TM 1-1500-204-23-1, Change 6
TM 1-1500-204-23-1, Change 6
TM 1-1500-204-23-1, Change 6
TECHNICAL MANUAL
FOR
VOLUME 1
An operating or maintenance procedure, practice, condition, statement, etc., which if not strictly observed,
could result in injury to or death of personnel.
An operating or maintenance procedure, practice, condition, statement, etc., which, if not strictly observed,
could result in damage to, or destruction of, equipment or loss of mission effectiveness or long term health
hazards to personnel.
NOTE
An essential operating or maintenance procedure, condition, or statement, which must be highlighted.
PRECAUTIONARY DATA
Personnel performing operations, procedures, and practices which are included or implied in this work requirement
shall observe the following warnings. Disregard of these warnings and precautionary information can cause serious
injury, death, or destruction of material.
ELECTRICAL TESTS
Electrical power up to 500 volts is used in testing the equipment. Exercise extreme caution during these tests.
Ensure the equipment is grounded and operated in accordance with the operator’s manual. Never operate electrical
equipment during 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 be
grounded to avoid the danger of igniting test f uid fumes or creating electrical shock.
USING SOLVENTS/PAINTS
Standard precautions such as f re prevention and adequate ventilation shall be exercised when using solvents or
applying primer and coating.
Wear gloves or gauntlets when handling solvents as solvents may cause skin disorders.
Cements and solvents used to repair liferafts are f ammable and shall be treated as such. Never smoke or permit
any type of open f ame near when using cements or solvents.
Dichloromethane (methylene chloride) vapor is heavier than air, adequate ventilation shall be provided for working
personnel. Dichloromethane (methylene chloride) is toxic when vapors are inhaled over an extended period of time.
Change 5 a
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 base plastics.
Provide adequate ventilation when working with Furane Plastics, Epocast H-991-A, Furane hard-
ener 941, or equivalents as 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 the skin. 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 on hands, body, or clothing.
HANDLING ACID
Wear protective clothing when mixing acid with water. Always pour acid into water, never water into
acid.
REMOVING CORROSION
Take precautions, such as wetting the area or exhausting debris, to prevent possible dust explosions
when removing corrosion from steel alloys. Use goggles or face shield when removing paint or
corrosion with a wire brush or by the grinding method.
b Change 5
TM 1-1500-204-23-1
OXYGEN SYSTEM
Do not allow petroleum base products to come in contact with oxygen system components, as an explosion or f re
may result.
Do not use masking tape to seal openings in oxygen regulators. Masking tape constitutes a safety hazard when use
on either serviceable or repairable oxygen equipment.
DELETED
RADIOGRAPHIC EQUIPMENT
Exercise extreme caution when performing radiographic inspections to prevent personnel from coming in contact
with radiation. Radiation from X-ray units and radioisotope sources is extremely destructive to living tissue.
Change 5 c
TM 1-1500-204-23-1
FIRE EXTINGUISHERS
Halon type re extinguishers, Monobromotriuoromethane (CF3BR) and Bromochloromethane (CB)
are odorless gasses. When used in conned areas, available oxygen for breathing may be depleted.
Use supplied breathing air when using these gasses in enclosed spaces.
HYDRAULIC FLUID
To avoid contamination, do not use previously opened cans of hydraulic uid. A new, sealed can
of uid must be opened and used. When opening can, clean top and use a clean, sharp, unplated
instrument to prevent contamination.
Acrylic monomer and polymer base adhesive, MIL-A-8576, contains a volatile liquid which may
prove toxic when vapors are inhaled over extended periods. Use only with adequate ventilation.
Observe re precautions when using aliphatic naphtha, Federal Specication TT-N-95.
COMPRESSED AIR
Compressed air shall not be used for cleaning purposes except if reduced to less than 30 psi and
then only with effective chip-guarding and personal protective equipment.
NOISE HAZARD
Noise levels reached during ground runup of Army aircraft are of a level that may cause permanent
hearing loss. Maintenance personnel shall wear adequate hearing protection when working on air-
craft with engines in operation.
MERCURY
A very small amount of mercury may produce hazardous vapors. Refer to TM 385-4, Safety Pre-
cautions for Maintenance of Electrical/Electronic Equipment, for safety precautions to use when
handling mercury and for methods that are used to clean up mercury spillage.
CARTRIDGES
Electrically activated re extinguisher cartridges, external stores release cartridges, external load
cable cutter cartridges and cargo hook thruster cartridges shall be protectively wrapped in aluminum
foil or electrically shunted whenever removed from the aircraft installation to preclude "stray" elec-
trical voltage activation and resulting personal injury.
d Change 5
TM 1-1500-204-23-1
SPECIAL INSTRUCTIONS
All equipment must be operated in accordance with the manufacturer’s operating instructions. If
unavailable, instructions for the use and care will be developed. Standard Operating Procedures
(SOPs) will be prepared and used for all shop operations (refer to AR 385-95). The supporting
Safety Ofce will use their expertise to provide assistance.
Guidance for industrial hazards can be found in the Code of Federal Regulations, Code of Federal
Regulations 29 CFR 1910.
DEGREASING SOLVENTS
Degreasing Solvent, MIL-PRF-680, is combustible and toxic to eyes, skin, and respiratory tract.
Wear protective gloves and goggles/face shield. Avoid repeated or prolonged contact. Use only in
well ventilated areas (or use approved respirator as determined by local safety/industrial hygiene
personnel). Keep away from open ames, sparks, or other sources of ignition.
ALIPHATIC NAPHTHA
Aliphatic Naphtha, TT-N-95, is extremely ammable and toxic to eyes, skin, and respiratory tract.
Wear protective gloves and goggles/face shield. Avoid repeated or prolonged contact. Use only in
well ventilated areas (or use approved respirator as determined by local safety/industrial hygiene
personnel). Keep away from open ames, sparks, or other sources of ignition.
CLEANING SOLVENT
Cleaning Solvent, HFE-71DE, is toxic to eyes, skin, and respiratory tract, and decomposes into
other hazardous products when exposed to extreme heat. Wear chemical protective gloves and
goggles/face shield. Avoid repeated or prolonged contact. Use only in well ventilated areas. If
ventilation is not adequate, use approved respirator as determined by local safety/industrial hygiene
personnel. Keep away from open ames, welding, or other sources of extreme heat.
CLEANING COMPOUND
Cleaning Compound, MIL-PRF-87937, Type II, can irritate eyes and skin. Wear protective gloves
and goggles. Avoid repeated or prolonged contact.
Change 5 e
TM 1-1500-204-23-1
CLEANING COMPOUND
Cleaning Compound, MIL-PRF-85570, Type II, can irritate eyes, skin, and respiratory tract. Wear
protective gloves and goggles. Avoid repeated or prolonged contact. Use in well ventilated areas.
ISOPROPYL ALCOHOL
Isopropyl Alcohol, TT-I735, is ammable and toxic to eyes, skin, and respiratory tract. Wear protec-
tive gloves and goggles/face shield. Avoid repeated or prolonged contact. Use only in well ventilated
areas (or use approved respirator as determined by local safety/industrial hygiene personnel). Keep
away from open ames, sparks, or other sources of ignition.
f Change 5
TM 1-1500-204-23-1
C6
URGENT
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 6 WASHINGTON, DC., 18 December 2009
This document has been reviewed for the presence of SOLVENTS containing hazardous materials as defined by the EPCRA 302
and 313 lists by the AMCOM G-4 (Logistics) Environmental Division. As of the base through C03, dated 13 January 2003, all ref-
erences to Solvents containing hazardous materials have been removed from this document by substitution with non-hazardous or
less hazardous materials where possible.
1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar
in the margin. An illustration change is indicated by a miniature pointing hand.
A and B A and B
2-9 and 2-10 2-9 and 2-10
3-5 through 3-8 3-5 through 3-8
9-29 and 9-30 9-29 and 9-30
11-13 and 11-14 11-13 and 11-14
13-1 and 13-2 13-1 and 13-2
JOYCE E. MORROW
Administrative Assistant to the
Secretary of the Army
Distribution:
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 5 WASHINGTON, DC., 31 May 2006
TECHNICAL MANUAL
OZONE DEPLETING
This document has been reviewed for the presence of Class I Ozone Depleting Chemicals by the
AMCOM G-4 (Logistics) Environmental Division. As of the base through C03, dated 13 January 2003,
all references to Class I Ozone Depleting Chemicals have been removed from this document by
substitution with chemicals that do not cause atmospheric ozone depletion EXCEPT
Bromotriffluoromethane (CF3BR); Fire Extinguisher Agent (Halon 1301).
This document has been reviewed for the presence of SOLVENTS containing hazardous materials as
defined by the EPCRA 302 and 313 lists by the AMCOM G-4 (Logistics) Environmental Division. As of
the base through C03, dated 13 January 2003, all references to Solvents containing hazardous
materials have been removed from this document by substitution with non-hazardous or less
hazardous materials where possible.
1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical
bar in the margin. An illustration change is indicated by a miniature pointing hand.
a through d a through f
A and B A and B
i through iv i through iv
2-3 through 2-6 2-3 through 2-6
6-1 through 6-6 6-1 through 6-6
7-19 through 7-24 7-19 through 7-24
7-29 and 7-30 7-29 and 7-30
7-37 and 7-38 7-37 and 7-38
8-17 through 8-20 8-17 through 8-20
9-7 through 9-10 9-7 through 9-10
9-29 through 9-32 9-29 through 9-32
9-43 and 9-44 9-43 and 9-44
TM 1-1500-204-23-1
PETER J. SCHOOMAKER
General, United States Army
Official: Chief of Staff
JOYCE E. MORROW
Administrative Assistant to the
Secretary of the Army
0612301
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 4 WASHINGTON, DC., 10 June 2005
TECHNICAL MANUAL
1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical
bar in the margin. An illustration change is indicated by a miniature pointing hand.
Official:
PETER J. SCHOOMAKER
General, United States Army
Chief of Staff
SANDRA R. RILEY
Administrative Assistant to the
Secretary of the Army
0512203
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 3 WASHINGTON, D.C., 13 January 2003
TECHNICAL MANUAL
FOR
GENERAL AIRCRAFT MAINTENANCE
VOLUME 1
1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical
bar in the margin. An illustration change is indicated by a miniature pointing hand.
Official:
ERIC K. SHINSEKI
General, United States Army
Chief of Staff
JOEL B. HUDSON
Administrative Assistant to the
Secretary of the Army
0233706
DISTRIBUTION:
To be distributed in accordance with initial distribution number (IDN) 313302, requirements for
TM 1-1500-204-23-1.
TM 1-1500-204-23-1
C 2
CHANGE
NO. 2 HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C. 1 MARCH, 2000
Technical Manual
ERIC K. SHINSEKI
General, United States Army
Official: Chief of Staff
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 1 WASHINGTON, D.C., 29 OCTOBER 1993
FOR
1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the
margin. An illustration change is indicated by a miniature pointing hand.
c and d c and d
i and ii i and ii
3-5 and 3-6 3-5 and 3-6
3-9 through 3-12 3-9 through 3-12
11-13 through 11-16 11-13 through 11-16
11-25 through 11-28 11-25 through 11-28
12-1 and 12-2 12-1 and 12-2
A-1 and A-2 A-1 and A-2
GORDON R. SULLIVAN
General, United States Army
Chief of Staff
Official:
MILTON H. HAMILTON
Administrative Assistant to the
Secretary of the Army
05627
Distribution:
To be distributed in accordance with DA Form 12-31-E, block no. 3302, requirements for TM 1-1500-204-23-1.
NOTE: On a changed page, the portion of the text affected by the latest change is indicated by a vertical
line, or other change 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.
................................................................
TECHNICAL MANUAL
For
VOLUME 1
You can improve this manual. If you find mistakes, or if you know of a way to improve these procedures, please
let us know. Mail your lett er or DA Form 2028 (Rec ommended Changes to Publications and Blan k Forms )
located in the back of this manual, directly to: Command er, U.S. Army Aviation and Missile Command, ATTN:
AMSAM-MMC-MA-NP, Redstone Arsena l, AL 3 5898-5000. A reply will be furnish ed to you. You may als o
provide DA Form 2028 information to AMCOM via e-mail, fax, or the World Wide Web. Our fax number is DSN
788-6546 or Commercial (256) 842-6546. Our e-mail address is: [email protected]. Instructions fo r
sending an electronic 2028 may be found at the back of this manual immediately preceding the hard copy
2028. For the World Wide Web use: https://amcom2028.redstone.army.mil.
OZONE DEPLETING
This document has been reviewed for the presence of Class I Ozone Depleting Chemicals by the AMCOM G-4
(Logistics) Environmental Division. As of the base through C03, dated 13 January 2003, all references to Class
I Ozone Depleting Chemic als have been removed from this docum ent by substit ution with che micals that d o
not cause atmospheric ozone depletion EXCEPT Bro motriffluoromethane (CF3BR); Fire Ex tinguisher Agent
(Halon 1301).
This document has been revie wed for the presence of SOLVENT S containing hazardous materials as defined
by the EPCRA 302 and 313 lists by the AMCOM G-4 (Logistics) Environmental Division. As of the base through
C03, dated 13 January 200 3, all referenc es to Solvents containing ha zardous materials have be en removed
from this document by substitution with non-hazardous or less hazardous materials where possible.
TABLE OF CONTENTS
Page
This manual together with TM 1-1500-204-23-2 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 5 i
TM 1-1500-204-23-1
Page
Volume 2
Volume 3
ii Change 5
*TM 1-1500-204-23-1
Page
Volume 4
Volume 5
Volume 6
Change 5 iii
TM 1-1500-204-23-1
Page
Volume 7
Volume 8
Volume 9
iv Change 5
TM 1-1500-204-23-1
GLOSSARY Glossary 1
Volume 10
Change 2 v
TM 1-1500-204-23-1
GLOSSARY Glossary 1
INDEX Index 1
vi
TM 1-1500-204-23-1
CHAPTER 1
INTRODUCTION
1-1. Purpose. This volume provides general 1-2. Scope. General information to guide aircraft
information pertaining to general maintenance and maintenance personnel is covered in this volume,
practices. Specific aircraft application, usage, and however, no attempt has been made to include special
substitution is found in the individual aircraft parts or equipment which are applicable only to
maintenance manual. This volume is of maximum individual or special aircraft. Chapters 1, 2, and 3 cover
benefit to the mechanic who desires general information the introduction, hangar and shop operations and
about general maintenance and practices. This volume flightline operations. Chapters 4, 5, and 6 explain
furnishes the mechanic a source of information about aircraft storage and shipment, marking of aeronautical
how to perform various maintenance practices used on items, and application and removal of decals. General
all aircraft. This volume is not a requisitioning authority, maintenance practices for reciprocating engines, turbine
and applicable repair parts and special tools list should engines, and airframes are described in Chapters 7, 8,
be consulted to obtain the unit of issue and National and 9. Arctic, desert, and tropic maintenance
Stock Number of the items required for maintenance. procedures are covered in Chapter 10. Life support
However, this manual may be used as authority to maintenance procedures are covered in Chapter 11.
obtain necessary assistance and safety related material Finally, Chapters 12 and 13 explain pyrotechnics and
aircraft cleaning
1-1/(1-2 blank)
TM 1-1500-204-23-1
CHAPTER 2
2-1. General. The maintenance instructions and g. Electrical Utilities. Electrical power is distributed
procedures contained in this chapter are general and throughout the permanent shop. Care should be taken
applicable to hangar and shop operations. Maintenance to allow clear access to each outlet.
instructions that are specific to a particular aircraft are
contained in the applicable maintenance manuals and h. Noise Levels. Noise levels from machinery in
will be used in conjunction with general information permanent shops are high. Personnel working in these
contained in this chapter. shops shall wear adequate hearing protection.
2-2. Permanent Shop Installations. The following i. Dust and Dirt Control. Use the following
paragraphs describe permanent shop installations, procedures for dust and dirt control in permanent shops.
operations, and equipment.
(1) Sweep the floors daily with an ordinary
a. Typical Layout. Permanent shop layout vanes push broom.
depending on shop purpose and the facility being used.
Care should be taken to provide proper spacing between NOTE
equipment so as not to prevent emergency access. Carefully clean areas where dust
producing operations have taken
b. Shop Size. The size of each permanent shop place
shall be adequate to allow shop personnel to accomplish
all normal shop operations. (2) Clean shop equipment in accordance with
the applicable maintenance manuals.
c. Shop Equipment Required. Permanent shops
shall be equipped with all required equipment as (3) Clean walls and tables periodically with a
specified by Army command. cloth dampened with a mild detergent.
2-1
TM 1-1500-204-23-1
be inspected regularly for damage and worn safety plugs may melt and allow discharge
components. of the cylinder.
• Keep empty cylinders separated from full
o. Storage of Shop Stocks. Repair Parts. and cylinders.
Consumable Materials. Storage of all shop items shall • Do not store cylinders near salt or corrosive
be in accordance with the applicable maintenance chemicals or fumes of any kind as the
manuals. Utmost care shall be taken to ensure the safe cylinders will become rusty and the valve
storage of all items. caps will stick.
• Keep valves closed on all cylinders after
p. Storage of Compressed Gases. The following usage.
precautions will be taken when storing compressed gas • Do not store cylinders near radiators or
cylinders. other sources of heat.
• Cylinders of one kind of gas should not be
• Cylinders must be protected against stored near cylinders of other kinds of gas.
excessive rise or fall of temperature. A fire-resistant partition should separate
flammable and nonflammable gases unless
NOTE the cylinders are otherwise widely
Cylinders will be stored inside separated. Oxygen, in particular, will be
wherever possible, and, if not, they separated from flammable gases or
may be stored in the open but must supplies.
be protected from extreme weather • Storage rooms must be well ventilated to
conditions and also from the ground prevent possible accumulation of explosive
to prevent rusting. Cylinders stored or harmful concentration of gas.
in the open must be protected from
accumulation of ice and snow in the q. Storage of High-Value Items. High value items
summer, cylinders stored in this shall be stored in areas that can be secured to prevent
manner will be protected or screened theft. Care shall be taken to store high-value items in
against direct rays of the sun such a manner as to prevent inadvertent damage.
Ventilation will be provided to keep
temperatures below 125°F (52.6°C) r. Open Storage for Repaired Equipment and
and carry off leakage of inflammable Consumable Material. Avoid storing repaired equipment
gases. and consumable materials in open storage areas where
they can be easily damaged.
• Cylinders must never be stored near highly
flammable substances such as oil, gasoline, 2-3. Temporary Shop Installations. The following
waste, etc. A minimum distance of 50 feet paragraphs describe temporary shop installations,
will be maintained between cylinders and operations and equipment.
flammable items.
a. Typical Shop Layout. A typical shop layout is
• Care will be taken to protect cylinders from
shown in figure 2-1 Layout of equipment vanes
any object which might cut or damage their
depending on the temporary shop purpose.
surfaces. Cylinders will not be stored at a
place where heavy moving objects may
b. Shop Size The exterior dimensions for a
strike or fall on them.
deployed temporary shop are as follows
• Cylinders will not be stored in an area which
is continually damp. Neither should they be
stored near live electric wires or rails of • Width ......................... 22 ft 3 in (6.78 meters)
electrical equipment.
• Valve protection caps will always be • Height ..................... 7 ft 11 in. (2.41 meters)
installed if they become frozen, they should
be thawed out in a warm room. Do not use • Length........................ 13 ft 4 in (4.06 meters)
a steam hose to thaw them out as fusible
2-2
TM 1-1500-204-23-1
c. Equipment Mounted in Mobile Shelters. f. Compressed Air Panels. The compressed air
Equipment shall be mounted in accordance with the panel connector installed through the wall of the S-280
specific shop requirements. shops may be replaced by removing the two bolts
securing it to the mounting plate. Apply sealant to the
d. Shop Equipment Arrangement. Shop replacement connector and reinstall mounting bolts.
equipment is arranged to best meet the needs of the
particular shop operation. All equipment must be g. Electrical Utilities. Electrical power is
arranged with utmost care to prevent danger to transmitted from 60 Hz mobile electric generators
personnel. through the power distribution panels to the shops by
heavy-duty power cables.
e. Chain Hoists. Chain hoists for temporary shops
shall be inspected daily for the following. h. Noise Levels. Noise levels in temporary shops
are high. Personnel working in these shops shall wear
• Excessive wear or stretch adequate hearing protection.
• Bent or twisted links i. Dust and Dirt Control. Use the following
procedures for dust and dirt control.
• Defective welds
(1) Sweep the floor each morning with an
• Nicks and gouges ordinary push broom.
2-3
TM 1-1500-204-23-1
(2) Once a week, clean the interior walls with r. Open Storage Areas. Open storage areas will
a cloth dampened with a mild detergent solution and be arranged be each shop facility as needed. Supplies
wipe dry. shall be organized to provide easy access, removal, and
use.
(3) Once a week, clean the exterior of the
shelter, using the same detergent as in step (2). Ap- 2-4. MAINTENANCE OF SHOP EQUIPMENT. The
ply with a soft bristle brush or sponge, scrubbing off all maintenance of machinery and shop equipment shall
dirt and grime. Rinse with clean water. Dry with a soft be divided into operator maintenance, major repair, and
cloth. painting.
j. Spray Painting. Spray painting can be used a. Operator Maintenance. Operator mainte-
to repaint any spots in need of ref nishing. The following nance consists of cleaning, lubrication, and minor
procedures explain spray painting of temporary shops: adjustment of belts, guards, gibs, etc. It also includes
periodic visual inspection to preclude possible damage,
failure, or breakdown due to loose or excessively worn
(1) Remove all loose or f aked paint. parts, defective wiring connections, insulation, safety
appliances, etc.
(2) Smooth with No. O sandpaper, feather
b. Major Repair. Major repair consists of all
edging all sanded spots to ensure a smooth surface for repair work not performed by operators. Major repair
the new paint. within the scope of facilities shall be accomplished
locally. Repairs not within the scope of local facilities
(3) Apply paint with a 2-inch spray pattern. shall be accomplished through a work order to direct
support or a commercial contractor.
NOTE
c. Painting. Painting consists of any ref nishing
Thin paint if necessary with an acceptable thin- of equipment, from touchup to complete repainting of the
ner conforming to TT-T-291. item.
NOTE
(4) Allow 4 to 8 hours to dry.
All color shades shall be in accordance with
k. Adhesive Operations. Adhesives join ob- Federal Specif cation FED-STD-595.
jects over a broad area, instead of localizing stresses
at one or more points, as with spot welding or metal
fastening. Adhesives simplify construction by eliminat- (1) Equipment repainting. When complete
ing bracing, stiffeners, local reinforcements, or framing. repainting is necessary, the original painted surface
Adhesive use is a reliable, eff cient assembly method. shall be ref nished with synthetic gloss enamel, Federal
Specif cation TT-E-489. The color shall be green, color
l. Balancing Equipment. The equipment used shade 14260.
for balancing measurements consists of a set of knife
edges, weights, a small accurate weighing scale, and a
steel tape measure. (2) Work areas and critical parts. Work ar-
eas and critical parts will be highlighted by painting with
m. Temperature and Humidity Control. Tem- Federal Specif cation TT-E-489. The color shade shall
perature and humidity is controlled in temporary shop be 13655 yellow enamel. To ensure maximum color
structures by environmental control units attached to the pattern uniformity on like items of equipment, painting
structure. and highlighting shall be accomplished in accordance
n. Flammable Materials. All f ammables shall with the general pattern shown in f gure 2-2. Equipment
be stored in accordance with existing command poli- other than the type illustrated, shall be painted in ac-
cies. cordance with these general instructions. The painted
f nish on this equipment may be touched up. The com-
o. Lighting. Light f xtures should be inspected manding off cer or his designated representative shall
for broken lamp contacts or other damage. The lamp determine the extent of the touchup allowed without
and protector may be replaced by removing the screws
holding the retaining straps to the light f xture. complete repainting.
p. Repair Parts Van. The repair parts van shall (3) Natural wood pieces. Wood pieces or
be fully stocked with repair parts for the specif c shop. equipment f nished in colors other than those listed in
The van shall be located as to provide easy access by paragraph c may be touched up with colors to match
maintenance personnel. existing f nish, provided touchup does not involve re-
q. Protected Storage Areas. Each command f nishing a total area equal to more than 10 percent of
shall provide protected storage areas for f ammable or painted surface area. When more than 10 percent of
hazardous materials. Care should be taken to provide painted surface area must be touched up, item shall be
security and proper handling of items in these areas. repainted with colors as specif ed.
2-4 Change 5
TM 1-1500-204-23-1
NOTE mine the use of this color and furnish instructions. Paint-
ing of machined parts, such as face plates, chucks, spin-
Instrument repair benches or other special dels, etc, is not authorized.
purpose benches, parts, and equipment hav-
ing natural wood nish may be renished in
(7) Preparation for painting. Prepare sur-
natural wood or white enamel, Federal Speci-
faces to be repainted using the following procedures:
cation TT-E-489, color shade 17875. Working
surfaces of bench tops covered with metal or
composition need not be repaired. (a) Surface should be clean, dry, and free
from dust, grease, oil, rust, and dirt. Glossy surfaces
should be sanded to dull the gloss to ensure adhesion.
(4) Start buttons. Start buttons shall be
Remove all rust and scale by scraping or wire brushing.
painted with Federal Specication TT-E-489, green
synthetic gloss enamel, color shade 14260.
Change 5 2-5
TM 1-1500-204-23-1
Allow first coat to dry thoroughly before applying second which require electrical circuits of a hazardous
coat. nature.
All switches and electrical equipment shall be
NOTE of the enclosed explosion-proof type.
Machines shall not be operated All metal apparatus shall be grounded to
during painting operation. avoid the danger of igniting test fluid fumes or
creating electrical shock.
d. Equipment Maintenance Form. The equipment
maintenance form is explained in the following b. Machine Tool Safety. Machine Tool safety
paragraph. precautions are explained in the following paragraphs.
DD Form 314. This form, properly initiated, (1) Face shields and safety glasses. Personnel
shall be attached to each piece of equipment. The operating machinery shall wear eye protection as
preventive maintenance requirements shall be prescribed. A protective face shield or safety glasses
accomplished and noted by operator by placing his shall be worn when operating a grinder regardless of
initials in the appropriate block. whether grinder is equipped with attached shields.
2-5. Hangar and Shop Safety. All supervisory (2) Drilling, grinding, or sawing precautions. The
personnel in Army hangars and shops are responsible following safety precautions shall be observed when
for a continuing and effective shop safety program. To drilling, grinding, or sawing.
implement and maintain this program, shop supervisors
will utilize bulletin boards, signs, and any other effective Clamp work securely so that work will not
method. Shop personnel will cooperate in the shop move.
safety program by making helpful recommendations, Stop machine prior to attempting to adjust
and continually exercising care and caution in the work that has become lammed.
operation of all shop equipment. The following Cutting tools must be kept sharp.
paragraphs describe electrical, machine tool, and fire Allow chuck to come to a stop on its own
safety precautions. accord. Do not use hand pressure to stop a
spinning chuck.
a. Electrical Safety. The following electrical Do not set tools while power is on. Examine
safety precautions shall be observed in Army hangars tools and chucks for cracks and defects prior
and shops. to use.
Stand to one side of grinding wheel when it is
Ensure that all unauthorized personnel are first started to avoid injury in case wheel
clear of area before opening valves or fractures.
energizing electrical circuits for starting Wear suitable gloves in addition to goggles
machinery. when buffing.
Electrical tools must be connected to a low
resistance ground. c. Fire Safety. Unsafe equipment and fire hazards
Electrical cables and air hoses to portable are the main factors to be observed while planning
units will be laid out so there is no danger of safety procedures for hangars and shops. Unsafe
tripping. equipment shall be reported immediately. A constant
Whenever possible, aircraft batteries will be vigilance must be maintained to seek out fire hazards.
disconnected when undergoing maintenance Fire hazards are constantly present in the shop where
performed in the hangar. sparks, friction, or careless handling can cause
Substantial low resistance conductors shall be
used to ground all stationary and portable
machines, equipment, or other devices in
which static charges may be generated, or
2-6
TM 1-1500-204-23-1
an explosion that may destroy equipment or buildings, (d) Replace with new cylinder immediately.
and injure or kill personnel. Refer to AR 385-10, Army
Safety Program and The Occupation Safety and Health (4) Inspection requirements for fire extinguishers.
Act of 1971. Inspect fire extinguishers in accordance with the
manufacturer inspection procedures.
(1) Classifications of fires. Fires are classified as
follows. (5) Identifying fire extinguishers. Since fire
extinguishers can be exchanged readily among aircraft,
Class A fire (wood, paper, trash, etc). Use a means is required to identify and assure control of
water or soda-acid fire extinguisher. inspection cycle. To accomplish this, all portable, hand-
Class B fire (oil, paint, fuel, grease, etc). Use operated fire extinguishers intended for use in Army
bromotrifluoromethane or carbon dioxide fire aircraft will be tagged as follows:
extinguisher.
Class C fire (electrical equipment). Use All serviceable fire extinguishers installed in
bromotrifluoromethane or carbon dioxide fire aircraft will have a DD Form 1574 (Serviceable
extinguisher. Tag Materiel) attached. The DD Form 1574 will
Class D fire (combust ible metals) magnesium, show next inspection due, as stated in DA PAM
titanium, zirconium, sodium, lithium, and 738-751.
potassium. Use dry powder type fire Fire extinguishers are considered unserviceable
extinguisher. if the gross weight stamped on data ring, as
shown in figure 2-3, is not legible or the data
(2) Types of fire extinguishers. Types of fire ring is missing.
extinguishers are listed below. Fire extin guishers determined unserviceable or
requiring a scheduled inspection will be replaced
Soda-acid (class A fires) with a serviceable fire extinguisher, tagged with
Bromotrifluoromethane (class B and C fires) a DD Form 1574.
Carbon dioxide (class B and C fires) Fire extinguishers received through supply
Dry powder (class D fires) channels that are in original manufacturer's
packaging and show no evidence of damage
(3) Use of fire extinguishers. Operate fire shall be considered serviceable and will be
extinguisher as follows: tagged accordingly, prior to installation in
aircraft.
(a) Pull ring pin.
(6) Location of fire extinguishers. Fire extinguishers
(b) Point horn close to fire. shall be located throughout the shop in readily
accessible areas.
(c) Depress trigger for discharge, an d keep
base of flames covered. (7) Marking of fire lanes. Fire lanes shall be
marked and kept clear for emergency personnel should
WARNING fire occur.
Do not remove cylinder head until
extinguisher has been fully
discharged. Injury to personnel may
otherwise result.
2-7
TM 1-1500-204-23-1
2-8
TM 1-1500-204-23-1
(8) Fire fighting equipment requirements. ond rows of aircraft placed tail to tail, shall
Fire fighting equipment requirements are listed as fol- be accomplished where possible.
lows:
• Aircraft shall be static-grounded from ba-
• Personnel shall be trained in the use, sic structure of aircraft to a low resistance
knowledge, and location of shop fire ground.
fighting equipment.
• After parking aircraft, chock securely and
• Each shop shall be equipped with fire release parking brake.
extinguishers suited for type fire most
likely to occur. c. Parking of Aircraft with Fuel Tanks Less Than
Full. Aircraft shall have all fuel cells fully serviced
• Oily waste, rags, and similar com- prior to being parked or stored in a hangar. All fuel
bustible trash shall be discarded in cells should be full in order to minimize the presence
self-closing metal containers which shall of flammable vapors within the fuel cell (for safety pur-
be emptied daily. poses) and additionally to minimize water condensation
and subsequent microbiological growth which results in
• Flammable supplies shall not be stored
contamination of the fuel.
in the shop.
2-9
TM 1-1500-204-23-1
a. Jacking. Use the following procedures for in Unauthorized persons will not be in, on or un-
and out of hangar jacking: der aircraft supported by jacks. Areas shall be
restricted by proper warning signs and barriers
(1) Do not stand, sit, or lie inside or on aircraft to preclude entry into the area.
during raising or lowering operations.
NOTE
(2) Ensure that all stress panels are installed on
aircraft. The use of auxiliary supports is recommended,
but not required, as standard jacks are designed
to withstand all vertical loads. When several
(3) Disengage aircraft brakes and remove
people are to be working on the aircraft, aux-
chocks.
iliary supports are highly recommended.
(4) Place all jacks on a level surface so that an
(8) Do not jack aircraft when wind velocity is
imaginary line drawn through any 2 feet of jack will be
greater than maximum amount specified in applicable
parallel to fuselage or load to be jacked. Jack only at
maintenance manual. When applicable maintenance
specified jack points.
manual does not list a maximum wind velocity, a velocity
of 15 miles per hour will be considered maximum.
(5) Position auxiliary supports as necessary to
adequately prevent accidental injury to personnel or
damage to aircraft.
2-10 Change 6
TM 1-1500-204-23-1
(9) Head aircraft into prevailing wind when (1) Remove all excess items such as
wind velocity does not exceed velocity given in step (8). baggage, etc, from aircraft. Do not allow personnel in or
on aircraft during hoisting operations.
(10) After jacks are extended, make no
attempt to lock hydraulic ram in place by use of a (2) Apply ballast as required by applicable
clamp. Jacks with threaded collar locks or locking pins maintenance manual.
will not permit load to lower, but may require additional
lift to disengage collar lock or remove pin. (3) Attach hoist sling at hoist location
specified in applicable maintenance manual.
(11) Prior to lowering aircraft, make a careful
inspection to ensure that retractable gear (when (4) Ensure that th ere is sufficient clearance
applicable) are in down-and-locked position, ground above aircraft to complete desired operation.
locking devices are installed, and that there are no
maintenance stands, support equipment, or other (5) Fasten ropes to mooring points of aircraft
objects under aircraft. and use ropes to steady and guide aircraft during
hoisting operation.
(12) After aircraft no longer rests on jacks,
remove jacks from under aircraft as quickly as possible. (6) Hoist aircraft cautiously and smoothly,
avoiding sudden starts, stops, and drops.
b. Hoisting. Use the following procedures for in
and out of hangar hoisting: (7) Ensure that retractable gear down-lock
pins are installed prior to lowering aircraft.
CAUTION
Hoist aircraft out-of-hangar only (8) Ensure that all maintenance and support
when wind is calm. Otherwise equipment which could injure personnel or damage
damage to aircraft may result. aircraft is removed from under aircraft.
2-11/(2-12 blank)
TM 1-1500-204-23-1
CHAPTER 3
FLIGHTLINE OPERATIONS
3-1. General. General flightline operations used on all After work has been accomplished, inspect to
aircraft are described in the following paragraphs. ensure that all accessories and attaching parts
are secure and that work areas are cleared of
3-2. Flightline Safety. To avoid injury to personnel or foreign objects prior to engine operation.
damage to aircraft, the procedures and general safety
rules will be followed when servicing, operating, Provide properly marked receptacles in all
mooring, maintaining, or moving aircraft on the ground. work areas into which trash, ferrous and
nonferrous scrap, safety wire, etc, may be
a. Hearing Protection. Noise levels reached placed.
during ground runup of Army aircraft are of a level that
may cause permanent hearing loss. Maintenance Adhere to applicable gas turbine-powered
personnel shall wear adequate hearing protection when aircraft taxiing and parking procedures as
working on aircraft with engines in operation. outlined in applicable technical bulletins. This
minimizes damage due to material being
b. Foreign Object Damage. To prevent Foreign thrown by the exhaust blast into the intake of
Object Damage (FOD), the following precautions shall other aircraft.
be observed during maintenance of turbine engines.
Ensure that gas turbine-powered aircraft
Regularly police parking areas, runways, takeoff and landing procedures are such as to
taxiways, and runup and exhaust areas to avoid the intake of foreign objects blasted
ensure against the presence of foreign objects from runways and runway shoulders by
which could enter the engine. Special preceding aircraft.
attention shall be given to cleaning of cracks
and expansion seams in hard surfaced areas Use inlet duct runup screens during all ground
where engines will be operated. Tests have operations, including taxiing to and from
indicated that these are the main source of takeoff position.
foreign objects which are ingested.
Inlet duct runup screens are not required on
Periodically instruct personnel concerned with aircraft using centrifugal flow engines.
aircraft maintenance of foreign object hazards
to ensure that maximum preventive measures When necessary to properly evaluate engine
are taken. performance or when icing conditions exist,
inlet duct runup screens should be removed.
Ensure that air inlet and tailpipe dust Runup with screens removed shall be made in
excluders are installed at all times when a designated, thoroughly cleaned area.
engines are not being operated, except when
it is known the engine will again be operated CAUTION
immediately following shutdown. Inlet duct runup screens shall not be
installed and removed with engines
Prior to each engine start, thoroughly inspect operating above idle rpm. Loose
and clean inlet ducting. Remove all loose items of clothing shall not be worn.
nuts, bolts, tools, or other objects which would Objects which might be drawn into
cause engine damage and possible the intake ducts shall not be carried
subsequent failure. when installing or removing screens.
Damage to equipment may otherwise
result.
3-1
TM 1-1500-204-23-1
Inlet duct runup screens may be left off during d. Parking and Mooring. The following instructions
taxiing to and from takeoff position when are general in nature, and are applicable to Army
requirements or existing conditions make the aircraft. For specific instructions on parking and
use of screens impractical. Since specific mooring particular aircraft, refer to the applicable
conditions warranting removal of screens as maintenance manual. The following are general
specified above cannot be predetermined, precautions for all aircraft.
specific conditions may be determined by
each command as necessary to conduct their Do not park or moor aircraft closer than wing
operations. Approval of screen removal or rotor span, except by authority of the
should include any additional precautions commanding officer or his designated
necessary to assure safe operation of representative.
engines.
NOTE
Use only nonmetallic-head hammers when When aircraft are to be parked in
required to install parts on engine. rows, position aircraft in adjacent
rows to most effectively reduce
c. Safety Around Aircraft. The following safety propeller wash during engine
precautions shall be employed to ensure safety around operation.
helicopters on the flightline.
When possible, park aircraft in such a location
Stand clear of plane-of-rotation of engine that transparent enclosures are not in direct
cooling fan during operation. rays of sun.
Stand clear of tail rotor plane-of-rotation Install gear locking devices (when applicable).
during operation.
Attach mooring ropes to aircr aft and
Main rotor blades tend to droop at decreased ground fittings at an angle of approximately
speeds, approach with caution, especially 45 degrees. Attach mooring ropes and install
blades with a low plane-of-rotation. mooring devices as specified in applicable
maintenance manual.
WARNING
Personnel shall exercise extreme NOTE
caution when hand-pulling a Allow sufficient slack in the mooring
propeller to keep their bodies as rope to prevent stress on ground
clear of the plane-of-propeller- fittings, rope, mooring devices, or
rotation as conditions permit. aircraft structure due to tire or strut
Ground crew-members should be inflation/deflation, or wet rope
conscious of the fact that an shrinkage.
accidental start may occur at any
time, and should therefore be alert to Place fully charged, 50 pound carbon dioxide
jump clear in such an event. A type fire extinguishers in readily accessible
suitable length of canvas strap or areas where aircraft are parked.
similar material, without metal
fittings, may be placed around When aircraft are to be moored for storage,
propeller blades to facilitate hand- they shall not be parked less than 750 feet
pulling. Be especially certain that from center of nearest taxiway. Provide
the ignition switch is in the OFF adequate clearance for maintenance,
position before turning propeller by servicing, fire lanes and taxiways.
hand. Death or injury may otherwise
result. All aircraft parked inside enclosures will be
grounded at all times.
3-2
TM 1-1500-204-23-1
Place chocks fore and aft of main landing Refer to the applicable aircraft maintenance
gear wheels. Do not use parking brakes as manual for the use of spoilers if severe wind
substitutes for chocks. Use steel chocks for is expected.
snow or ice operating only. Use sandbags on
steel matting. Use wooden chocks for all Ensure aircraft is chocked and tied down in
other operations. Set brakes only after they accordance with applicable maintenance
have cooled. manual storm procedures.
3-3
TM 1-1500-204-23-1
(c) Check powered ground support on smooth surface and jerk the paper liner off to half
equipment for operation at peak, rated output, and the length of strip. Fold loosened paper liner.
capacity for which it was designed.
(d) Position tape on equipment and adhere
(d) Check nonpowered ground support one edge with finger. Hold unapplied portion slightly
equipment for performance capabilities within the away from surface to prevent premature adhesion.
purpose for which it was designed. Wipe tape to surface with firm pressure, using a plastic
squeegee. Remove remaining liner and apply
(e) Check equipment for unusual noises remainder of tape. Any air bubbles should be pricked
during operation. An unusual noise is any sound that with pinpoint and air worked out with squeegee.
indicates malfunction or improper operation of a
component. NOTE
Apply only when equipment surface
g. Reflectorizing of Equipment. All non-tactical temperature is above 60°F (16°C).
ground support equipment (which is normally painted Activate adhesive lightly with a
yellow) will be outlined with reflective tape to ensure solvent activator as recommended by
high visibility during low light level operations. the reflective tape manufacturer.
(1) Outlining. Equipment shall be marked in (e) Apply clear edge sealer, as recommended
a manner to outline the entire piece of equipment, so by reflective tape manufacturer, to edges of tape to
that during periods of low visibility the entire outline of prolong life of marking.
the equipment will be obvious. Outline using the
following procedures: (f) Repair to damaged reflective areas can
be made without stripping of original material. Abrade
(a) Outline the equipment with 4-inch wide any rough edges, clean damaged area thoroughly and
silver-white tape conforming to Federal Specification L- apply a new piece of reflective tape over damaged area.
S-300, NSN 9390-00-949-8047.
NOTE
(b) Compound surfaces (corners, large bolts, The reflective tape cannot be
rivets, etc.) may be left unmarked. subjected to paint oven baking
process.
NOTE
If area to be striped can not (3) Use of flags. All support equipment which
accommodate 4-inch wide tape, use cannot be taped (i.e., tactical vehicles, tractors,
the widest width possible. sweepers, occasional use vehicles, etc) will display a
white-orange checkered flag conforming to MIL-F40047,
(2) Application of reflectorizing sheeting. The NSN 8345-00-027-3704. The flag will be flown while on
following procedures shall be used to apply the flight line or any area in which aircraft may be
reflectorizing sheeting, Federal Specification L-S-300: present. The flag shall be mounted to facilitate easy
removal when departing airfield area or when entering
(a) Clean surfaces of all loose sc ale and dirt into a tactical condition.
by brushing or applying cleaning compound, Federal
Specification P-C-437. Remove deposits of cleaning 3-3. Ground Handling. Aircraft shall not be moved
compound by washing with clear water. Dry surfaces where, or in such a manner that, injury to personnel or
with high-pressure compressed air. damage to the aircraft or property could result. Ensure
tow tug drivers are trained to tow all types of aircraft
(b) Measure reflectorizing sheeting and cut to prior to towing and exercise supervision when
desired lengths. necessary. For specific instructions on a particular
aircraft, refer to the applicable maintenance manual.
(c) Start removal of protective paper liner from Aircraft shall not be moved where, or in such a manner
adhesive by holding the tape reflective side in and flick that injury to personnel or damage to the aircraft or
one corner sharply in toward reflective face. When property could result. The following paragraphs contain
corner is loosened lay the reflective side of tape down general procedures for ground movements, towing,
pushing, and standard visual signals.
3-4
TM 1-1500-204-23-1
a. General Procedures. The following proce- (3) Use caution when towing aircraft in ex-
dures are for all ground movements: tremely low temperatures to prevent damage to hy-
draulic seals which would result in strut leakage.
(1) Disconnect and move clear all ground sup-
port, ground servicing, and maintenance equipment not c. Pushing. Push aircraft by hand in accordance
essential to movement of the aircraft. with the applicable maintenance manual. The following
procedures are for general hand moving of all aircraft:
(2) Assign an authorized ground crewmember
to operate aircraft brakes, as required, from the time
chocks are removed until they are reinstalled.
Keep clear of skids, aircraft wheels, and/or
(3) Assign a ground crewmember to stand near ground handling wheels.
tip of each wing to act as a guide during ground move-
ments. (1) Position ground handling wheels (when ap-
plicable) in down-and-locked position.
(4) Stand clear of aircraft immediately prior to
and during movement. (2) Apply physical pressure for pushing, lifting,
and turning only at authorized pressure points as desig-
(5) Assign a qualified ground crewmember to di- nated in applicable maintenance manual.
rect departure from, or approach to, a parking position.
Only approved standard signals will be used. Use a (3) Push by hand at proper pressure points.
flashlight or luminescent wand to signal instructions at
night. (4) Senior person will brief duties and dangers
of ground handling aircraft.
(6) Do not stand, sit, or lie on any external por-
tion of an aircraft while it is in motion. Do not jump from d. Standard Visual Signals. Visual signals for
or board a moving aircraft. movement of Army aircraft are contained in FM 1-105
or FM 21-60.
(7) When moving aircraft, avoid sudden stops
and starts. 3-4. STATIC GROUNDING OF AIRCRAFT. Standard
grounding of aircraft is explained in the following para-
(8) No person, vehicle, or aircraft shall ap- graphs.
proach close to an oncoming taxiing aircraft, pass closer
than 200 feet to the rear of an operating turbine-pow- a. Grounding Requirements. Positive require-
ered aircraft, or pass closer than 100 feet to the rear of ments for grounding or bonding of aircraft are as follows:
other operating aircraft.
NOTE
(9) Do not taxi or tow aircraft, or start or runup
engines within 50 feet of any fuel, oil, or water-alcohol Grounding of aircraft during refueling is no
servicing operation, or within 50 feet of any spill until the longer required by NFPA standards 77 and 407.
spill has been removed and the area rendered safe. Grounding will not prevent sparking at the fuel
surface. (See Chapter 2, Section III for more
b. Towing. Tow aircraft in accordance with the ap- information).
plicable maintenance manual. The following procedures • All aircraft parked outside will be grounded
are for general towing of all aircraft. and bonded, in accordance with FM 1-500,
to the aerospace ground equipment while
(1) Prior to towing aircraft, ensure that towing servicing (i.e., fueling or defueling, arming
attachments, lines, and bars are of adequate capacity, ammunition or explosives, oxygen, hy-
serviceable, and secured firmly to designated tow fit- draulic fluids, or any flammable liquids).
tings of aircraft and tow vehicle. Grounding is not necessary for aircraft
parked outside unless one of the above is
(2) Do not exceed the walking speed of the being accomplished.
slowest team member, with a maximum speed of 5
mph. Tow with extreme care over ice, snow, rough, • Gounding of aircraft is required when exter-
rocky or muddy ground and in congested areas. nal power is applied to the aircraft.
