive maintenance procedures:

(1) Protect aircraft from excessive surfacetemperatures by covering with canvas or native matting.Use protective covers as soon as possible prior tooperation. Covers over Plexiglas should be installed sothat they do not touch the surface of the glass. Barriermaterial may be installed for this purpose.

NOTEEnsure that all weather stripping ondoors, panels, covers, etc, isserviceable and that these items areadjusted to make proper contact withsealing surface

(2) Leave canopy partly open, exceptduring dust or rain storms, to permit circulation of airwithin the flight compartment.

NOTEEnsure that sealant Installed aroundwindows, seams, chin bubbles, andsheet metal repairs is serviceable.

(3) Install protective covers and dustexcluder plugs on all engine openings, vents, airintakes, exhaust outlets, breathers, propeller hubs andfeathering domes, cowls, and other vital openings toprevent entry of sand and dust. Keep aircraft pointedinto wind when not being serviced or prepared for flight.

(4) Run up engine on a hard surface, asshown In figure 10-3, such as a landing mat, or sandand dust-free area, to prevent sand blasting, rotor blade,propeller, fuselage, and tail surfaces. Landing/taxi areashould be located as far as possible from maintenancearea and allow as much space between aircraft astactically feasible.

(5) Never taxi aircraft under its own powerunless necessary. This will aid preventing pitting of therotor blade, propeller, fuselage, and tail surfaces Towaircraft, using proper tow fittings. Do not move aircraftover desert crust or hardpan any more than necessary.

(6) Keep pitot heads and gyro Instrumentventuri covered when not in use.

(7) Make all possible ground checks beforestarting engine. Inspect controls for freedom ofmovement to ensure no binding is caused by sand.

(8) Do not run up aircraft in such a manneras to damage other aircraft or injure personnel by blownsand. Engine should never be run on ground longerthan necessary. Use ground guides to prevent landinggear from resting on sharp rocks while parking aircraft.

(9) Do all shop (bench) repairs in enclosedshelter. Never use sand-encrusted tools on aircraft.

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Figure 10-3. Construction of Hard Stands

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(10) When possible, accomplish repairs andservicing during early morning hours, or in lateafternoon, evening, and night, when heat is less intense.Desert camouflage netting can be used for shade.

(11) Ground aircraft, funnel, and fuel nozzleduring refueling operation. Accomplish filling ofgasoline from cans, using a filter funnel that fits snuglyinto tank opening Exercise every precaution to excludesand from gasoline and oil during servicing operations.

(12) Where possible, service oil systemdirectly from can to oil tank, without using anintermediate measuring can.

(13) Keep lubricants and gasoline drumscovered, and where possible, maintain storagetemperature below 120°F (49oC).

(14) Use polarized sunglasses duringsunlight hours.

(15) Use eye protection in blowingsand/dust. Extra measures should be used to secureaircraft and shelter.

(16) Ensure voltage regulators are properlyset during all temperature changes.

(17) Tape all opening or seams aroundwindows, chin bubbles, seldom used access panels, etc,being sure not to Inhibit or restrict airflow required forcooling, or increase Infrared (IR) signature. An entry isrequired on DA Form 2408-13 in the aircraft log bookafter tape has been Installed. Use tape MIL-T-21595Type I.

10-4. Tropic Maintenance. The following paragraphscontain basic principles and procedures essential forefficient utilization of aircraft equipment and personnelin tropic areas. Factors having deteriorating influenceon fabrics in tropic areas can be categorized as highhumidity, high temperatures, salt-laden air, andsunshine. These factors create corrosion, rot, mildew,and mold Preventing these deteriorating effects toensure safety and proper operation requires constant,regular Inspections and preventive maintenancemeasures This paragraph is not to be considered as asubstitute for detailed maintenance and operatinginstruction, but as a supplement to each aircraftoperation and maintenance manual.

a. Inspection and Preventive Maintenance.Proper cleaning, packaging, and storing ensures longerlife and serviceability of aircraft and equipment. Thefollowing practices should be used as a guide:

(1) Treat corrosion-affected area.

(2) Prevent rot, mildew, and mold bykeeping fabrics, rubber, and other susceptible items asdry as possible. Clean fabrics in aircraft daily. Theeffects of moisture and fungus on fabrics are listed intable 10-1.

(3) Operate all heat-producing electricalequipment daily to remove moisture. When thisprocedure is not practical, dry equipment using a groundheater or by placing in sun.

(4) Wash aircraft often, and lubricatemoving parts when aircraft is exposed to salt-laden airor mud.

CAUTIONBefore drilling holes, ensure that theaircraft will not be weakenedstructurally and the operatingcharacteristics will not be adverselyaffected. Damage may otherwiseresult.

(5) Keep all drain holes clear ofobstructions, and drill holes where necessary in wings,fuselage, enclosed equipment, etc., (when approved bythe maintenance officer), to facilitate draining where anoticeable accumulation of water Is observed.

(6) Leave canopy windows or doors openwhen aircraft is parked In sun to permit air circulationwithin flight compartment Protect windshields andwindows from sun by covering with canvas.

(7) Blow out brakes frequently withcompressed air when operating from muddy or dustyfields to prevent damage to brake disks.

(8) To prevent rust, wipe control cables dailywith an oily rag.

(9) Check battery every third day tomaintain proper electrolyte level.

(10) Every 25 hours, dip paper air filtercartridges in leaded gasoline and dry thoroughly.

(11) Drain all fuel traps and strainersimmediately prior to flight.

(12) While aircraft is on ground, avoidexcessive water in fuel systems by keeping fuel tankscompletely filled.

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Table 10-1. Part and Fabrics Affected by Moisture and Fungi

Part or fabric Effects of moisture and fungi

Cotton, Linen, Paper, and Cellulose Derivatives: Insulating and dielectric properties are lost orInsulation, coverings, webbing, belting, laminations, impaired by moisture, causing arcing, flash-oversdielectrics, etc. and cross talk. Fungi causes rot and complete

destruction.

Fiber: Terminal strips and insulators. Moisture causes electrical leakage paths to form,in turn, causing flash-overs, cross talk, and lossof insulating properties Fiber terminal strips andinsulators are destroyed by fungi.

Fiber: Washers, supports, etc. Moisture causes swelling which, in turn, causessupports to misalign, resulting in binding ofsupported parts Washers are destroyed by fungi.

Glass Lenses, windows, etc. Fungi grow on organic dust, insect tracks, insectfeces, dead insects, etc. Dead mites and fungusgrowth on glass obscures visibility and corrodesnearby metal parts.

Laminated Plastics: Terminal strips and boards, Moisture causes electrical leakage paths to form,switchboard panels, etc, tube sockets and coil . in turn, causing flash-overs, cross talk, and lossforms, and connectors of insulating properties Delamination occurs

and fungi grow on surfaces and around edgesExtreme temperature changes cause expansionand contraction.

Leathers Straps, cases, gaskets, etc. Fungus destroys tanning and protectivematerials, causing rotting due to moisturebacteria fungi.

Metals High temperature and moisture vapor causerapid corrosion Fungus and bacterial growthproduce acids and other products which speedcorrosion, etching of surfaces, and oxidationThis interferes with the operation of movingparts, screws, etc. and causes dust betweenterminals, capacitor plates, air condensers, etc,thus causing noise, loss in sensitivity, and arc-overs.

Metals Two or more. Different metals which have different potentialswhen moisture is present cause electrolysis,thus causing formation of salts and beep etchingof surfaces as one metal is plated onto the otherThis happens at riveted and bolted joints,bearings, slides, and screw threads.

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Table 10-1. Parts and Fabrics Affected by Moisture and Fungi - CONT

Part or fabric Effects of moisture and fungi

Molded Plastics: Terminal strips and boards, switchboard Machined, sawed, or ground edges or surfacespanels, connectors, etc., and tube sockets and coil forms. are supporters of fungi, causing shorts and flash-

overs. Fungus growth reduces resistance be-tween parts mounted on plastic to such anextent that the item Is useless.

Soldered joints Excessive soldering flux on terminal boardsholds moisture, which speeds up corrosion andgrowth of fungi Soldering irons should notcome in contact with wire insulation.

Wax: For impregnation Fungus-inhibiting waxes which are not cleansupport fungi, thus causing destruction ofinsulating and protective qualities and permittingentrance of moisture which destroys parts andunbalances electrical circuit.

Wood: Cases, houses and housings, plastics fillers, Moisture and fungi cause dry rot, swelling, andmasts, etc. delamination.

(13) Run up reciprocating engines at leastonce every third day.

(14) Operate gas turbine engines at leastonce every seven days for approximately 10 minutes atflight idle.

(15) Inspect webbing for wear and fungi.

(16) Inspect canvas or duct covers forwear, torn seams, stains, fungi, etc.

b. Parts and Fabrics Affected by Moisture andFungi. Parts and fabrics affected by moisture and fungiare shown In table 10-1.

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CHAPTER 11AVIATION LIFE SUPPORT EQUIPMENT MAINTENANCE

11-1. General. Organizing Aviation Life SupportEquipment (ALSE) servicing facilities is based on manyfactors, such as the number of aircrew membersassigned, and the type and quantity of equipment. Withthis in mind, the ALSE maintenance shop should be tai-lored to the needs of the aviation unit, activity or facility.The minimum standards for the ALSE facility and equipment contained in this Technical Manual (TM) are notmandatory requirements, but are standards which canbe used for planning purposes. Local Commanders areauthorized to deviate from these standards whenevercircumstances cannot be reasonably obtained. It will bethe responsibility of the local Commander to be certainthat any deviation permitted will not foster unsafe orunsanitary practices, recognizing that ALSE has specificareas of supporting the user in hostile conditions i.e.,high altitude, in water, land survival, etc. This equipmentmust perform to standards the first time upon being acti-vated for use. These standards will not be compromised.

11-2. Administration. Administration of the unit LifeSupport Program must have the Commander’s approval.The unit Training Officer must provide scheduling timeand training for ALSE. Included should be Code of Con-duct/Survival, Evasion, Resistance, and Escape (SERE)Training in accordance with AR 350-30. The unit AviationALSE Officer must not only supervise the ALSE techni-cian’s work, but also the training of the unit aircrew per-sonnel in the care and use of ALSE, and survival training.The ALSE technician will inspect, repair/replace, andservice the equipment in accordance with the applicableTechnical Manuals (TMs), Technical Orders (TOs), andNaval Air Manuals (NAVAIRs), and maintain the requiredforms and records as well as supervise the ALSE trainingperformed by aircrew personnel.

11-3. Safety. The ALSE maintenance area will complywith all Army safety regulations and unit Standing Opera-tion Procedures (SOP). The area will have all regulatorysigns i.e., NO SMOKING, EXIT, OXYGEN, etc., conspic-uously posted. Horseplay will not be tolerated or per-mitted in the area at any time. Personal safety equipmentwill be used while working/servicing ALSE i.e., goggles,face shield, apron, gloves, etc. Fire extinguishers will belocated as needed by type and weight. It is recom-mended an extinguisher be located in e achof the uork, Tj -0.2648 -11.24 TD 0.0323 Tc 0.2515 Tw (Tsoryag, and Eaministratiov area s) Tj ET BT 0.9288 0 0 1 631.32 66768 Tm /F1 10.8 Tf 0.021 Tc -0.6166 Tw (11-34 Personael.) Tj ET BT 0.9262 0 0 1 6422.64 66762 Tm /F1 10.8 Tf 0.00276 Tc 1.2983 Tw (lMintenance af ALSE,will be)per-

formsd orly sy tcheool-rainie, aqalsifid oersonnel.

TM 1-1500-204-23-1

11-7. Maintenance Area. The ALSE maintenancearea consists of work, storage, and fitting areas. Accessto a classroom adjacent to or in close proximity of the lifesupport area is desired for lectures and instructions onthe equipment being used and survival conditions. Theshop should contain not less than 1,000 square feet ofusable area that is environmentally controlled within arange of +60°F (15.6°C) to 75°F (23.8°C) and have apotable water source i.e., hot and cold water. The areawill be protected from pilferage, dampness, fire, dust,insects, rodents, direct sunlight, and be free from uncon-trolled foot and vehicle traffic. To ensure that all ALSE ismaintained in a high state of readiness through inspect-ing, cleaning, fitting, testing, adjusting, and repairing, allmaintenance will be in accordance with the applicableTM, TO, or NAVAIR. For additional information refer toFM 1-508. Table 11-1 lists recommended test equipmentfor the ALSE work area.

11-8. Work Area Criteria. The work area will havebench surfaces free from rough or abrasive materials,splinter-free tops with a nonporous surface. The area isto be well-lighted with accessible electrical outlets to allbench and desk areas. Cabinets and work benches/tables with locks should be used for securing test equip-ment, tools, and supplies. Units that have oxygen equip-ment will have an area set aside for oxygen maintenancethat will have hot and cold running water, stainless steelsinks, and floors that are sealed and protected fromspills. The area will be restricted to ALSE personnel only.Units supporting flotation equipment will have a moistureand oil-free source of low-pressure, high-volume air anda vacuum source. A vacuum cleaner may be used; how-ever, the vacuum cleaner must not be used for cleaningat any time, because dirt and dust must not be inducedinto the flotation cells. The floor of the work shop will besealed and coated to prevent chemical spills from pene-trating the floor surface. The work area will have hot andcold running water for cleaning equipment as well as awash area. Cleanliness is very important in maintainingthe equipment. Smoking, eating or drinking should not bepermitted in the area.

11-9. Storage Area Criteria. The storage area will bewell-ventilated, out of direct sunlight, and well-lighted.The storage area will have storage shelves and cabinetsthat provide security for the stored equipment and be freefrom dust, moisture, fire, insects, and rodents. The flooris to be sealed and covered with a dust-free flooringmaterial. A refrigerator will be used to store batteriesused in life support equipment; because of health andfood service regulations, food will not be stored in refrig-erators.

11-10. Fitting Area Criteria. The fitting area will bewell-lighted and have enough space so personnel maybe fitted with clothing and equipment being assigned tothem, i.e. survival vest, flight clothing, flight helmet, para-chute harness, etc.

11-11. Tools and Special Repair Equipment. AllALSE items will be serviced and repaired in accordancewith applicable TM/TO. The required and authorizedtools and special repair equipment are found in theRepair Parts and Special Tools List (RPSTL) of the appli-cable TWO.

11-12. Training Equipment. Most equipment used fortraining can be returned to service, providing the equip-ment is serviceable and can pass all inspection criteriafor that item, before it is returned to service. The excep-tions are as follows:

All flotation equipment - these are to be markedFOR TRAINING ONLY in accordance with TM5-4220-202-14.

Sleeping bags - either those packed inside a 12”by 12” by 1” hard fiberglass container or the newvacuum packed soft plastic package.

Any clothing or equipment that has been sub-mersed in salt water or chlorine treated water, i.e.swimming pool.

11-13. Temporary Storage of Life Support Equipment. Equipment being stored is subject to dry rot,rodent damage, mildew and other contamination. It isimportant for the area to be environmentally controlled aswell as secured from pilferage.

a. Survival Kits. Survival kits to be in temporarystorage will:

l Be inspected, repaired, and if needed, cleaned.

l Have components replaced if necessary.

l Have matches and pyrotechnics removed andstored in accordance with post policy for unitsoperating within a military base, or local policy forthose units not operating on a military base.

l Have kits appropriately tagged with annotationsabout items not in the kit being stored.

11-2 Change 2

TM 1-1500-204-23-1

Table 11-1. Test Equipment

Nomenclature NSN

Multimeter, AN/PSM-45 6625-01-139-2512Test set, AN/PRM-32A 6625-01-013-9900Test set, AN/R/TS-24 6625-01-128-8588Test set, strobe 6625-01-085-9669Test set, TS-2530A/UR 6625-00-238-0223

For flotation equipment

Cleaner, vacuum (not for cleaning purposes) 7910-00-550-9123C02 Transfer unit 3655-00-288-0309Manometer 6685-00-526-5323Scale, dial and beam 6670-00-255-0239Separator, oil and water 4920-00-242-4100

For oxygen equipment

Parts kit, oxygen mask repair 1660-00-672-3945Regulator 1660-00-700-9776Tester, oxygen mask, MQ-1A 1660-01-097-0441Tester, oxygen regulator 4920-00-128-8584

NOTEStorage cabinets or workbenches/tables with storage shelves/drawers that can be secured withlocks should be used for securing test equipment, tools, equipment, and supplies The storagecabinets, workbenches/tables will be marked to identify the tools, equipment, supplies and testequipment contained within them

• Be stored on shelved well-ventilated and out ofdirect sunlight.

b Survival Vests. Survival vests to be put In temporarystorage will:

• Be inspected, repaired, and if needed,cleaned.

• Have components replaced if necessary

• Have signal kits, personnel distress removedand stored in accordance with post policy if unitis operating from a military base, or local policyif unit is operating off a military base.

• Have radios removed from vest. Battery will beremoved from the radio and put intorefrigerated storage.

• Have the light marker distress removed fromthe vest and the battery from the light markerremoved and put Into refrigerated storage.

• Have vest appropriately tagged and Items notIn vest annotated on the tag. The vest will behung on a hanger for storage, out of directsunlight.

11-3

TM 1-1500-204-23-1

Table 11-2. References for Flight Clothing

Publication Description

TM 10-8400-201-23 Organizational and Direct Support Maintenance Manual:General Repair Procedures for Clothing and Individual Equipment

TM 10-8400-202-13 Maintenance Instructions for NOMEX Flight Gear CoverallsTypes CWU-27/P and CWU-28P; Gloves, Type GS-FRP-2; JacketFlyer’s, Summer, Type CWU-35/P and Winter, Type CWU-45/PHood, Flyer’s (CWU-17/P Jacket); Trousers, Flyer’s Extreme ColdWeather, CWJ-18/P (TO 14P3-1-112)

TM 10-8415-206-12P&P Operator’s and Organizational Maintenance Manual Including RepairParts and Special Tools List for Helmet, Flyer’s, Protective, ModelSPH-4 Regular and X-Tra Large

TM 10-8470-202-13 Operation and Service Instructions for Ground and AircrewBody Armor (TO 14P3-1-102)

TM 10-8475-200-13 Use, Inspection, Fitting, and Maintenance Instructions for Anti-Expo-sure Assembly. Type CWU-21/P (TO 14P3-5-81)

TM 10-8475-202-13 Operation, Service and Maintenance Instructions for Quick DonningAnti-Exposure Flying Coverall, Type CWU-16/P TO 14P3-5-61

TM 10-227 Fitting of Army Uniforms and Footwear

FM 10-16 General Fabric Repair

FM 10-267 General Repair for Clothing and Textiles

FM 21-15 Care and Use of Individual Clothing and Equipment

CTA 50-900 Clothing and Individual Equipment

FED STD 757 Stitches, Seams, and Stitching

FM 1-508 Maintaining Aviation Life Support Equipment (ALSE):Maintenance Program

11-16. Flotation Equipment. Flotation equipment type of aircraft being flown and the number of aircrew andconsists of underarm flotation bladders (life preservers), passengers on board (refer to table 11-4, Liferafts forone man liferafts, seven man liferafts and 20 man multi- Aircraft.) Any and all flotation equipment used for trainingplace liferafts. All flotation equipment contains an airbladder or air chambers, an inflation device, inflating gas

will not be used as serviceable equipment for survival kitsor issued for individual use in lieu of serviceable flotation

(usually CO2) in cylinders of varying sizes and capacitiesto fit the particular piece of flotation equipment, and a

equipment. There will be no waivers for this policy. Flota-tion equipment used for training equipment will be visibly

topping off valve to replenish lost gas or to relieve excess marked FOR TRAINING ONLY in accordance with TMpressure. The device will either be an oral inflation tube 5-4220-202-14/TO 14S-1-102. Table 11-5 gives refer-or a hand pump in the case of multi-place rafts. The type ences for flotation equipment.and quantity of flotation equipment will depend on the

Change 2 11-5

TM 1-1500-204-23-1

Table 11-3. References for Survival Kits


TM 9-1370-203-20P& P

TM 10-8400-201-23

TM 55-1680-316-10

TM 55-1680-317-23P & P

TM 55-1680-322-12

TM 55-1680-348-10

TM 55-1680-349-10

TM 55-1680-350-10

TM 55-1680-351-10

FM 1-508

FM 10-16

FM 10-267

FM 10-1269

FM 21-15

FED STD 757

DA PAM 738-751

TB 9-1300385

TB 740-10

DOD Medical Catalog

DOD 5154.4S

SB 8-75 SERIES

SB11-6 FSC Class 6135; Dry Battery Supply Data

SB11-30 FSC Class 6135; Dry Battery Management Data

Organizational Maintenance Manual for Military Pyrotechnics

General Repair Procedures for Clothing and Individual Equipment

Operator’s Manual for Rigid Seat Survival Kit and SurvivalVest for OV-1 Aircrews

Maintenance Manual for Army Aircraft Survival Kits

Operation and Service for Distress Marker Light, P/N SDU-5/E

Survival Kit, Cold Climate, Individual

Operator’s Manual for Survival Kit, Hot Climate

Operator’s Manual for Survival Kit Overwater, Individual

Operator’s Manual for SRU-21/P Army Vest

Maintaining Aviation Life Support Equipment (ALSE):Maintenance Program

General Fabric Repair

General Repair for Clothing and Textiles

Repair of Canvas and Webbing

Care and Use of Individual Clothing and Equipment

Stitches, Seams and Stitching

Functional Users Manual for the Army MaintenanceManagement System-Aviation (TAMMS-A)

Munitions Suspended or Restricted

Quality Control Depot Storage Standards. Appendix MMedical Supplies.

VOL I, VOL II, VOL III MCRL I, II, Ill

DOD Ammunition and Explosives Safety Standards

Army Medical Department Supply Information 8-75-1thru 8-75-35

11-6 Change 2

TM 1-1500-204-23-1

Table 11-3. References for Survival Kits - CONT


SB742-1370-94-721 Signal, Smoke and Illumination, Marine MK13, MOD OSurveillance Function Test

a. Precautions. Comply with the following precau-tions when handling or accomplishing maintenance onliferafts:

(1) Prevent hydrocarbons, such as gasoline,oil, or grease from contacting liferaft materials.

(2) Do not drop or throw liferafts, as damage toliferaft or accessories may occur.

(3) Do not step or sit on packed liferafts, orplace weights or items on liferafts which are not required.

(4) Do not step on any part of liferaft while wear-ing shoes when accomplishing inspections or repairs.

b. Stowage in Aircraft. Liferafts shall be stowed inaircraft as follows:

Do not sit or place equipment or tools on life-rafts stowed in aircraft. Keep the liferaft freeof oil, grease, and other rubber deterioratingagents. Damage to liferaft may otherwiseresult.

Change 2 11-7

TM 1-1500-204-23-1

Table 11-5. References for Flotation Equipment

Publication

TM 55-1680-321-12

Description

Inspection, Maintenance and Disposition Instructions,Desalter Kit, Type MK-2

TM 5-4220-202-14/ Maintenance Instructions with Parts BreakdownTO 14S-1-102 USAF Flotation Equipment

FM 1-508 Maintaining Aviation Life Support Equipment (ALSE):Maintenance Program

Table 11-6. References for Oxygen Equipment

Publication

TM 55-1660-245-13TO 15X-1-1NAVAIR 03-50-1

Description

Maintenance Instructions:Oxygen Equipment

TM 55-1669-247-12TO 15X-3-6-1

TM 55-6695-217-13

Operation, Fitting, Inspection and Maintenance Instructionsfor MBU-12/P Pressure-demand Oxygen Mask.

Operation and Maintenance Instructions for Tester, Oxygen Mask,Headset, Microphone and Flash Goggles Type MQ-1 A

TM 55-6695-217-23 & P Aviation Unit and Aviation Intermediate Maintenance Repair Parts andSpecial Tools List, Tester Oxygen Mask, Headset, Microphone andFlash Goggles Type MQ-1A.

e. Cleaning. All cleaning of flotation equipment willbe in accordance with TM 5-4220-202-14 and TO14S-1-102.

11-17. Oxygen Equipment. Oxygen equipment forALSE consists of that equipment not a permanent/inte-gral part of the aircraft/aircraft airframe. Oxygen to beused is Oxygen, Breathing, Aviator’s, MIL-0-27210. Thecylinder is color-coded with a green top, white band,green band and a green body in accordance with MIL-STD 101. There are several types of oxygen. Aviationoxygen is dry compared to the wet medical oxygen. Dryoxygen for aviation is required because of high altitudeand low temperatures. Medical oxygen, which is wet, canfreeze causing malfunction of oxygen equipment andoxygen masks. The handling of oxygen demands thesafe handling, care, and attention to details. Refer to TM55-1660-245-13 and TO 15X-1-1. There are many

restrictions to servicing oxygen equipment; all must beadhered to. A clean environment is required to servicepersonal oxygen equipment, masks-regulators-oxygenbottles, etc. The mask, because it is on the users face,if not properly serviced, could cause facial skin, throat,and lung problems, or at worst, no oxygen flow whenneeded causing hypoxia and possible death. Table 11-6gives references for oxygen equipment.

a. Inspection. Inspection of all oxygen equipmentwill be in accordance with the applicable TM/TO.

b. Repair. Repair of all oxygen equipment will be inaccordance with the applicable TM/TO/NAVAIR. Themaintenance facility will conform to the requirements ofTM 55-1660-245-13/TO 15X-1-1/NAVAIR 03-50-1) a tri-service manual for oxygen and some oxygen equipmentmaintenance including the requirements for the oxygenmaintenance area.

Change 2 11-9

TM 1-1500-204-23-1

c. Cleaning. Cleaning of oxygen equipment will bein accordance with the applicable manual for that pieceof oxygen equipment.

11-18. Signaling Devices. Signaling devices areflares, whistles, reflections from shining surfaces (mir-rors, plexiglass from doors or windows etc.), smoke,radios, sea dye, cloth, vegetation, and rocks. The use ofthese items are found in FM 21-76 Survival Manual orAFM 64-5 Survival Manual or the applicable survivalradio TM/TO. Caution must be used with flares and firesignals. Table 11-7 gives references for signalingdevices.

a. Inspection. Inspection will be accomplished inaccordance with the applicable TM/TO/NAVAIR.

b. Repair. Repairs, if any, will be accomplished inaccordance with the applicable TM/TO/NAVAIR.

c. Cleaning. Cleaning will be accomplished inaccordance with the applicable TM/TO/NAVAIR.

11-19. First Aid Kits. This section establishes theresponsibility and procedures for installation and inspec-tion, and furnishes information regarding source of sup-ply of approved First Aid Kit, General Purpose, PanelMounted, NSN 6545-00-919-6650, for aircraft. This kitprovides first aid essentials for use by flight crews andpassengers sustaining injuries due to combat, accident,malfunctioning of equipment, or survival conditions.

NOTEThis publication will be used as authority toidentify and inspect first aid kits for Army air-craft. Other references in this chapter areused only for purposes specified.

a. Basis of Issue. The property book officer forauthorized activities will submit requests for first aid kitsto the supporting medical supply officer, based on oneper crew compartment in Army aircraft; and one for eachfive passenger seats/capacity or fraction thereof.

aircraft combined with the inability of securing and instal-ling required kits prior to flight shall warrant placing theaircraft in a limited (one kit in crew compartment and onekit for each five passenger seats installed or fractionthereof) operable status, IAW DA PAM 738-751. Kits willbe installed in aircraft locations indicated in the applica-ble aircraft maintenance technical manual. When therequired quantity of first aid kits, for troop transport mis-sion(s) is in excess of the provisions for installation of thekits, the additional kits will be carried on board as looseequipment. Upon completion of mission(s), the addi-tional first aid kit(s) will be removed and turned in.

c. Identification. There are two configurations ofauthorized first aid kits, with identical NSN part numbersfor use on aircraft. The older design as shown in figure11-1 is marked with a red cross, and the words First AidKit, Airplane, appear on the outer fabric case. It has aside pocket compartment. The newer configuration asshown in figure 11-2 is marked with a red cross and thewords First Aid Kit, General Purpose, appear on the outerfabric case. The older design kit will be used until stocksare depleted and the kit is no longer serviceable. Originalmarkings will not be changed for standardization pur-poses. See TM 55-1500-345-23 in the event that themarkings on kits must be restored.

d. Protection of Contents . The first aid kit will beclosed and sealed when carried in aircraft. Serviceablekits will always be tagged with a DD Form 1574 (Service-able Tag-Materiel) as shown in figure 11-3, properly com-pleted and attached. This will be the responsibility ofdesignated personnel.

NOTEThis seal will be broken on installed first aidkits only when the contents are to be used forfirst aid treatment of an injury. When the sealhas been broken, it will be annotated on DAForm 2408-13-1/DA Form 2408-13-1-E (Air-craft Inspection and Maintenance Record).

e. Controlled Substances. All narcotics and non-b. First Aid Kit Installation. Maintenance personnel narcotic controlled substances have been deleted from

will insure that serviceable first aid kits are installed in this medical kit. Controlled substances are normally notaircraft, as specified in the applicable -10 manual. The included in the medical kit. Amphetamines will not beabsence of required serviceable first aid kits from an added to medical kits under any circumstances.

11-10 Change 2

TM 1-1500-204-23-1

Table 11-7. References for Signaling Devices


TM 9-1300-200 Ammunition, General

TM 9-1300-206 Ammunition and Explosives Standards

TM 9-1300-214 Military Explosive

TM 9-1300-250 Ammunition Maintenance

TM 11-5820-640-15 Operator's, Organizational, Direct Support, General Support DepotMaintenance Radio Sets AN/URC-10, AN/URC-10A and ACR RT-10

TM 11-5820-640-25P Combined Organizational, DS, GS, and Depot Maintenance Including RepairParts and Special Tools List Radio Set AN/URC-10A

TM 11-5820-767-12 Operator's and Organizational Maintenance Manual Including Repair Partsand Special Tools List; AN/URC-68

TM 11 -5820-767-20P Organizational Maintenance Manual Including Repair Parts and SpecialTools List Radio Set AN/URC-68

TM 11 -5820-767-30P Direct Support Maintenance Repair Parts and Special Tools List for RadioSet AN/URC-68

TM 55-5820-767-34 Direct Support Maintenance and General Support Maintenance Manual forRadio Set AN/URC-68

TM 11-5820-800-13 & P Operator's Aviation Unit and Intermediate Maintenance Manual IncludingRepair Parts and Special Tools List for Radio Set AN/PR C90

TM 11-6625-2631-14 Operator's Organizational, Direct Support and General Support MaintenanceManual for Test Set Battery TS-2530/UR and Test Set TS-2530A/UR

TM 11-6625-2631-40P General Support Maintenance Repair Parts and Special Tools List for TestSet, Battery TS-2530/UR and TS-2530A/UR

TM 11-6625-2632-14 Operator's Organizational, Direct Support and General Support MaintenanceManual Including Depot Maintenance Repair Parts and Special Tools List forRadio Test Set AN/PRM-32

TM 11-6625-2632-14-1 Operator's, Organizational, Direct Support and General SupportMaintenance Manual Radio Set AN/PRM-32A

11-11

TM 1-1500-204-23-1

Table 11-7. References for Signaling Devices - CONT


TM 11 -6625-2632-24P-1 Organizational, Direct Support, and General Support MaintenanceRepair Parts and Special Tools List for Radio Test Set AN/PRM-32A

SB 11-6 FSC Class 6135, Primary Battery Supply Data

SB 11-30 FSC Class 6135; Primary Battery Management Data

SB 742-1370-94-721 Signal, Smoke and Illumination Marine: AN-MK 13, MOD O (L275)Ammunition Surveillance Surveillance Procedures

TM 55-1680-317-23 & P Maintenance Manual for Army Aircraft Survival Kits

TM 55-1680-322-12 Operator's and Service, Distress Marker, Light, SDU-5/E

Figure 11-1. First Aid Kit, Airplane (Older Configuration)

11-12

TM 1-1500-204-23-1

Figure 11-2. First Aid Kit, General Purpose (Newer Configuration)

Figure 11-3. Serviceable Tag-Materiel (DD Form 1574) (Yellow)

11-13

TM 1-1500-204-23-1

due, or when:

f. Inspection. Inspections of first aid kits by ALSEmedical personnel, or other certified personnel aredescribed in the following paragraphs.

(1) Inspection by ALSE, medical or other certi-fied personnel. First aid kits will be inspected for ser-viceability and completeness upon receipt. Inspectingpersonnel will annotate the DD Form 1574 with the dateof the shortest expiration dated item contained in the kit.This date will be used to schedule the next inspection

Suspension of the kit, or an item within the kit, isannounced by the supporting medical supply offi-cer, the US Army Medical Materiel Agency, or theMedical Supply Bulletin (SB 8-75 SERIES).The kit is turned in by using activities. Using activi-ties will ensure that the kit is removed for inspectionand quality assurance prior to the next inspectiondue/overage date or immediately upon receivingnotice from the supporting medical supply officer ofan applicable item suspension. Personnel may bemedical, ALSE, Tls or safety personnel as autho-rized in writing by the unit commander.

(a) Inspection procedures. ALSE medicalor certified personnel shall accomplish the followinginspection procedures:

g Ensure that component items offirst aid kit that are deleted through normal supply actions

1 Ensure kit is properly marked using the are replaced or withdrawn from the kit. It is not necessaryappropriate material condition tags and labels listed in to recall the kit in use to effect replacement of deletedparagraph 5-3. items unless otherwise specified.

2 Replace all expiration dated items withless than 12 months shelf/service life whenever possible.The NEXT INSPECTION DUE DATE annotated on theserviceability tag will be that of the item that has theshortest expiration date.

NOTE

3 Ensure that the kit contains no Sched-ule II controlled medical items unless a current MACOMauthorization is on file.

Using activities may use the inspection codesidentified in DLAM 4155.5, Quality Control,Depot Serviceability Standards manual, foradditional assistance in the identification ofserviceable/non-serviceable medical mate-rial contained in the first aid kit.

4 Ensure that contents of the kit are com-plete and serviceable.

5 Ensure that items are inspected inaccordance with the following inspection tests.

(2) Inspection by maintenance personnel.Installed First Aid Kit will be inspected by maintenance

personnel at the Preventive Maintenance Daily inspec-tion as prescribed in the applicable aircraft PreventiveMaintenance Daily (PMD) inspection checklist.

a Replace bandages, dressings, andcompresses when there is evidence of mildew, mold, dryrot, discoloration, or when instructions are illegible.

b Replace adhesive tape when theadhesive mass separates from the backing fabric uponunwinding (unwinding shall consist of not less than sixinches nor more than seven inches of length from thestarting end) or when the adhesive mass is not uniform.

c Replace petrolatum gauze whenthere is evidence of separation or delamination of thepackage material or evidence of petrolatum seepage.

d Replace ammonia inhalantampules when there is evidence of broken glass or thecontainer shows staining marks.

e Replace surgical razor blade whenthere is evidence of rust, corrosion or pitting on the metalsurface of the blade.

f Ensure that a list of contents isincluded in the kit. Local reproduction of the listing, Table11-8 is authorized.

11-14 Change 2

TM 1-1500-204-23-1

NOTEIf a seal has been broken, and no kit is imme-diately available, a circled red X status symbolwill be entered in block 16 and a statemententered in Part I, Fault Information Section ofDA Form 2408-13-V DA Form 2408-13-1-E(Aircraft Inspection and MaintenanceRecord) restricting the aircraft to a specifiednumber of passengers until a serviceable kitis installed. Kits on which seal has been bro-ken will be turned in to designated ALSE per-sonnel for a replacement kit.When kit is due for an inspection or kit is con-sidered unserviceable due to missing or illeg-ible materiel condition tag, torn case, brokenseal, or (on older design) incomplete sidepocket contents, etc., inspector will removeDD Form 1574 (Serviceable Tag-Materiel)and retag kit with DD Form 1577-2 Unservice-able (Repairable) Tag-Materiel, as shown infigure 11-4.

g. Sealing. The following paragraphs describe thematerials and procedures used to seal first aid kits.

( 1) Materials. Requisition the following materi-als through normal supply channels:

l Seal, lead, 3/8-inch-diameter, 1/8-inch-thick, with5-1/2-inch 27 AWG single-crimped copper wire,NSN 5340-00-391-4240.

l Flat-head pin, NSN 5315-00-989-7631.

l Seal, anti-pilferage, NSN 5340-00-779-3516(alternate seal).

l Copper wire, NSN 5340-00-391-4240.

Figure 11-4. Unserviceable (Repairable) Tag-Materiel (DD Form 1577-2) (Green).

Change 2 11-15

TM 1-1500-204-23-1

NOTEIf copper wire, NSN 5340-00-391-4240, is notavailable, use copper wire, NSN6145-00-234-4991, and lead seal NSN5340-00-598-3417. Use press seal NSN5120-00-221-1668 for crimping the lead seal.

(2) Sealing procedures. Accomplish the follow-ing procedures when sealing first aid kits:

(a) Complete DD Form 1574 in accordancewith DA PAM 738-751.

NOTEThe inspection DUE DATE will be no longerthan the first item with an expiration period.That date will become the DUE DATE for thenext inspection.

Supplies of Materiel Condition Tags will berequisitioned through normal publicationchannels.

(b) Reseal kit by closing zipper and placingslide fastener tab in down and locked position, and installflat-head pin into slide fastener loop.

(c)hole in

Slip free end of sealing wire throughend of flat-head pin already installed in loop and

pull wire through until lead seal is against end of pin.

(d) Continue by passing free end of wirethrough one of the holes in seal and pull wire so that sealis held tightly against end of pin.

(e) Proceed, by passing end of wirethrough hole of materiel condition tag.

(f) Position tag along with wire, approxi-mately one inch away from seal, continue by passing thefree end of wire through one of the holes in the lead seal.

(g) Extend wire so that both wires from tagto seal are even, then take free end of wire, and pass itthrough hole in materiel condition tag again.

(h) Crimp seal, then twist materiel condi-tion tag three or four times. This will create a loop that willhold tag in position.

(i) After completing the resealing action,position tag to the double edge of fabric, as shown infigure 11-5, with a minimum of two staples from a stan-dard office type stapler. This action is intended to reducethe inadvertent loss of the tag due to wind movementwhen operating aircraft with door/windows open.

Figure 11-5. Properly Attached Flat-Head Pin, Lead Seal, and Identification Tag.

11-16 Change 1

NOTEOnly one strand of 27 AWG is to be putthrough the lead seal. Using more than asingle strand of 27 AWG wire could make thebreaking of the seal more difficult and hinderready accessibility to the first aid compo-nents.

Any slack in wire between lead seal and endof pin is to be avoided; however, do not placepin under such extreme tension that the pos-sibility of accidental breakage is increased.

h. Replacement of Components. A kit will be con-sidered unserviceable after the expiration date of the firstitem that expires within the kit, or when the DD Form1574 tag is missing, or the seal is missing. The kit will beretagged with a DD Form 1577-2 tag and the inspectorwill annotate in Reason for Repairable Condition block,Inspection Due, per paragraph 11-19f or the applicableaircraft maintenance manual. Kits requiring replacementof items will be reconstituted by authorized unit ALSE/Certified personnel in accordance with the list of itemscontained inside each kit and with DOD Medical Catalog.Replenishment items will be requested from the support-ing medical supply officer.

i. First Aid Kit Components. First aid kit itemsrequired are listed in table 11-8 and references in table11-9.

j. Inspection Training Procedures. Only those per-sonnel medically trained (MOS 91B, C or 91Q) and quali-fied, or ALSE school trained (with an ASI of Q2), maycertify and instruct other unit personnel in the inspectionof first aid kit, general purpose, panel mounted, aircraft.ALSE personnel school trained, with an ASI of Q2, willnot be subject to retraining at the unit level. Only certifiedALSE, medical or other certified personnel will beappointed on unit orders by the Commander, to performinspections on the first aid kit, general purpose aircraft.

(1) Training. Training will consist of the follow-ing using an aircraft first aid kit:

(a) Using the instruction from paragraph ffor inspection procedures.

(b) Using the instructions from paragraph fand TB 740-10, Appendix M, for the replacement of timeexpired components of the first aid kit.

TM 1-1500-204-23-1

(c) Using the instructions from paragraphg for the sealing and tagging of the kits.

(d) Describing what effects outdated orcontaminated components would have on an injured orwounded person.

(2) Certification. Upon successfully completingthe course of instruction, will be noted on a memorandumfrom the certifying individual to the unit commander con-cerned.

NOTEUnder no circumstances will personnel, otherthan ALSE qualified, authorized under theguidance of this paragraph, maintain otherALSE equipment including those first aid kitsin survival kits in accordance with AR 95-3.

11-20. Nuclear, Biological, and Chemical Equipment. Unit chemical personnel are supposed to sup-port training and maintenance of all Nuclear, Biological,and Chemical (NBC) equipment. If the ALSE technicianhas been assigned this task, particularly the aircrewmembers equipment, the ALSE technician shouldbecome very proficient in the care, use, inspection, repairor replacement of NBC equipment and train the aircrew-members in the care and use of their NBC equipment.NBC equipment consists basically of the following: abreathing apparatus, mask with filters to eliminate air-borne chemicals, protective clothing to protect the indi-viduals from airborne chemicals, cooling apparatus tocool the individuals body while wearing the protectiveclothing, and warning devices to alert personnel of con-tamination by chemicals of the air in the immediate vicin-ity, or dangerous radiation levels in the area. Table 11-10gives references for NBC equipment.

a. Inspection. Inspections will be accomplished inaccordance with the applicable TM, TO, NAVAIR for theparticular item involved.

b. Repair. Repairs will be accomplished in accor-dance with the applicable TM, TO, or NAVAIR for the itemat the authorized maintenance level.

c. Cleaning. Cleaning will be accomplished inaccordance with the applicable TM, TO or NAVAIR for theparticular item needing to be cleaned.

Change 2 11-17

TM 1-1500-204-23-1

Table 11-8. First Aid Kit Components

Stock No. Nomenclature

Shelflife

Unit Quantity (months)

6545-00-9 12-9860

6510-00-200-3075

6510-00-201-1755

6510-01-112-6414

6515-00-754-0426

6510-01-060-1639 Adhesive tape, surgical, camouflaged,1 inch by 2 yards

PG 3 36

6510-00-159-4883 Dressing, first aid, field, camouflaged,4 by 7 inches

EA 3 Conditional

6545-00-853-6309 First aid kit, eye dressing EA 1 36

6510-01-010-0307

6510-00-200-3185

6510-00-913-7909

6515-01-364-8554

6520-00-926-9041

Case, medical instrument and supplyset, nylon non-rigid, No. 2, 7-1/2 incheslong by 4-3/8 inches wide by 4-1/2 incheshigh

Compress and bandage, camouflaged,2 by 2 inches, 4S

Bandage, muslin, compressed, camouflaged,37 by 37 by 52 inches.

Gauze, petrolatum, 3 by 36 inches, 3s

Blade, surgical prep razor, straight singleedge, 5s

Inside lower, pocket

In outside, pocket(If old type case is used)

Providone-iodine solution, USP, 10percent pads, individually packaged

Bandage, gauze, compressed,camouflaged, 3 inches by 6 yards

Bandage, adhesive, 3/4 by 3 inches(When newer kit is used, these threeitems will be located in lower pocket)

Glove, Patient Examining(Glove is placed inside ofDential Prosthesis Bag)

Bag, Dental Prosthesis

EA 1 Conditional

PG 1 Conditional

EA 1 Conditional

PG 3 Conditional

PG 1 Conditional

PK 10 36

EA 2 Conditional

EA 18 36

PG 48

PG Conditional

11-18 Change 2

TM 1-1500-204-23-1Table 11-9. References for First Aid Kits

PublicationDescriptionDOD Medical CatalogVOL I, Identification/Management DataVOL II, Sets, Kits, and OutfitsVOL III, MCRL 1, II, & IIISB 8-75-SeriesArmy Medical Department Supply Information 8-75-1 thru 8-75-33TB7460-10Quality Control Depot Storage Standards, Appendix M,Medical SuppliesTable 11-100 References for Nuclear, Biological, and Chemical EquipmentPublicationDescriptionTM 3-4230-216-10 Operator's Manual for Decontaminating Kit, Skin M258A1, andTraining Aid Skin Decontaminating M581ATM 3-4260-280-10 Operator's Manual for Mask Chemical-Biological: Aircraft ABC-M24and Accessories Mask Chemical-Biological, Tank M24/M24A1 andAccessoriesTM 3-4260-280-237& POrganizational and Direct Support Maintenance Manual IncludingRepair Parts and Special Tools List Mask Chemical-Biological:Aircraft ABC-M24 and Accessories and Mask, Chemical-Biological,Tank, M25/M25A1 and AccessoriesTM 3-4260-312-127& PAviation Unit Maintenance, Chemical-Biological Mask Aircrew M43TM 55-1660-248-12Operation and Maintenance Instructions AircrewChem-Defense EnsembleFM 3-3NBC Contamination AvoidanceFM 3-4NBC ProtectionFM 3-5NBC DecontaminationFM 3-6Field Behavior of NBC Agents (including smoke and incindaries)FM 3-10Employment of Chemical AgentsFM 3-100NBC Operations11-19

TM 1-1500-204-23-1

11-21. Restraint Equipment. Restraint equipment, asused in this section, includes safety lap belts, shoulderharnesses, and other fabric devices used in Armyaircraft for personnel restraint purposes. Restraintequipment is to be installed as directed in the applicablemaintenance manual. On all pilot/copilot and crewmanseat belts, the safety belt release handle should point tothe left.

NOTE

Seat belts will not be replaced forcosmetic reasons.

a. Inspection. All personnel restraint equipment isto be visually inspected at time of installation and atspecified intervals thereafter. Inspections are explainedin the following paragraphs.

• New Restraint Equipment. Performdaily inspection for new seat beltlatches (MS3488(AS)) also Inspect forfingertip access.

• New Assemblies of RestraintEquipment This equipment requiresno inspection during depot storage.

• Seat belt latch (MS3488(AS)).Inspect for fingertip clearance.Inspect each seat belt latch by using asteel scale to measure the clearancedistance between the inside face ofthe top of the grip and the top of thewebbing, as shown In figure 11-6.

WARNING

Except for leg garters used with theMK-5D ejection seat, all restraintassemblies made of cotton webbingshall be removed from service. Useextreme caution when inspectingrestraint equipment on ejection seatequipped aircraft. Ensureappropriate safety pins are installed.Injury to personnel may otherwiseresult.

Figure 11-6. Measuring Fingertip Clearance

(1) Installation inspection. Visually inspect allrestraint equipment prior to installation. Seat beltlatches shall be inspected for fingertip clearance inaccordance with the following procedures.

(a) Inspect each seat belt latch by using asteel scale to measure the clearance distance betweenthe inside face of the top of the grip and the top of thewedding, as shown in figure 11-6

(b) If the distance measured above is lessthan the thickness of gloved fingers (minimum 0.8 inch)alter latch using the following procedures:

1 Open latch so that sides may beplaced in vise equipped with aluminum or brassprotective plates on jaws.

2 Squeeze sides of latch handletogether using constant, even vise pressure until jawsare approximately 1 3/4 inches apart. Latch will deformupward and inward, as shown in figure 11-12.

3 Repeat as necessary to obtain7/8-inch clearance dimension due to spring back ofmetal.

4 Perform visual inspection forcracks.

5 Check operation of latch anddetent for complete lock and release.

11-20

TM 1-1500-204-23-1

NOTE

When new nylon webbing isinstalled, it will be flexed by pulling itacross or around a metal barapproximately 1/4 inch in diameter.This action is accomplished byholding each end of the newwebbing and pulling it in a back andforth motion. This will assist inmaking the webbing pliable bybreaking down the finishing glazethat is applied to new nylon fabric.Repeat the back and forth motionuntil the glaze on the fabric is brokendown to such an extent that the beltor harness can be readily adjusted.The flexing procedure will beaccomplished on both sides of thewebbing.

(2) Daily inspection. Perform the daily Inspectionusing the following procedures

(a) Check seat belt shoulder harness,restraint harness, inertia reel strap webbing for:

• Deterioration resulting from contact withforeign matter, (i.e acid, petroleum basedproducts, strong caustic soaps) shall be causefor removal from service. Surface mold ormildew may be removed by washing. If nodeterioration is evident after washing, webbingshall be considered serviceable.

NOTE

Surface mold or mildew may beremoved by washing if nodeterioration is evident afterwashing, webbing shall beconsidered serviceable.

• Cuts of the webbing caused by a sharp-edgedinstrument or object that severs the vertical orhorizontal yarns of the webbing, shall bereason for removal.

• Broken stitches Identified by missing, skipped,torn or ruptured threads in the stitch patternStitching may be repaired and will not because for rejection TM 1-1500-204-23-1.

• Fraying of the exterior surface of the webbing,causing separation or rupture of yamssufficient to obscure the identity of any yarnexceeding 20 percent of the width or 2 inchesin length, shall render the webbingunserviceable. Fuzzing of the exterior surfacecaused by broken individual filaments in theyarns is not cause for rejection.

NOTE

Fuzzing of the exterior surfacecaused by broken individualfilaments in the yams is not cause forrejection.

• Discoloration of webbing caused by contactwith strong caustic soaps, or acid shall bereason for removal from service. Webbingdiscoloration resulting from contact with metalarticles and hardware is not cause forremoval.

NOTE

Webbing discolored or soiled bygrease, oil, aviation fuels andhydraulic fluids shall be cleaned,I.A.W. paragraph d, c. Fading ofwebbing by subjection to sunlight isan unreliable indicator ofdeterioration and shall not be causealone for webbing rejection.

(b) Any metal restraint hardware which iscorroded or defective in operation shall be inspected foroperational use and replaced if found to be substandardor excessively damaged. Missing or unserviceableadjuster webbing retarder springs and loose or missingbolts will be replaced.

(c) Check buckle mechanisms for ease oflocking and releasing. When locked, the latch shouldnot have a tendency to release inadvertently, nor shouldit be excessively difficult to release.

(d) Pilot/troop type belts, check for freedomof movement of the link within the mated hook andguide bar. The link shall not bind in any position (i.e.pivot and hook tip) within Its operating limits.

11-21

TM 1-1500-204-23-1

(e) Inertia reels, check for damage, security,positive locking and unlocking, manual lock-unlockcontrol for proper operation.

(f) Examine restraint system attaching pointsto aircraft. Check for loose bolts, deformity, corrosion orsharp and jagged edges which may damage webbing.

b. Repair. Broken or missing stitches can berepaired using a sewing machine in accordance with thefollowing repair requirements

• If five or more stitches are broken or loosewithin one linear inch, restitching is required.

NOTE

When restitching safety belts,restraint harness, hoist operatorsharness, gunners harness, stitchdirectly over the original stitchingand follow the original stitch patternas closely as possible.

• Only one repair per stitch pattern isauthorized. Restitching should beaccomplished with thread which matches thecolor of the original stitching, when possible.Restitching should be locked by over stitchingeach end of the stitch formation by 1/2 inch.All stitching shall be with nylon threadconforming to Spec V-T-295, thread size,stitching pattern and stitches per inch shall beI.A.W. original construction.

• Restitching should be locked by over stitchingeach end of the stitch formation by 1/2 inch.

• All stitching shall be with nylon threadconforming to Spec V-T-295, thread size,stitching pattern and stitches per inch shall beIn accordance with original construction.

c. Cleaning. Cleaning of personnel restraintequipment will be accomplished when webbing is soiledusing the following procedures

CAUTION

Do not use a bleach. Bleach maycause webbing to deteriorate.

NOTE

No cleaning is authorized to inertiareel webbing strap.

(1) Prepare a concentrated soap and hotwater solution, using laundry soap chips, FederalSpecification P-S-1792, or equivalent. Cool the solutionto approximately 120°F (49°C), prior to application.

(2) Dampen an approved clean brush, suchas NSN 7920-00-244-7431, with the soap solution andrub lightly over the affected surface area.

(3) Rinse the webbing thoroughly with clear,lukewarm water.

(4) Place webbing In open air or a dryingroom to dry.

NOTE

Do not expose the wet webbing tofreezing temperatures or to directsunlight during cleaning, drying, orstorage. Redying or painting isprohibited

(5) After cleaning visually inspect inaccordance with paragraph a.

NOTE

Belts utilized in aircraft conductingsalt water pick-up training shall bewashed in fresh water and corrosionpreventive compound (MIL-C-81309,NSN 8030-00-938-1947) shall beapplied to metal components

d. Replacement Equipment determined to beunserviceable by visual inspection will be replaced.Unserviceable equipment will be disposed of throughnormal disposal channels to the nearest propertydisposal activity. The following personnel restraintequipment having dacron or nylon webbing is to bereplaced if determined to be unserviceable.

• Safety lap belts (crew or troop)• Shoulder harness (crew or troop)• Safety belt tiedown straps

11-22

TM 1-1500-204-23-1

• Personnel restraining harness (gunner andhoist operator)

• Safety belts (airline type)• Inertia reel strap (webbed strap only)• Leg restraints• Litter straps

NOTE

• Safety belts will not be replacedfor cosmetic reasons.

• Safety belts having cottonwebbing are to be removed fromservice.

• Replace loose, missing, ordamaged bolts, nuts, washer,and shims in the anchoringpoints.

