*TM 1-1500-204-23-1

TECHNICAL MANUAL

AVIATION UNIT MAINTENANCE (AVUM)

AND AVIATION INTERMEDIATE
MAINTENANCE (AVIM) MANUAL

FOR

GENERAL AIRCRAFT MAINTENANCE

(GENERAL MAINTENANCE AND PRACTICES)

VOLUME 1

*This manual together with TM 1-1500-204-23-2 through TM 1-1500-204-23-10, dated 31

July 1992, supersedes TM 55-1500-204-25/1, dated 6 April 1970, including all changes.

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

HEADQUARTERS, DEPARTMENT OF THE ARMY

31 JULY 1992

This copy is a reprint which includes

current pages from Change 1.
 TM 1-1500-204-23-1
C3

CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 3 WASHINGTON, D.C., 13 January 2003

TECHNICAL MANUAL

AVIATION UNIT MAINTENANCE (AVUM)

AND AVIATION INTERMEDIATE
MAINTENANCE (AVIM) MANUAL

FOR
GENERAL AIRCRAFT MAINTENANCE

(GENERAL MAINTENANCE AND PRACTICES)

VOLUME 1

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

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

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

Remove pages Insert pages

A/(B blank) A and B
i and ii i and ii
2-9 and 2-10 2-9 and 2-10
8-1 and 8-2 8-1 and 8-2
11-1 and 11-2 11-1 and 11-2
11-17 and 11-18 11-17 and 11-18
13-3/(13-4 blank) 13-3/(13-4 blank)
TM 1-1500-204-23-1
C3

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

By Order of the Secretary of the Army:

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

AVIATION UNIT MAINTENANCE (AVUM)

AND AVIATION INTERMEDIATE
MAINTENANCE (AVIM) MANUAL
FOR
GENERAL AIRCRAFT MAINTENANCE
(SHEET METAL SHOP PRACTICES)
VOLUME 1

DISTRIBUTION STATEMENT A: Approved for public release;

distribution is unlimited.

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

1. Remove and insert pages as indicated below. New or changed

A vertical bar in the margin indicates text material. A
miniature pointing hand indicates an illustration change.

Remove pages Insert pages

----------- A and B
i and ii i and ii
v and vi v and vi
3-9 and 3-10 3-9 and 3-10
3-19/(3-20/blank) 3-19/(3-20/blank)
6-1 and 6-2 6-1 and 6-2
9-43 and 9-44 9-43 and 9-44
11-1 and 11-2 11-1 and 11-2
11-5 through 11-10 11-5 through 11-10
11-13 through 11-18 11-13 through 11-18
11-33 through 11-38 11-33 through 11-38
13-1 and 13-2 13-1 and 13-2
A-1 and A-2 A-1 and A-2
Index 9 and Index 10 Index 9 and Index 10

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

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

By Order of the Secretary of the Army:

ERIC K. SHINSEKI
General, United States Army
Official: Chief of Staff

Administrative Assistant to the

Secretary of the Army
0001902

DISTRIBUTION: To be distributed in accordance with Initial Distribution

Number (IDN) 313302, requirements for TM 1-1600-204-23-1.
 TM 1-1500-204-23-1
C1

CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 1 WASHINGTON, D.C., 29 OCTOBER 1993

AVIATION UNIT MAINTENANCE (AVUM)

AND AVIATION INTERMEDIATE MAINTENANCE (AVIM) MANUAL

FOR

GENERAL AIRCRAFT MAINTENANCE

(General Maintenance and Practices)

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

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

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

Remove pages Insert pages

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

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

By Order of the Secretary of the Army:

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.

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

 TM 1-1500-204-23-1

PRECAUTIONARY DATA

Personnel performing instructions involving operations, procedures, and practices which are
included or implied in this technical manual shall observe the following instructions. Disregard of
these warnings and precautionary information can cause serious injury, death, or an aborted
mission.

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

WARNING: An operating or maintenance procedure, practice, condition, statement, etc , which if

not strictly observed, could result in injury to or death of personnel.

CAUTION: 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.

WARNING

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 fluid fumes or creating electrical shock..

USING SOLVENTS/PAINTS

Standard precautions such as fire 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 flammable and shall be treated as such. Never smoke or permit any
type of open flame 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.

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 hardener 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.

HANDLING PYROTECHNIC FLARES

Handle pyrotechnic flares with the same care as high explosives.

MAGNESIUM ALLOY FIRE

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

AIRCRAFT ENGINE VALVES

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

REMOVING CORROSION

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

TIRES AND WHEELS

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

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

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

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

b
 TM 1-1500-204-23-1

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

OXYGEN SYSTEM

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

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

GROUND SUPPORT EQUIPMENT

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

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

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

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

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

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

Disconnect power before changing belts on electrically-driven compressors.