Change 6 3-5
TM 1-1500-204-23-1
• All aircraft parked in a hangar must be (1) Frequency of testing. Each ground rod
grounded at all times. must be inspected when it is installed. Ground wires
are inspected monthly. The grounding system must be
• To prevent accidental falls, appropriate inspected and tested every five years or when there is
maintenance platforms/safety stands or a possibility of mechanical damage. If any damage is
any other approved locally procured/manu- found, it must be repaired immediately.
factured safety stands/restraint equipment
will be used when working (above 4 feet) (2) Method of testing. Ground rods are tested
on aircraft in a non-tactical environment. with a multimeter (Multimeter: TS-352B/U, LIN M81372,
NSN 6625-00-553-0142). Refer to FM 10–67–1 for spe-
b. Earth Grounds. An earth ground (electrode) is cific procedures when testing ground rods.
a conductive pipe or rod made of galvanized iron, galva-
nized steel, or copperweld steel. The rod regularly used d. Fabrication of Ground Cable. Fabricate static
for grounding is Rod, Ground: MX-148G Line Item Num- grounding cable assembly, as shown in figure 3-1, using
ber (LIN) S08698, National/NATO Stock Number (NSN) the following procedures:
5975-00-224-5260. This ground rod is ¾ inch in diam-
eter and 6 feet long, and it is made of galvanized steel. (1) Cut wire rope (figure 3-1, 1) to length
It has one pointed end to be driven into the earth and a needed.
bolt and nut at the other end for connecting a grounding
cable. (2) If coated wire rope (1) is used; remove ¾
inch of coating from each end.
(1) Use of earth grounds. The rod is driven
into the earth far enough to reach below the permanent (3) Loosen set screws (4) in clip (5).
ground-moisture level. On the apron or ramp of a fixed
airfield, the top of the rod should be level with the sur-
(4) Insert wire rope (1) into handle of clip (5) and
rounding surface; at other types of facilities, the top of
tighten set screws (4).
the rod should be either low enough or high enough so
that people will not trip over it. If the top of the rod is
(5) Insert unattached end of wire rope (1)
level with the surrounding surface, an area around the
through cap (2). Rope will extend past end of cap.
top of the rod must be dished out so ground cable clips
can be attached to the rod.
(6) Screw cap (2) into plug (3).
(2) Marking of earth grounds. A yellow circle
18 inches in diameter, with a 2-inch black border sur- (7) If desired, clips (5) may be attached to both
rounding it, should encircle each rod that is installed in a ends of wire rope (1) with a plug (3) attached to handle
hard surface. These circles should be painted on. The of one of the clips as follows:
words STATIC GROUND CONNECTION and a numeric
or alphanumeric identification of the rod should be sten- (a) Cut short length of wire rope to attach plug
ciled in black on the yellow circle. The number and spac- to clip.
ing of fixed rods should be determined by the require-
ments of the local situation. Markings of this type are (b) Assemble items for alternate configura-
not required for temporary ground rods. tion as in (2) through (6) above. See detail A for view
of alternate cable assembly.
c. Earth Ground Testing. The electrical resis-
tance of each grounding system should be as low NOTE
as possible but not greater than 10,000 ohms. A log
Never fasten electrical clip to a painted surface.
must be kept for airfields to show the identification of
each rod, the date tested, and the reading in ohms.
(8) Insert plug into receptacle on aircraft. Attach
If the measured resistance of a rod is greater than
clip to grounding stake.
10,000 ohms, the rod should immediately be marked
DEFECTIVE-DO NOT USE and it should be removed
or replaced as soon as possible. A log is not required (9) Attach warning streamers, NAS 1756-12 or
at temporary refueling points. MS 51700-12, to coated wire rope.
3-6 Change 6
TM 1-1500-204-23-1
KEY TO FIGURE
5935-00-572-5174 PLUG-TIP,
CONSISTING OF:
2. CAP
3. PLUG
4. SET SCREW
Change 6 3-7
TM 1-1500-204-23-1
(10) Attach yellow reflective tape, 9390-00-040- inches (1066.80 mm) and not less than 12
6102, to non-coated wire rope. inches (304.80 mm) from the filler opening.
(a) Wrap tape around handles of clip and • Receptacle can be grounded by mounting
around the wire at three-foot intervals. or bonding to aircraft structure.
(b) Do not apply tape to those parts of plug • Receptacle shall be used with ground-
and clip that complete electrical circuit. ing plug conforming to MIL-C-83413/MIL-
C83410.
(11) Test ground cable for resistance to ground.
• Dissimilar metals as defined by MIL-STD-
889 be used in intimate contact with each
e. Ground Receptacle Criteria. Aircraft ground- other.
ing receptacles, as shown in figure 3-2, shall conform to
the following criteria: • Place a fully charged fire extinguisher (50 lb
CO2 or 22 lb Halon 1211) in readily acces-
• For internal and external tanks, the recep- sible area where aircraft are parked.
tacle shall be installed at not more than 42
NOTES:
METRIC EQUIVALENTS (TO THE NEAREST .01 MM) ARE GIVEN FOR GENERAL INFORMATION ONLY AND ARE BASED UPON 1
INCH - 25.4 MM.
3-8
TM 1-1500-204-23-1
Change 4 3-9
TM 1-1500-204-23-1
b. Open-Port Hot Refueling. In combat oper- blades are secured, and armaments are set on SAFE,
ations, the open-port method of hot refueling may be the sequence of the refueling operation can start. The
used for helicopters when, in the judgment of the avia- following procedures are for all aircraft:
tion commander, the requirements of the tactical mission
and the benefits of reducing ground time outweigh the (a) Check the interior of the aircraft. No
inherent risks of this method of refueling. In noncombat
situations, helicopters may be refueled by this method one should be aboard during refueling unless the pilot
only when there are compelling reasons to do so. For or copilot are on board to monitor the quantity of fuel to
example, aviation commanders may decide that hot re- be loaded. When the D-1 nozzle is used, the only way
fueling must be done for purposes of training, or for field of knowing when to stop flow is for the pilot or copilot to
testing or combat testing for development. When the watch the fuel gauges in the aircraft.
FARE system is used for hot refueling in a training situ-
ation, a firewall should be built around 500-gallon drums (b) Drive the tank vehicle into position in
whenever it is possible. Refer to FM 10–67–1. front of the aircraft. Use the sort of approach route
shown in figure 3-3. Do not drive the refueler directly
NOTE at the aircraft because brake failure could cause a seri-
Nozzles of the open-port type must be held ous accident.
open by hand throughout use. If any automatic
device has been added to the nozzle to hold it (c) Keep a distance of at least 10 feet be-
open, the device must be removed; if notches tween the refueler and the aircraft. There must be at
have been made to hold open, they must be least 10 feet between the refueler and rotor blades of a
filed off. No exceptions to this rule are allowed helicopter. Keep a distance of at least 20 feet between
in aircraft refueling. the exhaust pipe of the pump engine (or truck engine)
and the aircraft fill port and tank vent as shown in figure
c. Rapid Hot Refueling. Aircraft may be rapid 3-4.
(hot) refueled (with engines running), electrical power
on, radios on, weapons system on with safety cov- (d) Park the refueler so that it has a clear
ers/guards/switches in safe position, and with any and open path to drive away from the aircraft in an emer-
computer systems operating that would require repro- gency. Do not detach a tank semitrailer from its tractor
gramming if shut down. See the applicable aircraft when refueling an aircraft; the tractor must be ready to
operator’s manuals (-10 and -CL) for detailed instruc-
tions. If rapid (hot) refueling is required (prescribed in pull the trailer away from the aircraft if the need arises.
FM 10–67–1), ground the aircraft properly. It is also
recommended that the aircraft be in a revetment type NOTE
shelter or separated from fuel storage by a fire wall.
If the refueler can be driven into position without
backing, do so. If it must be backed toward the
WARNING aircraft, bring the truck to a full stop when it is
20 to 25 feet away from the aircraft or its rotor
blades. Have another person act as a ground
Only emergency radio transmissions should guide. Follow signals to guide the final backing
be made during rapid (hot) refueling. Ra- approach until signaled to stop at the proper dis-
dio switches may electrically arc when being tance from the aircraft and its fill port and vent,
keyed. as shown in figure 3-5.
d. Fuel Truck Operations. Fuel truck operations
are covered in the following paragraphs. (e) Stop the refueler engine (unless it pow-
ers the pump) and set the brake. Chock the tires of the
(1) Fuel truck types. The M49A2C tank refueler and of the aircraft if appropriate.
truck with a 1,200 gallon stainless steel tank, the M559
tank truck with a 2,500 gallon stainless steel tank, and (f) Check the fuel in the tank to make sure
the M857 semitrailer with a 5,000 gallon tank are used it is the right type for the aircraft. Check the sight glass
to fuel Army aircraft. of the filter/separator to make sure all water has been
drained out.
(2) General operation. After the aircraft
parks and its engine or engines are shut down, the rotor
3-10 Change 4
TM 1-1500-204-23-1
3-11
TM 1-1500-204-23-1
(g) Place the truck fire extinguisher by (i) Ground the aircraft by attaching one
the pump. Place a fire extinguisher provided at the end of a ground cable to the ground rod (either the rod
refueling point by the aircraft fill port. that grounds the refueler or a separate ground rod) and
the other end to a bare metal part of the aircraft.
NOTE
Have members of the ground crew or the NOTE
air crew man these two fire Use the axle of the landing gear or some
extinguishers. If there are no people other unpainted metal part, but do not
available to man the fire extinguishers, clip the ground cable to the propeller or
place the extinguishers near the pump the radio antenna. Attaching this clip
and nozzle operators, but position them grounds the aircraft and bonds the
so that they will not be in the operators refueler to the aircraft. If the refueler
way and where they are not likely to be does not have a Y-cable that will ground
engulfed if a fire should start at either both the refueler and the aircraft to one
the pump or the nozzle. ground rod, a separate ground cable is
required to ground the aircraft. A wire,
(h) Unreel the ground cable and attach such as building wire (type TW, number
its ground-rod clip to the nearest ground rod. If refueling 14 AWG or larger, solid copper) or any
where no ground rod is installed, drive the refueler other solid copper wire, size number 14
ground rod into the earth to the required depth and or larger, may be used.
attach the clip to the rod.
Change 1 3-12
TM 1-1500-204-23-1
(l) Refuel using procedures outlined • Do not allow flashbulbs or electronic flash devices
in FM 10-68. to be used within 10 feet of refueling equipment
or the fill port or fuel tank vents of aircraft.
(m) Replace the cap on the fill port
and then replace the nozzle dust cap before • Do not remove any piece of clothing while within
disconnecting the nozzle bond. 50 feet of a refueling operation or in an area
where a flammable vapor-air mixture may exist.
(n) Remove the nozzle bond plug or
undo the alligator clip Reel up the hose and nozzle Do not NOTE
drag the nozzle across the ground. If fuel gets on clothing, leave the
refueling area as soon as refueling is
(o) Undo the clip that grounds the completed. Wet the clothes with
aircraft Replace the fire extinguisher used at the nozzle. water before taking them off if there
is not enough water at the site to wet
(p) Release the clip on the ground the clothes thoroughly, ground
rod and reel up the grounding cable. Do not drag the yourself to a piece of grounded
cable clips across the ground. If the refueling operation is
equipment by taking hold of it with
over and the refueler ground rod was used, pull the rod up
both hands before taking off the fuel-
and stow it in the refueler. Replace the fire extinguisher
soaked clothes. A skin irritation
in the refueler.
from fuel is not fatal, the fire that
(3) Safety requirements. The following may follow a static discharge from
safety requirements must be followed when refueling clothes may be.
Army aircraft.
• Do not enter a flammable atmosphere right after
• Do not allow any open flame, open-flame device, removing a garment. Wait at least 10 minutes
or lighted smoking materials within 50 feet of an before carrying the garment into such an
aircraft refueling operation. atmosphere.
3-13
TM 1-1500-204-23-1
NOTE NOTE
Before opening an aircraft fuel port Restrict vehicle access to the
or doing anything else that would let refueling area, allow only those
fuel vapors escape into the air, bond vehicles actually involved in
yourself to the container by taking servicing aircraft to come within 50
hold of it. If it is an aircraft or piece feet of the refueling operation.
of metal equipment, take hold of a Vehicles used in and around
bare metal part with both hands for a refueling areas must be maintained
few seconds. Although this bonding to a high standard of performance to
will not completely discharge the prevent the fire hazards of backfires
static electricity, it will equalize the and sparks. The electrical circuits of
charge with the charge on the piece vehicles used in refueling operations
of equipment. must be maintained in top condition
to prevent short circuits around
• Do not refuel an aircraft until its engines are shut defects.
down, except as provided in hot refueling.
(4) Fuel contamination. Care shall be
• Do not allow any work to be done on an aircraft's taken when refueling to prevent fuel contamination.
batteries while the aircraft is being refueled. Sediment, water, microbiological growth, and mixed fuels
can cause fuel contamination and danger for aircraft
NOTE operations.
The batteries should not be raised or
lowered, and battery chargers should (5) Protective clothing. To date, no regular
not be connected, used, or Army uniform (suitable for everyday field wear) has been
disconnected during refueling. developed for personnel who handle aviation fuels.
Therefore, wear the standard combat uniform. Air
• Stop refueling operations when there are lightning crewmembers should wear the nylon fire-retardant
discharges in the immediate area. uniform but should know that it loses its protective
properties if it is saturated with a petroleum product.
• Do not fuel an aircraft or store aviation fuel within Because combat uniforms and flight suits are not
100 feet of the antenna of an airfield surface- impervious to petroleum, use great care in refueling
detection radar. operations to avoid spilling fuel on your clothing.
• Do not fuel an aircraft or store aviation fuel within 3-6. Oil Servicing. Oil servicing precautionary
300 feet of the antenna of an airfield approach measures are required due to the flammable nature of oil.
and traffic control radar. General precautions for oil servicing are the same as for
fuel servicing. Additional safety precautions for oil
• Airborne surveillance units must be shut down servicing and draining are contained in the following
before the aircraft approaches within 300 feet of a procedures:
refueling or fuel storage area.
WARNING
• A weather-mapping radar unit mounted in an To avoid contamination in oil supply
aircraft must be shut down before and during for gas turbine and reciprocating
refueling of the aircraft. engines, do not use previously
opened cans of engine oil. A new
• Radio transmission from the aircraft being sealed can of oil must be opened and
refueled is not allowed because of the danger of used. When opening can, clean top
arcing. and use a clean, sharp, unplated
instrument to prevent contamination.
3-14
TM 1-1500-204-23-1
NOTE
Never use flammable solvents to remove oil
spillage.
Oxygen equipment shall be kept clean at all
b. Exercise caution to prevent overfilling or times. No organic matter or flammable sub-
spilling.
stance of any nature shall be allowed to con-
tact oxygen. Ensure that all components of the
NOTE systems are free of moisture, oil and grease
When oil has been spilled, immediate action at all times. Oxygen is a nonflammable gas;
shall be taken to remove spillage from aircraft however, it supports combustion and lowers the
and adjacent area. Clean rags may be used to flash ignition point of all combustible materials.
remove oil spillage from the aircraft. Sand, dirt, Oxygen shall be handled as a flammable gas.
sawdust, or commercial products may be used
to remove oil spillage from adjacent ground. When an aircraft is being serviced with oxygen
within 50 feet of an area where smoking is per-
3-7. Oxygen Servicing. Oxygen servicing requires mitted, NO SMOKING signs shall be placed at
the utmost precautionary measures due to the highly ex- a 50-foot radius around the servicing area. A
plosive and flammable capabilities of oxygen. Prior to spark in the servicing area could cause an ex-
servicing an aircraft oxygen system, personnel shall fa- plosion and damage to equipment.
miliarize themselves with the system, precautions, and
instructions for handling gaseous oxygen, operation of (1) To prevent overfilling of tanks, personnel
servicing equipment, and potential hazards involved. shall observe aircraft oxygen system gauges at all times
during servicing operation.
3-15
TM 1-1500-204-23-1
3-8. Hydraulic Fluid Servicing. Hydraulic fluid ser- for reciprocating and turbine engines are contained in
vicing precautions are explained in the following para- the following paragraphs.
graphs.
a. Safety Procedures. Safety procedures prior
to starting, during starting, during engine operation, and
WARNING after operating engines are covered in the following
paragraphs.
To avoid contamination, do not use previously (1) Safety procedures prior to starting.
opened cans of hydraulic fluid. Cans of hy- The following safety procedures should be accom-
draulic fluid cannot be resealed. Immediately plished prior to starting:
transfer unused hydraulic fluid to an approved
airtight, pressure venting, stainless steel stor- (a) Head aircraft so that exhaust blast is
age reservoir, an approved hydraulic servicing directed to least inhabited areas.
unit or a hydraulic test stand containing the
same hydraulic fluid. When opening can, clean
(b) Place approved chocks fore and aft of
top and use a clean sharp, unplated instru-
main landing gear wheels.
ment to prevent contamination. Can openers
attached to the aircraft must be cleaned before
using. (c) Clear aircraft and surrounding areas of
covers, tools, rags, work stands etc., and remove moor-
a. Do not overfill reservoir or spill fluid in sur- ing ropes.
rounding areas. When fluid is spilled, absorb with clean
rags. (d) Secure access doors by closing or re-
moving prior to ground testing turbine-powered aircraft
b. When filling reservoirs, extreme care shall be engines.
taken to ensure that no dirt or foreign matter enters the
system.
(e) Do not allow personnel on any external
c. Refer to applicable aircraft maintenance portion of an aircraft during engine start or operation.
manual for additional servicing and maintenance in-
structions. Use only specified hydraulic fluid. (f) Station ground crew member, equipped
with a carbon dioxide or equivalent fire extinguisher to
3-9. Pneumatic System Servicing. Safety precau- one side and forward of engine being started. This crew
tions for servicing pneumatic reservoirs are contained in member will observe for fire and fire hazards, such as
the following paragraphs. fuel from overflow lines, fuel/oil leakage, chock slippage,
and other irregular conditions.
a. Never use pressure oxygen to inflate gear
shock struts, pressure accumulators, etc.
e. Exercise care not to overcharge the system. If ground crewmember does not have radio
communication, he must stand in view of air-
f. Completely discharge pressure prior to remov- craft operator.
ing a component from the system.
(g) When appropriate, station a responsi-
3-10. Engine Operation. For operation and spe- ble ground crewmember off to one side, away from dan-
cific instructions on a particular fixed or rotary wing Army ger areas, and aft of operating turbine powered aircraft,
aircraft, refer to the applicable maintenance manual. to warn approaching traffic. Use a danger flag when
Safety procedures and general operating procedures necessary.
3-16 Change 4
TM 1-1500-204-23-1
(2) Safety procedures during starting. The (4) Safety procedures after operating
following safety procedures should be accomplished engines. The following safety procedures should be
during starting: accomplished after engine operation:
(a) Employ hand signals for directing (a) Place ignition switch in OFF
activity when engine operating noise will not permit voice position. It is imperative that the ignition switch of an
communication. aircraft engine be in OFF position when engine is not
operating. Master battery switch shall be turned off when
(b) Avoid excessive fuel pressure no longer required.
when starting turbine engines.
(b) Turn off all tank selector and
(c) When fire occurs during engine emergency fuel system valves.
start, or while operating, the operator shall take necessary
action, as outlined in applicable maintenance manual, to (c) When practicable, make
extinguish flame. Should this action fail, the fire guards adjustment to engine and rotors with engine stopped.
shall take immediate action with approved fire
extinguishing agent provided. Should fire get beyond b. Turbine Engines . Turbine engine starting,
control of operator and fire guard, all available approved ground checks, and shutdown are covered in the following
means of extinguishing an aircraft or engine fire shall be paragraphs.
used.
(1) Starting Start engines using the
(d) During start, and while engines following general procedures.
are operating, personnel shall stand well clear of
propellers and of areas affected by turbine air intake flow (a) Remove ice or frost from engine
and exhaust blast. cowling and inlet section prior to starting.
(e) All personnel will remain clear of (b) Connect an authorized auxiliary
engines necessitating close inspections or adjustment, as power unit.
directed by the specific equipment manual, until operating
engine speed (rpm) has been obtained. (c) When specified minimum starting
rpm cannot be obtained with available auxiliary power
(f) Do not use a quick, excessive unit, preheat accessory section and oil reservoir to reduce
throttle start on rotary aircraft This kind of start could starting loads. Aircraft battery may be used as a boost to
swing the tail rapidly, with the possibility of injury to obtain required rpm.
personnel or damage to equipment from the tail rotor
Keep personnel and equipment clear of aircraft at a NOTE
distance at least equal to its length In normal temperatures, starting
attempts below recommended
(3) Safety procedures during engine starting rpm increases the possibility
operation. The following safety procedures should be of engine damage due to hot starts.
accomplished during engine operation.
(d) Accomplish engine starts
(a) Do not operate engines in according to procedures outlined in the applicable
hangars. maintenance manual, using specified jet fuel or required
alternate.
(b) Do not operate aircraft engine
where propeller or turbine blast would cause injury to (e) When there is no oil pressure
personnel or damage to aircraft and property. after sufficient runup time, or if oil pressure drops below
operating range after a few minutes of ground operation,
(c) Nonrated personnel cannot run shut down engine and determine cause
up rotary wing aircraft under any conditions. .
3-17
TM 1-1500-204-23-1
3-18
TM 1-1500-204-23-1
(6) Avoid snow and slush blown by preceding (2) Inspect oil and fuel drains and crankcase
aircraft by increasing distance between aircraft when breathers for ice or frost. Remove any existing frost or
taxiing. ice.
(7) Reduce taxi speeds to ensure safe stop- (3) Inspect battery for charge at least once a
ping. week. If layovers are to be over 4 hours and temperature
(8) Exercise care when pulling out or turning is below -20°F (-29ºC), remove battery and store in a
from parking line to ensure that other aircraft will not be warm place.
damaged or covered by snow and ice from propeller
blast. (4) Drain oil system when there is no provision
available for preheating oil and a long layover period is
(9) Avoid taxiing into deep snow or snow drifts, anticipated.
as steering could become difficult, brakes could freeze,
and damage to propellers could result. (5) When temperature rises above freezing
during a long layover, drain fuel and oil tank sumps of
(10) Unless aircraft is equipped with an auxiliary water before temperature drops.
power unit, use only essential electrical equipment to
preserve battery life while taxiing at low engine speeds.
3-12. Test Flights and Maintenance Operational
b. Taxiing. The following are general procedures for Checks. Maintenance test flights are categorized as
taxiing: general test flights and limited test flights. Specific and
(1) Only personnel authorized to taxi as speci- mandatory requirements for accomplishment of aircraft
fied in AR 95-1 may taxi Army aircraft. test flights and maintenance operational checks are
found in Section III, TM 55-1500-328-23.
(2) Do not taxi aircraft on any taxiway which
runs within 100 feet of active runways unless necessi- a. Test Flight Safety Maintenance test flights will be
tated by terrain or directed to do so by proper authority. accomplished with assistance as necessary from the
most proficient flight crew available; i.e., copilot, techni-
(3) Upon approved signal from flight compart- cal inspectors, and observers. Aviators who are not grad-
ment, approach and remove wheel chocks. Exercise uates of The Aircraft Maintenance Test Flight course may
caution and consideration for operating propellers, tur- be designated as Maintenance Test Pilots upon success-
bine inlet, and exhaust areas. ful completion of an evaluation administered in accor-
(4) Use only sufficient engine power to gain roll- dance with FM 1-544. Minimum crew possible will be
ing momentum when taxiing aircraft from a row of parked aboard aircraft during test flight.
aircraft. When it is necessary to turn aircraft, gain
required momentum in straight movement to permit mak- b. Maintenance Operational Checks. Maintenance
ing turn with reduced power. operational checks (MCCs) are accomplished on the
ground through engine runup, aircraft taxiing or use of
(5) Under normal operations, wing guides will auxiliary power or testing equipment, in such a manner
not be mandatory. However, when an aircraft is maneu- as to simulate conditions under which the system is to
vered in proximity of other aircraft, buildings, or obstruc- operate. The purpose of an MOC is to assure that aircraft
tions, or in gusty or high wind conditions, there shall be systems or components which have been disturbed dur-
wing guides to ensure adequate guidance. ing an inspection or maintenance action have been
c. Postflight and Parking. The following procedures repaired, reassembled or adjusted satisfactorily.
are listed to prevent abortive flights following the last
c. Carbon Monoxide Detection. Determine the car-
flight of the day, and to protect parked aircraft: bon monoxide concentration in aircraft after every major
(1) Drain oil tank sump and main oil drain overhaul. Follow the procedures and limits in the instruc-
before condensation freezes. tions packed with the carbon monoxide detector.
Change 4 4-1
TM 1-1500-204-23-1
deteriorated locks, ground wires, chocks, mooring d. Operational Check. Perform Maintenance
ropes, and rods shall be replaced. Operational Check (MOC) and/or Maintenance Test
Flight (MTF) as required in accordance with TM
NOTE 1-1500-328-23.
Under some conditions, corrosion may attack 4-9. Shipment of Aircraft. Step by step pro-
the metal through the paint. In such cases, the cedures for the preparation, loading, tiedown, and
affected areas will be indicated by blisters or a unloading of Army aircraft for shipment by vessel, truck,
scaly appearance of the paint. and cargo aircraft are provided in the Preparation for
Shipment Manual applicable to the aircraft. Authority
4-6. Maintenance of Stored Aircraft. Precautions to take deviation from the procedures in the applicable
shall be taken to ensure that adequate maintenance will Preparation for Shipment Manual must be obtained, in
be accomplished to maintain the aircraft in the proper writing, from Commander, U.S. Army Aviation & Missile
state of preservation in accordance with applicable air- Command, ATTN: AMSAM-MMC-MM-DP, Packaging &
craft maintenance manual. For aircraft in flyable stor- Stock Readiness Branch, Redstone Arsenal, AL 35898
age, calender and dual criteria inspections will be com-
pleted as they become due. 4-10. Preservation and Packaging of Aircraft Com-
ponents. General information on the preservation
4-7. Entries in Aircraft Forms. When an aircraft is and packaging of Army materiel is provided by TM
placed in storage, process DA Form 2408 series forms 746-10, Marking, Packaging and Shipment of Supplies
in accordance with DA PAM 738-751. Include an entry and Equipment: General Packaging Instructions for
indicating the type of storage, the date placed in storage, Field Units. Detailed information is provided by TM
and the date represervation is due. 38-230-1 and TM 38-230-2, Preservation of Materiel
Preservation, Volumes I and II, respectively.
4-8. Removal of Aircraft from Storage. When an
a. Special Reusable Containers. Preservation
aircraft is removed from storage, the inspection and
and packaging instructions for major aircraft com-
maintenance performed will be dependent on the type ponents that have special reusable containers are
of storage the aircraft has been in. contained in the applicable Aviation Unit Maintenance
(AVUM) Technical Manual.
a. Depreservation. Depreserve aircraft in accor-
dance with applicable AVUM technical manuals. b. Packaging Procedures. Aircraft components
will normally be shipped in the same packaging the re-
b. Inspection. Perform preventative mainte- placement component was received in. When this is
nance daily inspection and all calendar and dual criteria not possible and assistance is required in determining
inspections that are due. the preservation and packaging of a specific compo-
nent, contact Commander, U.S. Army Aviation & Missile
c. Maintenance. Correct aircraft deficiencies as Command, ATTN: AMSAM-MMC-MM-DP, Packaging &
required. Stock Readiness Branch, Redstone Arsenal, AL 35898.
4-2 Change 4
TM 1-1500-204-23-1
CHAPTER 5
5-1. General. The marking system specified in the • Unserviceable (Repairable) Tag-Materiel (DD
following paragraphs provides the means for accurately Form 1577-2) and Unserviceable (Reparable)
identifying and indicating the condition of aeronautical Label-Materiel (DD Form 1577-3).
items.
• Unserviceable (Condemned) Tag-Materiel (DD
5-2. Marking Requirements. A single materiel Form 1577) and Unserviceable (Condemned)
condition tag shall be used to identify each aeronautical Label-Materiel (DD Form 1577-1).
component, assembly, kit, or set which is assigned a
Federal Stock Number and is stocked, stored, and issued • Suspended Tag-Materiel (DD Form 1575) and
as a single line item of supply. However, individual parts Suspended Label-Materiel (DD Form 1575-1).
of components, assemblies, kits, or sets which are
identified and listed as single line items of supply shall be • Test/Modification Tag-Materiel (DD Form 1576)
individually tagged when physically separated from the and Test/Modification Label Materiel (DD Form
component, assembly, kit, or set. 1576-1).
5-3. Materiel Marking. The following are the only 5-4. Method of Accomplishing Entries. When
materiel condition tags and labels authorized for use on initiating materiel condition tags or labels, entries will be
Army aeronautical items. These tags and labels are in made in the appropriate blocks as prescribed by DA PAM
addition to applicable maintenance forms, records, or tags 738-751.
required by DA PAM 738-751.
5-1/(5-2 blank)
TM 1-1500-204-23-1
CHAPTER 6
APPLICATION AND REMOVAL OF DECALS
6-1. General. Decals are suitable for exterior and inte- decal while immersed; allowing decals to soak
rior surface application as governed by MIL-D-8634 and less than one minute will result in the backing
MIL-D-8635 respectively. Prior to application of decals, not separating from decal.
the following instructions shall apply to assure proper
adhesion: (b) Place one edge of decal on prepared re-
ceiving surface and press lightly, then slide paper back-
ing from beneath decal.
Allowing decals to soak longer than three min- (c) Apply cyclohexanone, or equivalent, in
utes will cause the backing to separate from the rm, even strokes, to adhesive side of decal.
Change 5 6-1
TM 1-1500-204-23-1
6-2 Change 5
TM 1-1500-204-23-1
(3) No adhesive type. Application and re- tape adjacent to f rst tape or, alternatively, interposed
moval of no adhesive are explained in the following between words descriptive of main function.
paragraphs. (3) Systems not referenced. A white tape
(a) Application. Apply decals with no ad- with black lettering will be used for coding lines of sys-
hesive in accordance with the following procedures: tems such as the vacuum system not referenced in f g-
ure 6-1.
1 Apply one coat of cement, Federal
Specif cation MMM-A-1617, to decal and prepared
receiving surface. Table 6-1. Colors and Codes
2 Allow cement to dry until both surfaces
are tacky. Code
Color Specification No.
3 Apply decal and roll down to remove air
pockets. Light blue ANA Bulletin 166 501
Light green ANA Bulletin 166 503
Light yellow ANA Bulletin 166 505
Aliphatic Naphtha, TT-N-95, is extremely International ANA Bulletin 166 508
f ammable and toxic to eyes, skin, and res- orange
piratory tract. Wear protective gloves and
goggles/face shield. Avoid repeated or pro- Insignia red ANA Bulletin 166 509
longed contact. Use only in well-ventilated ar-
Maroon ANA Bulletin 166 510
eas (or use approved respirator as determined
by local safety/industrial hygiene personnel). Insignia ANA Bulletin 166 511
Keep away from open f ames, sparks, or other white
sources of ignition.
Aircraft gray ANA Bulletin 166 512
4 Remove excess adhesive with a cloth Gloss black ANA Bulletin 166 515
dampened with aliphatic naphtha, Federal Specif cation
TT-N-95. Brown Federal Standard 595 10049
(b) Removal. Remove metal decals by
moistening edge of foil with aliphatic naphtha, Federal (4) Type of tape. Aircraft tubing identif cation
Specif cation TT-N-95, and peeling decal from adhering marker tape (non-corrosive, heat, cold and solvent re-
surface. sistant), MIL-T-9906 conforming to MS87033, shall be
6-3. APPLICATION AND INSTALLATION OF IDEN- used.
TIFICATION TAPES. The Army uses two types b. Solid Color Band System. This alternate
of identif cation systems to code the plumbing lines system consists of the use of one, two, or three bands
and electrical conduits of aircraft. The two systems of ½-inch wide solid colored tape wrapped on various
used are the printed-symbolized tape system (the pre- lines for identif cation. This system is shown in f gure
ferred method), and the solid color band, (the alternate 6-2.
method). Identif cation tapes will be applied to plumbing (1) Tape colors. Colors for tapes used in this
lines and electrical conduits of all Army aircraft. system shall conform to color codes in ANA Bulletin 166
a. Printed-Symbolized System. This latest and and FED-STD-595 (refer to table 6-1).
preferred system utilizes printed colored tape (one inch
wide) with geometrical symbols. The main function of (2) Tape spacing. When more than one
the line is printed on the tape. Printing will be in accor- color of tape is required, tapes shall be placed approx-
dance with MIL-STD-1247. Colors will be in accordance imately 1/16 inch apart. When one color is used but
with ANA Bulletin 166 and FED-STD-595 (refer to table more than one tape is required, tapes shall be placed
6-1). approximately 1/8 inch apart.
(1) Colored tapes. Colored tapes as shown (3) Type of tape. Type II pressure-sensitive
in f gure 6-1 shall be used to identify aircraft system tape, A-A-113, shall be used for this system.
lines.
c. Application of Identification Tapes. The ap-
(2) Line content. Identif cation of system plication and use of both identif cation systems are the
line content or subsidiary functions may be indicated by same, and the following paragraphs are applicable to
additional words or abbreviations printed on a second both systems.
Change 5 6-3
TM 1-1500-204-23-1
THE ABOVE COLOR CODES REPRESENT DESIGNATION FOR SYSTEMS ONLY FOR CODING LINES WHICH DO NOT FALL INTO ONE
OF 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 OR
ABBREVIATIONS WHICH SHALL BE CARRIED ON A SECOND TAPE ADJACENT TO THE FIRST OR ALTERNATIVELY INTERPOSED BETWEEN
THE WORDS DESCRIPTIVE OF THE MAIN FUNCTION.
WARNING SYMBOL TAPES. 3/8 INCH WIDE. SHALL BE APPLIED TO THOSE LINES WITH CONTENTS CONSIDERED TO BE
DANGEROUS TO MAINTENANCE PERSONNEL WARNING TAPES ARE TO BE PLACED ADJACENT TO SYSTEM IDENTIFICATION TAPES ONE
BAND 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 BE
APPLIED WHEN THE TUBE SEGMENT PASSES THROUGH MORE THAN ONE COMPARTMENT OR BULKHEAD AT LEAST ONE BAND SHALL BE
VISIBLE 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 IS
BEING 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 NO
DELETERIOUS EFFECT ON THE MATERIAL USED FOR THE LINES, SHALL BE USED FOR IDENTIFICATION PURPOSES IN THESE CASES, THE
GEOMETRICAL SYMBOLS WAY BE OMITTED
AV 001903
6-4
TM 1-1500-204-23-1
6-5
TM 1-1500-204-23-1
(1) Secondary lines. Filler, vent, and drain piratory tract. Wear protective gloves and
lines will be identied by colors of the plumbing system goggles/face shield. Avoid repeated or pro-
for which they function. longed contact. Use only in well ventilated ar-
eas (or use approved respirator as determined
(2) Location of bands. One band will be lo- by local safety/industrial hygiene personnel).
cated on each tube segment of 24 inches or less when Keep away from open ames, sparks, or other
both ends of the segment are within the same compart- sources of ignition.
ment. One band shall be located at each end of tube
segments longer than 24 inches. When the tube seg-
ment passes through more than one compartment or
bulkhead, additional bands will be applied to the tube The low ash point of solvents make them a
so that a minimum of one band is visible in each com- re hazard, therefore, employ utmost care when
partment or on each side of the bulkhead. using them. Damage may otherwise result.
(3) Tapes in engine compartment. Tapes (1) Clean areas to be banded with Aliphatic
shall not be used on uid lines in the engine compart- Naphtha, Federal Specication TT-N-95.
ment where there is a possibility of the tape being drawn
into the engine intake. When tape cannot be employed,
(2) Coat exterior surfaces of metal tubing when
suitable paints conforming to the color codes in table
necessary, with epoxy primer, MIL-PRF-23377, prior to
6-1, and having no injurious effect on the metal used
application of tape.
for the lines, shall be used for identication purposes.
When paints are used, the geometrical symbols may
be omitted. (3) Install tape not having clear acetate covering
by tightly wrapping 1 ¼ turns of tape around the part be-
ing banded and press rmly to ensure adhesion. Apply
(4) Warning symbol. Warning symbol tapes,
one coat of clear lacquer, Federal Specication TT-L-32,
as shown in gure , shall be applied adjacent to the iden-
over band and extend ¼ inch beyond tape edges.
tication tape on those lines containing uids considered
to be dangerous to maintenance personnel. Warning
tapes shall be used when applicable on both identifying (4) Install tape having clear acetate covering by
systems. Warning tape shall be 3/8 inch wide. tightly wrapping 1 ¼ turns of tape around the part being
marked and press rmly to ensure adhesion.
d. Installation of Identication Tapes.
Installation of identication tape consists of the
following procedures:
6-6 Change 5
TM 1-1500-204-23-1
CHAPTER 7
7-1. General The maintenance instructions and b. Designation Examples. An example of radial
procedures contained in this chapter are general and engine designation is R-1820-103. The R denotes a
applicable to reciprocating engines used on Army aircraft. radial arrangement of the cylinders, 1820 denotes a total
Maintenance instructions that are specific and peculiar to of 1820 cubic inches displacement, and 103 denotes a
particular engines are contained in the applicable particular modification or characteristic of the engine. For
maintenance manuals and will be used in conjunction with opposed engine designations, such as IGSO-480-A1A6,
general information contained in this chapter. the I denotes injected, G denotes geared output drive, S
denotes supercharged, the O denotes opposed
7-2. Engine Types and Designations. Reciprocating arrangement of the cylinders, 480 denotes a total or 480
engine types and designations are explained in the cubic inches displacement, and the A1A6 denotes a
following paragraphs. particular modification of characteristic of the engine.
7-1
TM 1-1500-204-23-1
7-2
TM 1-1500-204-23-1
2 Power section. The power or main main crankcase web section are crankshaft bearing
section may be of one-piece or two-piece construction supports. Cylinder mounting pads are located radially
and usually consists of one, two, or possibly three pieces around the outside circumference of the power section.
of high-strength heat-treated aluminum-alloy or steel The cylinders are fastened to the pads by means of studs
forging, bolted together if there is more than one piece. and nuts or cap screws. Oil seals are located between the
The cam-operating mechanism is usually housed and nose section and the power section. Similar seals are
supported by the power section. At the center of each installed between the power section and the supercharger
section.
7-3
TM 1-1500-204-23-1
oll-flltering screens, Cuno filters, and other items of the counterweights and dampers The following
accessory equipment. In some aircraft powerplants, the paragraphs describe crankshaft types and general
cover for the supercharger rear housing is made of an maintenance.
aluminum-alloy or a magnesium-alloy casting in the form
of a heavily ribbed plate that provides the mounting pads (1) Types. Opposed-type and radial-type
for the accessory units; but in other powerplants, the engine crankshafts are described in the following
housings for the accessory units may be mounted directly paragraphs.
on the rear of the crankcase. Regardless of the
construction and location of the accessory housing, it (a) Opposed-type crankshaft. A typical
contains the gears for driving the accessories which are six cylinder opposed-type crankshaft is shown in figure 7-
operated by engine power. 6. This crankshaft is a one-piece, six-throw, 60-degree
crankshaft machined from an alloy-steel (SAE 4340)
(2) Maintenance. Crankcase maintenance forging. The crankpins and main bearing journals are
consists of inspection for cracks, warping, damage to ground to close limits of size and surface roughness.
machined surfaces, warn bushings and bearing bores,
loose or bent studs, corrosion damage, and other (b) Radial-type crankshaft. Figure 7-7
conditions which may lead to failure in service Refer to shows a single-throw 360-degree crankshaft used on
the applicable maintenance manual single-row radial engines. It may be of single-piece or
two-piece construction with two main bearings (one on
NOTE each end) This single piece crankshaft must be used with
Two-piece crankcases are a master rod having the large end split
manufactured with matched parts;
therefore it one half must be (2) Maintenance. Crankshaft maintenance is
discarded, the entire crankcase is critical to safe engine operation. The dimensions of the
replaced journals, the balance, and the alignment of the shaft must
be within tolerances when inspected and measured. The
b. Crankshafts. The crankshaft transforms the crankshaft should be inspected by the magnetic methods
reciprocating motion of the piston and connecting rod into to detect flaws and defects. Refer to the applicable
rotary motion for turning the propeller It Is a shaft maintenance manual for specific maintenance
composed of one or more cranks or throws The parts are procedures and tests.
the main journal, crankpln, crank cheek or crank arm, and
7-4
TM 1-1500-204-23-1
(b) Ball bearings A ball beanng aircraft engines to transmit propeller thrust to the engine
nose section
assembly consists of grooved Inner and outer races, one
or more sets of balls, and in bearings designed for
(c) Roller bearings Roller bearings are
disassembly, a bearing retainer They are used for
supercharger Impeller shaft beanngs and rocker arm made In many types and shapes, but the two types
bearings in some engines. Special deep-groove ball generally used in the aircraft engine are the straight roller
bearings are used in and the tapered roller beanngs. Tapered roller bearings
are always used In pairs Straight roller
7-5
TM 1-1500-204-23-1
bearings are used where the bearing is subjected to radial rebushing, and replacement of the bearings. Refer to the
loads only In tapered roller bearings, the inner and outer- applicable maintenance manual before accomplishing any
race bearing surfaces are cone shaped. Such bearings maintenance procedures.
will withstand both radial and thrust loads. Straight roller
bearings are used in high-power aircraft engines for the e. Pistons. Pins. and Rings. Pistons, pins, and
crankshaft main bearings. They are also used in other rings, as shown in figure 7-10, are described and
applications where radial loads are high. maintained as explained In the following paragraphs.
(2) Maintenance Clean, inspect, and replace (1) Pistons. The piston of a reciprocating
beanngs. in accordance with the applicable maintenance engine is a cylindrical member which moves back and
manual forth within a steel cylinder. The piston acts as a moving
wall within the combustion chamber. As a piston moves
d. Connecting Rods. The connecting rod is the link down the cylinder, it draws In the fuel-air mixture. As it
which transmits forces between the piston and the moves upward, it compresses the charge, ignition occurs,
crankshaft. Connecting rods must be strong enough to and the expanding gases force the piston downward. This
remain rigid under load and yet be light enough to reduce force is transmitted to the crankshaft through the
the inertia forces which are produced when the rod and connecting rod. On the return upward stroke, the piston
piston stop, change direction, and start again at the end of forces the exhaust gases from the cylinder.
each stroke.
(2) Pins. The piston pin joins the piston to the
(1) Types There are three types of connecting connecting rod It Is machined in the form of a tube from a
rod assemblies, as shown in figure 7-9. The plain, fork- nickel steel alloy forging, casehardened and ground. The
and-blade, and master-and-articulated connecting rod piston pin is sometimes called a wristpin because of the
assemblies are described in the following paragraphs. similarity between the relative motions of the piston and
the articulated rod and that of the human arm.
(a) Plain connecting rods. Plain
connecting rods are used In opposed engines. The end of (3) Rings. The piston rings prevent leakage of
the rod attached to the crankpin Is fitted with a cap and a gas pressure from the combustion chamber and reduce to
two-piece beanng. The beanng cap is held on the end of a minimum the seepage of oil into the combustion
the rod by bolts or studs. To maintain proper fit and chamber. The rings fit into the piston grooves but spring
balance, connecting rods should always be replaced. In out to press against the cylinder walls, when properly
the same cylinder and In the same relative position. lubricated, the rings form an effective gas seal. Rings are
always used in sets.
(b) Fork-and-blade connecting rods The
fork-and-blade rod assembly Is used primarily in V-type (4) Maintenance. Pistons and pins are
engines The forked rod is split at the crankpln end to Inspected and checked for cleanliness, wear, scoring,
allow space for the blade rod to fit between the prongs. A corrosion, cracks, and any apparent damage New rings
single two-piece bearing is used on the crankshaft end of are. Installed each time the engine is overhauled. Refer
the rod. to the applicable maintenance manual when
accomplishing maintenance on pistons, pins, and rings.
(c) Master-and-articulated connecting
rods. The master-and-articulated rod assembly is only f. Cylinders. The portion of the engine in which the
used in radial engines. In a radial engine the piston in power is developed is called the cylinder. The cylinder
one cylinder in each row is connected to the crankshaft by provides a combustion chamber where the burning and
a master rod. All other pistons. In the row are connected expansion of gases take place, and. It houses the piston
to the master rod by an articulated rod. and the connecting rod
(2) Maintenance. The maintenance of (1) Description. The cylinder used In the
connecting rods involves visual Inspection for nicks, aircooled engine is the overhead valve type shown in
cracks, bending, corrosion, and other damage, magnetic figure 7-11. Each cylinder assembly consists of the
particle inspection, checking alignment for parallelism and cylinder head and the cylinder barrel.
convergence between the bearing end and the piston end;
7-6
TM 1-1500-204-23-1
7-7
TM 1-1500-204-23-1
7-8
TM 1-1500-204-23-1
NOTE
Chrome-plated cylinders are further
Identified as illustrated In the
following example 6-44, SAX-3, 20
would designate the third cylinder
plated by San Antonio Air Material
Area in June 1944, and the cylinder
was 0.020 inch oversize when plated.
(b) Liquid lock. When an engine is shut Figure 7-11. Cylinder Assembly
down, the warm residual oil clinging to the power section
surfaces flows downward toward lower cylinders. Some
of this oil seeps past piston rings, accumulating in the
combustion chamber. When sufficient liquid is present,
the true compression ratio will be raised and extremely
high pressure will be produced when the piston moves
down on the compression stroke. These pressures can
damage the cylinder, piston, or rod. The piston may
actually press the liquid, forming what is known as a
hydraulic or liquid lock (see figure 7-13). Observe the
following precautions:
CAUTION
Do not rotate propeller in reverse
direction of normal engine rotation.
This will push the liquid Into intake
pipes and return to cylinders on the
next intake stroke.
7-9
TM 1-1500-204-23-1
Liquid locks are partial or complete. Hesitation 2 Determine whether blowby has
in propeller rotation usually denotes a partial been eliminated by turning engine by hand or turning it
lock. If propeller stops, it usually denotes a through with starter.
complete liquid lock. Forcing engine through a
complete liquid lock will cause Immediate 3 When blowby is still present,
engine failure. perform a compression test.
NOTE
If valve is stuck in the valve guide,
correct clearance cannot be
determined.