(1) Spring webbing retarder. Replace springwebbing retarder used in shoulder harness and seat beltwebbing adjusters as follows:

(a) For shoulder harness webbing adjuster,P/N MS22007, use spring, P/N 65D34083-7 and thefollowing procedures

1 Hook one end of webbing retarderspring around flat end of knurled locking bar as shown infigure 11-7.

2 Cut a 16-inch length of type 1nylon cord, and tie the loose ends together to form aloop in the cord.

3 Insert the nylon cord loop throughthe slot of the adjuster plate, and hook loop over thewebbing retarder spring hook end.

4 Pull the nylon cord throughadjuster plate slot and around the bar.

Figure 11-7. Shoulder Harness Webbing Retarder Spring Installation

11-23

TM 1-1500-204-23-1

5 Press the locking bar back with theleft thumb, leaving enough space to side the loopthrough adjuster plate slot once the hook end ofthe retarder spring has engaged on the locking bar.

6 Pull the nylon cord over the knurledlocking bar to disengage the cord from the retarderspring.

7 Work the center of the webbingretarder spring into the adjuster plate pull tab slot.

8 Ensure that shoulder harness webbingis centered on adjuster plate locking bar and can beadjusted, (fig. 11-7).

(b) For seat belt webbing adjuster P/NMS22004-1 NSN 1680-00-876-0971 use spring P/N62B4407 NSN 1680-00- 975-2987 and the followingprocedures.

1 For ease in replacing webbingretarder spring, remove adjustment webbing fromadjuster plate. Spring can be replaced withoutremoval of seat belt from aircraft.

2 Hook one end of webbing retarderspring around flat end of knurled locking bar. Workother end of spring around opposite flat end of knurledbar as shown in figure 11-8.

3 Insert center section of webbingretarder spring into adjuster plate tab release, (fig 11-8).

4 Replace adjuster webbing in adjusterplate. Ensure that webbing is centered on adjuster plateknurled bar and can be adjusted as desired.

(2) Installation or replacement of snapsafety pin. Install or replace snap safety pin onpersonnel restraint harness as follows:

(a) Secure the snap (MS22042-1)in a vise, and ensure that the snap guard Is notcontained within the jaws.

(b) Drill a 3/32-inch diameter holethrough both sides of snap guard as shown in figure 11-9. Remove all metal burrs and filings from the snap.

Figure 11-8. Seat belt webbing retarder spring installation

11-24

TM 1-1500-204-23-1

(c) Cut a five-inch length of 0.080-inchdiameter corrosion-resistant wire (NSN 9505-00-8924616), and construct a safety pin as shown in figure11-10.

(d) Cut a 15-inch length of type III nylon cord(NSN 4020-00-246-0688). Remove the inner corethreads and sear the ends of the cord.

(e) Pass half of the cord length through thesafety pin loop. Tie a square knot up against the loop.Tie another square knot about 4-1/2 inches frompreviously tied knots.

(d) Pass one loose end of the cord throughthe snap where the webbing Is attached. Tie the twocord ends together with a square knot as shown in figure11-11. Tie an overhand knot in each loose end of cord.

11-22. Personnel Parachute and Parachute Harness.Inspection criteria, procedures, and report for thepersonnel parachute assembly and parachute harnessare explained in the following paragraphs.

a. Inspection Criteria. Any of the equipment listedbelow which is in use, installed in aircraft as extraequipment, located in an aviation unit ready-for-usefacility, or in the possession of aircraft crew memberswill be inspected on a routine basis every 30 days andprior to issue for use. When an aviation unit Is notconveniently located, E.G. on same installation as theirsupporting parachute packing activity, designatedparachute inspectors will check and ensure thatshelf/service life items are withdrawn from use at theend of their service life in accordance with TB 43-0002-4and will sign the required document to support turn-in ofexpired items.

Figure 11-9. Snap Hook Safety Guard Drill Details

Figure 11-10. Snap Hook Safety Pin ConstructionDetails

Figure 11-11. Safety Pin Retaining Cord Securedto Snap Hook

Change 1 11-25

TM 1-1500-204-23-1

ORIGINAL SEAT BELT LATCH

MODIFIED SEAT BELT LATCH

NOTE:DIMENSIONS ARE IN INCHES

Figure 11-12. Seat Bet Latch Modification

11-26

TM 1-1500-204-23-1

NOTE• Aircrew members who perform flight

duties away from home station orassigned unit will ensure thatIndividual emergency typeparachutes and harnesses areinspected every 30 days by qualifiedparachute inspectors. However, if asituation occurs which precludesinspection due to a lack of qualifiedparachute inspection, personnel,parachutes and harnesses maycontinue to be used until arrival at afacility which can satisfy theinspection criteria, as soon aspractical. In no case will the 30 dayinspection requirement exceed 60days.

• Unit commanders/aviation lifesupport personnel will ensure thatindividual emergency typeparachutes, i.e., seat, back, chest, orejection seat type including droguechutes and harnesses when separatefrom the parachute, I.E. chestharnesses and ejection seatharnesses, including seat belts,when integrated into the harnesssuch as the MK-J5D parachutesystem, will be inspected every 30days by an individual qualified toperform 30-day parachuteinspections. These personnel willhave been trained in parachuteinspection methods by a qualifiedparachute rigger. This training willbe documented in individual trainingfolders and designated as parachuteinspectors on unit orders by theaviation unit commander.

• Generic Description of Equipment(1) Parachutes, personnel,

emergency type: back, chest andseat types.

(2) Parachutes, personnel anddrogue, ejection seat type.

(3) Harnesses, personnel parachute,used with above parachutes.

b. Inspection Procedures. Inspection proceduresfor personnel parachute assemblies and the MK-J5ejection seat personnel parachute harness are explainedin the following paragraphs.

(1) Personnel parachute assemblies.Inspection procedures for emergency type personnelparachute assemblies including back, seat, and chesttypes are as follows:

(a) Remove DA Form 3912 fromassembly log record and survival manual pocket.Check record for date of last pack. An emergency-type personnel parachute which has exceeded 120days (200 days for MK-J5 ejection seat parachute)since the last pack will be considered unserviceable.Process for repack according to step j. Afterdetermining the last pack date, return the form to thelog record and survival manual pocket.

NOTEAn emergency type chest parachutehas two parachute log records. Onelog record is located on theparachute pack, and the other isfound on the harness. Each of theselog records shall be maintained. Onan emergency type back parachute,the log record may be located eitheron the pack right wing flap or on thepack bottom stiffener panel.

(b) Ensure that a copy of TM 10-1670-1 is located in the log record and survivalmanual pocket. On a chest parachute assembly, thetechnical manual will be found in the pocket on theparachute harness.

(c) Without opening the pack,visually check external condition of pack and harnessfor defects or deterioration of webbing, canvas fabric,or stitching, and broken or loose tacking.

(d) Check metal components forcracks or rust. Check ripcord housing for dents orbreaks.

(e) Inspect the two canopy releaseassemblies, if applicable, to ensure that each releaseis assembled and locked properly.

(f) Inspect ripcord grip pocket toensure the ripcord grip is secure and the gripprotrudes enough to allow immediate accessibility.Ensure that removal of ripcord is not obstructed bymisplaced stitching or tacking and that harness cheststrap on back parachute is not routed through ripcordgrip.

(g) Ensure that each pack openingspring band is connected. Check the elasticity of eachband.

(h) Open ripcord protector flap andinspect ripcord pins for proper seating in the packrelease cones. Ensure that pins are not bent orcorroded. On back of personnel parachute, eachripcord pin shall extend 3/4 inch beyond pack releasecone (measuring from top of pin to eye of cone).

TM 1-1500-204-23-1

(i) On back personnel parachute, graspharness webbing at a point on the lift web above theripcord grip pocket. Pull against the weight of packassembly to ensure the ripcord pins will not move fromthe prepositioned location given in (h) above.

(j) If after completing steps (a) thru (i) above,it is determined conditions exist which require repair,repack, or more extensive Inspection, prepare DD Form1577-2 as shown in DA PAM 738-751. Attach form tothe item. The item then shall be segregated fromserviceable items by a physical barrier and evacuated toa parachute maintenance facility. An emergency typepersonnel parachute which is considered serviceable willhave the inspection recorded as described in paragraphc, and the parachute will be returned to service.

(2) MK-J5 ejection seat personnel parachuteharness. Inspection procedures for the MK-J5 ejectionseat personnel parachute harness are as follows:

(a) Remove DA Form 3912 from harness logrecord and survival manual pocket located on insidelower right of harness stiffener. Check record for date oflast 200 day MK-J5 ejection seat harness inspection. Aparachute harness which has exceeded 120 days (200days for MK-J5 ejection seat harness) since lasttechnical rigger-type inspection, will be consideredunserviceable. After determining the last inspectiondate, return the form to the log record and survivalmanual pocket.

(b) Ensure that a copy of TM 10-1670-1 islocated in the log record and survival manual pocket.

(c) Visually examine harness webbing forcuts, frays, tears, broken or loose stitching, worn areas,discoloration, dampness, or evidence of contact withpetroleum products.

(d) Check harness shoulder pads, chest strapejector snap pads, and leg strap ejector snap pads fordamage, broken or loose stitching, and broken or loosetacking. Ensure that tacking between each ejector snapand adjacent pad Is not broken or loose.

(e) Inspect strap fasteners, quick releaseadapters, connector links, ejector snaps and survival kitretention buckles for bends, breaks, and corrosionCheck all moving metal components for ease ofoperation. Ensure that spring tension is maintained ineach ejector snap.

(f) Check elastic webbing retainers for cuts,frays, tears, loose or broken stitching, and loss ofelasticity.

NOTEAn MK-J5 ejection seat personnelparachute harness with any defectsabove will be consideredunserviceable. Process forevacuation according to step (1) (j).A harness which is consideredserviceable will have the inspectionrecorded as described in paragraphc, and the harness will be returned toservice.

c. Inspection Report. Record and reportinspection MK-J5 ejection seat personnel parachuteharness on DA Form 2407 in accordance with DA PAM738-751. Further inspection record will be made on theindividual parachute harness DA Form 3912 as follows:

(1) Open DA Form 3912 to page, entitledjump inspection and repack data, for the routineinspection entry accomplishment.

(2) Enter inspection date In date column.(3) Make checkmark in routine Inspection

column.(4) Repeat the number entered

previously in the jumped or dropped columns.(5) Enter signature in the inspector's

name column.(6) Enter designation of the unit to which

inspector is assigned in the unit column.

NOTEThe 30-day routine inspectionrequires recording on DA Form 3912.

11-23. Consolidated List of ALSE References.Table 11-11 gives a list of references to be used as aguide only. Do not maintain manuals that do not pertainto the units Life Support Equipment authorized and onhand. Department of the Army Pamphlet 25-30 shouldbe consulted frequently for the latest changes orrevisions of the references listed in table 11-11 and fornew publications covered in this section. Instructions forestablishing and maintaining a library are found in DAPam 310-13.

11-28

TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References


Army Regulations (AR)

AR 25-400-2 The Modern Army Record Keeping Systems (Marks)

AR 32-15 Classification and Inspection

AR 40-5 Preventive Medicine

AR 40-8 Temporary Flying Restrictions Due to Exogenous Factors

AR 40-61 Medical Logistics Policies and Procedures

AR 40-501 Standards of Medical Fitness

AR 40-656 Veterinary Surveillance Inspection of Subsistence

AR 40- 657 Veterinary Medical Food Inspection and Laboratory Service

AR 40-660 DOD Hazardous Food and NON Prescription Drug Recall System

AR 95-1 Army Aviation Flight Regulations

AR 95-3 General Provisions; Training, Standardization and ResourceManagements

AR 190-11 Physical Security of Arms, Ammunition, and Explosives

AR 310-70 Equipment Interservicing of Technical Manuals and Related Technology

AR 340-1 Records Management Program

AR 350-30 Code of Conduct/Survival, Evasion, Resistance, and Escape (SERE)Training

AR 385-32 Protective Clothing and Equipment

AR 385-64 Ammunition and Explosives Safety Standards

AR 385-95 Army Aviation Accident Prevention

AR 700-89 Identification, Control, and Utilization of Shelf Life Items

AR 710-1 Centralized Inventory Management of the Army Supply System

AR 710-2 Supply Policy Below the Wholesale Level

AR 725-50 Requisitioning, Receipt, and Issue System

11-29

TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References- CONT


Army Regulations (AR) - CONT

AR 750-1 Army Material Maintenance PoliciesAR 750-32 Airdrop, Parachute Recovery and Aircraft Personnel Escape SystemsAR 755-1 Reporting, Utilization, and Redistribution of Installation USAMC, and

Overseas Command Excess PropertyAR 755-2 Disposal of Excess, Surplus, Foreign Excess, Captured and Unwanted

Material

Department of Defense Publications (DOD Pub)

DOD 4160.21-M Defense Utilization and Disposal ManualDOD 5154 4S DOD Ammunition and Explosives Safety Standards

Defense Logistics Agency

DLAM 4155 5 Quality Control Depot Serviceability Standards (Medical Supplies),Appendix M

Medical Catalog Containing VOL I, VOL II, VOL III

NOTE

Department of Defense Customer Assistance Programcall Autovon 284-7871. They will mail copies

FED STD 757 Stitches, Seams, and Stitching

Technical Manual (TM)

TM 3-4230-216-10 Operator's Manual for Decontaminating Kit Skin: M25H1 andTraining Aid, Skin Decontaminating M58A1

TM 3-4240-212-14&P Operator's Organizational, Direct Support and General SupportMaintenance Manual (Including Repair Parts and Special Tool List)Breathing Apparatus, Oxygen Generating, M20

TM 5-803-4 Planning of Army Aviation FacilitiesTM 5-4220-201-12 Operator's and Organizational, Maintenance, Life Preserver, Underarm,

Parachutist (B-7)

11-30

TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References-- CONT


Technical Manual (TM) (Cont)

TM 5-4220-202-14 Maintenance Instructions with Parts Breakdown USAF FlotationEquipment (TO. 14S-1-102)

TM 9-1290-333-15 Operators, Organizational, Direct Support, General Support, andDepot Maintenance Manual (Including Repair Parts and SpecialTools List) Compass Magnetic Unmounted M2

TM 9-1300-206 Ammunition and Explosives Standards

TM 9-1370-203-34&P Direct Support and General Support Maintenance Manual(Including Repair Parts and Special Tools List) Military Pyrotechnics

TM 9-1370-206-10 Operator's Manual: Pyrotechnic Signals

TM 9-4940-461-15P Operator's Organizational, DS, GS, and Depot MaintenanceRepair Parts and Special Tools List for Separator Oil and Water,Spray Gun, Wall MTD

TM 10-1670-1 Survival and Emergency Use of the Parachutes (AFP 64-15)

TM 10-1670-250-20 Organizational Maintenance Manual (Including Repair Partsand Special Tools List). Parachute System Used w/MartinBaker MK-J5D Ejection Seat

TM 10-1670-213-10 Operator's Manual for Parachute Personnel, Types 28 FootDiameter, Back, 28 Foot Diameter, Chest; NB-8 Back and MartinBaker Ejection Seat Harnesses

TM 10-1670-251-12 Operator's and Organizational Maintenance Manual (Including,Repair Parts and Special Tool List). Lowering Device, Cargo andPersonnel, 500 LB Capacity

TM 10-1670-262-12 Operator's and Organizational Maintenance Manual (Including, RepairParts and Special Tools List)' For Personnel Stabo Extractson Systemand Cargo and Personnel Lowering Anchor Device

TM 10-3530-202-24 Organizational and Field Maintenance Manual Sewing Machinesfor the Repair of Parachutes and Allied Equipment

TM 10-8400-201-23 Organizational and Direct Support Maintenance Manual GeneralRepair Procedures for Clothing and Individual Equipment

TM 10-8415-206-12&P Operator's and Organizational Maintenance Manual (IncludingRepair Parts and Special Tools List). For Helmet, Flyer's Protective,Model SPH-4 Regular and X-Tra Large

11-31

TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References -CONT


TM 1-1500-20423-1

Table 11-11. Consolidated List of ALSE References - CONT


TM 55-1680-317-23P&P

TM 55-4240-284-12&P

TM 55-1680-248-10

TM 55-1680-249-10

TM 55-1680-350-10

TM 55-1680-351-10

TM 55-1680-322-12

TM 750-244-1 -2

TM 750-244-1-5

FM 1-100

FM 10-16

FM 10-267

FM 20-151

FM 21-15

FM 21-76

FM 38-725-23

TB CML 93

TB 9-1300-385 Munitions: Suspended or Restricted

FM 1-508 Maintaining Aviation Life SupportEquipment (ALSE): Maintenance Program

Technical Manual (TM) - CONT)

Organizational and DS Maintenance Manual Including RepairParts and Special Tools List for Army Aircraft Survival Kits

Operating and Maintenance Manual, Rescue Seat, ForestPenetrating Including Repair Parts and Special Tools List

Operator’s Manual: Survival Kit, Cold Climate, Individual

Operator’s Manual: Survival Kit, Hot Climate, Individual

Operator’s Manual: Survival Kit, Overwater, Individual

Operator’s Manual for SRU-21/P Army Vest, Large/Small

Operations and Service, Distress Marker, Light Part No. SDU-5/E

Procedures for the Destruction of Life Support Equipment toPrevent Enemy Use

Procedures for Destruction of Aircraft and Associated Equipmentto Prevent Enemy Use

Field Manuals (FM)

Combat Aviation Operations

General Fabric Repair

General Repair for Clothing and Textiles

Aircraft Emergency Procedures Overwater

Care and Use of Individual Clothing and Equipment

Survival

Logistic Codes NICP/Depot and DS/GS/lnstallation

Technical Bulletins (TB)

Adapter, Compressed Air Breathing Apparatus, M4 (End Item Code201) and Detector Kit, Carbon Monoxide, Colormeter, M23

Change 2 11-33

TM 1-1500-204-23-1



Technical Bulletins (TB) - CONTTB 34-9-127TB 34-9-210

TB 34-9-242TB 34-9-243TB 34-9-245

TB 34-9-330

TB 43-0002-4

TB 43-180TB 740-10

SB 3-30-2SB 8-75 SERIESSB 11-6SB 11-30SB 11-576

SB700-20

SB708-30

Medical Gas CylindersNATO Standardization Agreement for Air Pyrotechnics InterchangeabilityChart STANG 3398Aircraft Gaseous Oxygen Replenishment ConnectionsAircraft Compressed Air Replenishment ConnectionsCompressed Breathing Air CharacteristicsMask, Protective, Aircraft, ABC-M24 and Hood Aircraft Protective Mask,ABC-M7Maintenance Expenditure Limits for FSC Group 16, FSC Classes 1610,1615, 1620, 1630, 1650, 1660, 1670, and 1680Calibration and Repair Requirements for the Maintenance of Army MaterialQuality Control Depot Serviceability Standards

Supply Bulletins (SB)Chemical, Biological Canisters and Filter Elements Serviceability ListsArmy Medical Department Supply Information SB 8-75-1 through 8-75-35FSC Class 6135; Dry Battery Supply DataFSC Class 6135; Primary Battery Management DataCold Weather Batteries for Radio Sets AN/PRC6,8,8A, 9A, 10, 10A, 25,28and 77 and Cable Assemblies for Cold Weather Operation of TransmittingSet Radio AN/PRT-4 and Receiving Set, Radio AN/PRR-9

TM 1-1500-204-23-1



SB 708-6

SB 708-21

SB 708-22

SB708-41/SB 708-42

SB 708-43

SB 742-1

SB742-1370-94-721

SC5180-91-CL-R07

SC5180-91-CL-R13

C 1 ARMY Introduction to the Federal Supply Catalog and Related Publications

C 6500-AL Federal Supply Catalog: Alphabetical Index (Medical Materiel)

Supply Bulletins (SB) - CONT

Federal Item Directory for Supply Cataloging

Federal Supply Classification; Part 1 -Groups and Classes (CatalogingHandbook H2-1)

Federal Supply Classification; Part 2 Numeric Index of Classes (CatalogingHandbook H2-2) (GSA-FSS-H2-2)

Federal Supply Code for Manufacturers; United States and Canada-Name toCode (Cataloging Handbook H4-1) (GSA-FSS-H4-1/H4-2)

Cataloging Handbook H4/H8 Commercial and Government Entity (GAGE)

Ammunition Surveillance Procedures

Signal, Smoke and Illumination, Marine: AN-MK 13 MOD O Ammunition(DODAC 1370-L 275) Surveillance Procedures

Supply Catalogs (SC)

Tool Kit, Electronic Equipment, TK-105/G

Tool Kit, Electronic Equipment, TK-101/G

Department of the Army Supply Catalogs (Federal)

Change 2 11-35

TM 1-1500-204-23-1



C 6505-GL

Department of the Army Supply Catalogs (Federal) - CONT

FSC Glossary of Colloquial Names and Therapeutic Index (FSC Class 6505)

MCRL-1 Master Cross Reference List - 1, Cross Reference from Part Number to NSN

MCRL-2 Master Cross Reference List - 2, Cross Reference from NSN toPart Number

C 6700/9500-ML Management Data List: FSC Groups 67 Thru 95 (Items of MedicalMateriel Only)

C 8900-SL Federal Supply Catalog: Stock List, FSC Group 89, Subsistence

PAM 25-30

Department of the Army Pamphlets (PAM)

Consolidated Index of Army Publications and Blank Forms

PAM 310-10 The Standard Army Publications System (STARPUBS) User’s Guide

PAM 310-13 Posting and Filing Publications

PAM 700-3 Why and How to Use SF 364 to Report Package Discrepancies

PAM 710-2-1 Using Unit Supply System Manual Procedures

PAM 738-751 Functional User’s Guide to the Army Maintenance ManagementSystem-Aviation (TAMMS-A)

CTA 8-100

CTA 50-900

CTA 50-909

CTA 50-970

Common Tables of Allowance (CTA)

Army Medical Department Expendable/Durable Items

Clothing and Individual Equipment

Field and Garrison Furnishings and Equipment

Expendable/Durable Items (Except: Medical, Class V, Repair Partsand Heraldic Items)

11-36 Change 2

TM 1-1500-204-23-1



TO: 0-1-01

TO: 0-1-02

TO: 00-5-1

TO: 00-5-2

TO: 00-35A-39

TO: 11A-1-1

TO: 11A10-24-7

TO 12R2-2PRC90-2

TO 12R2-2PRC90-3

TO 12R2-2PRC90-4

TO 14S-1-102

TO: 14S1-4-1

TO: 14S10-2-2-SDU-5/E

TO: 14S1-4-22

TO 15X1-1

TO: 15X1-4-2-4

TO: 15X1-4-2-12

TO: 15X3-3-4-3

TO: 15X5-3-6-1

Air Force Technical Orders (TO)

Numerical Index

Numerical Index

Technical Order System

Technical Order Distribution System

Instructions for Procurement, Issue, Use and Maintenance of Medical Kits

Ammunition Restricted or Suspended

Storage and Maintenance Procedures, Pyrotechnics

PRC-90 Survival Radio



Maintenance Instructions with Parts Breakdown USAF Flotation Equipment

Distillation Kit

Marker Distress Light

Desalting Kit

Oxygen Equipment

Bail Out Bottles (Parts Manual)

Bail Cut Bottles (Maintenance Manual)

MB4 Diluter Demand

MBU-12/P Pressure-Demand Oxygen Mask Operation, Fitting, Inspectionand Maintenance Instructions with Illustrated Parts Breakdown

TO: 15X5-4-1-101 Oxygen Mask Connector (CRU-60/P)

11-37

TM 1-1500-204-23-1



Naval Publications

DA Form 12-R

DA Form 12 Series

DA Form 17

DA Form 17-1

DA Form 581

Department of the Army (DA) FormsRequest for Establishment of a Publications Account

Requirements for DA Publications

Requisition for Publications and Blank Forms

Requisition for Publications and Blank Forms (Continuation Sheet)

Request for Issue and Turn-In of Ammunication

11-38 Change 2

TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References- CONT


Department of the Army (DA) Forms - CONT

DA Form 2028 Recommended Changes to Publications and Blank Forms

DA Form 2062 Hand Receipt/Annex Number

DA Form 2063-R Prescribed Load List (LRA)

DA Form 2064 Document Register for Supply Actions

DA Form 2402 Exchange Tag

DA Form 2404 Equipment Inspection and Maintenance Worksheet

DA Form 2405 Maintenance Request Register

DA Form 2407 Maintenance Request

DA Form 2407-1 Maintenance Request - Continuation Sheet

DA Form 2408-21 Life Raft Inspection Record

DA Form 2408-22 Helmet and Oxygen Mask/Connector Inspection Record

DA Form 2408-23 Survival Radio/Emergency Locator Transmitter (ELT) Inspection Record

DA Form 2408-24 Survival Kit Inspection and Maintenance Record

DA Form 2408-25 Mesh Net Survival Vest Inspection Record

DA Form 2408-26 Life Preserver Inspection Record

DA Form 2408-27 Life Preserver Data

DA Form 2408-28 Oxygen Console Service Record

DA Form 2408-29 Anti-Exposure Coveralls Inspection Record

DA Form 2696-R Operational Hazard Report

DA Form 2765-1 Request for Issue or Turn-In

DA Form 3161 Request for Issue or Turn-In

DA Form 3749 Equipment Receipt

DA Form 4569 USAPC Requisition Code Sheet

11-39

TM 1-1500-204-23-1



Department of Defense (DD) Forms - CONT

DD Form 173/1 Joint Message Form

DD Form 448 Military Interdepartmental Purchase Request

DD Form 1348 DOD Single Line Item Requisition System Document (MANUAL)

DD Form 1348-1 DOD Single Line Item Release/Receipt Document

DD Form 1348-6 DOD Single Line Item Requisition System Document (MANUAL-LINE FORM)

DD Form 1574 Serviceable Tag-Materiel

DD Form 1574-1 Serviceable Label-Materiel

DD Form 1575 Suspended Tag-Materiel

DD Form 1575-1 Suspended Label-Materiel

DD Form 1576 Test/Modification Tag-Materiel

DD Form 1576-1 Test/Modification Label-Materiel

DD Form 1577 Unserviceable (Condemned) Tag-Materiel

DD Form1577-1 Unserviceable (Condemned) Label-Materiel

DD Form 1577-2 Unserviceable (Repairable) Tag-Materiel

DD Form 1577-3 Unserviceable (Repairable) Label-Materiel

Standard Forms (SF)

SF 364 Report of Discrepancy (ROD)

SF 368 Quality Deficiency Report (Category II)

11-40

TM 1-1500-204-23-1

CHAPTER 12

PYROTECHNICS

12-1. General. The following paragraphs explainpyrotechnics used on Army aircraft. Refer to TM 9-1377200-20&P for descriptive information, care andhandling of stock class 1377 cartridges.

WARNINGElectrically activated cartridges shallbe protectively wrapped in aluminumfoil or electrically shunted wheneverremoved from the aircraft installationto preclude "STRAY" electricalvoltage activation and resultingpersonal injury.

12-2. Ejection Seats. Ejection seats use pyrotechnicsfor seat ejection, automatic parachute deployment, andseparation of seat from occupant after ejection.


12-3. Fire Bottle Cartridges. Fire bottles usecartridges to discharge extinguishing agents whenactivated by aircraft crewmember or automatic detectingdevice.

12-4. External Stores Cartridges. External storescartridges are used to release external stores from racks

CAUTIONDo not use damaged cartridges.Damaged cartridges may functionerratically and cause damage toequipment.

NOTE

• Shelf life (storage life) for thecartridge is established at 8years, beginning from date ofmanufacture stamped oncartridge or on hermetically

sealed metal container, of whichnot more than 12 months shallhave elapsed after openingcontainer. Cartridges areoverage if either of these timelimits is exceeded. When acontainer is opened, the servicelife expiration date (month andyear) shall be marked withindelible ink on the side of thecartridge.

• Cartridge is consideredunserviceable after ten insertionsand removals from ejector rack,or after the expiration datemarked on the side of thecartridge. Each time a cartridgeis removed, place a radial markon the base of cartridge withindelible ink. Monitor service lifeby record of inked markings andexpiration date.


12-5. Cable Cutter Cartridges. The cargo hoist cablecutter is a mechanical cable shearing device mountedon the hoist cable guide. It is actuated by an electricallyfired cartridge. When the pilot throws the CABLESHEAR switch or the aft pilot throws the HOIST CABLESHEAR switch, electrical power, supplied by the 28 vdcprimary bus through the HOIST CABLE SHEAR circuitbreaker on the overhead circuit breaker panel, fires thecartridge, actuating the cable cutter, and shearing thecable. After firing, the cable cutter assembly must bereplaced.

Change 1 12-1

TM 1-1500-204-23-1

12-6. Pyrotechnic Pistols. The pyrotechnic pistol firesdevices such as flares. The following procedures are forthe maintenance of these pistols:

a. Clean and oil pistol thoroughly after firing,using lightweight preservative lubricating oil, MIL-L-7870. Also, perform this maintenance function at regularinspection intervals as prescribed in aircraftorganizational maintenance manual.

b. Daily maintenance is required under dusty,wet, or salt. air conditions.

12-7. Pyrotechnics Storage and Handling. Existingsafety requirements and precautions shall be compliedwith by all personnel handling pyrotechnic signal flares.This type pyrotechnic is hazardous due to the nature ofits explosive, flammable, or toxic filler. The followingprecautions in handling. signals and flares used inpyrotechnic pistols will be followed in order to preventpersonal injuries.

a. Store flares and signals in a dry, well-ventilated place, out of direct rays of sun and protectedagainst excessive or variable temperatures.

b. Post NO SMOKING signs in storage area.

WARNINGHandle pyrotechnic flares with thesame care as high explosives.Personnel injury may result fromimproperly handled flares.

c. Protect flares and signals from moisture.

NOTEOpen all containers which showsigns of dampness or moisture.Destroy contents when there isevidence of moisture.

d. Disassembly of flares is strictly prohibited.

e. Do not use flares when dented or deformed.

f. Avoid any rough handling, throwing, ordropping of pyrotechnics.

g. Remove flares and signals from aircraft thatare parked in maintenance or storage hangars, and fromsurvival kits placed in storage.

Change 1 12-2

TM 1-1500-204-23-1

CHAPTER 13AIRCRAFT CLEANING

13-1. General. Proper and frequent cleaning is themost important part of a corrosion control program. Fre-quency of cleaning and related treatment will depend ontype of aircraft and local conditions. All aircraft shall bewashed and cleaned every 30 days, unless aircraft arestationed within two miles of salt water. Extended or lowlevel operations over salt water require daily fresh waterrising. External corrosion prone areas will require morefrequent cleaning.

Do not use synthetic wiping cloths with highlyflammable solvents having a flash point of100°F (37.8°C) or less, such as aliphaticnaphtha TT-N-95. Static electricity may buildup and cause ignition.

Do not use aircraft cleaning compoundsMIL-C-43616 or MIL-C-25769 at strengthother than specified because this will damageaircraft finish and components. Do not allowcleaning solutions to dry on aircraft surface.

NOTE

Use only authorized cleaning materials andequipment.

13-2. Cleaning Practices and Procedures. The fol-lowing paragraphs explain preparation for cleaning,cleaning methods, cleaning of corrosion prone areas,and post-cleaning.

a. Preparation for Cleaning. Prepare aircraft forcleaning by accomplishing the following procedures:

Make sure that static vents are not fouled bytape adhesive transfer. Cover static ventswith a properly sized disc of suitable material,then apply masking tape. Fouled vents willgive wrong readings.

(1) Prior to lubricating any components orparts, remove all foreign matter from joints, fittings, andbearing surfaces. Cleaning cloth CCC-C-46 shall beused for this purpose. Clean up all spilled or excess oilor grease. Some solvents can damage rubber, neo-prene, and electrical insulation. They can also damagepaint and should be removed as soon as possible.

(2) To protect against cleaning solution entrap-ment, inspect all lubrication points that have exposuretype lubrication fittings. Lubricate those that have notbeen regularly lubricated in accordance with the applica-ble maintenance manual.

(3) Close all doors and emergency openings.

(4) Make sure that all drain holes are clear byinserting a probe such as a pipe cleaner, except wherepressurized flapper valves are located.

b. Cleaning Methods. Various cleaning methodsare explained in the following paragraphs. The methodused depends upon the availability of tap water.

(1) Waterless wipedown. Waterless wipedownprocedures will be used when water is not available forrinsing or when cold weather prevents the use of water.The preferred waterless wipedown method for removingsoils and corrosive salt residues is accomplished usingthe following procedures.

Open all circuit breakers associated with bat-tery power prior to application ofMIL-C-43616 cleaning compound. Thiscompound is flammable.

When using cleaning compounds MIL-C-25769, MIL-C-43616 or MIL-C-85570,wear faceshield or goggles, rubber glovesand coveralls. These compounds are toxicand can cause skin irritation.

(a) Spray the exterior surfaces of the air-craft with water emulsion cleaning compoundMIL-C-43616.

Change 2 13-1

TM 1-1500-204-23-1

(b) When the foam begins to break, wipecleaner and soil from the surface.

(c) Rinsing with a cloth wet with fresh waterfollowing the use of MIL-C-43616 is desirable.

(d) Rinse the cleaned surface with freshwater when water becomes available.

Open all circuit breakers associated with bat-tery power prior to application ofMIL-C-43616 cleaning compound. This com-pound is flammable.

(2) Detergent cleaning with limited water.When limited water is available, the following no rinse

procedures may be used:

When using cleaning compounds MIL-C-25769, MIL-C-43616 or MIL-C-85570,wear faceshield or goggles, rubber glovesand coveralls. These compounds are toxicand can cause skin irritation.

Open all circuit breakers associated with bat-tery power prior to application of

(a) Mix one part of aircraft cleanerMIL-C-43616 or MIL-C-25769 with nine parts water.

(b) Apply the mixture using foaming equip-ment with aircraft washing kit or fiber brush.

MlL-C-43616 cleaning compound. This com-pound is flammable. (c) To prevent streaking, start at the lower

surfaces, working upward and out. Scrub the surfaceWhen using cleaning compounds MIL-C-25769, MIL-C-43616 or MILC-85570,wear faceshield or goggles, rubber glovesand coveralls. These compounds are toxicand can cause skin irritation.

(a) Mix one part of aircraft cleaning com-pound MIL-C-43616 or MIL-C-25769 and nine parts ofwater in a bucket.

with the washing-kit or fiber brush.

Do not rinse aircraft with a solid stream ofwater. Use a soft, spray pattern to avoid dam-aging fragile sections or causing water intru-sion.

(b) Apply the cleaner with a scrub brush,sponge, rag, or cleaning and polishing pad. Apply to onesmall area at a time.

(c) Scrub the area and remove the cleanerand loosened soil with a cloth.

NOTEFor soils that are resistant to the limited waterprocedure, clean again with a mixture of onepart cleaner in four parts water.

Apply MIL-C-81309 Type II and wipe(d)with a clean dry cloth.

(3) Water detergent cleaning (preferredmethod). Where water of suitable quality is available forrinsing purposes, the following procedures shall be used:

(d) Rinse away the loosened soil andcleaner with a stream of water. For rinsing, a rubberpadded shutoff -spray nozzle is recommended.

(4) Rinsing. Rinse the cleaner and loosenedsoil from aircraft surface with pressure equipment havinga fan spray nozzle. Direct water at an angle between 15and 30 degrees from the surface to rinse it. Continuerinsing until all evidence of cleaner and soils have beenremoved from aircraft.

(5) Deluge rinsing. To prevent buildup of saltdeposits, the deluge rinse facilities shall be used as fre-quently as possible.

NOTEUse of deluge rinsing facilities does notreplace aircraft washing requirements.

13-2

TM 1-1500-204-23-1

c. Cleaning of Corrosion Prone Areas. Specificefforts shall be made to clean all corrosion prone areasas frequently as possible, even if unusual conditionsprevent complete aircraft cleaning. Refer to theapplicable maintenance manual.

d. Post-Cleaning. Corrosion prevention dependson carrying out the prescribed preservation andlubrication procedures. Strict compliance with thefollowing procedures is essential Post-cleaningprocedures shall be done in the following order:

(1) Remove covers from all static vents,pilot tubes, air ducts, heater ducts, etc. Tape shall beremoved from all other openings sealed with maskingtape.

(2) Clean all drain holes by inserting aprobe such as a pipe cleaner except where pressurizedflapper valves are located. Assure that all areasaccumulating water have been drained. Whenever thisis recurring problem, procedures shall be developed andimplemented to remove entrapped water and preventaccumulation.

(3) Inspect for corrosion and deteriorationas part of routine maintenance procedures.

(4) Relubricate, preserve, and seal.

(5) Polish and wax.

13-3. Cleaning Safety. All cleaning procedures shouldbe accomplished with the applicable maintenancemanual. Proper precautions must be taken whenworking with cleaning substances.

13-3/(13-4 blank)

TM 1-1500-204-23-1

APPENDIX AREFERENCES

AFM 64-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ANA Bulletin 166 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AR 25-400-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Modern Army Record Keeping Systems (Marks)AR 32-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Classification and InspectionAR 40-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TM 1-1500-204-23-1

APPENDIX A - CONTREFERENCES

C 6505-GL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FSC Glossary of Colloquial Names and Therapeutic Index(FSC Class 6505)

C 6545-IL-VOL 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Federal Supply, Catalog: Identification List, FSC 6545, Medi-cal Sets, Kits and Outfits

C 6700/9500-ML . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Management Data List: FSC Groups 67 Thru 95 (Items ofMedical Materiel Only)

C 8900-SL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Federal Supply Catalog: Stock List, FSC Group 89, Subsis-tence

CTA 8-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Army Medical Department Expendable/Durable ItemsCTA 50-900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clothing and Individual EquipmentCTA 50-909 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Field and Garrison Furnishings and EquipmentCTA 50-970 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Expendable/Durable Items (Except: Medical, Class V,

Repair Parts and Heraldic Items)DA FORM 12-R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Request for Establishment of a Publications AccountDA FORM 12 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements for DA PublicationsDAFORM 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requisition for Publications and Blank FormsDA FORM 17-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requisition for Publications and Blank Forms (Continuation

Sheet)DA FORM 581 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Request for Issue and Turn-In of AmmunicationDA FORM 2028 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Changes to Publications and Blank FormsDA FORM 2062 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand Receipt/Annex NumberDA FORM 2063-R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prescribed Load List (LRA)DA FORM 2064 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Document Register for Supply ActionsDA FORM 2402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exchange TagDA FORM 2404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Inspection and Maintenance WorksheetDA FORM 2405 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Request RegisterDA FORM 2407 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance RequestDA FORM 2407-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Request - Continuation SheetDA Form 2408 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DA Form 2408-1-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DA Form 2408-13-1 DA Form 2408-13-1 . . . . . . . . . . . . . .DA FORM 2408-1-13-1-E . . . . . . . . . . . . . . . . . . . . . . . . . .DA Form 2408-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DA Form 2408-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DA FORM 2408-13-1 DA FORM 2408-13-1 . . . . . . . . . . .DA Form 2408-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DA Form 2408-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DA FORM 2408-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Life Raft Inspection RecordDA FORM 2408-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Helmet and Oxygen Mask/Connector Inspection RecordDA FORM 2408-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Survival Radio/Emergency Locator Transmitter (ELT)

Inspection RecordDA FORM 2408-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Survival Kit Inspection and Maintenance RecordDA FORM 2408-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mesh Net Survival Vest Inspection RecordDA FORM 2408-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Life Preserver Inspection RecordDA FORM 2408-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Life Preserver Data

A-2 Change 2

TM 1-1500-204-23-1

GLOSSARY

ATOMIZATION - The process of changing liquid particles to a fine spray.

BONDING - Two or more layers held together by adhesive.

DATUM - A reference used as a basis for calculating or measuring.

DESICCANT - A drying agent that absorbs moisture.

FOD - Foreign Object Damage.

GROUNDING - Electrically connecting an object with the earth.

HYPOXIA- A deficiency of oxygen reaching the tissues of the body.

OHM - A measurement of electrical resistance.

PHENOLIC - A cotton fabric filled with a phenolc resin to form a hard material.

SERVING - The process of winding wire tightly around cable for protection.

SPECIFIC GRAVITY - Ratio of solid or liquid density compared to pure water.

VAPORIZATION - The process of converting a liquid into a vapor.

VISCOSITY - A fluid's Internal resistance to flow.

Glossary 1/(Glossary 2 blank)

TM 1-1500-204-23-1

INDEX

VOLUME 1

Subject ParagraphFigure, Table

NumberA

Accessories...................................................................................................................................................... 7-4hAccessory Section............................................................................................................................................ 8-5hAdditional Metal Particles Test ......................................................................................................................... 7-5gAdhesive Operations................................................................................................................................2-2k, 2-3kAdhesives, Resins, and Solvents for Repair of Armor .....................................................................................9-23cAdjusting Mixture and Idle Speed......................................................................................................................7-9cAdjustment of Windshield Wiper System.........................................................................................................9-19bAdministration .................................................................................................................................................. 11-2Administration Area.......................................................................................................................................... 11-6Air Induction System .......................................................................................................................................... 7-7

Inspection, Maintenance, Cleaning, and Replacement ............................................................................ 7-7aTurbocharger and Supercharger Maintenance ........................................................................................ 7-7b

Aircraft and Equipment, Parking of, in Hangars .................................................................................................. 2-6Aircraft Cleaning, General................................................................................................................................ 13-1Aircraft Component, Preservation and Packing ................................................................................................ 4-12Aircraft Grounding Receptacle Installation........................................................................................................ F3-2Aircraft, Liferafts ............................................................................................................................................ T11-4Aircraft Litters................................................................................................................................................... 9-21

Installation .............................................................................................................................................9-21aRemoval................................................................................................................................................9-21b

Aircraft Preparation for Storage.......................................................................................................................... 4-4Aircraft Refueling ............................................................................................................................................... 3-5

Fuel Truck Operations ............................................................................................................................ 3-5dOpen-Port Hot Refueling......................................................................................................................... 3-5bOpen-Port Refueling ............................................................................................................................... 3-5aRapid Hot Refueling.................................................................................................................................3-5c

Aircraft Removal from Storage........................................................................................................................... 4-9Aircraft Seats ................................................................................................................................................... 9-20

Metal Seats ...........................................................................................................................................9-20bPolyester Fabric Seat Covers (UH-60) ...................................................................................................9-20eRaschel Knit Seat Covers ......................................................................................................................9-20dTroop Seats ...........................................................................................................................................9-20aUpholstered Seats .................................................................................................................................9-20c

Aircraft, Shipment ............................................................................................................................................ 4-11Aircraft, Static Grounding of ............................................................................................................................... 3-4Aircraft Storage and Shipment, General............................................................................................................. 4-1Aircraft Storage and Shipment, Responsibility.................................................................................................... 4-3Airframe Maintenance, General.......................................................................................................................... 9-1Airplane, First Aid Kit (Older Configuration).................................................................................................... F11-1Alignment, Landing Gear.................................................................................................................................... 9-6Anti-Icing, Deicing, and Defrosting ..................................................................................................................10-2dApplication and Installation of Identification Tapes ............................................................................................. 6-3Application and Removal of Decals, General ..................................................................................................... 6-1Application of Identification Tapes.....................................................................................................................6-3c

Index 1

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1


Number

A - Continued

Approach Route, Fuel Truck............................................................................................................................. F3-3Arctic-Type Mooring ....................................................................................................................................... F10-2Armor Plating ................................................................................................................................................... 9-23

Adhesives, Resins, and Solvents for Repair of Armor ............................................................................9-23cArmor Plating Inspection and Repair Definitions ....................................................................................9-23aGeneral Inspection of Armor Plating ......................................................................................................9-23bRepair of Armor Plating .........................................................................................................................9-23d

Armor Plating Definitions.................................................................................................................................. T9-8Armor Plating Inspection and Repair Definitions..............................................................................................9-23aArctic Maintenance........................................................................................................................................... 10-2

Anti-Icing, Deicing, and Defrosting.........................................................................................................10-2dPrecautions............................................................................................................................................10-2aPreflight.................................................................................................................................................10-2cPreheating .............................................................................................................................................10-2bPrevention and Removal of Snow, Ice, and Frost Deposits ....................................................................10-2e

Preventive Maintenance.................................................................................................................................. 10-2fArctic, Desert, and Tropic Maintenance, General ............................................................................................. 10-1Assemblies, Connecting Rod............................................................................................................................ F7-9Assemblies, Elastic Shock Cords ..................................................................................................................... 9-26Assembly, Cylinder . ...................................................................................................................................... F7-11Assembly, Turbine, Elements......................................................................................................................... F8-10Aviation Life Support Maintenance, General .................................................................................................... 11-1Axial Flow Compressor, Rotor and Stator Components of ................................................................................ F8-7Axial-Flow Engine ............................................................................................................................................ F8-2

B

Backing Approach, Fuel Truck ......................................................................................................................... F3-5Balance (of Tires and Tubes) ............................................................................................................................9-9cBalancing Equipment .................................................................................................................................2-2l, 2-3lBasic Mechanical Failure . ................................................................................................................................7-5kBasis of Issue, First Aid Kits ..........................................................................................................................11-19aBearing Types.................................................................................................................................................. F7-8Bearings............................................................................................................................................................7-4cBleeding Brakes .................................................................................................................................................9-7iABooste Comi................................................................................................................................

ABakes Assemblis............................................................................................................................................ 9-7ib Tj -4898.6 011.52 TD 0.0033 Tc 0.0029 Tw (Baakes Assembly Adjustent) Tj 926 0 TD 0.0072 Tc 0 Tw (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (..........................).. 9-7ig Tj -4898.6 011.52 TD 0.0033 Tc 0.0032 Tw (Baakes Assembly Clenicng Tj -11736 0 TD 0.0042 Tc 0 Tw (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (..........................)..)..