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

RADIOGRAPHIC EQUIPMENT

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

FIRE EXTINGUISHERS

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

c
 TM 1-1500-204-23-1

HYDRAULIC FLUID

To avoid contamination, do not use previously opened cans of hydraulic fluid. A new, sealed can of fluid 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 fire precautions when using aliphatic naphtha, Federal Specification 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 aircraft with engines in operation.

TURBINE ENGINE OIL

To avoid contamination, do not use previously opened cans of engine oil, new sealed can of fluid must be opened and
used. When opening can, clean top and use a clean, sharp un-plated instrument to prevent contamination.

MERCURY

A very small amount of mercury may produce hazardous vapors. Refer to TM 385-4, Safety Precautions 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 fire 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" electrical voltage activation and resulting personal injury.

PROPER USE OF PLATED TOOLS

Use only chrome plated steel or unplated steel tools for disassembly or reassembly procedures described in this manual.
Use of cadmium or zinc plated tools is not permitted since these platings are prone to chipping and flaking. Should these
chips or flakes become embedded in aircraft parts, galvanic corrosion will result. Should these chips or flakes enter fuel
or oil wetted components, they may eventually clog the filter or produce intergranular attack of nickel or titanium base
alloys at elevated temperature. All tools regardless of type plating should be serviceable and free of chipping.

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 Office will use their expertise to provide assistance.

Guidance for industrial hazards can be found in the Code of Federal Regulations, 29 CFR 1910.

Change 1 d
 TM 1-1500-204-23-1

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES

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 ILLUST-
RATIONS ARE INDICATED BY MINIATURE POINTING HANDS. CHANGES TO WIRING DIAGRAMS ARE
INDICATED BY SHADED AREAS.

Dates of issue for original and changed pages are:

Original................... 0 ....................31 July 1992
Change .................. 1 ............. 29 October 1993
Change .................. 2 .................. 1 March 2000
Change .................. 3 ............. 13 January 2003

Total number of pages in this publication is 426 consisting of the following:

Page *Change Page *Change

No. No. No. No.

Cover-1 ...................................... 0 6-2 ..............................................2

Cover-2 blank ............................ 0 6-3 through 6-6...........................0
a through c................................. 0 7-1 through 7-47.........................0
d ................................................ 1 7-48 blank ..................................0
A and B ...................................... 3 8-1 ..............................................3
i .................................................. 3 8-2 through 8-21.........................0
ii through iv ................................ 0 8-22 blank ..................................0
v ................................................. 2 9-1 through 9-43.........................0
vi ................................................ 0 9-44 ............................................2
1-1.............................................. 0 9-45 through 9-65.......................0
1-2 blank .................................... 0 9-66 blank ..................................0
2-1 through 2-9 .......................... 0 10-1 through 10-12.....................0
2-10............................................ 3 11-1 ............................................2
2-11 ........................................... 0 11-2 ............................................3
2-12 blank .................................. 0 11-3 and 11-4.............................0
3-1 through 3-4 .......................... 0 11-5 through 11-7.......................2
3-5.............................................. 1 11-8 ............................................0
3-6 through 3-8 .......................... 0 11-9 and 11-10...........................2
3-9.............................................. 2 11-11 through 11-13...................0
3-10............................................ 1 11-14 and 11-15 .........................2
3-11............................................ 0 11-16 ..........................................1
3-12............................................ 1 11-17 ..........................................2
3-13 through 3-18 ...................... 0 11-18 ..........................................3
3-19............................................ 2 11-19 through 11-24...................0
3-20 blank ................................. 0 11-25 ..........................................1
4-1 and 4-2 ................................ 0 11-26 ..........................................0
5-1.............................................. 0 11-27 ..........................................1
5-2 blank .................................... 0 11-28 through 11-32 ..................0
6-1.............................................. 0 11-33 ..........................................2

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LIST OF EFFECTIVE PAGES (CON’T)

Page *Change
No. No.

11-34.......................................... 0
11-35 and 11-36......................... 2
11-37.......................................... 0
11-38.......................................... 2
11-39 and 11-40......................... 0
12-1 and 12-2 ............................ 1
13-1............................................ 2
13-2............................................ 0
13-3............................................ 3
13-4 blank .................................. 0
A-1 and A-2................................ 2
Glossary 1.................................. 0
Glossary 2 blank ........................ 0
Index 1 through Index 8 ............ 0
Index 9 ....................................... 2
Index 10 through Index 170 ....... 0

*Zero in this column indicates an original page.