7-10
TM 1-1500-204-23-1
7-11
TM 1-1500-204-23-1
(e) Cylinders with below minimum of 302 to 338 °F (150 to 170 °C) is obtained or until
compression. Engines having cylinders with below temperature stabilizes at a lower reading.
minimum required compression will be processed using
the following procedures. NOTE
7-12
TM 1-1500-204-23-1
7-13
TM 1-1500-204-23-1
5 Position rocker box cover mounting g. Valves. The fuel-air mixture enters the cylinders
surface down on lapping plate, and use a figure eight through the intake valve ports, and burned gases are
motion to keep an even pressure on cover. expelled through the exhaust valve ports. The head of
each valve opens and closes these cylinder ports. The
6 When warpage cannot be valves used In aircraft engines are the conventional
eliminated without exceeding allowable limits given in the poppet type. The valves are also typed by their shape
applicable maintenance manual, replace rocker box and are called either mushroom or tulip because of their
cover. resemblance to the shape of these plants Figure 7-14
shows various shapes and types of these valves.
7 Replace leaking seals with like
serviceable items. (1) Description. The valve head has a ground
face which forms a seal against the ground valve seat in
8 Replace individual piston rin gs that the cylinder heads when the valve is closed. The valve
are damaged upon installation of a complete cylinder and stem acts as a pilot for the valve head and rides in the
piston assembly. Refer to illustrated parts breakdown valve guide installed in the cylinder head for this purpose.
manual of applicable engine for correct size and type ring. The valve stem is surface-hardened to resist wear The
neck is the part that forms the junction between the head
9 Replace cracked or broken rocker and the stem. The tip of the valve is hardened to
arms. withstand the hammenng of the valve rocker arm as it
opens the valve. A machined groove on the stem near
10 Replace bent pushrods. the tip receives the split-ring stem keys These stem keys
form a locking to hold the valve spring retaining washer in
11 Replace bent or cracked pushrod place
housing.
(2) Maintenance. Proper valve operation is of
(i) Cylinder replacement. Cylinders will vital importance to satisfactory operation of the engine
be replaced for the following reasons as described in the from the standpoint of stability and cylinder wear. Valve
applicable maintenance manual. clearances establish valve timing when the engine is
operating, and since cylinders receive fuel-air mixture
Low compression from a common supply, the valve clearances should be
NOTE
Engines that have spark plug copper
runout on more than 25 percent of the
cylinders will be removed from
service. Carbon deposits must not be
confused with copper runout
7-14
TM 1-1500-204-23-1
WARNING
Do not attempt to mutilate sodium-
filled valves. The metallic sodium
used in these valves, when
contracting moisture, gives off highly
flammable hydrogen gas, and when
brought into contact with the skin
often results in severe personal injury. Figure 7-15. Top Center Indicator
7-15
TM 1-1500-204-23-1
NOTE CAUTION
The compression stroke may be Use piston position indicator with
detected by a buildup of air pressure 18mm threads for 18mm spark plug
when thumb is held over open spark threads and 14mm threads for 14mm
plug hole. spark plug threads. Damage to
threads may otherwise result.
6 Continue rotating crankshaft until
piston contacts arm of indicator and moves pointer to any 1 Remove spark plug and install
marker on Indicator face. piston position indicator, as shown in figure 7-16, with
correct arm and calibrated scale.
7 Note mark reached and record
protractor reading. 2 Rotate crankshaft in direction of
rotation until piston is coming up on compression stroke.
8 Move crankshaft slowly in direction
of rotation until Indicator pointer shows that piston has 3 Separate body from indicator
moved to top of stroke and is going down. assembly and screw housing into spark plug bushing until
it seats firmly. Insert indicator assembly into body, as
9 Stop turn ing crankshaft when shown in figure 7-16.
pointer moves to exact same position as In step 6.
4 Push slide pointer upward in slot
10 Read and record protractor reading until it reaches end of slot and is stopped by pivot arm.
in degrees.
5 Pull crankshaft slowly in direction of
NOTE rotation until arm moves pointer maximum distance and
True top dead center is halfway starts to move back.
between two protractor readings
NOTE
When reinstalling pointer, allow for
gear backlash by moving pointer
opposite its direction of rotation.
7-16
TM 1-1500-204-23-1
7-17
TM 1-1500-204-23-1
plug gap In each cylinder. Magneto operation is timed to 4 Connect timing light and turn
the engine so that a spark occurs only when the piston is ignition switches to ON position.
on the proper stroke at a specified number of crankshaft
degrees before the top-dead-center piston position. 5 Apply even and equal torque to
Maintenance of magnetos consists primarily of replacing each of cam retaining screws In direction opposite normal
defective magnetos or components as explained in the rotation to remove gear train backlash.
following procedures:
6 While holding backlash out, turn
(a) Prior to installation, perform internal crankshaft until points begin to open as indicated by
timing check. timing light.
2 Use reference marks on breaker (d) Install and time low-tension I gnition
cam, distributor rotor, and magneto housing incorporated system magneto-to-engine, at a definite crankshaft
on most assemblies to perform internal timing check. position, using the following procedures.
2 Align internal timing marks, and 3 If magneto does not line up with
slide magneto into place. centerline of engine, remove magneto, release plunger,
and turn magneto drive shaft 90 degrees. Repeat until
3 Shift magneto to retard position, magneto lines up properly.
and turn magneto to advance until breaker points begin to
open as indicated by timing light. 4 Hold plunger depressed and turn
magneto counterclockwise on its flange as far as
4 Install mounting nuts, magneto necessary to remove gear backlash.
cover, and leads.
5 Install magneto bolts securely in
(c) Check timing of high-tension ignition place.
system magneto after a new magneto is Installed or if
incorrect timing is suspected, as follows. (e) Check timing of low-tension ignition
system magneto after a new magneto is installed or
1 Determine correct crankshaft incorrect timing is suspected.
position and check internal magneto timing marks.
1 Determine correct crankshaft
2 Turn crankshaft one-fourth turn in position.
opposite direction of normal rotation.
2 Rotate engine one-fourth turn in
3 If magneto has an impulse opposite direction of normal rotation and slide pointer of
coupling, rotate crankshaft in normal direction beyond piston position Indicator to top of scale.
timing cylinder top-dead-center position; when impulse
coupling clicks, rotate crankshaft in opposite direction to 3 Turn engine in direction of rotation
approximately 5 degrees advance of timing position. until slide pointer is starting to move down.
7-18
TM 1-1500-204-23-1
4 Depress and hold timing plunger on mag- (b) Repair or replace defective parts as nec-
neto, while continuing rotation of engine, until timing essary. Keep all parts clean and free of foreign matter.
plunger is fully engaged.
NOTE
5 See that timing indicator shows correct The high-tension system manifold is never
degree of advanced timing. taken apart in the eld, as this will destroy the
elastic gel seal.
(2) Ignition harness. The ignition harness, as
shown in gure7-18, contains an insulated wire for each 1 Clean dirt and grease from harness by
cylinder that the magneto serves in the engine. One end wiping with a clean, dry cloth.
of each wire is connected to the distributor block and the
other end is connected to the proper spark plug. The ig-
nition harness serves a dual purpose. It supports the
wires and protects them from damage by engine heat,
vibration, or weather. It also serves as a conductor for Cleaning Solvent, HFE-71DE, is toxic to eyes,
stray magnetic elds that surround the wires as they skin, and respiratory tract, and decomposes into
momentarily carry high-voltage current. By conducting other hazardous products when exposed to ex-
these magnetic lines of force to the ground, the igni- treme heat. Wear chemical protective gloves
tion harness cuts down electrical interference with the and goggles/face shield. Avoid repeated or pro-
aircraft radio and other electrically sensitive equipment. longed contact. Use only in well-ventilated ar-
When the radio and other electrical equipment are pro- eas. If ventilation is not adequate, use approved
tected in this manner, the ignition harness wiring is said respirator as determined by local safety/indus-
to be a shield. Without this shielding, radio communica- trial hygiene personnel. Keep away from open
tion would become virtually impossible. The ignition har- ames, welding, or other sources of extreme
ness check consists of a visual and an electrical check heat.
using the following procedures: Isopropyl Alcohol, TT-I-735, is ammable and
toxic to eyes, skin, and respiratory tract. Wear
(a) Examine all accessible parts of distribu- protective gloves and goggles/face shield.
tors, harnesses, and leads for chang, broken insula- Avoid repeated or prolonged contact. Use only
tors, corrosion, moisture, damaged or dirty terminals, in well-ventilated areas (or use approved res-
and security of mounting at the time specied in the ap- pirator as determined by local safety/industrial
plicable maintenance manual. hygiene personnel). Keep away form open
ames, sparks, or other sources of ignition.
NOTE
Replace ignition harness leads when more than
three wire strands are broken in one inch of har-
ness length or if insulation is damaged.
Change 5 7-19
TM 1-1500-204-23-1
4 Ground all leads, except one for number 1 Check all accessible parts of harness
1 cylinder, to engine. and leads for chang, broken conduit, corrosion, or
misaligned pins in electrical connectors at intervals
5 Connect ground lead of tester to engine, specied in inspection requirements manual.
and connect high-tension lead to number 1 cylinder lead.
10 Repeat steps through above. (5) Booster system. Starting aids such as an
induction vibrator or booster coil must be used to provide
(d) The low-tension system operates at rela- enough voltage to the spark plug. The induction vibrator
tively low voltages (150 to 400 volts) and is not seriously (or starting vibrator), as shown in gure 7-19, consists
affected by moisture. Check system as follows: essentially of an electrically operated vibrator,
7-20 Change 5
TM 1-1500-204-23-1
a condenser, and a relay. These units are mounted on 1 Remove front spark plug from most ac-
a base plate and enclosed in a metal case. The booster cessible cylinder.
coil assembly as shown in gure 7-20, consists of two
coils wound on a soft iron core, a set of contact points, 2 Turn crankshaft until piston is observed
and a condenser. General maintenance of the booster to be in top position on compression stroke.
system is described in the following procedures:
3 Reconnect spark plug and ground plug
(a) Repair induction vibrators in accordance shell to engine.
with the applicable maintenance manual and table 7-1.
4 Place carburetor in IDLE CUT-OFF posi-
(b) Replace defective booster coils and all tion.
broken or frayed wiring. Tighten all loose connections.
5 Place main fuel valve in CLOSED posi-
(c) Replace magneto if impulse coupling is tion.
defective.
Change 5 7-21
TM 1-1500-204-23-1
7-22
TM 1-1500-204-23-1
Cleaning Solvent, HFE-71DE, is toxic to eyes, skin, and respiratory tract, and decomposes into other
hazardous products when exposed to extreme heat. Wear chemical protective gloves and goggles/face
shield. Avoid repeated or prolonged contact. Use only in well-ventilated areas. If ventilation is not ad-
equate, use approved respirator as determined by local safety/industrial hygiene personnel. Keep away
from open f ames, welding, or other sources of extreme heat.
Isopropyl Alcohol, TT-I-735, is f ammable and toxic to eyes, skin, and respiratory tract. Wear protective
gloves and goggles/face shield. Avoid repeated or prolonged contact. Use only in well-ventilated areas
(or use approved respirator as determined by local safety/industrial hygiene personnel). Keep away form
open f ames, sparks, or other sources of ignition.
6 Turn fuel booster pump to OFF position. gine should be made before removal, except in cases of
complete internal failure or expiration of operating time
7 Turn ignition switch to BOTH position. limits. (Refer to AR 750-23.)
8 Place master ignition switch in ON posi- a. Expiration of Operating Time Limit. Engine
removal and replacement shall be accomplished in ac-
tion. cordance with TM 55-1500-328-25 when normal Maxi-
mum Allowable Operating Times (MAOT) are accumu-
9 Engage starter, observing all ground lated in accordance with the applicable aircraft -20 main-
safety rules. tenance manual (Chapter 3, Section IV ).
Change 5 7-23
TM 1-1500-204-23-1
c. Sudden Reduction in Engine RPM. When propeller drive shaft at front cone seat is less
the propeller or rotor strikes a small object which results than 0.015 inch full indicator reading, examine
in a sudden reduction in engine rpm, the engine shall be rear cone seat location.
thoroughly checked using the following procedures:
When any runout is found at rear cone seat lo-
(1) Make a thorough external examination cation, which is not in same plane as runout at
of engine crankcase and nose section to determine front cone seat location, remove engine.
whether any parts have been damaged. When damage
When crankshaft or propeller drive shaft runout
is found which cannot be corrected by line maintenance, does not exceed these limits, install service-
remove engine. able propeller and make an additional check by
tracking propeller at tip in same plane perpen-
(2) Remove magnetic sump plugs, if present, dicular to axis of rotation to assure that blade
and engine oil screens or f lters. Examine for presence track tolerance is within limits.
of metal particles.
(7) Start engine and examine for smooth op-
(3) Remove engine sump plugs, drain oil into eration and adequate power output. When engine oper-
a clean container, strain through a clean cloth, and ex- ates properly during this ground check, shut engine off
amine cloth and strained oil for metal particles. and again examine oil system for metal particles.
NOTE
Metal particles found in the sumps or in oil
screens or f lters will not be considered the
results of an internal failure caused by sud-
den stoppage, since the screens or f lters are
located at the oil inlet to the engine. Sudden
stoppage, therefore, will not permit circulation
of the oil to the extent that metal particles would
be deposited on the screens or f lters.
When heavy metal particles are found in the oil,
it indicates a def nite engine failure, and engine
must be removed. However, when metal parti-
cles present are similar to f ne f lings, continue
examination of engine to determine its service-
ability.
NOTE
When there is runout of more than 0.015 inch
full indicator reading of crankshaft or propeller
drive shaft at front cone seat location, remove
engine. Even though runout of crankshaft or
7-24
TM 1-1500-204-23-1
(8) When there are no heavy metal particles in e. Identification of Metal Particles. Metal particles
engine, give engine a two hour flight test. found in an engine may be of five kinds steel, tin,
aluminum, silver, and copper (or bronze). A visual
NOTE inspection as to color and hardness will occasionally be
When engine operated properly sufficient to determine the kind of metal present. When
during flight test, examine oil system visual inspection does not positively identify the metal,
for metal particles. If no metal is the kind of metal present may be determined by a few
found, continue engine in service, simple tests performed with a permanent magnet,
but examine oil screens for presence electric soldering iron, or approximately 2 ounces of
of metal after 10 hours of operation. hydrochloric acid and nitric acid as explained in the
If no indication of internal failure is following paragraphs.
found after 20 hours of operations,
engine requires no further special WARNING
examination. Exercise care in handling acid injury
or death to personnel may otherwise
d. Metal Particles in Oil. Generally, metal particles result.
on engine oil screens or on magnetic sump plugs
indicate partial internal failure of the engine. However, NOTE
due to the construction of aircraft oil systems, it is The information in this paragraph is
possible that metal particles may have collected in not intended to be a substitute for,
sludge in the oil system at the time of previous engine nor release from the requirement for
failure, consequently, this must be taken into account compliance with the Army Oil
when metal particles are found in engine oil screens or Analysis Program (AOAP) program
on magnetic sump plugs. Frequently, carbon breaks directed in accordance with TB 55-
loose from the interior of the engine in large pieces 6650-300-15.
which have the outward appearance of metal.
However, carbon can be distinguished from metal by (1) Steel particle identification. Steel
placing the foreign material on a flat metal object and particles can be Isolated by means of a permanent
hitting with a hammer. If material is carbon, it will magnet.
disintegrate when struck with a hammer, whereas metal (2) Tin particle Identification. Tin particles
will either remain intact or change shape, depending can be identified by their low melting point. A soldering
upon its malleability. iron should be cleaned, heated to approximately 260 °C
(500°F), and thinned with 50-50 solder (50 percent lead
CAUTION to 50 percent tin) Wipe off excess solder. A tin particle
An oil soaked rag can very easily dropped on heated Iron will melt and fuse with the
cause spontaneous combustion solder. Take care to avoid excessive overheating of
unless placed in a tightly closed iron during this test.
container, such as a quart or pint can (3) Aluminum particle identification.
with a press-fit lid. Aluminum particles may be identified by their respective
reaction with hydrochloric acid. When a particle of
NOTE aluminum is dropped into hydrochloric acid it will fizz
Before removing an engine for with a rapid emission of bubbles. The particle will
suspected internal failure, as gradually disintegrate and form a black residue
Indicated by foreign matter on the oil (aluminum chloride).
screens or oil sump plugs, collect all (4) Silver and copper particle identification.
obtainable metal particles for Silver and copper (or bronze) may be identified by their
analysis and samples. To save fine respective reactions in nitric acid. When a silver
metal particles, it may be necessary particle is dropped into nitric acid, it will react rather
slowly, producing a whitish fog in the acid. When a
to strain the oil through a cloth. The
particle of copper (or bronze) is dropped into nitric acid it
cloth and metal particles can be
will react rapidly, producing a bright green cloud in the
placed in a clean metal container and
acid. There is no need in this instance to separate
sent with engine for overhaul. copper from bronze.
7-25
TM 1-1500-204-23-1
7-26
TM 1-1500-204-23-1
5 If not more than two additional silver is quite soft, some small flakes will occasionally
granular particles are found during screen and sump be released by normal working of these parts. A very
inspection after runup, engine may be released for small quantity of silver from master rod bearings will
service in accordance with the applicable maintenance make a large number of tiny flakes as it passes through
manual. roller bearings or gears within engine. Large quantities
of silver flakes indicate an excessive loss of bearing or
(b) When aluminum flakes are found, plating surface and engine must be removed as a
proceed as follows: precautionary measure.
2 When not more than two faulty (2) Run engine to bring it to operating
pistons are found, change faulty piston and cylinder temperatures and make a minimum of three power
assemblies before continuing with procedure. When checks (Allow engine to cool between checks). Take
more than two faulty pistons are found, remove engine care not to exceed allowable limits for ground operation.
If two or less faulty pistons are found, continue with
procedure. (3) Again remove oil screens and examine
for metal accumulation. Examine main sump plug and
3 Drain oil system, flush oil tank, screen for metal accumulation. If engine is released for
and clean oil screen. service, it must be watched closely for next 25 hours for
any indications of malfunctions or internal failure.
4 Test engine In accordance with
the applicable maintenance manual. h. Excessive Spark Plug Copper or Silver Runout.
If copper runout is noted, replace cylinder from which
5 If more than five additional spark plug was removed as this Indicates the cylinder
aluminum flakes are found during screen and sump temperature has exceeded 1981 °F (1083 °C). Silver
inspection after runup, remove engine. If less than this runout may be caused on a fine wire electrode-type
quantity is found, engine may be released for service in spark plug if plug is subjected to pre-ignition and/or
accordance with the applicable maintenance manual. detonation. Excessive temperature may cause the
silver spindle of the center electrode to flow toward the
(4) Silver particles. Silver particles in granular firing end of the electrode. Copper or silver runout
form indicate a master rod bearing failure in advanced indicates affected cylinders should be replaced.
stages. When these particles are found in any quantity, Engines having runout on more than 25 percent of the
remove engine. Silver is used in plating numerous cylinders should be removed.
other parts, and silver flakes, not exceeding 10 in
number, do not necessarily indicate a part failure. Since
7-27
TM 1-1500-204-23-1
i. Low Cylinder Compression. Prior to removing (b) Examine oil system. When examination of
cylinders for low compression, check and adjust valve oil screens or filters discloses an abnormal amount of
clearance. Check cylinder compression. Replace metal particles, remove engine. When no metal
cylinder when compression is less than established particles are found, operate engine as specified.
limits.
(c) When examination of engine
j. Parts Failure. When some portion of a steel discloses no visible damage as a result of overspeeding,
part, such as a piston ring, valve, valve spring, washer, restrict aircraft to local flights for a period of 10 hours.
rocker arm, or rocker arm bearing cannot be located and
removed, the engine will be replaced, so other parts m. Excessive Manifold Pressure. Engines
within the engine will not be damaged. incorporating turbosuperchargers or auxiliary stage
superchargers are subject to excessive manifold
k. Basic Mechanical Failure. Remove engine pressure when automatic controls malfunction or fall. A
when any internal component such as impeller, boss, manifold pressure overboost control is usually employed
casting, propeller shaft, or studs, become cracked, to reduce the possibility of overboost occurring.
nicked, broken, or damaged to the extent that safe However, when overboost occurs, combustion
operation cannot be continued. Failures of this type are temperatures rise, and detonation or pre-ignition may
limited to Internal components of the engine such as result and cause serious structural damage to the
impeller, Impeller clutch, crankshaft, supercharger engine. When manifold pressure exceeds value
housing, and reduction gear housing, since external specified in the flight manual, it Is considered an
failures, such as cylinders or engine accessories, can be overboost condition and the engine will be removed.
corrected by replacing the unserviceable assembly.
n. Excessive Maintenance. If an aircraft engine
I. Engine Overspeed. When engine speeds requires consistent excessive maintenance or is a
exceed limits specified in the applicable maintenance definite hazard to flight, it should be replaced, provided
manual, the removal or inspection of the engine will be complete engine conditioning will not correct the
dependent upon the amount of overspeed reported. difficulty. Excessive and consistent oil fouling of spark
When engine speeds exceed limits, accomplish the plugs could cause excessive maintenance. However, if
following procedures fouling is limited to certain cylinders, the difficulty may
be eliminated by replacing defective cylinders, ignition
(1) When overspeed is above maximum rpm, leads, distributor block, or opening-clogged rocker box
replace engine. drains.
(2) When overspeed is below maximum rpm, o. Excessive Oil Consumption. Oil is consumed in
accomplish the following: the engine by being burned in the combustion chamber,
lost in the form of mist or vapor from the breather, or
(a) Examine engine for cracked, open, leakage where propeller shafts and other shafts protrude
or broken cylinder heads and barrels, and bent push rod from the crankcase. Consumption varies with engine
housing. power setting, however, one or more cylinders fouling
due to excessive oil consumption may call for cylinder
NOTE rather than engine change.
In the event a cylinder head is
cracked or broken and no particles of (1) Oil consumption. Some of the factors
pistons rings have entered crankcase which affect oil consumption are engine speed,
of engine (determined by Inspection temperature, wear condition, and lubricant
of magnetic sump plug or oil screen characteristics such as viscosity-temperature coefficient,
for metal), remove damaged cylinder volatility, and flash point. Each is explained in the
and piston and examine articulating following paragraphs
and master rods for misalignment. If
rods are satisfactory, replace (a) Engine speed. The most important
cylinder and piston assembly with a factor affecting oil consumption normally is engine
speed. oil pressure Increases with engine speed until the
serviceable unit and continue engine
, operating range pressure of the engine is reached,
in service as specified below.
then a pressure relief valve maintains a constant
pressure. Usually, maximum pressure is reached at
relatively low speeds. The effect of engine speed on oil
pressure
7-28
TM 1-1500-204-23-1
7-29
TM 1-1500-204-23-1
a. Complete Engine Conditioning. Complete It forms a long curved channel which conducts air and
engine conditioning is a complete investigation of the fuel-air mixture to the supercharger section. The chan-
condition of an engine and correction of any diff culty nel consists of an air scoop, temperature controlling de-
detected. Complete engine conditioning will be given vice, and a thermometer. General maintenance proce-
engines being overhauled with the exception of idle dures are explained in the following paragraphs.
mixture and speed, fuel, oil, and water pressure adjust-
ments, and f nal check and adjustment of the engine a. Inspection, Maintenance, Cleaning, and Re-
after the engine is installed on the aircraft. Perform this placement. Perform the following procedures for
conditioning using the instructions contained in table general inspection, maintenance, cleaning, and re-
7-2. placement of air induction system components:
b. Minor Engine Conditioning. Minor engine
conditioning is the investigation and correction of any (1) Check induction system for foreign matter
malfunction revealed during f ight or through the cock- and articles to prevent such items from damaging im-
pit checks (daily, intermediate, and complete cockpit peller or clogging air passages.
checks). Perform the following procedures for minor
engine conditioning: (2) Install f exible channel, joining certain
types of induction systems together, in such a manner
(1) Perform a complete cockpit check (steps to prevent f exible channel from being sucked down and
6 through 14, table 7-2) when a new engine is installed, restricting air f ow.
when an aircraft is removed from storage, at each major
and minor inspection, and when minor conditioning fails (3) Correct leaks in induction systems soon
to correct a malfunction. The engine cockpit check will as possible after detection, as fuel-air mixture will be
be handled in the following manner: adversely affected.
(a) Record all readings on cockpit check (4) Clean air f lters at intervals specif ed in ap-
sheet as shown in f gure 7-23. plicable maintenance manual using the following proce-
dures:
(b) File form in aircraft f ight log folder for
future reference by both maintenance and f ight person-
nel.
Degreasing Solvent, MIL-PRF-680, is com-
NOTE bustible and toxic to eyes, skin, and respiratory
tract. Wear protective gloves and goggles/face
The daily check will be carried out by the air
shield. Avoid repeated or prolonged con-
crew and will only be recorded in the f ight log
tact. Use only in well ventilated areas (or use
when performance is unsatisfactory. The ser-
approved respirator as determined by local
viceability of the engine is established by the air
safety/industrial hygiene personnel). Keep
crew by comparing its readings against those
away from open f ames or other sources of
recorded on the complete cockpit check made
ignition.
by the maintenance crew.
(a) Immerse f lter in degreasing solvent,
(2) Perform steps 6 through 13, 15, and 17,
MIL-PRF-680, and agitate to remove all imbedded dirt
table 7-2.
particles.
(3) Perform intermediate check after last f ight
(b) Drain by placing on a 25-degree angle
of day. The check may be made any time after the last
draining rack and allowing to dry thoroughly.
f ight of the day and before the next f ight by either the
air crew or maintenance personnel. Any diff culties en-
countered during f ight are corrected at this time. The (c) When completely dry, immerse f lter
intermediate check is outlined in steps 12 through 15 in a mixture of 1 part corrosion-preventive compound,
and 17, table 7-2. The readings obtained are recorded MIL-C-5545, and three parts lubricating oil, MIL-L-6082,
in the f ight log only when engine performance is unsat- Grade 1120, at a temperature of 70°F (21°C) for 2 to 5
isfactory. minutes.
7-30 Change 5
TM 1-1500-204-23-1
Complete
conditioning When Personnel
steps Procedure performed responsible
Step 1. Ignition System Time all phases of ignition. This in- Complete Maintenance
Timing. cludes breaker point-to-magneto Conditioning
timing, magneto-to-engine timing,
and, distributor finger-to-engine
timing.
Step 3. Valve Adjust- Check valves and adjust clearances Complete Maintenance
ment if necessary. Visually inspect valve Conditioning
mechanism.
Step 4. Ignition Harness Check Ignition harness for high Complete Maintenance
Check voltage leakage. Conditioning
Step 7. Blowby Check While performing step 6, listen for Complete Maintenance
an extended hissing sound from Conditioning
exhaust stack or stacks.
7-31
TM 1-1500-204-23-1
Complete
conditioning When Personnel
steps Procedure performed responsible
Step 10. Power Check Set engine at specified rpm Complete Maintenance
setting. Allow engine and instru- Conditioning
ments to stabilize.
Step 11. Ignition System After completing step 10, perform Complete Maintenance
Check step 17. Conditioning
Step 12. Cruising Mixture Set engine speed at rpm specified Complete Maintenance
Check In performance chart with mixture Conditioning
control in AUTO-RICH position. After
engine and instruments have stabilized, Cockpit Check Air Crew
move mixture control to AUTO-LEAN
and observe rpm change. Return mix- Daily Check Air Crew
ture control to AUTO-RICH position.
A change of rpm, other than that allowed
in performance chart, indicates an exces-
sively rich or lean carburetor or master
control or fuel Injection lines leaking.
7-32
TM 1-1500-204-23-1
Complete
conditioning When Personnel
steps Procedure performed responsible
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. On
carburetor engine, idle adjustment
will cause rich or lean mixture.
Step 13. Idle Speed Close throttle completely. Engine Complete Maintenance
Check should idle at specified rpm and Conditioning
cylinder head temperature of 150
to 170°C (302 to 338°F) if equip- Cockpit Check Air Crew
ped with individual exhaust stacks
or at lower specified rpm if equip- Daily Check Air Crew
ped with an exhaust collector ring.
Intermediate Air Crew or
Maintenance
Step 14. Idle Mixture Check Idle mixture and adjust mix- Complete Maintenance
Check ture and speed. Conditioning
Step 16. Engine Backfire Because of the nature of this test, Complete Maintenance
Test It should be conducted only after Conditioning
prescribed Inspection periods or
when 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.
7-33
TM 1-1500-204-23-1
Complete
conditioning When Personnel
steps Procedure performed responsible
Step 17. Ignition Set engine speed at specified rpm Complete Maintenance
Switch Check Momentarily move Ignition switch Conditioning
to OFF and determine that engine
completely ceases firing. Return Daily Check Air Crew
switch to BOTH as rapidly as possible
to eliminate possibility of backfiring. Intermediate Air Crew or
Check master switch same way. Maintenance
Step 18. Spark Plug Make cold cylinder check. Replace Complete Maintenance
Check only defective plugs and repeat Conditioning
steps 6 through 16.
7-34
TM 1-1500-204-23-1
• Oil leaks or dripping from any unit d. Tighten all nuts, bolts, and clamps in exhaust
system in accordance with maintenance manual for
• Security of oil lines engine involved.
• Security and condition of electric wiring 7-9. Carburetion and Fuel Injection. Fuel is metered
to the engine at a predetermined ratio to airflow by the
• Cracks in ducting and other metal parts fuel metering system. Fuel metering systems differ in
including the turbine and housing design, but their function is the same, regardless of type
or engine model. Improper maintenance of the fuel
• Warping of metal ducts metering system will result in rough engine
performance, detonation, spark plug fouling, low power
• Operation of the complete system to output, poor acceleration, and engine or part failure.
determine performance to discover
undesirable sounds, and to note evidence of a. Inspection. Inspect carburetors for mounting
vibration; unusual sounds and appreciable flange cracks and evidence of leakage and fuel strainers
vibration require removal and replacement of for foreign matter broken screens, corrosion, and
the turbocharger to correct the faulty condition distortion.
7-36
TM 1-1500-204-23-1
b. Depreservation. Carburetors are depre- (2) When diff culty is encountered with PD
served to make them operational after they have been and PR series injection-type carburetors, attributed to
preserved for extended storage. Observe the following sticking or binding of automatic mixture control unit,
precautions: clean unit as follows:
Depreserve f oat-type carburetors which do not
employ diaphragms by f ushing f oat chamber with
the type of fuel used to operate applicable engine,
then drain oil and fuel mixture from f oat chamber. Degreasing Solvent, MIL-PRF-680, is com-
Flush until all trace of preservative oil is removed. bustible and toxic to eyes, skin, and respiratory
tract. Wear protective gloves and goggles/face
Depreserve diaphragm-type carburetors by drain- shield. Avoid repeated or prolonged con-
ing oil from fuel chambers and passages and f ush- tact. Use only in well ventilated areas (or use
ing with fuel. Fill carburetor with type of fuel to approved respirator as determined by local
be used to operate applicable engine. Soak di- safety/industrial hygiene personnel). Keep
aphragm for at least 8 hours. This restores fuel away from open f ames or other sources of
diaphragms to normal operating condition. ignition.
c. Adjusting Idle Mixture and Idles Speed. If (a) Remove unit from carburetor, being
an engine will not respond to idle mixture and speed careful not to remove seal or lockwire or loosen siphon
adjustment, it is an indication that some other phase of locking nut.
engine operation is incorrect. Adjust idle mixture and
idle speed using the following procedures:
(b) Wash bushing with Degreasing Solvent,
Mil-PRF-680.
(1) Make idle mixture adjustments with oil and
cylinder head temperatures at normal values.
(c) Dry thoroughly with compressed air.
(2) Back idle speed stop off so that idle speed
is controlled during adjusting procedure by manually (d) Polish bushing sleeve with crocus
controlling throttle. cloth, Federal Specif cation P-C-458, until it is bright.
(3) Retard throttle to designated rpm. (e) Blow out any polishing dust that tends
to cling to inside walls.
(4) Screw idle mixture in or out in small in-
crements as required until proper idle mixture is estab-
lished.
DELETED
(5) After each idle mixture adjustment,
increase power to f eld barometric pressure for approx- (f) Clean needle with dry Degreasing Sol-
imately 1 minute to clean intermittent f ring spark plugs vent, MIL-PRF-680, and dry with compressed air.
caused by excessively rich or lean mixture.
(g) When needle is corroded, clean with
(6) Set idle speed stop to desired rpm. Degreasing Solvent, MIL-PRF-680, dry with compressed
air, polish with crocus cloth, Federal Specif cation P-C-
d. Repair or Replacement. Repair or replace 458, and lubricate with grease molybdenum disulf de
carburetor using the following procedures: MIL-G-21164.
(1) When improper operation of f oat-type (h) Reassemble and install lockwire or
carburetor is suspected, perform a test by manually seal, if broken.
leaning mixture with mixture control or by enriching
mixture by use of primer. Replace complete unit when
changes in rpm, other than those within allowable limits,
resuit.
Change 5 7-37
TM 1-1500-204-23-1
(3) All components of PS series injection type (4) Connect all lines.
carburetor are self-contained In one assembly. Any
difficulty that cannot be corrected by adjusting idle (5) Tighten mounting bolts in accordance with
mixture or speed or unplugging vapor bleed requires limits specified in maintenance manual.
replacement of carburetor.
(6) Tighten and lockwire all other nuts and
e. Preservation. When carburetors are removed bolts.
for placement of storage or for rework, they should be
preserved using the following procedures: (7) Check throttle and mixture control lever
for freedom of movement; connect linkage.
CAUTION
Exercise care to keep the (8) Remove lockwire from throttle valves.
preservative oil out of the air
chambers of the regulator unit, and (9) Ensure that vapor vent lines are free from
from contacting the air metering obstructions.
portion of the carburetor, including
the main venturi, impact tubes, and 7-10. Removal and Installation of Reciprocating
automatic mixture control. Damage Engines. Preparation for removal, preparation for
to carburetor may otherwise result. installation, and installation of reciprocating engines are
explained In the following paragraphs.
(1) Remove drain plugs from bottom of fuel
chamber on float-type carburetors and drain out all fuel. a. Preparation for Removal. The following
With drain plugs reinstalled, fill float chamber with preparations should be made prior to removing engines:
lubricating oil, MIL-L-6081, Grade 1010.
(1) Provide personnel with maintenance
(2) Drain fuel and air chambers and fuel manual, aircraft log book, and, when applicable, DA
control unit by removing drain plugs on PD and PR Form 2410.
series Injection-type carburetors Replace plugs to air
chambers and inject lubricating oil, MIL-L-6081, Grade (2) Provide proper special tools, hoist, and
1010, (under 10 to 15 psi regulated pressure) until fuel engine stand for engine as given in maintenance
outlet on fuel control unit shows oil seepage. Remove manual. Provide ground support equipment and hand
drain plugs and allow excess oil to drain out. Reinstall tools.
drain plugs.
(3) Provide working area with drip pans, fire
(3) Remove drain plugs from main fuel extinguishers, and NO SMOKING signs. Provide oily
chamber on PS series Injection-type carburetors and waste cans, Federal Specifications RR-C-114, for
force lubricating oil, MIL-L-6081, Grade 1010, into fuel storage of all rags used for cleaning engine components
inlet at 8 to 10 psi until oil seeps from fuel discharge and wiping up fuel and oil.
nozzle. Remove drain plug on bottom of main regulator
assembly and allow all excess oil to drain. Reinstall (4) Ensure that aircraft is properly grounded
drain plug. and choked and battery is disconnected Remove
necessary cowling
f. Installation. Install carburetors using the
following procedures. b. Removal. Remove engine from the aircraft In
accordance with basic instructions given herein and in
(1) Remove all burrs and gasket particles the specific engine maintenance manual.
from carburetor and engine mating surfaces
(1) Preserve engine in accordance with
(2) Cover fuel lines, subject to contamination paragraph 7-12.
by foreign matter, with masking tape, Federal
Specification PPP-T-42. (2) Disconnect all control rods and cables,
magneto conduits, fuel and oil lines, thermometer tubes,
(3) Place carburetor on engine, close and tachometer shafts or wires, and like connections.
secure throttle valves in closed position with lockwire.
7-38
TM 1-1500-204-23-1
(3) Remove propeller, or clean propeller (3) Attach main oil line to oil pump Inlet, then
control systems, depending on condition or time in connect oil scavenge line, oil tank vent line, oil pressure
service. gauge line, and any other required oil lines.
(4) Drain fuel from metering system and (4) Connect and adjust throttle control and
connecting lines to eliminate fuel spillage during carburetor air heater control.
removal.
(5) Install and adjust propeller governor and
(5) Remove remote fuel pump adapters, control.
propeller hub attaching parts, starters, ignition analyzer
synchronizer, generators, vacuum pumps, air pumps, (6) Install propeller. Tighten retaining nut to
hydraulic pumps, propeller governors, and engine driven specified torque value.
fuel pump.
(7) Connect, check, and safety any other
(6) Forward engine accessories to depot in lines and controls which are required on the aircraft.
separate containers.
(8) Accomplish depreservation run in
(7) Install cover plates and plugs in engine accordance with paragraph 7-13.
and accessory openings. Plug or cap all lines
disconnected to accomplish engine removal. (9) Lubricate exhaust port studs and nuts.
(8) Review TB 55-1500-328-25 for 7-11. Engine Mounting Systems. The engine
determination of accessories to accompany engine. mounting system consists primarily of an engine mount
and vibration dampers. The basic engine mount
(9)Lubricate exhaust port studs and nuts. consists of a welded chrome-molybdenum steel tubing
structure rigid enough to carry forces Imposed by the
c. Preparation for installation. In addition to the engine. Vibration Isolators or dampers are used to
preparations outlined in paragraph a, the following eliminate the transmission of excessive vibration from
examinations must be made prior to Installation. the engine to the aircraft structure. Perform the
following procedures for general maintenance of engine
(1) Examine any fuel, oil, or hydraulic lines mounting systems.
for serviceability Particular emphasis should be given to
all lines that run through firewall. a. Visually inspect engine mounting system in
accordance with applicable Inspection requirements
(2) Ensure that all disconnected lines, hoses, manual.
control rods, cables, and wiring on firewall are In
appropriate position required for connection to engine. NOTE
When rubber parts of Isolators must
d. Installation. Procedures to be followed in be cleaned to establish their physical
installing the engine will vary according to type of condition, use soap, A-A-50, and
engine and aircraft involved and whether or not a power water only.
package is used. The general procedure contained
herein and in the specific engine maintenance manual b. Repair of engine mounti ng system is limited to
will apply. the following steps.
(1) Swing engine into po sition with a suitable (1) Repair distorted, bent, cracked, or chafed
hoist and Install engine mounting bolts. Tighten areas.
mounting bolts to specified torque value.
7-39
TM 1-1500-204-23-1
(1) Without disconnecting lines or fittings, (3) Locate nozzle in a position so that
make every effort to prevent remaining fuel and oil In corrosion preventive mixture Is properly distributed to all
engines from leaking out cylinders. Modify nozzle discharge are to provide
sufficient restriction to prevent exhausting corrosion
(2) Plug all ports and cap all fittings and lines. preventive supply prior to cessation of engine rotation.
Seal openings with applicable covers.
NOTE
(3) Install engine in bottom half of metal, For radial engines, precautions shall
reusable shipping and storage container. be taken to ensure that the quantity
of mixture aspired and the location
(4) Ground engine to container to prevent a employed provides an even amount
possible explosion of dangerous vapors which may be of coating for both upper and lower
ignited by static electricity or a spark. cylinders.
7-40
TM 1-1500-204-23-1
(4) Thermostatically control corrosion (a) Operate engine on service fuel for a
preventive supply tank to maintain corrosion preventive, period of 15 minutes.
MIL-C-6529, Type II at a temperature of 221 to 250 °F
(105 to 121 C). (b) With engine operating at 1500 rpm,
release corrosion preventive mixture through nozzle. As
(5) Connect an air pressure line providing 60 soon as white smoke appears at upper cylinder exhaust
to 80 psi dry compressed air to the tank Mixture capacity stacks for radial engines and at all stacks for opposed
of the tank will be as follows: engines, move mixture control to IDLE CUT-OFF
position and allow engine to stop. Continue aspiration of
• One quart for engines up to 1340 cubic inch mixture until engine ceases to fire
displacement.
(7) Drain preservation mixture from oil
• Two quarts for engines up to and including system while engine Is warm, exercising care to keep
2000 cubic inch displacement. corrosion preventive mixture clean for future use.
• Three quarts for engines up to 3350 cubic (8) Clean filter and screen and coat with
inch displacement. corrosion preventive mixture and reinstall.
(6) Make final engine run with oil system (9) When rocker box covers have been
serviced with corrosion preventive as follows: removed for any reason, rocker box interior shall be
treated as follows:
CAUTION
At no time will engine be operated in (a) Drain oil from each rocker box from
excess of 1500 rpm while the oil which cover IS removed
system Is serviced with corrosion
preventive mixture. Damage may (b) Spray-coat rocker arms, valve
otherwise result. stems, springs, push rods, rocker box covers, and rocker
boxes with corrosion preventive, ML-C-16173, Grade 2.
7-41
TM 1-1500-204-23-1
(c) Reinstall covers with new gaskets (16) Remove cover plates from all accessory
and tighten holddown nuts to values specified in drives and spray-coat all drives with corrosion-
applicable engine maintenance manual. preventive, MIL-C-6529, Type II. Reinstall all cover
plates.
NOTE
The above rocker box preservation (17) Seal breather openings with oil and
procedures are mandatory for all moisture-resistant covers, dehydrator plugs, or pressure
0.435 series engines. sensitive tape, Federal Specification PPT-60.
(10) Spray interior of each cylinder with (18) Perform dehydration of Intake manifold as
corrosion preventive, MIL-C-6529, Type II maintained at follows:
a temperature of 221 to 2500F (105 to 121 °C). Spray
as follows: (a) Secure carburetor throttle valve In
open position with lockwire.
(a) Spraying shall be accomplished with
piston at bottom dead center. Spray cylinders in (b) Install one 16-unit bag of desiccant,
sequence of firing order. Continue in this manner until MIL-D-3464, in intake.
all cylinders are sprayed.
(c) Seal openings with moisture-
CAUTION resistant covers or barrier material, MIL-B-121, Grade A,
The crankshaft must not rotate after secured with pressure sensitive tape, Federal
final spraying as preservation Specification PPP-T-60.
coating will be scraped from cylinder
walls. CAUTION
Do not turn protective cap during
(b) Final-spray cylinders without installation or removal as damage
rotating crankshaft. may occur to contact spring.
(c) Install cylinder dehydrator plugs, (19) Protect spark plug lead terminals by
MIL-1-6131, Type II, In each spark plug opening. installing applicable protective cap.
(11) Spray interior of exhaust ports and seal (20) Preserve magnetos by applying oil to
Individuals ports with applicable exhaust port plug. cam, spring, and other steel parts. Seal all external
openings with pressure sensitive tape, Federal
(12) Preserve carburetors in accordance with Specification PPP-T-60.
approved preservation procedures.
NOTE
(13) Remove th rust bearing cover plate and Keep oil from breaker points.
spray-coat bearing with corrosion preventive, MIL-C-
6529, Type II Reinstall cover. (21) Install a crankcase dehydrator plug.
(14) Coat exposed propeller shaft with (22) Install engine in a metal shipping
corrosion preventive, MIL-C-16173, Grade 2 wrap container as follows:
propeller shaft with barrier material, and MIL-B-121,
Grade A, when applicable plastic cylinder protector is (a) Place preserved engine in a
not available. serviceable container in accordance with instructions
supplied with container.
(15) Seal oil line fittings with plugs conforming
to MIL-C-5501. (b) Close container and tighten closure
bolts to proper torque.
7-42
TM 1-1500-204-23-1
CAUTION CAUTION
Use only dehydrated air with a Use dehydrated air with a relative
maximum relative humidity of 30 humidity of 30 percent for all
percent for pressurizing shipping spraying operations. Damage may
containers in order to keep humidity otherwise result.
as low as possible in the air
surrounding the engine. (2) Spray exhaust valves with corrosion preventive,
MIL-C-6529, Type II Spraying shall be through exhaust
(c) Pressurize container to 5 psi with dehydrated port with exhaust valves fully open.
air.
NOTE
(d) Retighten engine container flange nuts to Engines with collector rings may be
original torque after 1 hour elapsed time. sprayed through spark plug ports
with exhaust valves fully open.
(e) After container has been pressurized, use
soapy water to check for leaks If a second pressure (3) Place and secure two 8-unit bags of desiccant,
check in 24 hours does not Indicate a leak, engine is Military Specification MIL-D-3464, in carburetor air
ready for storage or shipment. intake scoop or carburetor adapter.
(f) Maintain all markings and stencils on shipping (4) Cover open end of scoop with a suitable
container intact without additions or deletions. anchored, barrier paper, MIL-B-131.
c. Preservation of Inoperable Engines. Engines that (5) Firmly attach a red cloth streamer to bags
cannot be operated and are to be removed from aircraft containing desiccant and bring loose end out In such a
shall be treated as far as practicable as shown in manner that not less than 18 inches of cloth streamer
paragraph 7-11 b. Spray all possible interior surfaces, will be visible on outside of carburetor air Intake scoop.
as the engine will be shipped or stored without the In order to prevent streamer from action as a wick, a 3-
protection afforded It by a final operation using a to 4-inch length of lockwire shall be left between
corrosion-preventive compound in the lubrication streamer and desiccant.
system. An appropriate entry shall be made on DA
Form 2408-16 and DD Form 1577-2, stating Inability to (6) Install 16 units of desiccant, MIL-D-3464, in
accomplish preservation run of the engine DA Form exhaust outlet on engines incorporating an exhaust
2408-5 also will be sent with the, engine, if applicable collector ring. Place a total of four units of desiccant in
DA Form 2410 will be completed and mailed in exhaust openings on engines that do not have an
accordance with DA PAM 738-751. exhaust collector ring.
d. Intermediate Storage of Engines Mounted on (7) Firmly attach a red cloth streamer to bags
Aircraft. Intermediate storage shall be completed within containing desiccant and bring loose end out a minimum
24 hours after ground runup. When it is not definitely of 18 inches. Use a 3- to 4-inch length of lockwire
known that the aircraft will be operated within 45 days, between cloth and desiccant to prevent streamer from
the engine shall be preserved for intermediate storage acting as a wick.
and an entry shall be made on the applicable DA Form
2408 series stating this work has been accomplished. (8) Seal all openings, joints, drain holes, and outlets
The procedure for Intermediate storage is the same as with barrier material, MIL-B-1 21, and secure with
previously outlined in paragraph 7-11b with the following pressure sensitive tape, Federal Specification PPP-T-
additional procedures. 60.
7-43
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(9) Use following procedure as alternate method of (2) Engines undergoing repair or inspection that
exhaust sealing. cannot be operated shall be pulled through by hand or
starter at least eight revolutions on the third day of
(a) Remove exhaust stacks at cylinder outlet. idleness.