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1


NumberB - Continued

Brake Systems................................................................................................................................................... 9-7Bleeding Brakes........................................................................................................................................9-7iBrake Assemblies ................................................................................................................................... 9-7bBrake Assembly Adjustment ................................................................................................................... 9-7gBrake Assembly Cleaning ........................................................................................................................9-7cBrake Assembly Inspection..................................................................................................................... 9-7dBrake Assembly Servicing ...................................................................................................................... 9-7hBrake System Safety ................................................................................................................................9-7jBrake Types ........................................................................................................................................... 9-7aCorrosion Treatment of Brake Assemblies .............................................................................................. 9-7eRepair and Replacement of Brake Assembly Components ...................................................................... 9-7f

Brake Types..................................................................................................................................................... 9-7aBuilt-in Timing Marks ..................................................................................................................................... F7-17

C

Cable Cutter Cartridges.................................................................................................................................... 12-5Cable Damage Limits....................................................................................................................................... T9-3Cable Test ....................................................................................................................................................... T9-5Can-Annular Combustion Chamber Components and Arrangement ................................................................. F8-9Can-Type Combustion Chamber Arrangement ................................................................................................. F8-8Can-Type Combustion Chamber ...................................................................................................................... F8-9Carbon Monoxide Detection ............................................................................................................................3-12cCarburetion and Fuel Injection ........................................................................................................................... 7-9

Adjusting Idle Mixture and Idles Speed ....................................................................................................7-9cDepreservation ....................................................................................................................................... 7-9bInspection ............................................................................................................................................... 7-9aInstallation ............................................................................................................................................... 7-9fPreservation ........................................................................................................................................... 7-9eRepair or Replacement ........................................................................................................................... 7-9d

Cargo Tiedown Equipment ............................................................................................................................... 9-24Cartridges, Cable Cutter................................................................................................................................... 12-5Cartridges, External Storage ............................................................................................................................ 12-4Cartridges, Fire Bottle ...................................................................................................................................... 12-3Categories of Storage ........................................................................................................................................ 4-2

Flyable Storage ...................................................................................................................................... 4-2aIntermediate Storage ...............................................................................................................................4-2cLong Term Storage................................................................................................................................. 4-2dShort Term Storage ................................................................................................................................ 4-2b

Centrifugal-Flow Compressor Components ...................................................................................................... F8-6Centrifugal-Flow Engine ................................................................................................................................... F8-1

Index 3

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1


Number

C - Continued

Chain Hoists..................................................................................................................................................... 2-3eChecking Propeller Shaft Runout ................................................................................................................... F7-21Cleaning, Flight Clothing ...............................................................................................................................11-14cCleaning, Flotation Equipment ......................................................................................................................11-16eCleaning Methods ...........................................................................................................................................13-2bCleaning, Nuclear, Biological, and Chemical Equipment ...............................................................................11-20cCleaning of Corrosion Prone Areas .................................................................................................................13-2cCleaning, Oxygen Equipment........................................................................................................................11-17cCleaning Practices and Procedures.................................................................................................................. 13-2

Cleaning Methods..................................................................................................................................13-2bCleaning of Corrosion Prone Areas........................................................................................................13-2cPost-Cleaning ........................................................................................................................................13-2dPreparation for Cleaning . ......................................................................................................................13-2a

Cleaning, Restraint Equipment . ....................................................................................................................11-21cCleaning Safety................................................................................................................................................ 13-3Cleaning, Signaling Devices..........................................................................................................................11-18cCleaning, Survival Kits..................................................................................................................................11-15cCleaning, Tires and Tubes ............................................................................................................................... 9-9aClothing, Flight................................................................................................................................................11-14Cockpit Check Sheet, Engine Conditioning .................................................................................................... F7-23Coding, Color (Elastic Shock Cords) ................................................................................................................ T9-8Coil, Booster .................................................................................................................................................. F7-20Cold Section Maintenance................................................................................................................................ 8-6gColor Band, Solid, System ............................................................................................................................... F6-2Color Coding (Elastic Shock Cords) ................................................................................................................. T9-8Color-Coded Tapes .......................................................................................................................................... F6-1Combustion Chamber, Can-Type ..................................................................................................................... F8-9Combustion Chamber, Can-Type, Arrangement ............................................................................................... F8-8Combustion Section ......................................................................................................................................... 8-5eComplete Engine Conditioning ......................................................................................................................... 7-6aComponent Replacement Criteria .................................................................................................................... 8-7bComponents and Airflow of a Double-Annular Chamber . ............................................................................... F8-10Components and Arrangement, Can-Annular Combustion Chamber .............................................................. F8-11Components, Fabrication (for Cables) .............................................................................................................. T9-2Components, First Aid Kits . ........................................................................................................................... T11-8Compressed Air and Water Outlets ................................................................................................................... 2-2fCompressed Air Panels..................................................................................................................................... 2-3fCompressor Blade Damage ........................................................................................................................... F8-17Compressor Blade Inspection and Repair......................................................................................................... 8-6hCompressor Blade Repair Limits, Typical....................................................................................................... F8-18Compressor Cleaning........................................................................................................................................ 8-6f

Index 4

TM 1-1500-204-23-1

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1


NumberD - Continued

Deicing System Precautions............................................................................................................................9-14aDeicing System Preventive Maintenance ........................................................................................................9-14bDeicing System Troubleshooting .....................................................................................................................9-14cDeicing Systems ............................................................................................................................................. 9-14

Deicing System Maintenance.................................................................................................................9-14dDeicing System Precautions .................................................................................................................9-14aDeicing System Preventive Maintenance...............................................................................................9-14bDeicing System Troubleshooting............................................................................................................9-14c

Depreservation................................................................................................................................................. 4-9aDepreservation of Installed Reciprocating Engines, Supplemental Instructions................................................. 4-10Depreservation (of Carburetors) ....................................................................................................................... 7-9bDepreservation of Reciprocating Engines ........................................................................................................ 7-13

Depreservation Run...............................................................................................................................7-13bPreoiling ................................................................................................................................................7-13a

Depreservation Run .......................................................................................................................................7-13bDesert Maintenance ......................................................................................................................................... 10-3

Deterioration Factors .............................................................................................................................10-3aInspection and Maintenance .................................................................................................................10-3cPrecautions............................................................................................................................................10-3bPreventive Maintenance . ......................................................................................................................10-3d

Design and Construction, Turbine Engine........................................................................................................... 8-5Designation Examples...................................................................................................................................... 8-2bDesignation Examples (Reciprocating Engines) ............................................................................................... 7-2bDetails, Snap Hook Safety Guard Drill ........................................................................................................... F11-9Details, Snap Hook Safety Pin Construction................................................................................................. F11-10Detection and Extinguishing Systems, Fire....................................................................................................... 9-15Deterioration Factors ......................................................................................................................................10-3aDevices, Signaling ..........................................................................................................................................11-18Diffuser Section . ............................................................................................................................................. 8-5dDischarge Pressure Pickup Line, Turbine ....................................................................................................... F8-21Disconnect, Electrical..................................................................................................................................... F8-22Disconnect, Fuel Line .................................................................................................................................... F8-23Disconnect, Power Level................................................................................................................................ F8-24Divided Entrance Inlet Duct (Centrifugal-Flow Engine) ..................................................................................... F8-4Double-Annular Chamber, Components and Airflow of a................................................................................ F8-10Duplex Fuel Nozzle ....................................................................................................................................... F8-18Dust and Dirt Control..................................................................................................................................2-2i, 2-3i

Index 6

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1


Number

E

Earth Ground Testing .......................................................................................................................................3-4cEarth Grounds.................................................................................................................................................. 3-4bEjection Seats ................................................................................................................................................. 12-2Elastic Shock Cord Assemblies ........................................................................................................................ 9-26

Fabncation Procedures ..........................................................................................................................9-26dFabrication Requirements......................................................................................................................9-26bIdentification .........................................................................................................................................9-26cInspection and Testing ..........................................................................................................................9-26aProcess Control ..................................................................................................................................... 9-26fServing Elastic Shock Cord ...................................................................................................................9-26eStorage of Elastic Shock Cords..............................................................................................................9-26g

Electrical Disconnect...................................................................................................................................... F8-20Electncal Hoist System ..................................................................................................................................9-16bElectncal Safety . ............................................................................................................................................. 2-5aElectrical Utilities .....................................................................................................................................2-2g, 2-3gEmergency Evacuation of Aircraft from Hangar .................................................................................................2-6iEmergency Extension Systems . ...................................................................................................................... 9-3bEngine Components, Major (Reciprocating Engines).......................................................................................... 7-4Engine Conditioning ................................................................................................................................. 7-6, T7-2

Complete Engine Conditioning ............................................................................................................... 7-6aMinor Engine Conditioning ..................................................................................................................... 7-6b

Engine Conditioning Cockpit Check Sheet .................................................................................................... F7-23Engine Mounting Systems ............................................................................................................................... 7-11Engine Operation ............................................................................................................................................ 3-10

Reciprocating Engines . .........................................................................................................................3-10bSafety Procedures . ...............................................................................................................................3-10aTurbine Engines.....................................................................................................................................3-10c

Engine Overspeed ............................................................................................................................................7-5lEngine Removal Criteria (Reciprocating Engine)................................................................................................ 7-5

Additional Metal Particles Test ............................................................................................................... 7-5gBasic Mechanical Failure ........................................................................................................................7-5kEngine Overspeed . ..................................................................................................................................7-5lExcessive Maintenance .......................................................................................................................... 7-5nExcessive Manifold Pressure ................................................................................................................. 7-5mExcessive Oil Consumption .................................................................................................................... 7-5oExcessive Spark Plug Copper or Silver Runout ..................................................................................... 7-5hExpiration of Operating Time Limit ......................................................................................................... 7-5aIdentification of Metal Particles ............................................................................................................... 7-5eLow Cylinder Compression .......................................................................................................................7-5iMetal Particles in Oil .............................................................................................................................. 7-5dParts Failure ............................................................................................................................................7-5jSignificance of Metal Particles ................................................................................................................ 7-5f

Index 7

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1


Number

E - Continued

Sudden Engine Stoppage . ..................................................................................................................... 7-5bSudden Reduction In Engine RPM...........................................................................................................7-5c

Engine Replacement Criteria ........................................................................................................................... 8-7aEngine Types and Designations .................................................................................................................. 7-2, 8-2

Designation Examples ...................................................................................................................7-2b, 8-2bTypes .............................................................................................................................................7-2a, 8-2a

Engine, Axial-Flow ........................................................................................................................................... F8-2Engine, Centrifugal-Flow.................................................................................................................................. F8-1Engine, Opposed-Type .................................................................................................................................... F7-2Engine, Turbine, Theory..................................................................................................................................... 8-3Engines and Components, Replacement Criteria for .......................................................................................... 8-7Entries in Aircraft Forms..................................................................................................................................... 4-7Entries, Method of Accomplishing ...................................................................................................................... 5-4Environmental Control .................................................................................................................................... 2-2mEnvironmental Control Systems ....................................................................................................................... 9-13

Repair of Flexible Air Ducts . .................................................................................................................9-13bTypes ....................................................................................................................................................9-13a

Equipment, Flotation . .....................................................................................................................................11-16Equipment Maintenance Forms........................................................................................................................ 2-4dEquipment Mounted In Mobile Shelters .............................................................................................................2-3cEquipment, Nuclear, Biological, and Chemical ...............................................................................................11-20Equipment, Oxygen ........................................................................................................................................11-17Equipment, Restraint ......................................................................................................................................11-21Equipment, Test............................................................................................................................................. T11-1Equipment, Training .......................................................................................................................................11-12Excessive Maintenance.................................................................................................................................... 7-5nExcessive Manifold Pressure ......................................................................................................................... 7-5mExcessive Oil Consumption.............................................................................................................................. 7-5oExcessive Spark Plug Copper or Silver Runout................................................................................................ 7-5hExhaust Section ............................................................................................................................................... 8-5gExhaust System ................................................................................................................................................. 7-8Expiration of Operating Time Limit .................................................................................................................. 7-5aExternal Storage Cartridges ............................................................................................................................. 12-4

F

Fabncation Components (for Cables) ............................................................................................................... T9-2Fabrication of Ground Cable ........................................................................................................................... 3-4dFabrication of Static Grounding Cable Assembly.............................................................................................. F3-1Fabrication Procedures ..................................................................................................................................9-26dFabrication Requirements (Elastic Shock Cords).............................................................................................9-26b

Index 8

TM 1-1500-204-23-1

INDEX- CONT

VOLUME 1

Subject Paragraph,Figure, Table

Number

F - Continued

Flightline Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flightline Operations General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flightline Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flightline Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Foreign Object Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hearing Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Parking and Mooring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preparation of Aircraft for Storms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reflectorizing of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Around Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Around Helicopters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Float Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2g3-13-2

3-2g3-2b3-2a3-2e3-2f3-2h3-2d3-2c9-11

Flotation Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3c, 11-16Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16eInspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16cPrecautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16aRepair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16dStorage in Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16b

Flotation Equipment References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-5Flyable Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2a. 7-12eFlyable Storage for Depreservation of Installed Reciporcating Engines . . . . . . . . . . . . . . . 4-10aFlyable Storage for Preservation of Installed Reciporcating Engines . . . . . . . . . . . . . . . . . 4-5aForeign Object Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2bForeign Object Damage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6eForm Entries for Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Fuel Line Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-21Fuel Nozzle, Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-16Fuel Nozzle, Simplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-15Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6oFuel Systems.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5kFuel Truck Approach Route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-3Fuel Truck Backing Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-5Flue Truck Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5dFuel Truck Required Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-4

G

General Position Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Airframe Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Inspection of Armor Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3d9-1

9-23b

Index 10

PIN: 070482-002

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1


Number

H - Continued

Hoisting 2-7bHoisting and Jacking ......................................................................................................................................... 2-7Hot Section Maintenance ..................................................................................................................................8-6iHot Start Inspection...........................................................................................................................................8-6cHydraulic Fluid Servicing .................................................................................................................................. 3-8Hydraulic Hoist System ...................................................................................................................................9-16a

I

Identification, First Aid Kits ...........................................................................................................................11-19cIdentification of Elastic Shock Cords ...............................................................................................................9-26cIdentification of Metal Particles ....................................................................................................................... 7-5eIdentification Tag, Flat-Head Pin, Lead Seal, Properly Attached .................................................................... F11-5Identification Tapes, Application and Installation of ............................................................................................ 6-3Application of Identification Tapes ....................................................................................................................6-3cInstallation of Identification Tapes ................................................................................................................... 6-3dPrinted-Symbolized System ............................................................................................................................. 6-3aSolid Color Band System ................................................................................................................................. 6-3bIgniter Plugs, Typical...................................................................................................................................... F8-14Ignition Harness ............................................................................................................................................. F7-18Ignition System . ................................................................................................................................................7-4iIgnition System Maintenance ...........................................................................................................................8-6kIgnition System, Typical, One Side of a ......................................................................................................... F8-13Ignition Systems.................................................................................................................................................8-5jIndicator, Top Center .................................................................................................................................... F7-15Induction Vibrator .......................................................................................................................................... F7-19Induction Vibrators, Repairing .......................................................................................................................... T7-1Induction, Air, System ........................................................................................................................................ 7-7Inlet Duct, Divided Entrance (Centrifugal-Flow Engine) .................................................................................... F8-4Inlet Duct, Single Entrance (Axial-Flow Engine) .............................................................................................. F8-3Inlet Ducts........................................................................................................................................................ 8-5aInspection ....................................................................................................................................................... 4-9bInspection (Carburetors) . ................................................................................................................................. 7-9aInspection (First Aid Kits) .............................................................................................................................. 11-19fInspection (Flight Clothing)............................................................................................................................11-14aInspection (Flotation Equipment) ..................................................................................................................11-16cInspection (Nuclear, Biological, and Chemical Equipment)............................................................................11-20aInspection (Oxygen Equipment) ....................................................................................................................11-17aInspection (Restraint Equipment) ..................................................................................................................11-21aInspection (Signaling Devices) .....................................................................................................................11-18aInspection (Survival Kits) ..............................................................................................................................11-15a

Index 12

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1


Number

I - Continued

Inspection (Tires and Tubes) ............................................................................................................................ 9-9bInspection and Maintenance (Desert) ..............................................................................................................10-3cInspection and Maintenance, Turbine Engine ..................................................................................................... 8-6Inspection and Preventive Maintenance, (Tropics) .........................................................................................10-4aInspection and Testing (Elastic Shock Cords)..................................................................................................9-26aInspection Criteria, Personnel Parachute and Parachute Harness .................................................................11-22aInspection of Flight Controls............................................................................................................................9-12bInspection of Primer MNozzle............................................................................................................................ PT81

Fnspection of PStored Aircraft Tj 126 0 TD 0.0072 Tc 0 Tw (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (............................).. 84-5 Tj -494.16 -11.52 TD 0.0048 Tc 0.0024 Tw (Inspection af PVibraion aIsolator) Tj 120.840 TD 0.0072 Tc 0 Tw (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (........................ Tj 96.72 - TD 0.0044 Tc (1-265) Tj -483.6 -11.52 TD 0.0051 Tc 0.0022 Tw (Fnspection oProcedre,s Personnel Parachute and Parachute Harness) Tj 2307.440 TD 0.0072 Tc 0 Tw (................................) Tj 92.16 0 TD (............................ Tj 7280 TD 0.0058 Tc (11-22ab Tj -477.6 -11.52 TD 0.0041 Tc 0.0021 Tw (Inspection aReport Personnel Parachute and Parachute Harness) Tj 2987.2 0 TD 0.0072 Tc 0 Tw (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (... Tj 96.4 0 TD 0.00447 Tc (11-22a) Tj -487808 11.52 TD 0.0043 Tc 0.0029 Tw (Inspection aTrintng Procedre,s PFirst Aid Kit) Tj 290376 0 TD 0.0052 Tc 0 Tw (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (................................) Tj 92.14 0 TD 0.0059 Tc 011-219j Tj -483072 -11.52 TD 0.0048 Tc 0.0024 Tw (Inspection ,Maintenance, Cleatng ,and PReplacemnti(EReciprocaing gine))) Tj 234488 0 TD 0.0072 Tc 0 Tw (................................) Tj 92.16 0 TD (.................. Tj 5.1.60 TD 0.00581 Tc 0(7-7) Tj -483814 011.52 TD 0.0045 Tc 0.0027 Tw (Insptallaion a(Aircraft Literi) ) Tj 226 0 TD 0.0072 Tc 0 Tw (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (............................) Tj 80.64 0 TD 0.0057 Tc (9-121) Tj -483.12 -11.52 TD 0.0049 Tc 0.0024 Tw (Insptallaion a(f PCarbre,tor))) Tj 212.12 0 TD 0.0052 Tc 0 Tw (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (............................)..) Tj 921.440 TD 0.0073 Tc (87-9f Tj -4941.0 011.52 TD 0.0045 Tc 0.0029 Tw (Insptallaion a(f PFirst Aid Kit))................................................................................................ ................................................................................................ ................................................................................................

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1


Number

M - Continued

Maintenance, Desert ....................................................................................................................................... 10-3Maintenance, Float .......................................................................................................................................... 9-11Maintenance, Ski ............................................................................................................................................ 9-10Maintenance, Tropic ........................................................................................................................................ 10-4Maintenance, Wheel .......................................................................................................................................... 9-8Major Engine Components (Reciprocating Engines) .......................................................................................... 7-4

Accessones ............................................................................................................................................ 7-4hBearings . ................................................................................................................................................7-4cConnecting Rods .................................................................................................................................... 7-4dCrankcases............................................................................................................................................. 7-4aCrankshafts . .......................................................................................................................................... 7-4bCylinders ................................................................................................................................................ 7-4fIgnition System.........................................................................................................................................7-4iPistons, Pins, and Rings ........................................................................................................................ 7-4eValves ................................................................................................................................................... 7-4g

Major Repair .................................................................................................................................................... 2-4bMarking of Aeronautical Items, General ............................................................................................................. 5-1Marking of Cylinder ....................................................................................................................................... F7-12Marking of Defects on Turbine Engines.............................................................................................................. 8-8Marking Requirements (Aeronautical Items) ...................................................................................................... 5-2Marking, Materiel .............................................................................................................................................. 5-3Materals, Consumable ...................................................................................................................................... 1-3Materiel Marking ................................................................................................................................................ 5-3Measuring Fingertip Clearance ...................................................................................................................... F11-6Metal Decals ....................................................................................................................................................6-2cMetal Particles in Oil ....................................................................................................................................... 7-5dMetal Seats ....................................................................................................................................................9-20bMethod of Accomplishing Entries ........................................................................................................................54Minimum Serving Length ................................................................................................................................ T9-9Minor Engine Conditioning .............................................................................................................................. 7-6bModification, Seat Belt Latch ....................................................................................................................... F11-12Moisture and Fungi, Parts and Fabncs Affected by.............................................................................. 10-4b, T10-1Moonng, Arctic-Type .................................................................................................................................... F1 0-2Mounts, Turbine Engine ..................................................................................................................................... 8-9

N

Nameplates, Fire Extinguisher .......................................................................................................................... 2-3New Equipment ............................................................................................................................................ 11-13fNoise Levels ............................................................................................................................................2-2h, 2-3hNosewheel Centering ...................................................................................................................................... 9-3e

Index 15

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1


Number

N - Continued

Nuclear, Biological, and Chemical Equipment .................................................................................................11-20Cleaning 11-20cInspection .....................................................................................................................................................11-20aRepair . 11-20bNuclear, Biological, and Chemical Equipment References .......................................................................... T11-10

O

Oil Consumption ............................................................................................................................................. 8-6nOil Consumption Chart .................................................................................................................................. F7-22Oil Servicing ...................................................................................................................................................... 3-6One Side of a Typical Ignition System............................................................................................................ F8-15Open Storage Areas.......................................................................................................................................... 2-3rOpen Storage for Repaired Equipment and Consumable Material ..................................................................... 2-2rOpen-Port Hot Refueling ................................................................................................................................. 3-5bOpen-Port Refueling . ...................................................................................................................................... 3-5aOperating Cycle (Four-Stroke) Reciprocating Engine ...................................................................................... F7-3Operation, Engine ............................................................................................................................................ 3-10Operational Check .......................................................................................................................................... 4-9dOperator Maintenance...................................................................................................................................... 2-4aOperator Position, Painting of Shop Equipment to Highlight ............................................................................ F2-2Opposed-Type Crankcase................................................................................................................................ F7-4Opposed-Type Crankshaft (Six-Cylinder) (Six-Throw) ..................................................................................... F7-6Opposed-Type Engine ..................................................................................................................................... F7-2Overhead Chain Hoist...................................................................................................................................... 2-2eOxygen Equipment ...........................................................................................................................11-13e, 11-17

Cleaning . ............................................................................................................................................11-17cInspection ............................................................................................................................................11-17aRepair .................................................................................................................................................11-17b

Oxygen Equipment References...................................................................................................................... T11-6Oxygen Servicing............................................................................................................................................... 3-7

Safety Precautions ................................................................................................................................. 3-7aServicing ................................................................................................................................................ 3-7b

Oxygen System Types ....................................................................................................................................9-17aOxygen Systems.............................................................................................................................................. 9-17

Maintenance of Oxygen Systems...........................................................................................................9-17bOxygen System Types...........................................................................................................................9-17aServicing of Oxygen Systems................................................................................................................9-17c

Index 16

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1


Number

P

Packaging Procedures ....................................................................................................................................4-12bPainting 2-4cPainting of Shop Equipment to Highlight Operator Position ............................................................................. F2-2Paper Decals .................................................................................................................................................. 6-2aParachute Harness and Personnel Parachute..................................................................................................11-22Parking and Mooring ........................................................................................................................................ 3-2eParking of Aircraft and Equipment in Hangars .................................................................................................... 2-6

Emergency Evacuation of Aircraft from Hangar ........................................................................................2-6iLocation of Static Ground Points............................................................................................................. 2-6eParking of Aircraft in Hangars ................................................................................................................. 2-6bParking of Aircraft with Fuel Tanks Less Than Full...................................................................................2-6cSafety Lanes .......................................................................................................................................... 2-6aStatic Grounding of Aircraft .................................................................................................................... 2-6gStatic Grounding of Ground Support Equipment . ................................................................................... 2-6hTesting of Static Ground Points ............................................................................................................... 2-6fUsage of Drip Pans................................................................................................................................. 2-6d

Parking of Aircraft in Hangars .......................................................................................................................... 2-6bParking of Aircraft with Fuel Tanks Less Than Full ...........................................................................................2-6cParticle Separators ................................................................................................................................. 8-5b, F8-5Parts and Fabncs Affected by Moisture and Fungi .............................................................................. 10-4b, T10-1Parts Failure ......................................................................................................................................................7-5jPercent Dilution Versus Temperature for Grade 1100 Oil ............................................................................... F7-25Permanent Shop Installations............................................................................................................................. 2-2

Adhesive Operations ...............................................................................................................................2-2kBalancing Equipment.............................................................................................................................. 2-21Compressed Air and Water Outlets.......................................................................................................... 2-2fDust and Dirt Control ................................................................................................................................2-2iElectrical Utilities .................................................................................................................................... 2-2gEnvironmental Control ........................................................................................................................... 2-2mLighting Requirements . .......................................................................................................................... 2-2nNoise Levels .......................................................................................................................................... 2-2hOpen Storage for Repaired Equipment and Consumable Material ........................................................... 2-2rOverhead Chain Hoist ........................................................................................................................... 2-2eShop Equipment Arrangement................................................................................................................ 2-2dShop Equipment Required .......................................................................................................................2-2cShop Size ............................................................................................................................................... 2-2bSpray Painting ..........................................................................................................................................2-2jStorage of Compressed Gases ............................................................................................................... 2-2pStorage of High-Value Items................................................................................................................... 2-2qStorage of Shop Stocks, Repair Parts, and Consumable Matenals ......................................................... 2-2oTypical Layout ....................................................................................................................................... 2-2a

Index 17

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1


Number

P - Continued

Personnel ........................................................................................................................................................ 11-4Personnel Parachute and Parachute Harness..................................................................................................11-22

Inspection Criteria................................................................................................................................11-22aInspection Procedures . .......................................................................................................................11-22bInspection Report ................................................................................................................................11-22c

Pistols, Pyrotechnic.......................................................................................................................................... 12-6Piston Position Indicators, Installation of ....................................................................................................... F7-16Piston, Pin, and Ring Assemblies................................................................................................................... F7-10Pistons, Pins, and Rings .................................................................................................................................. 7-4ePlating, Armor .................................................................................................................................................. 9-23Pneumatic Deicing Systems, Troubleshooting ................................................................................................. T9-4Pneumatic System Servicing ............................................................................................................................. 3-9Polyester Fabric Seat Covers (UH-60) ...........................................................................................................9-20ePost- Cleaning ................................................................................................................................................13-2dPostflight and Parking .....................................................................................................................................3-11cPower Lever Disconnect ................................................................................................................................ F8-22Practices and ProcedurerA.52 TD 0.T................60.0072 Tc 0 Tw (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (............................ 0 TD .0072 Tc 0 T6) Tj -448364 -11.52 TD 0.0043 Tc 0.0024 Tw (Prac8ices andecauj 1 ) TArProc Maintenance)4 0 TD 0.0072 Tc 0 Tw (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (...................) Tj 56.88. 0 TD 70072 Tc 0 T6d

T 9 - w ( . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ) T j 9 2 . 1 6 0 T D ( . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ) T j 9 2 . 1 6 0 T D ( . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ) T j 9 2 . 1 6 0 T D ( . . . . . . . . . . . . . . . . . . . ) T j 5 6 . 8 0 T D . 0 8 4 7 2 T c 0 T 6 d

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1


Number

R - Continued

References for Signaling Devices .................................................................................................................. T11-7References for Survival Kits........................................................................................................................... T11-3Reflectorizing of Equipment ............................................................................................................................. 3-2hRefueling, Aircraft ............................................................................................................................................. 3-5Relief Tube System ......................................................................................................................................... 9-18Removal (Aircraft Litters) ...............................................................................................................................9-21bRemoval (of Turbine Engines) ........................................................................................................................8-11bRemoval (Reciprocating Engines) ...................................................................................................................7-10bRemoval and Installation of Reciprocating Engines .......................................................................................... 7-10

Installation ............................................................................................................................................7-10dPreparation for Installation .....................................................................................................................7-10cPreparation for Removal .......................................................................................................................7-10aRemoval . ..............................................................................................................................................7-10b

Removal and Installation of Turbine Engines ................................................................................................... 8-11Installation . ...........................................................................................................................................8-11dPreparation for Installation ....................................................................................................................8-11cPreparation for Removal .......................................................................................................................8-11aRemoval . ..............................................................................................................................................8-11b

Removal of Aircraft from Storage ...................................................................................................................... 4-8Depreservation ....................................................................................................................................... 4-8aInspection ............................................................................................................................................... 4-8bMaintenance............................................................................................................................................4-8cOperational Check . ................................................................................................................................ 4-8d

Repair (Flight Clothing) . ...............................................................................................................................11-14bRepair (Flotation Equipment) . ......................................................................................................................11-16dRepair (Nuclear, Biological, and Chemical Equipment) .................................................................................11-20bRepair (Oxygen Equipment)..........................................................................................................................11-17bRepair (Restraint Equipment) ........................................................................................................................11-21bRepair (Signaling Devices) ...........................................................................................................................11-18bRepair (Survival Kits) ...................................................................................................................................11-15bRepair and Replacement of Brake Assembly Components................................................................................ 9-7fRepair of Armor Plating ..................................................................................................................................9-23dRepair of Flexible Air Ducts.............................................................................................................................9-13bRepair of Flight Controls .................................................................................................................................9-12cRepair of Wheels .............................................................................................................................................9-8cRepair or Replacement (of Carburetors) .......................................................................................................... 7-9dRepair or Replacement of Fire Detection Components....................................................................................9-15eRepair Parts Van ............................................................................................................................................. 2-3pReparing Induction-Vibrators ........................................................................................................................... T7-1Replacement (Restraint Equipment) .............................................................................................................11-21dReplacement Cntena for Engines and Components .......................................................................................... 8-7

Component Replacement Criteria .......................................................................................................... 8-7b

Index 20

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1


Number

R - Continued

Engine Replacement Cntena............................................................................................................................ 8-7aReplacement Criteria for Wheels .................................................................................................................... 9-8dReplacement of Components (First Aid Kit) ..................................................................................................11-19hRequired Spacing, Fuel Truck .......................................................................................................................... F3-4Requirements, Marking (Aeronautical Items) ..................................................................................................... 5-2Responsibility, Aircraft Storage and Shipment.................................................................................................... 4-3Restraint Equipment........................................................................................................................................11-21

Cleaning ..............................................................................................................................................11-21cInspection ............................................................................................................................................11-21aRepair .................................................................................................................................................11-21bReplacement .......................................................................................................................................11-21d

Retractable Landing Gear Systems .................................................................................................................... 9-3Emergency Extension Systems .............................................................................................................. 9-3bGear Position Indicators.......................................................................................................................... 9-3dNosewheel Centenng.............................................................................................................................. 9-3eRetraction Test ........................................................................................................................................ 9-3fSafety Devices .......................................................................................................................................9-3cTypes ..................................................................................................................................................... 9-3a

Retraction Test (Retractable Landing Gear) ...................................................................................................... 9-3fRotor and Stator Components of an Axial-Flow Compressor ............................................................................ F8-7Runup and Taxiing ........................................................................................................................................... 3-11

Postflight and Parking ...........................................................................................................................3-11cSafety Procedures ................................................................................................................................3-11aTaxiing .................................................................................................................................................3-11b

S

Safety ......................................................................................................................................................... 11-3Safety Around Airplanes................................................................................................................................... 3-2dSafety Around Helicopters.................................................................................................................................3-2cSafety Devices (Retractable Landing Gear Systems) ........................................................................................9-3cSafety Lanes .................................................................................................................................................... 2-6aSafety Pin Retaining Cord Secured to Snap Hook ....................................................................................... F11-11Safety Precautions (Oxygen Servicing) ............................................................................................................ 3-7aSafety Procedures (Engine Operation) . ..........................................................................................................3-10aSafety Procedures (Runup and Taxiing) .........................................................................................................3-11aSafety, Cleaning............................................................................................................................................... 13-3Safety, Flightlene ............................................................................................................................................... 3-2Scope (of Manual).............................................................................................................................................. 1-2Sealing (First Aid Kits)...................................................................................................................................11-19gSeat Belt Latch Modification......................................................................................................................... F11-12Seat Belt Webbing Retarder Spnng Installation.............................................................................................. F11-8Seats, Aircraft . ................................................................................................................................................ 9-20

Index 21

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1


Number

S - Continued

Seats, Ejection ................................................................................................................................................. 12-2Separator, Particle ........................................................................................................................................... F8-5Servicable Tag-Matenel (DD Form 1574) (Yellow) ......................................................................................... F11-3Servicing (Oxygen) .......................................................................................................................................... 3-7bServicing of Oxygen Systems .........................................................................................................................9-17cServicing, Hydraulic Fluid ................................................................................................................................. 3-8Servicing, Oil ..................................................................................................................................................... 3-6Servicing, Oxygen.............................................................................................................................................. 3-7Servicing, Pneumatic System ............................................................................................................................ 3-9Serving Elastic Shock Cord.............................................................................................................................9-26eServing Length, Minimum ................................................................................................................................ T9-9Shipment of Aircraft . ......................................................................................................................................... 4-9Shock Strut Bleeding ........................................................................................................................................9-5cShock Strut Operation...................................................................................................................................... 9-5aShock Strut Servicing....................................................................................................................................... 9-5bShock Struts....................................................................................................................................................... 9-5

General Maintenance of Shock Struts .................................................................................................... 9-5dShock Strut Bleeding ..............................................................................................................................9-5cShock Strut Operation ........................................................................................................................... 9-5aShock Strut Servicing ............................................................................................................................. 9-5b

Shop and Hangar Safety .................................................................................................................................... 2-5Shop Equipment Arrangement ................................................................................................................2-2d, 2-3dShop Equipment Required ................................................................................................................................2-2cShop Equipment, Maintenance of....................................................................................................................... 2-4Shop Installations, Permanent............................................................................................................................ 2-2Shop Installations, Temporary ........................................................................................................................... 2-3Shop Size ...............................................................................................................................................2-2b, 2-3bShop, Temporary, Layout. ................................................................................................................................ F2-1Short Term Storage ......................................................................................................................................... 4-2bShort Term Storage for Depreservation of Installed Reciprocating EEngines .................................................... Tj 514.7 0 TD 0.0057 Tc 04-210

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1


Number

S -- Continued

Ski Inspection ........................................................................................................................................9-10aSki Repair .............................................................................................................................................9-10b

Ski Repair .......................................................................................................................................................9-10bSnap Hook Safety Guard Drill Details ............................................................................................................ F11-9Snap Hook Safety Pin Construction Details ................................................................................................. F11-10Snap Hook Secured to Safety Pin Retaining Cord ........................................................................................ F11-11Solid Color Band System . ...................................................................................................................... 6-3d, F6-2Special Repair Equipment and Tools...............................................................................................................11-11Special Reusable Containers .........................................................................................................................4-12aSpeed-Sensitive Control................................................................................................................................. F8-11Speed-Set Governor ...................................................................................................................................... F8-12Spray Nozzles, Types of ............................................................................................................................... F10-1Spray Painting ...........................................................................................................................................2-2j, 2-3jStandard Visual Signals .................................................................................................................................. 3-3dStatic Grounding Cable Assembly, Fabncation of............................................................................................. F3-1Static Grounding of Aircraft ...................................................................................................................... 2-6g, 3-4

Earth Ground Testing...............................................................................................................................3-4cEarth Grounds . ...................................................................................................................................... 3-4bFabrication of Ground Cable................................................................................................................... 3-4dGround Receptacle Critena .................................................................................................................... 3-4eGround Receptacle Testing ..................................................................................................................... 3-4fGrounding Requirements ........................................................................................................................ 3-4a

Static Grounding of Ground Support Equipment .............................................................................................. 2-6hStorage and Handling, Pyrotechnics ................................................................................................................ 12-7Storage Area Criteria ...................................................................................................................................... 11-9Storage Categories ............................................................................................................................................ 4-2Storage in Aircraft, Flotation Equipment........................................................................................................11-16bStorage of Compressed Gases......................................................................................................................... 2-2pStorage of Elastic Shock Cords .......................................................................................................................9-26gStorage of High-Value Items . .......................................................................................................................... 2-2qStorage of Shop Stocks, Repair Parts, and Consumable Materials................................................................... 2-2oStored Aircraft, Inspection of .............................................................................................................................. 4-6Stored Aircraft, Maintenance of . ........................................................................................................................ 4-7Struts, Shock...................................................................................................................................................... 9-5Sudden Engine Stoppage................................................................................................................................. 7-5bSudden Reduction In Engine RPM ...................................................................................................................7-5c

Index 23

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1


Number

S - Continued

Survival Kits.......................................................................................................................................11-13a, 11-15Cleaning ..............................................................................................................................................11-15cInspection ...........................................................................................................................................11-15aRepair .................................................................................................................................................11-15b

Survival Kit References.................................................................................................................................. T11-3Survival Vests...............................................................................................................................................11-13bSystem, DExhaust................................................................................................................................. 17-8 Tj -479416 -21.52 TD 0.0045 Tc 0 0027 Tw (Sustem,s, Brake.) Tj 37.60 0 TD 0.0072 Tc 0 Tw (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (..)............. 19-7 Tj -479416 -21.52 TD 0.0045 Tc 0 00232 Tw (Sustem,s, Deicng). .......................................................................................................................................

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1


Number

T - Continued

Typical Shop Layout . ............................................................................................................................. 2-3aTemporary Shop Layout................................................................................................................................... F2-1Temporary Storage of Life Support Equipment ...............................................................................................11-13

Flotation Equipment.............................................................................................................................11-13cNew Equipment ................................................................................................................................... 11-13fOxygen Equipment ..............................................................................................................................11-13ePyrotechnics ......................................................................................................................................11-1 3dSurvival Kits .......................................................................................................................................11-13aSurvival Vests ....................................................................................................................................11-1 3b

Test Equipment ............................................................................................................................................ T.11-1Test Flights and Maintenance Operational Checks ........................................................................................... 3-12

Carbon Monoxide Detection ..................................................................................................................3-12cMaintenance Operation Checks ............................................................................................................3-12bTest Flight Safety .................................................................................................................................3-12a

Test Flight Safety............................................................................................................................................3-12aTest Loads (Elastic Shock Cords)..................................................................................................................... T9-7Test, Cable ...................................................................................................................................................... T9-3

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1


Number

T - Continued

Tube, Relief, System........................................................................................................................................ 9-18Tubes and Tires ................................................................................................................................................ 9-9Turbine and Exhaust Maintenance ....................................................................................................................8-6jTurbine Assembly Elements........................................................................................................................... F8-10Turbine Bearing Maintenance........................................................................................................................... 8-61Turbine Discharge Pressure Pickup Line ....................................................................................................... F8-19Turbine Engine Analysis Ground Testing ......................................................................................................... 8-6dTurbine Engine Design and Construction............................................................................................................ 8-5

Accessory Section ................................................................................................................................. 8-5hCombustion Section................................................................................................................................ 8-5eCompressor Section ...............................................................................................................................8-5cDiffuser Section ...................................................................................................................................... 8-5dExhaust Section...................................................................................................................................... 8-5gFuel Systems...........................................................................................................................................8-5kGovernors and Fuel Controls .................................................................................................................. 8-51Ignition Systems . .....................................................................................................................................8-5jInlet Ducts . ............................................................................................................................................ 8-5aParticle Separators ................................................................................................................................. 8-5bTurbine Section ....................................................................................................................................... 8-5f

Turbine Engine Inspection and Maintenance ..................................................................................................... 8-6Cold Section Maintenance . .................................................................................................................... 8-6gCompressor Blade Inspection and Repair .............................................................................................. 8-6hCompressor Cleaning .............................................................................................................................. 8-6fForeign Object Damage Inspection......................................................................................................... 8-6eFuel System . ......................................................................................................................................... 8-60General Procedures................................................................................................................................ 8-6aHealth Indication Test ............................................................................................................................. 8-6bHot Section Maintenance..........................................................................................................................8-6iHot Start Inspection . ...............................................................................................................................8-6cIgnition System Maintenance...................................................................................................................8-6kOil Consumption . ................................................................................................................................... 8-6nThermocouple Maintenance .................................................................................................................. 8-6m

Turbine and Exhaust Maintenance ....................................................................................................................8-6JTurbine Bearing Maintenance........................................................................................................................... 8-61Turbine Engine Analysis Ground Testing.......................................................................................................... 8-6dTurbine Engine Maintenance, General .............................................................................................................. 8-1Turbine Engine Mounts ..................................................................................................................................... 8-9Turbine Engine Precautions ............................................................................................................................... 8-4Turbine Engine Theory....................................................................................................................................... 8-3Turbine Engines ..............................................................................................................................................3-10cTurbine Engines, Preservation and Depreservation of ..................................................................................... 8-10Turbine Engines, Removal and Installation of .................................................................................................. 8-11

Index 26

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1


Number

T - Continued

Turbine Section ................................................................................................................................................ 8-5fTurbocharger and Supercharger Maintenance.................................................................................................. 7-7bTypes (of Reciprocating Engines)..................................................................................................................... 7-2aTypes (of Turbine Engines) ............................................................................................................................. 8-2aTypes and Designations, Engine ....................................................................................................................... 7-2Types and Designations, Engine ....................................................................................................................... 8-2Types of Bearing.............................................................................................................................................. F7-8Types of Decals ................................................................................................................................................. 6-2Types of Environmental Control Systems........................................................................................................9-13aTypes of Fire Detection Systems.....................................................................................................................9-15bTypes of Flight Controls ..................................................................................................................................9-12a

Control Cables.......................................................................................................................................9-12eControl System Components ................................................................................................................ 9-12fFlight Control Operating Systems ..........................................................................................................9-12dInspection of Flight Controls .................................................................................................................9-12bRepair of Flight Controls .......................................................................................................................9-12cTypes ....................................................................................................................................................9-12a

Types of Retractable Landing Gear Systems.................................................................................................... 9-3aTypes of Spray Nozzles ................................................................................................................................. F10-1Types of Valves ............................................................................................................................................ F7-14Types of Vibration Isolators ............................................................................................................................9-25aTypical Compressor Blade Repair Limits ....................................................................................................... F8-18Typical Igniter Plugs....................................................................................................................................... F8-14Typical Layout .........................................................................................................................................2-2a, 2-3a

U

Unserviceable (Repairable) Tag-Materiel (DD Form 1577-2) (Green) ............................................................ F11-4Upholstered Seats...........................................................................................................................................9-20cUsage of Drip Pans . ........................................................................................................................................ 2-6d

V

Valve Cores .................................................................................................................................................... 9-9dValve Types .................................................................................................................................................. F7-14Valves 7-4gVibration Isolators ............................................................................................................................................ 9-25

Inspection of Vibration Isolators .............................................................................................................9-25cInstallation of Vibration Isolators ............................................................................................................9-25bTypes of Vibration Isolators....................................................................................................................9-25a

Index 27

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1


Number

V - Continued

Vibrator, Induction.......................................................................................................................................... F7-19Vinyl Film Decals ............................................................................................................................................. 6-2b

W

Wheel Cleaning . ............................................................................................................................................. 9-8aWheel Inspection ............................................................................................................................................ 9-8bWheel Maintenance ........................................................................................................................................... 9-8

Repair of Wheels.....................................................................................................................................9-8cReplacement Criteria for Wheels ............................................................................................................ 9-8dWheel Cleaning ...................................................................................................................................... 9-8aWheel Inspection .................................................................................................................................... 9-8b

Windshield Wiper System ................................................................................................................................ 9-19Adjustment of Windshield Wiper Systems ............................................................................................9-19bMaintenance of Windshield Wiper Systems . .........................................................................................9-19a

Wiper, Windshield, System .............................................................................................................................. 9-19Work Area Criteria .......................................................................................................................................... 11-8

Index 28

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 2


Number

A

Absorbing Units, Dampening and .................................................................................................................... 4-19Acceptable and Unacceptable Tube Bends ..................................................................................................... F4-5Accumulator, Cylindrical .............................................................................................................................. F4-118Accumulator, Operation .................................................................................................................................4-15bAccumulator, Spherical ............................................................................................................................... F4-119Accumulators .................................................................................................................................................. 4-15

Accumulator Operation .........................................................................................................................4-15bMaintenance .........................................................................................................................................4-15cTypes ...................................................................................................................................................4-15a

Actuating Cylinder, Double-Action (Extension) ............................................................................................ F4-134Actuating Cylinder, Double-Action (Retraction) ............................................................................................ F4-135Actuating Cylinder, Single-Action ................................................................................................................ F4-133Actuating Cylinders (Actuators) ......................................................................................................................4-16gActuators, Troubleshooting ............................................................................................................................ T4-42Adjuster Valve, Brake .................................................................................................................................. F4-157After Swage Dimensions ............................................................................................................................... F4-86Air Cylinder, Spherical ................................................................................................................................... F4-95Air Cylinders, Hydraulic Reservoirs ...............................................................................................................4-11 hAir Filters .......................................................................................................................................................4-12eAir Valve Cores, High-Pressure ................................................................................................................... F4-174Aircraft Brake Systems .................................................................................................................................... 4-18

Brake Deboosters .................................................................................................................................4-18cHelicopter Rotor Brake Systems ...........................................................................................................4-18dMaintenance of Brake Systems .............................................................................................................4-18eWheel Brake Assemblies ......................................................................................................................4-18bWheel Brake Systems ..........................................................................................................................4-18a

Alignment, Tube and Fitting .......................................................................................................................... F4-14Alignment, Tubing ......................................................................................................................................... F4-20Aluminum Protective Dust Plug and Moisture Seal ........................................................................................ F4-54AN Flared Fitting Identification ........................................................................................................................ T4-9Application of Mechanical Advantage .............................................................................................................. F2-5Application of Swaged Tubing Repairs ............................................................................................................ 4-9aApplications of MIL-H-83282 ...............................................................................................................4-21c, T4-43Aromatic And Heat-Resistant Hose, MIL-H-6000 ........................................................................................... F4-35Aromatic, Flame, and Oil-Resistant Hose, MIL-H-7938 ................................................................................. F4-36Aromatic-Resistant Hose, Flame and MIL-H-8794 ......................................................................................... F4-34Aromatic-Resistant Hose, Nonself-Sealing, MIL-H-5593 ................................................................................ F4-37Aromatic-Resistant Hose, Self-Sealing, MIL-H-7061 ..................................................................................... F4-38Assembly Clearance, Nipple ......................................................................................................................... F4-47Assembly of High-Pressure Tetrafluoroethylene (Teflon)

Hose Assemblies .....................................................................................................................................4-5jAssembly of Medium-and Low-Pressure Hose Assemblies ............................................................................ F4-43

Index 29

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 2


Number

A - Continued

Assembly of Medium - Pressure Tetrafluoroethylene (Teflon)Hose Assemblies ................................................................................................................................... 4-51

Assembly Surface, Nipple ............................................................................................................................. F4-46Assembly, V-Ring Packings in Various Positions of ....................................................................................... F4-71

B

Backup Ring Installation, Double ................................................................................................................... F4-76Backup Ring Installation, Single ..................................................................................................................... F4-75Backup Ring, Teflon, Installing ...................................................................................................................... F4-73Backup Ring, Teflon, Reversing Spiral of ...................................................................................................... F4-74Backup Ring, Teflon, Stretching .................................................................................................................... F4-72Backup Rings .................................................................................................................................................... 4-8

Identification .......................................................................................................................................... 4-8aInstallation ............................................................................................................................................44-8b

Backup Rings, Leather, Installation of ........................................................................................................... F4-77Baffles and Fins .............................................................................................................................................4-11cBaffles, Fins, and Finger Strainer, Reservoir with .......................................................................................... F4-91Ball Size, Inspection, Chart ........................................................................................................................... T4-13Band Identification, Solid Color ....................................................................................................................... F4-2Band Location, Tube Insertion ....................................................................................................................... T4-37Basic Swage Tool Assembly Showing Lower Die Block

Assembly and Position of Fitting Locator ............................................................................................. F4-84Bead Dimensions .......................................................................................................................................... F4-13Beaded Tubing Joints ...................................................................................................................................... 4-2hBeading Large Tubing ................................................................................................................................... F4-11Bend Radii for Conduit and Fluid Lines ........................................................................................................... T4-1Bend Radii of Hose for Fuel, Oil, and Coolant Systems ................................................................................. T4-32Bending Machine, Bending Tube with .............................................................................................................. F4-4Bending Tube with Bending Machine ............................................................................................................... F4-4Bending Tubing................................................................................................................................................ 4-2eBends, Installation of Flexible Hose ..................................................................................................................4-2cBent-Axis Constant-Volume Pump .............................................................................................................. F4-101Bleeding Brake Hydraulic System ............................................................................................................... F4-160Blocked Flowing Hydraulic Fuse .................................................................................................................. F4-142Boss Installation, Torque Valves for ................................................................................................................ T4-7Brake Assembly, Disc ................................................................................................................................. F4-151Brake Assembly, Disc, Cross Section .......................................................................................................... F4-152Brake Bleeding, Gravity Method for ............................................................................................................. F4-161Brake Hydraulic System, Bleeding .............................................................................................................. F4-160Brake System, Rotor Blade ......................................................................................................................... F4-159Brake Systems, Aircraft ................................................................................................................................... 4-18

Index 30

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 2


Number

B - Continued

Bulge, Coupling, Low-and Medium-Pressure Hose Assemblies ..................................................................... F4-44Bulge, Coupling, MIL-H-7061 Hose Assembly ...............................................................................................

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 2


Number

C - Continued

Control Valves ...............................................................................................................................................4-16bConversion of Aircraft to Fire-Resistant Hydraulic Fluid ................................................................................... 4-21

Applications of MIL-H-83282 .................................................................................................................4-21cConversion Procedures .........................................................................................................................4-21eHydraulic Fluid MIL-H-5606 ..................................................................................................................4-21aHydraulic Fluid MIL-H-83282 ................................................................................................................4-21bNon-Applicability of MIL-H-83282 .........................................................................................................4-21dOperating Temperature Limitations ....................................................................................................... 4-21f

Conversion Procedures (MIL-H-5606 to MIL-H-83282) ...................................................................................4-21eCoupling Bulge, Low-and Medium-Pressure Hose Assemblies ...................................................................... F4-44Coupling Bulge, MIL-H-7061 Hose Assembly ................................................................................................ T4-30Couplings, Quick-Disconnect ........................................................................................................................... 4-10Cross Section, Piston Damper ..................................................................................................................... F4-163Cross Section, Vane Damper ...................................................................................................................... F4-168Cutoff Factor, MIL-H-8788 or MIL-H-8790 (in Inches) .................................................................................... T4-15Cutoff Factors, MIL-H-38360 Hose (in Inches)................................................................................................ T4-27Cutoff Factors, Teflon Hose (in Inches) .......................................................................................................... T4-22Cutter, Chipless ............................................................................................................................................. F4-81Cutting Flexible Hose, Knife for ..................................................................................................................... F4-39Cutting, Marking Tube Prior to ....................................................................................................................... F4-46Cutting, Tube with Tube Cutter ........................................................................................................................ F4-3Cutting Tubing ................................................................................................................................................. 4-2d

D

Damaged Fittings .......................................................................................................................................... F4-29Dampening and Absorbing Units ..................................................................................................................... 4-19Hydraulic Damper ..........................................................................................................................................4-19aLiquid Springs ...................................................................................................................................4-19c, F4-174Shock Struts ...................................................................................................................................................4-19bDamper, Piston ........................................................................................................................................... F4-162Damper, Vane ............................................................................................................................................. F4-166Data Drawing, Tube Bend ............................................................................................................................... F4-6Detecting Fluid Contamination ........................................................................................................................ 2-4aDetermining Hose Assembly Length .............................................................................................................. F4-40Determining Tube Thickness and Burst Pressure .......................................................................................... T4-11Devices for Regulating Pressure ..................................................................................................................... 4-14Pressure Gauges ...........................................................................................................................................4-14aPressure Reducing Valves .............................................................................................................................4-14dPressure Relief Valves ...................................................................................................................................4-14cPressure Switches ..........................................................................................................................................4-14b

Index 32

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 2


Number

D - Continued

Differential Pressure Indicator (Clogged Filters) ............................................................................................ F4-99Differential Pressure Indicator (Normal Flow) .............................................................................................. F4-100Dimensions, After Swage .............................................................................................................................. F4-86Dimensions, Beading .................................................................................................................................... F4-13Dimensions for Double-Flared Tubing ............................................................................................................. F4-8Dimensions for Single-Flared Tubing .............................................................................................................. F4-7Disc Brake Assembly .................................................................................................................................. F4-154Disc Brake Assembly Cross Section ............................................................................................................ F4-155Distance Between Supports for Fluid Tubing, Maximum ................................................................................ T4-12Double Backup Ring Installation .................................................................................................................... F4-76Double Lap Flare, Tubing with ....................................................................................................................... F4-11Double-Action Actuating Cylinder (Extension) ............................................................................................. F4-134Double-Action Actuating Cylinder (Retraction) ............................................................................................. F4-135Double-Action Hand Pump .......................................................................................................................... F4-111Double-Flared Tubing, Dimensions for . ........................................................................................................... F4-8Dual Internal O-Ring Removal ...................................................................................................................... F4-64Dual Parking Brake Valve ........................................................................................................................... F4-156

Dual Parking Brake Valve (Off) .......................................................................................................... F4-157Dual Parking Brake Valve (On) ................................................................................................................... F4-158Dust Cap (AN-SAE Function), Plastic Protective ........................................................................................... F4-56Dust Cap, Plastic Protective .......................................................................................................................... F4-55Dust Cap, Steel Protective ............................................................................................................................ F4-53Dust Plug and Moisture Seal, Aluminum Protective ....................................................................................... F4-54Dust Plug and Moisture Seal (AN-SAE Threaded) Plastic Protective ............................................................. F4-51Dust Plug and Moisture Seal, Steel Protective .............................................................................................. F4-52

E

Ease of Installation (of Hydraulic Systems) ......................................................................................................2-2cEase of Operation (of Hydraulic Systems) ....................................................................................................... 2-2bEfficiency (of Hydraulic Systems) .................................................................................................................... 2-2aElliptical Rings ..................................................................................................................................... 4-7b, F4-70External O-Ring Installation ........................................................................................................................... F4-69External O-Ring Removal (Spoon-Type Tools) .............................................................................................. F4-65External O-Ring Removal (Wedge-Type Tools) ............................................................................................ F4-66

F

Failure Modes and Recommended (Permaswage) Repair Methods ............................................................... F4-79Field Assembly of High Pressure Teflon Hose, MIL-H-38360 ......................................................................... F4-50Field Disassembly of Teflon Hose ................................................................................................................. F4-45

Index 33

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 2


Number

F - Continued

Field Fabrication of High-Pressure Hose Assemblies .................................................................................... F4-41Filter Element Bypass Valve, Hydraulic Reservoirs ........................................................................................ 4-11fFilter Elements, Hydraulic Reservoirs .............................................................................................................4-11eFilter Elements, Hydraulic Systems Filters .....................................................................................................4-12cFilter Elements, Reservoir with ...................................................................................................................... F4-94Filter, Fluid, Assembly ................................................................................................................................... F4-96Filters, Hydraulic System ................................................................................................................................ 4-12Finger Strainers, Hydraulic Reservoirs ..........................................................................................................4-11 dFingertight-Plus Turns Methods, Hose Clamp Tightening .............................................................................. T4-10Fingertight-Plus Turns Methods, Hose Clamp Tightening, Beaded Tubing ....................................................... F4-3Fitting Dimensions After Swaging .................................................................................................................. T4-39Fittings 4-3Flared Fittings ................................................................................................................................................. 4-39Flareless Fittings ............................................................................................................................................. 4-3aOxygen System Tapered Pipe Thread ............................................................................................................. 4-3bRosan Fluid Fittings ......................................................................................................................................... 4-3fStraight Pipe Thread ........................................................................................................................................4-3cUniversal Fittings AN 832, AN 833, and AN 834, High Pressure .................................................................. 4-3e9AUniversal Fittings AN 832, AN 833, and AN 834, Low Pressure ....................................................................... 4-3dFittings, Damaged ......................................................................................................................................... F4-29Fittings, Tubing ............................................................................................................................................. F4-15Flame and Aromatic Resistant Hose, MIL-H-8794 ......................................................................................... F4-34Flame, Aromatic, and Oil-Resistant Hose, MIL-H-7938 ................................................................................. F4-36Flared Fitting Identification, AN ....................................................................................................................... T4-9Flared Fittings ................................................................................................................................................. 4-3gFlareless Fitting Installation, Bulkhead ................................................................................................. F4-24, T4-4Flareless Fittings ............................................................................................................................................. 4-3aFlareless Fittings, MS .................................................................................................................................... F4-18Flaring Tubing................................................................................................................................................... 4-2fFlexible Hose Assemblies

Assembly of High-Pressure Tetrafluoroethylene (Teflon)Hose Assemblies ...............................................................................................................................4-5j

Assembly of Medium-Pressure Tetrafluoroethylene (Teflon)Hose Assemblies ...............................................................................................................................4-5i

Identification of Flexible Hose ................................................................................................................ 4-5aIdentification Tags for Field Fabricated Hose Assemblies ........................................................... 4-5g, F4-42Instructions for ......... ........................................................... 4-5g, F4-42

TM 1-1500-204-23-1

INDEX - CONT

VOLUME XX


Number

F - Continued

Replacement of Flexible Hose ................................................................................................................4-5cSelf-Sealing Hose for Aromatic Fuel, MIL-H-7061 ...................................................................................4-5kStorage of Hose and Hose Assemblies .................................................................................................. 4-5bUse of Dust Plugs, Dust Caps, and Moisture Seals ................................................................................ 4-51

Flexible Hose, Installation of ............................................................................................................................. 4-6Floating Piston Shock Strut ......................................................................................................................... F4-173Floating Piston Shuttle Valve ...................................................................................................................... F4-132Flow Control Units ........................................................................................................................................... 4-16

Actuating Cylinders (Actuators) .............................................................................................................Check Valves .......................................................................................................................................

Control Valves ......................................................................................................................................Hydraulic Fuses .....................................................................................................................................