B Change 3
 *TM 1-1500-204-23-1

TECHNICAL MANUAL HEADQUARTERS

DEPARTMENT OF THE ARMY
TM 1-1500-204-23-1 WASHINGTON, D.C., 31 July 1992
TECHNICAL MANUAL
AVIATION UNIT MAINTENANCE (AVUM)
AND AVIATION INTERMEDIATE
MAINTENANCE (AVIM) MANUAL

for
GENERAL AIRCRAFT MAINTENANCE

(GENERAL MAINTENANCE AND PRACTICES)

VOLUME 1
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual. If you find any mistakes or if you know of a way to improve the
procedures, please let us know. Mail your letter or DA Form 2028 (Recommended Changes to Publications
and Blank Forms) or DA Form 2028-2 located in the back of this manual directly to: Commander, US Army
Aviation and Missile Command, ATTN: AMSAM-MMC-LS-LP, Redstone Arsenal, AL 35898-5230. You
may also submit your recommended changes by E-Mail directly to Is-lp@redstone.army.mil or by fax (256)
842-6546/DSN 788-6546. A reply will be furnished directly to you. Instruction for sending an electronic
2028 may be found at the back of this manual immediately preceding the hard copy 2028.

ENVIRONMENTAL/HAZARDOUS MATERIAL INFORMATION

This document has been reviewed for the presence of Class I Ozone Depleting Chemicals. As of 14 June
1995, the status is: 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.

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

TABLE OF CONTENTS

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

CHAPTER 2 HANGAR AND SHOP OPERATIONS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
CHAPTER 3 FLIGHTLINE OPERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
CHAPTER 4 AIRCRAFT STORAGE AND SHIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
CHAPTER 5 MARKING OF AERONAUTICAL ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
CHAPTER 6 APPLICATION AND REMOVAL OF DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
CHAPTER 7 GENERAL RECIPROCATING ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . 7-1
CHAPTER 8 GENERAL TURBINE ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
CHAPTER 9 GENERAL AIRFRAME MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
CHAPTER 10 ARCTIC, DESERT, AND TROPIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
*This manual together with TM 1-500-204-23-2 through TM 1-1500-204-23-10, dated 31 July 1992,
supersedes TM 55-1500-204-25/1, dated 6 April 1970, including all changes.

Change 2 i
TM 1-1500-204-23-1

CHAPTER 11 AVIATION LIFE SUPPORT EQUIPMENT MAINTENANCE . . . . . . . . . . . . . . . . . . 11-1

CHAPTER 12 PYROTECHNICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

CHAPTER 13 AIRCRAFT CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

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

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

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

Volume 2

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

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

CHAPTER 3 HYDRAULIC SHOP OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

CHAPTER 4 HYDRAULIC MAINTENANCE PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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

GLOSSARY Glossary 1

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

Volume 3

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

CHAPTER 2 FUELSYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

CHAPTER 3 OIL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

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

GLOSSARY Glossary 1

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

Volume 4

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

CHAPTER 2 ELECTRIC SHOP OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

CHAPTER 3 ELECTRICAL MAINTENANCE PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

ii
 TM 1-1500-204-23-1

Page

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

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

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

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

Volume 5

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

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

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

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

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

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

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

Volume 6

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

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

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

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

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

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

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

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

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

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

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 TM 1-1500-204-23-1

Page
Volume 7

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

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

CHAPTER 3 PENETRANT INSPECTIONS ............................................................................. 3-1

CHAPTER 4 MAGNETIC PARTICLE INSPECTIONS ............................................................. 4-1

CHAPTER 5 RADIOGRAPHY ................................................................................................. 5-1

CHAPTER 6 ULTRASONIC INSPECTIONS ............................................................................ 6-1

CHAPTER 7 ELECTROMAGNETIC INSPECTIONS ............................................................... 7-1

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

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

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

Volume 8

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

CHAPTER 2 MACHINE SHOP PRACTICES ........................................................................... 2-1

CHAPTER 3 WELDING SHOP PRACTICES .......................................................................... 3-1

APPENDIXA REFERENCES ................................................................................................... A-1

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

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

Volume 9

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

CHAPTER 2 TOOL PROCEDURES AND PRACTICES .......................................................... 2-1

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 TM 1-1500-204-23-1

CHAPTER 3 MEASURING TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

CHAPTER 4 GENERAL MAINTENANCE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

CHAPTER 5 PNEUMATIC TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

CHAPTER 6 ELECTRIC POWER TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

CHAPTER 7 SPECIAL AIRCRAFT TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

CHAPTER 8 TORQUE TOOLS AND TORQUING PRINCIPLES AND PROCEDURES . . . . . . 8-1

CHAPTER 9 GROUND SUPPORT EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

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

GLOSSARY Glossary 1

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

Volume 10

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

CHAPTER 2 SHEET METAL SHOP OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

CHAPTER 3 SHOP EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

CHAPTER 4 AIRCRAFT STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

CHAPTER 5 STRUCTURAL METALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

CHAPTER 6 FORMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Change 2 v
TM 1-1500-204-23-1

CHAPTER 7 RIVETS AND RIVETING TECHNIQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

CHAPTER 8 AIRFRAME SHEET METAL REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

CHAPTER 9 SANDWICH CONSTRUCTION REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

CHAPTER 10 AIRCRAFTPLASTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

CHAPTER 11 REBALANCING MOVABLE SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

CHAPTER 12 SPOT WELDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

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

APPENDIX B BLAND RIVET CONVERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-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

1-3. Consumable Materials. Refer to TM 1-1500204-

23-6 for consumable materials in this volume.