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(1) Prepare engine for preoiling as follows: (3) Provide suitable viscosity by heating and
maintaining lubricant used for preoiling at a temperature
(a) Service oil tank, oil sump, or crankcase with between 110 °to 175 °F (38 °to 80 °C) when using
engine oil specified In applicable maintenance manual. preoiling equipment incorporating provisions for heating.
When preoiling with engine oil pump or with equipment
(b) Provide an external power source. not incorporating a heating element, dilute lubricant, at a
temperature lower than 30 °F (-1 °C), with gasoline in
(c) When spark plugs have been installed, accordance with percentage calculated from chart
remove one spark plug from each cylinder to reduce shown In figure 7-25. Mix thoroughly prior to preoiling.
load on starter.
(4) Preoil O-series engines by servicing oil system
(d) Place engine controls in following positions, with grade oil specified for engine, and the turn engine
as applicable. through with starter until oil pressure is indicated on
aircraft oil pressure gauge.
Ignition switch ................................ .......OFF
Throttle ................................ .............. OPEN (5) Preoil all radial engines as follows:
Mixture control ..................... IDLE CUT-OFF
Fuel shutoff valve ................................ .OFF CAUTION
Oil shutoff valve ................................ . OPEN Do not energize starter over 15
seconds. Allow starter to cool after
(e) Provide suitable containers of approximately 5 each energizing. Damage to starter
gallons capacity to catch oil that drains from sumps may otherwise result
during preoiling operation.
(a) Prime oil pump by removing applicable plug
(f) On engines which utilize crankcase breathers and rotating crankshaft with starter until all air is
and which are equipped with a hydromatic propeller, expelled from vent and a steady flow of oil is coming
remove plug from propeller dome and pour a sufficient from vent. Reinstall plug.
amount of preoiling lubricant into dome to bring lubricant
level to plug hole. Reinstall and safety the plug In NOTE
propeller dome. On engines not having a plug,
disconnect oil inlet line and allow
NOTE sufficient oil to drain to assure air in
This step is not required for engines the line is eliminated.
having propeller shaft breathers,
reversible-type propellers, or engines (b) Remove drain plugs from front and rear
not equipped with hydromatic sumps on installations having sumps in these locations.
propellers.
7-45
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Figure 7-25. Percent Dilution Versus Temperature for Grade 1100 Oil
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NOTE NOTE
Newly installed engines shall be The metal shipping caps ground out
given a depreservation run as soon the ignition, thereby eliminating
as possible, but not later than 4 excessive voltage buildup in the
hours after preoiling has been magneto and possibility of flash-over
accomplished if more than 4 hours at terminal end of ignition lead.
has elapsed since preoiling engine,
complete preoiling procedure shall (4) Start engine and run at 800 to 1500 rpm for 30
again be accomplished. seconds to 1 minute. Operation may be accomplished
on either primer or carburetor, or both, to obtain
(1) Prior to starting engine, remove one spark plug smoothest possible operation.
from each cylinder below the horizontal centerline of
engine. Refer to TB 55-2925-200-25 for proper spark NOTE
plugs to be utilized during depreservation run.
• Normally, smoothest engine
NOTE operation is obtained at higher
On seven-cylinder engines which engine speeds and a higher air
would necessitate removal of spark velocity through Intake pipes will
plugs from four cylinders, thereby result In cases where extreme
resulting in excessively rough cold temperatures exist, engine
operation, the one cylinder below the to be started should be
horizontal centerline on right side of preheated prior to starting and
engine when viewing engine at should be allowed to run longer
propeller end may be left operative. than the 1-minute period,
This permits operation of four provided excessive vibration Is
cylinders rather than three, which not encountered.
greatly stabilizes engine operation.
• Corrosion-preventive compound,
(2) Install approved depreservation valve in each if present in Intake pipes, will
open plug hole. have adequate time to be heated
and flow from Intake pipes
NOTE through external drain or into
Install length of hose on each combustion chamber and be
depreservation valve to vent large expelled into exhaust system or
quantities of oil overboard. This through depreservation valve.
eliminates a fire hazard and
accumulation of oil around cylinder (5) Stop engine by closing throttle and discontinuing
or baffles. use of primer or by moving mixture control to IDLE
CUT-OFF position.
(3) All spark plug leads, except those removed to
permit Installation of depreservation valves, will remain (6) Install spark plugs, Ignition leads, engine
connected to spark plugs. Install metal shipping caps to cowling, etc., and proceed to start engine using
disconnected leads. prescribed starting procedures outlined in the applicable
flight manual.
NOTE
Spark plugs used for depreservation
runs shall be replaced with new or
overhauled spark plugs before
placing the engine in service.
7-47/(7-48 blank)
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CHAPTER 8
8-1. General. The maintenance Instructions and surfaced areas where engines will be operated, as tests
procedures contained in this chapter are general and have indicated that these are the main source of foreign
applicable to turbine engines used on Army aircraft objects which are ingested.
Maintenance Instructions that are specific and peculiar
to particular engines are contained In the applicable b Periodically instruct personnel concerned with
maintenance manuals and will be used in conjunction aircraft maintenance of foreign object hazards to ensure
with general information contained in this chapter. that maximum preventive measures are taken.
8-2. Engine Types and Designations. Turbine engine c Ensure that air inlet and tailpipe dust excluders are
types and designations are explained in the following installed at all times when engines are not being
paragraphs. operated, except when it is known the engine will again
be operated Immediately following shutdown.
a. Types. Types of aircraft turbine engines are the
centrifugal-flow and axial-flow turbine engines. d. Prior to each engine start, thoroughly Inspect and
Centrifugal-flow engines, as shown In figure 8-1, clean inlet ducting. Remove all loose nuts, bolts, tools,
compress the air by centrifugal force. The air enters the or other objects which would cause engine damage and
air inlet and is directed to the compressor inducer vanes possible subsequent failure.
through circumferential inlets located in front and back
of the Impeller. Axial-flow engines, as shown in figure e. After work has been accomplished, inspect to
8-2, compress the air axially. The air enters the air inlet ensure that all accessories and attaching parts are
and flows in a relatively straight path In line with the axis secure and that work areas are cleared of foreign
of the engine. objects prior to engine operation.
b. Designation Examples. On gas turbine engine f. Provide properly marked receptacles (FOD cans) in
designations, such as T53-L-1, T denotes gas turbine all work areas into which trash, ferrous and nonferrous
with drive shaft, numeral 53 is assigned to the engine by scrap, safety wire, etc. , may be placed.
the services, L denotes the manufacturer, and 1 denotes
major modification. g. Adhere to applicable gas turbine-powered aircraft
taxiing and parking procedures as outlined in applicable
8-3. Turbine Engine Theory. The gas turbine engine technical bulletins. This minimizes damage due to
is a type of internal combustion engine that produces objects being thrown by the exhaust blast Into the intake
power by a continuous and self-sustaining process of of other aircraft.
compression, combustion, expansion, and exhaust. Air
is compressed in the compressor section, mixed with h Ensure that gas turbine-powered aircraft takeoff
atomized fuel and burned in the combustion chambers. and landing procedures are such as to avoid the intake
As the fuel burns, the resultant gases expand through of foreign objects blasted from runways and runway
turbine wheels to convert heat energy to useful power shoulders by preceding aircraft.
8-4. Turbine Engine Precautions. The following i. Use inlet duct runup screens during all ground
precautions shall be observed during maintenance of operations, including taxiing to and from takeoff
turbine engines. position, with the following exceptions:
a. Regularly police parking areas, runways, • Inlet duct runup screens are not required on
taxiiways, and runup and exhaust areas to ensure aircraft using centrifugal flow engines.
against the presence of foreign objects which could
enter the engine. Special attention shall be given to
cleaning of cracks and expansion seams in hard
Change 3 8-1
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8-2
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• When necessary to properly evaluate engine such parts to prevent internal contamination of the body
performance or when icing conditions exist, through open cuts, sores, or inhaling. Personnel shall
inlet duct runup screens should be removed. adhere to following precautionary measures.
Runup with screens removed shall be made in
a designated, thoroughly cleaned area. • Change clothes daily.
8-3
TM 1-1500-204-23-1
air received from the air inlet duct and then discharge it
to the burners in the quantity and at the pressure
required. A secondary function of the compressor is to
supply bleed-air for various purposes In the engine and
aircraft.
8-4
TM 1-1500-204-23-1
d. Diffuser Section. The diffuser increases the chambers must be In a through-flow position to function
compressor discharge area and reduces the speed of efficiently.
the centrifugal impeller airflow, causing the air pressure
to increase. This pressurized air is directed to the Can-Type. The can-type combustion is typical of
combustor through the diffuser case The diffuser case the type used on both centrifugal and axial-flow engines
mounts on the rear flange of the compressor stator it Figure 8-8 illustrates the arrangement for can-type
directs compressor discharge air to the combustion combustion. The engine combustion cans are
chamber. numbered in a clockwise direction facing the rear of the
engine with the No. 1 can at the top. The can-type
e. Combustion Section. The combustion section combustion consist of an outer case or housing, which is
houses the combustion process, which raises the perforated stainless steel (highly heat resistant) (See
temperature of the air passing through the engine. This Figure 8-9).
process releases energy contained in the air-fuel
mixture. The major part of this energy is required at the f. Turbine Section. The turbine transforms a portion
turbine to drive the compressor. The remaining energy of the kinetic (velocity) energy of the exhaust gases into
creates the reaction or propulsion and passes out the mechanical energy to drive the compressor and
rear of the engine in the form of a high-velocity jet. The accessories. This is the sole purpose of the turbine and
location of the combustion section is directly between this function absorbs approximately 60 to 80 percent of
the compressor and the turbine sections. The the total pressure energy from the exhaust gases. The
combustion chamber is always arrange coaxially with turbine assembly consists of two basic elements, the
the compressor and turbine regardless of type, since the stator and the rotor, as does the compressor unit.
These two elements are shown in figure 8-10.
8-5
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8-6
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8-7
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8-8
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j. Ignition Systems. Turbine ignition systems are electrode gap of the typical igniter plug Is designed
operated for a brief period during the engine-starting much larger than that of a spark plug, since the
cycle, and, as a rule, more trouble-free than the typical operating pressures are much lower and the spark can
reciprocating engine ignition system. Most turbine arc more easily than Is the case for a spark. Finally,
engines are equipped with a high-energy, capacitor-type electrode fouling, so common to the spark plug, is
ignition system minimized by the heat of the high-intensity spark.
Typical igniter plugs are shown in figure 8-14.
(1) System components. A typical ignition system
includes two exciter units, two transformers, two k. Fuel Systems. The fuel system must deliver to the
intermediate ignition leads, and two high-tension leads. combustion chambers not only in the right quantity, but
Thus, as a safety factor, the Ignition system is actually a also in the right condition for satisfactory combustion.
dual system, designed to fire two igniter plugs. Figure The fuel nozzles form part of the fuel system and
8-13 shows one side of a typical Ignition system. atomize or vaporize the fuel so that it will ignite and bum
efficiently. The fuel system must also supply fuel so
(2) Igniter plugs. The igniter plug of a turbine that the engine can be easily started on the ground and
engine ignition system differs considerably from the In the air. This means that the fuel must be injected into
spark plug of a reciprocating engine ignition system. Its the combustion chambers in a combustible condition
electrode must be capable of withstanding a current of when the engine is being turned over slowly by the
much higher energy than the electrode of a conventional starting system, and that combustion must be sustained
spark plug. This high-energy current can quickly cause while the engine Is accelerating to its normal running
electrode erosion, but the short periods of operation speed.
minimize this aspect of Igniter maintenance. The
8-9
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8-10
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(1) Fuel controls. Regardless of the type, all fuel (b) Duplex fuel nozzle. The duplex fuel nozzle is
controls accomplish essentially the same functions, but the nozzle most widely used in present-day gas turbine
some sense more engine variables than others. The engines The duplex nozzle usually requires a dual
fuel control senses power lever position, engine rpm, manifold and a pressurizing valve or flow divider for
either compressor inlet pressure or temperature, and dividing primary and main fuel flow into a desirable
burner pressure or compressor discharge pressure. spray pattern for combustion over a wide range of
These variables affect the amount of thrust that an operating pressures. A nozzle typical of this type is
engine will produce for a given fuel flow. shown In figure 8-16.
(2) Fuel nozzles. The fuel nozzles inject fuel into (3) Fuel filters. A low-pressure filter Is installed
the combustion area In a highly atomized, precisely between the supply tanks and the engine fuel system to
patterned spray so that burning is completed evenly and protect the engine-driven fuel pump and various control
in the shortest possible time and in the smallest possible devices. An additional high-pressure fuel filter is
space. Fuel nozzle types vary considerably between installed between the fuel pump and the fuel control to
engines, although for the most part fuel is sprayed into protect the fuel control from contaminants. The three
the combustion area under pressure through small most common types of filters in use are the micron filter,
orifice in the nozzles The two types of fuel nozzles the wafer screen filter, and the plain screen mesh filter.
generally used are the simplex and the duplex The individual use of each of these filters is dictated by
configurations. the filtering treatment required at a particular location.
(a) Simplex fuel nozzle. The simplex fuel nozzle 8-6. Turbine Engine Inspection and Maintenance.
was the first type nozzle used in turbine engines and Turbine engines shall be Inspected and maintained in
was replaced in most installations with the duplex accordance with the applicable maintenance manual.
nozzle, which gave better atomization at starting and General procedures for various components and
idling speeds. The simplex nozzle, as shown in figure 8- systems are explained in the following paragraphs.
15, is still being used to a limited degree. Each of the
simplex nozzles consists of a nozzle tip, an insert, and a
strainer made up of fine-mesh screen and a support.
8-11
TM 1-1500-204-23-1
8-12
TM 1-1500-204-23-1
NOTE
Figure 8-15. Simplex Fuel Nozzle
A hot start may be expected when a
greater-than-normal starting fuel flow
a. General Procedures. The following procedures
Is observed just as the power lever is
shall be adhered to during turbine engine maintenance.
moved Into the IDLE position.
(1) Mark location of all attaching support brackets,
d. Turbine Engine Analysis Check (TEAC). A normal
clamps, and clips prior to removing lines, tubes, or
Turbine Engine Analysis Check (TEAC) is performed for
conduit to facilitate reassembly with a felt tip marker
comparison of normal TEAC data with baseline data.
Use ink conforming to Federal Specification TT-1-544.
This will confirm whether or not performance
degradation has occurred and to what degree. In
(2) Use new O-rings, packing rings, cotter pins,
addition, TEAC data can be an aid in determining the
lockpins, gaskets, and washers.
cause of the performance loss (Refer to TEAC
troubleshooting). A normal TEAC shall be performed
(3) Apply lubricating grease, MIL-G-4343, on all O-
whenever installed engine performance degradation Is
rings prior to installation.
suspected or as part of a general test flight (if
applicable).
(4) Apply thread compound, MIL-A-13881, to all
threaded parts attached to the hot section.
e. Foreign Object Damage Inspection. Most damage
incurred by the engine is the result of ingestion of
(5) When gears are replaced, examine for pattern
foreign objects Although screens are provided in the
wear and backlash.
lower aft cowling section and around the engine
compressor inlet case to prevent entry of larger objects,
b. Health Indication Test. The Health Indication Test
sand and grit will enter and cause compressor damage.
(HIT) is the method by which the aviator In day-to-day The resultant damage will be in the form of nicks or
flying monitors the aircraft engine condition. This is scratches on the compressor blades. Such a nick or
accomplished by the aviator selecting an N1 speed (%) scratch can cause fatigue failure hours later, with
predicated upon the existing Free Air Temperature disastrous effects to the entire engine.
(FAT). The interstate Turbine Temperature (ITT) must
then relate to a predicated value (Baseline ITT) within a
CAUTION
certain tolerance. ITT variation from baseline values
When maintenance is performed on
are logged by the aviator in accordance with the
applicable maintenance manual This log, part of the the engine, every effort shall be
engine records, is available to the maintenance officer made to retrieve any object (wire,
as an aid In monitoring performance trends and in rivets, nuts, screws, etc.) dropped
troubleshooting When the difference between a through the compressor inlet screen
recorded ITT and the baseline ITT is 20 °C (68 °F) or or into the cowling, even if engine
greater the aviator will make an entry on DA Form 2408- disassembly Is required. Damage to
13 to notify the maintenance officer. A difference of the engine may otherwise result.
30°C (86°F) or greater is cause for grounding the aircraft
8-13
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8-14
TM 1-1500-204-23-1
8-15
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8-16
TM 1-1500-204-23-1
Cleaning solvent, HFE-71DE, is toxic to eyes, 3 Replace igniter plugs that fail to produce
skin, and respiratory tract, and decomposes into continuous and regular sparking.
other hazardous products when exposed to ex-
treme heat. Wear chemical protective gloves (3) Ignition exciter. Refer to the applicable
and goggles/face shield. Avoid repeated or pro- maintenance manual for ignition exciter maintenance.
longed contact. Use only in well ventilated ar-
eas. If ventilation is not adequate, use approved l. Turbine Bearing Maintenance. Turbine engine
respirator as determined by local safety/indus- bearings shall be inspected, removed, and replaced in
trial hygiene personnel. Keep away from open accordance with the applicable maintenance manual.
ames, welding, or other sources of extreme
m. Thermocouple Maintenance. Replace ther-
heat. mocouple leads that indicate a short or an open condi-
tion. Clean carbon from thermocouples by dipping in
(a) Clean lead assembly with Isopropyl Alco- carbon removing compound, MIL-C-19853, and wiping
hol, TT-I-735, or HFE-71DE. Replace any lead having deposit away with a clean cloth.
fraying shielding, bent or mutilated socket contacts or
contact pins, and worn or stripped threads on coupling n. Oil Consumption. Check oil consumption in ac-
nuts. cordance with the applicable maintenance manual. The
following formula can be used to calculate oil consump-
NOTE tion in cc per hour:
Change 5 8-17
TM 1-1500-204-23-1
• Compressor rotor ground idle speed (a) Fuel nozzle inspection. Inspect fuel
nozzles in accordance with table 8-1.
• Air-bleed band closure
2. Inlet fitting Two threads total, Two threads total, AVUM: Replace
for 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 nut
for:
c. Wrench damage Any amount, without Not repairable Replace retaining nut.
on each corner high metal, if wrench
of hex flats. won't slip on nut.
f. Nicks and Any number, 1/64 Not repairable Replace retaining nut.
scratches, inch deep, without
except on high metal.
threads
8-18
TM 1-1500-204-23-1
(b) Fuel nozzle cleaning. Clean fuel noz- (b) Main fuel filter cleaning. Clean f lter
zles using the following procedures: with a cloth dampened in degreasing solvent. Dry using
compressed air.
1 Clean using degreasing solvent and a (4) Fuel control filter inspection and clean-
brush. ing. Inspect and clean fuel control f lter in accordance
with the applicable maintenance manual and the follow-
2 Remove residue with a clean lint-free ing paragraphs.
cloth.
(a) Fuel control filter inspection. In-
spect f lter for tears, punctures, broken wires, dents,
scratches, and corrosion.
When using compressed air for cleaning, use
approved protective equipment for eyes and (b) Fuel control filter cleaning. Clean f l-
face. Do not use more than 30 psig air pres- ter using the procedures in paragraph (3)(b).
sure. Do not direct air toward yourself or
another person. Failure to comply could result (5) Governor control inspection and adjust-
in injury to eyes or skin. In case of injury, get ment. Inspect and adjust the governor control in ac-
medical attention. cordance with the applicable maintenance manual.
3 Blow f ltered, compressed air through 8-7. REPLACEMENT CRITERIA FOR ENGINES
primer nozzle. Hold nozzle tip in water, and look for AND COMPONENTS. Replacement criteria for en-
stream of air bubbles coming from orif ces. The nozzle gines and components are explained in the following
is clogged if there is no bubbling. Replace nozzle if paragraphs.
clogged.
a. Engine Replacement Criteria. The following
(3) Main fuel filter inspection and cleaning. conditions require replacement of the engine:
When scheduled replacement time is accumulated,
Inspect and clean main fuel f lter in accordance with the as specif ed in the specif c engine maintenance manual.
applicable maintenance manual and the following para- When foreign objects enter air intake and damage
graphs. compressor.
When overspeeding occurs, inspection or replace-
(a) Main fuel filter inspection. Inspect ment shall be as indicated in the specif c engine main-
the main fuel f lter for cracks, corrosion, pitting, and ele- tenance manual.
ment contamination.
Change 5 8-19
TM 1-1500-204-23-1
• When hot starts or tall pipe temperatures (4) Remove the engine air-conditioning duct
exceed maximum allowable limit for given access plate, and disconnect the duct from the engine.
operating condition, inspection or replacement
shall be accomplished in accordance with the (5) Disconnect the turbine discharge pressure
applicable maintenance manual. pickup line as shown in figure 8-19.
• When oil system is contaminated with metal (6) Disconnect the electrical wiring and the
particles, proceed as directed in the thermocouple leads from the connectors as shown in
maintenance manual. figure 8-20.
b. Component Replacement. Criteria Replace (7) Disconnect the fuel line by removing the
individual turbine engine components as specified In the bolts from the hose flange as shown in figure 8-21.
applicable maintenance manual.
8-20
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8-21/(8-22 blank)
TM 1-1500-204-23-1
CHAPTER 9
9-1. General. The maintenance instructions and landing gear and the landing gear doors. Figure 9-2
procedures contained in this chapter are general and shows a typical hydraulic landing gear retraction system.
applicable to airframe maintenance of Army aircraft.
Maintenance instructions that are specific and peculiar b. Emergency Extension Systems. The emergency
to particular airframes are contained in the applicable extension system lowers the landing gear if the main
maintenance manuals and will be used in conjunction power system fails. Some aircraft have an emergency
with general information contained in this chapter. release handle in the cockpit, which is connected
through a mechanical linkage to the gear uplocks.
9-2. Landing Gear Systems. The landing gear of an When the handle is operated, it releases the uplocks
aircraft consists of main and auxiliary units, either of and allows the gear to free-fall, or extend, under their
which may or may not be retractable. The main landing own weight. On other aircraft, release of the uplock is
gear forms the principle support of the aircraft on land or accomplished using compressed air which IS directed to
water and may include any combination of wheels, uplock release cylinders. Some installations are
floats, skis, shock-absorbing equipment, brakes, designed so that either hydraulic fluid or compressed air
retracting mechanism with controls and warning provides the necessary pressure, while others use a
devices, cowling, fairing, and structural members manual system for extending the landing gears under
necessary to attach any of the foregoing to the primary emergency conditions. Hydraulic pressure for
structure. The auxiliary landing gear consists of tall or emergency operation of the landing gear may be
nose wheel Installations, outboard pontoons, skids, etc, provided by an auxiliary hand pump, an accumulator, or
with necessary cowling and reinforcement an electrically powered hydraulic pump, depending upon
the design of the aircraft.
9-3. Retractable Landing Gear Systems. Retractable
landing gear systems are explained in the following c. Safety Devices. Accidental retraction of a
paragraphs. landing gear may be prevented by such safety devices
as mechanical downlocks, safety switches, and ground
a. Types. The electric and hydraulic landing gear locks. Mechanical downlocks are built-in parts of a
retraction systems are explained in the following gear-retraction system and are operated automatically
paragraphs. by the gear-retraction system. To prevent accidental
operation of the downlocks, electrically operated safety
(1) Electric landing gear retraction system. The switches are Installed.
electric landing gear retraction system is an electrically
driven jack for raising or lowering the gear, as shown in (1) Safety switch. A landing gear safety switch,
figure 9-1. When a switch in the cockpit is moved to the as shown In figure 9-3, in the landing gear safety circuit
UP position, the electric motor operates. Through a is usually mounted in a bracket on one of the main gear
system of shafts, gears, adapters, an actuator screw, shock struts. This switch is actuated by a linkage
and a torque tube, a force is transmitted to the drag strut through the landing gear torque links. The torque links
linkages. Thus, the gear retracts and locks If the switch spread apart or move together as the shock strut piston
is moved to the DOWN position, the motor reverses and extends or retracts in its cylinder. When the strut is
the gear moves down and locks. compressed (aircraft on the ground), the torque links are
close together, causing the adjusting links to open the
(2) Hydraulic landing gear retraction system. safety switch. During takeoff, as the weight of the
Devices used In a typical hydraulically operated landing aircraft leaves the struts, the struts and torque links
gear retraction system include actuating cylinders, extend, causing the adjusting links to close the safety
selector valves, uplocks, downlocks, sequence valves, switch. As shown in figure 9-3, a ground is completed
turbine, and other conventional hydraulic components. when the safety switch closes. The solenoid then
These units are interconnected so that they permit energizes and
properly sequenced retraction and extension of the
9-1
TM 1-1500-204-23-1
unlocks the selector valve so that the gear handle can f. Retraction Test. Inspect landing gear for
be positioned to raise the gear obvious damage, then accomplish retraction test,
inspecting for the following items.
(2) Ground locks. Ground locks prevent
landing gear collapse when the aircraft is on the ground. • Landing gear for proper retraction and
One common type is a pin installed In aligned holes extension
drilled in two or more units of the landing gear support
structure. Another type is a spring-loaded clip designed • Switches, lights, and warning horn for proper
to fit around and hold two or more units of the support operation
structure together. All types of ground locks usually
have red streamers permanently attached to them to • Landing gear doors for clearance and freedom
readily indicate whether or not they are installed. from binding
d. Gear Position Indicators. To provide a visual • Landing gear linkage for proper operation,
indication of landing gear position, indicators are adjustment, and general condition
installed in the cockpit or flight compartment. Gear
warning devices are incorporated on all retractable gear • Latches and locks for proper operation and
aircraft and usually consist of a horn or some other aural adjustment
device and a red warning light.
• Alternate extension or retraction systems for
e. Nosewheel Centering. Aircraft are commonly proper operation
provided nosewheel steering capabilities through a
simple system of mechanical linkage hooked to the • Any unusual sounds such as those caused by
rudder pedals. Most common applications utilize rubbing, binding, chafing, or vibration.
pushpull rods to connect the pedals to horns located on
the pivotal portion of the nosewheel strut.
9-2
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9-3
TM 1-1500-204-23-1
WARNING
Always stand to one side of the Figure 9-4. Landing Gear Shock Strut of the
valve, since high-pressure air can Metering Pin Type
cause serious injury, e.g., loss of
eyesight .
9-4
TM 1-1500-204-23-1
9-5
TM 1-1500-204-23-1
(10) Re-install the air valve assembly, using (5) Fill the strut to the level of the filler port
a new O-ring packing. Torque the air valve assembly to with an approved type hydraulic fluid.
the values recommended in the applicable maintenance
manual. (6) Attach the bleed hose to the filler port and
insert the free end of the hose into a container of clean
(11) Install the air valve core. hydraulic fluid, making sure that this end of the hose is
below the surface of the hydraulic fluid.
(12) Inflate the strut, using a high-pressure
source of dry air or nitrogen. (7) Place an exerciser jack or other suitable
single-base jack under the shock strut jacking point.
NOTE Compress and extend the strut fully by raising and
Bottled gas should not be used to lowering the jack until the flow of air bubbles from the
inflate shock struts. On some shock strut has completely stopped. Compress the strut slowly
struts the correct amount of inflation and allow it to extend by its own weight.
is determined by using a high-
pressure air gauge. On others it is (8) Remove the exerciser jack, and then lower
determined by measuring the amount and remove all other jacks.
of extension (in inches) between two
given points on the strut. The proper (9) Remove the bleed hose from the shock
procedure can usually be found on strut.
the instruction plate attached to the
(10) Install the air valve and inflate the strut.
shock strut. Shock struts should
always be inflated slowly to avoid
d. General Maintenance of Shock Struts. All
excessive heating and over inflation.
maintenance personnel should study all technical
manuals which pertain directly to the shock strut in
(13) Tighten the swivel hex nut, using the
question, or aircraft maintenance publications which
torque values specified in the applicable maintenance
have a portion of the Instructions devoted to the
manual.
particular shock strut in question. General maintenance
for pneumatic, rubber block, and spring steel shock
(14) Remove the high-pressure air line
struts is described in the following paragraphs.
chuck and Install the valve cap Tighten the valve cap
finger-tight.
(1) Pneumatic type. Use the following
procedures for maintenance of pneumatic type shock
c. Shock Strut Bleeding. If the fluid level of a
struts.
shock strut has become extremely low, or if for any
other reason air is trapped in the strut cylinder, it may be (a) Clean the exposed part of the piston
necessary to bleed the strut during the servicing tube using the following procedures.
operation. Bleeding is usually performed with the
aircraft placed on jacks. In this position the shock struts
NOTE
can be extended and compressed during the filling
Cleaning of piston tubes reduces
operation, thus expelling all the entrapped air. The
excessive wear and possible failure
following is a typical bleeding procedure:
of shock strut packing rings.
(1) Construct a bleed hose containing a fitting
suitable for making an airtight connection to the shock 1 Remove ice, mud, dust, or
strut filler opening. The base should be long enough to sand, then wipe using a clean cloth saturated with
reach from the shock strut filler opening to the ground hydraulic fluid MIL-H-5606.
when the aircraft is on jacks.
2 When extreme Ice, dust, mud
(2) Jack the aircraft until all shock struts are or sand conditions are encountered, wipe piston tubes
fully extended. before and after each flight.
(3) Release the air pressure in the strut to be 3 When operating aircraft in
bled. freezing temperatures, piston tube can be cleaned more
easily
(4) Remove the air valve assembly.
9-6
TM 1-1500-204-23-1
Immediately after landing, as ice will form on tube when (2) Power control systems. Power brake
aircraft is left standing without tube being cleaned of control valve systems, as shown in figure 9-8, are used
water, mud and slush. on aircraft requiring a large volume of fluid to operate
the brakes. As a general rule, this applies to many large
(b) Maintain proper air-oil levels in struts as aircraft. Because of their weight and size, large wheels
specified on data plates. Use hydraulic fluid, MIL- and brakes are required. Larger brakes mean greater
H5606. fluid displacement and higher pressures, and for this
reason independent master cylinder systems are not
(c) Replace pistons having nicks, practical on heavy aircraft. In this system a line is
scratches, or dents deep enough to cause leakage. tapped off from the main hydraulic system pressure line.
Replace elongated bushings. Replace struts that have
cracked fittings. (3) Power boost systems. A typical power
boost brake system, as shown in figure 9-9, consists of a
(d) When overhauling a pneumatic shock reservoir, two power boost master cylinders, two shuttle
strut, all ferrous metal parts will be magnetic particle valves, and the brake assembly in each main landing
Inspected for cracks and flaws. Inspection will be wheel. In this type of system, a line is tapped off the
accomplished in accordance with applicable main hydraulic system pressure line, but main hydraulic
maintenance manual. system pressure does not enter the brakes. Main
system pressure is used only to assist the pedals
(2) Rubber block type. Replacement of through the use of power boost master cylinders.
compression and rebound rubber blocks, or adjustment
of preload tubes shall be as specified in applicable b. Brake Assemblies. Brake assemblies
aircraft maintenance manual commonly used on aircraft are the single-disk, dual-disk.
The single and dual-disk types are more commonly used
(3) Spring steel type. Repairs are limited to on small aircraft.
burnishing minor nicks, burrs, or scratches Replace
cracked struts. (1) Single-disk brakes. With the single-disk
brake, braking is accomplished by applying friction to
9-6. Landing Gear Alignment. The alignment of both sides of a rotating disk which is keyed to the
aircraft landing gear is too critical, and the tolerances landing gear wheel. There are several variations of the
too narrow to deal with the subject in a general manner. single-disk brake, however, all operate on the same
Reference will be made to applicable aircraft principle and differ mainly In the number of cylinders
maintenance manual for specific data relating to landing and the type
gear alignment.
9-7
TM 1-1500-204-23-1
Figure 9-8. Power Control Brake System (1) Visually inspect brake housing throughly
for cracks, chipped or worn mounting holes, stripped
threads, and corrosion.
Figure 9-9. Power Boost Brake System Figure 9-10. Single-Disk Brake
9-8 Change 5
TM 1-1500-204-23-1
(2) Inspect lining recesses in piston, center car- (1) Replace all seals, cups, and O-rings on an
rier, and anvil for indications of wear which could cause availability basis when assembling brakes to prevent
loss of lining. Wear of anvil lining recess circumference possible leakage and brake failure.
in excess of 0.005 inch is cause for replacement.
(2) Apply a light coat of insulating and sealing
(3) Examine piston cavity for corrosion, exces- compound, MIL-I-8660, to surface of piston cavity and
sive wear, or for being out-of-round. When light corro- to O-ring or cup seal.
sion extends more than 9/16 inch into piston cavity, or
heavy corrosion is evident, replace brake assembly. (3) Replace disks that have cracks extending
through disc. Any single crack that extends through
NOTE thickness of brake disk shall be reason for replacement.
Minor surface cracks and heat checks are normal and
Corrosion is usually found in carrier housing and are not cause for replacement.
in piston cavities. Corrosion in magnesium can
be identied by the rough honeycombed ap-
(4) When necessary to replace one lining be-
pearance of the pit. Pits are usually lled with a
cause of wear, all linings shall be replaced. Replace
yellow or gray powder. Heavy corrosion is de-
linings when any lining thickness is less than 1/16 inch,
ned as pits that exceed 0.025 inch in diameter
or shows indications of being overheated.
or grouped with three or more pits of any diam-
eter in an area of ¼ inch square. g. Brake Assembly Servicing. Service brake
assemblies in accordance with the applicable mainte-
e. Corrosion Treatment of Brake Assemblies. nance manual. The following are general procedures
Brake assemblies are manufactured from magnesium, for all aircraft.
aluminum, and steel. Most assemblies have magne-
sium housings which are very susceptible to corrosion, (1) Check for leaks while system is under oper-
especially in piston cavities. Treat the surface using the
following procedures: ating pressure.
9-9
TM 1-1500-204-23-1
NOTE
Bearings should be cleaned and repacked if
wheel is removed or was submerged in water.
9-10 Change 5
TM 1-1500-204-23-1
b. Wheel Inspection. Inspect aircraft wheels (3) Distortion. Check wheel carefully for
for corrosion, cracks, distortion and damage using the distortion Replace any wheel with this condition.
following procedures:
(4) Damage. Replace any wheel having
(1) Visually Inspect wheel thoroughly for dents, nicks, burrs, or scratches if the damage cannot
signs of corrosion, which can be identified by formation be repaired within limits specified in applicable
of pits in the metal and a powdery substance in and maintenance manual.
around exposed areas. Corrosion in split type wheel
usually will be found in the tie bolt area, torque key area, NOTE
bearing cavity area, and seal (tubeless tire) area. If one wheel half is determined
Corrosion in these areas is considered critical. nonrepairable, replace both halves.
(2) Visually inspect wheel for indications 9-9. Tires and Tubes. Aircraft tires, tubeless or tube
of cracks, using at least a six-power magnifying glass. type, provide a cushion of air that helps absorb the
shocks and roughness of landings and takeoffs they
(3) Visually Inspect for distortion and support the weight of the aircraft while on the ground
other damage. and provide the necessary traction for braking and
stopping aircraft on landing.
c. Repair of Wheels. Repair aircraft wheels in
accordance with the applicable maintenance manual a. Cleaning. Clean aircraft tires and tubes in
and the following procedures accordance with the applicable maintenance manual.
(1) Etching, corrosion, and minor defects b. Inspection. Inspection of tires and tubes is
are to be removed to relieve all sharp corners or explained In the following paragraphs.
indention’s which might result in concentration of
stresses. Use 100-grit emery cloth, followed by final (1) Tire Inspection. Inspect tires for leaks
polishing with 240 grit emery cloth so as to maintain or damage at valve, tread damage, sidewall damage,
repair limitations. and uneven wear when tire is mounted on wheel. When
tire is dismounted probe all damages to determine their
NOTE extent. Repair damage if necessary. Inspect for bulges,
Above rework limits are for use on all broken cords, and bead damage.
wheels which do not have repair
limitations in the specific aircraft (2) Tube inspection. Inspect tubes for
maintenance manual. proper size, wrinkles, chafing, and thinning. Examine
the tube carefully around the valve stem for leaks, signs
(2) Chemical film-treat bare metal of valve pad separation, and bent or damaged valve
surfaces, followed by painting. stems.
d. Replacement Cntena for Wheels. c. Balance. Balance in aircraft tires and tubes
Replacement criteria for wheels with corrosion, cracks, is very important. From a wear standpoint, when the
distortion, and other damage is explained in the wheels are in landing position a heavy spot in a wheel
applicable maintenance manual. assembly will have a tendency to remain at the bottom
and thus will always strike the ground or runway first.
(1) Corrosion. Wheel Is unserviceable If This results in severe wear at one area of the tire tread
it cannot be repaired within limits specified in applicable and can necessitate early replacement In addition,
maintenance manual unbalanced tires can cause severe vibration which may
affect the operation of the aircraft.
(2) Cracks. If any cracks are found,
wheel should be condemned. If any questionable d. Valve Cores. Valve cores must be replaced
indication of a crack is found, wheel should be inspected if leaks are present in the valve stem. Always inspect
further by means of fluorescent penetrants. Cracks the valve to be sure the threads are not damaged;
present in spilt-type wheel usually are located In the tie otherwise, the valve core and valve cap will not fit
bolt area, torque key area, and webbing and spoke area. properly. If threads are damaged, the valve can usually
Refer to TM 55-1500-335-23, Nondestructive be rethreaded, inside or outside, by use of a valve repair
Inspection Methods.
9-11
TM 1-1500-204-23-1
tool, without demounting the tire from the wheel. Make 9-12. Flight Controls. The flight control surfaces are
certain that every valve has a valve cap on it, screwed hinged or movable airfoils designed to change the
on firmly with the fingers. The cap prevents dirt oil and attitude of the aircraft during flight. Maintenance of
moisture from getting inside the valve and damaging the flight controls shall be accomplished by replacing worn,
core. It also seals In air and serves as protection in damaged, or defective components, adjusting rigging
case a leak develops in the valve core. components, and accomplishing preventive
maintenance to the system.
e. Installation. Install tires and tubes in
accordance with the applicable maintenance manual. a. Types. Ailerons, elevators, the rudder, flaps,
and trim tabs are the common types of flight controls.
9-10. Ski Maintenance. Maintenance of skis shall be Each is explained in the following paragraphs.
as specified In the applicable aircraft maintenance
manual and the following paragraphs. (1) Ailerons. The motion of the aircraft about
the longitudinal axis is called rolling or banking. The
a. Ski Inspection. It is advisable to examine ski ailerons, as shown in figure 9-13, are used to control this
installations frequently to keep them maintained in movement. The ailerons form a part of the wing and are
airworthy condition. If shock cord is used to keep the ski located in the trailing edge of the wing toward the tips.
runner in proper trim, periodically examine to assure Ailerons are the movable surfaces of an otherwise fixed-
that the cord has enough elasticity to keep the runner in surface wing. The aileron is in neutral position when it is
its required attitude and the cord is not becoming loose streamlined with the trailing edge of the wing.
or badly frayed. Replace old or weak shock cords.
When other means of restraint are provided, examine (2) Elevators. When the nose of an aircraft is
for excessive wear and binding, and replace or repair raised or lowered, it is rotated about its lateral axis.
when such conditions are found. Examine the points of Elevators are the movable control surfaces that cause
cable attachment, both on the ski and the airplane this rotation, as shown in figure 9-14. They are normally
structure, for bent lugs due to excessive loads having hinged to the trailing edge of the horizontal stabilizer.
been imposed while taxiing over rugged terrain, or by The elevator can be moved either up or down. If the
trying to break loose frozen skis. If skis which permit elevator is rotated up, it decreases the lift force on the
attachment to the wheels and tires are used, maintain tail causing the tail to lower and the nose to rise. If the
proper tire pressure, as under inflated tires may push off elevator is rotated downward, it increases the lift force
the wheels. if appreciable side loads are developed in on the tail, causing it to rise and the nose to lower.
landing or taxiing. Lowering the aircraft's nose increases forward speed,
and raising the nose decreases forward speed.
b. Ski Repair. Aluminum tubular members may
have negligible damage of surface scratches and (3) Rudder. Turning the nose of the aircraft
smooth contour dents not over 1/16 Inch in depth. All causes the aircraft to rotate about its vertical axis.
damage, other than negligible, shall necessitate Rotation of the aircraft about the vertical axis is called
replacement unless otherwise specified in applicable yawing. This motion is controlled by using the rudder as
aircraft maintenance manual. Steel tubular members shown In figure 9-15.
may have negligible damage of surface scratches and
small dents not over 0.004 inch in depth. Repairable (4) Flaps. Flaps are high-lift devices attached
damage shall consist of straightening slight bends and to the trailing edge of the wing. The flap is controlled
rewelding existing welds. from the cockpit, and when not in use fits smoothly into
the lower surface of each wing. The use of flaps
9-11. Float Maintenance. In order to maintain floats in increases the camber of a wing and therefore the lift of
an airworthy condition, frequent inspections should be the wing, making it possible for the speed of the aircraft
made because of the rapidity with which corrosion takes to be decreased without stalling. This also permits a
place on aluminum alloy metal parts, particularly when steeper gliding angle to be obtained such as in the
the aircraft Is operated in salt water. Examine metal landing approach. Flaps are primarily used during
floats and all metal parts on wooden or fiberglass floats takeoff and landing. Figure 9-16 shows various types of
for corrosion and take corrective action in accordance flaps used on aircraft.
with the applicable aircraft maintenance manual. All
maintenance of floats shall be as specified in the
applicable aircraft maintenance manual.
9-12
TM 1-1500-204-23-1
9-13
TM 1-1500-204-23-1
(5) Trim tabs. Trim tabs trim the aircraft in c. Repair of Flight Controls. Make all repairs to
flight. To trim means to correct any tendency of the flight controls in accordance with the applicable aircraft
aircraft to move toward an undesirable flight attitude. maintenance manual.
Trim tabs control the balance of an aircraft so that it
maintain straight and level flight without pressure on the d. Flight Control Operation Systems. Three types
control column, control wheel, or rudder pedals. Figure of control systems commonly used are the cable, push-
9-17 shows a trim tab. Note that the tab has a variable pull, and torque tube systems. The cable system is the
linkage which is adjustable from the cockpit. Movement most widely used because deflection of the structure to
of the tab in one direction causes a deflection of the which it is attached do not affect its operation Many
control surface in the opposite direction. Most of the aircraft incorporate control systems that are
trim tabs installed on aircraft are mechanically operated combinations of all three types. The systems which
from the cockpit through an individual cable system. operate the control surfaces, tabs, and flaps include
However, some aircraft have trim tabs that are operated flight control system hardware, linkage,and
by an electrical actuator. Trim tabs are either controlled mechanisms. These items connect the control surfaces
from the cockpit or adjusted on the ground before taking to the cockpit controls. Included in these systems are
off. Trim tabs are installed on elevators, rudders, and cable assemblies, cable guides, linkage, adjustable
ailerons. stops, control surface snubber or locking devices,
surface control booster units, actuators operated by
b. Inspection of Flight Controls. Inspect all flight electric motors, and actuators operated by hydraulic
control surfaces in accordance with the applicable motors.
aircraft maintenance manual.
9-14
TM 1-1500-204-23-1
9-15
TM 1-1500-204-23-1
9-16
TM 1-1500-204-23-1
NOTE NOTE
• Breakage usually occurs in that • Any 7x7 cable having three wires
length of a cable normally or less per inch worn not more
passing over a pulley or through than halfway through the wire
a fairlead, as shown in figure 9- diameter, or any 7 x 19 cable
20. having six wires or less per inch
worn not more than halfway
• Any cable not within specified through wire diameter, shall be
allowable limits listed in table considered serviceable if broken
shall be considered wires are present in the worn
unserviceable and must be area.
replaced.
• The cable shall be considered
• In addition to limits specified in serviceable if broken wires are
table 9-1 the maximum allowable present but are not in the worn
number of broken wires shall not area.
occur in any two consecutive
inches of cable, that is, if six • One less worn wire per inch is
wires are broken in one inch of a allowed for each broken wire
7 x 19 cable, none would be present in the same inch if more
allowed in the next consecutive than one worn area is found, but
inch For any flexible cable, a all are within specified limits, the
maximum of three broken wires cable is satisfactory, provided no
per inch shall be allowable in the two worn spots are adjacent
length of cables passing over circumferentially.
pulleys, drums, or through
fairleads. • Any wire worn completely
through, or worn to a point of
(b) Replace badly worn cables breaking, shall be considered
even if number of broken wires is less than specified for unserviceable.
replacement.
• Kinked, twisted, or birdcaged
cables must be repaired or
replaced.
9-17
TM 1-1500-204-23-1
9-18
TM 1-1500-204-23-1
9-19
TM 1-1500-204-23-1
9-20
TM 1-1500-204-23-1
9-21
TM 1-1500-204-23-1
9-22
TM 1-1500-204-23-1
NOTE
Cracks in solder located between
wrapping wire and short space
provide between wraps is a positive
indication of slippage in wrap
soldered splice.
WARNING
A suitable guard should be placed
over cable, during testing, to prevent
injury in event of cable failure.
9-23
TM 1-1500-204-23-1
f. Control System Components. Control through or between structural members of the aircraft.
system components are explained in the following Inspect fairleads for wear, breakage, alignment,
paragraphs. cleanness, and security. Examine cable routing at
fairleads to assure that deflection angles are no greater
(1) Turnbuckles. A turnbuckle assembly than 3 degrees maximum. Determine that all guides
is a mechanical screw device consisting of two threaded and anti-abrasion strips are secure and in good
terminals and a threaded barrel. Figure 9-25 shows a condition. Replace rubber or nylon grommets that show
typical turnbuckle assembly. Turnbuckles are fitted in evidence of excessive wear. Replace worn or cracked
the cable assembly for the purpose of making minor phenolic fairleads. Reposition fairleads that allow
adjustments in cable length and for adjusting cable cables to chafe.
tension. One of the terminals has right-hand threads
and the other has left-hand threads. The barrel has (4) Pulleys. Pulleys are used to guide
matching right- and left-hand internal threads. The end cables and change the direction of cable movement.
of the barrel with the left-hand threads can usually be Various cable system malfunctions may be detected by
identified by a groove or knurl around that end of the analyzing pulley conditions These include such
barrel. discrepancies as too much tension, misalignment, pulley
bearing problems, and size mismatches between cables
(a) Turnbuckle replacement criteria. and pulleys. Examples of these conditions are shown in
Replace turnbuckles and turnbuckle barrels that are figure 9-28 inspect pulleys using the following
cracked, corroded, or have stripped threads. procedures:
9-24
TM 1-1500-204-23-1
9-25
TM 1-1500-204-23-1
NOTE NOTE
It is good practice to rotate the pulley Operation or adjustment of some
90 degrees while inspecting, so as to accessories or flight controls
relocate the used area to another requires a rotating motion which
position and thereby prolong the life often is accomplished by means of
of the pulley torque tubes. To effect changes in
direction of the torque tube,
(5) Control rods. Control rod assemblies universal joints are required The
are used as links in mechanical systems to allow remote most common are MS20270 and
operation and adjustment of components. Push-pull MS20271, which are attached to the
linkage is designed and constructed so that both tube by bolts or rivets.
torsional and compression forces will be transmitted to
the component being operated. Two common types of (a) Inspection of control tubes. The
push-pull linkage are the control tube and the control procedure which follows is common to all control tube
rod. Control tubes, as shown in figure 9-29, consist of a assemblies Refer to the applicable manual for
metal tube, usually made of steel or an aluminum alloy, inspection of each particular component.
and two rod ends. One rod end is attached to each end
of the metal tube, which may be swaged, expanded, or 1 Check for bent or flattened
reamed at the ends to engage the rod ends. The rod tube.
ends are welded or riveted to the tube.