Hydraulic Servos ......................................................................................................................62P.i, F4-138........21.68 -11.52 TD 0.0045 Tc 0.0027 Tw (Irreversible Valves) Tj 84.48 0 TD 0.0072 Tc 0 Tw (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (.....................) Tj 60.72 0 TD 0.0049 Tc 0.0023 Tw (62P.j, F4-139........21.68 -11.52 TD 0.0042 Tc 0.003 Tw (Maintenance of Hydraulic Flow Control Units ) Tj 202.56 0 TD 0.0072 Tc 0 Tw (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (........................) Tj 69.12 Pist7...) Tj 92.162P.1.........6 -11.52 TD 0.0041 Tc 0.0031 Tw (Priority Valves ) Tj 70.08 0 TD 0.0072 Tc 0 Tw (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (......) Tj76Tc 0.0025 Tw (Floating Piston Shock Strut ) Tj 126 0 TD 0.007N.....rreg60 ValveP0p.ck Valves...... . . . . . . 5 . 8 . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .F4-173Floating Piston Shut1.52 TD 0.005 Tc 0.0022 Tw (Fl Tc 0 trol tors) ) Tj 142.08 0 a...............6 0 TD (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (.....) Tj 14.88 0 TD 0.0044 92.162P.k.........6.48 -11.52 TD 0.0038 Tc 0.0034 Tw (Hydra.......6.48 -11.52 TD 0.0038 8 -11.5.76 tors) ) Tj 142.08 0 d.................................................................................................Priority Valves ......9 92.16 0 TD (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (......) Tj76Tc 0.0025 Tw (Floating Piston Shock Strut ) Tj 126 0 TD 0.007N.....rreg60 ValveP0p.ck Valves...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . F l o a t i n g P i s t o n S h o c k S t r u t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .F4-173

......97.2.16 0 TD (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (......) Tj76Tc 0.0025 Tw (Floating Piston Shock Strut ) Tj 126 0 TD 0.007N...oating Piston Shock Strut Clogged).......10.................................................................................Priority Valves Normal Flow).......1 T3 TD (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (.....) Tj 14.88 0 TD 0.0044 92.162P.k.........6.48 -11.52 TD 0.0038 Tc 0.0034 Tw (Hydra.......6......68.5os ) Tj 81.65142.0F4-97........82.uaTj 92.16 0 TD3..................Fluid-P..ssurized Reservoir (P..ssurized).......189T3 TD (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (.....) Tj 14.88 0 TD 0.0044 92.162P.k.........6.48 -11.52 TD 0.0038 Tc ......16.5os Unp..ssurized).......20..8.............................................................................. ......................................................................F l o a t i n g P i s t o n S h o c k S t r u t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .F4-173Floating Piston Shut1.52 ......60 ......................................F l o a t i n g P i s t o n S h o c k S t r u t

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 2


NumberG - Continued

Shop Tools and Materials .......................................................................................................................3-1cGravity Method for Brake Bleeding .............................................................................................................. F4-161

H

Hand Pump Test Circuit .............................................................................................................................. F4-112Hand Pumps ..................................................................................................................................................4-13cHandling of Hydraulic Fluid in 55-Gallon Drums ................................................................................................ 3-3

Cleaning ................................................................................................................................................ 3-3bStorage .................................................................................................................................................. 3-3aTransporting Fluid to Aircraft .................................................................................................................. 3-3dWithdrawing Fluid from Drum .................................................................................................................3-3c

Helicopter Rotor Brake Systems .....................................................................................................................4-18dHigh-Pressure Air Valve Cores .................................................................................................................... F4-174High-Pressure Hose Assemblies, Field Fabrication of ................................................................................... F4-41High-Pressure Teflon Hose, MIL-H-38360, Field Assembly of ....................................................................... F4-50High-Pressure Tubing, Repairing.................................................................................................................... F4-33Hose Assemblies, Flexible ................................................................................................................................ 4-5Hose Assembly Length, Determining ............................................................................................................. F4-42Hose Clamp, In Installation of Flexible Hose ................................................................................................... 4-61Hose Clamp Tightening, Fingertight-Plus Tums Method ................................................................................ T4-10Hose Clamp Tightening, Fingertight-Plus Tums Method, Beaded Tubing ........................................................ T4-3Hose Clamp, Tightening, With Socket ........................................................................................................... F4-32Hose Connections to Engines, Installation of Flexible Hose ............................................................................. 4-6hHose Cutoff Factor, MIL-H-8788 or MIL-H-8790 Hose (in Inches) .................................................................. T4-14Hose Cutoff Factors, MIL-H-38360 Hose (in Inches) ...................................................................................... T4-27Hose End Fitting and Coupling Nut Installation Torque In Inch-Pounds ......................................................... T4-34Hose Installation, Flexible Hose ...................................................................................................................... 4-5bHose Line Installation Aids for All Types of Hoses ......................................................................................... F4-57Hose Markings, and Installation of Flexible Hose ..............................................................................................4-6jHose, MIL-F-27272, Tetrafluoroethylene (in Inches) ...................................................................................... T4-21Hose, MIL-H-38360, Tetrafluoroethylene (in Inches) ...................................................................................... T4-27Hose Restrictions, Installation of Flexible Hose ............................................................................................... 4-6dHydraulic Dampers .........................................................................................................................................4-19aHydraulic Filler and Bleeder Unit ..................................................................................................................... 3-2aHydraulic Fluid (Fire Resistant), Conversion of Aircraft to ............................................................................... 4-21Hydraulic Fluid in Army Aircraft, Types ............................................................................................................. 2-3Hydraulic Fluid in 55-Gallon Drums, Handling of ............................................................................................... 3-3Hydraulic Fluid MIL-H-5606 ............................................................................................................................4-21aHydraulic Fluid MIL-H-83282 ..........................................................................................................................4-21bHydraulic Fuse Assembly ............................................................................................................................ F4-140Hydraulic Fuse (Blocked Flow) .................................................................................................................... F4-142Hydraulic Fuse (Full Flow) ........................................................................................................................... F4-141

Index 36

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 2


Number

H - Continued

Hydraulic Hose Testing Unit ............................................................................................................................ 3-2dHydraulic Hose Testing Unit, Typical ............................................................................................................... F3-3Hydraulic Maintenance Practices, General ........................................................................................................ 4-1Hydraulic Motor ........................................................................................................................................... F4-113Hydraulic Motors ............................................................................................................................................4-13dHydraulic Packings and O-Rings ....................................................................................................................... 4-7

Elliptical Rings ............................................................................................................................ 4-7b, F4-70O-Rings ................................................................................................................................................. 4-7aV-Ring Packings .....................................................................................................................................4-7c

Hydraulic Reservoirs ....................................................................................................................................... 4-11Air Cylinders ........................................................................................................................................4-11 hBaffles and Fins ....................................................................................................................................4-11cFilter Element Bypass Valve ................................................................................................................. 4-11fFilter Elements ....................................................................................................................................4-11 eFinger Strainers ...................................................................................................................................4-11 dMaintenance of Reservoirs ...................................................................................................................4-111Standpipes ............................................................................................................................................4-11gTheory of Operation .............................................................................................................................4-11 bTypes of Hydraulic Reservoirs Used in Hydraulic Systems ...................................................................4-11 a

Hydraulic Servos................................................................................................................................4-161, F4-138Hydraulic System Filler and Bleeder, Typical .................................................................................................. F3-1Hydraulic System Filters ................................................................................................................................. 4-12

Air Filters ..............................................................................................................................................4-12eFilter Elements .....................................................................................................................................4-12cServicing Filters .................................................................................................................................... 4-12fTheory of Operation ..............................................................................................................................4-12bTwo-Stage Fluid Filters .........................................................................................................................4-12dUses of Filters In Hydraulic Systems .....................................................................................................4-12a

Hydraulic System, Open-Center (Valve Closed) .......................................................................................... F4-143Hydraulic System, Open-Center (Valve Open) ............................................................................................ F4-144Hydraulic Systems In Army Aircraft, Use of ....................................................................................................... 2-2Hydraulic Test Stand, Fixed ............................................................................................................................ 3-2bHydraulic Test Stand, Portable, Gasoline Engine-Driven ..................................................................................3-2cHydraulic Test Stand, Typical Gasoline Engine-Driven .................................................................................... F3-2

I

Identification of Backup Rings .................... F3-2

I

Identification of Backup Ri5gs

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 2


NumberI - Continued

Internal O-Ring Removal (Push-Type Extractor) ........................................................................................... F4-63Internal O-Ring Removal (Wedge-Type Extractor) ........................................................................................ F4-62Introduction

Consumable Materials ............................................................................................................................. 1-3Purpose .................................................................................................................................................... 1-1Scope ...................................................................................................................................................... 1-2

Irreversible Valves .............................................................................................................................4-16j, F4-139

J

Jamnut (AN924) Used on Fittings, Torque Values for ...................................................................................... T4-8

K

Kellogg Stroke Reduction Pump Assembly................................................................................................... F4-109Kellogg Stroke Reduction Pump (Reduced Output) ..................................................................................... F4-110Knife for Cutting2uer2exle VaHe . Tw (................................) Tj 92.16 0 TD (................................) Tj 92.16 0 TD (.....................) ..............................F4-63

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 2


NumberM - Continued

Hydraulic Test Stand, Fixed ................................................................................................................... 3-2bHydraulic Test Stand, Portable, Gasoline Engine-Driven ........................................................................3-2cMaster Gauge Unit .................................................................................................................................. 3-2fTube Bending Machine, Hand-Operated ................................................................................................ 3-2e

Marking MS Fittings ...................................................................................................................................... F4-23Marking, Tube End ........................................................................................................................................ F4-83Marking with Permaswage Marking Tool, D9862-S, M, and L ........................................................................ F4-82Master Cylinder, Compound ........................................................................................................................ F4-149Master Cylinder, Power-Boost (Brake Applied) ............................................................................................ F4-150Master Cylinder, Power-Boost (Brake Released) ......................................................................................... F4-151Master Cylinder, Simple .............................................................................................................................. F4-148Master Gauge Unit ........................................................................................................................................... 3-2fMaster Gauge Unit, Typical ............................................................................................................................. F3-5Maximum Distance Between Supports for Fluid Tubing ................................................................................. T4-12Mechanical Advantage ........................................................................................................................... 2-1e, F2-4Mechanical Advantage, Application of ............................................................................................................. F2-5Medium-and Low-Pressure Hose Assemblies, Assembly of ........................................................................... F4-45Medium-Pressure Teflon Hose Assembly Procedure ..................................................................................... F4-48MIL-H-83282, Applications of ........................................................................................................................ F4-43MIL-H-83282, Non-Applicability of....................................................................................................... 4-21d, T4-44MIL-H-83282, Operating Temperature Limitations of ..................................................................................... T4-45Minimum Bend Radii of Hose for Fuel Oil, and Coolant Systems .................................................................. T4-32Motor, Hydraulic .......................................................................................................................................... F4-113Motors, Pumps and ......................................................................................................................................... 4-13MS Fitting and Components .......................................................................................................................... F4-17MS Fitting Gasket Installation ........................................................................................................................ F4-19MS Fittings, Marking ..................................................................................................................................... F4-23MS Flared Swivel Connectors Torquing, and Installation of Flexible Hose ........................................................4-6kMS Flareless Fittings ..................................................................................................................................... F4-18MS Turns and Torque Valves ........................................................................................................................ F4-21MS21921 Coupling Nut, Torque Values for ...................................................................................................... T4-5MS33514 Fitting End, Installation of .............................................................................................................. F4-25

N

Nipple Assembly Clearance .......................................................................................................................... F4-47Nipple Assembly Surface .............................................................................................................................. F4-46Non-Applicability of MIL-H-83282 ...................................................................................................... 4-21 d, T4-44Nonself-Sealing, Aromatic and Heat-Resistant Hose, MIL-H-6000 ................................................................. F4-35Nonself-Sealing, Aromatic-Resistant Hose, MIL-H-5593 ................................................................................ F4-37Normal Flow in Differential Pressure Indicator ............................................................................................... F4-99Normal Flow in Fluid Filter ............................................................................................................................ F4-97

Index 40

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 2


NumberN - Continued

Nose Landing Gear with Piston Damper ...................................................................................................... F4-164Nose Landing Gear with Vane Damper ........................................................................................................ F4-168Nut Installation Torque in Inch-Pounds, Hose End Fitting and Coupling ......................................................... T4-34

O

O-Ring Identification ...................................................................................................................................... F4-59O-Ring Installation, External .......................................................................................................................... F4-69O-Ring Installation, Internal (Metallic Sleeve) ................................................................................................ F4-68O-Ring Installation, Internal (Paper Cover) .................................................................................................... F4-69O-Ring, Removal of ...................................................................................................................................... F4-60O-Ring Removal, Dual Internal ..................................................................................................................... F4-64O-Ring Removal, External (Spoon-Type Extractor) ....................................................................................... F4-65O-Ring Removal, External (Wedge-Type Extractor) ...................................................................................... F4-66O-Ring Removal, Internal (Pull-Type Extractor) ............................................................................................ F4-61O-Ring Removal, Internal (Push-Type Extractor) .......................................................................................... F4-63O-Ring Removal, Internal (Wedge-Type Extractor) ....................................................................................... F4-62O-Rings ......................................................................................................................................................... 4-7aOpen-Center Hydraulic System (Value Closed) ........................................................................................... F4-143Open-Center Hydraulic System (Value Open) ............................................................................................. F4-144Operating Pressure (psi) for MIL-H-7061, Proof Test and ............................................................................... T4-31Operating, Proof, and Burst Test Pressures for AN6270 Hose

Assembly using MIL-H-5593 Low Pressure Hose ................................................................................. T4-19Operating, Proof, and Burst Test Pressures for MIL-H-83796

Medium Pressure Hose Assembly, Lightweight .................................................................................... T4-17Operating, Proof, and Burst Test Pressures for MIL-H-83797

Medium Pressure Hose ........................................................................................................................ T4-18Operating, Proof, and Burst Test Pressures for MS28741 Medium

Pressure Hose Assemblies, using Single Wire Braid Hose,Military Specification MIL-H-8794 ........................................................................................................ T4-16

Operating, Proof, and Burst Test Pressures for MS28759 andMS28762 Hose Assemblies using MIL-H-8788 High Pressure Hose ..................................................... T4-15

Operating Temperature Limitations (of Hydraulic Fluid) .................................................................................. 4-21fOperating Temperature Limitations of MIL-H-83282 ...................................................................................... T4-45Orifice Check Valve .................................................................................................................................... F4-128Oxygen System Tapered Pipe Thread ............................................................................................................. 4-3b

P

Packing and Lubricant Selection ..................................................................................................................... T4-6Packings and O-Rings, Hydraulic ...................................................................................................................... 4-7

Index 41

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 2


NumberP - Continued

Parking Brake Valve, Dual .......................................................................................................................... F4-156Parking Brake Valve, Dual (Off) .................................................................................................................. F4-157Parking Brake Valve, Dual (On) .................................................................................................................. F4-158Pascal's Law .......................................................................................................................................... 2-1d, F2-3Permaswage Fittings, Typical Styles of ......................................................................................................... F4-78Permaswage Marking Tool, D9862-S, M, and L, Marking with ....................................................................... F4-82Permaswage Repair with D10000 Series Tooling-Tube

Material and Maximum Operating Pressure Limitations (psi) ................................................................ T4-35Petroleum-Base Fluid (Hydraulic) .................................................................................................................... 2-3bPipe Thread, Straight Thread and ................................................................................................................. F4-26Piston Damper ............................................................................................................................................ F4-162Piston Damper Cross Section ...................................................................................................................... F4-163Piston Damper, Nose Landing Gear with ..................................................................................................... F4-164Piston Dampers, Main Rotor Assembly with ................................................................................................ F4-165Piston-Type Pressure Switch ....................................................................................................................... F4-115Plastic Protective Dust Cap ........................................................................................................................... F4-55Plastic Protective Dust Cap (AN-SAE Friction) .............................................................................................. F4-56Plastic Protective Dust Plug and Moisture Seal (AN-SAE Threaded) ............................................................. F4-51Pneudraulic Systems, Types of ....................................................................................................................... 4-17

Closed-Center Hydraulic .......................................................................................................................4-17bOpen-Center Hydraulic .........................................................................................................................4-17aPneumatic System ................................................................................................................................4-17c

Pneudraulics Theory and Basic Principles ......................................................................................................... 2-1Computation of Force, Area, and Pressure ............................................................................................ 2-1bComputation of Volume, Area, and Length of Stroke ..............................................................................2-1cMechanical Advantage ................................................................................................................. 2-1e, F2-4Pascal's Law ................................................................................................................................. 2-1d, F2-3Qualities of Hydraulic Fluid ................................................................................................................... 2-1 aUse of Air in Hydraulic Systems .............................................................................................................. 2-1f

Pnuematic System ..........................................................................................................................................4-17cPower Brake Control Valve (Brake Applied) ................................................................................................ F4-152Power Brake Control Valve (Brake Released) ............................................................................................. F4-153Power Pumps .................................................................................................................................................4-13aPower-Boost Master Cylinder (Brake Applied) ............................................................................................. F4-150Power-Boost Master Cylinder (Brake Released) .......................................................................................... F4-151Precautions

for Hydraulic Fluid Selection and Contamination .................................................................................... 2-3dfor Repair of Tubing Assemblies ............................................................................................................ 4-4a

Pressure Gauge .......................................................................................................................................... F4-114Pressure Gauges ...........................................................................................................................................4-14aPressure Reducing Valve ...............................................................................................................................4-14dPressure Relief Valves ...................................................................................................................................4-14cPressure Switch, Piston-Type ...................................................................................................................... F4-115

Index 42

TM 1-1500-204-23-1

INDEX - CONT

VOLUME XX


Number

P - Continued

Pressure Switches ..........................................................................................................................................4-14bPressure-Actuated Sequence Valve ............................................................................................................ F4-130Pressure-Reducing Valve ............................................................................................................................ F4-117Pressures, Proof Test, High-Pressure Teflon Hose Assemblies ..................................................................... T4-30Pressures, Proof Test, Medium-Pressure Teflon Hose Assemblies ................................................................ T4-23Printed-Symbol Identification Tape .................................................................................................................. F4-1Priority Valve .............................................................................................................................................. F4-131Procedures, for Use of Test Stands ................................................................................................................4-20bProof Test and Operating Pressure (psi) for MIL-H-7061 ............................................................................... T4-31Proof Test Pressures, High-Pressure Teflon Hose Assemblies ...................................................................... T4-28Proof Test Pressures, Medium-Pressure Teflon Hose Assemblies ................................................................. T4-23Proof Test Torque Values MS Flared Swivel Nut Fittings

(Reference AND10064) ........................................................................................................................ T4-20Proof Testing of Flexible Hose Assemblies ...................................................................................................... 4-5fProperly Burred Tube ...................................................................................................................................... F4-9Pump Assembly, Kellogg Stroke Reduction ................................................................................................. F4-109Pump, Constant Volume, Bent-Axis ............................................................................................................ F4-101Pump, Constant Volume, Foot Valve .......................................................................................................... F4-104Pump, Constant Volume, (Piston Installation) .............................................................................................. F4-102Pump, Constant Volume, (Piston Operation) ............................................................................................... F4-103Pump, Hand, Double-Action ........................................................................................................................ F4-111Pump, Hand, Test Circuit ............................................................................................................................ F4-112Pump, Kellogg Stroke Reduction (Reduction Output) .................................................................................. F4-110Pump, Stratopower Effective Stroke (Full Flow) .......................................................................................... F4-105Pump, Stratopower Effective Stroke (Zero Flow) ......................................................................................... F4-106Pump, Vickers Stroke Reduction (Full Flow) ................................................................................................ F4-108Pump, Vlckers Stroke Reduction (Zero Flow) .............................................................................................. F4-107Pumps and Motors .......................................................................................................................................... 4-13

Hand Pumps .........................................................................................................................................4-13cHydraulic Motors ...................................................................................................................................4-13dMaintenance of Power Pumps ..............................................................................................................4-13bPower Pumps .......................................................................................................................................4-13a

Purpose (of Manual) .......................................................................................................................................... 1-1

Q

Qualities of Hydraulic Fluid ............................................................................................................................. 2-1aQuick-Disconnect Couplings ............................................................................................................................ 4-10

Inspection .............................................................................................................................................4-10bInstallation ............................................................................................................................................4-10a

Index 43

TM 1-1500-204-23-1

INDEX - CONT

VOLUME XX


NumberR

Rachet Valve .................................................................................................................................................4-16hRachet Valve (Moving) ................................................................................................................................ F4-137Rachet Valve (Static) .................................................................................................................................. F4-136Radial Cam-Operated Selector Valve .......................................................................................................... F4-124Recommended (Permaswage) Repair Methods, Failure Modes and .............................................................. F4-79Regulating Pressure, Devices for .................................................................................................................... 4-14Relief Valve, System ................................................................................................................................... F4-116Repair

of High-Pressure Tubing Assemblies ......................................................................................................4-4cof Low-Pressure Tubing Assemblies ...................................................................................................... 4-4bof Tubing Assemblies .............................................................................................................................. 4-4

Repair of Low-Pressure Tubing ..................................................................................................................... F4-30Repair of Tubing Assemblies ............................................................................................................................. 4-4

Precautions ............................................................................................................................................ 4-4aRepair of High-Pressure Tubing Assemblies ...........................................................................................4-4cRepair of Low-Pressure Tubing Assemblies ........................................................................................... 4-4bTemplate . .............................................................................................................................................. 4-4d

Repairing High-Pressure Tubing .................................................................................................................... F4-33Replacement of Flexible Hose .........................................................................................................................4-5cReservoir, Fluid-Pressurized (Pressurized) .................................................................................................... F4-93Reservoir, Fluid-Pressunzed (Unpressurized) ................................................................................................ F4-92Reservoir with Baffles, Fins and Finger Strainer ............................................................................................ F4-91Reservoir with Filter Elements ....................................................................................................................... F4-94Reservoirs, Hydraulic ...................................................................................................................................... 4-11Responsibility (for Hydraulic Shop Rules) ........................................................................................................ 3-1aReversing Spiral of Teflon Backup Ring ........................................................................................................ F4-74Rings, Backup ................................................................................................................................................... 4-8Rotary-Type, Closed-Center Selector Valve ................................................................................................ F4-120Rotor Blade Brake System .......................................................................................................................... F4-159

S

Safety (in Use of Test Stands) ........................................................................................................................4-20aScope (of Manual) ............................................................................................................................................. 1-2Selector Valve A Closed ............................................................................................................................. F4-145Selector Valve B Open ................................................................................................................................ F4-146Selector Valve C Open ................................................................................................................................ F4-147Selector Valve, In-Line Cam-Operated (Actuator Extending) ....................................................................... F4-123Selector Valve, In-Line Cam-Operated (Actuator Retracting) ....................................................................... F4-122Selector Valve, Radial Cam-Operated ......................................................................................................... F4-124Selector Valve, Rotary-Type, Closed-Center ............................................................................................... F4-120Selector Valve, Spool-Type, Open-Center (Closed) ..................................................................................... F4-121

Index 44

TM 1-1500-204-23-1

INDEX- CONT

VOLUME 2


Number

S - Continued

Selector Valves .................................................................................................................................. 4-16aSelf-Sealing, Aromatic-Resisting, Hose MIL-H-7061 ........................................................................... F4-38Self-Sealing, Hose for Aromatic Fuel, MIL-H-7061 ............................................................................. 4-5kSeparable Fittings, Utilizing 0.150 Tube End Gap Tolerance on ......................................................... F4-89Sequence Valve, Landing Gear System Using Mechanically Actuated ............................................... F4-129Sequence Valve, Pressure-Actuated .................................................................................................. F4-130Sequence Valves . .............................................................................................................................. 4-16dServicing Filters ................................................................................................................................. 4-12fShaped Fittings, Utilizing 0.300 Inch Tube End Gap Tolerance on ..................................................... F4-92Shock Strut, Complex (Metering Pin) ................................................................................................. F4-171Shock Strut, Complex (Plunger) ......................................................................................................... F4-172Shock Strut, Floating Pin .................................................................................................................... F4-173Shock Strut, Simple ........................................................................................................................... F4-170Shock Struts ....................................................................................................................................... 4-19bShop Equipment, Maintenance ........................................................................................................... 3-2Shop Housekeeping (Hydraulic Shop) . ............................................................................................... 3-1bShop Rules, General (Hydraulic Shop) ............................................................................................... 3-1Shop Safety (Hydraulic Shop) ............................................................................................................ 3-1cShop Tools and Materials (Hydraulic Shop) ........................................................................................ 3-1dShuttle Valve, Floating-Piston ............................................................................................................ F4-132Shuttle Valves .................................................................................................................................... 4-16fSimple Check Valve ........................................................................................................................... F4-127Simple Master Cylinder . ..................................................................................................................... F4-148Simple Shock Strut ............................................................................................................................ F4-170Single Backup Ring Installation .......................................................................................................... F4-75Single Flared Tubing, Dimensions for ................................................................................................. F4-7Single-Action Actuating Cylinder ........................................................................................................ F4-133Size (of Hydraulic Systems) ............................................................................................................... 2-2dSolenoid-Actuated Control Valve (De-energized) ............................................................................... F4-126Solenoid-Actuated Control Valve (Energized) ..................................................................................... F4-125Solid Color Band Identification ........................................................................................................... F4-2Spherical Accumulator ....................................................................................................................... F4-119Spherical Air Cylinder ......................................................................................................................... F4-95Spool-Type, Open-Center, Selector Valve (Closed) ............................................................................ F4-121Stabilizer Bar with Vane Dampers ...................................................................................................... F4-169Standard Union Fittings, Tube Insertion Limits when Using ................................................................ F4-90Standard Union Fittings, Utilizing 0.300 Inch Tube End Gap

Tolerance with ............................................................................................................................. F4-87Standpipes ......................................................................................................................................... 4-11gSteel Protective Dust Cap .................................................................................................................. F4-53Steel Protective Dust Plug and Moisture Seal .................................................................................... F4-52Storage of Hose and Hose Assemblies ............................................................................................... 4-5bStorage (55-Gallon Drums) ................................................................................................................ 3-3a

Index 45

TM 1-1500-204-23-1

INDEX- CONT

VOLUME 2


Number

S - Continued

Straight Pipe Thread .......................................................................................................................... 4-3cStraight Thread and Pipe Thread ....................................................................................................... F4-26Stratopower Effective Stroke Pump (Full Flow) .................................................................................. F4-105Stratopower Effective Stroke Pump (Zero Flow) ................................................................................. F4-106Stretching Teflon Backup Ring ........................................................................................................... F4-72Support Clamp Sizes (for Use with MIL-H-27267 Hose of Teflon) ....................................................... T4-24Support Clamp Sizes (for Use with MIL-H-38360 Hose of Teflon) ....................................................... T4-29Support, of Flexible Hose ................................................................................................................... 4-6eSwage Tool Assembly Showing Lower Die Block Assembly and

Position of Fitting Locator, Basic .................................................................................................. F4-84Swaged Joint, Checking, with D9892 Inspection Gauge ...................................................................... F4-85Swaged Tubing Repairs ..................................................................................................................... 4-9

Application.................................................................................................................................... 4-9aInspection of Swaged Joint .......................................................................................................... 4-9gSwaging Operation ...................................................................................................................... 4-9fTechnique .................................................................................................................................... 4-9bTube Cutting ................................................................................................................................ 4-9cTube Debumng ............................................................................................................................ 4-9dTube End Preparation .................................................................................................................. 4-9e

Swaging, Fitting Dimensions After ...................................................................................................... T4-39Swaging Operation ............................................................................................................................. 4-9fSynthetic-Base Fluid MIL-H-83282 ..................................................................................................... 2-3cSystem Flushing ................................................................................................................................ 2-4bSystem Relief Valve ........................................................................................................................... F4-116Systems and Repairs, Tubing.............................................................................................................. 4-2

T

Tallwheel Liquid Spring ...................................................................................................................... T4-176Technique, Swaged Tubing Repairs ................................................................................................... 4-9bTeflon Hose Assembly Procedure, Medium-Pressure ......................................................................... F4-48Teflon Hose Cutoff Factures (in Inches) ............................................................................................. F4-23Teflon Hose, Field Disassembly of ..................................................................................................... F4-47Teflon Hose Installation Procedures, Right and Wrong ....................................................................... F4-49Temperature Protection and Installation of Flexible Hose ................................................................... 4-6gTemplate for Repair of Tubing Assemblies ......................................................................................... 4-4dTest Pressures, Operating, Proof, and Burst, for AN6270 Hose

Assembly using MIL-H-5593 Low Pressure Hose ......................................................................... T4-19Test Pressures, Operating, Proof, and Burst, for MIL-H-83796

Medium Pressure Hose Assembly ................................................................................................ T4-17Test Pressures, Operating, Proof, and Burst, for MIL-H-83797

Medium Pressure Hose ................................................................................................................ T4-18Test Pressures, Operating, Proof, and Burst, for MS28741 Medium

Index 46

TM 1-1500-204-23-1

INDEX- CONT

VOLUME 2


NumberT - Continued

Test Pressures, Operating, Proof, and Burst, for MS28741 Medium Pressure HoseAssemblies, Using Single Wire Braid Hose, Military Specification MIL-H-8794 ............................. T4-16

Test Pressures, Operating, Proof, and Burst, for MS28759 andMS28762 Hose Assemblies ......................................................................................................... T4-15

Test Stands, Use of ............................................................................................................................ 4-20Tetrafluoroethylene Hose MIL-F-27272 (In Inches) ............................................................................. T4-21Tetrafluoroethylene Hose MIL-H-38360 (in Inches) ............................................................................. T4-26Theory and Basic Principles of Pneudraulics ...................................................................................... 2-1Theory of Operation, Hydraulic Reservoirs ......................................................................................... 4-11 bTheory of Operation, Hydraulics System Filters .................................................................................. 4-12bTightening Hose Clamp with Socket ................................................................................................... F4-32Tool, Flaring ....................................................................................................................................... F4-10Torque Values for AN924 Jamnut Used On Fittings ........................................................................... T4-8Torque Values for Boss Installation ..................................................................................................... T4-7Torque Values for MS21921 Coupling Nut .......................................................................................... T4-5Torque Values, Hydraulic Tubing B-Nut (AN818) ................................................................................ T4-2Torque Values, Installation, MS Flared Swivel .................................................................................... T4-25Torque Values, MS Flared Swivel Nut Fittings (Reference

....................................................Torque Values, MS Flared Swivel Nut Fittings (Reference

.................................................... Torque Values, MS FlTurnsj 66 Tj -4...52rence.................................................... ...... TD (......21........................) Tj (..................ransporngs laruid to Aircraf7) Tj -4310045 Tc (F4-32) Tj -477.84 -11.52 TD 0.0038 Tc 0.0034 Tw (Tool, Flaring ) Tj 59.76 0 TD 0.0072 Tc 0 Tw (................................) Tj 92.16 0 TD (...............................212.4 5.0 TD (.......TD (...3-3d.........4.0-11.52 TD 0.0051Tj 92.16 24Tw (Torroubleshoongs lActuato-475.68 -120.2 TD 0.0047 Tc 0.0025 Tw (Torque Values, Installation, MS Flared Swivel ) Tj 206.64 0 TD 0.0072 Tc 0 Tw (................................) Tj 72 Tc 0 Tw (................................) T92.16 1.1..) Tj 92.16 0 TD ...4.........................) Tj 92.16 0 TD (......roubleshoongs lGuide.2 0 wivpect FitCheckgs l(D 0Swaggs 83.36 -11. 0 ference) Tj 18 -11.52 TD 0.0051 Tc 0.0021 Tw (AND10064)..............TH.....)5pD (....................tings (0 f.52 TD 0.0047 Tc 0.008........................) Tj (..................roubleshoongs lWhe NuBrake System475.68 -1......TD 0.0047 Tc 0.0025 Tw (Torque Values, Installation, MS Flared Swivel ) Tj 206.64 0 TD 0.0072 Tc 0 Tw (................................) Tj 72 Tc 0 tings (5............... 0 TD ...41........................) Tj Tj 92.16 24Tw (Torubej 66ttings Alignmen7) Tj -4245 Tc (F4-32) Tj -477.84 -11.52 TD 0.0038 Tc 0.0034 Tw (Tool, Flaring ) Tj 59.76 0 TD 0.0072 Tc 0 Tw (................................) Tj 92.16 0 TD (............................... 212.4 5.36 -11.52 TD...........125 ai.a,4uw4 -11.52 TD 0.0045 Tc 0.002-balues,rubejBe66Data Drawgs tings (7.36 -11.52 TD 0.005 Tc 0.0022 Tw (Torque Values for MS21921 Coupling Nut ) Tj 189.36 0 TD 0.0072 Tc 0 Tw (................................) Tj 92.16 0 Tw (................................) Tj92.16 9.52rence) Tj ...........6................) Tj 92.16 0 9Tc 0.002-b3alues,rubejBe6gs Machine) Tj -40e.72rence

.................................................... T4-2.......................................

TM 1-1500-204-23-1

INDEX- CONT

VOLUME 2


NumberT- Continued

Tubing Assemblies, Repair of ............................................................................................................. 4-4Tubing Damage ................................................................................................................................. 4-2cTubing End Clearance for Low-Pressure Tubing-Repair ..................................................................... F4-31Tube Fittings ...................................................................................................................................... F4-15Tubing Identification ........................................................................................................................... 4-2bTubing Repairs, Swaged .................................................................................................................... 4-9Tubing Systems and Repairs .............................................................................................................. 4-2

Beaded Tubing Joints .................................................................................................................. 4-2hBending Tubing............................................................................................................................. 4-2eCleaning Tubing ........................................................................................................................... 4-2gCutting Tubing ............................................................................................................................. 4-2dFlaring Tubing .............................................................................................................................. 4-2fInstallation of Beaded Tubing........................................................................................................ 4-2jInstallation of Flared Tubing ......................................................................................................... 4-2iTubing Damage ........................................................................................................................... 4-2cTubing Identification ..................................................................................................................... 4-2bTypes............................................................................................................................................ 4-2a

Tubing with Double Lap Flare ............................................................................................................. F4-11Tubing-to-Tubing Connections ............................................................................................................ F4-22Two-Stage Fluid Filters ...................................................................................................................... 4-12dTypes of Accumulators ....................................................................................................................... 4-15aTypes of Hydraulic Fluid Used in Army Aircraft .................................................................................. 2-3

Petroleum-Base Fluid .................................................................................................................. 2-3bPrecautions .................................................................................................................................. 2-3dSynthetic-Base Fluid MIL-H-83282 ............................................................................................... 2-3cVegetable-Base Fluid.................................................................................................................... 2-3a

Types of Hydraulic Reservoirs Used in Hydraulic Systems ................................................................. 4-11aTypes of Pneudraulic Systems ........................................................................................................... 4-17Types of Tubing Systems and Repairs ............................................................................................... 4-2aTypical Gasoline Engine-Driven Hydraulic Test Stand ........................................................................ F3-2Typical Hydraulic Hose Testing Unit ................................................................................................... F3-3Typical Hydraulic System Filler and Bleeder ...................................................................................... F3-1Typical Master Gauge Unit ................................................................................................................. F3-5Typical Styles of Permaswage Fittings . .............................................................................................. F4-78

U

Universal Fittings AN832, AN833, AN834 High Pressure .................................................................... 4-3eUniversal Fittings AN832, AN833, AN834 Low Pressure ..................................................................... 4-3dUse of Air in Hydraulic Systems ......................................................................................................... 2-1fUse of Dust Plugs, Dust Caps, and Moisture Seals ............................................................................. 4-5lUse of Test Stands ............................................................................................................................. 4-20

Index 48

TM 1-1500-204-23-1

INDEX- CONT

VOLUME 2


Number

U - Continued

Procedures .................................................................................................................................. 4-20bSafety .......................................................................................................................................... 4-20a

Uses of Filter in Hydraulic Systems .................................................................................................... 4-12aUses of Hydraulic Systems in Army Aircraft ....................................................................................... 2-2

Ease of Installation ...................................................................................................................... 2-2cEase of Operation ........................................................................................................................ 2-2bEfficiency ..................................................................................................................................... 2-2aLubrication ................................................................................................................................... 2-2eSize ............................................................................................................................................. 2-2d

Utilizing 0.150 Inch Tube End Gap Tolerance on Separable Fittings .................................................. F4-89Utilizing 0.300 Inch Tube End Gap Tolerance on Shaped Fittings ...................................................... F4-88Utilizing 0.300 Inch Tube End Gap Tolerance with Standard Union Fittings ........................................ F4-87

V-Ring Packings .......................................................................................................................... 4-7cV-Ring Packings in Vanous Positions of Assembly ....................................................................... F4-71Valve A, Closed ........................................................................................................................... F4-145Valve B, Open ............................................................................................................................. F4-146Valve C, Open ............................................................................................................................. F4-147Valve, Pressure-Reducing ............................................................................................................ F4-117Valve, Priority .............................................................................................................................. F4-131Valve, Ratchet (Moving) .............................................................................................................. F4-137Valve, Ratchet (Static) ................................................................................................................. F4-136Valve, Priority .............................................................................................................................. F4-131Vane Damper ............................................................................................................................... F4-166Vane Damper Cross Section ........................................................................................................ F4-167Vane, Dampers, Nose Landing Gear ............................................................................................ F4-168Vane, Dampers, Stabilizer Bar ..................................................................................................... F4-169Vegetable-Base Fluid (Hydraulic) ................................................................................................. 2-3aVickers Stroke Reduction Pump (Full Flow) ................................................................................. F4-108Vickers Stroke Reduction Pump (Zero Flow)................................................................................. F4-107Volume, Length, and Area, Computing ......................................................................................... F2-2

W

Wheel Brake Assemblies ................................................................................................................... 4-18bWheel Brake Systems ........................................................................................................................ 4-18aWheel Brake Systems, Troubleshooting ............................................................................................. T4-41Withdrawing Fluid from Drum ............................................................................................................. T3-3c

Index 49/(index 50 blank)

TM 1-1500-204-23-1

INDEX- CONT

VOLUME 3


NumberA

Aeroquip Corporation Series 3700 and 3750 Quick Thread Couplings ................................................ 2-5hAuxiliary (Booster) Fuel Pump ............................................................................................................ F2-4AVGAS Identification ......................................................................................................................... T2-2

B

Ball Lock-Type Coupling .................................................................................................................... F2-19Bladder-Type Fuel Cells, Serviceable Limits ...................................................................................... T2-6Bridging, Sealant ................................................................................................................................ F2-12

C

Can and Drum Marking ...................................................................................................................... F2-23Characteristics of Vaporization ........................................................................................................... F2-1Clamp Location for Tube Bends ......................................................................................................... F2-3Closed-Circuit Fuel Receiver Installation ............................................................................................ F2-20Closed-Circuit Refueling Receptacles ................................................................................................ 2-51Cold Weather Maintenance, Oil Systems ........................................................................................... 3-61Consumable Materials ........................................................................................................................ 1-3Contaminant Characteristics (of Fuel), Visual ..................................................................................... T2-3Contamination of Fuels ...................................................................................................................... 2-4

Contamination Prevention ............................................................................................................ 2-4eMicrobiological Growths ............................................................................................................... 2-4cSolids............................................................................................................................................ 2-4bUses of Additives to Prevent Microbiological Growths .................................................................. 2-4dWater ........................................................................................................................................... 24a

Contamination Prevention (for Fuels) ................................................................................................. 2-4eCoupling

Ball Lock -Type ............................................................................................................................ F2-19Full Gnp PustuPull-TypeF ............................................................................................................ 2-17lnst-O-Matic Push/Pull Type ......................................................................................................... F2-16Quick-Threading/lndicating Type .................................................................................................. F2-15Screw-Type .................................................................................................................................. F2-14Straight Flow Balin Valve-Type .................................................................................................... F2-18

Covered Storage of Oils ..................................................................................................................... 3-7a

D

DA Form 1804 (Petroleum Sample) ................................................................................................... F2-22Drain Containers (Fuel Systems), Safety Precautions and Procedures ............................................... 2-2eDry-Sump Lubrication System for Reciprocating Engines ................................................................... F3-3Dry-Sump Lubrication System for Turbine Engines ............................................................................ F3-5

Index 51

TM 1-1500-204-23-1

INDEX- CONT

VOLUME 3


NumberE

Engine OilsReciprocating ............................................................................................................................... T3-1Turbine ......................................................................................................................................... T3-2Engine-Driven Fuel Pump ............................................................................................................ F2-5

F

Fasteners ............................................................................................................................................ F2-9Fillet Seal Deflection .......................................................................................................................... F2-13Filter, Oil ............................................................................................................................................ F3-6Float Switch Unit ................................................................................................................................ F2-7Float Switches .................................................................................................................................... 2-5eFlushing Oil Systems ......................................................................................................................... 3-6jFuel Cells and Tanks .......................................................................................................................... 2-5fFuel Identification ............................................................................................................................... 2-3

Aviation Gas ................................................................................................................................ 2-3bTurbine Fuels ............................................................................................................................... 2-3a

Fuel Lines .......................................................................................................................................... 2-5aFuel Lines and Drains, Safety Precautions and Procedures ................................................................ 2-2aFuel Pump ..........................................................................................................................................

Auxiliary........................................................................................................................................ F24Engine-Driven............................................................................................................................... F2-5

Fuel Pumps ........................................................................................................................................ 2-5bFuel Receiver Installation (Closed-Circuit) .......................................................................................... F2-20Fuel Strainers ..................................................................................................................................... 2-5d, F2-6Fuel Sumps ........................................................................................................................................ 2-5cFuel System Maintenance .................................................................................................................. 2-5

Aeroquip Corporation Series 3700 and 3750 Quick Thread Couplings .......................................... 2-5hClosed-Circuit Refueling Receptacles .......................................................................................... 2-5iFloat Switches ............................................................................................................................. 2-5eFuel Cells and Tanks ................................................................................................................... 2-5fFuel Lines .................................................................................................................................... 2-5aFuel Pumps ................................................................................................................................. 2-5bFuel Strainers .............................................................................................................................. 2-5dFuel Sumps ................................................................................................................................. 2-5cFuel System Troubleshooting ....................................................................................................... 2-5jTesting Fuel Systems and Tanks/Cells for Leaks ......................................................................... 2-59g

Fuel System Schematic, Typical ........................................................................................................ F2-21Fuel System Troubleshooting ............................................................................................................. 2-5jFuel System Troubleshooting, Typical, Chart ..................................................................................... T2-9Fuel Systems

Contamination of Fuels ................................................................................................................ 2-4Fuel Identification ........................................................................................................................ 2-3

Index 52

TM 1-1500-204-23-1

INDEX- CONT

VOLUME 3


Number

F - Continued

Fuel System Maintenance ............................................................................................................ 2-5General ........................................................................................................................................ 2-1Handling and Storage of Fuels ..................................................................................................... 2-6Safety Precautions and Procedures ............................................................................................. 2-2

Fuel Tanks, Integral ........................................................................................................................... F2-8Full Gnp Push/Pull-Type Coupling ...................................................................................................... F2-17

G

Gear-Type Oil Pump .......................................................................................................................... F3-13General

Fuel Systems ............................................................................................................................... 2-1Oil Systems ................................................................................................................................. 3-1

H

Handling and Storage of Fuels ........................................................................................................... 2-6Marking......................................................................................................................................... 2-6cReceipt ........................................................................................................................................ 2-6aStorage Practices ......................................................................................................................... 2-6b

Handling and Storage of Oils .............................................................................................................. 3-7Covered Storage .......................................................................................................................... 3-7aOutside Storage ........................................................................................................................... 3-7b

Heat Exchanger Cooler, Turbine Engine Fuel Oil ............................................................................... F3-1

I

Identification of AVGAS ..................................................................................................................... T2-2Identification of Oils ........................................................................................................................... 3-4

Reciprocating Engines ................................................................................................................. 3-4aTurbine Engines ........................................................................................................................... 3-4b

Inspection Valves, Quick-Disconnect Coupling ................................................................................... T2-8Inst-O-matic Push/Pull-Type Coupling ................................................................................................ F2-16Integral Fuel Tanks ............................................................................................................................ F2-8

J

Jet Fuel Used in Army Aircraft (MIL-T-5624), Critical Characteristicsand Specification Requirements for ............................................................................................. T2-1

Index 53

TM 1-1500-204-23-1

INDEX- CONT

VOLUME 3


Number

L

Leak Path Examples, Long Leak ........................................................................................................ F2-10Leaks, Fastener ................................................................................................................................. F2-9Long Leak Path Examples .................................................................................................................. F2-10Lubrication System for Reciprocating Engines

Dry-Sump .................................................................................................................................... F3-3Wet-Sump ................................................................

TM 1-1500-204-23-1

INDEX- CONT

VOLUME 3


Number

O - Continued

Oil Contamination ........................................................................................................................ 3-5Oil Systems Maintenance . ........................................................................................................... 3-6Preservation ................................................................................................................................ 3-8Safety Precautions and Procedures ............................................................................................. 3-2Types of Oil ................................................................................................................................. 3-3

Oil Systems Maintenance ................................................................................................................... 3-6Cold Weather Maintenance .......................................................................................................... 3-61Flushing Oil Systems . .................................................................................................................. 3-6Magnetic Plugs and Chip Detectors . ............................................................................................ 3-6fOil Coolers ................................................................................................................................... 3-6gOil Filters ..................................................................................................................................... 3-6cOil Jets ........................................................................................................................................ 3-6iOil Lines ...................................................................................................................................... 3-6bOil Screens .................................................................................................................................. 3-6dOil Tanks ..................................................................................................................................... 3-6ePressure Devices ......................................................................................................................... 3-6hPrevention of Sludge Buildup ....................................................................................................... 3-6kTypes of Oil Systems ................................................................................................................... 3-6a

P

Particle Size, Micron .......................................................................................................................... F2-2Personal Precautions and Procedures, Fuel Systems ......................................................................... 2-2fPetroleum Sample Form DA 1804 ...................................................................................................... F2-22Preservation of Oil Systems ............................................................................................................... 3-8Pressure Devices ............................................................................................................................... 3-6hPrevention (of Oil Contamination) ...................................................................................................... 3-5cPrevention of Sludge Buildup ............................................................................................................. 3-6kPurpose of Manual ............................................................................................................................. 1-1

Q

Quick-Disconnect Coupling Inspection Valves .................................................................................... T2-8Quick Threading/lndicating Type Coupling ......................................................................................... F2-15

R

Ratios (for Dye Mixing) ...................................................................................................................... T2-7Receipt (of Fuel Containers) ............................................................................................................... 2-6aReciprocating Engine Oil Cooler ........................................................................................................ F3-10Reciprocating Engines, Identification of Oils for ................................................................................. 3-4aRelief Valves, Oil Pressure ................................................................................................................ F3-12

Index 55

TM 1-1500-204-23-1

INDEX- CONT

VOLUME 3


Number

Safety Precautions and Procedures, Fuel Systems ............................................................................ 2-2Drain Containers .......................................................................................................................... 2-2eFuel tines and Drains ................................................................................................................... 2-2aPersonal ...................................................................................................................................... 2-2fTool Boxes ................................................................................................................................... 2-2cTools ............................................................................................................................................ 2-2b

Work Stands ...................................................................................................................................... 2-2dSafety Precautions and Procedures, Oil Systems ............................................................................... 3-2Safety Precautions, Fuel Storage ....................................................................................................... T2-10Scope of Manual ................................................................................................................................ 1-2Screen, Oil, Type ............................................................................................................................... F3-9Screw-Type Coupling ......................................................................................................................... F2-14Seal Deflection, Fillet ......................................................................................................................... F2-13Sealant Bridging ................................................................................................................................. F2-12Self Sealing Fuel Cells, Serviceable Limits ........................................................................................ T2-5Serviceable Limits (Bladder-Type Fuel Cells) ..................................................................................... T2-6Serviceable Limits (Self-Sealing Fuel Cells) ....................................................................................... T2-5Single Leak Source, Multiple Leak Path ............................................................................................. F2-11Solids (Contaminating Fuel) ............................................................................................................... 2-4bSolids (Contaminating Oil) ................................................................................................................. 3-5bSpacers and Screens Oil Filter ........................................................................................................... F3-7Spacing, Support Clamp .................................................................................................................... T2-4Storage Practices, Fuel ...................................................................................................................... 2-6bStraight Flow Ball Valve Type Coupling .............................................................................................. F2-18Support Clamp Spacing ..................................................................................................................... T2-4Surge Valve Example ........................................................................................................................ F3-14

T

Testing Fuel Systems and Tanks/Cells for Leaks ............................................................................... 2-5gTool Box (Fuel Systems), Safety Precautions and Procedures ........................................................... 2-2cTools (Fuel Systems), Safety Precautions and Procedures ................................................................. 2-2bTube Bends, Clamp Location for ........................................................................................................ F2-3Turbine Engine Fuel Oil Heat Exchanger Cooler ................................................................................ F3-11Turbine Engine, Identification of Oils for ............................................................................................. 3-4bTurbine Engine Oil Use Temperature Chart ........................................................................................ F3-1Turbine Engine Oils ............................................................................................................................ T3-2Types of Oil Systems ......................................................................................................................... 3-6aTypes of Oils ...................................................................................................................................... 3-3Typical Fuel System Schematic ......................................................................................................... F2-21Typical Fuel System Troubleshooting Chart ....................................................................................... T2-9

Index 56

TM 1-1500-204-23-1

INDEX- CONT

VOLUME 3


Number

U

Use of Brayco .................................................................................................................................... 3-5dUse Temperature Chart, Turbine Engine Oil ....................................................................................... F3-1Uses of Additives to Prevent Microbiological Growth (in Fuels) .......................................................... 2-4d

V

Valve, Surge, Example of .................................................................................................................. F3-14Vaporization Characteristics, Fuel ...................................................................................................... F2-1Visual Contaminant Characteristics, Fuel ............................................................................................ T2-3

W

Water (Contamination of Fuel) ........................................................................................................... 2-4aWater (Contamination of Oil) ............................................................................................................. 3-5aWet-Sump Lubrication System for Reciprocating Engines .................................................................. F3-2Wet-Sump Lubrication System for Turbine Engines ........................................................................... F3-4Work Stands (Fuel Systems), Safety Precautions and Procedures ..................................................... 2-2d

Index 57/(Index 58 blank)

TM 1-1500-204-23-1

INDEX- CONT

VOLUME 4


Number

A

AC Meter ............................................................................................................................................ 2-6hAirspeed Indicator .............................................................................................................................. F4-11

Test Tolerances ........................................................................................................................... T4-1Alternating Current, Basic Principles and Theory for ........................................................................... 2-3Alternating Current, Cycle .................................................................................................................. F2-2Altimeter ............................................................................................................................................ 4-3g, F4-13Ammeter ............................................................................................................................................ 2-6dAutomatic Wire Marking Machines ..................................................................................................... F3-2

B

B-16 Master Sighting Compass Alignment Method ............................................................................. F4-23Basic Circuits ..................................................................................................................................... 2-5

Compound ................................................................................................................................... 2-5c, F2-7Parallel ........................................................................................................................................ 2-5b, F26Senes .......................................................................................................................................... 2-5a, F2-5

Basic Principles and Theory for Alternating Current ............................................................................ 2-3Basic Principles and Theory for Direct Current ................................................................................... 2-2Bonds ................................................................................................................................................. 3-1 k

C

Centigrade-Fahrenheit Conversion Chart ........................................................................................... T4-13Circuit Breakers .................................................................................................................................. 3-1 nCircuit, Thermocouple ........................................................................................................................ F3-13Circuits, Basic .................................................................................................................................... 2-5Cleaning Apparatus, Mercury ............................................................................................................. F4-3Compass

Alignment, B-16 Master Sighting Method ..................................................................................... F4-23Correction Card ........................................................................................................................... F4-20Rose ............................................................................................................................................ F4-21

Components, of Electrical Systems .................................................................................................... 3-4Compound Circuits ............................................................................................................................. 2-5c, F2-7Conduits ............................................................................................................................................. 3-1jConnectors

Inspection of ................................................................................................................................ 3-3bInstallation of (on Wires) .............................................................................................................. 3-3cMS ............................................................................................................................................... F3-4Potting ......................................................................................................................................... F3-7Rectangular Shell ........................................................................................................................ F3-6Subminiature ............................................................................................................................... F3-5

Consumable Materials ........................................................................................................................ 1-3

Index 59

TM 1-1500-204-23-1

INDEX- CONT

VOLUME 4


Number

C - Continued

Continuity Tester ................................................................................................................................ 2-6b, F2-8Copper Wire Strippers ........................................................................................................................ T3-1Correction Card, Compass ................................................................................................................. F4-20Counter Drum Pointer Altimeter ......................................................................................................... F4-13

Friction Stop and Jump Error ....................................................................................................... T4-8Pressure Altitude Difference ........................................................................................................ T4-10Scale Error ................................................................................................................................... T4-6Static Friction Error (Vibrator Inoperative) .................................................................................... T4-9Test Tolerances ........................................................................................................................... T4-7

Cycle of Alternating Current . .............................................................................................................. F2-2

D

D'Arsonval Meter ................................................................................................................................ 2-6c, F2-9DD Form 1613 (Pilot Compass Correction Card) ................................................................................ F4-22Dead Weight Testers ......................................................................................................................... 4-2dDirect Current Wave Form ................................................................................................................. F2-1Direct Current, Basic Principles and Theory for .................................................................................. 2-2Direct Reading Pressure Indicator ...................................................................................................... 4-3h

Tolerances ................................................................................................................................... T4-11Dual Synchronous Rotor Tachometer Wiring Diagram

(Grounded Two-Wire System) ...................................................................................................... F4-17Dual Synchronous Rotor Tachometer Wiring Diagram

(Ungrounded Three-Wire System) ............................................................................................... F4-16

E

Electrical Connectors and Common Plugs, Installation of ................................................................... 3-3Electrical Liquid Indicating Systems and Indicators ............................................................................ 4-3qElectrical Resistance Temperature Indicators ..................................................................................... 4-3kElectrical System Components ........................................................................................................... 3-4

Built-In Test Equipment ................................................................................................................ 3-4jElectronic Control Units ............................................................................................................... 3-4kGenerators.................................................................................................................................... 3-4dIgnition Systems .......................................................................................................................... 3-4nInverters ...................................................................................................................................... 3-4g, F3-9Lighting Systems ......................................................................................................................... 3-40Motors ......................................................................................................................................... 3-4lOvervoltage Protection System ................................................................................................... 34bParallel Generators ...................................................................................................................... 3-4cRelays ......................................................................................................................................... 34fStarters ........................................................................................................................................ 3-4hStorage Battery ............................................................................................................................ 34e

Index 60

TM 1-1500-204-23-1

INDEX- CONT

VOLUME 4


Number

E - Continued

Switches ...................................................................................................................................... 3-4iThermocouples ............................................................................................................................ 3-4mVoltage Regulators ...................................................................................................................... 3-4a

Electrical System Troubleshooting ..................................................................................................... 3-2Electrodynamic Meters ....................................................................................................................... 2-6iEquipment, Measuring ....................................................................................................................... 2-6Equipment Safety

Electric Shop ............................................................................................................................... 2-1cInstrument Shop .......................................................................................................................... 4-1c

F

Fahrenheit-Centigrade Conversion Chart ........................................................................................... T4-13Fire Safety

Electric Shop ............................................................................................................................... 2-1dInstrument Shop .......................................................................................................................... 4-1d

Frequency Meters .............................................................................................................................. 2-6mFriction Stop and Jump Error, Counter Drum Pointer Altimeter .......................................................... T4-8Friction Test Tolerances, Three Pointer Altimeter ............................................................................... T44Fuse and Fuse Holders ...................................................................................................................... 3-1h

G

Gauge, Wire ...................................................................................................................................... F3-1General Shop Rules, Electric Shop .................................................................................................... 2-1

Equipment Safety ........................................................................................................................ 2-1cFire Safety ................................................................................................................................... 2-1dMaintenance of Shop Equipment ................................................................................................. 2-1eResponsibility ............................................................................................................................... 2-1aShop Housekeeping ..................................................................................................................... 2-1b

General Shop Rules, Instrument Shop ............................................................................................... 4-1Equipment Safety ........................................................................................................................ 4-1cFire Safety ................................................................................................................................... 4-1dResponsibility ............................................................................................................................... 4-1aShop Housekeeping ..................................................................................................................... 4-1 b

H

Hand Wire Marking Machine .............................................................................................................. F3-3

Index 61

TM 1-1500-204-23-1

INDEX- CONT

VOLUME 4


NumberI - Continued

Remote Reading Pressure Indicators ............................................................................................ 4-3iRepair and Replacements ............................................................................................................ 4-3sTachometer Systems ................................................................................................................... 4-3jThermocouple Temperature Indicators ......................................................................................... 4-3l

J

Vacuum System and Instrument Testing ...................................................................................... 4-3nVertical Speed Indicators .............................................................................................................. 4-31, F4-12

Inverter ............................................................................................................................................... F3-9Jetcal System Tester........................................................................................................................... 3-1lJunctions............................................................................................................................................. 4-21, F4-6

K

Kapton Wiring ..................................................................................................................................... 3-1o

L

Leak Test ConnectionsPitot ............................................................................................................................................. F4-8Sta0.015 Tw 7stems ................................................................................................................................Kaptonystems F3-9JroubleshooInstrChartre Indicat9ems .................................................................................re Indi (P0.......) Tj 78 0 TT3-40055 Tc (36-6) Tj -191.28 -23.28 TD /F0 1348 0 TM0.0005 536-6

.......................................................................................................................0...Vacuum System a3 Tw s015 Tw 38Tester................................................................