1-1/(1-2 blank)
 TM 1-1500-204-23-1

CHAPTER 2

HANGAR AND SHOP OPERATIONS

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.

d. Shop Equipment Arrangement. Shop j. Spray Painting. All painting shall be

equipment is arranged to best meet the needs of the accomplished in the paint shop in accordance with
particular shop operation. All equipment must be proper procedures as set forth by the facility supervisor.
arranged with utmost care to prevent danger to
personnel. k. Adhesive Operations. Adhesives join objects
over a broad area, instead of localizing stresses at one
e. Overhead Chain Hoist. Overhead chain hoists or more points, as with spot welding or metal fastening.
shall be inspected daily for the following. Adhesives simplify construction by eliminating bracing,
stiffeners, local reinforcements, or framing Adhesive use
• Excessive wear or stretch is a reliable, efficient assembly method.

• Bent or twisted links l. Balancing Equipment. The equipment used for

balancing measurements consists of a set of knife
• Defective welds edges, weights, weighing scale, and a steel tape
measure.
• Nicks and gouges
m. Environmental Control. The permanent shop
f. Compressed Air and Water Outlets Permanent environment is controlled by environmental control units
shops are equipped with compressed air and water installed throughout the shop.
outlets. Care should be taken to allow clear access to
each outlet. n. Lighting Requirements. Adequate lighting shall
be provided for all shop operations. Light fixtures
should

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

Figure 2-1. Temporary Shop Layout

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 van shall be located as to provide easy access by
a cloth dampened with a mild detergent solution and maintenance personnel.
wipe dry.
q. Protected Storage Areas. Each command shall
(3) Once a week, clean the exterior of the provide protected storage areas for flammable or
shelter, using the same detergent as in step 2 . Apply hazardous materials. Care should be taken to provide
with a soft bristle brush or sponge, scrubbing off all dirt security and proper handling of items in these areas.
and grime. Rinse with clean water. Dry with a soft cloth
r. Open Storage Areas. Open storage areas will
j. Spray Painting. Spray painting can be used to be arranged be each shop facility as needed. Supplies
repaint any spots in need of refinishing. The following shall be organized to provide easy access, removal, and
procedures explain spray painting of temporary shops. use.

(1) Remove all loose or flaked paint. 2-4. Maintenance of Shop Equipment. The
maintenance of machinery and shop equipment shall be
(2) Smooth with No. 0 sandpaper, feather divided into operator maintenance, major repair, and
edging all sanded spots to ensure a smooth surface for painting.
the new paint.
a. Operator Maintenance. Operator maintenance
(3) Apply paint with a 2-inch spray pattern. consists of cleaning, lubrication, and minor adjustment
of belts, guards, gibs, etc. It also includes periodic
NOTE visual inspection to preclude possible damage, failure,
Thin paint if necessary with an or breakdown due to loose or excessively worn parts,
acceptable thinner conforming to TT- defective wiring connections, insulation, safety
T-291. appliances, etc.

(4) Allow 4 to 8 hours to dry b. Major Repair. Major repair consists of all repair
work not performed by operators. Major repair within
k. Adhesive Operations. Adhesives join objects the scope of facilities shall be accomplished locally.
over a broad area, instead of localizing stresses at one Repairs not within the scope of local facilities shall be
or more points, as with spot welding or metal fastening. accomplished through a work order to direct support or a
Adhesives simplify construction by eliminating bracing, commercial contractor.
stiffeners, local reinforcements, or framing. Adhesive
use is a reliable, efficient assembly method. c. Painting. Painting consists of any refinishing of
equipment, from touchup to complete repainting of the
l. Balancing Equipment. The equipment used for item
balancing measurements consists of a set of knife
edges, weights, a small accurate weighing scale, and a NOTE
steel tape measure. All color shades shall be in
accordance with Federal
m. Temperature and Humidity Control. Specification FED-STD-595.
Temperature and humidity is controlled in temporary
shop structures by environmental control units attached (1) Equipment repainting. When complete
to the structure. repainting is necessary, the original painted surface
shall be refinished with synthetic gloss enamel, Federal
n. Flammable Materials. All flammables shall be Specification TT-E-489. The color shall be green, color
stored in accordance with existing command policies. shade 14260.

o. Lighting Light fixtures should be inspected for (2) Work areas and critical parts. Work areas
broken lamp contacts or other damage. The lamp and and critical parts will be highlighted by painting with
protector may be replaced by removing the screws Federal Specification TT-E-489. The color shade shall
holding the retaining straps to the light fixture. be 13655 yellow enamel. To ensure maximum color.