2 Check tube for nicks, dents,
gouges, scores or scratches, corrosion, and cracks.
9-26
TM 1-1500-204-23-1
NOTE NOTE
If in doubt as to presence of cracks Do not attempt tube repair if center
in tube, strip the paint and make a one-third of assembly is damaged.
magnetic-particle or fluorescent- When replacing rod ends that are
penetrant inspection. riveted to control tube, rotate tube 90
degrees and redrill prior to riveting in
3 Check rod ends for security emergency, repair tubular type
(loose rivets), cracks or breaks, and damaged threaded control rod by inserting a scarfed or
portions. fishmouth sleeve reinforcement.
9-27
TM 1-1500-204-23-1
9-28
TM 1-1500-204-23-1
(8) Mixing units. Mixing units combine four (b) Lubricate valve cranks and push-pull
motions from the cockpit (pitch, roll, yaw, and thrust) levers with a small amount of molybdenum-disulfide
and convert them into two outputs. Inspect and maintain technical powder, MIL-M-7866.
in accordance with the applicable maintenance manual.
(c) Pressure-test any repair made to heat ex-
(9) Drive chains. Replace defective links in changer tube before installation. A repaired tube is con-
chains and maintain in accordance with applicable sidered a temporary measure and will be replaced when
maintenance manual. parts become available.
Change 5 9-29
TM 1-1500-204-23-1
9-30 Change 6
TM 1-1500-204-23-1
NOTE
Repairs of exible ducts made of berglass
impregnated with chloroprene shall be made
with adhesive , NSN 8040-00-390-7960 (P/N
Bostick 4006A and 4006B) utilizing ber-
glass cloth. Repairs will be accomplished in a
well-ventilated area.
DELETED
Change 5 9-31
TM 1-1500-204-23-1
(1) Thoroughly clean affected Aliphatic Naph- (g) Allow patch to set 15 minutes, then wipe
tha, TT-N-95. patch and surrounding area with Aliphatic Naphtha.
9-32 Change 5
TM 1-1500-204-23-1
3. Pressure gauge shows no a. Faulty pressure gauge line Repair or replace line.
pressure while vacuum gauge
shown normal reading.
4 Cycling period irregular a. Loose or faulty tubing and Tighten, repair, or replace as
connection necessary.
9-33
TM 1-1500-204-23-1
• Rate-of-temperature rise detectors are joined and will be exposed to the heat of a fire is
called a hot junction. There is also a reference junction
• Radiation sensing detectors enclosed in a dead air space between two insulation
blocks. A metal cage surrounds the thermocouple to give
• Smoke detectors mechanical protection without hindering the free
movement of air to the hot junction. If there is a fire, the
• Overheat detectors hot junction will heat more rapidly than the reference
junction. This will complete a circuit from the aircraft
• Carbon monoxide detectors power system to the coil of the slave relay which closes
and completes the circuit to the fire-warning light
• Combustible mixture detectors
(3) Continuous-loop system . A continuous loop
• Fiber-optic detectors detector or sensing system permits more complete
coverage of a fire hazard area than any type of spot-type
• Flame detectors temperature detectors. Continuous-loop systems are
versions of the thermal switch system. They are overheat
• Observation by crewmembers systems, heat-sensitive units that complete electrical
circuits at a certain temperature. There is no rate-of-heat-
b. Types of Fire Detection Systems. A fire rise sensitivity in a continuous-loop system. Two widely
detection system should signal the presence of a fire. used types of continuous-loop system are the Kidde and
Units of the system are installed in locations where there the Fenwal systems.
are greater possibilities of a fire Three detector systems in
common use are the thermal switch system, (a) Kidde system. The Kidde continuous-loop
thermocouple system, and the continuous-loop detector system, as shown in figure 9-33, has two wires Imbedded
system. In a special ceramic core within an Inconel tube. One of
the two wires In the Kidde sensing system is welded to the
(1) Thermal switch system. The thermal switch case at each end and acts as an internal ground The
system uses a bimetallic thermostat switch or spot second wire is a hot lead (above ground potential) that
detector similar to that shown in figure 9-32. Each provides a current signal when the ceramic core material
detector unit consists of a bimetallic thermoswitch. These changes its resistance with a change in temperature.
thermal switches are heat-sensitive units that complete
electrical circuits at a certain temperature. If the
temperature rises above a set value in any one section of
the circuit, the thermal switch will close, completing the
light circuit to indicate the presence of a fire or overheat
condition
9-34
TM 1-1500-204-23-1
• Dents and kinks In sensing element sections • Broken or frayed flexible leads, if used.
NOTE
The flexible leads is made up of
many fine metal strands woven into a
protective covering surrounding the
inner insulated wire. Continuous
bending of the cable or rough
treatment can break these fine wires,
especially those near the connectors
Broken strands can also protrude
into the insulated gasket and short
the center electrode.
9-35
TM 1-1500-204-23-1
• Rubbing between a cowl brace and a sensing e. Repair or Replacement of Fire Detection
element. Components. Repair or replace fire detection
components using the following procedures:
• Correct grommet installation.
(1) Replace defective control unit with a
• Thermocouple detector mounting brackets serviceable unit.
should be repaired or replaced when cracked,
corroded, or damaged. CAUTION
Do not bend sharply, kink, or twist
d. Troubleshooting of Fire Detection Systems . A sensing element during installation
typical troubleshooting chart for fire detection systems is Minimum allowance curve radius is
shown in table 9-5. one inch. Damage may otherwise
result
3. Failure to obtain an alarm a. Defective test switch or control Replace test switch or control
signal when the test switch unit unit.
Is actuated
9-36
TM 1-1500-204-23-1
• Polarity, ground, resistance, and continuity tests h. Maintenance of Fire Extinguishing Systems.
are required for systems with thermocouple Maintenance of fire extinguisher system consists of
detect or units. Inspection and replacement of defective parts using the
following procedures:
• Resistance and continuity tests are required for
systems with sensing elements or cable (1) Check for specific pressure on pressure
detector units. gauge as given In applicable aircraft maintenance manual
9-37
TM 1-1500-204-23-1
CAUTION NOTE
Do not flush system with water. Install cartridges in the assigned
Damage to system may otherwise locations (see DA Form 2408-18) to
result preclude incorrect age life control
removals at a later date.
(3) Purge system thoroughly with clean, dry,
compressed air immediately after landing when system 9-16. Hoist Systems. The hoist system which provides
has been used In flight, or immediately after discharged a means of raising and lowering equipment or personnel
on the ground. Absorb residual bromochloromethane during flight or ground operation is of two types: hydraulic
remaining on surface areas with dry cloths and clean, dry, and electric.
compressed air
a. Hydraulic Hoist System. Maintenance and
(4) Inspect compartments and components that testing procedures for hydraulic hoist systems are
may have come in contact with extinguishing agent for explained in the following paragraphs
possible damage Replace defective parts
(1) Maintenance of hydraulic hoist system.
(5) Inspect rubber materials and insulations Maintenance of the hydraulic hoist system consists of
where extinguisher was used Replace when found replacement of defective parts using the following
defective. procedures
(6) Relubricate all lubricated parts exposed to (a) Service system with fluid, MIL-H-
extinguishing agent 5606, and maintain indicated reservoir level
(7) Replace overboard discharge indicator disc (b) Cap all tubing disconnected during
after system has been discharged. removal of units to prevent entry of foreign matter.
9-38
TM 1-1500-204-23-1
b. Electrical Hoist System. Maintenance and testing b. Maintenance of Oxygen Systems . Maintenance
procedures for electric hoist systems are explained in the of oxygen systems Is described in the following
following paragraphs paragraphs.
(1) Maintenance of electric hois t system. (1) Oxygen leaks. Use soap test to
Maintenance of the electric hoist system consists locate leaks unless individual leaks are large enough for
primarily of replacement of defective parts using the personnel to hear or feel. Apply soap solution, using mild
following procedures. soap, A-A-50, to suspected part using a soft brush and
watch carefully for frothing, bubbling, or growing bubbles
(a) Replace hoist cable when kinked or
when cable has been broken strands. WARNING
Do not allow petroleum base products
(b) Replace monorail attaching parts to come in contact with components
when found to be defective. of the oxygen system, as explosion or
fire may result.
(c) Lubricate hoist as prescribed in the
applicable aircraft maintenance manual. CAUTION
(2) Testing of electric hoist system Perform a Drain tubing of all solutions and blow
functional check, to test the electric hoist system for out with oxygen prior to installation in
operation periodically, and when a unit or electrical wiring aircraft. Contamination may otherwise
is replaced in the system. result.
9-17. Oxygen Systems. Oxygen system types, (2) Tubing and fittings. Maintenance,
maintenance, and servicing is explained in the following repair, replacement, and Installation of oxygen system
paragraphs. tubing is given in TM 1-1500-204-23-2.
a Oxygen System Types. The design of the various (3) Cylinders Replace all damaged
oxygen system types used in aircraft depends largely on cylinders. No maintenance is authorized on installed low
the type of aircraft, Its operational requirements, and, or high pressure cylinders.
where applicable, the pressurization system. In some
aircraft a continuous-flow oxygen system is installed for NOTE
both passengers and crew. The pressure demand system All low pressure oxygen cylinders
is widely used as a crew system, especially on the larger which carry a maximum charge of 450
transport aircraft. Many aircraft have a combination of psi will be painted yellow. High
both systems which may be augmented by portable
pressure oxygen cylinders which carry
equipment.
a maximum of 2000 psi will be painted
green.
(1) Continuous-flow system. The continuous
flow oxygen system is shown in figure 9-35. The oxygen
9-39
TM 1-1500-204-23-1
9-40
TM 1-1500-204-23-1
(4) Check valves. Replace all faulty check oxygen system is not charged within two hours after
valves as complete units. Check valves cannot be landing, system will be purged.
repaired.
NOTE
WARNING
Do not use masking tape to seal • Do not use lubricant other than
openings in oxygen regulators. Its antiseize tape, MIL-T-27730, on
use on either serviceable or aircraft oxygen systems
repairable oxygen equipment
constitutes a safety hazard
• Do not use cleaning solutions, or
(5) Regulators. Do not apply oil or grease to any other solutions, inside any
any part of an oxygen regulator. part of oxygen system when
Installed in aircraft.
(6) Flexible hose. Maintain flexible hose using
the following procedures
• Do not use any gases other than
(a) To remove contamination other than oxygen Inside any part of oxygen
oil and grease from flexible hose, remove hose and clean system when Installed in aircraft.
with mild soap, A-A-50, and warm water solution,
thoroughly rinse with fresh water and thoroughly dry with a c. Servicing of Oxygen Systems. Prior to servicing
stream of clean, dried, water-pumped air or nitrogen an aircraft oxygen system, personnel shall familiarize
themselves with the system, precautions, and instructions
(b) Replace hoses damaged or for handling gaseous oxygen, operation of servicing
contaminated with oil or grease. Repair and replacement equipment, and potential hazards involved. Oxygen
procedures for flexible hose are outlined in TM 1-1500- servicing requires the utmost precautionary measures due
204-23-2. to the highly explosive and flammable capabilities of
oxygen All personnel shall heed the following
(c) Examine fittings for tightness. precautionary procedures when servicing:
(7) Open lines. Plug or cap all open lines and CAUTION
equipment when opening system for replacement of any Only qualified personnel shall be
part When system has been accidentally left open, authorized to operate equipment for
system will be purged by one of the following methods servicing of an aircraft oxygen system
Damage to equipment may otherwise
• In aircraft having filler lines connected to one result.
end of cylinder, and distribution lines connected
to opposite ends of cylinder, purging will be (1) Aircraft shall not be serviced with oxygen
accomplished by connecting a service trailer to when any of the following conditions prevail,
aircraft filler valve With all regulators open,
pass oxygen through system for at least 30 • Aircraft electrical switches are on.
minutes at a pressure of 50 psi at filler valve
9-41
TM 1-1500-204-23-1
(2) When aircraft is being serviced with oxygen All electrical power shall be shut off during oxygen
within 50 feet of an area where smoking is permitted, NO discharge operations.
SMOKING signs shall be placed at a 50-foot radius (10) Refer to applicable aircraft maintenance
around the servicing area. manual for additional information and maintenance
procedures.
(3) All aircraft parked outside will be grounded
and bonded, in accordance with FM 1-500, to the 9-18. Relief Tube System. Maintenance of relief tubes
aerospace ground equipment while servicing oxygen primarily consists of cleaning and replacing of parts.
systems Clean or replace parts using the following procedures:
(6) Service aircraft from cylinders clearly 9-19. Windshield Wiper System. Maintenance and
labeled DRY or AVIATOR'S BREATHING OXYGEN. adjustment of the windshield wiper system is explained in
Other Oxygen may have moisture which could cause flow the following paragraphs.
stoppage at temperatures below freezing.
a. Maintenance of Windshield Wiper System. The
(7) Always use a pressure-reducing device maintenance of the windshield wiper system consists
when servicing low-pressure oxygen system from high primarily of replacement of defective parts, as follows.
pressure bottles.
(1) Replace wiper motor, wiper units, wiper
(8) Fill oxygen system slowly to prevent arms, and flexible cables that are inoperative, cracked,
explosion resulting from heat generated by filling too fast. bent or otherwise defective.
(9) An aircraft oxygen system not equipped (2) Replace wiper blades that are worn,
with shutoff devices at cylinders shall be completely deteriorated, or torn, or when rubber has lost its elastic
discharged of all pressure prior to removing components. qualities.
9-42
TM 1-1500-204-23-1
a. Troop Seats. Cleaning, repair and installation (3) Installation and removal. Follow instruc-
and removal procedures for fabric or cotton canvas troop tions contained in the applicable aircraft maintenance
seats are explained in the following paragraphs. manual for installation and removal procedures.
(1) Cleaning. Clean troop seats as follows: b. Metal Seats. Cleaning, repair, and installation
and removal procedures are explained in the following
paragraphs.
(a) Unfold and place parts face up.
(d) Work up heavy suds by repeatedly (2) Repair. Patches and reinforcement repairs
squeezing of a sponge saturated with detergent solu- to metal seats will be accomplished in accordance with
tion. Apply heavy suds to soiled areas. repair procedures in TM 1-1500-204-23-10.
(e) Scrub soiled areas briskly, using a rm (3) Installation and removal. Follow instruc-
bristle brush or heavy cloth. Wipe off with a damp cloth. tions contained in the applicable aircraft maintenance
manual for installation and removal procedures.
(f) Allow treated area to dry. Brush to raise
nap.
Change 5 9-43
TM 1-1500-204-23-1
9-44 Change 2
TM 1-1500-204-23-1
NOTE
The water temperature should not a. Installation. Install Litters using litter kits provided
exceed 100°F (37°C). with each aircraft. Refer to the applicable aircraft
maintenance manual for specific installation procedure.
(d) Immerse one cover at a time in the
soap solution, let stand for 20-25 minutes, and hand wash b. Removal. Upon completion of mission involving
for 5 minutes. litters, remove from aircraft and return to supplying
agency. Stow litter kit in original container in aircraft
(e) Rinse cover In clean water until all when applicable.
soap is removed
9-22. Protective Covers. The instructions contained
NOTE below are applicable to all types of aircraft protective
If machine washed, use complete covers and shields used by the Army.
wash and rinse cycles.
a. Installation and Removal Precautions.
(f) Spread covers on a clean surface out Installation and removal precautions for the protective
of direct sunlight to dry. covers are as follows.
(2) Repair. Repair polyester fabric covers • Protective covers shall be Installed to protect
using the following procedures. airframe ccmponents which are affected by
extreme weather conditions.
(a) Inspect for cuts, tears, punctures,
bums and broken stitches. Any damage less than 2-1/2
inches long x 1 inch wide in the seat bottom may be • Covers shall be Installed when aircraft is to
repaired. Replace seat bottoms with damage greater than remain in an exposed area for any extended
2-1/2 inches long x 1 inch wide. length of time, or when snow or ice is
anticipated.
NOTE
Seat backs do not have a damage size
• To keep out dust, rain, and foreign matter,
limit for repair protective shields, such as intake duct and
exhaust covers, shall be Installed to cover
(b) All seats will be repaired using openings and passages in the aircraft structure
polyester thread, Specification Federal V.T. 285 and and engine nacelle which leads to internal
cloth polyester (P/N SS9512) as required. components of aircraft.
(c) Repairs will be accomplished using
the details in figure 9-37. • Do not drag covers over sharp objects; prevent
contact with ground when Installing and
(d) Damage that Is close to the edge of removing.
the seat cover which has insufficient space to allow a
complete patch pattern will not be repaired. • Spread wet covers out to dry before folding and
storing.
(3) Installation and removal. For instructions
on installation and removal, refer to the applicable
maintenance manual for the particular aircraft. • When installing and removing covers, do not
allow attaching buckles to scratch or mar
9-21. Aircraft Litters. Litters installed in Army aircraft plexiglass sections of aircraft.
shall be installed and removed as described in the
following paragraphs.
9-45
TM 1-1500-204-23-1
9-46
TM 1-1500-204-23-1
b. Maintenance of Protective Covers. Cleaning, damage immediately after use and make repairs using
repair, waterproofing, and storage of protective covers are the following paragraphs.
explained in the following paragraphs. (a) Puncture, snagged, or torn areas.
Repair punctured, snagged or torn areas as follows:
(1) Cleaning. Protective covers contaminated
with salts from the atmosphere, specifically chlorides (in 1 Repair punctured, snagged, or
marine areas) and sulphur compounds (in industrial torn areas by sewing in place a patch of material equal to
areas), can promote corrosion of aircraft skins. Grease, basic material in weight, quality, and color.
oil, or dirt can mar or discolor plexiglas portions of the
aircraft Therefore, only clean covers will be used. Clean 2 Reinforce and darn punctures
protective covers using the following procedures. and small holes (1/2 Inch or less).
9-47
TM 1-1500-204-23-1
(c) Attaching equipment damage. Repair (b) Store covers in a dry place on a
attaching equipment damage as follows. platform or on slats of wood. Never store covers on
ground or concrete.
1 Repair, when practicable, or
replace all damaged attaching equipment such as straps, 9-23. Armor Plating. The repair instructions that follow
buckles, webbing, keepers, cords, cables, cable fittings, are limited to composite armor composed of a ceramic
grommets, etc. facing bonded to a fiberglass reinforced plastic backing.
The ceramic facing is covered with a flexible spall shield
2 Dip ends of all new webbing in to protect the crew members from ballistic fragments. A
a mixture of 50 percent paraffin, Federal Specification rubber molding is also provided on the edges of some
VV-W-95, and 50 percent beeswax, Federal Specification panels for crew protection. These repair procedures were
C-B-191 developed with the objective of matching, to a high
degree, the original strength and ballistic properties of the
3 Dip ends of sash cords In undamaged armor panel, with a minimum increase in
shellac, Federal Specification TT-S-271. weight. Extending the service life of armor panels will
facilitate the mission capabilities of organizational units by
(3) Waterproofing. Restore water, mildew, and the effective use of material assets. The ceramic facing
weather resistant qualities of a protective cover by coating may consist of one of the following materials.
with water repellent textile finish compound as follows
• Aluminum Oxide (AI203)
WARNING
Solvents contained in the
compounds are highly flammable • Boron Carbide (B4C)
and toxic; therefore all work shall be
accomplished In an open area away
• Silicon Carbide (SiC)
from any flame
a Armor Plating Inspection and Repair Definitions.
(a) Stir compound thoroughly until
Table 9-6 gives definitions relative to inspection and
uniform mixture is obtained.
repair criteria.
(b) Spread cover out completely on a
b. General Inspection of Armor Plating.
clean flat surface, with Inside of cover down.
Radiographic inspection of the assembled armor panel is
the primary method used for nondestructive testing in
WARNING
determining the extent and location of internal damage.
Solvents contained In compound may The radiographic skills and equipment required for this
tend to irritate skin, therefore, type of testing, while available at Depot installations, are
prolonged contact shall be avoided. not available to Army field units. Therefore, for field
units, a visual inspection of the panels must be made,
(c) Apply moderate application of which requires removal of the nylon spall shield. Remove
compound to outside of cover with a brush or spray. the edge molding and peel off the nylon spall shield.
Exercise care when removing the spall shield to avoid
(d) Apply compound well into seams, as damage to the cloth. Use the following inspection
they are particularly susceptible to mildew and leakage procedures.
(e) Dry cover thoroughly until odor of CAUTION
compound has completely disappeared Handle armor panels with care.
Ceramic tile is brittle and cracks
(4) Storage. Store protective covers as
easily.
follows:
9-48
TM 1-1500-204-23-1
Terms Definitions
9-49
TM 1-1500-204-23-1
(2) Refer to the repair procedures in para- reaction between the Diethylene Triamine (DTA) curing
graph 9-23 d for inspection of damage and for damage agent and EPON resin. Although catalysts are used to
limitations other than those specif ed. If the panel control the curing rate of resins, they reduce the pot life
is damaged beyond the limits specif ed, it cannot be of a mixture formulation, such as DTA and EPON. Do
repaired. not use any curing agent accelerators. Since water is an
accelerator, avoid any contact of the mixture formulation
with water.
9-50 Change 5
TM 1-1500-204-23-1
(a) Open curing agent Pro-Seal 890A and mor panels where a crack (or cracks) wider than
thoroughly mix it in the container until it becomes a 1/16 if an inch is found. Total allowable defects
smooth paste. are three or less cracks, chips, or spalls in any
2-inch square area.
(b) Thoroughly mix 10 parts of Pro-Seal
890A to 100 parts of Pro-Seal 890 by weight, or 8.4 (b) Repair cracked tile by bonding a 1/8
parts of Pro-Seal 890A to 100 parts of Pro-Seal 890 by inch thick sheet of f berglass, type GEE, MIL-P-18177,
volume. over the crack (or Cracks) overlapping the damaged
area by three (3) inches on each side, using Polysul-
(c) Carefully fold the material upon itself f de Sealant Pro-Seal 890 (FSCM 83527).
and blend for a period of at least f ve minutes. This will
give a satisfactory mix. (c) Bevel all edges of the f berglass patch
¼ inch deep and 30 degrees from the top surface so the
NOTE nylon spa shield will f t smoothly over the patch.
Avoid violent agitation in order to beat as little air NOTE
into mixture as possible. Also, frictional heat de-
veloped from violent agitation may reduce work For ceramic having raised edges at the joints,
life of the material. one side of the patch may be cut short of the
3 inch overlap requirement. If the crack ex-
(5) Curing requirements for Pro-Seal 890 tends through a raised edge on the tile, shape
sealant (2 cure option). Requirements are as fol- the patch, by undercutting, to f t over the raised
lows: edge. Use good judgment in determining this,
bearing in mind that the patch is to restore struc-
Mixed, uncured Pro-Seal 890 sealant material tural integrity of the panel. When patching along
(Class A-2 or B-2) requires 72 hours at room a panel edge, cut patch to f t the edge boundary
temperature for a full cure. along periphery of the tile.
Change 5 9-51
TM 1-1500-204-23-1
(b) Repair spalled areas or chips in the ce- (f) Remove existing sealant residue from
ramic tile, except at the tile joints that do not exceed 1 the tile surface by using Aliphatic Naphtha, TT-N-95.
square inch, and whose depth (at any point) does not
exceed 1/10 of the thickness of the ceramic material. (g) Lightly abrade the f berglass patch, the
ceramic surface surrounding the spalled or chipped area
NOTE where the patch (or patches) are to be bonded, and the
inside surface of the chipped or spalled area.
Do not repair armor panels where spalled areas
or chips have a total area greater than 1 square
9-52 Change 5
TM 1-1500-204-23-1
Change 5 9-53
TM 1-1500-204-23-1
(a) Inspect panels for internal (e) Attach metal clamps or brace the
deliminations You can find the location and size of any panel in a fixture to apply the required high contact
internal delamination by lightly tapping the fiberglass pressure to seal the filled area. Use care to distribute
reinforced plastic backing using a coin or small hammer. the contact pressure to prevent damage to the ceramic
tile.
NOTE
(f) Cure the panel at room temperature
• The tapping sound will be a clear for five days.
metallic ring over well-bonded
areas, and a dull thudding sound NOTE
over delaminated areas. Trace
the outline of and delaminated • Maintenance activities desiring to
area with chalk for reference repair internal delaminations
during repair. must have the required tools and
fixtures to assure a tight
• Internal delamination up to 4 relamination.
inches in diameter are acceptable
without repair. Although a • If the delamination cavity is filled
ballistic degradation does occur with resin without rebonding the
from a delamination of fiberglass fiberglass plies, the repair will
plies, excessive resin in the have reduced ballistic protection.
delamination cavity has a greater
degrading effect. Excessive (5) Repair and inspection of minor
resin promotes ballistic shearing scars and fraying of backing. Repair and inspection
as opposed to bulging of the procedures are as follows:
fiberglass backing. Do not repair
armor panels with any internal (a) Inspect panel for scars or
delamination in excess of 4 surface abrasion, and for fraying along edges of the
inches in diameter or with more backing.
than one area of internal
delamination. NOTE
After a time, fraying will occur on
(b) Repair internal delaminations by some permanent, exposed edges of
using a resign and curing agent mixed as specified in the panel having no protective edge
paragraph 9-23d(3)(c). molding. You may repair frayed
edges, but only to edges normally
(c) Drill a small hole at each end of the having no protective molding.
void (marked during inspection).
9-54
TM 1-1500-204-23-1
Change 5 9-55
TM 1-1500-204-23-1
9-56 Change 5
TM 1-1500-204-23-1
(g) Apply a sufcient amount of contact ad- a. Type of Vibration Isolators. Vibration isolators
are commonly classied in three types: open-type,
hesive 1300L to cover the inside surface of the rubber closed-type, and combined vibration isolator mounting
and the mating surface. base type.
(h) Allow adhesive to dry until tacky. (1) Open-type. Open-type vibration isolators
are those on which the shock absorbing material is ex-
(i) Carefully t and press the molding over the posed, and are usually so constructed that the load is
edge of the panel. supported on rubber in shear (A and B, gure 9-40) or
compression (C, gure 9-40).
(j) Clean dirt and dust accumulation from the
repaired panel using general purpose detergent. Do not (2) Closed-type. Closed-type vibration isola-
use methyl ethyl ketone for cleaning the berglass back- tors are those on which the shock absorbing material
ing. is enclosed by a metal cup or housing. The shock ab-
sorbing material is usually a coil spring, rubber, or metal
mesh in compression, or a combination of these mate-
rials as shown in gure 9-41.
Prolonged contact of the berglass to methyl
ethyl ketone or acetone will result in deteriora- (3) Combined vibration isolator mounting
tion of the resin. base type. Combined vibration isolator mounting
base type vibration isolators are formed by combining
(k) Rinse the washed area with clear water resilient material such as sponge rubber, metal mesh
and dry panel with a soft cloth. Then permit panel to dry pads, or coil springs with a mounting base and support-
out thoroughly. ing structure as shown in gure 9-42.
(o) Appy two coats of acrylic lacquer to match A vertical and horizontal clearance of 1/16 inch
the original nish color as applicable. shall be maintained. Maintain adequate dis-
tance between mounted equipment and nearest
object (bracket, pipe, line, structure, etc.).
9-24. Cargo Tiedown Equipment. Cargo tiedown
equipment devices may be assembled from webbing,
nets, rope, cables, or ttings. Use snaps, hooks,
Change 5 9-57
TM 1-1500-204-23-1
(2) Move equipment to extreme positions in ev- lator mounting cup, mounting base, or aircraft structure)
ery direction to ensure that retaining fasteners are se- with vibration isolators with any vertical or horizontal
cure and the isolators have not sagged. clearances of less than 1/16 inch.
9-58
TM 1-1500-204-23-1
9-59
TM 1-1500-204-23-1
9-60
TM 1-1500-204-23-1
(2) Testing. Cords requiring testing shall be (g) Reject cords which elongate more
tested when facilities are available. When facilities are than 100 percent during test
not available, return cords to depot for testing.
Elongation testing should be accomplished in the (h) Reject cords which have gauge
following manner: marks more than 6 1/4 inches apart 10 minutes after
pressure is released.
(a) Test bungee or endless ring type
cord as a complete unit using suitable jigs or spools and (i) After testing, fill in and attach a n
test load specified in table 9-7. Acceptable or Serviceable Tag (DD Form 1574) to cord
with a note:
(b) Jigs or spools for stretching shock
absorber cords should be smooth and not less than 1 To be reinspected and retested 6
1/2 inches in diameter to prevent damaging cords during months from date hereon.
testing.
b. Fabrication Requirements. Elastic shock cord
(c) Prepare straight and elastic used for fabrication of assemblies shall not be over 20
exerciser cords for testing by marking 6-inch gauge quarters (5 years)old from date of manufacture. Date of
lengths on one side of cord. Use soft lead pencil for manufacture of elastic shock cord shall be determined
marking. from table 9-8 Date of manufacture is indicated by
colored threads in the cotton braid. The first two colored
(d) Mark bungee cords with 6-inch threads indicate the year of manufacture and the third
gauge marks penciled on opposite sides of ring. colored thread indicates the quarter Replace cord using
the following procedures'
(e) Attach cord to be tested to suitable
jigs or spools. Apply specified test pressure slowly (1) Cut the elastic shock cord square with a
knife or other sharp cutting tool.
(f) After test load has been applied,
remove cord from rig and measure between gauge
marks.
9-61
TM 1-1500-204-23-1
9-62
TM 1-1500-204-23-1
Table 9-9. Minimum Serving Length (4) Measure back from each end of marked
finished assembly length a distance equal to lockring
Elastic cord diameter Serving length dimension specified in table 9-10, and mark this
(Inches) dimension.
(Inches)
Table 9-10. Lockring Locating Dimensions
1/4 1 1/2
3/8 2
1/2 2 1/2 Cord size 3/8 Inch 1/2 Inch 5/8 Inch
5/8 3
¾ 4 Lockrlng
1 4 Locating dim 1.5 Inch 2.0 inch 2.25 inches
9-63
TM 1-1500-204-23-1
e. Serving Elastic Shock Cord. Serve elastic (7) Continue serving elastic shock cord as
shock cord using the following procedures: specified above until required length of serving has
been applied.
(1) Secure adjacent sections of elastic shock
cord in stretch fixture and mark minimum length of cord NOTE
to be served. Minimum serving lengths are specified In While serving, keep tail end of loop
table 9-9. outside of half hitches for a distance
of half the length of the required
(2) Stretch elastic shock cords until marked serving. Keep it under serving for
serving length has Increased 100 percent. Maintain this reminder of required distance as
length during entire serving operation. shown in figure 9-45.
(3) Use a piece of serving cord of sufficient (8) When the required length of elastic shock
length to form a loop extending a minimum of 1 inch cord has been served, put end of serving cord through
past mark used to designate one end of elongated loop and pull tail end until both ends have been pulled
serving area. through. Cut ends of serving cord as close as practical
to serving wraps.
(4) Form a tail extending a minimum of 6-
inches past mark used to designate other end of f. Process Control. The following procedures are
elongated area, as shown in figure 9-44. used for elastic shock cord process control:
(5) Place loop on top of elastic shock cords (1) Accomplish periodic checks of storage
over area to be served. area to assure requirements of paragraph 9-26b are
complied with
NOTE
Types of serving cord are specified (2) Maintain control of elastic shock cord as
in paragraph 9-26b, step (8). specified in TM 1-1500-204-23-6.
(6) Hold loop firmly on top of adjacent (3) Crimp lockrings securely in place with
sections of elastic shock cord and wrap serving cord ends of ring in contact with each other.
around elastic shock cord. Make wraps over loop using
a half hitch knot in serving cord at completion of each
wrap. Pull serving cord tight.
NOTE:
LOOPS AROUND ELASTIC CORD ARE SHOWN
SEPARATED FOR CLARITY OF SERVING
OPERATION.
Figure 9-44. Preparation for Serving Shock Cord Figure 9-45. Serving Elastic Shock Cord
9-64
TM 1-1500-204-23-1
9-65/(9-66 blank)
TM 1-1500-204-23-1
CHAPTER 10
10-1
TM 1-1500-204-23-1
(5) Preheat for accessories. At temperature (2) Inspect entire aircraft for snow, frost, or ice.
below -22°F (- 30oC), apply heat to batteries, feathering Any deposit can cause loss of lift and treacherous
pumps, master brake cylinder, and actuating cylinders. stalling characteristics. Brush off loose snow or frost.
Aircraft with constant speed drives for alternators should Remove remaining ice by spraying or brushing on a coat
have drives heated. of anti-icing and deicing-defrosting fluid, MIL-A-8243.
Work from upper surfaces downward to prevent
(6) Heater placement. Prevent possible heat accumulation of ice on previously cleared surfaces.
loss during preheat period by placing heaters as close
as possible to aircraft, but avoid areas under fuel and oil (3) When rapid frosting occurs after initial
drains, vents, or supplies Inspect heater ducts for leaks. removal, apply a coat of defrosting fluid to retard
Cover heater and ducts with noncombustible canvas accumulation of frost before taxiing. Also apply a coat
covers Provide adequate fire bottles In flight area. of defrosting fluid after the last flight of the day to help
retard further accumulation of ice, snow, or frost.
CAUTION
Do not apply heat directly against (4) Inspect control surfaces for freedom of
plastic or plexi-glass windshields or operation. Sudden temperature drops will cause ice to
windows. Directly applied heat will form on the inside of the surfaces as well as on the
cause crazing, cracking, and outside. When evident that ice has formed on the inside
discoloration. Remove existing restricting control surface movement, remove by
snow deposits before heating crew application of heat.
compartment. When cabin heat is
applied on the ground with (5) Inspect windows and windshields for
cracks. To prevent cracking, open all windows before
temperatures below freezing, the
removing aircraft from heated hanger.
snow will melt and cause
accumulation of Ice on top of
(6) Inspect fuel and oil tank caps and vents
fuselage and windshields and crank-case breathers for presence of ice, snow, or
frozen condensate. Plugged lines or vents can cause
(7) Preheat off light compartment. Apply heat collapsing fuel tanks and swelling of oil tanks.
to flight compartment and cabin to ensure operation of
instruments and equipment, reduce windshield frosting, (7) Inspect wing and fuselage drains and
soften canopy seals, and Increase crew comfort. Heater vents for ice and snow. Thaw clogged drains or vents.
ducts may also be positioned so as to direct heated air
toward any valves found to be sticking. Preheat (8) Inspect fuel and oil tank sumps for ice.
vacuum pumps in aircraft employing vacuum-driven Where water condensate has frozen, heat to permit
Instruments to ensure low viscosity of oil In and around drainage.
pumps and to prevent pump drive shaft from shearing.
(9) Inspect hydraulic reservoirs for
c. Pre flight. The following procedures and evidence of freezing. If evident, apply heat to thaw.
inspections shall be accomplished during preflight for
aircraft operating in arctic conditions. (10) Inspect cylinder struts and hydraulic
pistons for accumulation of dirt and ice. Ice and grit
(1) During severe weather, delay removal of which will damage cylinder strut packings shall be
engine covers, propeller covers, flight compartment removed. Pistons shall be wiped with a clean cloth
covers, and miscellaneous covers until just prior to saturated in hydraulic fluid, MIL-H-5606.
engine start. Leave wing and empennage covers in
place until just prior to taxiing. (11) Using an auxiliary power source, check
radios and electrically operated controls and equipment
CAUTION for proper operation.
Exercise care to prevent flow of
melted Ice into areas where freezing (12) Inspect exposed limit switches and
would cause restricted movement of microswitches for presence of Ice or snow and for
flight controls and restricted flow of proper operation.
air through vents. Where water flows
toward any of these areas, It shall be
mopped up Immediately.
10-2
TM 1-1500-204-23-1
(13) Inspect hydraulic accumulators, landing contact with a short across bare or
gear struts, and tires for proper inflation. Air pressures defective insulated silver or silver-
will drop due to a temperature drop. coated electrical circuits such as
wiring, switches, and circuit breakers
NOTE which carry positive direct current
Exposure of aircraft to low (dc), such as electronic black boxes.
temperatures will cause contraction
of metals and hardening of rubber NOTE
seals. Frequent inspections for The fluid shall be homogenous and
leakage and looseness of free of sediment and abrasive. A
connections is necessary to prevent slight waxy separation in the fluid
leakage. shall be no cause for rejection if the
separation is dispersable by several
d. Anti-Icing, Deicing, and Defrosting. A protective seconds of moderate agitation Fluid
coating of unheated, undiluted, anti-icing and deicing- shall remain dispersed for at least 24
defrosting fluid will prevent frozen accumulations from hours.
forming on aircraft surfaces if applied before freezing
conditions begin and as often as necessary during the (2) Fluid application. The following
precipitation. Any frost or thin layer of ice that does paragraphs describe methods and equipment used to
form can be removed easily by application of additional apply antiicing, deicing, and defrosting fluids.
fluid. A protective coating of fluid applied before
installation of covers will permit easy removal with a WARNING
minimum sticking of covers. Special care must be taken by
personnel to prevent slipping and
WARNING falling when walking on wing
When handling and applying glycol- surfaces coated with deicing fluid.
water products, wear eye, hand, and Otherwise death or injury may
body protection. Avoid Inhaling result.
vapors and skin contact. Follow
Material Safety Data Sheet
procedures for individual product (a) Spray method. If hangars,
covers, or equipment for heating fluid-water solutions
use Injury may otherwise result.
are unavailable, the preventive spray method will be
used to maintain standby and alert aircraft in a state of
(1) Types of fluid Anti-icing, deicing, and
readiness. The preventive spray method Is application
defrosting fluid characteristics are explained in the
of cold, undiluted fluid on surface to be protected in a
following paragraphs.
quantity to wet the area thoroughly without excessive
(a) Ethylene/propylene glycol. Anti-
drainage
icing and deicing-defrosting fluid, specification MIL-A-
8243B, is basically a mixture of ethylene glycol and (b) Spray pattern. Suitable spray
propylene glycol and Is recommended for preventing equipment should be used, as application of fluid is
formation and removing deposits of frost, ice, and snow done best by spraying surfaces. Spray should not be
on exterior aircraft surfaces on the ground in applied in a solid stream, but be fine enough to prevent
temperatures ranging from -65 to 32 °F (-54 to 0 °C). waste. A fanshaped pattern is recommended
Ethylene glycol and propylene glycol are formulated with (c) Spray equipment. Cleaning or
intrinsic corrosion Inhibitor, as prescribed In MIL-A- other decontaminating equipment may be modified to
8243B. spray deicing fluids. Spray guns on this equipment can
(b) Glycol-water. Glycol-water anti- be used as they are, but better spray coverage can be
icing and deicing-defrosting fluids, including MIL-A-8243 obtained if they are modified slightly. A common
anti-Icing fluid, are not recommended for use around garden hose nozzle will give satisfactory result In
aircraft electronic equipment which employs silver or accumulation removal if the solid stream is used. This
silver coated electrical/electronic circuitry. nozzle also can be used to apply a protective coating of
fluid if a fine conical spray is used.
WARNING
Rapid oxidation and fire can occur
when glyco-water solutions come in
10-3
TM 1-1500-204-23-1
(d) Spray nozzles. The three nozzles (f) Support equipment. Use of
shown in figure 10-1 may be fabricated in any base shop maintenance stands and work platforms is
and used with equipment in the preceding paragraph (c) recommended to position personnel safely near wing
with good results. Each is explained in the following and tail surfaces during application of fluid.
paragraphs.
e. Prevention and Removal of Snow, Ice,
1 Bent tube nozzle. The bent and Frost Deposits. The following paragraphs contain
tube nozzle is made by drilling approximately 60 holes methods for the prevention and removal of snow, ice,
along the longitudinal axis through one side of an and frost deposits.
aluminum, brass, or steel tube. Holes are 0.043-inch
diameter. Tube is capped and bent in a tube bender to (1) Prevention of deposits. The
give about a 90-degree fan spray. following paragraphs explain the prevention of snow,
ice, and frost deposits.
2 Pipe nipple nozzle. The pipe
nipple nozzle consists of a one-inch pipe nipple with (a) Snow deposit
0.0512-inch holes drilled radially around 90 degrees prevention. If snow is expected, wing and tail covers
from outer edge. should be used. Deicing fluid should not be used for
protective coating if snow is predicted, except in
3 Pipe cap nozzle. The pipe cap conjunction with installation of covers. If attempts are
nozzle is hardest to fabricate. It consists of a 3/4 or made to use the fluid to prevent snow accumulation, a
one-inch pipe cap with 0.0312-inch drilled holes in frozen deposit will be encountered which is difficult to
center and 0.0469-inch drilled holes toward edges, all remove. The fluid is diluted by the melting snow to form
radiating from a point In base of cap. a slush which freezes in place. Use of covers after
coating aircraft surfaces with fluid will prevent snow
(e) Aftemate application method. from forming directly on aircraft and permit easy
Cold deicing fluid may be applied with a mop, broom, or removal of covers. If covers are unavailable, the best
soft bristle brush if spray equipment is unavailable. method of preventing heavy snow accumulation is
constant removal by brushing or sweeping during the
snowfall.
10-4
TM 1-1500-204-23-1
(b) Ice deposit prevention. Deicing fluid removal, a layer of rough ice remains. This frozen crust
will protect aircraft surfaces as long as it remains on the can be removed with hot, diluted, deicing fluid. In an
surfaces. However, freezing rain will tend to wash emergency when aircraft must get off ground as quickly
surfaces clean of fluid, as well as dilute the fluid to the as possible, thin layers of snow can be removed with hot,
point at which ice will form. The amount of protection diluted, deicing fluid. If sufficient fluid is used, the
afforded by the fluid depends on the amount of freezing combination of heat from fluid and force of the stream will
rain. The following steps should be taken if ice caused by permit removal of slush, as it Is formed without
freezing rain is expected. refreezing. Quantity of heated fluid required for snow
removal Is prohibitive. Remove snow, water and Ice from
1 On aircraft for which covers are aircraft fuel filler cap wells before removing fuel filler cap.
available, a coating of fluid applied before covers are Only one filler cap should be removed at a time, and it
installed will prevent covers from freezing on aircraft should be replaced immediately after servicing is
surfaces and make removal of covers much easier. completed.
However, care should be taken to ensure that only a
minimum amount of rain is allowed to blow under covers (b) Ice and frost removal. If hangars
Otherwise, dilution of fluid will allow freezing to occur and covers cannot be used to prevent frozen formations
on aircraft, but equipment is available for heating
2 On larger aircraft for which fluidwater solutions, removal of frozen formations by hot,
covers are unavailable, the best method of prevention is diluted, deicing fluid will be used in place of preventive
to keep the surfaces wet with fluid. As long as this fluid spraying. Accumulations should be allowed to form and
remains on the surface, protection is afforded. Since rain then be removed just after each precipitation or just
eventually will dilute the fluid and render it ineffective for before each flight, whichever is most practicable or
preventing ice formation, protection must be maintained compatible with operational mission of the aircraft
during precipitation by continual spraying of fluid. If
weather conditions are such that It is impossible to f. Preventive Maintenance. Accomplish the
prevent ice formation, removal should be accomplished following preventive maintenance procedures
(c) Frost deposit prevention. A (1) Avoid parking aircraft in wet or slushy
satisfactory procedure for protection of aircraft from frost areas.
is the application of a layer of unheated, undiluted, de-
icing fluid to aircraft surfaces after the last flight of the day (2) Use caution when towing aircraft In
or as close to midnight as possible, whichever is later. extremely low temperatures to prevent damage to
This should permit early morning departure without further hydraulic seals which would result In strut leakage.
fluid application. The length of time that an aircraft will be
protected by a single coat of fluid depends on the climatic
conditions. (3) Inspect oil and fuel drains and crankcase
breathers for ice and frost Remove any existing frost or
(2) Removal of deposits. The following ice.
paragraphs explain the removal of snow, ice, and frost
deposits. (4) If layovers are to be over 4 hours and
temperature is below -20 °F (-290°C), remove battery and
CAUTION store in a warm place.
Extreme care shall be taken to
prevent damage to aircraft. Sharp (5) Drain oil system when there is no provision
instruments, such as picks, knives, available for preheating oil and a long layover period is
or screwdrivers, will not be used to anticipated.
loosen ice formation
(6) When temperature rises above freezing
(a) Snow removal. Deicing fluids should not
during a long layover, drain fuel and oil tank sumps of
be used to remove heavy snow accumulation. Snow
water before temperature drops.
absorbs wasteful amounts of fluid to form a slush which is
difficult to remove and eventually will refreeze. The slush
will get into control surface hinges and freeze, causing (7) Install protective covers and shields to
additional difficulty. Snow will be removed by brushing or protect aircraft from accumulation of snow, frost, or ice.
sweeping or by moving the covers. Usually after snow
10-5
TM 1-1500-204-23-1
10-6
TM 1-1500-204-23-1
10-7
TM 1-1500-204-23-1
10-8
TM 1-1500-204-23-1
10-9
TM 1-1500-204-23-1
(10) When possible, accomplish repairs and (1) Treat corrosion-affected area.
servicing during early morning hours, or in late
afternoon, evening, and night, when heat is less intense. (2) Prevent rot, mildew, and mold by
Desert camouflage netting can be used for shade. keeping fabrics, rubber, and other susceptible items as
dry as possible. Clean fabrics in aircraft daily. The
(11) Ground aircraft, funnel, and fuel nozzle effects of moisture and fungus on fabrics are listed in
during refueling operation. Accomplish filling of table 10-1.
gasoline from cans, using a filter funnel that fits snugly
into tank opening Exercise every precaution to exclude (3) Operate all heat-producing electrical
sand from gasoline and oil during servicing operations. equipment daily to remove moisture. When this
procedure is not practical, dry equipment using a ground
(12) Where possible, service oil system heater or by placing in sun.
directly from can to oil tank, without using an
intermediate measuring can. (4) Wash aircraft often, and lubricate
moving parts when aircraft is exposed to salt-laden air
(13) Keep lubricants and gasoline drums or mud.
covered, and where possible, maintain storage
temperature below 120°F (49oC). CAUTION
Before drilling holes, ensure that the
(14) Use polarized sunglasses during aircraft will not be weakened
sunlight hours. structurally and the operating
characteristics will not be adversely
(15) Use eye protection in blowing affected. Damage may otherwise
sand/dust. Extra measures should be used to secure result.
aircraft and shelter.