................................................................(......5.8....) Tj 72.92 0 T2-1e0041 Tc 44-3n

......................................................................5.ems 4-31,71.12Jetcals015 Tw99stems ............................................................................................................0.7....Jetcal015 Tw99stems ...........................................................................................................n6t9ems 4-24unc3n

4-5Tj -s ................................................................................................................................4-24unc...Je15 Tw99s8..........................................................................................................0P0.......J e t c a l 0 1 5 T w 1 4 8 T e s t e r........................................................................................................................................................................................................................101j -s J e t c 0 S t a a c u . . . . . . 1 0 - 6 s ................................................................................................ ................................................................................................4-24unc-3n

................................................................................................

................................................................................................4-245736-6................................................................................................4-31,83.3.................................................................................15 Tw121.4....

TM 1-1500-204-23-1

INDEX- CONT

VOLUME 4


Number

M - Continued

Materials, Consumable ....................................................................................................................... 1-3Measuring Equipment ........................................................................................................................ 2-6

AC Meters .................................................................................................................................... 2-6hAmmeter ...................................................................................................................................... 2-6dContinuity Tester .......................................................................................................................... 2-6bD'Arsonval Meter ......................................................................................................................... 2-6cElectrodynamic Meters ................................................................................................................ 2-6iFrequency Meters ........................................................................................................................ 2-6mMeter Safety Precautions ............................................................................................................. 2-6nMultimeter .................................................................................................................................... 2-6gOhmmeter ................................................................................................................................... 2-6fRectifier Meter ............................................................................................................................. 2-6jTest Lights ................................................................................................................................... 2-6aVarmeter ...................................................................................................................................... 2-6lVoltmeter ..................................................................................................................................... 2-6eWattmeter .................................................................................................................................... 2-6k

Mercury Cleaning Apparatus .............................................................................................................. F4-3Meter, D'Arsonval ............................................................................................................................... 2-6c, F2-9Meter Safety Precautions ................................................................................................................... 2-6nMicroswitch ........................................................................................................................................ F3-11MS Connectors ................................................................................................................................... F3-4Multimeter .......................................................................................................................................... 2-6g

O

Ohmmeter .......................................................................................................................................... 2-6fOperational Check (of Electrical Systems) ......................................................................................... 3-2aOutside Air Temperature Gauges ....................................................................................................... 4-3m

P

Parallel Circuits .................................................................................................................................. 2-5b, F2-6Pilot Compass Correction Cards, DD Form 1613 ................................................................................ F4-22Pitot

Leak Test Connections ................................................................................................................. F4-8Static System ............................................................................................................................... 4-3c, F4-7Static System Heater ................................................................................................................... 4-3dStatic System Tester .................................................................................................................... 4-2hTube ............................................................................................................................................ F4-10

Position Indicating Systems and Indicators ......................................................................................... 4-3rPotting Connectors ............................................................................................................................. F3-7Precautions (for Troubleshooting Electrical Systems) ......................................................................... 3-2b

Index 64

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 4


Number

P - Continued

Pressure Altitude DifferenceCounter Drum Pointer Altimeter. ........................................................................................................... T4-10Three Pointer Altimeter........................................................................................................................... T4-5

Purpose (of Manual) .......................................................................................................................................... 1-1

R

Reading Level, Manometer . ............................................................................................................................ F4-2Recommended Sizes of Marking Type ............................................................................................................ T3-2Rectangular Shell Connectors ......................................................................................................................... F3-6Rectifier Meter ...................................................................................................................................................2-6jRelays, Typical ................................................................................................................................................ F3-8Remote Indicating Compass ........................................................................................................................... 4-3p

Wiring Diagram ................................................................................................................................... F4-24Remote Reading Pressure Indicator ..................................................................................................................4-3i

Tolerances ........................................................................................................................................... T4-12Repair and Replacements, Instruments and Instrument Systems .....................................................................4-3sReplacement Criteria for Wires and Cables ..................................................................................................... 3-1bResponslbllty

for Electric Shop Rules .......................................................................................................................... 2-1afor Instrument Shop Rules ...................................................................................................................... 4-1a

Rose, Compass ............................................................................................................................................. F4-21Rotary-Selector Switch................................................................................................................................... F3-12

S

Scale ErrorCounter Drum Pointer Altimeter ............................................................................................................. T4-6Three Pointer Altimeter .......................................................................................................................... T4-3

Schematic, of Typical Electrical System .......................................................................................................... F2-4Scope (of Manual) ............................................................................................................................................. 1-2Scorsby Base ......................................................................................................................................... 4-2g, F4-5Series Circuits ........................................................................................................................................ 2-5a, F2-5Shop Housekeeping

Electrical Shop ...................................................................................................................................... 2-1bInstrument Shop .................................................................................................................................... 4-1b

Sizes of Marking Type, Recommended ........................................................................................................... T3-2Splices ............................................................................................................................................................ 3-11Static Friction Error (Vibrator Inoperative), Counter Drum Pointer Altimeter .................................................... T4-9Subminiature Connectors ................................................................................................................................ F3-5Switch

Rotary-Selector .................................................................................................................................... F3-12Toggle ................................................................................................................................................. F3-10

Index 65

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 4


Number

S - Continued

Symbols, Charts, and Schematics for Wiring Diagrams ..................................................................................... 2-4Symbols, Wiring Diagram ............................................................................................................................... F2-3Synchronous Rotor Tachometer Wiring Diagram

(Grounded Two-Wire System) ............................................................................................................. F4-15Synchronous Rotor Tachometer Wiring Diagram

(Ungrounded Three-Wire System) ....................................................................................................... F4-14

T

Tachometer Systems .........................................................................................................................................4-3j..........Tw (Figure, Table) Tj 12.72 -12 TD 0.0049 Tc 0 Tw (Number) Tj -230.16 -23.52 TD 0.0029 Tc 0.0043 Tw (S - Continued) Tj -236.88 -23.28 TD /F1 10.08 Tf 0.0041 Tc 0.0031 Tw (Symbols, Charts, and Schematics for Wiring Diagrams ) Tj 246.96 0 TD 0.o624892.........................4-3j

Symbols, Wiring Diagram ................................. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 4


Number

V

Vacuum Chambers

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 5


Number

A

Aerodynamic Balancing ..................................................................................................................................2-13bAlignment, Rotor Blade ................................................................................................................................... 3-14Angle of Bend, Measuring ............................................................................................................................... F2-6Anti-Icing ........................................................................................................................................................ 2-1 bAnti-Icing System, Typical ............................................................................................................................. F2-12

B

Balance (of Tall Rotor Blades) ..........................................................................................................................3-9cBalance Check, Three-Blade ........................................................................................................................... F2-8Balance Check, Two-Blade ............................................................................................................................. F2-7Balance, Blade ................................................................................................................................................ 3-10Balancing, Propeller ........................................................................................................................................ 2-13Bends and Twists ...........................................................................................................................................2-12cBlade Balance ................................................................................................................................................. 3-10

General ................................................................................................................................................3-10aMass Balance Weights (Bars) ...............................................................................................................3-10bSpanwise Balance Weights ...................................................................................................................3-10cTracking Weights...................................................................................................................................3-10dTrim Tabs .............................................................................................................................................3-10e

Blade Classification Data (Main Rotor Blades) ................................................................................................ 3-7dBlade Construction (Main Rotor Blades) ...........................................................................................................3-7cBlade Flapping Action (Vertical Plane) ............................................................................................................ F3-7Blade Leading and Lagging (Horizontal Plane) ................................................................................................ F3-8Blade Tracking ...............................................................................................................................................2-13dBlade Tracking, Electronic, Equipment .......................................................................................................... F3-12Blade Tracking, Reflector .............................................................................................................................. F3-13Blade, Rotor, Repair ........................................................................................................................................ 3-12Blade, Rotor, Tracking ......................................................................................................................... 3-17, F3-11

C

Classification, Propeller ..................................................................................................................................... 2-5Cleaning (of Rotors) .......................................................................................................................................3-11bCleaning, Powertrain Components of ................................................................................................................ 4-5Collective Pitch Control .......................................................................................................................... 3-5b, F3-5Components, Drive ........................................................................................................................................... 4-4Configurations, Helicopter ................................................................................................................................. 3-4Construction (of Tail Rotor Blades) .................................................................................................................. 3-9bConsumable Materials ....................................................................................................................................... 1-3

Index 69

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 5


Number

C - Continued

Control System, Helicopter .............................................................................................................................. F3-1Controllable Pitch Propeller ............................................................................................................................. 2-6bCyclic Pitch Control ................................................................................................................................ 3-5a, F3-4

D

Damaged Square Tip Repair ........................................................................................................................... F2-5Damaged Tip Repair ....................................................................................................................................... F2-4Defects, Propeller .................................................................................................................................... 2-9, T2-2Deicing ...........................................................................................................................................................2-18cDescription, Propeller ........................................................................................................................................ 2-6Drive Components ............................................................................................................................................ 4-4

Clutches ................................................................................................................................................ 4-4bDrive Shafting ......................................................................................................................................... 4-4fEngine Cooling Fans .............................................................................................................................. 4-4dFreewheeling Units .................................................................................................................................4-4cGearboxes ............................................................................................................................................. 4-4aRotor Brakes .......................................................................................................................................... 4-4e

Drive Shafting .......................................................................................................................................... 4-41, 4-5Dynamic Balancing ......................................................................................................................................... 2-13

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 5


Number

F - Continued

Fixed - Pitch Propeller ..................................................................................................................................... 2-6aFlag and Pole .................................................................................................................................................3-17aFlapping Action, Blade (Vertical Plane) ........................................................................................................... F3-7Freewheeling Units ....................................................................................................................................4-4c, 4-5Fully Articulated Rotor ......................................................................................................................................3-6cFully Articulated Rotor Head ........................................................................................................................... F3-6

G

Gearboxes ..............................................................................................................................................4-4a, 4-5aGeneral (Blade Balance) ................................................................................................................................3-10aGeneral (Tall Rotor Hubs) ............................................................................................................................... 3-8aGeneral Shop Rules ................................................................................................................................... 2-2, 3-2

................................................................................................................................................................. 4-2Responsibility ................................................................................................................................2-2a, 3-2a............................................................................................................................................................... 4-2aShop Housekeeping ......................................................................................................................2-2b, 3-2b,............................................................................................................................................................... 4-2bShop Safety ..................................................................................................................................2-2c, 3-2c,................................................................................................................................................................4-2cShop Tools and Materials .............................................................................................................2-2d, 3-2d,............................................................................................................................................................... 4-2d

General, Powertrain Maintenance Practices and Procedures ............................................................................. 4-1General, Propeller Maintenance Practices and Procedures . .............................................................................. 2-1General, Rotor Maintenance Practices and Procedures ..................................................................................... 3-1Governed Propellers, Rigging .......................................................................................................................... 2-16Governor, Woodward .................................................................................................................................... F2-10Governors, Propellers ..................................................................................................................................... 2-15

H

Hartzell Constant-Speed Propeller ......................................................................................................... F2-2, 2-6cHartzell Pitch Change Mechanism ................................................................................................................... F2-1Helicopter Configurations .................................................................................................................................. 3-4

Single Rotor............................................................................................................................................ 3-4aTandem Rotor ........................................................................................................................................ 3-4b

Helicopter Control System ............................................................................................................................... F3-1Helicopter Flight Controls .................................................................................................................................. 3-5

Collective Pitch Control ........................................................................................................................... 3-bCyclic Pitch Control ............................................................................................................................... 3-5aSwashplate ..............................................................................................................................................3-5c

Index 71

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 5


Number

H - Continued

Throttle Control ...................................................................................................................................... 3-2dTorque Control ....................................................................................................................................... 3-2e

Helicopter Vibrations ....................................................................................................................................... 3-16Extreme Low Frequency Vibration ........................................................................................................3-16aLow Frequency Vibration ......................................................................................................................3-16bMedium Frequency Vibration ................................................................................................................3-16cHigh Frequency Vibration .....................................................................................................................3-16d

I

Icing, Propeller ................................................................................................................................................ 2-18Icing Types ....................................................................................................................................................2-18aInspection (of Rotors) .....................................................................................................................................3-11cInsallation (of Governors)................................................................................................................................2-16bInstallation, Propeller ....................................................................................................................................... 2-14Integrated Oil Control Assembly ..................................................................................................................... 2-15f

L

Low Frequency Vibration ................................................................................................................................3-16b

M

Main Rotor Assemblies ..................................................................................................................................... 3-6Fully Articulated Rotor ............................................................................................................................3-6cRigid Rotor ............................................................................................................................................ 3-6aSemi-Rigid Rotor ................................................................................................................................... 3-6b

Main Rotor Blade Terms ................................................................................................................................. T3-1Main Rotor Blades ............................................................................................................................................. 3-7

Blade Classification Data ....................................................................................................................... 3-7dBlade Construction .................................................................................................................................3-7cNomenclature ........................................................................................................................................ 3-7bTypes ..................................................................................................................................................... 3-7a

Main Rotor Hub and Blade Assembly ............................................................................................................ F3-10Main Rotor Hub and Blade Removal ............................................................................................................... F3-9Main Rotor Painting ........................................................................................................................................3-13aMass Balance Weights (Bars) ........................................................................................................................3-10bMaterials, Consumable ...................................................................................................................................... 1-3Measuring Angle of Bend ................................................................................................................................ F2-6Mechanical Efficiency ..................................................................................................................................... 2-8aMedium Frequency Vibration ..........................................................................................................................3-16c

Index 72

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 5


Number

M - Continued

Metal Blade Repair .........................................................................................................................................3-12aMetal Propellers (Preservation and Storage) ..................................................................................................2-19bMinor Defects (in Propellers) ..........................................................................................................................2-12aModel Designation (Propellers Governors) .....................................................................................................2-15bModel Number, Propeller ................................................................................................................................ T2-1

N

Nomenclature (for Main Blades) ...................................................................................................................... 3-7b

O

Oil Control Plugging .......................................................................................................................................2-16aOil Coolers ...................................................................................................................................................... 4-5gOil Filters .........................................................................................................................................................4-5cOil Lines .......................................................................................................................................................... 4-5bOil Pumps ........................................................................................................................................................ 4-5fOil Screens ..................................................................................................................................................... 4-5dOperation Checks (of Governors) ...................................................................................................................2-16d

P

Painting, Rotor Blade ...................................................................................................................................... 3-13Pitch Change Mechanism, Hartzell .................................................................................................................. F2-1Pitch Control, Collective .................................................................................................................................. F3-5Pitch Control, Cyclic ........................................................................................................................................ F3-4Powertrain ......................................................................................................................................................... 4-3

Single Rotor Powertrain ......................................................................................................................... 4-3aTandem Rotor Powertrain ...................................................................................................................... 4-3b

Powertrain Maintenance Practices and Procedures ........................................................................................... 4-1Powertrain, Single Rotor ........................................................................................................................... 4-3a, F4Powertrain, Tandem Rotor ..................................................................................................................... 4-3b, F4-2Preservation and Storage, Propeller ................................................................................................................ 2-19Preservation and Storage, Rotor Blade ........................................................................................................... 3-18Pnnciples of Operation and Design of Rotor Systems ........................................................................................ 3-3Procedures, Troubleshooting (Propeller System) ............................................................................................. 2-10Procedures, Troubleshooting (Rotor Systems) ................................................................................................. 3-15Propeller Balancing ......................................................................................................................................... 2-13

Aerodynamic Balancing ........................................................................................................................2-13bBlade Tracking ......................................................................................................................................2-13dDynamic Balancing ...............................................................................................................................2-13c

Index 73

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 5


Number

P - Continued

Static Balancing ....................................................................................................................................2-13aPropeller Classification ...................................................................................................................................... 2-5

Pusher Propeller .................................................................................................................................... 2-5bTractor Propeller .................................................................................................................................... 2-5a

Propeller Cleaning ..........................................................................................................................................2-11bPropeller defects ...................................................................................................................................... 2-9, T2-2Propeller Description ......................................................................................................................................... 2-6

Controllable-Pitch Propeller ................................................................................................................... 2-6bFeathering Propeller .............................................................................................................................. 2-6eFixed-Pitch Propeller ............................................................................................................................. 2-6aHartzell Constant-Speed Propeller ..........................................................................................................2-6cReverse-Pitch Propeller .......................................................................................................................... 2-6fTurboprop Propeller ............................................................................................................................... 2-6d

Propeller Efficiency ........................................................................................................................................... 2-7Propeller Governors ........................................................................................................................................ 2-15

Integrated Oil Control Assembly ........................................................................................................... 2-15fModel Description .................................................................................................................................2-15bPrinciples of Operation .........................................................................................................................2-15aSingle Capacity Governors ...................................................................................................................2-15cTurbo Prop Overspeed Governors ........................................................................................................2-15eTurbo Prop Governors ..........................................................................................................................2-15d

Propeller Icing ................................................................................................................................................. 2-18Anti-Icing ..............................................................................................................................................2-18bDeicing .................................................................................................................................................2-18c ................................................................................................ ........

P r o p e l l e r I c i n e e d c o n ........................................................................................................................................2-18c1 Tj -483. P r o p e l l e r I c i n e t a l l a o n ................................................................................................................................ 2-15f4Tj -483.84 0 j 38.4 0 TD 9Tc 0.003826Tw (Propeller IcMaintenanceropaconce) androp cedure ................................................................

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 5


Number

P - Continued

Propeller RPM Adjusting Screw ..................................................................................................................... F2-11Propeller Theory ............................................................................................................................................... 2-3Propeller Tracking ........................................................................................................................................... F2-9Purpose (of Manual)........................................................................................................................................... 1-1

R

Refinishing (Rotor Blades) ..............................................................................................................................3-13dReflector Blade Tracking ............................................................................................................................... F3-13Removal (of Rotors) .......................................................................................................................................3-11aRemoval, Main Rotor Hub and Blade .............................................................................................................. F3-9Repair of Surface Defects (Propeller) .............................................................................................................. F2-3Repair, Propeller ............................................................................................................................................. 2-12Responsibility (for General Shop Rules) ..................................................................................................2-2a, 3-2a

............................................................................................................................................................... 4-2aReverse-Pitch Propeller .................................................................................................................................... 2-6fRigging (of Governors)....................................................................................................................................2-16cRogging Governed Propellers ......................................................................................................................... 2-16

Installation ............................................................................................................................................2-16bOil Control Plugging ..............................................................................................................................2-16aOperation Checks .................................................................................................................................2-16dRigging .................................................................................................................................................2-16c

Rigid Rotor ...................................................................................................................................................... 3-6aRotor Assemblies, Main .................................................................................................................................... 3-6Rotor Blade Alignment .................................................................................................................................... 3-14

String Method .......................................................................................................................................3-14bTelescopic Method ................................................................................................................................3-14a

Rotor Blade Painting ....................................................................................................................................... 3-13Main Rotor Painting ..............................................................................................................................3-13aRefinishing ............................................................................................................................................3-13dSpot Painting ........................................................................................................................................3-13cTail Rotor Painting ................................................................................................................................3-13b

Rotor Blade Preservation and Storage ............................................................................................................ 3-18Rotor Blade Repair .......................................................................................................................................... 3-12

Fiberglass Blade Repair ........................................................................................................................3-12bMetal Blade Repair ...............................................................................................................................3-12a

Rotor Blade Tracking ........................................................................................................................... 3-17, F3-11Electronic Blade Tracker .......................................................................................................................3-17b

Flag and Pole .................................................................................................................................................3-17aTall Rotor Tracking .........................................................................................................................................3-17cRotor Brakes ...........................................................................................................................................4-4e, 4-5k

Index 75

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 5


Number

R - Continued

Rotor Hub, Main, and Blade Assembly .......................................................................................................... F3-10Rotor Maintenance Practices and Procedures, General ..................................................................................... 3-1Rotor Removal, Cleaning, and Inspection ....................................................................................................... 3-11

Cleaning ...............................................................................................................................................3-11bInspection .............................................................................................................................................3-11cRemoval ...............................................................................................................................................3-11a

Rotor Systems, Principles of Operation and Design Features of ........................................................................ 3-3Rotor, Fully Articulated, Head ......................................................................................................................... F3-6Rotor, Main, Blades............................................................................................................................................ 3-7Rotor, Single, Configuration ............................................................................................................................ F3-2Rotor, Tail, Blades ............................................................................................................................................ 3-9Rotor, Tail, Hubs ............................................................................................................................................... 3-8Rotor, Tandem, Configuration ......................................................................................................................... F3-3RPM Adjusting Screw Propeller ..................................................................................................................... F2-11

S

Scope (of Manual) ............................................................................................................................................. 1-2Semi-Rigid Rotor ............................................................................................................................................. 3-6bShop Housekeeping ................................................................................................................................2-2b, 3-2b

............................................................................................................................................................... 4-2bShop Rules, General ................................................................................................................................... 2-2, 3-2

................................................................................................................................................................. 4-2Shop Safety ............................................................................................................................................2-2c, 3-2c

................................................................................................................................................................4-2cShop Tools and Materials ........................................................................................................................2-2d, 3-2d

................................................................................................................................................................. 4-2Single Capacity Governors .............................................................................................................................2-15cSingle Rotor .................................................................................................................................................... 3-4aSingle Rotor Configuration .............................................................................................................................3-10cSpanwise Balance Weights ............................................................................................................................3-13cSpot Painting (Rotors) ....................................................................................................................................3-13cSquare Tip, Damaged, Repair ......................................................................................................................... F2-5Static Balancing .............................................................................................................................................2-13aString Method .................................................................................................................................................3-14bSurface Defects (Propeller), Repair of ............................................................................................................. F2-3Swashplate ......................................................................................................................................................3-5c

Index 76

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 5


Number

T

Tail Rotor Blades .............................................................................................................................................. 3-9Balance ..................................................................................................................................................3-9cConstruction .......................................................................................................................................... 3-9bTrammeling ............................................................................................................................................ 3-9dTypes ..................................................................................................................................................... 3-9a

Tail Rotor Hubs ................................................................................................................................................. 3-8General .................................................................................................................................................. 3-8aTypes ..................................................................................................................................................... 3-8b

Tail Rotor Painting .........................................................................................................................................3-13bTall Rotor Tracking ..............................................................................................................................3-17c, F3-14Tandem Rotor ................................................................................................................................................. 3-4bTandem Rotor Configuration ........................................................................................................................... F3-3Telescopic Method .........................................................................................................................................3-14aTerms, Main Rotor Blade ................................................................................................................................ T3-1Theory, Propeller .............................................................................................................................................. 2-3Thermal Efficiency .......................................................................................................................................... 2-8bThree-Blade Balance Check ............................................................................................................................ F2-8throttle Control ................................................................................................................................................ 3-5dTip Damage ...................................................................................................................................................2-12bTip, Damaged, Repair ..................................................................................................................................... F2-4Torque Control ................................................................................................................................................. 3-5eTracking Weights ...........................................................................................................................................3-10dTracking, Propeller .......................................................................................................................................... F2-9Tracking, Tail Rotor ....................................................................................................................................... F3-14Tractor Propeller ............................................................................................................................................. 2-5aTrammeling (of Tail Rotor Blades) .................................................................................................................. 3-9dTrim Tabs ......................................................................................................................................................3-10eTroubleshooting Procedures (Propeller System) .............................................................................................. 2-10Troubleshooting Procedures (Rotor Systems) ......................................................................................... 3-15, T3-2Troubleshooting Procedures for Hamilton Standard 53C51-23 ........................................................................ T2-3Troubleshooting Procedures for Hartzell HC93Z20-2C Propeller ..................................................................... T2-5Troubleshooting Procedures for Hartzell HCB3TN-3 Propeller ......................................................................... T2-5Turboprop Overspeed Governors ...................................................................................................................2-15eTurboprop Governors .....................................................................................................................................2-15dTurboprop Propeller ........................................................................................................................................ 2-6dTwo-Blade Balance Check. .............................................................................................................................. F2-7Types (of Main Rotor Blades) . ......................................................................................................................... 3-7aTypes (of Tail Rotor Blades) ............................................................................................................................ 3-9aTypes (of Tail Rotor Hubs) .............................................................................................................................. 3-8bTypical Anti-Icing System .............................................................................................................................. F2-12Typical Electrical Deicing System .................................................................................................................. F2-13

Index 77

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 5


Number

V

Valves ............................................................................................................................................................. 4-5eVibrations, Helicopter ...................................................................................................................................... 3-16Volumetnc Efficiency .......................................................................................................................................2-8c

W

Wood Propellers (Preservation and Storage) .................................................................................................2-19aWood Propellers ............................................................................................................................................. 2-17

Inspection Requirements ......................................................................................................................2-17aRefinishing ............................................................................................................................................2-17dRepair ...................................................................................................................................................2-17cReplacement Criteria ............................................................................................................................2-17b

Woodward Governor . .................................................................................................................................... F2-10

Index 78

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 6


Number

A

Acrylic Monomer and Polymer Base Adhesive, MIL-A-8576, Type II, Non-Solvent ...........................................6-2cAcrylic Monomer and Polymer Base Adhesive, MIL-A-8576, Type II,

Non-Solvent, Shelf Life .......................................................................................................................... T6-3Acrylic Monomer Base Adhesive, MIL-A-8576, Type I, Solvent Type .............................................................. 6-2bAcrylic Monomer Base Adhesive, MIL-A-8576, Type I, Solvent Type .............................................................. T6-1Adhesive and Cements ...................................................................................................................................... 6-2Acrylic Monomer and Polymer Base Adhesive, MIL-A-8576, Type II, Non-Solvent ...........................................6-2c

Acrylic Monomer Base Adhesive MIL-A-8576,Type I, Solvent Type ....................................................... 6-2bCement Pnmer . ..................................................................................................................................... 6-21Cement Types ....................................................................................................................................... 6-2aChemigum Coating Cement ................................................................................................................... 6-2dColored Cement .................................................................................................................................... 6-2eComposite Adhesives ........................................................................................................................... 6-2mDeicer Repair Cement ............................................................................................................................6-2kDeicer Shoe Electrical Conducting Neoprene Surface Coat Cement ....................................................... 6-2fGeneral Purpose Synthetic Rubber Base Cement MIL-Spec MMM-1617 ............................................... 6-2gNatural Base Rubber Adhesive, MIL-Spec MMM-A-1 39, Class 3 ............................................................6-2iNeoprene Base Synthetic Rubber Cement ...............................................................................................6-2jNon-Hardening Distic Brand Cement ..................................................................................................... 6-2hOther Adhesives .................................................................................................................................... 6-2n

Adhesives and Cements, Specific Gravity Ranges .......................................................................................... T6-2Adhesives, Sealants, and Cements, General ..................................................................................................... 6-1

Curing .................................................................................................................................................... 6-1dMixing .....................................................................................................................................................6-1cPrecautionary Measures ........................................................................................................................ 6-1aPreparation of Surface ........................................................................................................................... 6-1b

Airframe Castle Nuts ..................................................................................................................................... F2-22Airframe Plain Nuts ............................................................................................................................... 2-3j, F2-28Alloys

Magnesium .............................................................................................................................................. 4-3Steel .............................................................................................................................................. 4-5,T4-11Titanium .................................................................................................................................................. 4-4

Aluminum Alloy Designation Conversions (Old to New) ................................................................................... T4-2Aluminum Alloy Temper Designations ............................................................................................................. T4-3Aluminum Alloy Types .................................................................................................................................... T4-6Aluminum Alloys ................................................................................................................................................ 4-2

Handling ................................................................................................................................................. 4-2bIdentification .......................................................................................................................................... 4-2aStorage ...................................................................................................................................................4-2c

Aluminum Alloys, Designation for Alloy Groups ............................................................................................... T4-1Aluminum Bolts ............................................................................................................................................... 2-2nAnaerobic Adhesive MIL-R-46082 ................................................................................................................... 6-31Anchor Nuts, Floating .................................................................................................................................... F2-17Application Time (Room Temperature), Sealing Compound MIL-S-8802 ......................................................... T6-4

Index 79

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 6


Number

A - Continued

Assemblies, Channel ..................................................................................................................................... F2-19Authority for Substitutions and Interchangeability of Material (Air Items) ........................................................... 1-3AVSCOM, Responsibilities of ............................................................................................................................ 1-5

B

Blind Rivets ....................................................................................................................................................... 2-8Bolt and Screw Markings ................................................................

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 6


Number

C - Continued

Castle Nut, Airframe ...................................................................................................................................... F2-22Castle Nut, Shear ................................................................

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 6


Number

C - Continued

Cord Storage ................................................................................................................................................... 3-5dCord Testing ....................................................................................................................................................3-5cCord, Test Loads ............................................................................................................................................. T3-2Corrosion Resistance (of Rivets) ..................................................................................................................... 2-8dCotter Pin Installation .......................................................................................................................... 2-17a, F2-77Cotter Pins ........................................................................................................................................... 2-7g, F2-52Countersunk Close Tolerance Bolt .................................................................................................................. F2-4Countersunk Washer ..................................................................................................................................... F2-34Cross Reference of Old and New Color Code (for Aluminum Alloys) ............................................................... T4-5Cross Reference (Part Number/Military Standard Part Number) CherryMAX Rivets ...................................... T2-11Cure Time (Room Temperature), Sealing Compound MIL-S-8802 .................................................................. T6-4Curing (of Adhesives, Sealants, and Cements) . .............................................................................................. 6-1d

D

Deicer Repair Cement...................................................................................................................................... 6-21Deicer Shoe Electrical Conducting Neoprene Surface Coat Cement ................................................................ 6-2fDescription of Bolt-Ends .................................................................................................................................. F2-1Designation Conversions (Old to New), Aluminum Alloy .................................................................................. T4-2Designation for (Aluminum) Alloy Groups ........................................................................................................ T4-1Diameter by Part Number, Bolt ....................................................................................................................... T2-2Dill Lok-Skru .........................................................................................................................................2-9c, F2-62Drilled Head Bolts ................................................................................................................................... 2-2f, F2-3Dzus Fasteners .................................................................................................................................... 2-9a, F2-60

E

Electrical Screws .............................................................................................................................................. 2-5fEngine Self-Locking Nut ................................................................................................................................ F2-20Example of Color Marking (for Aluminum Alloys) ............................................................................................ F4-1External Wrenching Bolts ........................................................................................................................ 2-2i, F2-6Eye Bolts ................................................................................................................................................ 2-2k, F2-8

F

Fastener, Lockring .......................................................................................................................................... 2-15Fasteners .......................................................................................................................................................... 2-9

Camloc . ...................................................................................................................................... 2-9b, F2-61Dill Lok-Skru .................................................................................................................................2-9c, F2-62Dzus Fasteners ........................................................................................................................... 2-9a, F2-60Interlocking Slide ........................................................................................................................ 2-9e, T2-12Snap and Curtain ................................................................................................................................... 2-9d

Index 82

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 6


Number

F - Continued

Fillister Head Screws ..................................................................................................................................... F2-39Fitting Identification ........................................................................................................................................2-16aFitting Structural Bolts ..................................................................................................................................... 2-2qFittings ................................................................................................................................................. 2-16, T2-18

Fitting Identification ..............................................................................................................................2-16aSpecial Fitting Types ............................................................................................................................2-16b

Fitting Material Code ..................................................................................................................................... T2-17Fittings, Typical ............................................................................................................................................. F2-76Flat-Head Screws .......................................................................................................................................... F2-37Floating Anchor Nuts ..................................................................................................................................... F2-17Flush Head Jo-Bolt ........................................................................................................................................ F2-10Forming Titanium and Titanium Alloys ............................................................................................................ 4-5aFuel and Oil Cells ................................................................................................................................................34

Fuel Cell Identifications ......................................................................................................................... 3-4aFuel Cell Storage ................................................................................................................................... 3-4bOil Cell Identification ...............................................................................................................................3-4cOil Cell Storage ..................................................................................................................................... 3-4d

Fuel Cell Identification ..................................................................................................................................... 3-4aFuel Cell Storage ............................................................................................................................................ 3-4b

G

Gasket and Packing Identification ................................................................................................................... 3-6bGasket and Packing Types .............................................................................................................................. 3-6aGasket and Packings ........................................................................................................................................ 3-6

Gasket and Packing Identification .......................................................................................................... 3-6bGasket and Packing Types .................................................................................................................... 3-6aStorage ...................................................................................................................................................3-6c

GeneralAdhesive Sealants, and Cements ............................................................................................................ 6-1Consumable Materials .............................................................................................................................. 7-1Hardware ................................................................................................................................................. 2-1Metals ...................................................................................................................................................... 4-1Phenolic and Plastic Materials ................................................................................................................. 5-1Rubber Materials ..................................................................................................................................... 3-1

General Purpose Synthetic Rubber Base Cement MIL-Spec MMM-A-1617 ..................................................... 6-2gGeneral Usage (of Rivets) ................................................................................................................................2-8cGnp Length (for Bolts) ..................................................................................................................................... 2-2a

Index 83

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 6


Number

H

Handling of Aluminum Alloys .......................................................................................................................... 4-2bHardware General ............................................................................................................................................. 2-1Heat Treatment of Rivets ................................................................................................................................. 2-8fHelical Insert and Tools Data ........................................................................................................................ T2-15Helical Insert National Fine Thread Sizes ...................................................................................................... T2-14Helical Insert Part Numbers ........................................................................................................................... T2-13Helical Thread Inserts ..................................................................................................................................... 2-11

Insert Tolerance ....................................................................................................................................2-11cInspection Criteria for Helical Springs ...................................................................................................2-11dInstallation of Helical Insert ...................................................................................................................2-11eInstallation of Spark Plug Helical Insert .................................................................................................2-11hInstallation of Twinsert ...........................................................................................................................2-11iOversize Insert and Twinsert Kits ..........................................................................................................2-11kRemoval of Helical Insert ...................................................................................................................... 2-11fRemoval of Twinsert ..............................................................................................................................2-11jTypes ...................................................................................................................................................2-11a

Hexagon Head Bolt Identification .................................................................................................................. F2-11Hexagon Head Bolts ....................................................................................................................................... 2-2eHi-Shear Rivets .................................................................................................................................... 2-8h, F2-54High Tensile Washer ..................................................................................................................................... F2-33Hinge Pins ....................................................................................................................................................... 2-7fHole Location by Letter, Bolt ........................................................................................................................... T2-4Hose Clamp .................................................................................................................................................. F2-43Huck and Hi-Lock Bolt Substitution ................................................................................................................. 12-6Huck Bolts (Lockbolt) ...................................................................................................................................... 2-2pHuck Rivet .................................................................................................................................................... F2-57

Identificationof Aluminum Alloys ................................................................................................................................ 4-2aof Hose .................................................................................................................................................. F3-1of Magnesium Alloys ..................................................................................................................... 4-3a, T4-7of Nuts ................................................................................................................................................... 2-31of Phenolic Compositions ...................................................................................................................... 5-2aof Plastic Materials ....................................................................................................................... 5-3a, T5-1of Rubber Materials ............................................................................................................................... T3-3of Steel ................................................................................................................................................ T4-10of Steel Alloys ........................................................................................................................................ 4-4aof Steels, SAE Numbers Used in ........................................................................................................... T4-8of Tie Rods ...........................................................................................................................................2-13aof Titanium and Titanium Alloys ..............................................................................................................4-5c

Insert Tolerance (for Helical Inserts) ..............................................................................................................2-l11cInspection Criteria for Helical Springs .............................................................................................................2-11d

Index 84

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 6


Number

I - Continued

Inspection of Rubber Materials ........................................................................................................................ 3-1bInspection of Titanium and Titanium Alloys ..................................................................................................... 4-5bInstallation Data, Spacer ............................................................................................................................... F2-69Installation of Helical Insert ............................................................................................................................2-11eInstallation of Spark Plug Helical Insert ..........................................................................................................2-11hInstallation of Twinsert .........................................................................................................................2-11i, F2-66Installation, Stud ........................................................................................................................................... F2-65Installation, Stud and Grommet ..................................................................................................................... F2-59Installing New Stud ........................................................................................................................................2-10bInterlocking Slide Fasteners ................................................................................................................. 2-9e, T2-12Internal Wrenching Bolts ....................................................................................................................... 2 -2h, F2-5Internal Wrenching Nuts .................................................................................................................................. 2-3h

J

Jamnuts .......................................................................................................................................................... 2-3dJo-and V-Bolts Substitution ...................................................................................................................22-2s, T2-7Jo-Bolts ........................................................................................................................................................... 2-20

Flush Head .......................................................................................................................................... F2-10Hexagon Head ..................................................................................................................................... F2-11Millable Head ....................................................................................................................................... F2-12

Joint with Oversize Hole, Bolted .................................................................................................................... F2-13

L

Length by Dash Number, Bolt .......................................................................................................................... T2-5

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 6


Number

M

Machine Screws ............................................................................................................................................ F2-38Magnesium Alloys ............................................................................................................................................. 4-3

Identification .................................................................................................................................. 4-3a, T4-7Storage....................................................................................................................................................4-3cTesting. .................................................................................................................................................. 4-3b

Maintenance Activities, Responsibility of ........................................................................................................... 1-4Marking Steel Alloys ........................................................................................................................................ 4-4bMarking Titanium Alloys .................................................................................................................................. 4-5dMarkings, Bolt and Screw ................................................................................................................................ T2-1Material, by Letter Preceding Dash Number, Bolt ............................................................................................ T2-3Materials, Consumable ...................................................................................................................................... 1-7Materials Used in Fabrication (of Rivets) ........................................................................................................... 7-1Metals, General ................................................................................................................................................. 4-1Millable Hexagon Head Jo-Bolt ..................................................................................................................... F2-12Minimum Breakaway Torque for Used All-Metallic and Nonmetallic Self-Locking Nuts .................................... T2-8Mixing (Adhesives, Sealants, and Cements) ...................................................................................................6-1 c

N

National Fine Thread Sizes (for Helical Inserts) ............................................................................................. T2-14Natural Rubber Adhesive, MIL-Spec MMM-A-139, Class 3 ................................................................................6-2iNeoprene Base Synthetic Rubber Cement ........................................................................................................6-2jNon-Hardening Distic Brand Cement ............................................................................................................... 6-2hNumbering System, CherryMAX Rivets ......................................................................................................... T2-10Nut Installation Limits, Self-Locking ............................................................................................................... F2-21Nuts ................................................................................................................................................................. 2-3

Airframe Plain Nuts ...................................................................................................................... 2-3j, F2-28Castellated Nuts .................................................................................................................................... 2-3bChecknuts................................................................................................................................................2-3cIdentification of Nuts .................................................................................................................................2-3iInternal Wrenching Nuts ......................................................................................................................... 2-3hJamnuts.................................................................................................................................................. 2-3dLight Hexagon Nuts .................................................................................................................... 2-3e, F2-25Self-Locking Nuts . ................................................................................................................................. 2-3aSheet Spring Nuts ....................................................................................................................... 2-3g, F2-27Wingnuts ...................................................................................................................................... 2-3f, F2-26

O

Oil Caps, Drain Cocks, and Valves, Lockwiring of ......................................................................................... F2-79Oil Cell Identification ........................................................................................................................................3-4cOil Cell Storage................................................................................................................................................ 3-4dOld and New Color Code (for Aluminum Alloys), Cross Reference .................................................................. T4-5

Index 86

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INDEX - CONT

VOLUME 6


Number

R

Recommended Changes to Department of the Army Publications ..................................................................... 1-6Recommended Torque Values .......................................................................................................................2-18cRecommended Torque Values, Nut ................................................................................................................. T2-9Removal of Bent, Damaged, or Broken Studs ................................................................................................2-10aRemoval of Helical Insert ............................................................................................................................... 2-11fRemoval of Twinsert .......................................................................................................................................2-11jRemoval, Stud .............................................................................................................................................. F2-64Repair of Damaged Spark Plug Threads ........................................................................................................2-11gResponsibilities

of AVSCOM ............................................................................................................................................. 1-5of Maintenance Activities ......................................................................................................................... 1-4

Rivet, Cherry MAX ........................................................................................................................................ F2-55Rivet, Huck ................................................................................................................................................... F2-57Rivets .................................................................................................................................................... 2-8, F2-53

Blind Rivets .............................................................................................................................................2-8iCommon Solid Shank Rivets ................................................................................................................. 2-8aCorrosion Resistance ............................................................................................................................. 2-8dGeneral Usage ........................................................................................................................................2-8cHeat Treatment ....................................................................................................................................... 2-8fHi-Shear Rivets .......................................................................................................................... 2-8h, F2-54Materials Used in Fabrication ................................................................................................................. 2-8bRivnuts ....................................................................................................................................................2-8jStrength ................................................................................................................................................. 2-8e

Rivets, Cherrylock ......................................................................................................................................... F2-56Rivnut Types ................................................................................................................................................. F2-58Rivnuts ..............................................................................................................................................................2-8jRod End Safetying (Key Type NAS 559) ............................................................................................. 2-17h, F2-82Rubber Materials

General ................................................................................................................................................... 3-1Identification .......................................................................................................................................... T3-3Inspection .............................................................................................................................................. 3-1bStorage .................................................................................................................................................. 3-1a

S

SAE Numbers Used in Identification of Steels ................................................................................................. T4-8Safety Retaining Pins ............................................................................................................................2-7c, F2-49Safetying Emergency Devices .......................................................................................................................2-17eScope (of Manual) ............................................................................................................................................. 1-2Screw Heads ................................................................................................................................................... 2-5aScrews ............................................................................................................................................................... 2-5

Electrical Screws .................................................................................................................................... 2-5fLength Measurement ............................................................................................................................. 2-5b

Index 88

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VOLUME 6


Number

S - Continued

Cord Storage ......................................................................................................................................... 3-5dCord Testing ...........................................................................................................................................3-5c

Single-Wire Method .......................................................................................................................................2-17dSnap and Curtain Fasteners ............................................................................................................................ 2-9dSpacer Identification ......................................................................................................................................2-12aSpacer Installation ..........................................................................................................................................2-12bSpacer Installation Data ................................................................................................................................ F2-69Spacer Part Number Breakdown ................................................................................................................... F2-68Special Fitting Types ......................................................................................................................................2-16bSpecial Washers ..............................................................................................................................................2-4cSpecific Gravity Ranges (for Adhesives and Cements) ................................................................................... T6-2Speed Rig Lockwiring .................................................................................................................................... F2-81Speed Rig Safetying ......................................................................................................................................2-17gSplit Lockwasher ........................................................................................................................................... F2-30Spring Pins .......................................................................................................................................... 2-7d, F2-50Steel Alloys ....................................................................................................................................................... 4-4

Identification .......................................................................................................................................... 4-4aMarking .................................................................................................................................................. 4-4b

Steel, Identification of ................................................................................................................................... T4-10Storage

of Aluminum Alloys .................................................................................................................................4-2cof Gaskets and Packing ..........................................................................................................................3-6cof Magnesium Alloys ...............................................................................................................................4-3cof Phenolic Compositions .......................................................................................................................5-2cof Plastic Materials .................................................................................................................................5-3cof Rubber Materials ............................................................................................................................... 3-1a

Strength (of Rivets) ......................................................................................................................................... 2-8eStructural Screws ..................................................................................................................................2-5c, F2-36Stud and Grommet Installation ...................................................................................................................... F2-59Stud Installation ............................................................................................................................................ F2-65Stud Removal ............................................................................................................................................... F2-64Stud Types .................................................................................................................................................... F2-63Studs .............................................................................................................................................................. 2-10

Installating New Stud ............................................................................................................................2-10bRemoval of Bent, Damaged, or Broken Studs .......................................................................................2-10a

Styles of Plate Nuts ....................................................................................................................................... F2-18Substitution and Interchangeability of Material (Air Items), Authority for ............................................................ 1-3Substitution and Interchangeability (of Rivets) ................................................................................................. 2-8gSubstitutions for Huck, Hi-Lok, and NAS Bolts .................................................................................................. 2-2rSubstitutions for Jo-Bolts, and V-Bolts .....................................................................................................2-2s, T2-7

Index 90

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VOLUME 6


Number

T

Taper Pin Washer ......................................................................................................................................... F2-32Taper Pins ...................................................................................................................................................... 2-7bTee-Head Bolts .............................................................................................................................................. 2-2mTeeth-Type Lockwashers .............................................................................................................................. F2-31Temper Designations (of Aluminum Alloys) ..................................................................................................... T3-3Terminals, Turnbuckle ................................................................................................................................... F2-72Test Loads (of Cords)....................................................................................................................................... T3-2Testing of Magnesium Alloys ........................................................................................................................... 4-3bThin Nut, Self-Locking ................................................................................................................................... F2-14Threaded Taper Pins ..................................................................................................................................... F2-48Tie Rod Terminal Fittings ................................................................................................................... 2-13b, F2-71Tie Rods .......................................................................................................................................................... 2-13

Identification ..........................................................................................................................................2-13aTie Rod Terminal Fitting ........................................................................................................... 2-13b, F2-71

Tire Identification ............................................................................................................................................. 3-2aTire Storage ..................................................................................................................................................... 3-2bTires ................................................................................................................................................................. 3-2

Tire Identification ................................................................................................................................... 3-2aTire Storage ........................................................................................................................................... 3-2b

Titanium and Titanium Alloys ................................................................................................................. 4-5, T4-11Forming ................................................................................................................................................. 4-5aIdentification ...........................................................................................................................................4-5cInspection .............................................................................................................................................. 4-5bMarking ................................................................................................................................................. 4-5d

Tools Data, Helical Insert and ....................................................................................................................... T2-15Tools Data, Metri-Thread Insert and .............................................................................................................. T2-16Tools Data, Twinsert and ............................................................................................................................... T2-17Torque ............................................................................................................................................................ 2-18

Considerations to be Taken Before Torquing ........................................................................................2-18bRecommended Torque Values ..............................................................................................................2-18cTorque Definitions ................................................................................................................................2-18a

Torque Definitions ..........................................................................................................................................2-18aTorque for Used All-Metallic and Nonmetallic Self-Locking Nuts,

Minimum Breakaway ............................................................................................................................. T2-8Torque Values, Nut, Recommended ................................................................................................................ T2-9Tube Clamps.................................................................................................................................................. F2-44Tube Identification ........................................................................................................................................... 3-3aTube Storage .................................................................................................................................................. 3-3bTubes ................................................................................................................................................................ 3-3

Tube Identification ................................................................................................................................. 3-3aTube Storage ......................................................................................................................................... 3-3b

Turnbuckle Assemblies, Typical .................................................................................................................... F2-80Turnbuckle Inspection ....................................................................................................................................2-14bTurnbuckle Installation ...................................................................................................................................2-14a

Index 91

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VOLUME 6


Number

T - Continued

Turnbuckle Terminals .................................................................................................................................... F2-72Turnbuckles .................................................................................................................................................... 2-14

Turnbuckle Inspection ...........................................................................................................................2-14bTurnbuckle Installation ..........................................................................................................................2-14a

Twinsert and Tools Data ................................................................................................................................ T2-16Twinsert Installation ...................................................................................................................................... F2-66Types of Aluminum Alloys ............................................................................................................................... T4-6Types of Helical Inserts ..................................................................................................................................2-11aTypes of Plastic Materials ............................................................................................................................... 5-3bTypes of Rivnuts ........................................................................................................................................... F2-58Typical Fittings............................................................................................................................................... F2-76Typical Turnbuckle Assemblies ..................................................................................................................... F2-80

U

Usage (of Phenolic Compositions) ................................................................................................................... 5-2b

W

Washer, Countersunk .................................................................................................................................... F2-34Washer, High Tensile .................................................................................................................................... F2-33Washer, Taper Pin ........................................................................................................................................ F2-32Washers ............................................................................................................................................................ 2-4

Lockwashers .......................................................................................................................................... 2-4bPlainwashers .............................................................................................................................. 2-4a, F2-29Special Washers .....................................................................................................................................2-4c

Washers, Preload Indicating .......................................................................................................................... F2-35Wingnuts ............................................................................................................................................... 2-3f, F2-26

Index 92

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VOLUME 7


Number

A

Advantages (of Radiography) ............................................................................................................................ 5-3Advantages (of Ultrasonic Inspection) ............................................................................................................... 6-2Amperage (Circular Magnetization) ................................................................................................................. 4-9bAmperage (Longitudinal Magnetization) .........................................................................................................4-10bAngle Beam Method ........................................................................................................................................ 6-9bApplication, Field. .............................................................................................................................................. 7-4Application of Cleaner ....................................................................................................................................3-14bApplication of Developer ................................................................................................................................3-14eApplications (of Longitudinal Magnetization) ...................................................................................................4-10cApplications (of Radiography) ........................................................................................................................... 5-5Applying Transparent Tape ............................................................................................................................4-12bAvailability of Penetrants ................................................................................................................................. 3-8b

B

Basic Principles of Penetrant Inspection ............................................................................................................ 3-3Basic Terminology (of Magnetism) .................................................................................................................... 4-3

Ferromagnetic Metals ............................................................................................................................ 4-3aLeakage Field ........................................................................................................................................ 4-3bMagnetic Substances ............................................................................................................................. 4-3dMagnetic Flux ........................................................................................................................................ 4-3eMagnetism...............................................................................................................................................4-3cPermeability ............................................................................................................................................ 4-3fResidual Magnetism .............................................................................................................................. 4-3gRetentivity ............................................................................................................................................. 4-3h

Basic Testing Methods (Ultrasonics) .................................................................................................................. 6-4Beam Divergence ............................................................................................................................................6-7cBest Access to Object ...................................................................................................................................... 5-6fBlack Light .....................................................................................................................................................3-11d

C

Calibration of Ultrasonic Equipment ................................................................................................................ 6-10Capabilities and Limitations (Magnetic Particle Inspection) ................................................................................ 4-5Changing Magnitude of Current ........................................................................................................................7-5cCharacteristics, Transmission ............................................................................................................................ 6-7Circular Magnetization ...................................................................................................................................... 4-9

Amperage .............................................................................................................................................. 4-9bTechnique .............................................................................................................................................. 4-9a

Compatibility ................................................................................................................................................... 3-8aConditions Not Requiring Demagnetization ....................................................................................................4-13bConsumable Materials ....................................................................................................................................... 1-3Continuous Method .......................................................................................................................................... 4-8b

Index 93

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VOLUME 7


Number

C - Continued

Couplants ........................................................................................................................................................ 6-8dCurrent and Particle Application ........................................................................................................................ 4-8Continuous Method ......................................................................................................................................... 4-8b

Field Direction ........................................................................................................................................4-8cField Measurement ................................................................................................................................ 4-8dResidual Method .................................................................................................................................... 4-8aSensitivity Level .................................................................................................................................... 4-8e

Currents, Eddy .................................................................................................................................................. 7-3

D

Data, Use of ...................................................................................................................................................... 2-6Defects, Honeycomb, Fiberglass, and Composite ........................................................................................... T2-2Definitions (Magnetic Particle Inspection Terms) ............................................................................................4-11aDegree of Sensitivity ........................................................................................................................................ 5-6dDemagnetization ............................................................................................................................................. 4-13

Conditions Not Requiring Demagnetization ...........................................................................................4-13bLimits of Demagnetization ....................................................................................................................4-13dReasons for Demagnetization ...............................................................................................................4-13aTechniques for Demagnetization ...........................................................................................................4-13a

Destructive Tests ............................................................................................................................................ 2-4aDetection Standards (Radiation) ...................................................................................................................... T5-1Detection, Flaw ........................................................................................................................................ 2-7, T2-1Developer Application .....................................................................................................................................3-10jDeveloper Draining ........................................................................................................................................3-10kDeveloper Dwell Time ....................................................................................................................................3-101Disadvantages (of Radiography) ....................................................................................................................... 5-4Disadvantages (of Ultrasonic Inspection) ........................................................................................................... 6-3Draining .........................................................................................................................................................3-10eDry Particle Indications ..................................................................................................................................4-12cDrying .............................................................................................................................................................3-10c