p. Repair Parts Van. The repair parts van shall be

fully stocked with repair parts for the specific shop. The

2-4
 TM 1-1500-204-23-1

pattern uniformity on like items of equipment, painting (5) Stop buttons. Stop buttons for electrical
and highlighting shall be accomplished in accordance switches used for emergency stopping of machinery
with the general pattern shown in figure 2-2. Equipment shall be painted with red synthetic gloss enamel,
other than the type illustrated, shall be painted in Federal Specification TT-E-489, color shade 11105.
accordance with these general instructions. The painted
finish on this equipment may be retouched. The (6) Hazardous areas. On some equipment,
commanding officer or his designated representative extremely hazardous conditions may exist, such as open
shall determine the extent of the touchup allowed flywheels, gears, or other moving parts which cannot be
without complete repainting. guarded or which might be impractical to guard. These
parts may be painted with Federal Specification TT-E-
(3) Natural wood pieces. Wood pieces or 489, orange synthetic gloss enamel, color shade 12197.
equipment finished in colors other than those listed in Overuse of orange color will defeat the intended
paragraph 2-4c may be touched up with colors to match purpose, therefore, the local safety engineer shall
existing finish, provided touchup does not involve determine the use of this color and furnish instructions.
refinishing a total area equal to more than 10 percent of Painting of machined parts, such as face plates, chucks,
painted surface area. When more than 10 percent of spindels, etc, is not authorized.
painted surface area must be touched up, item shall be
repainted with colors as specified. (7) Preparation for painting. Prepare surfaces to be
repainted using the following procedures:
NOTE
Instrument repair benches or other (a) Surface should be clean, dry, and free
special purpose benches, parts, and from dust, grease, oil, rust, and dirt. Glossy surfaces
equipment having natural wood should be sanded to dull the gloss to ensure adhesion .
finish may be refinished in natural Remove all rust and scale by scraping or wire brushing.
wood or white enamel, Federal
Specification TT-E-489, color shade WARNING
17875. Working surfaces of bench Under no circumstances shall
tops covered with metal or flammable material be used near an
composition need not be repaired. open flame. Otherwise injury or
death may result to personnel.
(4) Start buttons. Start buttons shall be painted
with Federal Specification TT-E-489, green synthetic (b) Remove oil and grease deposits from
gloss enamel, color shade 14260. machinery to be repainted with kerosene, ASTM D3699.

WARNING
Drycleaning solvent is flammable
and solvent vapors are toxic. Use P-
D-680, Type II Solvent in a well-
ventilated area. Keep away from
open flames. Avoid prolonged
solvent contact with skin.

(c) Wipe surface with a clean cloth moistened

with a grease-free solvent, such as drycleaning solvent,
Federal Specification P-D-680, or paint thinner, Federal
Specification TT-T-291. Repeat this procedure until
machinery surfaces are completely clean.

(d) Bare spots resulting from scraping or

chipping should be sanded to a feather edge and spot
primed with lacquer proof primer, Federal Specification
Figure 2-2. Painting of Shop Equipment to TT-P-664. Allow priming coats to dry thoroughly and
Highlight Operator Position. apply two coats of enamel, Federal Specification TT-E-
489, in prescribed colors.

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 (combustible 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 extinguishers 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, and 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