(5) Keep all drain holes clear of
(16) Ensure voltage regulators are properly obstructions, and drill holes where necessary in wings,
set during all temperature changes. fuselage, enclosed equipment, etc., (when approved by
the maintenance officer), to facilitate draining where a
(17) Tape all opening or seams around noticeable accumulation of water Is observed.
windows, chin bubbles, seldom used access panels, etc,
being sure not to Inhibit or restrict airflow required for (6) Leave canopy windows or doors open
cooling, or increase Infrared (IR) signature. An entry is when aircraft is parked In sun to permit air circulation
required on DA Form 2408-13 in the aircraft log book within flight compartment Protect windshields and
after tape has been Installed. Use tape MIL-T-21595 windows from sun by covering with canvas.
Type I.
(7) Blow out brakes frequently with
10-4. Tropic Maintenance. The following paragraphs compressed air when operating from muddy or dusty
contain basic principles and procedures essential for fields to prevent damage to brake disks.
efficient utilization of aircraft equipment and personnel
in tropic areas. Factors having deteriorating influence (8) To prevent rust, wipe control cables daily
on fabrics in tropic areas can be categorized as high with an oily rag.
humidity, high temperatures, salt-laden air, and
sunshine. These factors create corrosion, rot, mildew, (9) Check battery every third day to
and mold Preventing these deteriorating effects to maintain proper electrolyte level.
ensure safety and proper operation requires constant,
regular Inspections and preventive maintenance (10) Every 25 hours, dip paper air filter
measures This paragraph is not to be considered as a cartridges in leaded gasoline and dry thoroughly.
substitute for detailed maintenance and operating
instruction, but as a supplement to each aircraft (11) Drain all fuel traps and strainers
operation and maintenance manual. immediately prior to flight.
a. I nspection and Preventive Maintenance . (12) While aircraft is on ground, avoid
Proper cleaning, packaging, and storing ensures longer excessive water in fuel systems by keeping fuel tanks
life and serviceability of aircraft and equipment. The completely filled.
following practices should be used as a guide:
10-10
TM 1-1500-204-23-1
Cotton, Linen, Paper, and Cellulose Derivatives: Insulating and dielectric properties are lost or
Insulation, coverings, webbing, belting, laminations, impaired by moisture, causing arcing, flash-overs
dielectrics, 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 loss
of insulating properties Fiber terminal strips and
insulators are destroyed by fungi.
Fiber: Washers, supports, etc. Moisture causes swelling which, in turn, causes
supports to misalign, resulting in binding of
supported parts Washers are destroyed by fungi.
Glass Lenses, windows, etc. Fungi grow on organic dust, insect tracks, insect
feces, dead insects, etc. Dead mites and fungus
growth on glass obscures visibility and corrodes
nearby 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 loss
forms, and connectors of insulating properties Delamination occurs
and fungi grow on surfaces and around edges
Extreme temperature changes cause expansion
and contraction.
Leathers Straps, cases, gaskets, etc. Fungus destroys tanning and protective
materials, causing rotting due to moisture
bacteria fungi.
10-11
TM 1-1500-204-23-1
Table 10-1. Parts and Fabrics Affected by Moisture and Fungi - CONT
Molded Plastics: Terminal strips and boards, switchboard Machined, sawed, or ground edges or surfaces
panels, 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 an
extent that the item Is useless.
Wood: Cases, houses and housings, plastics fillers, Moisture and fungi cause dry rot, swelling, and
masts, etc. delamination.
(13) Run up reciprocating engines at least (16) Inspect canvas or duct covers for
once every third day. wear, torn seams, stains, fungi, etc.
(14) Operate gas turbine engines at least b. Parts and Fabrics Affected by Moisture and
once every seven days for approximately 10 minutes at Fungi. Parts and fabrics affected by moisture and fungi
flight idle. are shown In table 10-1.
10-12
TM 1-1500-204-23-1
CHAPTER 11
AVIATION LIFE SUPPORT EQUIPMENT MAINTENANCE
11-1. General. Organizing Aviation Life Support 11-4. Personnel. Maintenance of ALSE will be per-
Equipment (ALSE) servicing facilities is based on many formed only by school-trained, qualified personnel,
factors, such as the number of aircrew members either military or civilian personnel trained in accordance
assigned, and the type and quantity of equipment. With with paragraph 11-19 may inspect first aid kit. General
this in mind, the ALSE maintenance shop should be tai- purpose, panel mounted, NSN 6545-00-919-6650, for
lored to the needs of the aviation unit, activity or facility. aircraft. Also maintenance personnel must be graduates
The minimum standards for the ALSE facility and equip of the U.S. Army 600-ASIQ2, U.S. Air Force
ment contained in this Technical Manual (TM) are not C3AABR92230-000, U.S. Navy LSE C-602-2010, or
mandatory requirements, but are standards which can other courses of instruction approved by U.S. Army Avi-
be used for planning purposes. Local Commanders are ation Logistics School (USAALS), Ft. Eustis, VA.
authorized to deviate from these standards whenever USAALS has responsibility for training ALSE mainte-
circumstances cannot be reasonably obtained. It will be nance personnel. Refresher courses do not qualify per-
the responsibility of the local Commander to be certain sonnel to service ALSE.
that any deviation permitted will not foster unsafe or
unsanitary practices, recognizing that ALSE has specific 11-5. Publications. ALSE consists of equipment
areas of supporting the user in hostile conditions i.e., unique to aviation needs while flying or in a survival con-
high altitude, in water, land survival, etc. This equipment dition. This equipment covers several Federal Supply
must perform to standards the first time upon being acti- classifications i.e., Clothing 8415, Flotation Equipment
vated for use. These standards will not be compromised. 4220, Aircraft Air-Conditioning, Heating and Pressuriz-
ing 1660, etc. Each stock classification is initially
assigned to a command to manage i.e., stock classifica-
11-2. Administration. Administration of the unit Life tion 1660 is assigned to the Air Force Logistics Com-
Support Program must have the Commander’s approval. mand while 4220 is assigned to Naval Sea Systems
The unit Training Officer must provide scheduling time Command. Army Technical Manuals are assigned num-
and training for ALSE. Included should be Code of Con- bers by basic series and stock classification i.e., (TM
duct/Survival, Evasion, Resistance, and Escape (SERE) 55-1600, 55 signifies transportation while 1660 signifies
Training in accordance with AR 350-30. The unit Aviation aircraft air-conditioning and pressurizing equipment).
ALSE Officer must not only supervise the ALSE techni- Because the management responsibility is fragmented
cian’s work, but also the training of the unit aircrew per- between many managers, which includes engineering
sonnel in the care and use of ALSE, and survival training. and maintenance, all ALSE items cannot be combined
The ALSE technician will inspect, repair/replace, and into a single TM. The following paragraphs will described
service the equipment in accordance with the applicable the ALSE items and then reference the repair manuals
Technical Manuals (TMs), Technical Orders (TOs), and for that item.
Naval Air Manuals (NAVAIRs), and maintain the required
forms and records as well as supervise the ALSE training 11-6. Administration Area. The ALSE administration
performed by aircrew personnel. area should have a desk and chair, bookcase file cabinet,
and enough chairs for the efficient use of the area. A
library containing the necessary Army Regulations (ARs)
11-3. Safety. The ALSE maintenance area will comply and the applicable TMs, TOs, and NAVAIRs for the ALSE
with all Army safety regulations and unit Standing Opera- being used by the unit/units being serviced. Included
tion Procedures (SOP). The area will have all regulatory should be a microfiche viewer with current maintenance
signs i.e., NO SMOKING, EXIT, OXYGEN, etc., conspic- and publications fiche. A supply of ALSE maintenance
uously posted. Horseplay will not be tolerated or per- forms will be maintained and used in accordance with DA
mitted in the area at any time. Personal safety equipment PAM 738-751. Visual boards relating to ALSE mainte-
will be used while working/servicing ALSE i.e., goggles, nance scheduling shall be located near the desk of the
face shield, apron, gloves, etc. Fire extinguishers will be individual assigned to that particular equipment for quick
located as needed by type and weight. It is recom- reference, (Refer to FM 1-508). Loitering of personnel in
mended an extinguisher be located in each of the work, the ALSE area will not be permitted. Loitering fosters
storage, and administrative areas. horseplay and other unsafe actions by personnel.
Change 2 11-1
TM 1-1500-204-23-1
11-7. Maintenance Area. The ALSE maintenance 11-10. Fitting Area Criteria. The fitting area will be
area consists of work, storage, and fitting areas. Access well-lighted and have enough space so personnel may
to a classroom adjacent to or in close proximity of the life be fitted with clothing and equipment being assigned to
support area is desired for lectures and instructions on them, i.e. survival vest, flight clothing, flight helmet, para-
the equipment being used and survival conditions. The chute harness, etc.
shop should contain not less than 1,000 square feet of
usable area that is environmentally controlled within a 11-11. Tools and Special Repair Equipment. All
range of +60°F (15.6°C) to 75°F (23.8°C) and have a ALSE items will be serviced and repaired in accordance
potable water source i.e., hot and cold water. The area with applicable TM/TO. The required and authorized
will be protected from pilferage, dampness, fire, dust, tools and special repair equipment are found in the
insects, rodents, direct sunlight, and be free from uncon- Repair Parts and Special Tools List (RPSTL) of the appli-
trolled foot and vehicle traffic. To ensure that all ALSE is cable TWO.
maintained in a high state of readiness through inspect-
ing, cleaning, fitting, testing, adjusting, and repairing, all
maintenance will be in accordance with the applicable 11-12. Training Equipment. Most equipment used for
TM, TO, or NAVAIR. For additional information refer to training can be returned to service, providing the equip-
FM 1-508. Table 11-1 lists recommended test equipment ment is serviceable and can pass all inspection criteria
for the ALSE work area. for that item, before it is returned to service. The excep-
tions are as follows:
11-8. Work Area Criteria. The work area will have
bench surfaces free from rough or abrasive materials, All flotation equipment - these are to be marked
splinter-free tops with a nonporous surface. The area is FOR TRAINING ONLY in accordance with TM
to be well-lighted with accessible electrical outlets to all 5-4220-202-14.
bench and desk areas. Cabinets and work benches/ Sleeping bags - either those packed inside a 12”
tables with locks should be used for securing test equip- by 12” by 1” hard fiberglass container or the new
ment, tools, and supplies. Units that have oxygen equip- vacuum packed soft plastic package.
ment will have an area set aside for oxygen maintenance
that will have hot and cold running water, stainless steel DELETED
sinks, and floors that are sealed and protected from
spills. The area will be restricted to ALSE personnel only.
Units supporting flotation equipment will have a moisture
and oil-free source of low-pressure, high-volume air and
a vacuum source. A vacuum cleaner may be used; how-
ever, the vacuum cleaner must not be used for cleaning
at any time, because dirt and dust must not be induced 11-13. Temporary Storage of Life Support Equip
into the flotation cells. The floor of the work shop will be ment. Equipment being stored is subject to dry rot,
sealed and coated to prevent chemical spills from pene- rodent damage, mildew and other contamination. It is
trating the floor surface. The work area will have hot and important for the area to be environmentally controlled as
cold running water for cleaning equipment as well as a well as secured from pilferage.
wash area. Cleanliness is very important in maintaining
the equipment. Smoking, eating or drinking should not be a. Survival Kits. Survival kits to be in temporary
permitted in the area. storage will:
11-9. Storage Area Criteria. The storage area will be l Be inspected, repaired, and if needed, cleaned.
well-ventilated, out of direct sunlight, and well-lighted. l Have components replaced if necessary.
The storage area will have storage shelves and cabinets
that provide security for the stored equipment and be free l Have matches and pyrotechnics removed and
from dust, moisture, fire, insects, and rodents. The floor stored in accordance with post policy for units
is to be sealed and covered with a dust-free flooring operating within a military base, or local policy for
material. A refrigerator will be used to store batteries those units not operating on a military base.
used in life support equipment; because of health and
food service regulations, food will not be stored in refrig- l Have kits appropriately tagged with annotations
erators. about items not in the kit being stored.
11-2 Change 3
TM 1-1500-204-23-1
Nomenclature NSN
NOTE
Storage cabinets or workbenches/tables with storage shelves/drawers that can be secured with
locks should be used for securing test equipment, tools, equipment, and supplies The storage
cabinets, workbenches/tables will be marked to identify the tools, equipment, supplies and test
equipment contained within them
• Be stored on shelved well-ventilated and out of • Have radios removed from vest. Battery will be
direct sunlight. removed from the radio and put into
refrigerated storage.
b Survival Vests . Survival vests to be put In temporary
storage will: • Have the light marker distress removed from
the vest and the battery from the light marker
• Be inspected, repaired, and if needed, removed and put Into refrigerated storage.
cleaned.
• Have vest appropriately tagged and Items not
• Have components replaced if necessary In vest annotated on the tag. The vest will be
hung on a hanger for storage, out of direct
• Have signal kits, personnel distress removed sunlight.
and stored in accordance with post policy if unit
is operating from a military base, or local policy
if unit is operating off a military base.
11-3
TM 1-1500-204-23-1
c. Flotation Equipment. Flotation equipment to be vest kits; the SRU-21 IP is used by all aircrew personnel
put into storage will be stored in accordance with TM 5- except OV-1 aircrews who wear the vest designed for the
4220-202-1 4/T.O.14S-1-102. OV-1 aircraft. Both types of vests come in two sizes; the
median chest size is 37 inches, and that determines which
d Pyrotechnics. Pyrotechnics will be stored in size is to be used by the wearer The survival kits contain
accordance with post policy, if unit is operating on a items to support the aircrew personnel in a particular
military post, or in accordance with local policy if unit environment, i e. , land, either Hot or Cold Climate, or
operates off a military base. Overwater The Overwater kit contains a one man liferaft
This is the only kit that contains flotation equipment. The
e. Oxygen Equipment . Oxygen equipment to be survival vests ensure the individual will have a limited
put into storage in accordance with TM 55-1660- amount of survival equipment. The vests are a
24513/TO 15X-1-1. supplement to the survival kits. Individual underarm
flotation equipment is available to those aircrew personnel
f. New Equipment . All newly assigned ALSE who fly overwater and is worn with the vest. AR 95-1 and
equipment prior to storage will be inspected upon receipt AR 95-3 regulate the use of survival equipment for Army
from supply/individual turn-in, and prior to issue/reissue, aircraft and aircrews. Table 11-3 gives references for
and then in accordance with TM 55-1680-317-23&P or the survival kits.
applicable TM/TO for that piece of equipment.
a. Inspection. Inspection of the survival kits will be
11-14. Flight Clothing. Flight clothing consists of flight in accordance with TM 55-1680-317-23&P, Army Aircraft
coveralls, nomex flight jackets, nomex or leather flight Survival Kit Maintenance Manual.
gloves, anti-exposure suits, flight helmet, and aircrew
body armor. Nylon flight jackets are no longer authorized b. Repair. Repair/replacement will be in
for flight duty use. accordance with TM 55-1680-317-23&P, and FM 10-16,
General Fabric Repair Most survival items will be required
a. Inspection. Inspection of flight clothing, anti- to be replaced rather than repaired This is due to the
exposure suits, flight helmet, and aircrew body armor will nature of packaging for the particular item or the shelf life.
be in accordance with the applicable TM, TO, or NAVAIR. The RSSK lid and lower container may be repaired in
accordance with TM 55-1500-204-25/1, using Parts Kit
b. Repair. Repair will be In accordance with TM Repair, Fiberglass NSN 1560-00-8569222. This Is for the
10-8400-201-23, General Repair Procedure for Clothing fiberglass repair of the container.
and Inspection Equipment The applicable TM/TO, for the
item to be repaired, will be the damage repair criteria c. Cleaning. Clean survival kits using the following
guidance. procedures.
c. Cleaning. Cleaning will be done in accordance (1) Clean the canvas inner or outer cases
with the applicable TM/TO Clothing will not be returned to using procedures. In TM 10-8400-201-23 for lightweight
unit supply, Repairable Exchange (RX) point, or salvage load carrying equipment.
points needing to be cleaned. Cleaning of all flight
clothing is the responsibility of the aircrew member The (2) Clean the RSSK lid and lower case using
ALSE technician will instruct the users in the proper use soap and warm water; rinse with clean, warm water, and
and care of flight clothing. Table 11-2 gives references dry with a clean cloth. On the lid, finish the drying
for flight clothing. process by using compressed air to ensure no moisture
remains In the release mechanism.
11-15. Survival Kits. Survival kits currently are issued
only to individual aircrew personnel and only for the (3) Empty the contents of all pockets of the
climatic zone they will be operating in. The current survival vest and remove any flotation equipment. Wash
survival kits are' Individual Hot Climate, Individual Cold the empty vest using soap and warm water. Rinse with
Climate, Individual Overwater, and the Rigid Seat clean, warm water. Put vest on a hanger and air dry out
Survival Kit (RSSK). The RSSK kit will contain only one of direct sunlight. The vest may be machine washed
of the following climatic conditions: Hot Climate, Cold using a delicate wash cycle.
Climate or Overwater Included are two types of survival
11-4
TM 1-1500-204-23-1
Publication Description
11-16. Flotation Equipment. Flotation equipment type of aircraft being flown and the number of aircrew and
consists of underarm flotation bladders (life preservers), passengers on board (refer to table 11-4, Liferafts for
one man liferafts, seven man liferafts and 20 man multi- Aircraft.) Any and all flotation equipment used for training
place liferafts. All flotation equipment contains an air will not be used as serviceable equipment for survival kits
bladder or air chambers, an inflation device, inflating gas or issued for individual use in lieu of serviceable flotation
(usually CO 2) in cylinders of varying sizes and capacities equipment. There will be no waivers for this policy. Flota-
to fit the particular piece of flotation equipment, and a 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 TM
pressure. 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
Publication Description
TM 9-1370-203-20P& P Organizational Maintenance Manual for Military Pyrotechnics
TM 55-1680-316-10 Operator’s Manual for Rigid Seat Survival Kit and Survival
Vest for OV-1 Aircrews
TM 55-1680-322-12 Operation and Service for Distress Marker Light, P/N SDU-5/E
DOD Medical Catalog VOL I, VOL II, VOL III MCRL I, II, Ill
11-6 Change 2
TM 1-1500-204-23-1
Publication Description
a. Precautions. Comply with the following precau- (4) Do not step on any part of liferaft while wear-
tions when handling or accomplishing maintenance on ing shoes when accomplishing inspections or repairs.
liferafts:
b. Stowage in Aircraft. Liferafts shall be stowed in
aircraft as follows:
(1) Prevent hydrocarbons, such as gasoline,
oil, or grease from contacting liferaft materials.
(2) Do not drop or throw liferafts, as damage to Do not sit or place equipment or tools on life-
liferaft or accessories may occur. rafts stowed in aircraft. Keep the liferaft free
of oil, grease, and other rubber deteriorating
(3) Do not step or sit on packed liferafts, or agents. Damage to liferaft may otherwise
place weights or items on liferafts which are not required. result.
Change 2 11-7
TM 1-1500-204-23-1
Maximum Authorized
Aircraft number Authorized optional Authorized- Optional
on board liferaft liferaft liferaft liferaft
Type Model Crew Pax Total one-man 7-man 10-12 man 20-man
OV-1 B,C,D 1 1 2 2
RV-1 C,D 1 1 2 2
U-8 F 1 5 6 6 1 1
UV-18 A 2 18 20 20 3 2
U-21 A,D,F,H,J 2 8 1 1
RU-21 A,B,C,D 2 8 1 1
AH-1 G,S 2 2
TH-1 G 2 2
AH-64 A 2 2
RC-12 D,G 2 3
C-12 A,C,D
CH-47 A,B,C,D 3 33 36
CH-54 A,B 5 0 5 5
CH-54 A,B, 5 45 50 50
with pod
OH-6 A 1 3 4 4
OH-58 A,C 1 3 4 4
OH-58 D 2 0 2 2
UH-1 B,X 2 4 6 6 1
UH-1 B,C,M 2 7 9 9 1 1
UH-1 D,H 2 11 13 13 2
UH-60 A 3 14 17 17 2
T-42 A 1 3 4 4 1
NOTE
Underarm flotation devices must be worn by all persons on board all Army
Aircraft flying over water. This requirement complies with AR 95-3.
(1) Prior to stowing liferaft assemblies in air- (4) Heavy multi-place liferafts are to be carried,
craft, inspect liferaft compartment or stowage area to not dragged over floor areas.
ensure freedom from oil, dust, water, sharp protruding
edges, or any foreign substances or articles that could c. Inspection. All flotation equipment will be
cause damage to the liferaft. inspected in accordance with TM 5-4220-202-14/TO
(2) Refer to aircraft manuals for proper installa- 14S-1-102.
tion and location within the particular aircraft.
d. Repair. All repairs of flotation equipment will be
(3) Leave liferaft assemblies stowed in fuse- in accordance with TM 5-4220-202-14/TO 14S-1-102.
lage (not in compartment) in the carrying cases. Stow The flotation maintenance facility will conform to the
auxiliary kit in same manner. requirements of the same TM/TO.
11-8
TM 1-1500-204-23-1
Publication Description
Publication Description
TM 55-6695-217-23 & P Aviation Unit and Aviation Intermediate Maintenance Repair Parts and
Special Tools List, Tester Oxygen Mask, Headset, Microphone and
Flash Goggles Type MQ-1A.
e. Cleaning. All cleaning of flotation equipment will restrictions to servicing oxygen equipment; all must be
be in accordance with TM 5-4220-202-14 and TO adhered to. A clean environment is required to service
14S-1-102. personal oxygen equipment, masks-regulators-oxygen
bottles, etc. The mask, because it is on the users face,
11-17. Oxygen Equipment. Oxygen equipment for if not properly serviced, could cause facial skin, throat,
ALSE consists of that equipment not a permanent/inte- and lung problems, or at worst, no oxygen flow when
gral part of the aircraft/aircraft airframe. Oxygen to be needed causing hypoxia and possible death. Table 11-6
used is Oxygen, Breathing, Aviator’s, MIL-0-27210. The gives references for oxygen equipment.
cylinder is color-coded with a green top, white band,
green band and a green body in accordance with MIL- a. Inspection. Inspection of all oxygen equipment
STD 101. There are several types of oxygen. Aviation will be in accordance with the applicable TM/TO.
oxygen is dry compared to the wet medical oxygen. Dry b. Repair. Repair of all oxygen equipment will be in
oxygen for aviation is required because of high altitude accordance with the applicable TM/TO/NAVAIR. The
and low temperatures. Medical oxygen, which is wet, can maintenance facility will conform to the requirements of
freeze causing malfunction of oxygen equipment and TM 55-1660-245-13/TO 15X-1-1/NAVAIR 03-50-1) a tri-
oxygen masks. The handling of oxygen demands the service manual for oxygen and some oxygen equipment
safe handling, care, and attention to details. Refer to TM maintenance including the requirements for the oxygen
55-1660-245-13 and TO 15X-1-1. There are many maintenance area.
Change 2 11-9
TM 1-1500-204-23-1
c. Cleaning. Cleaning of oxygen equipment will be aircraft combined with the inability of securing and instal-
in accordance with the applicable manual for that piece ling required kits prior to flight shall warrant placing the
of oxygen equipment. aircraft in a limited (one kit in crew compartment and one
kit for each five passenger seats installed or fraction
11-18. Signaling Devices. Signaling devices are thereof) operable status, IAW DA PAM 738-751. Kits will
flares, whistles, reflections from shining surfaces (mir- be installed in aircraft locations indicated in the applica-
rors, plexiglass from doors or windows etc.), smoke, ble aircraft maintenance technical manual. When the
radios, sea dye, cloth, vegetation, and rocks. The use of required quantity of first aid kits, for troop transport mis-
these items are found in FM 21-76 Survival Manual or sion(s) is in excess of the provisions for installation of the
AFM 64-5 Survival Manual or the applicable survival kits, the additional kits will be carried on board as loose
radio TM/TO. Caution must be used with flares and fire equipment. Upon completion of mission(s), the addi-
signals. Table 11-7 gives references for signaling tional first aid kit(s) will be removed and turned in.
devices.
c. Identification. There are two configurations of
a. Inspection. Inspection will be accomplished in authorized first aid kits, with identical NSN part numbers
accordance with the applicable TM/TO/NAVAIR. for use on aircraft. The older design as shown in figure
b. Repair. Repairs, if any, will be accomplished in 11-1 is marked with a red cross, and the words First Aid
accordance with the applicable TM/TO/NAVAIR. Kit, Airplane, appear on the outer fabric case. It has a
side pocket compartment. The newer configuration as
c. Cleaning. Cleaning will be accomplished in shown in figure 11-2 is marked with a red cross and the
accordance with the applicable TM/TO/NAVAIR. words First Aid Kit, General Purpose, appear on the outer
fabric case. The older design kit will be used until stocks
11-19. First Aid Kits. This section establishes the are depleted and the kit is no longer serviceable. Original
responsibility and procedures for installation and inspec- markings will not be changed for standardization pur-
tion, and furnishes information regarding source of sup- poses. See TM 55-1500-345-23 in the event that the
ply of approved First Aid Kit, General Purpose, Panel markings on kits must be restored.
Mounted, NSN 6545-00-919-6650, for aircraft. This kit
provides first aid essentials for use by flight crews and d. Protection of Contents . The first aid kit will be
passengers sustaining injuries due to combat, accident, closed and sealed when carried in aircraft. Serviceable
malfunctioning of equipment, or survival conditions. kits will always be tagged with a DD Form 1574 (Service-
able Tag-Materiel) as shown in figure 11-3, properly com-
NOTE pleted and attached. This will be the responsibility of
This publication will be used as authority to designated personnel.
identify and inspect first aid kits for Army air- NOTE
craft. Other references in this chapter are
used only for purposes specified. This seal will be broken on installed first aid
kits only when the contents are to be used for
a. Basis of Issue . The property book officer for first aid treatment of an injury. When the seal
authorized activities will submit requests for first aid kits has been broken, it will be annotated on DA
to the supporting medical supply officer, based on one Form 2408-13-1/DA Form 2408-13-1-E (Air-
per crew compartment in Army aircraft; and one for each craft Inspection and Maintenance Record).
five passenger seats/capacity or fraction thereof. All narcotics and non-
e. Controlled Substances.
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 not
aircraft, as specified in the applicable -10 manual. The included in the medical kit. Amphetamines will not be
absence 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
Publication Description
TM 11-5820-640-25P Combined Organizational, DS, GS, and Depot Maintenance Including Repair
Parts and Special Tools List Radio Set AN/URC-10A
TM 11 -5820-767-30P Direct Support Maintenance Repair Parts and Special Tools List for Radio
Set AN/URC-68
TM 55-5820-767-34 Direct Support Maintenance and General Support Maintenance Manual for
Radio Set AN/URC-68
TM 11-5820-800-13 & P Operator's Aviation Unit and Intermediate Maintenance M anual Including
Repair Parts and Special Tools List for Radio Set AN/PR C90
TM 11-6625-2631-40P General Support Maintenance Repair Parts and Special Tools List for Test
Set, Battery TS-2530/UR and TS-2530A/UR
11-11
TM 1-1500-204-23-1
Publication Description
SB 742-1370-94-721 Signal, Smoke and Illumination Marine: AN-MK 13, MOD O (L275)
Ammunition Surveillance Surveillance Procedures
11-12
TM 1-1500-204-23-1
11-13
TM 1-1500-204-23-1
11-14 Change 6
T M 1- 150 0- 204 -2 3- 1
Change 4 11- 15
T M 1- 15 00- 2 04- 23 -1
Supplies of Materiel Condition Tags will be req- (i) After completing the resealing action,
uisitioned through normal publication channels. position tag to the double edge of fabric, as shown
in figure 11-5, with a minimum of two staples from a
(b) Reseal kit by closing zipper and plac- standard office type stapler. This action is intended
ing slide fastener tab in down and locked position, and to reduce the inadvertent loss of the tag due to wind
install flat-head pin into slide fastener loop. movement when operating aircraft with door/windows
open.
(c) Slip free end of sealing wire through
hole in end of flat-head pin already installed in loop and
pull wire through until lead seal is against end of pin.
Figure 11-5. Properly Attached Flat-Head Pin, Lead Seal, and Identification Tag.
11-16 Change 1
TM 1-1500-204-23-1
Change 2 11-17
TM 1-1500-204-23-1
Shelf
life
Stock No. Nomenclature Unit Quantity (months)
11-18 Change 3
TM 1-1500-204-23-1
Publication Description
Publication Description
11-19
TM 1-1500-204-23-1
NOTE
Seat belts will not be replaced for
cosmetic reasons. Figure 11-6. Measuring Fingertip Clearance
a. Inspection. All personnel restraint equipment is (1) Installation inspection. Visually inspect all
to be visually inspected at time of installation and at restraint equipment prior to installation. Seat belt
specified intervals thereafter. Inspections are explained latches shall be inspected for fingertip clearance in
in the following paragraphs. accordance with the following procedures.
• New Restraint Equipment. Perform
daily inspection for new seat belt (a) Inspect each seat belt latch by using a
latches (MS3488(AS)) also Inspect for steel scale to measure the clearance distance between
fingertip access. the inside face of the top of the grip and the top of the
wedding, as shown in figure 11-6
• New Assemblies of Restraint
Equipment This equipment requires (b) If the distance measured above is less
no inspection during depot storage. than the thickness of gloved fingers (minimum 0.8 inch)
alter latch using the following procedures:
• Seat belt latch (MS3488(AS)).
Inspect for fingertip clearance. 1 Open latch so that sides may be
Inspect each seat belt latch by using a placed in vise equipped with aluminum or brass
steel scale to measure the clearance protective plates on jaws.
distance between the inside face of 2 Squeeze sides of latch handle
the top of the grip and the top of the together using constant, even vise pressure until jaws
webbing, as shown In figure 11-6. are approximately 1 3/4 inches apart. Latch will deform
upward and inward, as shown in figure 11-12.
WARNING
3 Repeat as necessary to obtain
Except for leg garters used with the 7/8-inch clearance dimension due to spring back of
MK-5D ejection seat, all restraint metal.
assemblies made of cotton webbing 4 Perform visual inspection for
shall be removed from service. Use cracks.
extreme caution when inspecting 5 Check operation of latch and
restraint equipment on ejection seat detent for complete lock and release.
equipped aircraft. Ensure
appropriate safety pins are installed.
Injury to personnel may otherwise
result.
11-20
TM 1-1500-204-23-1
NOTE
• Fraying of the exterior surface of the webbing,
When new nylon webbing is causing separation or rupture of yams
installed, it will be flexed by pulling it sufficient to obscure the identity of any yarn
across or around a metal bar exceeding 20 percent of the width or 2 inches
approximately 1/4 inch in diameter. in length, shall render the webbing
This action is accomplished by unserviceable. Fuzzing of the exterior surface
holding each end of the new caused by broken individual filaments in the
webbing and pulling it in a back and yarns is not cause for rejection.
forth motion. This will assist in
making the webbing pliable by NOTE
breaking down the finishing glaze Fuzzing of the exterior surface
that is applied to new nylon fabric. caused by broken individual
Repeat the back and forth motion filaments in the yams is not cause for
until the glaze on the fabric is broken rejection.
down to such an extent that the belt
or harness can be readily adjusted. • Discoloration of webbing caused by contact
The flexing procedure will be with strong caustic soaps, or acid shall be
accomplished on both sides of the reason for removal from service. Webbing
webbing. discoloration resulting from contact with metal
articles and hardware is not cause for
(2) Daily inspection. Perform the daily Inspection removal.
using the following procedures
NOTE
(a) Check seat belt shoulder harness, Webbing discolored or soiled by
restraint harness, inertia reel strap webbing for: grease, oil, aviation fuels and
• Deterioration resulting from contact with hydraulic fluids shall be cleaned,
foreign matter, (i.e acid, petroleum based I.A.W. paragraph d, c. Fading of
products, strong caustic soaps) shall be cause webbing by subjection to sunlight is
for removal from service. Surface mold or an unreliable indicator of
mildew may be removed by washing. If no deterioration and shall not be cause
deterioration is evident after washing, webbing alone for webbing rejection.
shall be considered serviceable.
(b) Any metal restraint hardware which is
NOTE corroded or defective in operation shall be inspected for
operational use and replaced if found to be substandard
Surface mold or mildew may be or excessively damaged. Missing or unserviceable
removed by washing if no adjuster webbing retarder springs and loose or missing
deterioration is evident after bolts will be replaced.
washing, webbing shall be
considered serviceable. (c) Check buckle mechanisms for ease of
locking and releasing. When locked, the latch should
• Cuts of the webbing caused by a sharp-edged
not have a tendency to release inadvertently, nor should
instrument or object that severs the vertical or
it be excessively difficult to release.
horizontal yarns of the webbing, shall be
reason for removal.
(d) Pilot/troop type belts, check for freedom
• Broken stitches Identified by missing, skipped, of movement of the link within the mated hook and
torn or ruptured threads in the stitch pattern guide bar. The link shall not bind in any position (i.e.
Stitching may be repaired and will not be pivot and hook tip) within Its operating limits.
cause for rejection TM 1-1500-204-23-1.
11-21
TM 1-1500-204-23-1
Do not use a bleach. Bleach may • Safety lap belts (crew or troop)
cause webbing to deteriorate. • Shoulder harness (crew or troop)
• Safety belt tiedown straps
11-22
TM 1-1500-204-23-1
• Personnel restraining harness (gunner and (1) Spring webbing retarder. Replace spring
hoist operator) webbing retarder used in shoulder harness and seat belt
• Safety belts (airline type) webbing adjusters as follows:
• Inertia reel strap (webbed strap only) (a) For shoulder harness webbing adjuster,
• Leg restraints P/N MS22007, use spring, P/N 65D34083-7 and the
• Litter straps following procedures
1 Hook one end of webbing retarder
NOTE spring around flat end of knurled locking bar as shown in
• Safety belts will not be replaced figure 11-7.
for cosmetic reasons. 2 Cut a 16-inch length of type 1
nylon cord, and tie the loose ends together to form a
• Safety belts having cotton loop in the cord.
webbing are to be removed from
3 Insert the nylon cord loop through
service.
the slot of the adjuster plate, and hook loop over the
• Replace loose, missing, or webbing retarder spring hook end.
damaged bolts, nuts, washer, 4 Pull the nylon cord through
and shims in the anchoring adjuster plate slot and around the bar.
points.
11-23
TM 1-1500-204-23-1
5 Press the locking bar back with the 2 Hook one end of webbing retarder
left thumb, leaving enough space to side the loop spring around flat end of knurled locking bar. Work
through adjuster plate slot once the hook end of other end of spring around opposite flat end of knurled
the retarder spring has engaged on the locking bar. bar as shown in figure 11-8.
6 Pull the nylon cord over the knurled 3 Insert center section of webbing
locking bar to disengage the cord from the retarder retarder spring into adjuster plate tab release, (fig 11-8).
spring.
4 Replace adjuster webbing in adjuster
7 Work the center of the webbing plate. Ensure that webbing is centered on adjuster plate
retarder spring into the adjuster plate pull tab slot. knurled bar and can be adjusted as desired.
(b) For seat belt webbing adjuster P/N (a) Secure the snap (MS22042-1)
MS22004-1 NSN 1680-00-876-0971 use spring P/N in a vise, and ensure that the snap guard Is not
62B4407 NSN 1680-00-975-2987 and the following contained within the jaws.
procedures.
(b) Drill a 3/32-inch diameter hole
1 For ease in replacing webbing through both sides of snap guard as shown in figure 11-
retarder spring, remove adjustment webbing from 9. Remove all metal burrs and filings from the snap.
adjuster plate. Spring can be replaced without
removal of seat belt from aircraft.
11-24
TM 1-1500-204-23-1
Change 1 11-25
TM 1-1500-204-23-1
NOTE:
DIMENSIONS ARE IN INCHES
11-26
TM 1-1500-204-23-1
(2) MK-J5 ejection seat personnel parachute c. Inspection Report. Record and report
harness. Inspection procedures for the MK-J5 ejection inspection MK-J5 ejection seat personnel parachute
seat personnel parachute harness are as follows: harness on DA Form 2407 in accordance with DA PAM
738-751. Further inspection record will be made on the
(a) Remove DA Form 3912 from harness log individual parachute harness DA Form 3912 as follows:
record and survival manual pocket located on inside
lower right of harness stiffener. Check record for date of (1) Open DA Form 3912 to page, entitled
last 200 day MK-J5 ejection seat harness inspection. A jump inspection and repack data, for the routine
parachute harness which has exceeded 120 days (200 inspection entry accomplishment.
days for MK-J5 ejection seat harness) since last (2) Enter inspection date In date column.
technical rigger-type inspection, will be considered (3) Make checkmark in routine Inspection
unserviceable. After determining the last inspection column.
date, return the form to the log record and survival
(4) Repeat the number entered
manual pocket.
previously in the jumped or dropped columns.
(b) Ensure that a copy of TM 10-1670-1 is (5) Enter signature in the inspector's
located in the log record and survival manual pocket. name column.
(c) Visually examine harness webbing for (6) Enter designation of the unit to which
cuts, frays, tears, broken or loose stitching, worn areas, inspector is assigned in the unit column.
discoloration, dampness, or evidence of contact with
petroleum products. NOTE
(d) Check harness shoulder pads, chest strap The 30-day routine inspection
ejector snap pads, and leg strap ejector snap pads for requires recording on DA Form 3912.
damage, broken or loose stitching, and broken or loose
tacking. Ensure that tacking between each ejector snap 11-23. Consolidated List of ALSE References.
and adjacent pad Is not broken or loose. Table 11-11 gives a list of references to be used as a
guide only. Do not maintain manuals that do not pertain
(e) Inspect strap fasteners, quick release to the units Life Support Equipment authorized and on
adapters, connector links, ejector snaps and survival kit hand. Department of the Army Pamphlet 25-30 should
retention buckles for bends, breaks, and corrosion be consulted frequently for the latest changes or
Check all moving metal components for ease of revisions of the references listed in table 11-11 and for
operation. Ensure that spring tension is maintained in new publications covered in this section. Instructions for
each ejector snap. establishing and maintaining a library are found in DA
Pam 310-13.
11-28
TM 1-1500-204-23-1
Publication Description
11-29
TM 1-1500-204-23-1
Publication Description
NOTE
11-30
TM 1-1500-204-23-1
Publication Description
11-31
TM 1-1500-204-23-1
Publication Description
11-32
TM 1-1500-20423-1
Publication Description
Change 2 11-33
TM 1-1500-204-23-1
Publication Description
Technical Bulletins (TB) - CONT
TB 34-9-127 Medical Gas Cylinders
TB 34-9-210 NATO Standardization Agreement for Air Pyrotechnics Interchangeability
Chart STANG 3398
TB 34-9-242 Aircraft Gaseous Oxygen Replenishment Connections
TB 34-9-243 Aircraft Compressed Air Replenishment Connections
TB 34-9-245 Compressed Breathing Air Characteristics
TB 34-9-330 Mask, Protective, Aircraft, ABC-M24 and Hood Aircraft Protective Mask,
ABC-M7
TB 43-0002-4 Maintenance Expenditure Limits for FSC Group 16, FSC Classes 1610,
1615, 1620, 1630, 1650, 1660, 1670, and 1680
TB 43-180 Calibration and Repair Requirements for the Maintenance of Army Material
TB 740-10 Quality Control Depot Serviceability Standards
Supply Bulletins (SB)
SB 3-30-2 Chemical, Biological Canisters and Filter Elements Serviceability Lists
SB 8-75 SERIES Army Medical Department Supply Information SB 8-75-1 through 8-75-35
SB 11-6 FSC Class 6135; Dry Battery Supply Data
SB 11-30 FSC Class 6135; Primary Battery Management Data
SB 11-576 Cold Weather Batteries for Radio Sets AN/PRC6,8,8A, 9A, 10, 10A, 25,28
and 77 and Cable Assemblies for Cold Weather Operation of Transmitting
Set Radio AN/PRT-4 and Receiving Set, Radio AN/PRR-9
SB700-20 Army Adopted/Other Items Selected for Authorization/List of Reportable
Items
SB708-30 Department of Defense Ammunition Code (Cataloging Handbook H3) (GSA-
FSS-H-3)
11-34
TM 1-1500-204-23-1
Publication Description
Change 2 11-35
TM 1-1500-204-23-1
Publication Description
11-36 Change 2
TM 1-1500-204-23-1
Publication Description
11-37
TM 1-1500-204-23-1
Publication Description
Naval Publications
11-38 Change 2
TM 1-1500-204-23-1
Publication Description
11-39
TM 1-1500-204-23-1
Publication Description
DD Form 1348 DOD Single Line Item Requisition System Document (MANUAL)
DD Form 1348-6 DOD Single Line Item Requisition System Document (MANUAL-LINE FORM)
11-40
TM 1-1500-204-23-1
CHAPTER 12
PYROTECHNICS
12-1. General. The following paragraphs explain sealed metal container, of which
pyrotechnics used on Army aircraft. Refer to TM 9- not more than 12 months shall
1377200-20&P for descriptive information, care and have elapsed after opening
handling of stock class 1377 cartridges. container. Cartridges are
overage if either of these time
WARNING limits is exceeded. When a
Electrically activated cartridges shall container is opened, the service
be protectively wrapped in aluminum life expiration date (month and
foil or electrically shunted whenever year) shall be marked with
removed from the aircraft installation indelible ink on the side of the
to preclude "STRAY" electrical cartridge.
voltage activation and resulting
personal injury. • Cartridge is considered
unserviceable after ten insertions
12-2. Ejection Seats. Ejection seats use pyrotechnics and removals from ejector rack,
for seat ejection, automatic parachute deployment, and or after the expiration date
separation of seat from occupant after ejection. marked on the side of the
cartridge. Each time a cartridge
WARNING is removed, place a radial mark
Electrically activated cartridges shall on the base of cartridge with
be protectively wrapped in aluminum indelible ink. Monitor service life
foil or electrically shunted whenever by record of inked markings and
removed from the aircraft installation expiration date.
to preclude "STRAY" electrical
voltage activation and resulting WARNING
personal injury. Electrically activated cartridges shall
be protectively wrapped in aluminum
12-3. Fire Bottle Cartridges. Fire bottles use foil or electrically shunted whenever
cartridges to discharge extinguishing agents when removed from the aircraft installation
activated by aircraft crewmember or automatic detecting
to preclude "STRAY" electrical
device.
voltage activation and resulting
personal injury.
12-4. External Stores Cartridges. External stores
cartridges are used to release external stores from racks
12-5. Cable Cutter Cartridges. The cargo hoist cable
cutter is a mechanical cable shearing device mounted
CAUTION
on the hoist cable guide. It is actuated by an electrically
Do not use damaged cartridges.
fired cartridge. When the pilot throws the CABLE
Damaged cartridges may function
SHEAR switch or the aft pilot throws the HOIST CABLE
erratically and cause damage to SHEAR switch, electrical power, supplied by the 28 vdc
equipment. primary bus through the HOIST CABLE SHEAR circuit
breaker on the overhead circuit breaker panel, fires the
NOTE cartridge, actuating the cable cutter, and shearing the
cable. After firing, the cable cutter assembly must be
• Shelf life (storage life) for the replaced.
cartridge is established at 8
years, beginning from date of
manufacture stamped on
cartridge or on hermetically
Change 1 12-1
TM 1-1500-204-23-1
Change 1 12-2
TM 1-1500-204-23-1
CHAPTER 13
AIRCRAFT CLEANING
13-1. GENERAL. Proper and frequent cleaning is the grease. Some solvents can damage rubber, neoprene,
most important part of a corrosion control program. Fre- and electrical insulation. They can also damage paint
quency of cleaning and related treatment will depend on and should be removed as soon as possible.
type of aircraft and local conditions. All aircraft shall be
washed and cleaned every 30 days, unless aircraft are (2) To protect against cleaning solution entrap-
stationed within two miles of salt water. Extended or low ment, inspect all lubrication points that have exposure
level operations over salt water require daily fresh water type lubrication fittings. Lubricate those that have not
rising. External corrosion prone areas will require more been regularly lubricated in accordance with the appli-
frequent cleaning. cable maintenance manual.
Do not use synthetic wiping cloths with highly (4) Make sure that all drain holes are clear by
flammable solvents having a flash point of inserting a probe such as a pipe cleaner, except where
100°F (37.8°C) or less, such as aliphatic naph- pressurized flapper valves are located.
tha TT-N-95. Static electricity may build up and
cause ignition.
Change 5 13-1
TM 1-1500-204-23-1
DELETED
(a) Mix one part of aircraft cleaning com- Do not rinse aircraft with a solid stream of wa-
pound MIL-C-43616 or MIL-C-25769 and nine parts of ter. Use a soft, spray pattern to avoid damaging
water in a bucket. fragile sections or causing water intrusion.
(b) Apply the cleaner with a scrub brush, (d) Rinse away the loosened soil and cleaner
sponge, rag, or cleaning and polishing pad. Apply to with a stream of water. For rinsing, a rubber padded
one small area at a time. shutoff-spray nozzle is recommended.
(c) Scrub the area and remove the cleaner (4) Rinsing. Rinse the cleaner and loosened
and loosened soil with a cloth. soil from aircraft surface with pressure equipment hav-
ing a fan spray nozzle. Direct water at an angle between
15 and 30 degrees from the surface to rinse it. Continue
NOTE
rinsing until all evidence of cleaner and soils have been
For soils that are resistant to the limited water removed from aircraft.
procedure, clean again with a mixture of one
part cleaner in four parts water. (5) Deluge rinsing. To prevent buildup of salt
deposits, the deluge rinse facilities shall be used as fre-
(d) Apply MIL-C-81309 Type II and wipe with quently as possible.
a clean dry cloth.