E

Eddy Current Inspection, Uses of .................................................................................................................... T7-1Eddy Current Test Set Model ED-520 ................................................................................................................ 7-5

Changing Magnitude of Current ..............................................................................................................7-5cNeedle Defections ................................................................................................................................. 7-5dOperation ............................................................................................................................................... 7-5aTesting Procedure ................................................................................................................................. 7-5b

Eddy Currents ................................................................................................................................................... 7-3Electrical Precautions .....................................................................................................................................5-11dElectromagnetic Inspections, General ............................................................................................................... 7-1

Index 94

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VOLUME 7


Number

E - Continued

Emulsifier Application .....................................................................................................................................3-10gEmulsifier Draining..........................................................................................................................................3-10hEmulsifier Dwell Time ....................................................................................................................................3-101Equipment (Longitudinal Magnetization) .........................................................................................................4-10dEvaluate Discontlnuity ....................................................................................................................................3-14gExposure ......................................................................................................................................................... 5-8aExposure and Processing, Film ......................................................................................................................... 5-8Exposure Limits .............................................................................................................................................5-11 b

F

Ferromagnetic Metals ..................................................................................................................................... 4-3aField Application ............................................................................................................................................... 7-4Field Direction ..................................................................................................................................................4-8cField Measurement ......................................................................................................................................... 4-8dFiling Radiographs .......................................................................................................................................... 5-10Film Exposure and Processing .......................................................................................................................... 5-8

Exposure ............................................................................................................................................... 5-8aProcessing ............................................................................................................................................. 5-8b

Film Placement ............................................................................................................................................... 5-6bFilm Processing, Manual ................................................................................................................................. F5-1Fixing Indications with Lacquer .......................................................................................................................4-12aFlaw Detection .......................................................................................................................................... 2-7, T21Fluorescent Indications ..................................................................................................................................4-12eFluorescent Penetrant Inspection, Specific Procedures for .............................................................................. 3-11Fluorescent Penetrant Processes ..................................................................................................................... 3-13Fluoroscopy .................................................................................................................................................... 5-7aFundamentals of Magnetic Particle Inspection ................................................................................................... 4-4

G

General (Inspection Techniques) ..................................................................................................................... 5-6aGeneral Penetrant Inspections .......................................................................................................................... 3-1General Procedures for Penetrant Inspection .................................................................................................... 3-6General Shop Rules .......................................................................................................................................... 2-2

Maintenance of Shop Equipment ........................................................................................................... 2-2eResponsibility ........................................................................................................................................ 2-2aShop Housekeeping ............................................................................................................................... 2-2bShop Safety ............................................................................................................................................2-2cShop Tools and Materials ...................................................................................................................... 2-2d

General, Electromagnetic Inspections ................................................................................................................ 7-1General, Magnetic Particle Inspections ............................................................................................................. 4-1General, Nondestructive Inspection ................................................................................................................... 2-1

Index 95

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VOLUME 7


Number

G - Continued

General, Radiography ....................................................................................................................................... 5-1General (Radiography Safety and Equipment) ...............................................................................................5-11aGeneral (Ultrasonic Inspection Equipment) ..................................................................................................... 6-8aGeneral, Ultrasonic Inspections ......................................................................................................................... 6-1

H

Honeycomb, Fiberglass, and Composite Defects ............................................................................................ T2-2

I

Importance of Skilled Operators ........................................................................................................................ 3-5Indicators, Magnetic Particle ........................................................................................................................... 4-11Inspection (Penetrant) ....................................................................................................................................3-12aInspection and Interpretation ........................................................................................................................... 3-12

Inspection .............................................................................................................................................3-12aInterpretation .........................................................................................................................................3-12b

Inspection Conditions .....................................................................................................................................3-11aInspection of Bar Stock .................................................................................................................................... 6-9fInspection of Metal Plates and Sheets ............................................................................................................. 6-9eInspection of the Part ..................................................................................................................................... 3-14fInspection of Tubes and Pipes ........................................................................................................................ 6-9gInspection Preparation ...................................................................................................................................... 4-6Inspection Process, Selection of ........................................................................................................................ 3-9Inspection Techniques ....................................................................................................................................... 5-6

Best Access to Object ............................................................................................................................. 5-6fDegree of Sensitivity .............................................................................................................................. 5-6dFilm Placement ..................................................................................................................................... 5-6bGeneral ................................................................................................................................................. 5-6aSource-to-Film Distance .........................................................................................................................5-6cThickness Measurement ........................................................................................................................ 5-6e

Inspection, Penetrant, Types and Methods ...................................................................................................... T3-2Inspection, Ultrasonic, Equipment ..................................................................................................................... 6-8Inspection, Ultrasonic, Techniques .................................................................................................................... 6-9Inspections, Types of ........................................................................................................................................ 2-4Interpretation and Inspection ........................................................................................................................... 3-12Interpretation (Penetrant Inspection) ..............................................................................................................3-12bInterpretation (Radiographic) .................................................................................................................... 5-9, 5-9a

Index 96

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VOLUME 7


Number

L

Lamb Waves ................................................................................................................................................... 6-6dLeakage Field ................................................................................................................................................. 4-3bLighting and Facilities .....................................................................................................................................3-11cLimitations (Penetrant Inspection) ..................................................................................................................... 3-4Limitations and Capabilities (Magnetic Particle Inspection) ................................................................................ 4-5Limits of Demagnetization ..............................................................................................................................4-13dLongitudinal Magnetization .............................................................................................................................. 4-10

Amperage..............................................................................................................................................4-10bApplications ..........................................................................................................................................4-10cEquipment ............................................................................................................................................4-10dTechnique .............................................................................................................................................4-10a

Longitudinal Waves.......................................................................................................................................... 6-6a

M

Magnetic Flux .................................................................................................................................................. 4-3eMagnetic Particle Indicators ............................................................................................................................ 4-11

Definitions .............................................................................................................................................4-11aSteps of Inspection ...............................................................................................................................4-11b

Magnetic Particle Inspection, Fundamentals of ................................................................................................. 4-4Magnetic Particle Inspections, General ............................................................................................................. 4-1Magnetic Substances ...................................................................................................................................... 4-3dMagnetism .......................................................................................................................................................4-3cMagnetism, Theory of ....................................................................................................................................... 4-2Magnetization, Circular . .................................................................................................................................... 4-9Magnetization, Longitudinal ............................................................................................................................. 4-10Maintenance of Shop Equipment ..................................................................................................................... 2-2eManual Film Processing .................................................................................................................................. F5-1Materials, Consumable ...................................................................................................................................... 1-3Methods of Application (Magnetic Particles) .................................................................................................... 4-7bMethods of Application, Particles and ................................................................................................................ 4-7Methods of Recording Indications (Magnetic Particle Inspection) .................................................................... 4-12

Applying Transparent Tape ...................................................................................................................4-12bDry Particle Indications .........................................................................................................................4-12cFixing Indications with Lacquer .............................................................................................................4-12aFluorescent Indications .........................................................................................................................4-12ePhotographing Indications ..................................................................................................................... 4-12fWet Particle Indications ........................................................................................................................4-12d

Minimum Penetration Time For Penetrants ..................................................................................................... T3-1Misinterpretation (Radiographic) ...................................................................................................................... 5-9bModes of Vibration ............................................................................................................................................. 6-6

Lamb Waves ......................................................................................................................................... 6-6d

Index 97

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VOLUME 7


Number

M - Continued

Longitudinal Waves ............................................................................................................................... 6-6aRayleigh Waves .....................................................................................................................................6-6cTransverse Waves ................................................................................................................................. 6-6b

N

Nature of Sound Waves .................................................................................................................................... 6-5NDI Shop Requirements .................................................................................................................................... 2-3Need for Both Types of Tests ...........................................................................................................................2-4cNeedle Deflections .......................................................................................................................................... 7-5dNondestructive Inspection, General ................................................................................................................... 2-1Nondestructive Tests ....................................................................................................................................... 2-4b

O

Operation (Eddy Current Test Set) .................................................................................................................. 7-5aOperative Precautions ..................................................................................................................................... 3-7b

P

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 7


Number

P - Continued

Operative Precautions ........................................................................................................................... 3-7bPre-operative Precautions ..................................................................................................................... 3-7aSafety Precautions ................................................................................................................................. 3-7dTemperature Limitations .........................................................................................................................3-7c

Precleaning.....................................................................................................................................................3-10bPrecleaning Process (for Type C Penetrant) ...................................................................................................3-14aPreparation, Inspection ..................................................................................................................................... 4-6Pretesting .......................................................................................................................................................3-10aPretesting, Precleaning, Drying, Application, and Removal ............................................................................. 3-10

Developer Application ............................................................................................................................3-10jDeveloper Draining ...............................................................................................................................3-10kDeveloper Dwell Time ..........................................................................................................................3-101Draining ................................................................................................................................................3-10eDrying ...................................................................................................................................................3-10cEmulsifier Application .........................................................................................................................3-109gEmulsifier Draining ...............................................................................................................................3-10hEmulsifier Dwell Time ............................................................................................................................3-10iPenetrant Application ............................................................................................................................3-10dPenetration Times ................................................................................................................................ 3-10fPrecleaning ..........................................................................................................................................3-10bPretesting .............................................................................................................................................3-10aRemoval Methods ............................................................................................................................... 3-10m

Processing ...................................................................................................................................................... 5-8bPurpose (of Electromagnetic Inspections) ......................................................................................................... 7-2Purpose (of Manual) .......................................................................................................................................... 1-1Purpose (of Penetrant Inspections) .................................................................................................................... 3-2Purpose (of Radiography) ................................................................................................................................. 5-2

Q

Quality Control of Penetrants ............................................................................................................................ 3-8Availability ............................................................................................................................................. 3-8bCompatibility .......................................................................................................................................... 3-8a

Index 99

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VOLUME 7


Number

R

Radiation Detection Standards ........................................................................................................................ T5-1Radiation Detectors ........................................................................................................................................5-11cRadiographic Interpretation ............................................................................................................................... 5-9

Interpretation ......................................................................................................................................... 5-9aMisinterpretation .................................................................................................................................... 5-9b

Radiographs, Filing ......................................................................................................................................... 5-10Radiography, General ....................................................................................................................................... 5-1Radiography Safety Precautions and Equipment.............................................................................................. 5-11

Electrical Precautions ...........................................................................................................................5-11dExposure Limits ....................................................................................................................................5-11bGeneral ................................................................................................................................................5-11aRadiation Detectors ..............................................................................................................................5-11c

Rayleigh Waves ...............................................................................................................................................6-6cReasons for Demagnetization ........................................................................................................................4-13aRecording Indications, Methods of (Magnetic Particle Inspection) ................................................................... 4-12Reflection......................................................................................................................................................... 6-7aRefraction and Mode Conversion .................................................................................................................... 6-7bRelative Response of Survey Meters .............................................................................................................. T5-2Removal of Developer ...................................................................................................................................3-14hRemoval of Excess Penetrant ........................................................................................................................3-14dRemoval Methods (Penetrants) ..................................................................................................................... 3-10mRequirements, Personnel .................................................................................................................................. 2-5Residual Magnetism ........................................................................................................................................ 4-3gResidual Method ............................................................................................................................................. 4-8aResponsibility (for Shop Rules) ....................................................................................................................... 2-2aRetentivity ....................................................................................................................................................... 4-3h

S

Safety Precautions .......................................................................................................................................... 3-7dSafety Precautions and Equipment ................................................................................................................. 5-10Scope (of Manual) ............................................................................................................................................. 1-2Search Units ................................................................................................................................................... 6-8bSelection of Inspection Process ......................................................................................................................... 3-9Sensitivity Level .............................................................................................................................................. 4-8eShop Housekeeping ........................................................................................................................................ 2-2bShop Requirements, NDI ................................................................................................................................... 2-3Shop Rules, General ......................................................................................................................................... 2-2Shop Safety .....................................................................................................................................................2-2cShop Tools and Materials................................................................................................................................. 2-2dSkilled Operators, Importance of ....................................................................................................................... 3-5Sound Waves, Nature of ................................................................................................................................... 6-5Source-to-Film Distance ...................................................................................................................................5-6cSpecial Techniques (Radiography) .................................................................................................................... 5-7

Index 100

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VOLUME 7


Number

S - Continued

Fluoroscopy ........................................................................................................................................... 5-7aPortable X-Ray Units ............................................................................................................................. 5-7b

Specific Procedures for Fluorescent Penetrant Inspection ............................................................................... 3-11Black Light.............................................................................................................................................3-11dInspection Conditions ............................................................................................................................3-11aLighting and Facilities ...........................................................................................................................3-11c

Surface Preparation .......................................................................................................................................3-11bSteps of Inspection (Magnetic Particle Inspection) ..........................................................................................4-11bStraight Beam Method .................................................................................................................................... 6-9aSurface Preparation ..............................................................................................................................3-11b, 6-9dSurface Wave Method .....................................................................................................................................6-9cSurvey Meters, Relative Response of ............................................................................................................. T5-2

T

Technique (of Circular Magnetization) ............................................................................................................. 4-9aTechnique (of Longitudinal Magnetization) .....................................................................................................4-10aTechniques for Demagnetization ....................................................................................................................4-13cTechniques, Inspection ...................................................................................................................................... 5-6Techniques, Special (Radiography) ................................................................................................................... 5-7Temperature Limitations ..................................................................................................................................3-7cTerminology, Basic (of Magnetism) ................................................................................................................... 4-3Test Set, Eddy Current, Model ED-520 .............................................................................................................. 7-5Testing Methods, Basic (Ultrasonics) ................................................................................................................. 6-4Testing Procedure (Eddy Current) ................................................................................................................... 7-5bTheory of Magnetism ........................................................................................................................................ 4-2Thickness Measurement .................................................................................................................................. 5-7eTransducers .....................................................................................................................................................6-8cTransmission BCharacteritinc ................................................................................................

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 7


Number

T - Continued

Types of Fluorescent Penetrant Processes ...................................................................................................... 3-13Types of Inspections ......................................................................................................................................... 2-4

Destructive Tests ................................................................................................................................... 2-4aNeed for Both Types of Tests .................................................................................................................2-4cNondestructive Tests ............................................................................................................................. 2-4b

U

Ultrasonic Equipment, Calibration of ................................................................................................................ 6-10Ultrasonic Inspection Equipment ....................................................................................................................... 6-8

General ................................................................................................................................................. 6-8aSearch Units .......................................................................................................................................... 6-8bTransducers.............................................................................................................................................6-8c

Ultrasonic Inspection Techniques ...................................................................................................................... 6-9Angle Beam Method .............................................................................................................................. 6-9bInspection of Bar Stock............................................................................................................................ 6-9fInspection of Metal Plates and Sheets ................................................................................................... 6-9eInspection of Tubes and Pipes ............................................................................................................... 6-9gStraight Beam Method ........................................................................................................................... 6-9aSurface Preparation ............................................................................................................................... 6-9dSurface Wave Method ............................................................................................................................6-9c

Ultrasonic Inspections, General ......................................................................................................................... 6-1Use of Data ....................................................................................................................................................... 2-6Uses of Eddy Current Inspection ..................................................................................................................... T7-1

V

Vibration, Modes of ........................................................................................................................................... 6-6

W

Wet Particle Indications .................................................................................................................................4-12d

Index 102

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VOLUME 8


Number

A

Aluminum Alloys, Typical Machine Setting for Spot Welding ........................................................................... T3-4Aluminum Arc Welding ................................................................................................................................... 3-5dAluminum Gas Welding ....................................................................................................................................3-5cAluminum Spot Welding .................................................................................................................................. 3-5eAluminum Welding............................................................................................................................................. 3-5

Arc Welding ........................................................................................................................................... 3-5dCleaning ................................................................................................................................................ 3-5bGas Welding ...........................................................................................................................................3-5cSpot Welding ......................................................................................................................................... 3-5eTypes of Alloys ...................................................................................................................................... 3-5a

Arc Welding Defects, Causes, and Remedies ................................................................................................. T3-3Arc Welding Magnesium ................................................................................................................................. T3-6

B

BandsawsCare and Use ......................................................................................................................................... 2-4bCutoff-Type ........................................................................................................................................... F2-3Vertical-Contour Type ............................................................................................................................ F2-2

Bearing Roll Staking ........................................................................................................................................ 2-6eBrazing ............................................................................................................................................................ 3-9aBrazing and Silver Soldering ............................................................................................................................. 3-9

Brazing .................................................................................................................................................. 3-9aPost Brazing and Silver Soldering Cleaning ............................................................................................3-9cSilver Soldering ..................................................................................................................................... 3-9b

Brush Method of Starting Electric Arc .............................................................................................................. F3-5

C

Care and Use of Equipment. .............................................................................................................................. 2-4Bandsaws .............................................................................................................................................. 2-4bDrilling Machines ................................................................................................................................... 2-4aGrinders .................................................................................................................................................. 2-4fLathes .....................................................................................................................................................2-4cMilling Machines .................................................................................................................................... 2-4dShapers ................................................................................................................................................. 2-4e

CleaningAluminum Welding ................................................................................................................................. 3-5bMagnesium Welding .............................................................................................................................. 3-6a

Consumable Materials ....................................................................................................................................... 1-3Corrosion-Resistant Steel and Nickel Chromium Alloy Welding ......................................................................... 3-7

Index 103

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VOLUME 8


Number

C - Continued

Arc Welding ........................................................................................................................................... 3-7dDistinguishing Corrosion-Resistant Steels and Nickel-Base Alloys ......................................................... 3-7aGas Welding ...........................................................................................................................................3-7cSpecial Welding Considerations ............................................................................................................ 3-7bSpot Welding ......................................................................................................................................... 3-7eWelding Stresses and Distortion ............................................................................................................. 3-7f

Corrosion-Resistant Steel Arc Welding ............................................................................................................ 3-7dCorrosion-Resistant Steel Gas Welding ............................................................................................................3-7cCorrosion-Resistant Steel Spot Welding .......................................................................................................... 3-7eCorrosion-Resistant Steels and Nickel Alloys,

Relation Between Sheet Thickness and Current Requiredfor Metallic Arc Welding of ..................................................................................................................... T3-8

Corrosion-Resistant Steels and Nickel-Base Alloys,Relation Between Sheet Thickness and Current Requiredfor Inert-Arc Welding of ......................................................................................................................... T3-9

Counterboring and Spotfacing ..........................................................................................................................2-6cCut-off Type Bandsaw ..................................................................................................................................... F2-3

D

Distinguishing Corrosion-Resistant Steels and Nickel-Base Alloys ................................................................... 3-7aDrill Press ....................................................................................................................................................... F2-1Drilling Machines

Care and Use ......................................................................................................................................... 2-4aSafety Precautions ................................................................................................................................. 2-3aSpecial Operations on .............................................................................................................................. 2-6

E

Electric Arc Welding Equipment ...................................................................................................................... 3-3bElectric Arc Welding Equipment ...................................................................................................................... F3-2Electrodes .............................................................................................................................................. 3-4a ,T3-1Equipment Safety .............................................................................................................................................2-2c

F

Fire Safety ...................................................................................................................................................... 2-2dFlames, Gas Welding ...................................................................................................................................... F3-4Fluxes ..............................................................................................................................................................3-4c

Index 104

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VOLUME 8


Number

G

Gas Welding .................................................................................................................................................... 3-3aGas Welding Equipment .................................................................................................................................. F3-1Gas Welding Equipment, Guide to Regulation of ............................................................................................. T3-5Gas Welding Flames........................................................................................................................................ F3-4General

Machine Shop Practices ........................................................................................................................... 2-1Weld Shop Practices ................................................................................................................................ 3-1

General Layout Practices ................................................................................................................................. 2-5aGrinder............................................................................................................................................................. F2-7Grinder Wheel Installation................................................................................................................................ F2-8

Grinding MachinesCare and Use........................................................................................................................................... 2-4fSafety Precautions.................................................................................................................................. 2-3bWheel Installation ................................................................................................................................... F2-8

Guide to Regulation of Gas Welding Equipment .............................................................................................. T3-5

IInert-Arc Welding of Corrosion-Resistant Steels and Nickel-

Base Alloys, Relation Between Sheet Thickness and Current Required for ............................................. T3-9Introduction

Consumable Materials .............................................................................................................................. 1-3Purpose .................................................................................................................................................... 1-1Scope ....................................................................................................................................................... 1-2

L

Lapping ............................................................................................................................................................ 2-6dLathes .............................................................................................................................................................. F2-4

Care and Use...........................................................................................................................................2-4cSafety Precautions...................................................................................................................................2-3c

Laying Out and Mounting Work .......................................................................................................................... 2-5General Layout Practices........................................................................................................................ 2-5aMounting................................................................................................................................................. 2-5b

M

Machine Safety Precautions............................................................................................................................... 2-3Drilling Machines .................................................................................................................................... 2-3aGrinding Machines.................................................................................................................................. 2-3bLathes......................................................................................................................................................2-3cMilling Machines ..................................................................................................................................... 2-3d

Index 105

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VOLUME 8


NumberM - Continued

Miscellaneous Machine Tools .................................................................................................................. 2-3fPortable Machine Tools .......................................................................................................................... 2-39Shapers and Planers............................................................................................................................... 2-3e

Machine Settings for Arc Welding Magnesium ................................................................................................. T3-6Machine Shop Practices

Care and Use of Equipment...................................................................................................................... 2-4General .................................................................................................................................................... 2-1Laying Out and Mounting Work................................................................................................................. 2-5Machine Safety Precautions ..................................................................................................................... 2-3Shop Rules ............................................................................................................................................... 2-2Special Operations on Drilling Machines................................................................................................... 2-6

Magnesium Arc Welding ...................................................................................................................................3-6cMagnesium Gas Welding ................................................................................................................................. 3-6bMagnesium Spot Welding ................................................................................................................................ 3-6dMagnesium Welding .......................................................................................................................................... 3-6

Arc Welding.............................................................................................................................................3-6cCleaning ................................................................................................................................................. 3-6aGas Welding........................................................................................................................................... 3-6bSpot Welding.......................................................................................................................................... 3-6d

Metallic Arc Welding of Corrosion-Resistant Steels and Nickel Alloys,Relation Between Sheet Thickness and Current Required for ................................................................. T3-8

Milling MachinesCare and Use.......................................................................................................................................... 2-4dSafety Precautions.................................................................................................................................. 2-3dMiscellaneous Machine Tools, Safety Precautions................................................................................... 2-3fMounting Work ....................................................................................................................................... 2-5b

P

Portable Machine Tools, Safety Precautions .................................................................................................... 2-3gPost Brazing and Silver Soldering Cleaning ......................................................................................................3-9cPurpose of Manual ............................................................................................................................................. 1-1

R

Reaming .......................................................................................................................................................... 2-6aRelation Between Sheet Thickness and Current Required for

Inert-Arc Welding of Corrosion-Resistant Steels andNickel-Base Alloys .................................................................................................................................. T3-9

Relation Between Sheet Thickness and Current Required forMetallic Arc Welding of Corrosion-Resistant Steels andNickel Alloys ........................................................................................................................................... T3-8

Index 106

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VOLUME 8


Number

T - Continued

Types of Welding ............................................................................................................................................... 3-3Electric Arc Welding ............................................................................................................................... 3-3bGas Welding........................................................................................................................................... 3-3aSpot Welding...........................................................................................................................................3-3c

Typical Machine Setting for Spot Welding Aluminum Alloys ............................................................................ T3-4

V

Vertical-Contour Bandsaw................................................................................................................................ F2-2

W

Welding EquipmentElectric Arc ............................................................................................................................................. F3-2Gas......................................................................................................................................................... F3-1Schematic .............................................................................................................................................. F3-3

Welding, Arc; Defects, Causes, and Remedies ................................................................................................ T3-3Welding Materials .............................................................................................................................................. 3-4

Electrodes .............................................................................................................................................. 3-4aFluxes......................................................................................................................................................3-4cWelding Rods ......................................................................................................................................... 3-4b

Welding on Aircraft ............................................................................................................................................ 3-8Welding Rod Information ................................................................................................................................. T3-2Welding Rods .................................................................................................................................................. 3-4bWelding Shop Practices

Aluminum Welding ................................................................................................................................... 3-5Brazing and Silver Soldering..................................................................................................................... 3-9Corrosion-Resistant Steel and Nickel Chromium Alloy Welding ................................................................ 3-7General .................................................................................................................................................... 3-1Magnesium Welding ................................................................................................................................. 3-6Shop Rules ............................................................................................................................................... 3-2Types of Welding...................................................................................................................................... 3-3Welding Materials..................................................................................................................................... 3-4Welding on Aircraft ................................................................................................................................... 3-8

Welding Stresses and Distortion, Corrosion-Resistant Steels and NickelChromium Alloy Welding ......................................................................................................................... 3-7f

Index 108

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VOLUME 9


Number

A

Accuracy Limits, Torque Tool........................................................................................................................... T8-1Action of Preload Indicating Washers............................................................................................................. F8-30Adjustable Hook Spanner Wrench.................................................................................................................. F4-39Adjustable Reamer......................................................................................................................................... F4-92Adjustable Wrench......................................................................................................................................... F4-25Adjusting the Snap Gauge.............................................................................................................................. F3-65Adjustment of Spray Pattern ............................................................................................................................ F5-4Air Blow Cleaning Gun ................................................................................................................................... F5-13Air Compressors, Typical ............................................................................................................................... F9-14Aircraft Landing Gear Jack............................................................................................................................. F9-10Aircraft Pre-Heater ......................................................................................................................................... F9-15Alternate Method for Tightening to 15 Degree Wrench Arc............................................................................. F8-25Angle Extension Torque Wrench Attachment ................................................................................................. F8-20Angle, Checking............................................................................................................................................. F3-19Application of Blade Pitch for Certain Materials.............................................................................................. F4-98Application of Force, Improper ....................................................................................................................... F8-19Applying Paint at an Angle, Effect of ................................................................................................................ F5-6Army Aviation, Types of Tools Used in............................................................................................................... 2-2Attachment - Offset Reverse Extension, Torque Wrench ............................................................................... F8-17Audible-Indicating Torque Wrench ................................................................................................................... F8-4Automatic Center Punch ................................................................................................................................ F4-60Awl 4-6, F4-48Awl, Scribing with an ...................................................................................................................................... F4-49

B

Ball Peen Hammer........................................................................................................................................... F4-1Beading Large Tubing .................................................................................................................................. F4-124Bench Vise............................................................................................................................................ 4-8a, F4-53Bench Vise, Using a ......................................................................................................................................... 4-54Bender, Tube ............................................................................................................................................... F4-117Bending Tube Tool..........................................................................................................................................4-123Bending Tube............................................................................................................................................... F4-118Bevel Protractor ............................................................................................................................................. F3-12Bits, Drill .......................................................................................................................................................... 4-13Blade Set, Hacksaw ....................................................................................................................................... F4-97Bobs, Plumb ............................................................................................................................................. 3-3, F3-6Body Hammer.................................................................................................................................................. F4-2Box-End Wrench Offset ................................................................................................................................. F4-23Box-End Wrenches ........................................................................................................................................ F4-22Boxes, Tool........................................................................................................................................................ 2-9Boxes, Typical Tool.......................................................................................................................................... F2-1Breast Drill ..................................................................................................................................................... F4-80Brown and Sharpe Tapered Reamer .............................................................................................................. F4-94

Index 109

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VOLUME 9


Number

C

Cable Rigging Tension Chart, Typical .............................................................................................................. F7-7Cable Tensionmeter........................................................................................................................................... 7-3Calibration, Repair and....................................................................................................................................... 8-8Calipers.............................................................................................................................................................. 3-8

Slide ..................................................................................................................................................... F3-28Vernier.................................................................................................................................................. F3-29

Calipers, Hermaphrodite ................................................................................................................................ F3-27Calipers, Simple............................................................................................................................................. F3-24Calipers, Spring-Joint..................................................................................................................................... F3-25Calipers, Transfer........................................................................................................................................... F3-26Care of Torque Tools ......................................................................................................................................... 8-6Carpenters Square ......................................................................................................................................... F3-10Carriage Clamp.............................................................................................................................................. F4-55Carriage Clamp, Using ................................................................................................................................... F4-56Center Head, Setting the................................................................................................................................ F3-14Center Punch ................................................................................................................................................. F4-50Center Punch for Drilling ................................................................................................................................ F4-84Check and Chuck Key, Three-Jaw.................................................................................................................... F6-3Checkered Flags, Reflectorizing and.................................................................................................................. 9-4Checking Angle.............................................................................................................................................. F3-19Checking Diameters, Snap Gauge for ............................................................................................................ F3-64Checking Dimension Between Surfaces, Snap Gauge for .............................................................................. F3-62Checking Flat or Cylindrical Work, Snap Gauge for........................................................................................ F3-63Checking Propeller Shaft Run Out.................................................................................................................. F3-76Chisels ........................................................................................................................................................... F4-57Chisels, Cold...................................................................................................................................................... 4-9Clamp, Carriage............................................................................................................................................. F4-55Clamping Devices .............................................................................................................................................. 4-8

Bench Vise ........................................................................................................................................... F4-53Cleaner, File .................................................................................................................................................. F4-79Cleaning Gun, Air Blow .................................................................................................................................. F5-13Cleaning Guns ................................................................................................................................................... 5-5Cleaning Solvent Gun .................................................................................................................................... F5-12Cold Chisels....................................................................................................................................................... 4-9Combination Flaring Tools ........................................................................................................................... F4-120Combination Square ...................................................................................................................................... F3-11Combination Wrench ..................................................................................................................................... F4-24Common Screwdriver..................................................................................................................................... F4-13Concentric Torque Wrench Attachments ........................................................................................................ F8-15Consumable Materials........................................................................................................................................ 1-3Control Surface Angle, Measuring at Full Throw............................................................................................... F7-3Conversion of Tensiometer Reading in Pounds................................................................................................ F7-6Correct and Incorrect Stroke Technique ........................................................................................................... F5-5

Index 110

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VOLUME 9


Number

C - Continued

Correct Drill Sizes for Tapping ..................................................................................................................... F4-102Correct GO Dimension for Cylindrical Part ..................................................................................................... F3-68Correct NO-GO Dimension for Cylindrical Part............................................................................................... F3-69Cotter Pin Extractor................................................................................................................................. 7-7, F7-11Cranes and Hoists, Typical............................................................................................................................. F9-18Crossfiling ...................................................................................................................................................... F4-76Crowfoot Wrench ........................................................................................................................................... F7-20Crowfoot Wrench, Using a ............................................................................................................................. F7-21Crowfoot Wrenches.......................................................................................................................................... 7-15Curved Tooth File .......................................................................................................................................... F4-74Cutters, Pipe ................................................................................................................................................ F4-114Cutters, Tube ............................................................................................................................................... F4-115Cutting Edge and Heel Angles, Usual............................................................................................................. F4-86Cutting Edge, Hand Grinding of...................................................................................................................... F4-87Cutting Edge, Hand Grinding of Heel to.......................................................................................................... F4-88Cutting, Flush............................................................................................................................................... F4-113Cutting Tube with Tube Cutter.......................................................................................................................... 4-23Cutting Wire................................................................................................................................................. F4-112Cylinder, Locating Diameter of ....................................................................................................................... F3-15Cylinder, Marking Diameter of........................................................................................................................ F3-16Cylindrical Part, Correct GO Dimension for .................................................................................................... F3-68Cylindrical Part, Correct NO-GO Dimension for.............................................................................................. F3-69Cylindrical Part, Placing Snap Gauge on........................................................................................................ F3-67

D

Deflecting Beam Torque Wrench ..................................................................................................................... F8-2Deicer Boot Pliers ............................................................................................................................................ 7-12Deicer Boot Pliers, Using ............................................................................................................................... F7-19Deicer Boot Roller............................................................................................................................................ 7-14Depth Gauge, Micromete ............................................................................................................................... F3-48Depth Gauge, Rule ........................................................................................................................................ F3-47Depth Gauge, Vernier .................................................................................................................................... F3-49Depth Gauges.................................................................................................................................................. 3-11Depth Micrometer .......................................................................................................................................... F3-36DescriptionLeather Punch.................................................................................................................................................. 7-13Determining Correct Torque Value ..................................................................................................................... 8-4Determining Depth with the Square Head....................................................................................................... F3-20

Index 111

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VOLUME 9


Number

D - Continued

Diagonal Cutting Pliers................................................................................................................................... F4-42Dial Indicator Installed on Propeller Shaft....................................................................................................... F3-75Dial Indicators .................................................................................................................................................. 3-20Dies ........................................................................................................................................................... F4-104Dies, Taps and................................................................................................................................................. 4-18Diestock ....................................................................................................................................................... F4-105Divider, Spring ............................................................................................................................................... F3-21Divider, Wing ................................................................................................................................................. F3-22Dividers.............................................................................................................................................................. 3-7Dividers, Scribing a Circle with....................................................................................................................... F3-23Double Cutting Shears ..................................................................................................................................... 4-21Double-Flaring Tool...................................................................................................................................... F4-122Drawfiling....................................................................................................................................................... F4-78Dressing a Grinding Wheel .............................................................................................................................. F6-6Drill Bit, Machine Grinding a........................................................................................................................... F4-85Drill Bit, Typical.............................................................................................................................................. F4-83Drill Bits ........................................................................................................................................................... 4-13Drill Grinding Gauge, Using............................................................................................................................ F4-89Drill Jaws, V-Grooves in................................................................................................................................. F4-82Drill Sizes......................................................................................................................................................... T4-2Drill, Breast .................................................................................................................................................... F4-80Drill, Hand...................................................................................................................................................... F4-81Drill, Pneumatic.................................................................................................................................................. 5-7Drilling, Center Punch for ............................................................................................................................... F4-84Drills, Electric..................................................................................................................................................... 6-3Drills, Hand ...................................................................................................................................................... 4-12Drills, Pneumatic............................................................................................................................................ F5-15Drive Punch ................................................................................................................................................... F4-61

Index 112

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VOLUME 9


NumberP E T j - 2 0 6 6 . 6 - 2 3 . 5 2 8 4 9 T / F 1 1 0 . 0 8 T f 0 . 0 0 5 5 2 T c 0 . 0 0 2 2 T w ( N E f f c t ) o f A p p l y i n g P a i n t a t a n A n g e

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 9


Number

F - Continued

Flat File.......................................................................................................................................................... F4-70Flat Parts, Gauging ........................................................................................................................................ F3-66Flat Surface, Filing for a................................................................................................................................. F4-77Flat-Nose Pliers .............................................................................................................................................. F444Flush Cutting................................................................................................................................................ F4-113Flushing Paint Gun with Thinner or Solvent (Cup) ............................................................................................ F5-7Flushing Paint Gun with Thinner or Solvent (Pressure Tank or Gravity Bucket)................................................ F5-8

G

Gauge Tolerances, Ring................................................................................................................................... T3-1Gauge Tolerances, Snap.................................................................................................................................. T3-2Gauge Types, Ring ........................................................................................................................................ F3-57Gauge, Flanged Ring ..................................................................................................................................... F3-56Gauge, Plug..................................................................................................................................................... 3-14Gauge, Surface..................................................................................................................................... F3-45, 3-10Gauge Thread................................................................................................................................................ F3-52Gauges, Ring ........................................................................................................................................ F3-55, 3-15Gauges, Snap ....................................................................................................................................... F3-59, 3-16Gauges, Thread ............................................................................................................................................... 3-13Gauging Flat Parts ......................................................................................................................................... F3-66General

Electrical Power Tools .............................................................................................................................. 6-1General Maintenance Tools ...................................................................................................................... 4-1Ground Support Equipment ...................................................................................................................... 9-1Measuring Tools ....................................................................................................................................... 3-1Special Aircraft Tools................................................................................................................................ 7-1Storage of Ground Support Equipment ..................................................................................................... 9-6Tool Procedures and Practices ................................................................................................................. 2-1Torque Tools and Torque Principles and Procedures ................................................................................ 8-1Use Torque Multiplier............................................................................................................................ F8-21

General, Ground Support Equipment ................................................................................................................. 9-1Grinder, Pneumatic ............................................................................................................................................ 5-8Grinders ........................................................................................................................................................... F6-4Grinding Wheel Installation .............................................................................................................................. F6-5Grinding Wheel, Dressing a ............................................................................................................................. F6-6Grinding, Screwdriver Tip............................................................................................................................... F4-19GSE - Three Color Camouflage Pattern ........................................................................................................... T9-1Guns, Paint ........................................................................................................................................................ 5-3

Index 114

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VOLUME 9


Number

H

Hacksaw Blade Set ........................................................................................................................................ F4-97Hacksaw Blade, Installing a............................................................................................................................ F4-99Hacksaw, Proper Way to Hold a................................................................................................................... F4-100Hacksaws.............................................................................................................................................. 4-17, F4-96Half-Pound File .............................................................................................................................................. F4-73Hammer Face Substances, Soft-Faced............................................................................................................ T4-1Hammer, Ball Peen.......................................................................................................................................... F4-1Hammer, Body................................................................................................................................................. F4-2Hammer, Lead or Copper................................................................................................................................. F4-5Hammer, Riveting ............................................................................................................................................ F4-3Hammer, Setting.............................................................................................................................................. F4-4Hammer, Soft-Faced........................................................................................................................................ F4-6Hammers and Mallets ........................................................................................................................................ 4-2Hand Drill ....................................................................................................................................................... F4-81Hand Drills ....................................................................................................................................................... 4-12Hand Grinding of Cutting Edge....................................................................................................................... F4-87Hand Grinding of Heel to Cutting Edge........................................................................................................... F4-88Hand Seamer and Groover .............................................................................................................................. 4-27Handle and Wedges, New.............................................................................................................................. F4-11Handle, Hinged .............................................................................................................................................. F4-29Handle, Ratchet ............................................................................................................................................. F4-27Handle, Removing Broken ............................................................................................................................. F4-10Handle, Sliding T-Bar ..................................................................................................................................... F4-28Handle, Speed ............................................................................................................................................... F4-30Heel Angle, Measuring ................................................................................................................................... F4-90Height Gauge, Typical.................................................................................................................................... F3-51Height Gauges ................................................................................................................................................. 3-12

Typical.................................................................................................................................................. F3-51Hermaphrodite Calipers ................................................................................................................................. F3-27Hexagonal Setscrew Wrench (Allen Wrench) ................................................................................................. F4-31Hinged Handle ............................................................................................................................................... F4-29Hole Gauges, Small .............................................................................................................................. 3-22, F3-79Hollow Punch ................................................................................................................................................. F4-64Hook Spanner Wrench................................................................................................................................... F4-36Hub Nut Torque Multiplier .............................................................................................................................. F8-22

Index 115

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VOLUME 9


Number

I

Identification of Parts of Reamers .................................................................................................................. F4-91Improper Application of Force ........................................................................................................................ F8-19Individual Flaring Tool.................................................................................................................................. F4-121Inside Micrometer .......................................................................................................................................... F3-35Installation of Preload Washer on a Bolt......................................................................................................... F8-32Installation of Preload Washers on a Stud...................................................................................................... F8-31Installing a Hacksaw Blade............................................................................................................................. F4-99Installing Protractor Head on Rule.................................................................................................................. F3-17Installing Wooden Wedge .............................................................................................................................. F4-12

J

Jack Hydraulic Schematic Diagram.................................................................................................................. F9-6Jack, 3-Ton, Tripod .......................................................................................................................................... F9-9Jack, 5-Ton, Tripod .......................................................................................................................................... F9-8Jack, 10-Ton, Self-Contained......................................................................................................................... F9-11Jack, 12-Ton, Tripod ........................................................................................................................................ F9-7Jack, Aircraft Landing Gear............................................................................................................................ F9-10Jobber's (Machine) Reamer ........................................................................................................................... F4-93

K

Knife, Putty .................................................................................................................................................... F4-52Knife, Utility ................................................................................................................................................... F4-50Knives................................................................................................................................................................ 4-7Knives, Pocket ............................................................................................................................................... F4-51

L

Laying Out Angle ........................................................................................................................................... F3-24Lead or Copper Hammer.................................................................................................................................. F4-5Leather Punch.................................................................................................................................................. 7-13Level Condition ................................................................................................................................................ F3-5Level

Machinist's Level .................................................................................................................................... F3-2Master Precision Level ........................................................................................................................... F3-1Mechanic's Level .................................................................................................................................... F3-4Striding Level ......................................................................................................................................... F3-3

Levels ................................................................................................................................................................ 3-2Locating Diameter of Cylinder ........................................................................................................................ F3-15Lockwire Pliers...................................................................................................................................... 7-11, F7-16

Index 116

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VOLUME 9


Number

L - Continued

Long-Nose Pliers............................................................................................................................................ F4-43Loosening Protractor Adjustment Screws ....................................................................................................... F3-18Lubricants for Tapping and Die-Cutting Threads............................................................................................... T4-3Lubricating Equipment ................................................................................................................................... F9-20

M

Machine Grinding a Drill Bit............................................................................................................................ F4-85Magnet, Telescoping ............................................................................................................................... 7-9, F7-14Maintenance Platform, Type B-1 ...................................................................................................................... F9-1Maintenance Stand, Type B-4A........................................................................................................................ F9-2Maintenance Stand, Engine ............................................................................................................................. F9-3Mallet, Rawhide ............................................................................................................................................... F4-7Mallet, Rubber.................................................................................................................................................. F4-8Mallet, Tinner's................................................................................................................................................. F4-9Mallets, Hammers and ....................................................................................................................................... 4-2Marking.............................................................................................................................................................. 9-5Marking a Square Line ................................................................................................................................... F3-13Marking Diameter of Cylinder......................................................................................................................... F3-16Master Precision Level..................................................................................................................................... F3-1Materials, Consumable....................................................................................................................................... 1-3Measuring Control Surface Angle at Full Throw................................................................................................ F7-3Measuring Heel Angle .................................................................................................................................... F4-90Measuring Hole with a Small Hole Gauge ...................................................................................................... F3-80Measuring Hole with Telescoping Gauge........................................................................................................ F3-78Measuring Sheet Metal and Wire ................................................................................................................... F3-72Mechanic's Level.............................................................................................................................................. F3-4Mechanical Fingers ................................................................................................................................. 7-8, F7-12Mechanist's Scribers ........................................................................................................................................ F3-7Micrometer Depth Gauge ............................................................................................................................... F3-48Micrometer with Extension Rod, Using Inside................................................................................................. F3-40Micrometer, Reading a Vernier....................................................................................................................... F3-43Micrometers ....................................................................................................................................................... 3-9

Depth.................................................................................................................................................... F3-36Extension Rods for Inside and Depth .................................................................................................... F3-37Inside.................................................................................................................................................... F3-35Outside................................................................................................................................................. F3-34Parts of a Micrometer ........................................................................................................................... F3-41Reading a Measurement on a Micrometer ............................................................................................ F3-42Reading a Metric Micrometer........................................................................................................ 3-9f, F3-44Using Inside.......................................................................................................................................... F3-38Using Outside ....................................................................................................................................... F3-39

Index 117

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VOLUME 9


Number

P - Continued

Pipe and Tube Cutters ..................................................................................................................................... 4-23Pipe Cutters ................................................................................................................................................. F4-114Placing Snap Gauge on Cylindrical Part......................................................................................................... F3-67Pliers ................................................................................................................................................................. 4-5

Deicer Boot............................................................................................................................................. 7-12Lockwire ...................................................................................................................................... 7-11, F7-16

Pliers, Diagonal Cutting.................................................................................................................................. F4-42Pliers, Flat Nose............................................................................................................................................. F4-44Pliers, Long-Nose........................................................................................................................................... F4-43Pliers, Retaining Ring..................................................................................................................................... F4-40Pliers, Round-Nose ........................................................................................................................................ F4-45Pliers, Slip-Joint. ............................................................................................................................................ F4-41Pliers, Vise-Grip ............................................................................................................................................. F4-47Pliers, Water Pump........................................................................................................................................ F4-46Plug Gauges ......................................................................................................................................... F3-54, 3-14Plug, Three-Prong Grounded ........................................................................................................................... F6-1Plumb Bobs .............................................................................................................................................. 3-3, F3-6Plumb Bobs, Polished Brass ............................................................................................................................ F3-6Plumb Bobs, Solid Steel................................................................................................................................... F3-6Pneumatic Drill................................................................................................................................................... 5-7Pneumatic Drills............................................................................................................................................. F5-15Pneumatic Grinder .................................................................................................................................. 5-8, F5-16Pneumatic Hammer. ............................................................................................................................... 5-9, F5-17Pneumatic Tools ................................................................................................................................................ 5-1Pneumatic Vacuum Cleaner.................................................................................................................... 5-6, F5-14Pocket Knives ................................................................................................................................................ F4-51Polished Brass Plumb Bobs ............................................................................................................................. F3-6Portable Power Supply................................................................................................................................... F9-23Power Application of Force When Using Extension ........................................................................................ F8-18Power Supply, Portable.................................................................................................................................. F9-23Power Wrench Torque Multiplier .................................................................................................................... F8-23Practices and Procedures, Safety....................................................................................................................... 9-2Practices, Shop.................................................................................................................................................. 2-8Pre-Oiler and Pickler...................................................................................................................................... F9-19Precautions, Safety ............................................................................................................................................ 5-2Preload Indicating Washers............................................................................................................................ F8-29Preload Indicating Washers, Torque Procedures Without a Torque Wrench..................................................... 8-11Preset Torque Screwdriver............................................................................................................................... F8-1Prick Punch.................................................................................................................................................... F4-58Progressive Snap Gauge ............................................................................................................................... F3-61Propeller Shaft Runout, Checking .................................................................................................................. F3-76Propeller Shaft, Dial Indicator Installed on...................................................................................................... F3-75Proper Fit of Screwdrivers.............................................................................................................................. F4-17

Index 119

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INDEX - CONT

VOLUME 9


Number

P- Continued

Proper Procedure for Pulling Adjustable Wrenches ........................................................................................ F4-35Proper Way to Hold a Hacksaw.................................................................................................................... F4-100Protractor .................................................................................................................................................. 7-2, F7-1Protractor Adjustment Screws, Loosening ...................................................................................................... F3-18Protractor Head on Rule, Installing................................................................................................................. F3-17Protractor, Bevel ............................................................................................................................................ F3-12Protractor, Setting, with Flight Control Surface in Neutral Position ................................................................... F7-2Punch, Automatic Center ............................................................................................................................... F4-60Punch, Center ................................................................................................................................................ F4-59Punch, Drive .................................................................................................................................................. F4-61Punch, Hollow ................................................................................................................................................ F4-64Punch, Leather................................................................................................................................................. 7-13Punch, Pin ..................................................................................................................................................... F4-62Punch, Prick................................................................................................................................................... F4-58Punch, Transfer ............................................................................................................................................. F4-63Punches........................................................................................................................................................... 4-10Purpose

of Manual ................................................................................................................................................. 1-1Putty Knife ..................................................................................................................................................... F4-52

Tools on Army Aircraft .............................................................................................................................. 2-5

R

Radius Gauges, Fillet and ................................................................................................................................ 3-19Ratchet Handle .............................................................................................................................................. F4-27Ratchet Screwdrivers ..................................................................................................................................... F4-16Rawhide Mallet ................................................................................................................................................ F4-7Reading a Measurement on a Micrometer...................................................................................................... F3-42Reading a Measurement on a Vernier Caliper ................................................................................................ F3-32Reading a Metric Caliper................................................................................................................................ F3-33Reading a Metric Micrometer ......................................................................................................................... F3-44Reading a Vernier Micrometer........................................................................................................................ F3-43Reamer, Adjustable........................................................................................................................................ F4-92Reamer, Brown and Sharpe Tapered ............................................................................................................. F4-94Reamer, Jobber's (Machine) .......................................................................................................................... F4-93Reamer, Repairman's Hand ........................................................................................................................... F4-95Reamers .......................................................................................................................................................... 4-14Reamers, Identification of Parts of ................................................................................................................. F4-91Recommended Torque Values ......................................................................................................................... T8-2Reflectorizing and Checkered Flags ................................................................................................................... 9-4Removing Broken Handle .............................................................................................................................. F4-10

Index 120

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VOLUME 9


Number

R - Continued

Repairand Calibration ......................................................................................................................................... 8-8Tool, Valve .................................................................................................................................... 7-6, F7-10

Rigid Frame Torque Wrench............................................................................................................................ F8-3Ring Gauge Types ......................................................................................................................................... F3-57Ring Gauges .................................................................................................................................................... 3-15

Tolerances.............................................................................................................................................. T3-1Ring Gauges, Using ....................................................................................................................................... F3-58Riveting Hammer ............................................................................................................................................. F4-3Roller, Deicer Boot........................................................................................................................................... 7-14Round File ..................................................................................................................................................... F4-72Round-Nose Pliers ......................................................................................................................................... F4-45Rubber Mallet................................................................................................................................................... F4-8Rule Depth Gauge ......................................................................................................................................... F3-47Rule, Typical .................................................................................................................................................... F3-9Rules, Tapes and ............................................................................................................................................... 3-5

S

SafetyElectrical Power Tools .............................................................................................................................. 6-2Precautions............................................................................................................................................... 5-2Tool .......................................................................................................................................................... 2-7

Safety Practices and Procedures........................................................................................................................ 9-2Schematic Diagram, Jack Hydraulic................................................................................................................. F9-6Scope of Manual ................................................................................................................................................ 1-2Screwdriver Tip Grinding................................................................................................................................ F4-19Screwdriver, Offset ........................................................................................................................................ F4-15Screwdriver, Phillips....................................................................................................................................... F4-14Screwdriver, Preset Torque.............................................................................................................................. F8-1Screwdrivers ...................................................................................................................................................... 4-3Screwdrivers, Common.................................................................................................................................. F4-13Screwdrivers, Proper Fit of............................................................................................................................. F4-17Screwdrivers, Ratchet .................................................................................................................................... F4-16Scribers.............................................................................................................................................................. 3-4Scribers, Mechanist's ....................................................................................................................................... F3-7Scribing a Circle with Dividers........................................................................................................................ F3-23Scribing with an Awl ....................................................................................................................................... F4-49Selection, Torque Wrench.................................................................................................................................. 8-3Self-Contained Jack, 10-Ton.......................................................................................................................... F9-11Servicing Unit, Nitrogen ................................................................................................................................. F9-17Servicing Unit, Oxygen .................................................................................................................................. F9-24

Index 121

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INDEX - CONT

VOLUME 9


Number

S - Continued

Setscrew Wrench (Allen Wrench) Hexagonal ................................................................................................. F4-31Setting Hammer............................................................................................................................................... F4-4Setting Height on a Surface Gauge ......................................................................................................3-10c, F3-46Setting Protractor with Flight Control Surface in Neutral Position ..................................................................... F7-2Setting the Center Head................................................................................................................................. F3-14Shears and Double Flares ............................................................................................................................ F4-119Shears, Double Cutting .................................................................................................................................... 4-21Sheet Metal and Wire Gauge ................................................................................................................ F3-72, 3-18Sheet Metal and Wire, Measuring .................................................................................................................. F3-72Shop Practices................................................................................................................................................... 2-8Simple Calipers.............................................................................................................................................. F3-24Single- and Double-Cut File Teeth ................................................................................................................. F4-66Sizes, Drill........................................................................................................................................................ T4-2Slide Caliper .................................................................................................................................................. F3-28Sliding T-Bar Handle ...................................................................................................................................... F4-28Slip-Joint Pliers .............................................................................................................................................. F4-41Small Hole Gauge, Measuring Hole with a ..................................................................................................... F3-80Small Hole Gauges ............................................................................................................................... F3-79, 3-22Snap Gauge for Checking Diameters ............................................................................................................. F3-64Snap Gauge for Checking Dimension Between Surfaces ............................................................................... F3-62Snap Gauge for Checking Flat or Cylindrical Work......................................................................................... F3-63Snap Gauge, Adjusting the............................................................................................................................. F3-65Snap Gauge, Progressive .............................................................................................................................. F3-61Snap Gauge, Solid Nonadjustable.................................................................................................................. F3-60Snap Gauges ........................................................................................................................................ F3-59, 3-16

Tolerances.............................................................................................................................................. T3-2Soaking a Paint Gun ........................................................................................................................................ F5-9Sockets .......................................................................................................................................................... F4-26Soft-Faced Hammer......................................................................................................................................... F4-6Soft-Faced Hammer Face Substances............................................................................................................. T4-1Soldering Tools ..................................................................................................................................... F7-22, 7-16Solid Nonadjustable Snap Gauge................................................................................................................... F3-60Solid Steel Plumb Bobs.................................................................................................................................... F3-6Solvent, Cleaning Gun ................................................................................................................................... F5-12Spacing and Fineness, File Teeth .................................................................................................................. F4-67Special Aircraft Tools, General........................................................................................................................... 7-1Speed Handle ................................................................................................................................................ F4-30SPEM Stand .................................................................................................................................................... F9-4Spiral Screw Extractors ................................................................................................................................ F4-108Spray Gun, Oil ............................................................................................................................................... F5-11Spray Guns, Oil.................................................................................................................................................. 5-4Spray Pattern ................................................................................................................................................... F5-2Spray Pattern, Adjustment of ........................................................................................................................... F5-4

Index 122

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VOLUME 9


Number

S - Continued

Spring Divider ................................................................................................................................................ F3-21Spring-Joint Calipers...................................................................................................................................... F3-25Square

Carpenter's ........................................................................................................................................... F3-10Combination ......................................................................................................................................... F3-11