Figure 2-3. Fire Extinguisher Nameplates

2-8
 TM 1-1500-204-23-1

(8) Fire fighting equipment requirements. Fire Aircraft shall be static-grounded from basic
fighting equipment requirements are listed as follows: structure of aircraft to a low resistance ground.
After parking aircraft, chock securely and
Personnel shall be trained in the use, release parking brake.
knowledge, and location of shop fire fighting
equipment. c. Parking of Aircraft with Fuel Tanks Less Than
Each shop shall be equipped with fire Full. Aircraft shall have all fuel cells fully serviced prior
extinguishers suited for type fire most likely to to being parked or stored in a hangar. All fuel cells
occur. should be full in order to minimize the presence of
Oily waste, rags, and similar combustible flammable vapors within the fuel cell (for safety
trash shall be discarded in self-closing metal purposes) and additionally to minimize water
containers which shall be emptied daily. condensation and subsequent microbiological growth
Flammable supplies shall not be stored in the which results in contamination of the fuel.
shop.
Use correct fire extinguisher for class of fire. NOTE
This procedure should be adhered to
2-6. Parking of Aircraft and Equipment In Hangars. at all times, except when impending
The following paragraphs explain the parking of aircraft mission requirements shall
and equipment in hangars. necessitate a reduced fuel load or
when an aircraft shall require
a. Safety Lanes. Safety Lanes should be clearly maintenance to the fuel system.
marked and kept clear of parked aircraft and equipment.
The width of fire lanes between parked aircraft should d. Usage of Drip Pans. Drip pans shall be placed
be slightly greater than the wing span of parked aircraft under aircraft engines to collect oil. Drip pans shall be
in order to facilitate removal of any one aircraft from emptied daily.
parking area and also to permit ease of movement for
mobile fire fighting equipment within the area. e. Location of Static Ground Points. Static ground
points are located throughout the hangar for static
b. Parking of Aircraft in Hangars. Aircraft parked grounding of aircraft. The grounding point is marked by
in hangars shall be spaced a sufficient distance apart to a yellow circle 18 inches in diameter, with a 2 inch black
provide adequate clearance for maintenance, servicing, border surrounding it. The words STATIC GROUND
and fire lanes. Observe the following parking CONNECTION and a numeric or alphanumeric
precautions: identification of the grounding rod shall be stenciled in
black on the yellow circle.
NOTE
Aircraft shall be secured in f. Testing of Static Ground Points. The electrical
accordance with the existing resistance of each grounding system should be as low
mooring instructions contained in as possible but not greater than 10,000 ohms. A log
the applicable aircraft maintenance must be kept for permanent or semi-permanent airfields
manuals. to show the identification of each rod, the date tested,
and the reading in ohms. If the measured resistance of
The direction in which the aircraft are to be a rod is greater than 10,000 ohms, the rod should
parked shall be determined by ease of immediately be marked DEFECTIVE DO NOT USE and
maintenance and servicing. it should be removed or replaced as soon as possible.
Parking arrangement shall vary to utilize local A log is not required at temporary refueling points. Each
space facilities to the maximum. Double row ground rod must be inspected when it is installed.
lateral parking, with first and second rows of Ground wires are inspected monthly. The grounding
aircraft placed tail to tail, shall be system must be inspected and tested
accomplished where possible.

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 TM 1-1500-204-23-1

annually or when there is a possibility of mechanical NOTE

damage. If any damage is found, it must be repaired Place tail stands under all aircraft
immediately. equipped with tricycle landing gear.
Secure a ground-supported weight to
g. Static Grounding of Aircraft. All aircraft parked tail of conventional gear aircraft.
in a hangar must be grounded (earthed) at all times.
When tail wheel is to remain in
contact with ground, lock it after
h. Static Grounding of Ground Support Equipment.
aircraft reaches desired height.
Ground support equipment in a hangar must be
Leave tail wheel free to roll fore and
grounded at all times when in contact with the aircraft
being worked on. aft during jacking and lowering
operations.
i. Emergency Evacuation of Aircraft from Hangar.
A plan for the emergency evacuation of aircraft from a (6) Operate all jacks simultaneously, both up
hangar must be established and implemented by the and down, to prevent binding of aircraft struts. Binding
maintenance officer using the expertise of the aviation may be corrected by tapping strut with a rawhide mallet
safety officer and other applicable elements. Care or kicking tire.
must be taken to ensure the safe evacution of as many
aircraft as possible in an emergency.
(7) Ensure that there is sufficient clearance
above aircraft to complete desired operation.
2-7. Jacking and Hoisting. General instructions for
lacking and hoisting are explained in the following
paragraphs. For specific instructions on a particular WARNING
aircraft, refer to the applicable maintenance manual. Aircraft on jacks shall be so labeled,
and access restricted to prevent
a. Jacking. Use the following procedures for in injury to personnel.
and out of hangar jacking:
CAUTION
(1) Do not stand, sit, or lie inside or on Unauthorized persons will not be in,
aircraft during raising or lowering operations. on or under aircraft supported by
jacks. Areas shall be restricted by
(2) Ensure that all stress panels are installed proper warning signs and barriers to
on aircraft. preclude entry into the area.

(3) Disengage aircraft brakes and remove NOTE

chocks. The use of auxiliary supports is
recommended, but not required, as
(4) Place all jacks on a level surface so that standard jacks are designed to
an imaginary line drawn through any 2 feet of jack will withstand all vertical loads. When
be parallel to fuselage or load to be jacked. Jack only at several people are to be working on
specified jack points. the aircraft, auxiliary supports are
highly recommended.
(5) Position auxiliary supports as necessary
to adequately prevent accidental injury to personnel or (8) Do not jack aircraft when wind velocity is
damage to aircraft. greater than maximum amount specified in applicable
maintenance manual. When applicable maintenance
manual does not list a maximum wind velocity, a
velocity of 15 miles per hour will be considered
maximum.

2-10 Change 3
 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 there 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 aircraft 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.