NOTE
(3) Water detergent cleaning (preferred
Use of deluge rinsing facilities does not replace
method). Where water of suitable quality is available
aircraft washing requirements.
for rinsing purposes, the following procedures shall be
used:
13-2 Change 6
TM 1-1500-204-23-1
c. Cleaning of Corrosion Prone Areas. Specific (2) Clean all drain holes by inserting a
efforts shall be made to clean all corrosion prone areas probe such as a pipe cleaner except where pressurized
as frequently as possible, even if unusual conditions flapper valves are located. Assure that all areas
prevent complete aircraft cleaning. Refer to the accumulating water have been drained. Whenever this
applicable maintenance manual. is recurring problem, procedures shall be developed and
implemented to remove entrapped water and prevent
d. Post-Cleaning. Corrosion prevention depends accumulation.
on carrying out the prescribed preservation and
lubrication procedures. Strict compliance with the (3) Inspect for corrosion and deterioration
following procedures is essential Post-cleaning as part of routine maintenance procedures.
procedures shall be done in the following order:
(4) Relubricate, preserve, and seal.
(1) Remove covers from all static vents,
pilot tubes, air ducts, heater ducts, etc. Tape shall be (5) Polish and wax.
removed from all other openings sealed with masking
tape. 13-3. Cleaning Safety. All cleaning procedures should
be accomplished with the applicable maintenance
manual. Proper precautions must be taken when
working with cleaning substances.
NOTE
The use of cleaning agents with high
alkaline content should not be used.
Failure to comply with this note will cause
components and assemblies to corrode
at an accelerated rate. At no time should
cleaners high in alkaline be used in areas
that have parts made of magnesium or
aluminum or other areas not protected
by a corrosion protective coating.
APPENDIX A
REFERENCES
AFM 64-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ANA Bulletin 166 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
Resource Management
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 385-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Army Safety Program
AR 385-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Color Code Markings and Signs
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 Sys-
tem
AR 710-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Supply Policy Below the Wholesale Level
AR 725-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requisitioning, Receipt, and Issue System
AR 746-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Packing of Army Materiel for Shipment and Storage
AR 750-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Army Material Maintenance Policies
AR 750-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Army Materiel Maintenance Policies
AR 750-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Operating Time Limits
AR 750-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Airdrop, Parachute Recovery and Aircraft Personnel Escape
Systems
AR 755-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reporting, Utilization, and Redistribution of Installation
USAMC, and Overseas Command Excess Property
AR 755-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disposal of Excess, Surplus, Foreign Excess, Captured and
Unwanted Material
C 1 ARMY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction to the Federal Supply Catalog and Related Pub-
lications
C 6500-AL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Federal Supply Catalog: Alphabetical Index (Medical Mate-
riel)
Change 2 A-1
TM 1-1500-204-23-1
APPENDIX A - CONT
REFERENCES
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 of
Medical Materiel Only)
C 8900-SL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Federal Supply Catalog: Stock List, FSC Group 89, Subsis-
tence
CTA 8-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Army Medical Department Expendable/Durable Items
CTA 50-900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clothing and Individual Equipment
CTA 50-909 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Field and Garrison Furnishings and Equipment
CTA 50-970 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Expendable/Durable Items (Except: Medical, Class V,
Repair Parts and Heraldic Items)
DA FORM 12-R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Request for Establishment of a Publications Account
DA FORM 12 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements for DA Publications
DAFORM 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requisition for Publications and Blank Forms
DA FORM 17-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requisition for Publications and Blank Forms (Continuation
Sheet)
DA FORM 581 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Request for Issue and Turn-In of Ammunication
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 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
A-2 Change 2
TM 1-1500-204-23-1
GLOSSARY
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.
INDEX
VOLUME 1
Subject Paragraph
Figure, Table
Number
A
Accessories................................ ................................ ................................ ................................ ...................... 7-4h
Accessory Section................................ ................................ ................................ ................................ ............ 8-5h
Additional Metal Particles Test ................................ ................................ ................................ ......................... 7-5g
Adhesive Operations................................ ................................ ................................ ................................ 2-2k, 2-3k
Adhesives, Resins, and Solvents for Repair of Armor ................................ ................................ ..................... 9-23c
Adjusting Mixture and Idle Speed................................ ................................ ................................ ...................... 7-9c
Adjustment of Windshield Wiper System ................................ ................................ ................................ .........9-19b
Administration ................................ ................................ ................................ ................................ .................. 11-2
Administration Area................................ ................................ ................................ ................................ .......... 11-6
Air Induction System ................................ ................................ ................................ ................................ .......... 7-7
Inspection, Maintenance, Cleaning, and Replacement................................ ................................ ............ 7-7a
Turbocharger and Supercharger Maintenance................................ ................................ ........................ 7-7b
Aircraft and Equipment, Parking of, in Hangars ................................ ................................ ................................ .. 2-6
Aircraft Cleaning, General ................................ ................................ ................................ ................................ 13-1
Aircraft Component, Preservation and Packing ................................ ................................ ................................ 4-12
Aircraft Grounding Receptacle Installation................................ ................................ ................................ ........ F3-2
Aircraft, Liferafts ................................ ................................ ................................ ................................ ............ T11-4
Aircraft Litters................................ ................................ ................................ ................................ ................... 9-21
Installation ................................ ................................ ................................ ................................ .............9-21a
Removal ................................ ................................ ................................ ................................ ................ 9-21b
Aircraft Preparation for Storage................................ ................................ ................................ .......................... 4-4
Aircraft Refueling ................................ ................................ ................................ ................................ ............... 3-5
Fuel Truck Operations ................................ ................................ ................................ ............................ 3-5d
Open-Port Hot Refueling................................ ................................ ................................ ......................... 3-5b
Open-Port Refueling ................................ ................................ ................................ ............................... 3-5a
Rapid Hot Refueling................................ ................................ ................................ ................................ .3-5c
Aircraft Removal from Storage ................................ ................................ ................................ ........................... 4-9
Aircraft Seats ................................ ................................ ................................ ................................ ................... 9-20
Metal Seats ................................ ................................ ................................ ................................ ...........9-20b
Polyester Fabric Seat Covers (UH-60) ................................ ................................ ................................ ...9-20e
Raschel Knit Seat Covers ................................ ................................ ................................ ...................... 9-20d
Troop Seats................................ ................................ ................................ ................................ ...........9-20a
Upholstered Seats ................................ ................................ ................................ ................................ .9-20c
Aircraft, Shipment ................................ ................................ ................................ ................................ ............ 4-11
Aircraft, Static Grounding of ................................ ................................ ................................ ............................... 3-4
Aircraft Storage and Shipment, General ................................ ................................ ................................ ............. 4-1
Aircraft Storage and Shipment, Responsibility................................ ................................ ................................ .... 4-3
Airframe Maintenance, General................................ ................................ ................................ .......................... 9-1
Airplane, First Aid Kit (Older Configuration) ................................ ................................ ................................ .... F11-1
Alignment, Landing Gear................................ ................................ ................................ ................................ .... 9-6
Anti-Icing, Deicing, and Defrosting ................................ ................................ ................................ .................. 10-2d
Application and Installation of Identification Tapes ................................ ................................ ............................. 6-3
Application and Removal of Decals, General ................................ ................................ ................................ ..... 6-1
Application of Identification Tapes ................................ ................................ ................................ ..................... 6-3c
Index 1
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
A - Continued
Index 2
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
B - Continued
Index 3
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
C - Continued
Index 4
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
C - Continued
Index 5
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
D - Continued
Index 6
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
Index 7
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
E - Continued
Index 8
TM 1-1500-204-23-1
INDEX
VOLUME 1
Paragraph,
Figure, Table
Subject Number
F - Continued
Change 2 Index 9
TM 1-1500-204-23-1
INDEX- CONT
VOLUME 1
Subject Paragraph,
Figure, Table
Number
F - Continued
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
G - Continued
Index 11
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
H - Continued
Hoisting 2-7b
Hoisting and Jacking ................................ ................................ ................................ ................................ ......... 2-7
Hot Section Maintenance ................................ ................................ ................................ ................................ ..8-6i
Hot Start Inspection................................ ................................ ................................ ................................ ........... 8-6c
Hydraulic Fluid Servicing ................................ ................................ ................................ ................................ .. 3-8
Hydraulic Hoist System ................................ ................................ ................................ ................................ ...9-16a
Index 12
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
I - Continued
Jacking 2-7a
Jacking and Hoisting ................................ ................................ ................................ ................................ .......... 2-7
Hoisting ................................ ................................ ................................ ................................ ................. 2-7b
Jacking ................................ ................................ ................................ ................................ .................. 2-7a
Index 13
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
Index 14
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
M - Continued
Index 15
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
N - Continued
Index 16
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
Index 17
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
P - Continued
Index 18
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
P - Continued
Index 19
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
R - Continued
Index 20
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
R - Continued
Index 21
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
S - Continued
Index 22
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
S -- Continued
Index 23
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
S - Continued
Tag-Materiel, Serviceable (DD Form 1574) (Yellow) ................................ ................................ ...................... F11-3
Tag-Materiel, Unserviceable (Repairable) (DD Form 1577-2) (Green)................................ ............................ F11-4
Tapes, Color-Coded................................ ................................ ................................ ................................ ......... F6-1
Taxiing 3-11b
Taxiing and Runup................................ ................................ ................................ ................................ ........... 3-11
Temperature and Humidity Control................................ ................................ ................................ .................. 2-3m
Temporary Shop Installations ................................. ................................ ................................ ........................... 2-3
Adhesive Operations ................................ ................................ ................................ ............................... 2-3k
Balancing Equipment ................................. ................................ ................................ .............................. 2-3l
Chain Hoists . ................................ ................................ ................................ ................................ ......... 2-3e
Compressed Air Panels ................................ ................................ ................................ ........................... 2-3f
Dust and Dirt Control ................................ ................................ ................................ ................................ 2-3i
Electrical Utilities ................................ ................................ ................................ ................................ ... 2-3g
Equipment Mounted in Mobile Shelters................................ ................................ ................................ ....2-3c
Flammable Materials ................................ ................................ ................................ ............................. 2-3n
Lighting................................ ................................ ................................ ................................ ................... 2-3o
Noise Levels ................................ ................................ ................................ ................................ .......... 2-3h
Open Storage Areas ................................ ................................ ................................ ................................ 2-3r
Protected Storage Areas................................ ................................ ................................ ......................... 2-3q
Repair Parts Van ................................ ................................ ................................ ................................ .... 2-3p
Shop Equipment Arrangement................................ ................................ ................................ ................ 2-3d
Shop Size . ................................ ................................ ................................ ................................ ............. 2-3b
Spray Painting ................................ ................................ ................................ ................................ ..........2-3j
Temperature and Humidity Control ................................ ................................ ................................ ........ 2-3m
Index 24
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
T - Continued
Index 25
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
T - Continued
Index 26
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
T - Continued
Unserviceable (Repairable) Tag-Materiel (DD Form 1577-2) (Green) ................................ ............................ F11-4
Upholstered Seats................................ ................................ ................................ ................................ ........... 9-20c
Usage of Drip Pans . ................................ ................................ ................................ ................................ ........ 2-6d
Index 27
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 1
Subject Paragraph
Figure, Table
Number
V - Continued
Index 28
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 2
Subject Paragraph
Figure, Table
Number
Index 29
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 2
Subject Paragraph
Figure, Table
Number
A - Continued
Index 30
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 2
Subject Paragraph
Figure, Table
Number
B - Continued
Bulge, Coupling, Low-and Medium-Pressure Hose Assemblies ................................ ................................ ..... F4-44
Bulge, Coupling, MIL-H-7061 Hose Assembly ................................ ................................ ............................... T4-30
Bulkhead and Universal Fitting Assembly, Combination ................................ ................................ ................ T4-27
Index 31
TM 1-1500-204-23-1
INDEX - CONT
VOLUME 2
Subject Paragraph
Figure, Table
Number
C - Continued
Index 32
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INDEX - CONT
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Failure Modes and Recommended (Permaswage) Repair Methods ................................ ............................... F4-79
Field Assembly of High Pressure Teflon Hose, MIL-H-38360 ................................ ................................ ......... F4-50
Field Disassembly of Teflon Hose ................................ ................................ ................................ ................. F4-45
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F - Continued
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In-Line Cam-Operated Selector Valve (Actuator Retracting) ................................ ................................ ........ F4-122
Inspection
of Quick Disconnect Coupling ................................ ................................ ................................ ............... 4-10b
of Swaged Joint ................................ ................................ ................................ ................................ ..... 4-9g
Inspection Ball Size Chart ................................ ................................ ................................ ............................. T4-13
Inspection Checking (of Swaging), Troubleshooting Guide for ................................ ................................ ....... T4-38
Installation
Hose ................................ ................................ ................................ ................................ ...................... 4-6b
of Backup Rings ................................ ................................ ................................ ................................ .... 4-8b
of Beaded Tubing ................................ ................................ ................................ ................................ ....4-2j
of Flared Tubing ................................ ................................ ................................ ................................ ....4-21i
of Flexible Hose ................................ ................................ ................................ ................................ ....... 4-6
of Quick-Disconnect Couplings ................................ ................................ ................................ .............4-10a
Installation Aids, Hose Line, for all Types of Hose ................................ ................................ ......................... F4-57
Installation of Flexible Hose ................................ ................................ ................................ .............................. 4-6
Bends ................................ ................................ ................................ ................................ ..................... 4-6c
Chafing ................................ ................................ ................................ ................................ ................... 4-6f
Hose Clamp ................................ ................................ ................................ ................................ .............4-6i
Hose Connections to Engines ................................ ................................ ................................ ................ 4-6h
Hose Installation ................................ ................................ ................................ ................................ .... 4-6b
Hose Markings ................................ ................................ ................................ ................................ .........4-6j
Hose Restrictions ................................ ................................ ................................ ................................ ... 4-6d
Lubrication ................................ ................................ ................................ ................................ ............. 4-6a
MS Flared Swivel Connections Torquing ................................ ................................ ................................ 4-6k
Support ................................ ................................ ................................ ................................ .................. 4-6e
Temperature Protection ................................ ................................ ................................ ......................... 4-6g
Installation of Leather Backup Rings ................................ ................................ ................................ ............. F4-77
Installation of MS33514 Fitting End ................................ ................................ ................................ ............... F4-25
Installation Procedures, Teflon Hose, Right and Wrong ................................ ................................ ................. F4-49
Installation Torque Values MS Flared Swivel ................................ ................................ ................................ . F4-25
Installation Torque Values MS Flared Swivel Nut Fittings
(Reference AND100064) ................................. ................................ ................................ ..................... T4-33
Installed Low-Pressure Hose ................................ ................................ ................................ ......................... F4-16
Installing Teflon Backup Ring ................................ ................................ ................................ ........................ F4-73
Instructions
for Assembly of High Pressure (3000 psi) Hose Assemblies
MS28759 and MS28762 ................................ ................................ ................................ .................. 4-5e
for Assembly of Medium-Pressure, MS28741, and
Low-Pressure, AN6270, Hose Assemblies ................................ ................................ ....................... 4-5h
for Repair of Flexible Rubber Hose ................................ ................................ ................................ ........ 4-5d
Internal O-Ring Installation (Metallic Sleeve) ................................ ................................ ................................ . F4-68
Internal O-Ring Installation (Paper Cover) ................................ ................................ ................................ ..... F4-67
Internal O-Ring Removal (Pull-Type Extractor) ................................ ................................ ............................. F4-61
Index 38
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I - Continued
Jamnut (AN924) Used on Fittings, Torque Values for ................................ ................................ ...................... T4-8
Landing Gear System Using Mechanically Actuated Sequence Valves ................................ ........................ F4-129
Large Tubing, Beading ................................ ................................ ................................ ................................ .. F4-12
Liquid Spring, Tailwheel ................................ ................................ ................................ .............................. F4-176
Liquid Springs ................................ ................................ ................................ ................................ ...4-19c, F4-175
Low-Pressure Hose, Installed ................................ ................................ ................................ ........................ F4-16
Low-Pressure Tubing, Repair of ................................ ................................ ................................ .................... F4-30
Low-Pressure Tubing Repair, Tubing End Clearance for ................................ ................................ ............... F4-31
Lubricant Selection, Packing and ................................ ................................ ................................ .................... T4-6
Lubrication (during Installation of Flexible Hose) ................................ ................................ ............................. 4-6a
Lubrication (of Hydraulic Systems) ................................ ................................ ................................ .................. 2-2e
Main Rotor Assembly with Piston Dampers ................................ ................................ ................................ . F4-168
Maintenance of Accumulators ................................ ................................ ................................ ........................ 4-15c
Maintenance of Brake Systems ................................ ................................ ................................ ...................... 4-18e
Maintenance of Power Pumps ................................ ................................ ................................ ........................ 4-13b
Maintenance of Reservoirs ................................ ................................ ................................ ............................. 4-111
Maintenance of Shop Equipment ................................ ................................ ................................ ....................... 3-2
Hydraulic Filler and Bleeder Unit ................................ ................................ ................................ ............ 3-2a
Hydraulic Hose Testing Unit ................................ ................................ ................................ ................... 3-2d
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M - Continued
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N - Continued
Nose Landing Gear with Piston Damper ................................ ................................ ................................ ...... F4-164
Nose Landing Gear with Vane Damper ................................ ................................ ................................ ........ F4-168
Nut Installation Torque in Inch-Pounds, Hose End Fitting and Coupling ................................ ......................... T4-34
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P - Continued
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R
Safety (in Use of Test Stands) ................................ ................................ ................................ ........................ 4-20a
Scope (of Manual) ................................ ................................ ................................ ................................ ............. 1-2
Selector Valve A Closed ................................ ................................ ................................ ............................. F4-145
Selector Valve B Open ................................ ................................ ................................ ................................ F4-146
Selector Valve C Open ................................ ................................ ................................ ................................ F4-147
Selector Valve, In-Line Cam-Operated (Actuator Extending) ................................ ................................ ....... F4-123
Selector Valve, In-Line Cam-Operated (Actuator Retracting) ................................ ................................ ....... F4-122
Selector Valve, Radial Cam-Operated ................................ ................................ ................................ ......... F4-124
Selector Valve, Rotary-Type, Closed-Center ................................ ................................ ............................... F4-120
Selector Valve, Spool-Type, Open-Center (Closed) ................................ ................................ ..................... F4-121
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S - Continued
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T - Continued
Test Pressures, Operating, Proof, and Burst, for MS28741 Medium Pressure Hose
Assemblies, Using Single Wire Braid Hose, Military Specification MIL-H-8794 ............................. T4-16
Test Pressures, Operating, Proof, and Burst, for MS28759 and
MS28762 Hose Assemblies ................................ ................................ ................................ ......... T4-15
Test Stands, Use of ................................ ................................ ................................ ............................ 4-20
Tetrafluoroethylene Hose MIL-F-27272 (In Inches) ................................ ................................ ............. T4-21
Tetrafluoroethylene Hose MIL-H-38360 (in Inches) ................................ ................................ ............. T4-26
Theory and Basic Principles of Pneudraulics ................................ ................................ ...................... 2-1
Theory of Operation, Hydraulic Reservoirs ................................ ................................ ......................... 4-11 b
Theory of Operation, Hydraulics System Filters ................................ ................................ .................. 4-12b
Tightening Hose Clamp with Socket ................................ ................................ ................................ ... F4-32
Tool, Flaring ................................ ................................ ................................ ................................ ....... F4-10
Torque Values for AN924 Jamnut Used On Fittings ................................ ................................ ........... T4-8
Torque Values for Boss Installation ................................ ................................ ................................ ..... T4-7
Torque Values for MS21921 Coupling Nut ................................ ................................ .......................... T4-5
Torque Values, Hydraulic Tubing B-Nut (AN818) ................................ ................................ ................ T4-2
Torque Values, Installation, MS Flared Swivel ................................ ................................ .................... T4-25
Torque Values, MS Flared Swivel Nut Fittings (Reference
AND10064), Installation ................................ ................................ ................................ ............... T4-33
Torque Values, MS Flared Swivel Nut Fittings (Reference
AND10064), Proof Test ................................ ................................ ................................ ................ T4-20
Torque Values, MS Turns and ................................ ................................ ................................ ............ F4-21
Transporting Fluid to Aircraft ................................ ................................ ................................ .............. 3-3d
Troubleshooting Actuators ................................ ................................ ................................ .................. T4-40
Troubleshooting Guide for Inspection Checking (of Swaging) ................................ ............................. T4-38
Troubleshooting Wheel Brake Systems ................................ ................................ .............................. T4-41
Tube and Fitting Alignment ................................ ................................ ................................ ................ T4-13
Tube Bend Data Drawing ................................ ................................ ................................ ................... F4-6
Tube Bending Machine ................................ ................................ ................................ ...................... F3-4
Tube Bending Machine, Hand-Operated ................................ ................................ ............................. 3-2e
Tube Bends, Acceptable and Unacceptable ................................ ................................ ....................... F4-5
Tube Cutter, Cutting Tube with................................ ................................ ................................ ............ F4-3
Tube Cutting ................................ ................................ ................................ ................................ ...... 4-9c
Tube Deburnng ................................ ................................ ................................ ................................ .. 4-9d
Tube End Marking ................................ ................................ ................................ .............................. F4-83
Tube Insertion Band Location ................................ ................................ ................................ ............. T4-37
Tube Insertion Limits when Using Standard Union Fittings ................................ ................................ . F4-90
Tube Material and Maximum Operating Pressure Limitations (psi)
for Permaswage Repair with D10000 Senes Tooling ................................ ................................ .......... T4-35
Tube, Properly Burred ................................ ................................ ................................ ........................ F4-9
Tube Thickness and Burst Pressure, Determining ................................ ................................ .............. T4-11
Tubing Alignment ................................ ................................ ................................ ............................... F4-20
Index 47
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T- Continued
Universal Fittings AN832, AN833, AN834 High Pressure ................................ ................................ .... 4-3e
Universal Fittings AN832, AN833, AN834 Low Pressure ................................ ................................ ..... 4-3d
Use of Air in Hydraulic Systems ................................ ................................ ................................ ......... 2-1f
Use of Dust Plugs, Dust Caps, and Moisture Seals ................................ ................................ ............. 4-5l
Use of Test Stands ................................ ................................ ................................ ............................. 4-20
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A
Aeroquip Corporation Series 3700 and 3750 Quick Thread Couplings ................................ ................ 2-5h
Auxiliary (Booster) Fuel Pump ................................ ................................ ................................ ............ F2-4
AVGAS Identification ................................ ................................ ................................ ......................... T2-2
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E
Engine Oils
Reciprocating ................................ ................................ ................................ ............................... T3-1
Turbine ................................ ................................ ................................ ................................ ......... T3-2
Engine-Driven Fuel Pump ................................ ................................ ................................ ............ F2-5
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F - Continued
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Leak Path Examples, Long Leak ................................ ................................ ................................ ........ F2-10
Leaks, Fastener ................................ ................................ ................................ ................................ . F2-9
Long Leak Path Examples ................................ ................................ ................................ .................. F2-10
Lubrication System for Reciprocating Engines
Dry-Sump ................................ ................................ ................................ ................................ .... F3-3
Wet-Sump ................................ ................................ ................................ ................................ ... F3-2
Lubrication System for Turbine Engines
Dry-Sump ................................ ................................ ................................ ................................ .... F3-5
Wet-Sump ................................ ................................ ................................ ................................ ... F34
Magnetic Plugs and Chip Detectors ................................ ................................ ................................ .... 3-6f
Main Oil Strainers ................................ ................................ ................................ .............................. F3-8
Marking, Can and Drum ................................ ................................ ................................ ..................... F2-23
Marking (Fuel Containers) ................................ ................................ ................................ .................. 2-6c
Microblological Growths (Contaminating Fuels) ................................ ................................ .................. 2-4c
Micron Particle Size ................................ ................................ ................................ ........................... F2-2
Mixing Ratios (for Dyes) ................................ ................................ ................................ ..................... T2-7
Multiple Leak Paths (Single Leak Source) ................................ ................................ .......................... F2-11
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O - Continued
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Safety Precautions and Procedures, Fuel Systems ................................ ................................ ............ 2-2
Drain Containers ................................ ................................ ................................ .......................... 2-2e
Fuel tines and Drains ................................ ................................ ................................ ................... 2-2a
Personal ................................ ................................ ................................ ................................ ...... 2-2f
Tool Boxes ................................ ................................ ................................ ................................ ... 2-2c
Tools ................................ ................................ ................................ ................................ ............ 2-2b
Work Stands ................................ ................................ ................................ ................................ ...... 2-2d
Safety Precautions and Procedures, Oil Systems ................................ ................................ ............... 3-2
Safety Precautions, Fuel Storage ................................ ................................ ................................ ....... T2-10
Scope of Manual ................................ ................................ ................................ ................................ 1-2
Screen, Oil, Type ................................ ................................ ................................ ............................... F3-9
Screw-Type Coupling ................................ ................................ ................................ ......................... F2-14
Seal Deflection, Fillet ................................ ................................ ................................ ......................... F2-13
Sealant Bridging ................................. ................................ ................................ ................................ F2-12
Self Sealing Fuel Cells, Serviceable Limits ................................ ................................ ........................ T2-5
Serviceable Limits (Bladder-Type Fuel Cells) ................................ ................................ ..................... T2-6
Serviceable Limits (Self-Sealing Fuel Cells) ................................ ................................ ....................... T2-5
Single Leak Source, Multiple Leak Path ................................ ................................ ............................. F2-11
Solids (Contaminating Fuel) ................................ ................................ ................................ ............... 2-4b
Solids (Contaminating Oil) ................................ ................................ ................................ ................. 3-5b
Spacers and Screens Oil Filter ................................ ................................ ................................ ........... F3-7
Spacing, Support Clamp ................................ ................................ ................................ .................... T2-4
Storage Practices, Fuel ................................ ................................ ................................ ...................... 2-6b
Straight Flow Ball Valve Type Coupling ................................ ................................ .............................. F2-18
Support Clamp Spacing ................................ ................................ ................................ ..................... T2-4
Surge Valve Example ................................ ................................ ................................ ........................ F3-14
Testing Fuel Systems and Tanks/Cells for Leaks ................................ ................................ ............... 2-5g
Tool Box (Fuel Systems), Safety Precautions and Procedures ................................ ........................... 2-2c
Tools (Fuel Systems), Safety Precautions and Procedures ................................ ................................ . 2-2b
Tube Bends, Clamp Location for ................................ ................................ ................................ ........ F2-3
Turbine Engine Fuel Oil Heat Exchanger Cooler ................................ ................................ ................ F3-11
Turbine Engine, Identification of Oils for ................................ ................................ ............................. 3-4b
Turbine Engine Oil Use Temperature Chart ................................ ................................ ........................ F3-1
Turbine Engine Oils ................................ ................................ ................................ ............................ T3-2
Types of Oil Systems ................................ ................................ ................................ ......................... 3-6a
Types of Oils ................................ ................................ ................................ ................................ ...... 3-3
Typical Fuel System Schematic ................................ ................................ ................................ ......... F2-21
Typical Fuel System Troubleshooting Chart ................................ ................................ ....................... T2-9
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B-16 Master Sighting Compass Alignment Method ................................ ................................ ............. F4-23
Basic Circuits ................................ ................................ ................................ ................................ ..... 2-5
Compound ................................ ................................ ................................ ................................ ... 2-5c, F2-7
Parallel ................................ ................................ ................................ ................................ ........ 2-5b, F26
Senes ................................ ................................ ................................ ................................ .......... 2-5a, F2-5
Basic Principles and Theory for Alternating Current ................................ ................................ ............ 2-3
Basic Principles and Theory for Direct Current ................................ ................................ ................... 2-2
Bonds ................................ ................................ ................................ ................................ ................. 3-1 k
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C - Continued
Electrical Connectors and Common Plugs, Installation of ................................ ................................ ... 3-3
Electrical Liquid Indicating Systems and Indicators ................................ ................................ ............ 4-3q
Electrical Resistance Temperature Indicators ................................ ................................ ..................... 4-3k
Electrical System Components ................................ ................................ ................................ ........... 3-4
Built-In Test Equipment ................................ ................................ ................................ ................ 3-4j
Electronic Control Units ................................ ................................ ................................ ............... 3-4k
Generators................................ ................................ ................................ ................................ .... 3-4d
Ignition Systems ................................ ................................ ................................ .......................... 3-4n
Inverters ................................ ................................ ................................ ................................ ...... 3-4g, F3-9
Lighting Systems ................................ ................................ ................................ ......................... 3-40
Motors ................................ ................................ ................................ ................................ ......... 3-4l
Overvoltage Protection System ................................ ................................ ................................ ... 34b
Parallel Generators ................................ ................................ ................................ ...................... 3-4c
Relays ................................ ................................ ................................ ................................ ......... 34f
Starters ................................ ................................ ................................ ................................ ........ 3-4h
Storage Battery ................................ ................................ ................................ ............................ 34e
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E - Continued
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I
Ignition System Troubleshooting Chart................................ ................................ ................................ T3-3
Indicator, Airspeed ................................ ................................ ................................ ............................. 4-3e, F4-11
Indicator Tolerances
Direct Reading Pressure Indicator ................................ ................................ ................................ T4-11
Remote Reading Pressure Indicator ................................ ................................ ............................. T4-12
Inspection of Installations of Wires and Cables ................................ ................................ .................. 3-1
Inspection of Instrument Systems ................................ ................................ ................................ ....... 4-3a
Inspection Requirements for Installations of Wires and Cables ................................ ........................... 3-1a
Inspection Requirements, Instruments and Instrument Systems ................................ ......................... 4-3b
Installation Inspection of Wires and Cables ................................ ................................ ........................ 3-1
Bonds ................................ ................................ ................................ ................................ .......... 3-1 k
Circuit Breakers ................................ ................................ ................................ ........................... 3-1 n
Conduits ................................ ................................ ................................ ................................ ...... 3- j
Fuses and Fuse Holders ................................ ................................ ................................ .............. 3-1 h
Inspection Requirements ................................ ................................ ................................ .............. 3-1a
Junctions ................................ ................................ ................................ ................................ ..... 3-1l
Kapton Wiring ................................ ................................ ................................ .............................. 3-1o
Marking of Wires with Marking Machines ................................ ................................ ..................... 3-1f
Replacement Criteria ................................ ................................ ................................ ................... 3-1 b
Splices ................................ ................................ ................................ ................................ ......... 3-11
Terminals and Terminal Blocks ................................ ................................ ................................ .... 3-1g
Toggle Switches ................................ ................................ ................................ ........................... 3-1 m
Wire Identification ................................ ................................ ................................ ........................ 3-1d
Wire Sizes ................................ ................................ ................................ ................................ ... 3-1 c
Wire Stripping ................................ ................................ ................................ .............................. 3-1e
Installation of Electrical Connectors and Common Plugs ................................ ................................ .... 3-3
Inspection of Connectors ................................ ................................ ................................ .............. 3-3b
Installation of Connectors on Wires ................................ ................................ .............................. 3-3c
Types of Connectors ................................ ................................ ................................ .................... 3-3a
Instruments and Instrument System Maintenance ................................ ................................ ............... 4-3
Airspeed Indicators ................................ ................................ ................................ ...................... 4-3e
Altimeters ................................ ................................ ................................ ................................ .... 4-3g, F4-13
Direct Reading Pressure Indicators ................................ ................................ .............................. 4-3h
Electrical Liquid Indicating Systems and Indicators ................................ ................................ ...... 4-3q
Electrical Resistance Temperature Indicators ................................ ................................ ............... 4-3k
Inspection of Instrument Systems ................................ ................................ ................................ 4-3a
Inspection Requirements ................................ ................................ ................................ .............. 4-3b
Magnetic Compass ................................ ................................ ................................ ...................... 4-3o, F4-19
Outside Air Temperature Gauges ................................ ................................ ................................ . 4-3m
Pitot Static System ................................ ................................ ................................ ...................... 4-3c, F4-7
Pitot Static System Heater ................................ ................................ ................................ ........... 4-3d
Position Indicating Systems and Indicators ................................ ................................ .................. 4-3r
Remote Indicating Compass ................................ ................................ ................................ ........ 4-3p
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I – Continued
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P - Continued
Scale Error
Counter Drum Pointer Altimeter ................................ ................................ ................................ ............. T4-6
Three Pointer Altimeter ................................ ................................ ................................ .......................... T4-3
Schematic, of Typical Electrical System ................................ ................................ ................................ .......... F2-4
Scope (of Manual) ................................ ................................ ................................ ................................ ............. 1-2
Scorsby Base ................................ ................................ ................................ ................................ ......... 4-2g, F4-5
Series Circuits ................................ ................................ ................................ ................................ ........ 2-5a, F2-5
Shop Housekeeping
Electrical Shop ................................ ................................ ................................ ................................ ...... 2-1b
Instrument Shop ................................ ................................ ................................ ................................ .... 4-1b
Sizes of Marking Type, Recommended ................................ ................................ ................................ ........... T3-2
Splices ................................ ................................ ................................ ................................ ............................ 3-11
Static Friction Error (Vibrator Inoperative), Counter Drum Pointer Altimeter ................................ .................... T4-9
Subminiature Connectors ................................ ................................ ................................ ................................ F3-5
Switch
Rotary-Selector ................................ ................................ ................................ ................................ .... F3-12
Toggle ................................ ................................ ................................ ................................ ................. F3-10
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S - Continued
Symbols, Charts, and Schematics for Wiring Diagrams ................................ ................................ ..................... 2-4
Symbols, Wiring Diagram ................................ ................................ ................................ ............................... F2-3
Synchronous Rotor Tachometer Wiring Diagram
(Grounded Two-Wire System) ................................ ................................ ................................ ............. F4-15
Synchronous Rotor Tachometer Wiring Diagram
(Ungrounded Three-Wire System) ................................ ................................ ................................ ....... F4-14
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Balance (of Tall Rotor Blades) ................................ ................................ ................................ .......................... 3-9c
Balance Check, Three-Blade ................................ ................................ ................................ ........................... F2-8
Balance Check, Two-Blade ................................ ................................ ................................ ............................. F2-7
Balance, Blade ................................ ................................ ................................ ................................ ................ 3-10
Balancing, Propeller ................................ ................................ ................................ ................................ ........ 2-13
Bends and Twists ................................ ................................ ................................ ................................ ........... 2-12c
Blade Balance ................................ ................................ ................................ ................................ ................. 3-10
General ................................ ................................ ................................ ................................ ................ 3-10a
Mass Balance Weights (Bars) ................................ ................................ ................................ ............... 3-10b
Spanwise Balance Weights ................................ ................................ ................................ ................... 3-10c
Tracking Weights................................ ................................ ................................ ................................ ...3-10d
Trim Tabs ................................ ................................ ................................ ................................ .............3-10e
Blade Classification Data (Main Rotor Blades) ................................ ................................ ................................ 3-7d
Blade Construction (Main Rotor Blades) ................................ ................................ ................................ ........... 3-7c
Blade Flapping Action (Vertical Plane) ................................ ................................ ................................ ............ F3-7
Blade Leading and Lagging (Horizontal Plane) ................................ ................................ ................................ F3-8
Blade Tracking ................................ ................................ ................................ ................................ ............... 2-13d
Blade Tracking, Electronic, Equipment ................................ ................................ ................................ .......... F3-12
Blade Tracking, Reflector ................................ ................................ ................................ .............................. F3-13
Blade, Rotor, Repair ................................ ................................ ................................ ................................ ........ 3-12
Blade, Rotor, Tracking ................................ ................................ ................................ ......................... 3-17, F3-11
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C - Continued
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R - Continued
Rotor Hub, Main, and Blade Assembly ................................ ................................ ................................ .......... F3-10
Rotor Maintenance Practices and Procedures, General ................................ ................................ ..................... 3-1
Rotor Removal, Cleaning, and Inspection ................................ ................................ ................................ ....... 3-11
Cleaning ................................ ................................ ................................ ................................ ............... 3-11b
Inspection ................................ ................................ ................................ ................................ ............. 3-11c
Removal ................................ ................................ ................................ ................................ ............... 3-11a
Rotor Systems, Principles of Operation and Design Features of ................................ ................................ ........ 3-3
Rotor, Fully Articulated, Head ................................ ................................ ................................ ......................... F3-6
Rotor, Main, Blades................................ ................................ ................................ ................................ ............ 3-7
Rotor, Single, Configuration ................................ ................................ ................................ ............................ F3-2
Rotor, Tail, Blades ................................ ................................ ................................ ................................ ............ 3-9
Rotor, Tail, Hubs ................................ ................................ ................................ ................................ ............... 3-8
Rotor, Tandem, Configuration ................................ ................................ ................................ ......................... F3-3
RPM Adjusting Screw Propeller ................................ ................................ ................................ ..................... F2-11
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Figure, Table
Number
Acrylic Monomer and Polymer Base Adhesive, MIL-A-8576, Type II, Non-Solvent .......................... 6-2c
Acrylic Monomer and Polymer Base Adhesive, MIL-A-8576, Type II,
Non-Solvent, Shelf life ............................................................................................................ T6-3
Acrylic Monomer and Polymer Base Adhesive, MIL-A-8576, Type I, Solvent Type.......................... 6-2b
Acrylic Monomer and Polymer Base Adhesive, MIL-A-8576, Type I, Solvent Type.......................... T6-1
Adhesive and Cements ...................................................................................................................... 6-2
Acrylic Monomer Base Adhesive, MIL-A-8576, Type I, Solvent Type .................................. 6-2c
Cement Primer ...................................................................................................................... 6-21
Cement Types....................................................................................................................... 6-2a
Chemigum Coating Cement.................................................................................................. 6-2d
Colored Cement .................................................................................................................... 6-2e
Compos ite Adhesives ........................................................................................................... 6-2m
Deic er Repair Cement........................................................................................................... 6-2k
Deicer Shoe Electrical Conducting Neoprene Surface Coat Cement................................... 6-2f
General Purpose Synthetic Rubber Base Cement MIL-Spec MMM-1617 ........................... 6-2g
Natural Base Rubber Adhesive, MIL-Spec MMM-A-139, Class 3 ........................................ 6-2i
Neoprene Base Synthetic Rubber Cement........................................................................... 6-2j
Non-Hardening Distic Brand Cement.................................................................................... 6-2h
Other Adhesives.................................................................................................................... 6-2n
Adhesives and Cements, Specific Gravity Ranges .......................................................................... T6-2
Adhesives, Sealants, and Cements, General .................................................................................... 6-1
Curing .................................................................................................................................... 6-1d
Mixing .................................................................................................................................... 6-1c
Precautionary Measures ....................................................................................................... 6-1a
Preparation of Surface ....................................................................................................... .. 6-1b
Airframe Castle Nuts .......................................................................................................................... F2-22
Airframe Plain Nuts ............................................................................................................................ 2-3j, F2-28
Alloys
Magnesium ............................................................................................................................ 4-3
Steel ...................................................................................................................................... 4-5,T4-11
Titanium ................................................................................................................................ 4-4
Aluminum Alloy Designation Conversions (Old To New)................................................................... T4-2
Aluminum Alloy Temper Designations ............................................................................................... T4-3
Aluminum Alloy Types........................................................................................................................ T4-6
Aluminum Alloys................................................................................................................................. 4-2
Handling ................................................................................................................................ 4-2b
Identific ation .......................................................................................................................... 4-2a
Storage .................................................................................................................................. 4-2c
Aluminum Alloys, Designation for Alloy Groups................................................................................. T4-1
Aluminum Bolts .................................................................................................................................. 2-2n
Anaerobic Adhesive MIL-R-46082 ..................................................................................................... 6-31
Anchor Nuts, Floating......................................................................................................................... F2-17
Application Time (Room Temperature), Sealing Compound PR-1826 B1/2 ..................................... T6-4
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F - Continued
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Identification
of Aluminum Alloys ................................ ................................ ................................ ................................ 4-2a
of Hose ................................ ................................ ................................ ................................ .................. F3-1
of Magnesium Alloys ................................ ................................ ................................ ..................... 4-3a, T4-7
of Nuts ................................ ................................ ................................ ................................ ................... 2-31
of Phenolic Compositions ................................ ................................ ................................ ...................... 5-2a
of Plastic Materials ................................ ................................ ................................ ....................... 5-3a, T5-1
of Rubber Materials ................................ ................................ ................................ ............................... T3-3
of Steel ................................ ................................ ................................ ................................ ................ T4-10
of Steel Alloys ................................ ................................ ................................ ................................ ........ 4-4a
of Steels, SAE Numbers Used in ................................ ................................ ................................ ........... T4-8
of Tie Rods ................................ ................................ ................................ ................................ ...........2-13a
of Titanium and Titanium Alloys ................................ ................................ ................................ .............. 4-5c
Insert Tolerance (for Helical Inserts) ................................ ................................ ................................ .............. 2-l11c
Inspection Criteria for Helical Springs ................................ ................................ ................................ .............2-11d
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I - Continued
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National Fine Thread Sizes (for Helical Inserts) ................................ ................................ ............................. T2-14
Natural Rubber Adhesive, MIL-Spec MMM-A-139, Class 3 ................................ ................................ ................ 6-2i
Neoprene Base Synthetic Rubber Cement ................................ ................................ ................................ ........6-2j
Non-Hardening Distic Brand Cement ................................ ................................ ................................ ............... 6-2h
Numbering System, CherryMAX Rivets ................................ ................................ ................................ ......... T2-10
Nut Installation Limits, Self-Locking ................................ ................................ ................................ ............... F2-21
Nuts ................................ ................................ ................................ ................................ ................................ . 2-3
Airframe Plain Nuts ................................ ................................ ................................ ...................... 2-3j, F2-28
Castellated Nuts ................................ ................................ ................................ ................................ .... 2-3b
Checknuts................................ ................................ ................................ ................................ ................ 2-3c
Identification of Nuts ................................ ................................ ................................ ................................ .2-3i
Internal Wrenching Nuts ................................ ................................ ................................ ......................... 2-3h
Jamnuts................................ ................................ ................................ ................................ .................. 2-3d
Light Hexagon Nuts ................................ ................................ ................................ .................... 2-3e, F2-25
Self-Locking Nuts . ................................ ................................ ................................ ................................ . 2-3a
Sheet Spring Nuts ................................ ................................ ................................ ....................... 2-3g, F2-27
Wingnuts ................................ ................................ ................................ ................................ ...... 2-3f, F2-26
Oil Caps, Drain Cocks, and Valves, Lockwiring of ................................ ................................ ......................... F2-79
Oil Cell Identification ................................ ................................ ................................ ................................ ........3-4c
Oil Cell Storage................................ ................................ ................................ ................................ ................ 3-4d
Old and New Color Code (for Aluminum Alloys), Cross Reference ................................ ................................ .. T4-5
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O - Continued
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Recommended Changes to Department of the Army Publications ................................ ................................ ..... 1-6
Recommended Torque Values ................................ ................................ ................................ ....................... 2-18c
Recommended Torque Values, Nut ................................ ................................ ................................ ................. T2-9
Removal of Bent, Damaged, or Broken Studs ................................ ................................ ................................ 2-10a
Removal of Helical Insert ................................ ................................ ................................ ............................... 2-11f
Removal of Twinsert ................................ ................................ ................................ ................................ .......2-11j
Removal, Stud ................................ ................................ ................................ ................................ .............. F2-64
Repair of Damaged Spark Plug Threads ................................ ................................ ................................ ........2-11g
Responsibilities
of AVSCOM ................................ ................................ ................................ ................................ ............. 1-5
of Maintenance Activities ................................ ................................ ................................ ......................... 1-4
Rivet, Cherry MAX ................................ ................................ ................................ ................................ ........ F2-55
Rivet, Huck ................................ ................................ ................................ ................................ ................... F2-57
Rivets ................................ ................................ ................................ ................................ .................... 2-8, F2-53
Blind Rivets ................................ ................................ ................................ ................................ .............2-8i
Common Solid Shank Rivets ................................ ................................ ................................ ................. 2-8a
Corrosion Resistance ................................ ................................ ................................ ............................. 2-8d
General Usage ................................ ................................ ................................ ................................ ........2-8c
Heat Treatment ................................ ................................ ................................ ................................ ....... 2-8f
Hi-Shear Rivets ................................ ................................ ................................ .......................... 2-8h, F2-54
Materials Used in Fabrication ................................ ................................ ................................ ................. 2-8b
Rivnuts ................................ ................................ ................................ ................................ .................... 2-8j
Strength ................................ ................................ ................................ ................................ ................. 2-8e
Rivets, Cherrylock ................................ ................................ ................................ ................................ ......... F2-56
Rivnut Types ................................ ................................ ................................ ................................ ................. F2-58
Rivnuts ................................ ................................ ................................ ................................ .............................. 2-8j
Rod End Safetying (Key Type NAS 559) ................................ ................................ ............................. 2-17h, F2-82
Rubber Materials
General ................................ ................................ ................................ ................................ ................... 3-1
Identification ................................ ................................ ................................ ................................ .......... T3-3
Inspection ................................ ................................ ................................ ................................ .............. 3-1b
Storage ................................ ................................ ................................ ................................ .................. 3-1a
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S – Continued
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T - Continued
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C - Continued
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E - Continued
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G - Continued
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M - Continued
Operation (Eddy Current Test Set) ................................ ................................ ................................ .................. 7-5a
Operative Precautions ................................ ................................ ................................ ................................ ..... 3-7b
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P - Continued
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S - Continued
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Aluminum Alloys, Typical Machine Setting for Spot Welding ................................ ................................ ........... T3-4
Aluminum Arc Welding ................................ ................................ ................................ ................................ ... 3-5d
Aluminum Gas Welding ................................ ................................ ................................ ................................ ....3-5c
Aluminum Spot Welding ................................ ................................ ................................ ................................ .. 3-5e
Aluminum Welding. ................................ ................................ ................................ ................................ ............ 3-5
Arc Welding ................................ ................................ ................................ ................................ ........... 3-5d
Cleaning ................................ ................................ ................................ ................................ ................ 3-5b
Gas Welding ................................ ................................ ................................ ................................ ........... 3-5c
Spot Welding ................................ ................................ ................................ ................................ ......... 3-5e
Types of Alloys ................................ ................................ ................................ ................................ ...... 3-5a
Arc Welding Defects, Causes, and Remedies ................................ ................................ ................................ . T3-3
Arc Welding Magnesium ................................ ................................ ................................ ................................ . T3-6
Bandsaws
Care and Use ................................ ................................ ................................ ................................ ......... 2-4b
Cutoff-Type ................................ ................................ ................................ ................................ ........... F2-3
Vertical-Contour Type ................................ ................................ ................................ ............................ F2-2
Bearing Roll Staking ................................ ................................ ................................ ................................ ........ 2-6e
Brazing ................................ ................................ ................................ ................................ ............................ 3-9a
Brazing and Silver Soldering ................................ ................................ ................................ ............................. 3-9
Brazing ................................ ................................ ................................ ................................ .................. 3-9a
Post Brazing and Silver Soldering Cleaning ................................ ................................ ............................ 3-9c
Silver Soldering ................................ ................................ ................................ ................................ ..... 3-9b
Brush Method of Starting Electric Arc ................................ ................................ ................................ .............. F3-5
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C - Continued
Distinguishing Corrosion-Resistant Steels and Nickel-Base Alloys ................................ ................................ ... 3-7a
Drill Press ................................ ................................ ................................ ................................ ....................... F2-1