Square File .................................................................................................................................................... F4-71Square Head, Determining Depth with the...................................................................................................... F3-20Square Line, Marking a .................................................................................................................................. F3-13Squares ............................................................................................................................................................. 3-6Stand, SPEM ................................................................................................................................................... F9-4Stand, Type D5B Hydraulic Test ...................................................................................................................... F9-5Storage of Ground Support Equipment............................................................................................................... 9-6Straight Screw Extractor............................................................................................................................... F4-107Striding Level................................................................................................................................................... F3-3Stroke Technique, Correct and Incorrect .......................................................................................................... F5-5Suggested Corrections, Faulty Pattern and .................................................................................................... F5-10Surface Gauge................................................................................................................................................. 3-10

Setting Height on a ............................................................................................................................... F3-46

T

Tap Extractor ............................................................................................................................................... F4-109Tap Extractor, Use of ................................................................................................................................... F4-110Tap Wrenches.............................................................................................................................................. F4-103Tapes and Rules ................................................................................................................................................ 3-5Tapes, Typical.................................................................................................................................................. F3-8Tapping and Die-Cutting Threads, Lubricants for.............................................................................................. T4-3Tapping, Correct Drill Sizes for .................................................................................................................... F4-102Taps and Dies .................................................................................................................................................. 4-18Taps ........................................................................................................................................................... F4-101Telescoping Gauge, Measuring Hole with....................................................................................................... F3-78Telescoping Gauges ............................................................................................................................. 3-21, F3-77

Index 123

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VOLUME 8


Number

T - Continued

Telescoping Magnet ................................................................................................................................ 7-9, F7-14Tensiometer..................................................................................................................................................... F7-4Tensiometer Reading in Pounds, Conversion of............................................................................................... F7-6Tensiometer, Cable............................................................................................................................................ 7-3Tensiometer, Using a ....................................................................................................................................... F7-5Testing of Torque Tools ..................................................................................................................................... 8-7Thickness Gauge .................................................................................................................................. 3-17, F3-70Thread Chasers................................................................................................................................... 4-19, F4-106Thread Gauge................................................................................................................................................ F3-52Thread Gauges ................................................................................................................................................ 3-13Three-Jaw Chuck and Chuck Key..................................................................................................................... F6-3Three-Prong Grounded Plug ............................................................................................................................ F6-1Tightening Preload Washers .......................................................................................................................... F8-33Tightening to 15-Degree Wrench Arc ............................................................................................................. F8-24Tightening to 30-Degree Wrench Arc ............................................................................................................. F8-27Tightening to 60- or 120-Degree Wrench Arc ................................................................................................. F8-26Tightening to 90- or 180-Degree Wrench Arc ................................................................................................. F8-28Tinner's Mallet.................................................................................................................................................. F4-9Tolerances

Ring Gauges.................................................................................................................................. 3-15, T3-1Snap Gauges.......................................................................................................................................... T3-2

Tool Boxes......................................................................................................................................................... 2-9Tool Care ........................................................................................................................................................... 2-3Tool Safety ........................................................................................................................................................ 2-7Tool Selection ......................................................................................................................................................24Tool Selection ................................................................................................................................................. 10-2fTool Use ............................................................................................................................................................ 2-6Tool, Double Flaring..................................................................................................................................... F4-122Tool, Individual Flaring Tool......................................................................................................................... F4-121Tool, Tube Bending.......................................................................................................................................... 4-26Tools, Combination Flaring .......................................................................................................................... F4-120Tools, Flaring ................................................................................................................................................... 4-25Tools, Pneumatic ............................................................................................................................................... 5-1Tools, Soldering .................................................................................................................................... F7-22, 7-16Torque Multiplier Power Wrench ........................................................................................................... 8-10, F8-23Torque Multiplier, General Use....................................................................................................................... F8-21Torque Multiplier, Hub Nut ............................................................................................................................. F8-22Torque Multipliers .............................................................................................................................................. 8-9Torque Procedures Without a Torque Wrench ................................................................................................. 8-11Torque Tool Accuracy Limits............................................................................................................................ T8-1Torque Tools, Care of ........................................................................................................................................ 8-6

Index 124

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VOLUME 9


Number

T - Continued

Torque Tools, Testing of .................................................................................................................................... 8-7Torque Tools, Types of ...................................................................................................................................... 8-2Torque Value, Determining Correct .................................................................................................................... 8-4Torque Values, Recommended ........................................................................................................................ T8-2Torque Wrench Attachment - Offset Reverse Extension ................................................................................ F8-17Torque Wrench Attachment, Angle Extension ................................................................................................ F8-20Torque Wrench Attachments, Concentric ....................................................................................................... F8-15Torque Wrench Operation and Use.................................................................................................................... 8-5Torque Wrench Selection................................................................................................................................... 8-3Torque Wrench - Deflecting Beam with Indicating Dial (Direct Reading with

Audible Signal), Type I, Class 2, Style B................................................................................................. F8-8Torque Wrench - Deflecting Beam with Indicator Plate (Direct Reading with

Feel Impulse and Audible Signal), Type I, Class 1, Style B ..................................................................... F8-6Torque Wrench - Deflecting Beam with Indicator Plate (Direct Reading),

Type I, Class 1, Style A .......................................................................................................................... F8-5Torque Wrench - Rigid Case with Indicator Dial (Direct Reading) Type II, Style A............................................ F8-9Torque Wrench - Rigid Case with Indicator Dial, Presetting Torque Dial

(Direct Reading with Audible Signal),Type II, Style B............................................................................ F8-10Torque Wrench - Rigid Case with Presetting Dial (Direct Reading with

Flashlight Signal), Type II, Style C........................................................................................................ F8-11Torque Wrench - Rigid Case, Micrometer-Style Torque Presetting, Audible

Signal, Plain Head Type Ill, Class 1 ...................................................................................................... F8-12Torque Wrench - Rigid Case, Micrometer-Style Torque Presetting,

Audible Signal, Ratchet Reversible Head, Type III, Class 2 .................................................................. F8-13Torque Wrench - Rigid Case, Preset Torque, Audible Signal, Type V ............................................................ F8-14Torque Wrench, Audible-Indicating .................................................................................................................. F8-4Torque Wrench, Deflecting Beam .................................................................................................................... F8-2Torque Wrench, Nonconcentric Attachments to.............................................................................................. F8-16Torque Wrench, Rigid Frame........................................................................................................................... F8-3Torque Wrenches - Deflecting Beam with Indicating Dial (Direct Reading),

Type I, Class 2, Style A .......................................................................................................................... F8-7

Index 125

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VOLUME 9


Number

T - Continued

Tow Vehicle, Type MB-4 ................................................................................................................................ F9-21Towbar........................................................................................................................................................... F9-16Trailer, Engine ............................................................................................................................................... F9-12Trammel ........................................................................................................................................................ F3-30Transfer Calipers............................................................................................................................................ F3-26Transfer Punch .............................................................................................................................................. F4-63Triangular File................................................................................................................................................ F4-68Tripod Jack, 3-Ton ........................................................................................................................................... F9-9Tripod Jack, 5-Ton ........................................................................................................................................... F9-8Tripod Jack, 12-Ton ......................................................................................................................................... F9-7Tube Beading Tool.............................................................................................................................. 4-26, F4-123Tube Bender ................................................................................................................................................ F4-117Tube Benders................................................................................................................................................... 4-24Tube Cutter, Cutting Tube............................................................................................................................ F4-116Tube Cutters ................................................................................................................................................ F4-115Tube Cutters, Pipe and .................................................................................................................................... 4-23Tube, Bending.............................................................................................................................................. F4-118Tubing, Beading Large ................................................................................................................................. F4-124Turnbuckle Wrench................................................................................................................................... 7-4, F7-8Type I, Class 1, Style A Torque Wrench - Deflecting Beam with Indicator Plate

(Direct Reading) ..................................................................................................................................... F8-5Type I, Class 1, Style B Torque Wrench - Deflecting Beam with Indicator

Plate (Direct Reading and Feel Impulse and Audible Signal) .................................................................. F8-6Type I, Class 2, Style A Torque Wrenches - Deflecting Beam with

Indicating Dial (Direct Reading) .............................................................................................................. F8-7Type I, Class 2, Style B Torque Wrench - Deflecting Beam with Indicating

Dial (Direct Reading with Audible Signal)................................................................................................ F8-8Type II Style A Torque Wrench - Rigid Case with Indicator Dial (Direct Reading) ............................................. F8-9Type II, Style B Torque Wrench - Rigid Case with Indicator Dial, Presetting

Torque Dial (Direct Reading with Audible Signal).................................................................................. F8-10Type II, Style C Torque Wrench - Rigid Case with Presetting Dial

(Direct Reading with Flashlight Signal).................................................................................................. F8-11Type III, Class 1 Torque Wrench Rigid Case, Micrometer-Style Torque

Presetting, Audible Signal, Plain Head.................................................................................................. F8-12Type III, Class 2 Torque Wrench - Rigid Case, Micrometer-Style Torque

Presetting, Audible Signal, Ratchet Reversible Head............................................................................ F8-13Type B-1 Maintenance Platform....................................................................................................................... F9-1Type B-4A, Maintenance Stand........................................................................................................................ F9-2Type D5B Hydraulic Test Stand ....................................................................................................................... F9-5

Index 126

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VOLUME 9


Number

T - Continued

Type MB-4 Tow Vehicle ................................................................................................................................. F9-21Type V Torque Wrench - Rigid Case, Preset Torque, Audible Signal ............................................................. F8-14Types of Ground Support Equipment ................................................................................................................. 9-9Types of Tools Used in Army Aviation................................................................................................................ 2-2Types of Torque Tools ....................................................................................................................................... 8-2Typical Air Compressors ................................................................................................................................ F9-14Typical Aircraft Pre-Heater............................................................................................................................. F9-15Typical Cable Rigging Tension Chart ............................................................................................................... F7-7Typical Cranes and Hoists.............................................................................................................................. F9-18Typical Drill Bit............................................................................................................................................... F4-83Typical Height Gauge..................................................................................................................................... F3-51Typical Paint Gun............................................................................................................................................. F5-1Typical Rule ..................................................................................................................................................... F3-9Typical Tapes................................................................................................................................................... F3-8Typical Tool Boxes........................................................................................................................................... F2-1

U

Use of Tap Extractor .................................................................................................................................... F4-110Using a Bench Vise ........................................................................................................................................ F4-54Using a Crowfoot Wrench .............................................................................................................................. F7-21Using a File Handle........................................................................................................................................ F4-75Using a Tensiometer ........................................................................................................................................ F7-5Using a Thickness Gauge............................................................................................................................... F3-71Using a Vernier Depth Gauge......................................................................................................................... F3-50Using Carnage Clamp .................................................................................................................................... F4-56Using Deicer Boot Pliers ................................................................................................................................ F7-17Using Deicer Boot Roller ................................................................................................................................ F7-19Using Drill Grinding Gauge............................................................................................................................. F4-89Using Fillet and Radius Gauges ..................................................................................................................... F3-74Using Inside Micrometer................................................................................................................................. F3-38Using Inside Micrometer with Extension Rod.................................................................................................. F3-40Using Leather Punch...................................................................................................................................... F7-18Using Offset Screwdriver ............................................................................................................................... F4-18Using Outside Micrometer.............................................................................................................................. F3-39Using Ring Gauges ........................................................................................................................................ F3-58Using Thread Gauges .................................................................................................................................... F3-53Usual Cutting Edge and Heel Angles.............................................................................................................. F4-86

Index 127

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VOLUME 9


Number

V

V-Grooves in Drill Jaws.................................................................................................................................. F4-82Vacuum Cleaner, Pneumatic.............................................................................................................................. 5-6Valve Repair Tool ................................................................................................................................... 7-6, F7-10Valve Stem Fishing Tool ........................................................................................................................... 7-5, F7-9Vernier Caliper ............................................................................................................................................... F3-29Vernier Caliper, Operation of.......................................................................................................................... F3-31Vernier Caliper, Reading a Measurement on a ............................................................................................... F3-32Vernier Depth Gauge ..................................................................................................................................... F3-49Vernier Depth Gauge, Using a........................................................................................................................ F3-50Vertical Fan, Nozzle Position to Produce.......................................................................................................... F5-3Vise, Bench.................................................................................................................................................... F4-53Vise-Grip Pliers .............................................................................................................................................. F4-47

W

Washer on a Bolt, Installation of Preload........................................................................................................ F8-32Washers on a Stud, Installation of Preload..................................................................................................... F8-31Washers, Action of Preload Indicating............................................................................................................ F8-30Washers, Preload Indicating........................................................................................................................... F8-29Washers, Tightening Preload ......................................................................................................................... F8-33Water Pump Pliers......................................................................................................................................... F4-46Wedge, Installing Wooden ............................................................................................................................. F4-12Wing Divider .................................................................................................................................................. F3-22Wire Gauge, Sheet Metal and ............................................................................................................... 3-18, F3-72Wire, Cutting................................................................................................................................................ F4-112Wrench Arc, Alternate Method for Tightening to 15 Degree............................................................................ F8-25Wrench Arc, Tightening to 15-Degree ............................................................................................................ F8-24Wrench Arc, Tightening to 30-Degree ............................................................................................................ F8-27Wrench Arc, Tightening to 60- or 120-Degree ................................................................................................ F8-26Wrench Arc, Tightening to 90- or 180-Degree ................................................................................................ F8-28Wrench Jaw Offset, Open-End....................................................................................................................... F4-21Wrench, Adjustable........................................................................................................................................ F4-25

Index 128

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VOLUME 9


Number

W - Continued

Wrench, Adjustable Hook Spanner................................................................................................................. F4-39Wrench, Combination .................................................................................................................................... F4-24Wrench, Crowfoot .......................................................................................................................................... F7-20Wrench, Face Pin Spanner ............................................................................................................................ F4-38Wrench, Hook Spanner. ................................................................................................................................. F4-36Wrench, Open-End ........................................................................................................................................ F4-20Wrench, Pin Spanner ..................................................................................................................................... F4-37Wrench, Torque Multiplier Power ..................................................................................................................... 8-10Wrench, Turnbuckle.................................................................................................................................. 7-4, F7-8Wrench, Use of Box-End................................................................................................................................ F4-33Wrench, Use of Open-End ............................................................................................................................. F4-32Wrench, Use of Socket .................................................................................................................................. F4-34Wrenches........................................................................................................................................................... 4-4Wrenches, Box-End ....................................................................................................................................... F4-22Wrenches, Crowfoot......................................................................................................................................... 7-20Wrenches, Proper Procedure for Pulling Adjustable ....................................................................................... F4-35Wrenches, Tap............................................................................................................................................. F4-103

Index 129/(Index 130 blank)

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VOLUME 10


Number

A

Abrasion Resistance...........................................................................................................................................5-2lAcceptability Limits, Rivet .............................................................................................................................. F7-22Acceptable Spotweld Spacing .........................................................................................................................12-6aAccess Door, Flush .......................................................................................................................................... F8-8Acrylic Plastic, Minimum Annealing Time....................................................................................................... T10-4Acrylic Plastics, Drill for.................................................................................................................................. F10-3Acrylic Plastics, Oven Temperatures for......................................................................................................... T10-1Addition of Weights.........................................................................................................................................11-4cAdhesives and Resins ........................................................................................................................................ 9-4

Application.............................................................................................................................................. 9-4eCombination or Two-Step Adhesives ...................................................................................................... 9-4bHigh-Temperature Setting Adhesives...................................................................................................... 9-4aRoom Temperature Setting Adhesives.....................................................................................................9-4cStorage................................................................................................................................................... 9-4d

After Deburring............................................................................................................................................... F7-50Aging Time and Temperature (Aluminum Alloys) .............................................................................................. 5-7fAircraft Mating Jig ............................................................................................................................................ F8-1Aircraft Metals, Shaping ..................................................................................................................................... 6-2Aircraft Plastics, General.................................................................................................................................. 10-1Aircraft Structures, General................................................................................................................................ 4-1Airframe Sheet Metal Repair, General................................................................................................................ 8-1Airframe Sheet Metal, Basic Principles of Repair ............................................................................................... 8-2Airplane Structural Parts .................................................................................................................................. F4-5Airplanes (Fuselage) ........................................................................................................................................ 4-2bAlclad Alloys, Reheat Treatment of ................................................................................................................ T5-12Alclad Construction .......................................................................................................................................... F5-8Allowable Percentage of Defective Spotwelds.................................................................................................12-6bAllowance, Bend, 90-Degree Bend................................................................................................................... F6-3Allowance, Bend, Table.................................................................................................................................... T6-1Alloy Characteristics and Uses (Aluminum) ...................................................................................................... 5-7bAlloying ............................................................................................................................................................ 5-4aAlloying Elements (for Steel)............................................................................................................................ 5-6bAlloying Elements, Major.................................................................................................................................. T5-5Alloys, Aluminum ............................................................................................................................................... 5-7Alloys, Copper.................................................................................................................................................. 5-10Alloys, Magnesium............................................................................................................................................. 5-8Alloys, Metals and.............................................................................................................................................. 5-4Alloys, Titanium ................................................................................................................................................. 5-9Alternate Transparent Plastic Plug Repair .....................................................................................................10-13bAluminum Alloy Designations and Conversions to 4 Digit System .................................................................... T5-6Aluminum Alloy Facing Material ....................................................................................................................... 9-3aAluminum Alloy Rivets, Single Shear, Strength of............................................................................................ T7-2Aluminum Alloy Sheet Substitution.....................................................................................................................5-7i

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Number

A - Continued

Aluminum Alloy, Hardness Conversion for ..................................................................................................... F5-16Aluminum and Aluminum Alloys......................................................................................................................... 5-7

Aging Time and Temperature .................................................................................................................. 5-7fAlloy Characteristics and Uses................................................................................................................ 5-7bAluminum Alloy Sheet Substitution ...........................................................................................................5-7iCorrosion Resistance...............................................................................................................................5-7cHeat-Treatment Methods ........................................................................................................................ 5-7eHeat-Treating Procedures....................................................................................................................... 5-7gIdentification ........................................................................................................................................... 5-7aInsulation of Dissimilar Metals ................................................................................................................ 5-7hMaterial Substitution .................................................................................................................................5-7jShop Working Practice ........................................................................................................................... 5-7d

Aluminum, Bare, Sheet, Plate, Extrusions, and Forgings, Rockwell Hardness Values for ............................... T5-21Aluminum Identification Marking Example........................................................................................................ F5-7Aluminum Lockbolt Rivet Gun, Pull- and Blind-Type ...................................................................................... F7-73Aluminum Sheet and Plate, 0.050 Inch Minimum, Rockwell Hardness Values for........................................... T5-20Aluminum, Model B, Hardness Range............................................................................................................ F5-13Aluminum-Alloy Sheet Substitution ................................................................................................................ T5-14Annealing......................................................................................................................................................10-10cApplication (of Adhesives and Resins) ............................................................................................................. 9-4eApproved Edge Attachment for Laminated Enclosure................................................................................... F10-19Approved Edge Attachment for Monolithic Enclosure ................................................................................... F10-18Ashing...........................................................................................................................................................10-14bAssembling (Joined Plastics)...........................................................................................................................10-9hAssembly Tools, Cherry ................................................................................................................................. F7-45Assembly, Empennage .................................................................................................................................. F4-14Automatic Center Punch ................................................................................................................................ F3-18Aviation Snips ........................................................................................................................................ 3-4f, F3-12

B

Balance Considerations, Surface...................................................................................................................... 11-2Balanced and Unbalanced Conditions ............................................................................................................ F11-4Balancing Jig, Field-Expedient ....................................................................................................................... F11-6Balancing Principles......................................................................................................................................... 11-3

Effects of Moments................................................................................................................................11-3aEffects of Weight and Distance..............................................................................................................11-3b

Band Saw......................................................................................................................................................... 3-5dBand Saw, Contour ........................................................................................................................................ F3-27Bandsaw Widths for Various Radii of Cuts (of Plastic).................................................................................... T10-3Bar Folding Machine ............................................................................................................................. 3-6a, F3-31Bars, Bucking................................................................................................................................................... F7-6Basic Part Numbers, Jo-Bolt .......................................................................................................................... F7-81Basic Principles of Repair (of Airframe Sheet Metal) .......................................................................................... 8-2

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Number

B - Continued

Brake or Sight Line of Flange, Locating.......................................................................................................... F6-10Brake, Cornice ............................................................................................................................................... F3-32Brass and Mild Steel, Hardness Conversion for.............................................................................................. F5-15Bucking Bar Weights, Recommended .............................................................................................................. T7-6Bucking Bars.................................................................................................................................................... F7-6Buckles, Working Out .................................................................................................................................... F6-17Bulkhead and Skin Repair .............................................................................................................................. F8-28Bulkhead Flanged Member Repairs ............................................................................................................... F8-26Bulkhead Installation ...................................................................................................................................... F4-18Bulkhead Repair.................................................................................................................................................8-9iBulkheads, Frames, and Formers..................................................................................................................... 4-8aBumping .......................................................................................................................................................... 6-4aBumping Block............................................................................................................................................... F6-26Bumping, Sandbag......................................................................................................................................... F6-29Burning (of Plastics) ........................................................................................................................................10-4bBurrs After Drilling.......................................................................................................................................... F7-49

C

Cabin and Tail Cone Sections .......................................................................................................................... F4-4Calculation Method (of Balancing).................................................................................................................. F11-8Camlock Fastener ........................................................................................................................................ F7-107Camlock Fasteners .........................................................................................................................................7-15bCamlock Punch, Use of................................................................................................................................ F7-109Camlock Stud Installation............................................................................................................................. F7-112Capacity, Tool, Chart (for Rivets) ................................................................................................................... T7-14Catcher Bag, Stem 670A20............................................................................................................................ F7-44Cemented Assemblies, Jigs for Holding ......................................................................................................... F10-9Cemented Joint, Effect of Heat Treating on a............................................................................................... F10-10Cemented Plastic Joint ................................................................................................................................. F 10-4Cementing Procedures..................................................................................................................................... 10-9

Assembling............................................................................................................................................10-9hDirect Application Method......................................................................................................................10-9dFitting ....................................................................................................................................................10-9eGlue Method..........................................................................................................................................10-9cJigs.........................................................................................................................................................10-9iMasking ................................................................................................................................................. 10-9fSoak Method .........................................................................................................................................10-9bSoaking .................................................................................................................................................10-9gType of Cement.....................................................................................................................................10-9a

Center Punch ................................................................................................................................................. F3-17Center Punch for Drilling ................................................................................................................................ F7-15Center Punch, Automatic ............................................................................................................................... F3-18Centering Inner Sleeve in Steel Tube............................................................................................................. F8-68

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Number

C - Continued

Chamfered Flanging Block ............................................................................................................................. F6-32Channel Repair by Insertion ........................................................................................................................... F8-30Channel Repair by Patching........................................................................................................................... F8-29Channel, Sample ............................................................................................................................................. F6-6Characteristics (of Aircraft Plastics).................................................................................................................. 10-2Characteristics (of Titanium Alloys) .................................................................................................................. 5-9bChart, Setback - K -.......................................................................................................................................... T6-2Chem-Milled Skin Repair ........................................................................................................................ 8-6k, F8-2Chem-Milling.................................................................................................................................................... 6-2bChemical Composition (Copper Alloys) by Trade Name ................................................................................. T5-16Chemical Reaction (of Plastics).......................................................................................................................10-4eCherry Assembly Tools .................................................................................................................................. F7-45Cherry Grip Gauge 269C3, Use of.................................................................................................................. F7-36CherryMax Blind Heads, Typical .................................................................................................................... F7-53CherryMAX Cross Reference (Part Number/Military Standard Part Number) .................................................... T7-9CherryMAX Drilling Dimensions ..................................................................................................................... T7-15CherryMAX Inspection...................................................................................................................................... 7-8eCherryMAX Installation..................................................................................................................................... 7-8dCherryMAX Part Number Breakdown ............................................................................................................. T7-10CherryMAX Removal ....................................................................................................................................... 7-8gCherryMAX Removal ..................................................................................................................................... F7-55CherryMAX Rivet ........................................................................................................................................... F7-31CherryMAX Rivets.............................................................................................................................................. 7-8

CherryMAX Inspection ............................................................................................................................ 7-8eCherryMAX Installation ........................................................................................................................... 7-8dCherryMAX Removal .............................................................................................................................. 7-8gCherryMAX Tooling .................................................................................................................................7-8cCherryMAX Troubleshooting .................................................................................................................... 7-8fIdentification ........................................................................................................................................... 7-8aSelection ................................................................................................................................................ 7-8b

CherryMAX Rivet Shaving ............................................................................................................................. F7-51CherryMAX Sleeve Stretch Marks .................................................................................................................. F7-54CherryMAX Stem and Collar Flushness.......................................................................................................... F7-52CherryMAX Tooling...........................................................................................................................................7-8cCherryMAX Troubleshooting .................................................................................................................. 7-8f, T7-17CherryMAX, Countersinking Dimensions for................................................................................................... F7-46Circle Snips........................................................................................................................................... 3-4h, F3-14Circular Damage Repair for Lightly Stressed Areas........................................................................................ F8-46Circular Damage Repair in Heavily Stressed Area ......................................................................................... F8-51Circular External Repair ........................................................................................................................ 8-8b, F8-11Clamp Pliers .................................................................................................................................................... F3-9Classification of Damage (to Sandwich Construction)......................................................................................... 9-5

Coin-Tapping Technique......................................................................................................................... 9-5aDents...................................................................................................................................................... 9-5e

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Number

C - Continued

Double Skin Damage.............................................................................................................................. 9-5hLarge Single Skin Damage ..................................................................................................................... 9-5gMissing Core........................................................................................................................................... 9-5bScotchply Edge Member and Corfil Edge Filler Damage...........................................................................9-5iSkin Core Voids.......................................................................................................................................9-5cSkin Doubler Voids ................................................................................................................................. 9-5dSmall Single Skin Damage ...................................................................................................................... 9-5fUnbonding and Ply Separation..................................................................................................................9-5j

Class I Damage (of Fiber Laminate)............................................................................................................... F9-19Class I Repair (of Radomes) ..............................................................................................................................9-9iClass II Damage (of Fiber Laminate).............................................................................................................. F9-20Class II or Class III Repair to Plastic with Fluted Core ..................................................................................... 9-9mClass II or Class III Repair to Plastic with Foamed-In Core .................................................................................9-9lClass II Repair (of Radomes) .............................................................................................................................9-9jClass II Repair (of Radomes), Typical Scarf Method for ................................................................................. F9-26Class III Damage (of Fiber Laminate)............................................................................................................. F9-21Class III Repair (of Radomes) ...........................................................................................................................9-9kClasses of Repair (of Fiber Laminate) ...............................................................................................................9-9cClassification of Damage (Impregnated Glass Cloth Parts) .............................................................................. 9-8aClassification, of Damage (Airframe Sheet Metal Repair)................................................................................... 8-5Cleaning (of Glass Windshields) ...................................................................................................................10-17bCleaning (Plastic Enclosures)........................................................................................................................10-15aCleanliness of Repair Area............................................................................................................................... 9-6aCleco Fastener................................................................................................................................................. F3-7Cleco Fasteners Pliers ..................................................................................................................................... F3-8Codes, Color (for Aluminum)............................................................................................................................ T5-7Coin Dimpling ................................................................................................................................................ F7-10Coin-Tapping Technique .................................................................................................................................. 9-5aCold Climate Precautions.............................................................................................................................10-1 5eCold Forming (of Plastics)...............................................................................................................................10-7aCold-Working ....................................................................................................................................................5-5cCollar Numbering System, Lockbolt ............................................................................................................... T7-25Color Codes (for Aluminum)............................................................................................................................. T5-7Combination or Two-Step Adhesives................................................................................................................ 9-4bCommonly Used Alloys (Magnesium)............................................................................................................... 5-8bCompleted Double Face Patch Repair ........................................................................................................... F9-27Compression.................................................................................................................................................... F5-2Compressive Strength.......................................................................................................................................5-2cConcave Flange, Forming a ........................................................................................................................... F6-24Conductivity .................................................................................................................................................... 5-2mConstruction (Sandwich) .................................................................................................................................. 9-1aConstruction Materials (Fuselage) .....................................................................................................................4-2cConstruction, Alclad ......................................................................................................................................... F5-8Construction, Monocoque................................................................................................................................. F4-1

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Number

C - Continued

Construction, Rib............................................................................................................................................ F4-13Construction, Semi-Monocoque ....................................................................................................................... F4-2Construction, Spar ......................................................................................................................................... F4-12Consumable Materials........................................................................................................................................ 1-3Contour Band Saw ......................................................................................................................................... F3-27Contraction and Expansion Allowances (for Transparent Plastics).................................................................. T10-5Control Surface, Establishing Neutral Position of............................................................................................ F11-7Control Surfaces, Flight........................................................................................................................... 4-7, F4-16Control Surface Static Balance....................................................................................................................... F11-1Conversions to 4 Digit System, Aluminum Alloy Designations and ................................................................... T5-6Convex Flange, Forming a............................................................................................................................. F6-25Copper and Copper Alloys................................................................................................................................ 5-10

Identification ..........................................................................................................................................5-10aMajor Alloying Elements ........................................................................................................................5-10b

Copper, Model BB-75, Hardness Range......................................................................................................... F5-14Core Materials.................................................................................................................................................... 9-2

Foamed-In-Place Core Materials .............................................................................................................9-2cFoamed or Cellular Core Materials ......................................................................................................... 9-2bHoneycomb Core Materials..................................................................................................................... 9-2dNatural Core Materials ............................................................................................................................ 9-2a

Cornice Brake ....................................................................................................................................... 3-6b, F3-32Correcting Oval Shaped Steel Tubing Distortion ............................................................................................ F8-63Correctly and Incorrectly Driven Rivets ................................................................................................. 7-5a, F7-20Corrosion ......................................................................................................................................................... 8-3aCorrosion Resistance (of Aluminum Alloys).......................................................................................................5-7cCorrosion Resistance ........................................................................................................................................5-2kCorrosion Treatment ........................................................................................................................................ 8-6hCountersink, Standard...................................................................................................................................... F7-7Countersink, Stop............................................................................................................................................. F7-8Countersinking Dimensions (100 Degrees) for CherryMAX............................................................................. F7-46Countersinking ............................................................................................................................................... F7-17Countersinking Practices................................................................................................................................ F7-18Countersinking, Incorrect................................................................................................................................ F7-47Countersinks .......................................................................................................................................... 3-4i, F3-15Countersinks for Shaving, Recommended...................................................................................................... T7-16Countersunk Head Nominal Diameter CherryMAX Rivet ................................................................................ F7-32Countersunk Head Oversize Diameter, CherryMAX Rivet .............................................................................. F7-34Countersunk Head Rivet, Removal of ............................................................................................................ F7-24Countersunk-Head Rivet Removal ................................................................................................................... 7-6bCrack or Scratch Repair ................................................................................................................................... F9-5Crack Repair for Lightly Stressed Areas ......................................................................................................... F8-47Cracking, Rivet Head ..................................................................................................................................... F7-21Cracks (in Plastics) .......................................................................................................................................10-12d

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Number

D - Continued

Damage, Class III (of Fiber Laminate)............................................................................................................ F9-21Damaged Face Plies, Removal of, by Scarf Method ...................................................................................... F9-25Damaged Honeycomb Skin.............................................................................................................................. F9-1Damaged Swage in Aileron and Flap Skin, Patch Repair to............................................................................ F8-58Deburring, After.............................................................................................................................................. F7-50Deep Scratches, Sanding............................................................................................................................. F10-11Delamination and Discoloration.....................................................................................................................10-12eDent at a Steel Tube Cluster Joint, Reinforcing a ........................................................................................... F8-65Dent or Crack, Sharp, in Length of Steel Tubing, Repair of ............................................................................ F8-66Dents (in Sandwich Construction)..................................................................................................................... 9-5eDents and Creases, Repair of......................................................................................................................... F8-32Design (Sandwich Construction)...................................................................................................................... 9-1 bDetermining Rivnut Grip Length ..................................................................................................................... F7-57Die, Joggling .................................................................................................................................................. F6-30Dimensions, Drill Bit....................................................................................................................................... F7-16Dimpling and Reaming................................................................................................................................... F7-48Dimpling........................................................................................................................................................... F7-9Dimpling, Coin ............................................................................................................................................... F7-10Direct Application Method (Cementing) ...........................................................................................................10-9dDouble Face Patch Repair, Completed .......................................................................................................... F9-27Double Row of Rivets, Rivet Spacing for Repair with ..................................................................................... F8-42Double Skin Damage ....................................................................................................................................... 9-5hDouble Skin Repair (Flush) ............................................................................................................................ F9-10Double Skin Repair (Nonflush) ....................................................................................................................... F9-11Drill Angle for Stainless Steel ........................................................................................................................... F6-1Drill Bit Dimensions........................................................................................................................................ F7-16Drill for Acrylic Plastics................................................................................................................................... F10-3Drill Press ...................................................................................................................................................... F3-29Drill Sizes for Various Diameter Rivets............................................................................................................. T7-4Drill Sizes, Hole and, for Self-Plugging (Friction Lock) Rivets........................................................................... T7-8Drilling (for Olympic Blind Rivets) ...................................................................................................................7-11dDrilling (Plastics) ............................................................................................................................................. 10-8fDrilling Dimensions, CherryMAX .................................................................................................................... T7-15Drilling Material .............................................................................................................................................. F7-68Drilling Procedures for Blind-Type Lockbolts .................................................................................................. T7-30Drilling Procedures for Pull- and Stump-Type Lockbolts ................................................................................. T7-29Drilling Spotwelds............................................................................................................................................. 12-2Drilling, Burrs After......................................................................................................................................... F7-49Drilling, Center Punch for ............................................................................................................................... F7-15Drills and Drill Presses ..................................................................................................................................... 3-5eDrive Punch ................................................................................................................................................... F3-19Driving Hi-Shear Rivet ................................................................................................................................... F7-63Ductility............................................................................................................................................................. 5-2f

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Number

D - Continued

Duplicating Patterns ......................................................................................................................................... 6-3gDynamic Balance ............................................................................................................................................11-2bDzus Fastener (Stud, Grommet, and Receptacle) .......................................................................................... F7-95Dzus Fastener (Stud, Grommet, and Receptacle), Installation Tools for ....................................................... F7-104Dzus Fastener (Stud, Grommet, and Spring).................................................................................................. F7-96Dzus Fastener Head Styles ............................................................................................................................ F7-97Dzus Fastener Installation Secondary Procedures........................................................................................ F7-103Dzus Fastener Installation, Wing-Type......................................................................................................... F7-102Dzus Fastener Receptacle, Installation of..................................................................................................... F7-105Dzus Fastener Stud and Grommet, Installation of ........................................................................................ F7-106Dzus Fasteners ...............................................................................................................................................7-15aDzus Fasteners, Installation of Type A-AJ .................................................................................................... F7-100Dzus Fasteners, Installation of Type F-FA-FJ............................................................................................... F7-101Dzus Fasteners, Installation Tools for Type A-AJ and F-FA-FJ....................................................................... F7-98

E

Edge Attachment, Typical Sighting Dome .................................................................................................... F10-20Edge Band Sealing, Typical ........................................................................................................................... F9-29Edge Distance, Rivet........................................................................................................................................ F7-4Edge Preparation, Edge Patch ......................................................................................................................... F8-6Effect of Heat Treating on a Cemented Joint................................................................................................ F10-10Effects of Moments .........................................................................................................................................11-3aEffects of Weight and Distance ........................................................................................................... 11-3b, F11-3Elasticity .......................................................................................................................................................... 5-2dEliminating Gaps and Leveling Installations ........................................................................................ 8-9aa, F8-59Empennage........................................................................................................................................................ 4-6Empennage Assembly ................................................................................................................................... F4-14Enclosure, Laminated, Approved Edge Attachment for................................................................................. F10-19Enclosure, Monolithic, Approved Edge Attachment for ................................................................................. F10-18Enclosures, Acrylic Plastic, Maintenance of on Army Aircraft ..........................................................................10-15Engine Mount (Tubing)....................................................................................................................................8-11aEngine Mount................................................................................................................................................... F4-6Engine Mounts ................................................................................................................................................... 4-3

Maintenance............................................................................................................................................4-3cPiston-Engine Mounts............................................................................................................................. 4-3aTurbine-Engine Mounts........................................................................................................................... 4-3b

Equipment, Shop (Sheet Metal) .................................................................................................................. 2-2, 3-1Establishing Neutral Position of a Control Surface.......................................................................................... F11-7Example of Structural Tubing......................................................................................................................... F8-62Expansion and Contraction Allowances (for Transparent Plastics).................................................................. T10-5Expansion and Contraction Allowances (of Transparent Plastics) ..................................................................10-16bExternal and Internal Repairs ............................................................................................................................. 8-9External Repair, Circular ................................................................................................................................ F8-11

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Number

F

Face Plies, Replacing .................................................................................................................................... F9-24Facing Materials................................................................................................................................................. 9-3

Aluminum Alloy Facing Material ............................................................................................................. 9-3aGlass Fiber Mat Facing Material .............................................................................................................. 9-3fMagnesium Alloy Facing Material ............................................................................................................9-3cPlywood Facing Material......................................................................................................................... 9-3dResin-Impregnated Glass Cloth Facing Material ..................................................................................... 9-3eSteel Facing Material .............................................................................................................................. 9-3b

Factors in Determining Rivet Length ................................................................................................................ F7-3Failure, Spotweld ............................................................................................................................................. 12-4Failure, Spotweld, with No Skin Breaks ............................................................................................................ 12-5Fastener, Camlock ....................................................................................................................................... F7-107Fastener, Cleco................................................................................................................................................ F3-7Fastener, Dzus (Stud, Grommet, and Receptacle) ......................................................................................... F7-95Fastener, Dzus (Stud, Grommet, and Spring)................................................................................................. F7-96Fastener, Dzus, Head Styles .......................................................................................................................... F7-97Fasteners, Hi-Lock ........................................................................................................................................... 7-14Fasteners, Turn-Lock ....................................................................................................................................... 7-15Fiber Laminate Material Repair .......................................................................................................................... 9-9

Blanket and Seals................................................................................................................................... 9-9eClass I Repair ...........................................................................................................................................9-9iClass II Repair ..........................................................................................................................................9-9jClass II or Class III Repair to Plastic with Foamed-In Core........................................................................9-9lClass II or Class III Repair to Plastic with Fluted Core............................................................................ 9-9mClass III Repair ........................................................................................................................................9-9kClasses of Repair ....................................................................................................................................9-9cGeneral Principles of Materials and Repair Procedures .......................................................................... 9-9dGeneral Repair Consideration................................................................................................................. 9-9gGeneral Repair Requirements................................................................................................................. 9-9aInspection after Repair............................................................................................................................. 9-9rMaterials Used in Repair......................................................................................................................... 9-9bParting Films and Compounds................................................................................................................. 9-9fProcedure for Edge Band Sealing........................................................................................................... 9-9qProcedure for Obtaining Void-Free Laminate .......................................................................................... 9-9pProcedure for Preventing Moisture and Oil Contamination...................................................................... 9-9oRepair of Pre-Drilled Attachment Holes .................................................................................................. 9-9nRepair Procedures .................................................................................................................................. 9-9h

Field-Expedient Balancing Jig ........................................................................................................................ F11-6Finishing Procedures.......................................................................................................................................10-14

Ashing .................................................................................................................................................10-14bMachine Buffing...................................................................................................................................10-14cPolishing..............................................................................................................................................10-14dSanding ...............................................................................................................................................10-14a

First Flange, Layout of ..................................................................................................................................... F6-7

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Number

F - Continued

Fishmouth Splice, Steel Tube, Using Large Diameter Replacement Tube ...................................................... F8-70Fitting (Cementing) .........................................................................................................................................10-9eFlanged Member Repair, Bulkhead ................................................................................................................ F8-26Flanging Block, Chamfered............................................................................................................................ F6-32Flat Pattern Layout........................................................................................................................................... 6-3eFlexing (of Plastics).........................................................................................................................................10-4dFlight Control Surfaces............................................................................................................................ 4-7, F4-16Floor Channel Repair ............................................................................................................................ 8-9o, F8-36Floor Repair, Metal-Covered Wooden................................................................................................................ 9-7Flush Access Door ........................................................................................................................................... F8-8Flush Head Jo-Bolts, Grip Ranges, Sizes, and Diameters of .......................................................................... F7-83Flush Patch...................................................................................................................................................... F8-5Flush Patch Repair Procedure.......................................................................................................................... F8-7Flush-Head Jo-Bolt ........................................................................................................................................ F7-78Foamed or Cellular Core Materials................................................................................................................... 9-2bFoamed-In-Place Core Materials.......................................................................................................................9-2cFolding............................................................................................................................................................. 6-4eForces, Stress and Strain ................................................................................................................................... 5-3Forgings, Rockwell ......................................................................................................................................... T5-21Formation of Cushion on Acrylic Plastic by Immersion in Cement .................................................................. F10-5Formed Angle, Stringer Repair with................................................................................................................ F8-17Formed Patch, Rivet Spacing for Repair Using .............................................................................................. F8-43Formed Sections (of Stored Plastics) ..............................................................................................................10-5dFormer and Frame Installation ....................................................................................................................... F4-17Former Repair....................................................................................................................................... 8-9h, F8-25Former Repair, Bonded (Cap) ........................................................................................................................ 037r,3n 0.0072 9...General........ TDringer Repair with................................................................................................................................5-341........ 1....00Aircraft Me028 Sections 2TD 0.nger Repair with....................................................................................................... 9 Tj 92.16 0 55 (...)6-2a71.28 0 8pair0057 Tc (10-5d) Tj -483.12 -11.52 T Tw a Concave Fla.00ctions 2TD 0.nger Repair with................................................................................................ ............47Tj -483.15 -11.52 T Tw a Convex Fla.00ctions 17.36.nger Repair with................................................................................................037r,3n 0.0072 9... ................................................................

TM 1-1500-204-23-1

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VOLUME 10


Number

F - Continued

Heating for Forming...............................................................................................................................10-7bForming Operations ........................................................................................................................................... 6-4

Bumping ................................................................................................................................................. 6-4aCrimping................................................................................................................................................. 6-4bFolding ................................................................................................................................................... 6-4eShrinking ................................................................................................................................................ 6-4dStretching ................................................................................................................................................6-4c

Forming Procedures, Hand ................................................................................................................................ 6-5Forms (for Plastics).........................................................................................................................................10-7cFrame and Former Installation ....................................................................................................................... F4-17Frame and Nonstressed Skin Repair .............................................................................................................. F8-38Frame and Skin Repair .................................................................................................................................. F8-27Frame and Stringer Joint, Repair of ............................................................................................................... F8-35Friction Lock (Self-Plugging Rivets) ................................................................................................................... 7-7Further Treatment (of Heat-Treated Plastics) ................................................................................................10-10bFuselage ............................................................................................................................................................ 4-2

Airplanes ................................................................................................................................................ 4-2bConstruction Materials .............................................................................................................................4-2cHelicopters ............................................................................................................................................. 4-2a

G

Gauge, Radius ................................................................................................................................................. F3-6General Precautions (Cutting Plastics) ............................................................................................................10-8aGeneral Principles of Materials and Repair Procedures (with Fiber Laminate) .................................................. 9-9dGeneral Repair Consideration (for Radome Repair) ......................................................................................... 9-9gGeneral Repair Practices ................................................................................................................................... 8-6

Chem-Milled Skin Repair .........................................................................................................................8-6kCorrosion Treatment............................................................................................................................... 8-6hDamage Evaluation ................................................................................................................................ 8-6bDamage Removal....................................................................................................................................8-6cRepair Material Selection........................................................................................................................ 8-6dRepair Parts Layout ................................................................................................................................ 8-6eRivet Selection ........................................................................................................................................ 8-6fRivet Spacing and Edge Distance........................................................................................................... 8-6gRiveting ....................................................................................................................................................8-6iStructural Support During Repair ............................................................................................................ 8-6aTolerance .................................................................................................................................................8-6j

General Repair Requirements (Fiber Laminate) ............................................................................................... 9-9aGeneral Shop Rules (Sheet Metal Shop)............................................................................................................ 2-1

Responsibility ......................................................................................................................................... 2-1aShop Housekeeping................................................................................................................................ 2-1bShop Safety.............................................................................................................................................2-1c

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Number

G - Continued

Shop Tools and Materials ....................................................................................................................... 2-1dGeneral, Aircraft Plastics.................................................................................................................................. 10-1General, Aircraft Structures................................................................................................................................ 4-1General, Airframe Sheet Metal Repair................................................................................................................ 8-1General, Forming............................................................................................................................................... 6-1General, Rebalancing Movable Surfaces ......................................................................................................... 11-1General, Rivets and Riveting Techniques........................................................................................................... 7-1General, Sandwich Construction Repair ............................................................................................................. 9-1General, Shop Equipment .................................................................................................................................. 3-1General, Spotwelds .......................................................................................................................................... 12-1General, Structural Metals.................................................................................................................................. 5-1Glass Cloth Repair of Lack-of-Material Damage............................................................................................. F9-18Glass Cloth Repair of Large Crack or Perforation........................................................................................... F9-17Glass Cloth Repair of Small Crack ................................................................................................................. F9-16Glass Fiber Mat Facing Material........................................................................................................................ 9-3fGlass Windshields...........................................................................................................................................10-17

Cleaning ..............................................................................................................................................10-17bInspection ............................................................................................................................................10-17aRemoval and Installation .....................................................................................................................10-17c

Glue Method ...................................................................................................................................................10-9cGrinder, Bench............................................................................................................................................... F3-30Grinding and Sanding Machines........................................................................................................................ 3-5fGrip Lengths for Solid Shank Rivets................................................................................................................. T7-1Grip Lengths, Hi-Lok ...................................................................................................................................... F7-90Grip Lengths, Jo-Bolts.................................................................................................................................... F7-82Grip Range (CherryMAX Rivets) .................................................................................................................... T7-11Grip Range (Olympic Blind Rivets)..................................................................................................................7-11bGrip Range for Blind-Type Lockbolts.............................................................................................................. T7-27Grip Range for Olympic Rivets....................................................................................................................... T7-20Grip Range for Pull- and Stump-Type Lockbolts............................................................................................. T7-26Grip Ranges, Sizes, and Diameters of Flush Head Jo-Bolts ........................................................................... F7-83Grip Ranges, Sizes, and Diameters of Hex Head Jo-Bolts.............................................................................. F7-84Grip Ranges, Sizes, and Diameters of Millable Hex Head Jo-Bolts................................................................. F7-85

H

Hammers, Peening with ............................................................................................................................... F7-110Hand Forming Procedures ................................................................................................................................. 6-5

Curving Formed or Extruded Angles ....................................................................................................... 6-5bForming by Bumping .............................................................................................................................. 6-5eForming Curved Flanged Parts ............................................................................................................... 6-5dForming Flanged Angles..........................................................................................................................6-5c

Index 144

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Number

H - Continued

Joggling .................................................................................................................................................. 6-5fLightening Holes .................................................................................................................................... 6-5hRelief Holes ..........................................................................................................................................6-59gStraight Line Bends . .............................................................................................................................. 6-5a

Hand Router Template for Milling Plug Cavity.............................................................................................. F10-15Hand Shears ......................................................................................................................................... 3-4d, F3-10Hand Tools (for Riveting) ................................................................................................................................ 7-4aHand-Type Tester, Webster ........................................................................................................................... F5-10Handling and Storage (of Plastics) .................................................................................................................. 10-5Hand Tools and Devices ................................................................................................................................... 3-4

Aviation Snips ......................................................................................................................................... 3-4fBench Shears ......................................................................................................................................... 3-4eCircle Snips ............................................................................................................................................ 3-4hCountersinks ............................................................................................................................................3-4iForming Blocks .......................................................................................................................................3-4kHand Shears .......................................................................................................................................... 3-4dMicrometers ........................................................................................................................................... 3-4aPunches ..................................................................................................................................................3-4jRadius Gauge......................................................................................................................................... 3-4bSheet Metal Holders ................................................................................................................................3-4cStraight Snips ........................................................................................................................................... 3-4

Hardness Conversion for Aluminum Alloy ...................................................................................................... F5-16Hardness Conversion for Brass and Mild Steel................................................................................................5-13eHardness Conversion for Brass and Mild Steel............................................................................................... F5-15Hardness Range (for Aluminum) .....................................................................................................................5-13cHardness Range (for Copper)..........................................................................................................................5-13dHardness Range, Aluminum, Model B............................................................................................................ F5-13Hardness Range, Copper, Model BB-75 ........................................................................................................ F5-14Hardness Tester, Rockwell ............................................................................................................................. F5-12Hardness Testing of Metals . ............................................................................................................................ 5-13

Hardness Conversion for Brass and Mild Steel .....................................................................................5-13eHardness Range for Aluminum ..............................................................................................................5-13cHardness Range for Copper ..................................................................................................................5-13dHardness Values for Clad Aluminum Sheet and Plate, and Bare Aluminum Sheet,

Plate, Extrusions, and Forgings .................................................................................................... 5-13fRockwell Hardness Test ........................................................................................................................5-13bWebster Hardness Tester ......................................................................................................................5-13a

Hardness Values, Rockwell, for 0.050 Inch Minimum Thickness Class Aluminum Sheet and Plate ................ T5-20Hardness Values, Rockwell, for Bare Aluminum Sheet, Plate, Extrusions, and Forgings ................................ T5-21Hardness Values for Clad Aluminum Sheet and Plate, and Bare Aluminum Sheet,

Plate, Extrusions, and Forgings .................................................................................................... 5-13fHardness ...........................................................................................................................................................5-2iHat and Longeron Sections ............................................................................................................................ F4-21

Index 145

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H - Continued

Hat Sect ion, Splice Repair of ........................................................................................................................ F8-37Hatch Seal, Typical ....................................................................................................................................... F8-60Head Radius, Hi-Lok ..................................................................................................................................... F7-92Head Types (Jo-Bolts) ....................................................................................................................................7-13aHeat Treating (Soaking) Temperature ........................................................................................................... T5-10Heat Treatment ................................................................................................................................................. 5-5

Cold-Working ..........................................................................................................................................5-5cHot Working .......................................................................................................................................... 5-5bTypes ..................................................................................................................................................... 5-5a

Heat Treatment, Curing and (of Plastics) ........................................................................................................10-10Heat-Treatable Rivet Identification .................................................................................................................. F5-9Heat-Treatment Methods ................................................................................................................................. 5-7eHeat-Treatment Procedures . ........................................................................................................................... 5-7gHeating for Forming (Acrylic Plastics) ............................................................................................................10-7bHeavily Stressed Area, Circular Damage Repair in ........................................................................................ F8-51Heavily Stressed Area, Damage Repair Near Adjacent Member in ................................................................ F8-52Heavily Stressed Area, Insertion Skin Repair Across Stiffeners in .................................................................. F8-53Heavily Stressed Areas, Damage Repair Near Existing Structure in . ............................................................. F8-49Heavily Stressed Areas, Rectangular Damage Repair for .............................................................................. F8-48Helicopter Stabilizer . ..................................................................................................................................... F4-15Helicopters (Fuselage) .................................................................................................................................... 4-2aHex Head Jo-Bolt ........................................................................................................................................... F7-79Hex Head Jo-Bolts, Grip Ranges, Sizes, and Diameters of ............................................................................ F7-84Hi-Lok Fasteners ............................................................................................................................................. 7-14

Hole Preparation ...................................................................................................................................7-14cIdentification .........................................................................................................................................7-14aInspection .............................................................................................................................................. 7-14fInstallation ............................................................................................................................................7-14eRemoval ...............................................................................................................................................7-149Selection ..............................................................................................................................................7-14bTooling .................................................................................................................................................7-14d

Hi-Lok Grip Lengths ...................................................................................................................................... F7-90Hi-Lok Head Radius ...................................................................................................................................... F7-92Hi-Lok Installation ......................................................................................................................................... F7-93Hi-Lok Numbering System ............................................................................................................................. T7-32Hi-Lok Protrusion Limits ................................................................................................................................ F7-94Hi-Shear Rivet Inspection............................................................................................................................... F7-64Hi-Shear Rivet Parts ..................................................................................................................................... F7-60Hi-Shear Rivet Sets ...................................................................................................................................... F7-61Hi-Shear Rivet, Driving ................................................................................................................................. F7-63Hi-Shear Rivets ............................................................................................................................................... 7-10

Identification .........................................................................................................................................7-10aInspection .............................................................................................................................................7-10eInstallation Procedures ..........................................................................................................................7-10d

Index 146

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Number

I - Continued

Installation Procedures for Self-Plugging Rivets .............................................................................................. 7-7eInstallation Tools for Dzus Fastener (Stud, Grommet, and Receptacle) ....................................................... F7-104Installation Tools for Hi-Shear Rivets .............................................................................................................7-10cInstallation Tools for Huck Lockbolts .............................................................................................................. 7-12fInstallation Tools for Rivnuts . ...........................................................................................................................7-9cInstallation Tools for Self-Plugging Rivets ........................................................................................................ 7-7dInstallation Tools for Type A-AJ and F-FA-FJ Dzus Fasteners ....................................................................... F7-98Installation Tools, Rivnut ............................................................................................................................... F7-58Installation Tools, Self-Plugging Rivet ........................................................................................................... F7-28Installation, Bulkhead ..................................................................................................................................... F4-18Installation, Hi-Lok ........................................................................................................................................ F7-93Installation, Self-Plugging Rivet .................................................................................................................... F7-29Insulation of Dissimilar Materials ...................................................................................................................... 5-7hInternal and External Repairs ............................................................................................................................. 8-9

Bulkhead Repair .......................................................................................................................................8-9iEliminating Gaps and Leveling Installations ..........................................................................................8-9aaFloor Channel Repair ............................................................................................................................. 8-9oFormer Repair ........................................................................................................................................ 8-9hLongeron Repair .................................................................................................................................... 8-9bLongitudinal Skin Joint ............................................................................................................................ 8-9rNonstressed Skin and Frame Repair ...................................................................................................... 8-9qPatch Repair to Damaged Swage in Aileron and Flap Skin .....................................................................8-9zPatch Repairs to Beaded Skin .................................................................................................................8-9yRepair for Damaged Skin Close to a Frame.............................................................................................8-9xRepair of C rack by Stop-Drilling .............................................................................................................8-9kRepair of Damaged Channels ..................................................................................................................8-9jRepair of Damaged Frame or Beam ...................................................................................................... 8-9mRepair of Dents and Creases ................................................................................................................. 8-91Repair of Heavily Stressed Support and Stiffener ................................................................................... 8-9vRepair of Frame and Stringer Joint ........................................................................................................ 8-9nRib Repair by Insertion .......................................................................................................................... 8-9gRib Repair by Patching ........................................................................................................................... 8-9fRivet Spacing, Selection and Acceptability Limits for a Nonstressed Skin Patch ..................................... 8-9tSkin and Web Repairs ........................................................................................................................... 8-9uSpar Angle Repair ................................................................................................................................. 8-9dSpar Repair by Insertion ..........................................................................................................................8-9cSpar Web Repair .................................................................................................................................... 8-9eSplice Repair of Hat Section .................................................................................................................. 8-9pStressed Skin Repair .............................................................................................................................8-9wStringer Repair ...................................................................................................................................... 8-9aTransverse Skin Joint ..............................................................................................................................8-9s

Internal Construction, Wing .................................................................................................................. 4-5b, F4-11Introduction ........................................................................................................................................................ 1-1

Index 149

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Number

J

J-Section Stringer Splice Repair .................................................................................................................... F8-16Jigs (Cementing) . ............................................................................................................................................10-9iJigs for Holding Cemented Assemblies .......................................................................................................... F10-9Jo-Bolt Basic Part Numbers ........................................................................................................................... F7-81Jo-Bolt Grip Lengths ...................................................................................................................................... F7-82Jo-Bolt Hole Sizes and Countersink Diameters .............................................................................................. T7-31Jo-Bolt Stem Break-Off Limits ....................................................................................................................... F7-87Jo-Bolt Tooling............................................................................................................................................... F7-86Jo-Bolt, Flush-Head ...................................................................................................................................... F7-78Jo-Bolt, Hex Head.......................................................................................................................................... F7-79Jo-Bolt, Millable Hex Head ............................................................................................................................ F7-80Jo-Bolts ........................................................................................................................................................... 7-13

Head Type.............................................................................................................................................7-13aHole Preparation .................................................................................................................................