NOTE In case of emergency, tie down aircraft using

Do not set brakes of aircraft in a trees or arctic-type (dead-man) mooring
hangar or outside during subzero anchor.
temperature
f. Flightline Equipment. All flightline equipment
Service aircraft systems as required by should be inspected and functionally checked to ensure
applicable maintenance manual. Exercise safety prior to use.
care during servicing to prevent moisture from
entering systems being serviced. (1) General inspection. The following
paragraphs describe inspection requirements for
Avoid parking aircraft in wet or slushy areas flightline equipment.
saturated with fuel or oil.
(a) Cleanliness. Inspect equipment internally
Install pitot tube covers and wheel covers. and externally for cleanliness. Equipment will be dry
and free of mud or other debris.
• Move controls to neutral position and lock by
either internal or external means. (b) Serviceability. Perform serviceability
inspection of all new equipment.
• When parking helicopters overnight for
storage, or during adverse weather, set (c) Lubrication. Lubrication will conform to
ground handling wheels (when applicable) the applicable maintenance manual.
in retracted position.
(d) Oil seals. Inspect oil seals for leakage.
• Rotate or fold main rotor blades (when Oil seals that are wet and show only a slight drip, after
applicable) in accordance with instructions operation or standing, are considered as seeping and
contained in applicable maintenance manual. are acceptable. Seals that show definite leakage will be
replaced.
e. Preparation of Aircraft for Storms. The following
general precautions are to be observed when storms are (e) Performance. Ensure that ground support
anticipated: equipment is in such condition that its performance will
approximately equal new equipment and meet all
Install all protective covers and shields to general safety requirements.
protect aircraft from accumulation of snow,
frost, or ice. (2) Functional check. The following
procedures explain functional checks for flightline
NOTE equipment.
If wings are wet or a freezing rain is
expected, cover aircraft with a coat (a) Check all levers, switches, valves,
of anticing and deicing-defrosting shutters, etc ,to ensure proper operation.
fluid, MIL-A-8243, before installing
fabric covers. (b) Check all meters and gauges for proper
operation and adjustment.

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 scale 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 procedures (3) Use caution when towing aircraft in
are for all ground movements: extremely low temperatures to prevent damage to
hydraulic seals which would result in strut leakage.
(1) Disconnect and move clear all ground
support, ground servicing, and maintenance equipment c. Pushing. Push aircraft by hand in accordance
not 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 WARNING
chocks are removed until they are reinstalled. Keep clear of skids, aircraft wheels,
and/or ground handling wheels.
(3) Assign a ground crewmember to stand
near tip of each wing to act as a guide during ground (1) Position ground handling wheels (when
movements. applicable) in down-and-locked position.

(4) Stand clear of aircraft immediately prior to (2) Apply physical pressure for pushing,
and during movement. lifting, and turning only at authorized pressure points as
designated in applicable maintenance manual.
(5) Assign a qualified ground crewmember to
direct departure from, or approach to, a parking position. (3) Push by hand at proper pressure points.
Only approved standard signals will be used. Use a
flashlight or luminescent wand to signal instructions at (4) Senior person will brief duties and
night. dangers of ground handling aircraft.

(6) Do not stand, sit, or lie on any external d. Standard Visual Signals. Visual signals for
portion of an aircraft while it is in motion. Do not jump movement of Army aircraft are contained in FM 1-105 or
from or board a moving aircraft. FM 21-60.

(7) When moving aircraft, avoid sudden stops 3-4. Static Grounding of Aircraft. Standard
and starts. grounding of aircraft is explained in the following
paragraphs.
(8) No person, vehicle, or aircraft shall
approach close to an oncoming taxiing aircraft, pass a. Grounding Requirements. Positive
closer than 200 feet to the rear of an operating turbine- requirements for grounding or bonding of aircraft are as
powered aircraft, or pass closer than 100 feet to the rear follows:
of other operating aircraft.
NOTE
(9) Do not taxi or tow aircraft, or start or Grounding of aircraft shall be in
runup engines within 50 feet of any fuel, oil, or water- accordance with the same
alcohol servicing operation, or within 50 feet of any spill requirements as FM 10-69, Petroleum
until the spill has been removed and the area rendered Supply Point Equipment and
safe. Operations.
b. Towing. Tow aircraft in accordance with the All aircraft parked outside will be grounded
applicable maintenance manual. The following and bonded, in accordance with FM 1-500, to
procedures are for general towing of all aircraft. the aerospace ground equipment while
servicing (i.e., fueling or defueling, arming
(1) Prior to towing aircraft, ensure that towing ammunition or explosives, oxygen, hydraulic
attachments, lines, and bars are of adequate capacity, fluids, or any flammable liquids). Grounding
serviceable, and secured firmly to designated tow is not necessary for aircraft parked outside
fittings of aircraft and tow vehicle. unless one of the above is being
accomplished.
(2) Do not exceed the walking speed of the
slowest team member, with a maximum speed of 5 Grounding of aircraft is required when
mph. Tow with extreme care over ice, snow, rough, external power is applied to the aircraft.
rocky or muddy ground and in congested areas.