Drilling Machines
Care and Use ................................ ................................ ................................ ................................ ......... 2-4a
Safety Precautions ................................ ................................ ................................ ................................ . 2-3a
Special Operations on ................................ ................................ ................................ .............................. 2-6
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Number
I
Inert-Arc Welding of Corrosion-Resistant Steels and Nickel-
Base Alloys, Relation Between Sheet Thickness and Current Required for................................ ............. T3-9
Introduction
Consumable Materials ................................ ................................ ................................ .............................. 1-3
Purpose................................ ................................ ................................ ................................ .................... 1-1
Scope ................................ ................................ ................................ ................................ ....................... 1-2
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M - Continued
Portable Machine Tools, Safety Precautions ................................ ................................ ................................ .... 2-3g
Post Brazing and Silver Soldering Cleaning ................................ ................................ ................................ ......3-9c
Purpose of Manual................................ ................................ ................................ ................................ ............. 1-1
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R - Continued
Responsibility
Machine Shop Rules, for................................ ................................ ................................ ......................... 2-2a
Welding Shop Rules, for ................................ ................................ ................................ ......................... 3-2a
Rod Information, Welding ................................ ................................ ................................ ................................ T3-2
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T - Continued
Welding Equipment
Electric Arc ................................ ................................ ................................ ................................ ............. F3-2
Gas................................ ................................ ................................ ................................ ......................... F3-1
Schematic ................................ ................................ ................................ ................................ .............. F3-3
Welding, Arc; Defects, Causes, and Remedies ................................ ................................ ................................ T3-3
Welding Materials ................................ ................................ ................................ ................................ .............. 3-4
Electrodes ................................ ................................ ................................ ................................ .............. 3-4a
Fluxes................................ ................................ ................................ ................................ ...................... 3-4c
Welding Rods ................................ ................................ ................................ ................................ ......... 3-4b
Welding on Aircraft ................................ ................................ ................................ ................................ ............ 3-8
Welding Rod Information ................................ ................................ ................................ ................................ . T3-2
Welding Rods ................................ ................................ ................................ ................................ .................. 3-4b
Welding Shop Practices
Aluminum Welding ................................ ................................ ................................ ................................ ... 3-5
Brazing and Silver Soldering................................ ................................ ................................ ..................... 3-9
Corrosion-Resistant Steel and Nickel Chromium Alloy Welding ................................ ................................ 3-7
General ................................ ................................ ................................ ................................ .................... 3-1
Magnesium Welding ................................ ................................ ................................ ................................ . 3-6
Shop Rules................................ ................................ ................................ ................................ ............... 3-2
Types of Welding................................ ................................ ................................ ................................ ...... 3-3
Welding Materials ................................ ................................ ................................ ................................ ..... 3-4
Welding on Aircraft ................................ ................................ ................................ ................................ ... 3-8
Welding Stresses and Distortion, Corrosion-Resistant Steels and Nickel
Chromium Alloy Welding ................................ ................................ ................................ ......................... 3-7f
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Cable Rigging Tension Chart, Typical ................................ ................................ ................................ .............. F7-7
Cable Tensionmeter................................ ................................ ................................ ................................ ........... 7-3
Calibration, Repair and................................ ................................ ................................ ................................ ....... 8-8
Calipers................................ ................................ ................................ ................................ .............................. 3-8
Slide ................................ ................................ ................................ ................................ ..................... F3-28
Vernier................................ ................................ ................................ ................................ .................. F3-29
Calipers, Hermaphrodite ................................ ................................ ................................ ................................ F3-27
Calipers, Simple................................ ................................ ................................ ................................ ............. F3-24
Calipers, Spring-Joint................................ ................................ ................................ ................................ ..... F3-25
Calipers, Transfer................................ ................................ ................................ ................................ ........... F3-26
Care of Torque Tools ................................ ................................ ................................ ................................ ......... 8-6
Carpenters Square................................ ................................ ................................ ................................ ......... F3-10
Carriage Clamp................................ ................................ ................................ ................................ .............. F4-55
Carriage Clamp, Using................................ ................................ ................................ ................................ ... F4-56
Center Head, Setting the................................ ................................ ................................ ................................ F3-14
Center Punch................................ ................................ ................................ ................................ ................. F4-50
Center Punch for Drilling ................................ ................................ ................................ ................................ F4-84
Check and Chuck Key, Three-Jaw................................ ................................ ................................ .................... F6-3
Checkered Flags, Reflectorizing and................................ ................................ ................................ .................. 9-4
Checking Angle................................ ................................ ................................ ................................ .............. F3-19
Checking Diameters, Snap Gauge for ................................ ................................ ................................ ............ F3-64
Checking Dimension Between Surfaces, Snap Gauge for ................................ ................................ .............. F3-62
Checking Flat or Cylindrical Work, Snap Gauge for................................ ................................ ........................ F3-63
Checking Propeller Shaft Run Out................................ ................................ ................................ .................. F3-76
Chisels................................ ................................ ................................ ................................ ........................... F4-57
Chisels, Cold................................ ................................ ................................ ................................ ...................... 4-9
Clamp, Carriage................................ ................................ ................................ ................................ ............. F4-55
Clamping Devices ................................ ................................ ................................ ................................ .............. 4-8
Bench Vise ................................ ................................ ................................ ................................ ........... F4-53
Cleaner, File ................................ ................................ ................................ ................................ .................. F4-79
Cleaning Gun, Air Blow ................................ ................................ ................................ ................................ .. F5-13
Cleaning Guns ................................ ................................ ................................ ................................ ................... 5-5
Cleaning Solvent Gun ................................ ................................ ................................ ................................ .... F5-12
Cold Chisels................................ ................................ ................................ ................................ ....................... 4-9
Combination Flaring Tools ................................ ................................ ................................ ........................... F4-120
Combination Square ................................ ................................ ................................ ................................ ...... F3-11
Combination Wrench ................................ ................................ ................................ ................................ ..... F4-24
Common Screwdriver................................ ................................ ................................ ................................ ..... F4-13
Concentric Torque Wrench Attachments ................................ ................................ ................................ ........ F8-15
Consumable Materials................................ ................................ ................................ ................................ ........ 1-3
Control Surface Angle, Measuring at Full Throw................................ ................................ ............................... F7-3
Conversion of Tensiometer Reading in Pounds................................ ................................ ................................ F7-6
Correct and Incorrect Stroke Technique ................................ ................................ ................................ ........... F5-5
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C - Continued
Correct Drill Sizes for Tapping ................................ ................................ ................................ ..................... F4-102
Correct GO Dimension for Cylindrical Part ................................ ................................ ................................ ..... F3-68
Correct NO-GO Dimension for Cylindrical Part................................ ................................ ............................... F3-69
Cotter Pin Extractor................................ ................................ ................................ ................................ . 7-7, F7-11
Cranes and Hoists, Typical................................ ................................ ................................ ............................. F9-18
Crossfiling ................................ ................................ ................................ ................................ ...................... F4-76
Crowfoot Wrench ................................ ................................ ................................ ................................ ........... F7-20
Crowfoot Wrench, Using a ................................ ................................ ................................ ............................. F7-21
Crowfoot Wrenches................................ ................................ ................................ ................................ .......... 7-15
Curved Tooth File ................................ ................................ ................................ ................................ .......... F4-74
Cutters, Pipe ................................ ................................ ................................ ................................ ................ F4-114
Cutters, Tube ................................ ................................ ................................ ................................ ............... F4-115
Cutting Edge and Heel Angles, Usual................................ ................................ ................................ ............. F4-86
Cutting Edge, Hand Grinding of................................ ................................ ................................ ...................... F4-87
Cutting Edge, Hand Grinding of Heel to................................ ................................ ................................ .......... F4-88
Cutting, Flush................................ ................................ ................................ ................................ ............... F4-113
Cutting Tube with Tube Cutter................................ ................................ ................................ .......................... 4-23
Cutting Wire ................................ ................................ ................................ ................................ ................. F4-112
Cylinder, Locating Diameter of ................................ ................................ ................................ ....................... F3-15
Cylinder, Marking Diameter of ................................ ................................ ................................ ........................ F3-16
Cylindrical Part, Correct GO Dimension for ................................ ................................ ................................ .... F3-68
Cylindrical Part, Correct NO-GO Dimension for................................ ................................ .............................. F3-69
Cylindrical Part, Placing Snap Gauge on................................ ................................ ................................ ........ F3-67
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D - Continued
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F - Continued
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M - Continued
Paint Gun with Thinner or Solvent (Cup), Flushing ................................ ................................ ........................... F5-7
Paint Gun with Thinner or Solvent (Pressure Tank or
Gravity Bucket), Flushing................................ ................................ ................................ ........................ F5-8
Paint Gun, Soaking ................................ ................................ ................................ ................................ .......... F5-9
Paint Gun, Typical................................ ................................ ................................ ................................ ............ F5-1
Paint Guns ................................ ................................ ................................ ................................ ......................... 5-3
Painting Requirements................................ ................................ ................................ ................................ ....... 9-3
Parts of a Micrometer................................ ................................ ................................ ................................ ..... F3-41
Pattern, Spray ................................ ................................ ................................ ................................ .................. F5-2
Phillips Screwdriver................................ ................................ ................................ ................................ ........ F4-14
Pickler, Pre-Oiler and ................................ ................................ ................................ ................................ ..... F9-19
Pin Punch ................................ ................................ ................................ ................................ ...................... F4-62
Pin Spanner Wrench ................................ ................................ ................................ ................................ ...... F4-37
Pinchers, Nippers and................................ ................................ ................................ ......................... 4-22, F4-111
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P - Continued
Pipe and Tube Cutters ................................ ................................ ................................ ................................ ..... 4-23
Pipe Cutters ................................ ................................ ................................ ................................ ................. F4-114
Placing Snap Gauge on Cylindrical Part................................ ................................ ................................ ......... F3-67
Pliers ................................ ................................ ................................ ................................ ................................ . 4-5
Deicer Boot................................ ................................ ................................ ................................ ............. 7-12
Lockwire ................................ ................................ ................................ ................................ ...... 7-11, F7-16
Pliers, Diagonal Cutting................................ ................................ ................................ ................................ .. F4-42
Pliers, Flat Nose................................ ................................ ................................ ................................ ............. F4-44
Pliers, Long-Nose................................ ................................ ................................ ................................ ........... F4-43
Pliers, Retaining Ring................................ ................................ ................................ ................................ ..... F4-40
Pliers, Round-Nose ................................ ................................ ................................ ................................ ........ F4-45
Pliers, Slip-Joint. ................................ ................................ ................................ ................................ ............ F4-41
Pliers, Vise-Grip ................................ ................................ ................................ ................................ ............. F4-47
Pliers, Water Pump ................................ ................................ ................................ ................................ ........ F4-46
Plug Gauges ................................ ................................ ................................ ................................ ......... F3-54, 3-14
Plug, Three-Prong Grounded ................................ ................................ ................................ ........................... F6-1
Plumb Bobs ................................ ................................ ................................ ................................ .............. 3-3, F3-6
Plumb Bobs, Polished Brass ................................ ................................ ................................ ............................ F3-6
Plumb Bobs, Solid Steel................................ ................................ ................................ ................................ ... F3-6
Pneumatic Drill................................ ................................ ................................ ................................ ................... 5-7
Pneumatic Drills ................................ ................................ ................................ ................................ ............. F5-15
Pneumatic Grinder ................................ ................................ ................................ ................................ .. 5-8, F5-16
Pneumatic Hammer. ................................ ................................ ................................ ............................... 5-9, F5-17
Pneumatic Tools ................................ ................................ ................................ ................................ ................ 5-1
Pneumatic Vacuum Cleaner................................ ................................ ................................ .................... 5-6, F5-14
Pocket Knives ................................ ................................ ................................ ................................ ................ F4-51
Polished Brass Plumb Bobs ................................ ................................ ................................ ............................. F3-6
Portable Power Supply................................ ................................ ................................ ................................ ... F9-23
Power Application of Force When Using Extension ................................ ................................ ........................ F8-18
Power Supply, Portable................................ ................................ ................................ ................................ .. F9-23
Power Wrench Torque Multiplier ................................ ................................ ................................ .................... F8-23
Practices and Procedures, Safety................................ ................................ ................................ ....................... 9-2
Practices, Shop................................ ................................ ................................ ................................ .................. 2-8
Pre-Oiler and Pickler ................................ ................................ ................................ ................................ ...... F9-19
Precautions, Safety ................................ ................................ ................................ ................................ ............ 5-2
Preload Indicating Washers................................ ................................ ................................ ............................ F8-29
Preload Indicating Washers, Torque Procedures Without a Torque Wrench................................ ..................... 8-11
Preset Torque Screwdriver................................ ................................ ................................ ............................... F8-1
Prick Punch................................ ................................ ................................ ................................ .................... F4-58
Progressive Snap Gauge ................................ ................................ ................................ ............................... F3-61
Propeller Shaft Runout, Checking ................................ ................................ ................................ .................. F3-76
Propeller Shaft, Dial Indicator Installed on................................ ................................ ................................ ...... F3-75
Proper Fit of Screwdrivers................................ ................................ ................................ .............................. F4-17
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Proper Procedure for Pulling Adjustable Wrenches ................................ ................................ ........................ F4-35
Proper Way to Hold a Hacksaw................................ ................................ ................................ .................... F4-100
Protractor ................................ ................................ ................................ ................................ .................. 7-2, F7-1
Protractor Adjustment Screws, Loosening................................ ................................ ................................ ...... F3-18
Protractor Head on Rule, Installing................................ ................................ ................................ ................. F3-17
Protractor, Bevel ................................ ................................ ................................ ................................ ............ F3-12
Protractor, Setting, with Flight Control Surface in Neutral Position ................................ ................................ ... F7-2
Punch, Automatic Center ................................ ................................ ................................ ............................... F4-60
Punch, Center ................................ ................................ ................................ ................................ ................ F4-59
Punch, Drive ................................ ................................ ................................ ................................ .................. F4-61
Punch, Hollow ................................ ................................ ................................ ................................ ................ F4-64
Punch, Leather................................ ................................ ................................ ................................ ................. 7-13
Punch, Pin ................................ ................................ ................................ ................................ ..................... F4-62
Punch, Prick................................ ................................ ................................ ................................ ................... F4-58
Punch, Transfer ................................ ................................ ................................ ................................ ............. F4-63
Punches................................ ................................ ................................ ................................ ........................... 4-10
Purpose
of Manual ................................ ................................ ................................ ................................ ................. 1-1
Putty Knife ................................ ................................ ................................ ................................ ..................... F4-52
Tools on Army Aircraft ................................ ................................ ................................ .............................. 2-5
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Repair
and Calibration ................................ ................................ ................................ ................................ ......... 8-8
Tool, Valve ................................ ................................ ................................ ................................ .... 7-6, F7-10
Rigid Frame Torque Wrench ................................ ................................ ................................ ............................ F8-3
Ring Gauge Types ................................ ................................ ................................ ................................ ......... F3-57
Ring Gauges................................ ................................ ................................ ................................ .................... 3-15
Tolerances................................ ................................ ................................ ................................ .............. T3-1
Ring Gauges, Using ................................ ................................ ................................ ................................ ....... F3-58
Riveting Hammer ................................ ................................ ................................ ................................ ............. F4-3
Roller, Deicer Boot ................................ ................................ ................................ ................................ ........... 7-14
Round File ................................ ................................ ................................ ................................ ..................... F4-72
Round-Nose Pliers ................................ ................................ ................................ ................................ ......... F4-45
Rubber Mallet................................ ................................ ................................ ................................ ................... F4-8
Rule Depth Gauge ................................ ................................ ................................ ................................ ......... F3-47
Rule, Typical ................................ ................................ ................................ ................................ .................... F3-9
Rules, Tapes and................................ ................................ ................................ ................................ ............... 3-5
Safety
Electrical Power Tools ................................ ................................ ................................ .............................. 6-2
Precautions................................ ................................ ................................ ................................ ............... 5-2
Tool ................................ ................................ ................................ ................................ .......................... 2-7
Safety Practices and Procedures................................ ................................ ................................ ........................ 9-2
Schematic Diagram, Jack Hydraulic ................................ ................................ ................................ ................. F9-6
Scope of Manual ................................ ................................ ................................ ................................ ................ 1-2
Screwdriver Tip Grinding................................ ................................ ................................ ................................ F4-19
Screwdriver, Offset ................................ ................................ ................................ ................................ ........ F4-15
Screwdriver, Phillips................................ ................................ ................................ ................................ ....... F4-14
Screwdriver, Preset Torque................................ ................................ ................................ .............................. F8-1
Screwdrivers ................................ ................................ ................................ ................................ ...................... 4-3
Screwdrivers, Common ................................ ................................ ................................ ................................ .. F4-13
Screwdrivers, Proper Fit of................................ ................................ ................................ ............................. F4-17
Screwdrivers, Ratchet ................................ ................................ ................................ ................................ .... F4-16
Scribers................................ ................................ ................................ ................................ .............................. 3-4
Scribers, Mechanist's ................................ ................................ ................................ ................................ ....... F3-7
Scribing a Circle with Dividers ................................ ................................ ................................ ........................ F3-23
Scribing with an Awl ................................ ................................ ................................ ................................ ....... F4-49
Selection, Torque Wrench................................ ................................ ................................ ................................ .. 8-3
Self-Contained Jack, 10-Ton ................................ ................................ ................................ .......................... F9-11
Servicing Unit, Nitrogen ................................ ................................ ................................ ................................ . F9-17
Servicing Unit, Oxygen ................................ ................................ ................................ ................................ .. F9-24
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Aluminum Alloy, Hardness Conversion for ................................ ................................ ................................ ..... F5-16
Aluminum and Aluminum Alloys ................................ ................................ ................................ ......................... 5-7
Aging Time and Temperature ................................ ................................ ................................ .................. 5-7f
Alloy Characteristics and Uses................................ ................................ ................................ ................ 5-7b
Aluminum Alloy Sheet Substitution ................................ ................................ ................................ ...........5-7i
Corrosion Resistance................................ ................................ ................................ ............................... 5-7c
Heat-Treatment Methods ................................ ................................ ................................ ........................ 5-7e
Heat-Treating Procedures................................ ................................ ................................ ....................... 5-7g
Identification ................................ ................................ ................................ ................................ ........... 5-7a
Insulation of Dissimilar Metals ................................ ................................ ................................ ................ 5-7h
Material Substitution ................................ ................................ ................................ ................................ .5-7j
Shop Working Practice ................................ ................................ ................................ ........................... 5-7d
Aluminum, Bare, Sheet, Plate, Extrusions, and Forgings, Rockwell Hardness Values for ............................... T5-21
Aluminum Identification Marking Example ................................ ................................ ................................ ........ F5-7
Aluminum Lockbolt Rivet Gun, Pull- and Blind-Type ................................ ................................ ...................... F7-73
Aluminum Sheet and Plate, 0.050 Inch Minimum, Rockwell Hardness Values for................................ ........... T5-20
Aluminum, Model B, Hardness Range................................ ................................ ................................ ............ F5-13
Aluminum-Alloy Sheet Substitution ................................ ................................ ................................ ................ T5-14
Annealing................................ ................................ ................................ ................................ ...................... 10-10c
Application (of Adhesives and Resins) ................................ ................................ ................................ ............. 9-4e
Approved Edge Attachment for Laminated Enclosure................................ ................................ ................... F10-19
Approved Edge Attachment for Monolithic Enclosure ................................ ................................ ................... F10-18
Ashing................................ ................................ ................................ ................................ ........................... 10-14b
Assembling (Joined Plastics)................................ ................................ ................................ ........................... 10-9h
Assembly Tools, Cherry ................................ ................................ ................................ ................................ . F7-45
Assembly, Empennage ................................ ................................ ................................ ................................ .. F4-14
Automatic Center Punch ................................ ................................ ................................ ................................ F3-18
Aviation Snips ................................ ................................ ................................ ................................ ........ 3-4f, F3-12
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Cabin and Tail Cone Sections ................................ ................................ ................................ .......................... F4-4
Calculation Method (of Balancing)................................ ................................ ................................ .................. F11-8
Camlock Fastener................................ ................................ ................................ ................................ ........ F7-107
Camlock Fasteners ................................ ................................ ................................ ................................ .........7-15b
Camlock Punch, Use of................................ ................................ ................................ ................................ F7-109
Camlock Stud Installation................................ ................................ ................................ ............................. F7-112
Capacity, Tool, Chart (for Rivets) ................................ ................................ ................................ ................... T7-14
Catcher Bag, Stem 670A20................................ ................................ ................................ ............................ F7-44
Cemented Assemblies, Jigs for Holding ................................ ................................ ................................ ......... F10-9
Cemented Joint, Effect of Heat Treating on a ................................ ................................ ............................... F10-10
Cemented Plastic Joint ................................ ................................ ................................ ................................ . F 10-4
Cementing Procedures................................ ................................ ................................ ................................ ..... 10-9
Assembling................................ ................................ ................................ ................................ ............10-9h
Direct Application Method ................................ ................................ ................................ ...................... 10-9d
Fitting ................................ ................................ ................................ ................................ .................... 10-9e
Glue Method................................ ................................ ................................ ................................ .......... 10-9c
Jigs................................ ................................ ................................ ................................ ......................... 10-9i
Masking................................ ................................ ................................ ................................ ................. 10-9f
Soak Method ................................ ................................ ................................ ................................ .........10-9b
Soaking ................................ ................................ ................................ ................................ ................. 10-9g
Type of Cement ................................ ................................ ................................ ................................ .....10-9a
Center Punch................................ ................................ ................................ ................................ ................. F3-17
Center Punch for Drilling ................................ ................................ ................................ ................................ F7-15
Center Punch, Automatic ................................ ................................ ................................ ............................... F3-18
Centering Inner Sleeve in Steel Tube................................ ................................ ................................ ............. F8-68
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Damage, Class III (of Fiber Laminate)................................ ................................ ................................ ............ F9-21
Damaged Face Plies, Removal of, by Scarf Method ................................ ................................ ...................... F9-25
Damaged Honeycomb Skin................................ ................................ ................................ .............................. F9-1
Damaged Swage in Aileron and Flap Skin, Patch Repair to................................ ................................ ............ F8-58
Deburring, After................................ ................................ ................................ ................................ .............. F7-50
Deep Scratches, Sanding................................ ................................ ................................ ............................. F10-11
Delamination and Discoloration................................ ................................ ................................ ..................... 10-12e
Dent at a Steel Tube Cluster Joint, Reinforcing a ................................ ................................ ........................... F8-65
Dent or Crack, Sharp, in Length of Steel Tubing, Repair of ................................ ................................ ............ F8-66
Dents (in Sandwich Construction)................................ ................................ ................................ ..................... 9-5e
Dents and Creases, Repair of................................ ................................ ................................ ......................... F8-32
Design (Sandwich Construction)................................ ................................ ................................ ...................... 9-1 b
Determining Rivnut Grip Length ................................ ................................ ................................ ..................... F7-57
Die, Joggling ................................ ................................ ................................ ................................ .................. F6-30
Dimensions, Drill Bit ................................ ................................ ................................ ................................ ....... F7-16
Dimpling and Reaming................................ ................................ ................................ ................................ ... F7-48
Dimpling................................ ................................ ................................ ................................ ........................... F7-9
Dimpling, Coin ................................ ................................ ................................ ................................ ............... F7-10
Direct Application Method (Cementing) ................................ ................................ ................................ ...........10-9d
Double Face Patch Repair, Completed ................................ ................................ ................................ .......... F9-27
Double Row of Rivets, Rivet Spacing for Repair with ................................ ................................ ..................... F8-42
Double Skin Damage ................................ ................................ ................................ ................................ ....... 9-5h
Double Skin Repair (Flush) ................................ ................................ ................................ ............................ F9-10
Double Skin Repair (Nonflush) ................................ ................................ ................................ ....................... F9-11
Drill Angle for Stainless Steel ................................ ................................ ................................ ........................... F6-1
Drill Bit Dimensions ................................ ................................ ................................ ................................ ........ F7-16
Drill for Acrylic Plastics................................ ................................ ................................ ................................ ... F10-3
Drill Press ................................ ................................ ................................ ................................ ...................... F3-29
Drill Sizes for Various Diameter Rivets ................................ ................................ ................................ ............. T7-4
Drill Sizes, Hole and, for Self-Plugging (Friction Lock) Rivets ................................ ................................ ........... T7-8
Drilling (for Olympic Blind Rivets) ................................ ................................ ................................ ................... 7-11d
Drilling (Plastics) ................................ ................................ ................................ ................................ ............. 10-8f
Drilling Dimensions, CherryMAX ................................ ................................ ................................ .................... T7-15
Drilling Material ................................ ................................ ................................ ................................ .............. F7-68
Drilling Procedures for Blind-Type Lockbolts ................................ ................................ ................................ .. T7-30
Drilling Procedures for Pull- and Stump-Type Lockbolts ................................ ................................ ................. T7-29
Drilling Spotwelds................................ ................................ ................................ ................................ ............. 12-2
Drilling, Burrs After ................................ ................................ ................................ ................................ ......... F7-49
Drilling, Center Punch for ................................ ................................ ................................ ............................... F7-15
Drills and Drill Presses ................................ ................................ ................................ ................................ ..... 3-5e
Drive Punch ................................ ................................ ................................ ................................ ................... F3-19
Driving Hi-Shear Rivet ................................ ................................ ................................ ................................ ... F7-63
Ductility ................................ ................................ ................................ ................................ ............................. 5-2f
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D - Continued
Edge Attachment, Typical Sighting Dome ................................ ................................ ................................ .... F10-20
Edge Band Sealing, Typical ................................ ................................ ................................ ........................... F9-29
Edge Distance, Rivet................................ ................................ ................................ ................................ ........ F7-4
Edge Preparation, Edge Patch ................................ ................................ ................................ ......................... F8-6
Effect of Heat Treating on a Cemented Joint ................................ ................................ ................................ F10-10
Effects of Moments ................................ ................................ ................................ ................................ .........11-3a
Effects of Weight and Distance ................................ ................................ ................................ ........... 11-3b, F11-3
Elasticity ................................ ................................ ................................ ................................ .......................... 5-2d
Eliminating Gaps and Leveling Installations ................................ ................................ ........................ 8-9aa, F8-59
Empennage................................ ................................ ................................ ................................ ........................ 4-6
Empennage Assembly ................................ ................................ ................................ ................................ ... F4-14
Enclosure, Laminated, Approved Edge Attachment for................................ ................................ ................. F10-19
Enclosure, Monolithic, Approved Edge Attachment for ................................ ................................ ................. F10-18
Enclosures, Acrylic Plastic, Maintenance of on Army Aircraft ................................ ................................ ..........10-15
Engine Mount (Tubing)................................ ................................ ................................ ................................ ....8-11a
Engine Mount................................ ................................ ................................ ................................ ................... F4-6
Engine Mounts ................................ ................................ ................................ ................................ ................... 4-3
Maintenance................................ ................................ ................................ ................................ ............ 4-3c
Piston-Engine Mounts................................ ................................ ................................ ............................. 4-3a
Turbine-Engine Mounts................................ ................................ ................................ ........................... 4-3b
Equipment, Shop (Sheet Metal) ................................ ................................ ................................ .................. 2-2, 3-1
Establishing Neutral Position of a Control Surface................................ ................................ .......................... F11-7
Example of Structural Tubing ................................ ................................ ................................ ......................... F8-62
Expansion and Contraction Allowances (for Transparent Plastics)................................ ................................ .. T10-5
Expansion and Contraction Allowances (of Transparent Plastics)................................ ................................ ..10-16b
External and Internal Repairs ................................ ................................ ................................ ............................. 8-9
External Repair, Circular ................................ ................................ ................................ ................................ F8-11
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Fishmouth Splice, Steel Tube, Using Large Diameter Replacement Tube ................................ ...................... F8-70
Fitting (Cementing) ................................ ................................ ................................ ................................ .........10-9e
Flanged Member Repair, Bulkhead ................................ ................................ ................................ ................ F8-26
Flanging Block, Chamfered ................................ ................................ ................................ ............................ F6-32
Flat Pattern Layout................................ ................................ ................................ ................................ ........... 6-3e
Flexing (of Plastics)................................ ................................ ................................ ................................ .........10-4d
Flight Control Surfaces................................ ................................ ................................ ............................ 4-7, F4-16
Floor Channel Repair ................................ ................................ ................................ ............................ 8-9o, F8-36
Floor Repair, Metal-Covered Wooden ................................ ................................ ................................ ................ 9-7
Flush Access Door ................................ ................................ ................................ ................................ ........... F8-8
Flush Head Jo-Bolts, Grip Ranges, Sizes, and Diameters of ................................ ................................ .......... F7-83
Flush Patch................................ ................................ ................................ ................................ ...................... F8-5
Flush Patch Repair Procedure................................ ................................ ................................ .......................... F8-7
Flush-Head Jo-Bolt ................................ ................................ ................................ ................................ ........ F7-78
Foamed or Cellular Core Materials................................ ................................ ................................ ................... 9-2b
Foamed-In-Place Core Materials................................ ................................ ................................ ....................... 9-2c
Folding................................ ................................ ................................ ................................ ............................. 6-4e
Forces, Stress and Strain................................ ................................ ................................ ................................ ... 5-3
Forgings, Rockwell................................ ................................ ................................ ................................ ......... T5-21
Formation of Cushion on Acrylic Plastic by Immersion in Cement ................................ ................................ .. F10-5
Formed Angle, Stringer Repair with................................ ................................ ................................ ................ F8-17
Formed Patch, Rivet Spacing for Repair Using ................................ ................................ .............................. F8-43
Formed Sections (of Stored Plastics) ................................ ................................ ................................ ..............10-5d
Former and Frame Installation ................................ ................................ ................................ ....................... F4-17
Former Repair................................ ................................ ................................ ................................ ....... 8-9h, F8-25
Former Repair, Bonded (Cap) ................................ ................................ ................................ ........................ F9-13
Former Repair, Bonded (Web) ................................ ................................ ................................ ....................... F9-14
Former, Slip Roll ................................ ................................ ................................ ................................ ............ F3-33
Forming (General)................................ ................................ ................................ ................................ .............. 6-1
Forming (of Aircraft Metals)................................ ................................ ................................ .............................. 6-2a
Forming a Concave Flange ................................ ................................ ................................ ............................ F6-24
Forming a Convex Flange ................................ ................................ ................................ .............................. F6-25
Forming a Flanged Angle by Shrinking................................ ................................ ................................ ........... F6-16
Forming a Flanged Angle by Stretching................................ ................................ ................................ .......... F6-18
Forming Blocks ................................ ................................ ................................ ................................ ......3-4k, F3-23
Forming Blocks, Metal and................................ ................................ ................................ ............................. F6-23
Forming by Bumping ................................ ................................ ................................ ................................ ........ 6-5e
Forming Curved Flanged Parts ................................ ................................ ................................ ........................ 6-5d
Forming Flanged Angles ................................ ................................ ................................ ................................ ...6-5c
Forming Methods (for Plastics)................................ ................................ ................................ ........................ 10-7d
Forming of Plastics ................................ ................................ ................................ ................................ .......... 10-7
Cold Forming................................ ................................ ................................ ................................ .........10-7a
Forming Methods................................ ................................ ................................ ................................ ...10-7d
Forms ................................ ................................ ................................ ................................ .................... 10-7c
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Hat Sect ion, Splice Repair of ................................ ................................ ................................ ........................ F8-37
Hatch Seal, Typical ................................ ................................ ................................ ................................ ....... F8-60
Head Radius, Hi-Lok ................................ ................................ ................................ ................................ ..... F7-92
Head Types (Jo-Bolts) ................................. ................................ ................................ ................................ ...7-13a
Heat Treating (Soaking) Temperature ................................ ................................ ................................ ........... T5-10
Heat Treatment ................................ ................................ ................................ ................................ ................. 5-5
Cold-Working ................................. ................................ ................................ ................................ .........5-5c
Hot Working ................................ ................................ ................................ ................................ .......... 5-5b
Types ................................ ................................ ................................ ................................ ..................... 5-5a
Heat Treatment, Curing and (of Plastics) ................................. ................................ ................................ .......10-10
Heat-Treatable Rivet Identification ................................ ................................ ................................ .................. F5-9
Heat-Treatment Methods ................................. ................................ ................................ ................................ 5-7e
Heat-Treatment Procedures . ................................ ................................ ................................ ........................... 5-7g
Heating for Forming (Acrylic Plastics) ................................ ................................ ................................ ............10-7b
Heavily Stressed Area, Circular Damage Repair in ................................ ................................ ........................ F8-51
Heavily Stressed Area, Damage Repair Near Adjacent Member in ................................. ............................... F8-52
Heavily Stressed Area, Insertion Skin Repair Across Stiffeners in ................................ ................................ .. F8-53
Heavily Stressed Areas, Damage Repair Near Existing Structure in ................................. ............................. F8-49
Heavily Stressed Areas, Rectangular Damage Repair for ................................. ................................ ............. F8-48
Helicopter Stabilizer . ................................ ................................ ................................ ................................ ..... F4-15
Helicopters (Fuselage) ................................ ................................ ................................ ................................ .... 4-2a
Hex Head Jo-Bolt................................ ................................ ................................ ................................ ........... F7-79
Hex Head Jo-Bolts, Grip Ranges, Sizes, and Diameters of ................................ ................................ ............ F7-84
Hi-Lok Fasteners ................................ ................................ ................................ ................................ ............. 7-14
Hole Preparation ................................ ................................ ................................ ................................ ...7-14c
Identification ................................ ................................ ................................ ................................ .........7-14a
Inspection ................................ ................................ ................................ ................................ .............. 7-14f
Installation ................................ ................................ ................................ ................................ ............7-14e
Removal ................................ ................................ ................................ ................................ ............... 7-149
Selection ................................ ................................ ................................ ................................ ..............7-14b
Tooling ................................ ................................ ................................ ................................ ................. 7-14d
Hi-Lok Grip Lengths ................................ ................................ ................................ ................................ ...... F7-90
Hi-Lok Head Radius ................................ ................................ ................................ ................................ ...... F7-92
Hi-Lok Installation ................................ ................................ ................................ ................................ ......... F7-93
Hi-Lok Numbering System ................................ ................................ ................................ ............................. T7-32
Hi-Lok Protrusion Limits ................................ ................................ ................................ ................................ F7-94
Hi-Shear Rivet Inspection................................ ................................ ................................ ............................... F7-64
Hi-Shear Rivet Parts ................................ ................................ ................................ ................................ ..... F7-60
Hi-Shear Rivet Sets ................................ ................................ ................................ ................................ ...... F7-61
Hi-Shear Rivet, Driving ................................ ................................ ................................ ................................ . F7-63
Hi-Shear Rivets ................................ ................................ ................................ ................................ ............... 7-10
Identification ................................ ................................ ................................ ................................ .........7-10a
Inspection ................................ ................................ ................................ ................................ .............7-10e
Installation Procedures ................................ ................................ ................................ .......................... 7-10d
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H - Continued
Identification and Types (of Aircraft Plastics) . ................................ ................................ ................................ .. 10-4
Identification Marking Code (Steel) ................................ ................................ ................................ ................. T5-2
Identification of Aluminum Alloys ................................ ................................ ................................ .................... 5-7a
Identification of CherryMAX Rivets ................................ ................................ ................................ .................. 7-8a
Identification of Copper Alloys ................................ ................................ ................................ ......................... 5-10a
Identification of Hi-Lok Fasteners ................................ ................................ ................................ .................... 7-14a
Identification of Hi-Shear Rivets ................................ ................................ ................................ ...................... 7-10a
Identification of Huck Lockbolts ................................ ................................ ................................ ....................... 7-12d
Identification of Inconel ................................ ................................ ................................ ...................... 5-12a, T5-18
Identification of Jo-Bolts ................................ ................................ ................................ ................................ ..7-13b
Identification of Magnesium Alloys ................................ ................................ ................................ .................. 5-8a
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Old and New Color Code (for Aluminum), Cross Reference of ................................ ................................ ......... T5-8
Old Color Code (Steel) Cross Reference................................ ................................ ................................ .......... T5-3
Olympic Blind Rivets ................................ ................................ ................................ ................................ ....... 7-11
Drilling ................................ ................................ ................................ ................................ ................. 7-11 d
Grip Range ................................ ................................ ................................ ................................ ...........7-11 b
Hole Size Limits ................................. ................................ ................................ ................................ ....7-1 c
Identification . ................................ ................................ ................................ ................................ .......7-11 a
Inspection ................................ ................................ ................................ ................................ ............ 7-11 f
Installation . ................................ ................................ ................................ ................................ ...........7-11e
Removal ................................ ................................ ................................ ................................ ..............7-11 g
Olympic Rivet Grip Length . ................................ ................................ ................................ ........................... F7-67
Olympic Rivet Material Codes ................................ ................................ ................................ ........................ T7-18
Olympic Rivet Part Number Cross Reference ................................ ................................ ............................... T7-19
Olympic Rivet Pulling Head Operation . ................................ ................................ ................................ ......... F7-69
Olympic Rivet Stem Styles . ................................ ................................ ................................ ........................... F7-66
Olympic Rivet, Removing ................................ ................................ ................................ .............................. F7-71
Olympic Rivets, Grip Range for ................................ ................................ ................................ ...................... T7-20
Olympic Rivets, Hole Size Limits for . ................................ ................................ ................................ ............ T7-21
Olympic Rivets, Installation of . ................................ ................................ ................................ ...................... F7-70
Open and Closed Skin Area Repair................................ ................................ ................................ .................. 8-7b
Operations, Forming ................................ ................................ ................................ ................................ ......... 6-4
Operator Maintenance, (Sheet Metal) Shop Equipment ................................. ................................ .................. 3-2a
Optical Quality (of Aircraft Plastics) ................................ ................................ ................................ .................. 10-3
Outer Sleeve Splice, Steel Tube Using . ................................ ................................ ................................ ........ F8-69
Oven Temperature for Acrylic Plastics ................................ ................................ ................................ .......... T10-1
Overlay Patch to Reinforce a Crack ................................ ................................ ................................ ............. F10-16
Oversize Diameter, Countersunk Head, CherryMAX Rivet ................................ ................................ ............. F7-34
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Oversize Diameter, Protruding Head, CherryMAX Rivet ................................ ................................ ................ F7-35
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Pull- and Blind-Type Aluminum Lockbolt Rivet Gun ................................ ................................ ....................... F7-73
Pull- and Blind-Type Steel Lockbolt Rivet Gun ................................ ................................ .............................. F7-74
Pull- and Stump-Type Lockbolts, Drilling Procedures for ................................ ................................ ................ T7-29
Pull- and Stump-Type Lockbolts, Grip Range for................................ ................................ ............................ T7-26
Pull-Type Lockbolt Numbering System ................................ ................................ ................................ .......... T7-22
Pull-Type Lockbolt, Installation of................................ ................................ ................................ ................... F7-75
Punch, Center ................................ ................................ ................................ ................................ ............... F3-17
Punch, Drive ................................ ................................ ................................ ................................ ................. F3-19
Punch, Pin ................................ ................................ ................................ ................................ ..................... F3-20
Punch, Prick................................ ................................ ................................ ................................ ................... F3-16
Punch, Rotary ................................ ................................ ................................ ................................ .................. F3-4
Punch, Transfer ................................ ................................ ................................ ................................ ............ F3-21
Punches ................................ ................................ ................................ ................................ ............................ 3-4j
Purposes (of Manual) ................................ ................................ ................................ ................................ ........ 1-1
Quality Assurance for Repair (of Sandwich Construction) ................................ ................................ ................ 9-6q
Quality, Optical (of Aircraft Plastics) ................................ ................................ ................................ ................. 10-3
Quency Delay, Recommended Maximum, Wrought Alloys (for Immersion Type Quenching) ......................... T5-13
Radii of Cuts (of Plastic), Various, Bandsaw Widths for ................................. ................................ ................ T10-3
Radius Gauge ................................ ................................ ................................ ................................ ......... 3-4b, F3-6
Radius of Bend ................................ ................................ ................................ ................................ ............... 6-3a
Range, Grip (CherryMAX Rivets) ................................ ................................ ................................ ................... T7-11
Reaming, Dimpling and................................ ................................ ................................ ................................ .. F7-48
Rebalancing Movable Surfaces, General ................................ ................................ ................................ ......... 11-1
Reciprocating Saw ................................ ................................ ................................ ................................ .3-5c, F3-26
Recommended Bucking Bar Weights ................................ ................................ ................................ ............... T7-6
Recommended Countersinks for Shaving................................ ................................ ................................ ....... T7-16
Recommended Installation Procedures for Transparent Plastics ................................ ................................ .....10-16
Bolt and Rivet Mounting ................................ ................................ ................................ ...................... 10-16c
Expansion and Contraction Allowances ................................. ................................ .............................. 10-16b
Installation Considerations................................ ................................ ................................ ................... 10-16a
Recommended Maximum Quench Delay, Wrought Alloys (for Immersion Type Quenching) .......................... T5-13
Rectangular Damage Cutout Repair (Lightly Stressed)................................ ................................ ................... F8-44
Rectangular Damage Repair for Heavily Stressed Areas................................ ................................ ................. F848
Reheat Treatment of Alclad Alloys . ................................ ................................ ................................ ............... T5-12
Reinforced Shell Construction ................................ ................................ ................................ .......................... F4-3
Reinforcing a Dent at a Steel Tube Cluster Joint ................................ ................................ ........................... F8-65
Relief Holes . ................................ ................................ ................................ ................................ ........ 6-59, F6-31
Relief Holes, Nose Rib with................................ ................................ ................................ ............................ F6-20
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Tail Cone and Cabin Sections ................................ ................................ ................................ ............................... F4-4
Techniques, Cutting (for Plastics)................................ ................................ ................................ .......................... 10-8
Temperature (for Heat Treatment of Plastics) ................................ ................................ ................................ .. 10-10a
Template, Hand Router, for Milling Plug Cavity ................................ ................................ ................................ . F10-15
Temporary Patch Repairs................................ ................................ ................................ ................................ ........8-&
Tensile Strength................................ ................................ ................................ ................................ .................... 5-2a
Tension................................ ................................ ................................ ................................ ........................ 5-3a, F5-1
Terms and Symbols (Balancing)................................ ................................ ................................ .......................... 11-2c
Terms and Symbols (Balancing), Identification of ................................ ................................ .............................. Fll11-2
Thickness Variation, Material (and Hi-Lok Rivets) ................................ ................................ ............................... F7-91
Thickness, Cushion................................ ................................ ................................ ................................ ............. F10-8
Throatless Shears................................ ................................ ................................ ................................ ........ 3-3c, F3-5
Tightly Installed Jo-Bolt, Removal of ................................ ................................ ................................ ................... F7-88
Titanium and Titanium Alloys ................................ ................................ ................................ ................................ .. 5-9
Characteristics................................ ................................ ................................ ................................ ................ 5-9b
Identification ................................ ................................ ................................ ................................ ................... 5-9a
Methods of Working ................................ ................................ ................................ ................................ ........ 5-9c
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Typical Sighting Dome Edge Attachment ................................ ................................ ................................ .......... F10-20
Typical Stringer Cross Sections................................ ................................ ................................ ........................... F4-20
Index 170
These are the instructions for sending an electronic 2028
The following format must be used if submitting an electronic 2028. The subject line must be
exactly the same and all fields must be included; however only the following fields are
mandatory: 1, 3, 4, 5, 6, 7, 8, 9, 10, 13, 15, 16, 17, and 27.
From: “Whomever” <[email protected]>
To: [email protected]
Subject: DA Form 2028
1. From: Joe Smith
2. Unit: home
3. Address: 4300 Park
4. City: Hometown
5. St: MO
6. Zip: 77777
7. Date Sent: 19--OCT--93
8. Pub no: 55--2840--229--23
9. Pub Title: TM
10. Publication Date: 04--JUL--85
11. Change Number: 7
12. Submitter Rank: MSG
13. Submitter FName: Joe
14. Submitter MName: T
15. Submitter LName: Smith
16. Submitter Phone: 123--123--1234
17. Problem: 1
18. Page: 2
19. Paragraph: 3
20. Line: 4
21. NSN: 5
22. Reference: 6
23. Figure: 7
24. Table: 8
25. Item: 9
26. Total: 123
27. Text:
This is the text for the problem below line 27.
Use Part II (reverse) for Repair Parts and Spe- DATE
RECOMMENDED CHANGES TO PUBLICATIONS AND cial Tool Lists (RPSTL) and Supply Catalogs/
Supply Manuals (SC/SM)
BLANK FORMS
For use of this form, see AR 25--30; the proponent agency is ODISC4. 8/30/02
TO: (Forward to proponent of publication or form)(Include ZIP Code) FROM: (Activity and location)(Include ZIP Code)
Commander, U.S. Army Aviation and Missile Command MSG, Jane Q. Doe
ATTN: AMSAM--MMC--MA--NP 1234 Any Street
Redstone Arsenal, AL 35898 Nowhere Town, AL 34565
PART 1 -- ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE Organizational, Direct Support, And General
Support Maintenance Manual for Machine Gun, .50
TM 9--1005--433--24 16 Sep 2002 Caliber M3P and M3P Machine Gun Electrical Test Set
Used On Avenger Air Defense Weapon System
ITEM PAGE PARA-- LINE FIGURE TABLE
RECOMMENDED CHANGES AND REASON
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SUPPORTED
PART III -- REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)
TO: (Forward to proponent of publication or form)(Include ZIP Code) FROM: (Activity and location)(Include ZIP Code)
Commander, U.S. Army Aviation and Missile Command
ATTN: AMSAM-MMC-MA-NP
Redstone Arsenal, AL 35898
PART 1 -- ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE
DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPA V3.01
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
Commander, U.S. Army Aviation and Missile Command
ATTN: AMSAM-MMC-MA-NP
Redstone Arsenal, AL 35898
PART II -- REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE
TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
RECOMMENDED ACTION
NO. NO. NO. NUMBER NO. NO. NO. ITEMS
SUPPORTED
PART III -- REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)
USAPA V3.01
The Metric System and Equivalents
Temperature (Exact)