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L - Continued

Lightening Holes

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Number

M - Continued

Operator Maintenance ............................................................................................................................ 3-2aStorage of Tools, Equipment, and Materials ............................................................................................3-2c

Major Alloying Elements (for Copper) .............................................................................................................5-10bMajor Alloying Elements .................................................................................................................................. T5-5Major Repair (of Shop Equipment) .................................................................................................................. 3-2bMalleability ...................................................................................................................................................... 5-2gMarking Code (Steel), Identification ................................................................................................................ T5-2Marking Example, Aluminum Identification ...................................................................................................... F5-7Marking Example, Steel Identification ............................................................................................................. F5-6Masking (Cementing) . .................................................................................................................................... 10-9fMasking (Paper)............................................................................................................................................... 10-6

Removal . ..............................................................................................................................................10-6aReplacement . .......................................................................................................................................10-6b

Masking Paper . ..............................................................................................................................................10-5cMaterial Substitution (of Metals) .........................................................................................................................5-7jMaterial Thickness Variation (and Hi-Lok Rivets) .......................................................................................... F7-91Material, Drilling . ........................................................................................................................................... F7-68Material, Patch, Selection ............................................................................................................................... T8-5Materials (Huck Lockbolts) .............................................................................................................................7-12bMaterials and Use (Solid Shank Rivets) .......................................................................................................... 7-2aMaterials Used In Repair (of Fiber Laminate) ................................................................................................... 9-9bMaterials, Core (Sandwich Construction) ........................................................................................................... 9-2Materials, Facing ............................................................................................................................................... 9-3Materials, Substitute (Aluminum) ................................................................................................................... T5-15Mating Jig, Aircraft .......................................................................................................................................... F8-1Members, Structural .......................................................................................................................................... 4-8Metal and Forming Blocks ............................................................................................................................. F6-23Metal Forming Machines ................................................................................................................................... 3-6

Bar Folding Machine .............................................................................................................................. 3-6aCornice Brake......................................................................................................................................... 3-6bShrinking and Stretching Machine .......................................................................................................... 3-6dSlip Roll Former ......................................................................................................................................3-6c

Metal-Covered Wooden Floor Panels, Repair of . .......................................................................................... F9-15Metal-Covered Wooden Floor Repair ................................................................................................................. 9-7

Negligible Damage ................................................................................................................................. 9-7aPatching ................................................................................................................................................. 9-7b

Metals and Alloys ............................................................................................................................................... 5-4Alloying .................................................................................................................................................. 5-4aIndustrial Alloys ........................................................................................................................................54bPreparing Alloys . ....................................................................................................................................5-4c

Metals, Hardness Testing of ............................................................................................................................. 5-13Metals, Properties of ......................................................................................................................................... 5-2Method, Calculation (of Balancing) ................................................................................................................ F11-8Method, Lacing ........................................................................................................................................... F10-12

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Number

M - Continued

Method, Scale (of Balancing) ........................................................................................................................ F11-9Method, Soak ................................................................................................................................................ F10-6Methods (of Rebalancing) ...............................................................................................................................11-4bMethods for Working (of Inconel) ...................................................................................................................5-12bMethods for Working and Uses (of Monel) .....................................................................................................5-11 bMethods of Working (Magnesium Alloys) .........................................................................................................5-8cMethods of Working (Titanium Alloys) ..............................................................................................................5-9cMicrometer ...................................................................................................................................................... F3-5Micrometers ..................................................................................................................................................... 3-4aMicroshaver ................................................................................................................................................... F7-14Military Specification Number (of Plastics) ......................................................................................................104aMillable Hex Head Jo-Bolts, Grip Ranges, Sizes, and Diameters of ............................................................... F7-85Millable Hex Head Jo-Bolt .............................................................................................................................. F7-80Minimizing Weight (Airframe Sheet Metal Repair).............................................................................................8-2cMinimum Annealing Time for Acrylic Plastic .................................................................................................. T10-4Minimum Rivet Edge Distances ....................................................................................................................... T8-1Minimum Rivet Shear and Tensile Strength (Pounds) in Steel Coupons ........................................................ T7-12Missing Core ................................................................................................................................................... 9-5bModern Use (Sandwich Construction)................................................................................................................9-1cMoisture and Contamination, Preventing ....................................................................................................... F9-28Monel............................................................................................................................................................... 5-11

Identification ......................................................................................................................................... 5-1 aMethods for Working and Using ...........................................................................................................5-11 b

Monel, Identification of .................................................................................................................................. T5-17Monocoque Construction ................................................................................................................................. F4-1Monospar Wing Construction .......................................................................................................................... F4-8Mount, Engine.................................................................................................................................................. F4-6Mounts, Engine . ................................................................................................................................................ 4-3MS 20600 Protruding-Head Rivet Identification ............................................................................................. F7-26MS 20601 Countersunk-Head Rivet Identification ......................................................................................... F7-27Multispar Wing Construction ........................................................................................................................... F4-9

N

Nacelle Structure . ........................................................................................................................................... F4-7Nacelles ............................................................................................................................................................ 4-4Natural Core Materials ..................................................................................................................................... 9-2aNearest Corresponding Numbers, Specifications, Cross Reference of (Steel) .................................................. T5-4Negligible Damage (of Metal-Covered Wooden Floor) ..................................................................................... 9-7aNegligible Damage (to Airframe Sheet Metal) .................................................................................................. 8-5aNeutral Axis and Stresses Resulting from Bending........................................................................................... F6-2Nicks and Dents (in Plastics) .........................................................................................................................10-12aNominal Diameter, Countersunk Head, CherryMAX Rivet .............................................................................. F7-32Nominal Diameter, Protruding Head, CherryMAX Rivet.................................................................................. F7-33

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Number

N - Continued

Non-Destructive Inspection .............................................................................................................................. 8-3fNon-Powered Metal Cutting Machines ............................................................................................................... 3-3

Rotary Punch.......................................................................................................................................... 3-3dScroll Shears .......................................................................................................................................... 3-3bSquaring Shears .................................................................................................................................... 3-3aThroatless Shears....................................................................................................................................3-3c

Nonstressed Frame Repair ............................................................................................................................ F8-33Nonstressed Skin and Frame Repair .................................................................................................... 8-9q, F8-38Nose Rib Repair ............................................................................................................................................ F8-22Nose Rib Using Beads, Crimps, Relief Holes, and Riveted Angles ................................................................. F6-22Nose Rib with Crimps and Beads ................................................................................................................... F6-21Nose Rib with Relief Holes ............................................................................................................................ F6-20Nose Rib, Plain . ............................................................................................................................................ F6-19Numbering System, Hi-Lok ........................................................................................................................... T7-32

O

Old and New Color Code (for Aluminum), Cross Reference of ......................................................................... T5-8Old Color Code (Steel) Cross Reference.......................................................................................................... T5-3Olympic Blind Rivets ....................................................................................................................................... 7-11

Drilling .................................................................................................................................................7-11 dGrip Range ...........................................................................................................................................7-11 bHole Size Limits .....................................................................................................................................7-1 cIdentification . .......................................................................................................................................7-11 aInspection ............................................................................................................................................ 7-11 fInstallation . ...........................................................................................................................................7-11eRemoval ..............................................................................................................................................7-11 g

Olympic Rivet Grip Length . ........................................................................................................................... F7-67Olympic Rivet Material Codes........................................................................................................................ T7-18Olympic Rivet Part Number Cross Reference ............................................................................................... T7-19Olympic Rivet Pulling Head Operation . ......................................................................................................... F7-69Olympic Rivet Stem Styles ............................................................................................................................ F7-66Olympic Rivet, Removing .............................................................................................................................. F7-71Olympic Rivets, Grip Range for...................................................................................................................... T7-20Olympic Rivets, Hole Size Limits for . ............................................................................................................ T7-21Olympic Rivets, Installation of . ...................................................................................................................... F7-70Open and Closed Skin Area Repair.................................................................................................................. 8-7bOperations, Forming ......................................................................................................................................... 6-4Operator Maintenance, (Sheet Metal) Shop Equipment ................................................................................... 3-2aOptical Quality (of Aircraft Plastics).................................................................................................................. 10-3Outer Sleeve Splice, Steel Tube Using . ........................................................................................................ F8-69Oven Temperature for Acrylic Plastics .......................................................................................................... T10-1Overlay Patch to Reinforce a Crack ............................................................................................................. F10-16Oversize Diameter, Countersunk Head, CherryMAX Rivet ............................................................................. F7-34

Index 154

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Number

O - Continued

Oversize Diameter, Protruding Head, CherryMAX Rivet ................................................................................ F7-35

P

Pan Void, Repair of ......................................................................................................................................... F9-7Panel Repair, Bonded Magnesium ................................................................................................................... F9-3Part Number Breakdown, CherryMAX ............................................................................................................ T7-10Part Number Cross Reference, Olympic Rivet . ............................................................................................. T7-19Parting Films and Compounds .......................................................................................................................... 9-9fParts Repair, Spotwelded................................................................................................................................. 12-6Patch Material Selection .................................................................................................................................. T8-5Patch Repairs to Beaded Skin................................................................................................................8-9y, F8-57Patch Repair to Damaged Swage In Aileron and Flap Skin ...................................................................8-9z, F8-58Plywood Facing Material .................................................................................................................................. 9-3dPatch, Flush..................................................................................................................................................... F8-5Patch, Flush, Repair Procedure........................................................................................................................ F8-7Patch, Machine Screw.................................................................................................................................. F10-14Patch, Overlay, to Reinforce a Crack ........................................................................................................... F10-16Patches ........................................................................................................................................................... 8-7aPatching (of Metal-Covered Wooden Floor) ..................................................................................................... 9-7bPatching Procedures (for Metal-Covered Wooden Floors) ................................................................................8-7cPatching Procedures (for Acrylic Plastics) . .....................................................................................................10-13

Alternate Transparent Plastic Plug Repair ...........................................................................................10-13bTransparent Overlay Plastic Patch.......................................................................................................10-13cTransparent Plastic Plug Repair ..........................................................................................................10-13a

Peening with Hammers . .............................................................................................................................. F7-110Penetrator Identification ................................................................................................................................. F5-11Pin Punch ..................................................................................................................................................... F3-20Piston-Engine Mounts ...................................................................................................................................... 4-3aPlain Nose Rib ............................................................................................................................................... F6-19Plastic Joint, Cemented ................................................................................................................................. F10-4Plastics, Forming of ......................................................................................................................................... 10-7Plate, Hold-Down .......................................................................................................................................... F6-28Pliers and Strip Extractor ............................................................................................................................ F7-111Pliers, Clamp .................................................................................................................................................. F3-9Pliers, Cleco Fasteners ................................................................................................................................... F3-8Plies and Core, Replaced............................................................................................................................... F9-23Pneumatic Rivet Gun Structure...................................................................................................................... F7-12Pneumatic Rivet Gun, Riveting Procedures Using a ...................................................................................... F7-19Pneumatic Rivet Guns ................................................................................................................................... F7-11Polishing (of Acrylic Plastics) ..........................................................................................................10-14d, 10-15bPortable Power Drills ..................................................................................................................................... F3-28Position (of Stored Plastics) ............................................................................................................................10-5bPower Drills, Portable .................................................................................................................................... F3-28

Index 155

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Number

P - Continued

Pull- and Blind-Type Aluminum Lockbolt Rivet Gun ....................................................................................... F7-73Pull- and Blind-Type Steel Lockbolt Rivet Gun .............................................................................................. F7-74Pull- and Stump-Type Lockbolts, Drilling Procedures for ................................................................................ T7-29Pull- and Stump-Type Lockbolts, Grip Range for............................................................................................ T7-26Pull-Type Lockbolt Numbering System .......................................................................................................... T7-22Pull-Type Lockbolt, Installation of................................................................................................................... F7-75Punch, Center ............................................................................................................................................... F3-17Punch, Drive ................................................................................................................................................. F3-19Punch, Pin ..................................................................................................................................................... F3-20Punch, Prick................................................................................................................................................... F3-16Punch, Rotary .................................................................................................................................................. F3-4Punch, Transfer ............................................................................................................................................ F3-21Punches ............................................................................................................................................................3-4jPurposes (of Manual) ........................................................................................................................................ 1-1

Q

Quality Assurance for Repair (of Sandwich Construction) ................................................................................ 9-6qQuality, Optical (of Aircraft Plastics)................................................................................................................. 10-3Quency Delay, Recommended Maximum, Wrought Alloys (for Immersion Type Quenching) ......................... T5-13

R

Radii of Cuts (of Plastic), Various, Bandsaw Widths for ................................................................................. T10-3Radius Gauge ......................................................................................................................................... 3-4b, F3-6Radius of Bend ............................................................................................................................................... 6-3aRange, Grip (CherryMAX Rivets) ................................................................................................................... T7-11Reaming, Dimpling and.................................................................................................................................. F7-48Rebalancing Movable Surfaces, General ......................................................................................................... 11-1Reciprocating Saw .................................................................................................................................3-5c, F3-26Recommended Bucking Bar Weights ............................................................................................................... T7-6R e c o m m e n d C o u n t I m m e n k d t h s f S h a v u c k r a l................................................................................................ ...................................................................................................................uge

T 6 c - 4 8

...........................................................................................Saw T 6 b - 4 8

...................................................................................................................T 6 6 - 3 a

.......................(..) Tj7149.04 0 TD 0.0045 Tc5-13-48...................................................................................

t ( R u l g B D a m a g e R e p a i r r h s f H e a v u l y S t r e d s e d A r e a t . . . ) T j 1 0 5 . 8 4 0 T D 0 . 0 0 7 2 T c 0 T w ( . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ) T j 9 2 . 1 6 0 T D ( . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ) T j 9 2 . 1 6 0 T D ( . . . . . . . . . . . . . . . . . ) T j 1 1 8 3 . 6 0 T D 0 . 0 0 4 8 T F 8 F 7 - 4 8

...............................................................................................................................................................................................................

........................................................................................................................................................................................................

.........................................................................................................................Saw

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Number

R - Continued

Removal (of Hi-Lok Fasteners) .......................................................................................................................7-14gRemoval (of Huck Lockbolts) ..........................................................................................................................7-12iRemoval (of Jo-Bolts) ......................................................................................................................................7-13iRemoval (of Masking) .....................................................................................................................................10-6aRemoval (of Olympic Blind Rivets) .................................................................................................................7-11gRemoval and Installation (of Glass Windshields)...........................................................................................10-17cRemoval of Countersunk Head Rivet ............................................................................................................. F7-24Removal of Damaged Face Plies by Scarf Method ........................................................................................ F9-25Removal of Hi-Shear Rivets........................................................................................................................... F7-65Removal of Loose Jo-Bolt .............................................................................................................................. F7-89Removal of Protruding Head Rivets ............................................................................................................... F7-23Removal of Rivets ............................................................................................................................................. 7-6Removal of Self-Plugging Rivets ................................................................................................................... F7-30Removal of Tightly Installed Jo-Bolt ............................................................................................................... F7-88Removal Procedures (Hi-Shear Rivets)........................................................................................................... 7-10fRemoval Procedures (Rivnuts) ........................................................................................................................ 7-9eRemoval Procedures (Self-Locking Rivets) ..................................................................................................... 7-7gRemoval, CherryMAX .................................................................................................................................... F7-55Removing Damaged Face Plies Using Step Joint Method ............................................................................. F9-22Removing Olympic Rivet .............................................................................................................................. F7-71Repair by Insertion, Stringer, When Damage Affects More than One Stringer . .............................................. F8-15Repair by Insertion, Stringer, When Damage Affects Only One Stringer ....................................................... F8-14Repair by insertion, Stringer, When Damage Exceeds Two Thirds of One Leg in Width................................. F8-13Repair by Patching, Stringer .......................................................................................................................... F8-12Repair for Damaged Skin Close to a Frame .......................................................................................... 8-9x, F8-56Repair for Heavily Stressed Support and Stiffener ......................................................................................... F8-54Repair for Short Edge Distance and Broken Spotwelds .................................................................................. F12-7Repair Layout .................................................................................................................................................... 7-3

Rivet Selection ...................................................................................................................................... 7-3aRivet Spacing .........................................................................................................................................7-3cRivet Strength ........................................................................................................................................ 7-3bRivet Substitutions.................................................................................................................................. 7-3dRivet Selection ..........................................................................................................4..16 0 TD (........)8-6Tj 8.4 0 TD 0.0055 Tc (7-3d)3Tj -485ex9...en Pla049cs)tressed Support and Stiffener................................................................

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Number

R - Continued

Repair of Dents .................................................................................................................................................9-6iRepair of Dents and Creases ................................................................................................................ 8-91, F8-32Repair of Double-Skin Damage....................................................................................................................... 9-6mRepair of Frame and Stringer Joint ...................................................................................................... 8-9n, F8-35Repair of Heavily Stressed Support and Stiffener ............................................................................................ 8-9vRepair of Honeycomb Panel Edge ................................................................................................................. F9-12Repair of Honeycomb Panel Edges ................................................................................................................. 9-60Repair of Impregnated Glass Cloth Parts .......................................................................................................... 9-8Repair of Large, Single-Skin Damage ............................................................................................................. 9-61Repair of Metal-Covered Wooden Floor Panels . ........................................................................................... F9-15

Classification of Damage ........................................................................................................................ 9-8aDamage Repair . .................................................................................................................................... 9-8b

Repair of Missing Core...................................................................................................................................... 9-6fRepair of Pan Void . ......................................................................................................................................... F9-7Repair of Pre-Drilled Attachment Holes............................................................................................................ 9-9nRepair of Sandwich Construction........................................................................................................................ 9-6

Bonded Former Assemblies ................................................................................................................... 9-6pBonded Magnesium Panels ................................................................................................................... 9-6dBonded Stiffeners . ..................................................................................................................................9-6cCleanliness of Repair Area ..................................................................................................................... 9-6aQuality Assurance for Repair ................................................................................................................. 9-6qRepair of Dents ........................................................................................................................................9-6iRepair of Double-Skin Damage ............................................................................................................ 9-6mRepair of Honeycomb Panel Edges ....................................................................................................... 9-60Repair of Large, Single-Skin Damage .................................................................................................... 9-61Repair of Missing Core ........................................................................................................................... 9-6fRepair of Scotchply Edge Member and Corfil Edge Filler Damage ........................................................ 9-6nRepair of Skin Core Voids....................................................................................................................... 9-6gRepair of Skin Doubler Voids . ................................................................................................................ 9-6hRepair of Skin Panels . ........................................................................................................................... 9-6eRepair of Small, Single-Skin Damage ......................................................................................................9-6jRepair of Small, Single-Skin Holes . ........................................................................................................ 9-5fSample Honeycomb Repair . .................................................................................................................. 9-6b

Repair of Scotchply Edge Member and Corfil Edge Filler Damage................................................................... 9-6nRepair of Sharp Dent or Crack in Length of Steel Tubing .............................................................................. F8-66Repair of Skin Core Doubler Voids .................................................................................................................. 9-6hRepair of Skin Core Voids ...................................................................................................................... 9-6g, F9-6Repair of Skin Panels....................................................................................................................................... 9-6eRepair of Small, Single-Skin Damage ...............................................................................................................9-6jRepair of Small, Single-Skin Holes....................................................................................................................9-6kRepair Parts Layout.......................................................................................................................................... 8-6eRepair Practices, General .................................................................................................................................. 8-6Repair Procedures (for Radome Repair) . ........................................................................................................ 9-9hRepair, Channel, by Insertion ......................................................................................................................... F8-30

Index 159

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Number

R - Continued

Repair, Channel, by Patching......................................................................................................................... F8-29Repair, Floor Channel .................................................................................................................................... F8-36Repair, Former............................................................................................................................................... F8-25Repair, Honeycomb ......................................................................................................................................... F9-2Repair, Machine Screw . .............................................................................................................................. F10-13Repair, Nonstressed Frame............................................................................................................................ F8-33Repair, Nose Rib ........................................................................................................................................... F8-22Repair, Rib, by Insertion ................................................................................................................................ F8-24Repair, Spar Angle ........................................................................................................................................ F8-20Repair, Spar, by Insertion .............................................................................................................................. F8-19Repair, Stressed Beam ................................................................................................................................. F8-34Repair, Trailing Edge . ..................................................................................................................................... F9-4Repair, Tubing ................................................................................................................................................ 8-11Repair, Wing Rib ........................................................................................................................................... F8-23Repairing Aluminum Alloy Parts, Rivet Selection and Spacing When .............................................................. T8-2Repairing Corrosion-Resistant Steel Parts, Rivet Selection and Spacing When ............................................... T8-3Repairing Magnesium Alloy Parts, Rivet Selection and Spacing When ............................................................ T8-4Repairs for Cracks in Radius of Stringer End, Typical . .................................................................................. F8-18Replaced Plies and Core ............................................................................................................................... F9-23Replacement (of Masking) . ............................................................................................................................10-6bReplacement and Repair, Skin ........................................................................................................................ F8-8Replacing Face Plies .................................................................................................................................... F9-24Requirements (for Rebalancing) ....................................................................................................................11 -4aResin-Impregnated Glass Cloth Facing Material .............................................................................................. 9-3eResins, Adhesives and ...................................................................................................................................... 9-4Responsibility for Shop Rules (Sheet Metal Shop) ........................................................................................... 2-1aRetainer, Seal ................................................................................................................................................ F8-61Rib Construction ............................................................................................................................................ F4-13Rib Repair by Insertion ......................................................................................................................... 8-9g, F8-24Rib Repair by Patching ..................................................................................................................................... 8-9fRight and Wrong Methods of Horizontal Stacking of Small (Plastic) Sheets . ................................................. F10-1Rivet Acceptability Limits .............................................................................................................................. F7-22Rivet Edge Distance ........................................................................................................................................ F7-4Rivet Edge Distances, Minimum ..................................................................................................................... T8-1Rivet Failure ................................................................................................................................................... 7-5bRivet Grip Length, Olympic ........................................................................................................................... F7-67Rivet Gun, Pneumatic, Structure ................................................................................................................... F7-12Rivet Guns, Pneumatic ................................................................................................................................. F7-11Rivet Head Cracking ..................................................................................................................................... F7-21Rivet Head Markings, Solid Shank ................................................................................................................... F7-2Rivet Heat-Treating...........................................................................................................................................7-2cRivet Identification .......................................................................................................................................... 7-2bRivet Identification, MS 20600 Protruding-Head ............................................................................................ F7-26Rivet Identification, MS 20601 Countersunk-Head ........................................................................................ F7-27

Index 160

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Number

R - Continued

Rivet Inspection ................................................................................................................................................. 7-5Correctly and Incorrectly Driven Rivets .................................................................................................. 7-5aRivet Failure .......................................................................................................................................... 7-5bRivet Inspection Procedures ...................................................................................................................7-5c

Rivet Inspection Procedures..............................................................................................................................7-5cRivet Inspection, Hi-Shear.............................................................................................................................. F7-64Rivet Installation ................................................................................................................................................ 7-4

Hand Tools ............................................................................................................................................. 7-4aPower Tools ........................................................................................................................................... 7-4bRiveting Procedure . ................................................................................................................................7-4c

Rivet Length, Factors in Determining . ............................................................................................................. F7-3Rivet Material Codes, Olympic . ..................................................................................................................... T7-18Rivet Parts, Hi-Shear .................................................................................................................................... F7-60Rivet Pulling Head Operation, Olympic .......................................................................................................... F7-69Rivet Removal ................................................................................................................................................... 7-6

Countersunk-Head Rivet Removal.......................................................................................................... 7-6bProtruding-Head Rivet Removal ............................................................................................................ 7-6a

Rivet Selection...........................................................................................................................................73a, 8-6fRivet Selection and Spacing When Repairing Aluminum Alloy Parts................................................................ T8-2Rivet Selection and Spacing When Repairing Corrosion-Resistant................................................................... T8-3Rivet Selection and Spacing When Repairing Magnesium Alloy Parts ............................................................. T8-4Rivet Sets, Hi-Shear ..................................................................................................................................... F7-61Rivet Shaving, CherryMAX ............................................................................................................................ F7-51Rivet Shear, Minimum, and Tensile Strength (Pounds) in Steel Coupons....................................................... T7-12Rivet Spacing.......................................................................................................................................... 7-3c, F7-5Rivet Spacing and Edge Distance .................................................................................................................... 8-6gRivet Spacing for Repair Using Formed Patch ............................................................................................... F8-43Rivet Spacing for Repair with Double Row of Rivets ...................................................................................... F8-42Rivet Spacing for Repair with Single Row of Rivets ....................................................................................... F8-41Rivet Spacing, Selection and Acceptability Limits for a Nonstressed Skin Patch ............................................... 8-9tRivet Squeezers............................................................................................................................................. F7-13Rivet Stem Styles, Olympic............................................................................................................................ F7-66Rivet Strength .................................................................................................................................................. 7-3bRivet Styles and Materials, Solid Shank ........................................................................................................... F7-1Rivet, CherryMAX ......................................................................................................................................... F7-31Rivet, Heat-Treatable, Identification of ............................................................................................................ F5-9Riveting ............................................................................................................................................................8-6iRiveting Procedure ..........................................................................................................................................7-4cRiveting Procedures Using a Pneumatic Rivet Gun........................................................................................ F7-19Rivets and Riveting Techniques, General........................................................................................................... 7-1Rivets Substitutions.......................................................................................................................................... 7-3dRivets, CherryMAX ............................................................................................................................................ 7-8Rivets, Correctly and Incorrectly Driven ......................................................................................................... F7-20Rivets, Hi-Shear............................................................................................................................................... 7-10

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Number

R - Continued

Rivets, Olympic Blind....................................................................................................................................... 7-11Rivets, Solid Shank ........................................................................................................................................... 7-2Rivnut Grip Length, Determining ................................................................................................................... F7-57Rivnut Installation Procedure ........................................................................................................................ F7-59Rivnut Installation Tools ................................................................................................................................. F7-58Rivnuts ................................................................................................................................................... 7-9, F7-56

Identification .......................................................................................................................................... 7-9aInstallation Procedures .............................................................................................................................79dInstallation Tools ......................................................................................................................................79cRemoval Procedures .............................................................................................................................. 7-9eSelection ............................................................................................................................................... 7-9b

Rockwell Hardness Scales, Standard ............................................................................................................. T5-19Rockwell Hardness Test . ................................................................................................................................5-13bRockwell Hardness Tester . ............................................................................................................................ F5-12Rockwell Hardness Values for 0.050 Inch Minimum Thickness Clad Aluminum Sheet and Plate ................... T5-20Rockwell Hardness Values for Bare Aluminum Sheet, Plate, Extrusions, and Forgings ................................. T5-21Room Temperature Setting Adhesives ..............................................................................................................9-4cRotary Punch ......................................................................................................................................... 3-3d, F3-4Router Cutter, Typical .................................................................................................................................... F10-2Routers ..........................................................................................................................................................10-8d

S

SAE Numbers, Steel ........................................................................................................................................ T5-1Safety of Powered Metal Cutting Machines ........................................................................................................ 3-5Sample Channel . ............................................................................................................................................ F6-6Sample Honeycomb Repair ............................................................................................................................. 9-6bSandbag ........................................................................................................................................................ F3-24Sandbag Bumping ......................................................................................................................................... F6-29Sanding (Plastics) . .......................................................................................................................................10-14aSanding Deep Scratches . ............................................................................................................................ F10-11Sandwich Construction Repair, General ............................................................................................................ 9-1

Construction .......................................................................................................................................... 9-1aDesign . ................................................................................................................................................. 9-1 bModern Use ............................................................................................................................................9-1c

Sandwich Construction, Repair of ...................................................................................................................... 9-6Saw, Ketts...................................................................................................................................................... F3-25Saw, Reciprocating ....................................................................................................................................... F3-26Saws (Used to Cut Plastics) . ..........................................................................................................................10-8cScab or Lap Patch (Crack) .............................................................................................................................. F8-3Scab or Lap Patch (Hole) ................................................................................................................................. F8-4Scale Method (of Balancing) . ........................................................................................................................ F11-9Scope (of Manual).............................................................................................................................................. 1-2Scotchply Edge Member and Corfil Edge Filler Damage ....................................................................................9-5i

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Number

S - Continued

Scratch or Crack Repair .................................................................................................................................. F9-5Scratches (in Plastics) ..................................................................................................................................10-12bScribing and Edge Sanding .............................................................................................................................10-8eScroll Shears .......................................................................................................................................... 3-3b, F3-2Seal Retainer . ................................................................................................................................................. 8-61Sealant Defects...............................................................................................................................................8-10cSealant Repair or Replacement ......................................................................................................................8-10dSealing of Hardware .......................................................................................................................................8-10eSealing, Structural ........................................................................................................................................... 8-10Secondary Procedures, Dzus Fastener Installation ...................................................................................... F7-103Selection of CherryMAX Rivets ........................................................................................................................ 7-8bSelection of Hi-Lok Fasteners ........................................................................................................................7-14bSelection of Hi-Shear Rivets ..........................................................................................................................7-10bSelection of Huck Lockbolts . ..........................................................................................................................7-12eSelection of Rivnuts. ........................................................................................................................................ 7-9bSelf-Plugging Rivet Installation ...................................................................................................................... F7-29Self-Plugging Rivet Installation Tools ............................................................................................................. F7-28Self-Plugging Rivet Selection ...........................................................................................................................7-7cSelf-Plugging Rivet Stem Features ................................................................................................................ F7-25Self-Plugging Rivets (Friction Lock) ................................................................................................................... 7-7

Identification ........................................................................................................................................... 7-7aInspection ................................................................................................................................................ 7-7fInstallation Procedures ........................................................................................................................... 7-7eInstallation Tools .................................................................................................................................... 7-7dRemoval Procedures .............................................................................................................................. 7-7gSelf-Plugging Rivet Selection . ................................................................................................................7-7cSubstitution for Common Rivets ............................................................................................................. 7-7b

Self-Plugging Rivets, Removal of .................................................................................................................. F7-30Semi-Monocoque Construction ........................................................................................................................ F4-2Setback ....................................................................................................................................................6-3c, F64Setback - K - Chart........................................................................................................................................... T6-2Shaping Aircraft Metals ...................................................................................................................................... 6-2

Chem-Milling .......................................................................................................................................... 6-2bForming.................................................................................................................................................. 6-2a

Shear ..................................................................................................................................................... 5-3d, F5-4Shear Strength................................................................................................................................................. 5-2bShear, Hand................................................................................................................................................... F3-10Shear, Scroll ................................................................................................................................................... F3-2Shearing Spotwelds ........................................................................................................................................ 12-3Shears, Bench ............................................................................................................................................... F3-11Shears, Squaring ............................................................................................................................................ F3-1Shears, Throatless .......................................................................................................................................... F3-3Sheet and Plate, Rockwell.............................................................................................................................. T5-20Sheet Metal Holders .........................................................................................................................................3-4c

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Number

S - Continued

Sheet Metal, Bending . ....................................................................................................................................... 6-3Sheet Substitution, Aluminum Alloy................................................................................................................ T5-14Shell, Reinforced, Construction ........................................................................................................................ F4-3Shop Equipment (Sheet Metal Shop) ................................................................................................................. 2-2Shop Housekeeping (Sheet Metal Shop) .......................................................................................................... 2-1bShop Rules, General (Sheet Metal Shop) .......................................................................................................... 2-1Shop Safety (Sheet Metal Shop) ............................................................................................................2-1 e, 2-1cShop Tools and Materials (Sheet Metal Shop) ................................................................................................. 2-1dShop Working Practice (Aluminum Alloys) ........................................................................................................5-7cShrinking ...............................................................................................................................................6-4c, F6-14Shrinking and Stretching Machine ......................................................................................................... 3-6d, F3-34Shrinking by V-Block Method ......................................................................................................................... F6-15Shrinking, Forming a Flanged Angle by.......................................................................................................... F6-16Sight Line, Brake or.......................................................................................................................................... F6-5Single Row of Rivets, Rivet Spacing for Repair with........................................................................................ F841Single Shear Strength of Aluminum Alloy Rivets ............................................................................................. T7-2Sizes (of Jo-Bolts)...........................................................................................................................................7-13cSizes of Twist Drills with Decimal Equivalents ................................................................................................. T7-5Skin and Bulkhead Repair ............................................................................................................................. F8-28Skin and Frame Repair ................................................................................................................................. F8-27Skin and Web Repairs . ................................................................................................................................... 8-9uSkin Core Voids ...............................................................................................................................................9-5cSkin Core Voids, Repair of ............................................................................................................................... F9-6Skin Cracks...................................................................................................................................................... 8-3dSkin Cutout Patching Using Spotwelds............................................................................................................ 12-6fSkin Cutout Repair Near Stiffener Using Spotwelds .......................................................................................12-6gSkin Doubler Void Repair (0.255 Inch or Greater) ............................................................................................ F9-8Skin Doubler Void Repair (Less Than 0.255 Inch) ........................................................................................... F9-9Skin Doubler Voids .......................................................................................................................................... 9-5dSkin Joint, Longitudinal .................................................................................................................................. F8-39Skin Joint, Transverse.................................................................................................................................... F8-40Skin Patch, Nonstressed, Rivet Spacing, and Acceptability Limits for................................................................ 8-9tSkin Repair, Chem-Milled ................................................................................................................................ F8-2Skin Repair, Double (Flush) ........................................................................................................................... F9-10Skin Repair, Double (Nonflush) ...................................................................................................................... F9-11Skin Repair, Stressed......................................................................................................................................... 8-7Skin Replacement............................................................................................................................................ 8-8aSkin Replacement and Repair ........................................................................................................................... 8-8

Circular External Repair.......................................................................................................................... 8-8bSkin Replacement .................................................................................................................................. 8-8aTemporary Patch Repairs .......................................................................................................................8-8c

Skin Wrinkles ...................................................................................................................................................8-3cSkin, Damaged, Close to a Frame, Repair for . .............................................................................................. F8-56Skin, Stressed, Repair.................................................................................................................................... F8-55

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Number

S - Continued

Sleeve Stretch Marks, CherryMAX ......................................................................................................................F7-54Slip Roll Former ......................................................................................................................................... 3-6c, F3-33Small Crack, Glass Cloth Repair of .....................................................................................................................F9-16Small Single Skin Damage.....................................................................................................................................9-5fSnips, Aviation ....................................................................................................................................................F3-12Snips, Circle........................................................................................................................................................F3-14Snips, Straight.....................................................................................................................................................F3-13Soak Method............................................................................................................................................ 10-9b, F10-6Soaking............................................................................................................................................................... 10-9gSoaking (Heat Treating) Temperature .................................................................................................................T5-10Soaking Time for Solution Treatment of Cast Alloys ...........................................................................................T5-11Solid Shank Rivet Head Markings .........................................................................................................................F7-2Solid Shank Rivet Styles and Materials .................................................................................................................F7-1Solid Shank Rivets.................................................................................................................................................. 7-2

Materials and Use ........................................................................................................................................... 7-2aRivet Heat-Treating......................................................................................................................................... 7-2cRivet Identification .......................................................................................................................................... 7-2b

Solid Shank Rivets, Grip Lengths for.....................................................................................................................T7-1Solution Treatment of Cast Alloys, Soaking Time for ..........................................................................................T5-11Spacing, and Rivet Selection, When Repairing Corrosion-Resistant Steel Parts....................................................T8-3Spacing, Rivet.......................................................................................................................................................F7-5Spar Angle Repair...................................................................................................................................... 8-9d, F8-20Spar Construction ...............................................................................................................................................F4-12Spar Repair by Insertion............................................................................................................................. 8-9c, F8-19Spar Web Repair ....................................................................................................................................... 8-9e, F8-21Specific Gravity..................................................................................................................................................... 5-2nSpecifications, Cross Reference of Nearest Corresponding Numbers (Steel) ........................................................T5-4Specified Defects (of Plastics), Repair Methods for ............................................................................................. 10-12Splice Repair of Hat Section ...................................................................................................................... 8-9p, F8-37Spotfacing...........................................................................................................................................................F7-62Spotweld Failure ................................................................................................................................................... 12-4Spotweld Failure with No Skin Breaks ................................................................................................................... 12-5Spotweld Repair to Crack in Stiffener................................................................................................................... 12-6iSpotweld Repair to Stiffener................................................................................................................................ 12-6hSpotwelded Parts Repair....................................................................................................................................... 12-6

Acceptable Percentage of Defective Spotwelds . .......................................................................................... 12-6bAcceptable Spotweld Spacing ....................................................................................................................... 12-6aPreparing Materials for Spotwelding ............................................................................................................. 12-6dRepair for Short Edge Distance and Broken Spotwelds . ............................................................................... 12-6eRepair of Defective Spotwelds Exceeding Allowable Percentage .................................................................. 12-6cSkin Cutout Patching Using Spotwelds........................................................................................................... 12-6fSkin Cutout Repair Near Stiffener Using Spotwelds ...................................................................................... 12-6gSpotweld Repair to Crack in Stiffener ............................................................................................................ 12-6iSpotweld Repair to Hole in Stiffener . ........................................................................................................... 12-6h

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Number

S - Continued

Spotwelds, Drilling ................................................................................................................................................ 12-2Spotwelds, General ............................................................................................................................................... 12-1Spotwelds, Shearing ............................................................................................................................................. 12-3Spring Installation, Standard ...............................................................................................................................F7-99Squaring Shears .........................................................................................................................................3-3a, F3-1Squeezers, Rivet ................................................................................................................................................F7-13Stabilizer, Helicopter ..........................................................................................................................................F4-15Stacking, Horizontal, of Small (Plastic) Sheets, Right and Wrong Methods of .....................................................F10-1Stainless Steel, Drill Angle for ...............................................................................................................................F6-1Standard Countersink............................................................................................................................................F7-7Standard Rockwell Hardness Scales ...................................................................................................................T5-19Standard Spring Installation ................................................................................................................................F7-99Standard Tools for Stump-Type Lockbolts...........................................................................................................T7-28Static Balance..................................................................................................................................................... 11-2aStatic Balance, Control Surface............................................................................................................................ Fl1-1Steel ....................................................................................................................................................................... 5-6

Alloying Materials ........................................................................................................................................... 5-6bIdentification of Steels..................................................................................................................................... 5-6aTypes of Steels and Their Uses ...................................................................................................................... 5-6c

Steel Facing Material ............................................................................................................................................ 9-3bSteel Identification Marking Example ....................................................................................................................F5-6Steel Lockbolt Rivet Gun, Pull- and Blind-Type...................................................................................................F7-74Steel SAE Numbers ..............................................................................................................................................T5-1Steel Tube Fishmouth Splice Using Large Diameter Replacement Tube ............................................................F8-70Steel Tube Inner Sleeve Splice ...........................................................................................................................F8-67Steel Tube Using Outer Sleeve Splice ...............................................................................................................F8-69Steel Tubing Distortion, Correcting Oval Shaped ................................................................................................F8-63Stem and Collar Flushness, CherryMAX..............................................................................................................F7-52Stem Break-Off Limits, Jo-Bolt............................................................................................................................F7-87Stem Catcher Bag 670A20 .................................................................................................................................F7-44Stem Features, Self-Plugging Rivet ....................................................................................................................F7-25Step Joint Method, Removing Damaged Face Plies Using ..................................................................................F9-22Stop Countersink ..................................................................................................................................................F7-8Stop-Drilling, Repair of Cracks by .......................................................................................................................F8-31Storage (of Adhesives and Resins) ....................................................................................................................... 9-4dStorage and Handling (of Plastics) ........................................................................................................................ 10-5

Formed Sections........................................................................................................................................... 10-5dLocation........................................................................................................................................................ 10-5aMasking Paper ............................................................................................................................................. 10-5cPosition......................................................................................................................................................... 10-5b

Storage of Tools, Equipment, and Materials .......................................................................................................... 3-2cStraight Line Bends............................................................................................................................................... 6-5aStraight Snips............................................................................................................................................. 3-4g, F3-13Straightening Bowed Steel Tubes........................................................................................................................F8-64

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Number

S - Continued

Strength, Bearing (Pounds) ...................................................................................................................................T7-3Stress and Strain Forces ......................................................................................................................................... 5-3

Bending .......................................................................................................................................................... 5-3eCompression................................................................................................................................................... 5-3bShear.............................................................................................................................................................. 5-3dTension........................................................................................................................................................... 5-3aTorsion ........................................................................................................................................................... 5-3c

Stressed Beam Repair ........................................................................................................................................F8-34Stressed Skin Repair...........................................................................................................................8-7, 8-9w, F8-55

Flush Access Door .......................................................................................................................................... 8-7dOpen and Closed Skin Area Repair................................................................................................................. 8-7bPatches........................................................................................................................................................... 8-7aPatching Procedures....................................................................................................................................... 8-7c

Stresses Resulting from Bending, Neutral Axis and...............................................................................................F6-2Stretching................................................................................................................................................... 6-4d, F6-13Stretching Machine, Shrinking and ......................................................................................................................F3-34Stretching, Forming a Flanged Angle by..............................................................................................................F6-18String Repair by Insertion When Damage Affects Only One Stringer...................................................................F8-14Stringer and Longeron Installation .......................................................................................................................F4-19Stringer Cross-Section, Typical ...........................................................................................................................F4-20Stringer Repair...................................................................................................................................................... 8-9aStringer Repair by Insertion When Damage Affects More than One Stringer .......................................................F8-15Stringer Repair by Insertion When Damage Exceeds Two Thirds of One Leg in Width........................................F8-13Stringer Repair by Patching.................................................................................................................................F8-12Stringer Repair with Formed Angle......................................................................................................................F8-17Stringer Splice Repair, J-Section.........................................................................................................................F8-16Stringers and Longerons ....................................................................................................................................... 4-8bStrip Extractor, Pliers and ................................................................................................................................. F7-111Structural Inspection ............................................................................................................................................... 8-3

Corrosion ........................................................................................................................................................ 8-3aNon-Destructive Inspection ..............................................................................................................................8-3fProtective Coatings......................................................................................................................................... 8-3eSkin Cracks .................................................................................................................................................... 8-3dSkin Wrinkles.................................................................................................................................................. 8-3cSurface Indications ......................................................................................................................................... 8-3b

Structural Members................................................................................................................................................. 4-8Bulkheads, Frames, and Formers ................................................................................................................... 4-8aStringers and Longerons ................................................................................................................................. 4-8b

Structural Metals, General....................................................................................................................................... 5-1Structural Parts, Airplane ......................................................................................................................................F4-5Structural Sealing.................................................................................................................................................. 8-10

Sealant Defects ............................................................................................................................................ 8-10cSealant Repair or Replacement .................................................................................................................... 8-10dSealing of Hardware ..................................................................................................................................... 8-10e

Index 167

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INDEX - CONT

VOLUME 10


Number

S - Continued

Types of Seals .............................................................................................................................................. 8-10aWires and Tubes........................................................................................................................................... 8-10b

Structural Support During Repair........................................................................................................................... 8-6aStructural Tubing................................................................................................................................................ 8-11 bStructural Tubing, Example of.............................................................................................................................F8-62Structure, Nacelle .................................................................................................................................................F4-7Stud, Camlock, Installation ............................................................................................................................... F7-112Stump-Type Lockbolt Numbering System ...........................................................................................................T7-23Stump-Type Lockbolt, Installation of ...................................................................................................................F7-76Stump-Type Lockbolts, Standard Tools for..........................................................................................................T7-28Substitute Materials (Aluminum)..........................................................................................................................T5-15Substitution (by Huck Lockbolts) ......................................................................................................................... 7-12cSubstitution (of Self-Plugging Rivets) for Common Rivets..................................................................................... 7-7bSupport and Stiffener, Heavily Stressed, Repair for ...........................................................................................F8-54Supporting Ring, Use of .................................................................................................................................... F7-108Surface Balance Considerations............................................................................................................................ 11-2

Addition of Weights....................................................................................................................................... 11-4cMethods........................................................................................................................................................ 11-4bRequirements ............................................................................................................................................... 11-4a

Surface Indications ............................................................................................................................................... 8-3bSurface Rebalancing Procedures .......................................................................................................................... 11-4

Dynamic Balance ......................................................................................................................................... 11-2bStatic Balance............................................................................................................................................... 11-2aTerms and Symbols ...................................................................................................................................... 11-2c

T

Tail Cone and Cabin Sections ...............................................................................................................................F4-4Techniques, Cutting (for Plastics).......................................................................................................................... 10-8Temperature (for Heat Treatment of Plastics) .................................................................................................. 10-10aTemplate, Hand Router, for Milling Plug Cavity................................................................................................. F10-15Temporary Patch Repairs........................................................................................................................................8-&Tensile Strength.................................................................................................................................................... 5-2aTension ........................................................................................................................................................5-3a, F5-1Terms and Symbols (Balancing).......................................................................................................................... 11-2cTerms and Symbols (Balancing), Identification of.............................................................................................. Fll11-2Thickness Variation, Material (and Hi-Lok Rivets) ...............................................................................................F7-91Thickness, Cushion .............................................................................................................................................F10-8Throatless Shears ........................................................................................................................................ 3-3c, F3-5Tightly Installed Jo-Bolt, Removal of ...................................................................................................................F7-88Titanium and Titanium Alloys .................................................................................................................................. 5-9

Characteristics ................................................................................................................................................ 5-9bIdentification ................................................................................................................................................... 5-9aMethods of Working........................................................................................................................................ 5-9c

Index 168

TM 1-1500-204-23-1

INDEX - CONT

VOLUME 10


Number

T - Continued

Tolerance (for Repairs) .......................................................................................................................................... 8-6jTool Capacity Chart (for Rivets) ..........................................................................................................................T7-14Tooling (for Hi-Lok Fasteners) .............................................................................................................................. 7-15Tooling (for Jo-Bolts) ........................................................................................................................................... 7-13fTooling, Jo-Bolt ...................................................................................................................................................F7-86Torsion......................................................................................................................................................... 5-3c, F5-3Toughness ........................................................................................................................................................... 5-2hTrailing Edge Repair .............................................................................................................................................F9-4Transfer Punch ...................................................................................................................................................F3-21Transfer Punch, Use of .........................................................................................................................................F8-9Transparent Overlay Plastic Patch .................................................................................................................... 10-13cTransparent Plastic Plug Repair ........................................................................................................................ 10-13aTransparent Plastics, Recommended Installation Procedures for ........................................................................ 10-16Transverse Skin Joint.................................................................................................................................. 8-9s, F840Treatment, Heat ...................................................................................................................................................... 5-5Troubleshooting, CherryMAX .............................................................................................................................T7-17Tubing Repair ....................................................................................................................................................... 8-11

Engine Mount............................................................................................................................................... 8-11 aStructural Tubing ......................................................................................................................................... 8-11 b

Turbine-Engine Mounts ......................................................................................................................................... 4-3bTurn-Lock Fasteners ............................................................................................................................................. 7-15

Camlock Fasteners ...................................................................................................................................... 7-15bDzus Fasteners ............................................................................................................................................ 7-15a

Twist Drills with Decimal Equivalents, Sizes of......................................................................................................T7-5Type of Cement .................................................................................................................................................. 10-9aTypes and Identification (of Aircraft Plastics)........................................................................................................... 1-4

Burning ......................................................................................................................................................... 10-4bChemical Reaction........................................................................................................................................ 10-4eFlexing.......................................................................................................................................................... 10-4dMilitary Specification Number ....................................................................................................................... 10-4aVisual Inspection........................................................................................................................................... 10-4c

Types of Circular Saw Blades for Cutting Acrylic Plastic Sheets .........................................................................T10-2Types of Design (Wing)......................................................................................................................................... 4-5aTypes of Heat Treatment....................................................................................................................................... 5-5aTypes of Lockbolts ..............................................................................................................................................F7-72Types of Seals .................................................................................................................................................... 8-10aTypes of Steel and Their Uses .............................................................................................................................. 5-6cTypical Bolt Installation (in Transparent Plastic) ............................................................................................... F10-17Typical CherryMAX Blind Heads .........................................................................................................................F7-53Typical Edge Band Sealing .................................................................................................................................F9-29Typical Hatch Seal ..............................................................................................................................................F8-60Typical Repairs for Cracks in Radius of Stringer End ..........................................................................................F8-18Typical Router Cutter .........................................................................................................................................F10-2Typical Scarf Method for Class II Repair (of Radomes) .......................................................................................F9-26

Index 169

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INDEX - CONT

VOLUME 10


Number

T - Continued

Typical Sighting Dome Edge Attachment .......................................................................................................... F10-20Typical Stringer Cross Sections...........................................................................................................................F4-20

U

Unbalanced and Balanced Conditions ................................................................................................................ Fl11-4Unbonding and Ply Separation ............................................................................................................................... 9-5jUse of Camlock Punch...................................................................................................................................... F7-109Use of Hole Finder ..............................................................................................................................................F8-10Use of Supporting Ring ..................................................................................................................................... F7-108Use of Transfer Punch ..........................................................................................................................................F8-9Use of 269C3 Cherry Grip Gauge........................................................................................................................F7-36Uses (of Jo-Bolts)................................................................................................................................................ 7-13d

V

V-Block ...............................................................................................................................................................F3-22Various Diameter Rivets, Drill Sizes for.................................................................................................................T7-4Visual Inspection (of Plastics).............................................................................................................................. 10-4cVoid Repair, Skin Doubler (Less Than 0.255 Inch) ................................................................................................F9-9Void Repair, Skin Doubler (0.255 Inch or Greater).................................................................................................F9-8

W

Waxing ............................................................................................................................................................. 10-15cWeb Repair, Spar ...............................................................................................................................................F8-21Webster Hardness Tester.................................................................................................................................... 5-13aWeight and Distance, Effects of ..........................................................................................................................F11-3Windshields, Glass.............................................................................................................................................. 10-17Wing Construction, Box Beam ............................................................................................................................F4-10Wing Construction, Monospar ...............................................................................................................................F4-8Wing Construction, Multispar ................................................................................................................................F4-9Wing Internal Construction ..................................................................................................................................F4-11Wing Rib Repair..................................................................................................................................................F8-23Wing-Type Dzus Fastener Installation .................................................................................................................F-102Wings ..................................................................................................................................................................... 4-5

Internal Construction....................................................................................................................................... 4-5bTypes of Design.............................................................................................................................................. 4-5a

Wires and Tubes................................................................................................................................................. 8-10b

Index 170

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tm 1-1500-204-23-1 technical manual aviation unit maintenance