Change 1 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 annually or when there is a
maintenance platforms/safety stands or any possibility of mechanical damage. If any damage is
other approved locally procured/manufactured found, it must be repaired immediately.
safety stands/restraint equipment will be used
when working (above 10 feet) on aircraft in a (2) Method of testing. Ground rods are tested
non-tactical environment. with a multimeter (Multimeter: TS-352B/U, LIN M81372,
NSN 6625-00-553-0142). Refer to FM 10-68 for specific
b. Earth Grounds. An earth ground (electrode) is a procedures when testing ground rods.
conductive pipe or rod made of galvanized iron,
galvanized steel, or copperweld steel. The rod regularly d. Fabrication of Ground Cable. Fabricate static
used for grounding is Rod, Ground: MX-148G Line Item grounding cable assembly, as shown in figure 3-1, using
Number (LIN) S08698, National/NATO Stock Number the following procedures:
(NSN) 5975-00-224-5260. This ground rod is 3/4 inch in
diameter and 6 feet long, and it is made of galvanized (1) Cut wire rope (figure 3-1, 1) to length
steel. It has one pointed end to be driven into the earth needed.
and a 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 (4) Insert wire rope (1) into handle of clip (5)
surrounding surface, at other types of facilities, the top and tighten set screws (4).
of 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 (7) If desired, clips (5) may be attached to
18 inches in diameter, with a 2-inch black border both ends of wire rope (1) with a plug (3) attached to
surrounding it, should encircle each rod that is installed handle of one of the clips as follows:
in a hard surface. These circles should be painted on.
The words STATIC GROUND CONNECTION and a (a) Cut short length of wire rope to attach
numeric or alphanumeric identification of the rod should plug to clip.
be stenciled in black on the yellow circle. The number
and spacing of fixed rods should be determined by the (b) Assemble items for alternate configuration
requirements of the local situation. Markings of this type as in (2) through (6) above. See detail A for view of
are not required for temporary ground rods. alternate cable assembly.

c. Earth Ground Testing. The electrical resistance NOTE

of each grounding system should be as low as possible Never fasten electrical clip to a
but not greater than 10,000 ohms. A log must be kept painted surface.
for airfields to show the identification of each rod, the
date tested, and the reading in ohms. If the measured (8) Insert plug into receptacle on aircraft.
resistance of a rod is greater than 10,000 ohms, the rod Attach clip to grounding stake.
should immediately be marked DEFECTIVE-DO NOT
USE and it should be removed or replaced as soon as (9) Attach warning streamers, NAS 1756-12
possible. A log is not required at temporary refueling or MS 51700-12, to coated wire rope.
points.

3-6
 TM 1-1500-204-23-1

Figure 3-1. Fabrication of Static Grounding Cable Assembly

3-7
 TM 1-1500-204-23-1

(10) Attach yellow reflective tape, 9390-00- Receptacle can be grounded by mounting or
040-6102, to non-coated wire rope. bonding to aircraft structure.

(a) Wrap tape around handles of clip Receptacle shall be used with grounding plug
and around the wire at three-foot intervals. conforming to MIL-C-83413/10.

(b) Do not apply tape to those parts of Dissimilar metals as defined by MIL-STD-889
plug and clip that complete electrical circuit. shall not be used in intimate contact with each
other.
(11) Test ground cable for resistance to
ground. Place a fully charged fire extinguisher (50 lb
CO2 or 22 lb. Halon 1211) in readily accessible
e. Ground Receptacle Criteria. Aircraft grounding area where aircraft are parked.
receptacles, as shown in figure 3-2, shall conform to the
following criteria:

For internal and external tanks, the receptacle

shall be installed at not more than 42 inches
(1066.80 mm) and not less than 12 inches
(304.80 mm) from the filler opening.

Figure 3-2. Aircraft Grounding Receptacle Installation

3-8
 TM 1-1500-204-23-1

NOTE (3) Recheck OHM reading as stated in para-

Precautions should be taken to ensure that graph 3-4g(1). If it does not meet requirement, repeat
these parking area extinguishers are periodi- procedure.
cally inspected and adequately marked to (4) When a satisfactory measured resistance
ensure high visibility (for ease of location in has been reached, touch-up paint as required per TM
the event of an emergency and to prevent 55-1500-345-23.
accidents during aircraft movement). Due to
the smaller size of the Halon 1211 portable- 3-5. Aircraft Refueling. Servicing aircraft with fuel
type extinguishers, these bottles should be and defueling aircraft requires the utmost precaution due
secured in a permanent location to facilitate to the highly flammable characteristics of fuel. Personnel
recognition and prevent damage to the extin- performing fueling and defueling operations must be
guisher. thoroughly familiar with FM 10-68, Aircraft Fueling, and
FM 10-69, Petroleum Supply Point Equipment and
i. Ground Receptacle Testing. Test ground recep- Operations. Personnel must also be completely familiar
tacle using the following procedures: with the aircraft being serviced.
(1) Using an ohmmeter, check resistance from NOTE
the receptacle to a point on the aircraft skin adjacent to Aircraft shall have all fuel cells fully serviced
the receptacle. Contact point used must be free of paint prior to being parked or stored in a hangar. All
and corrosion and cleaned for good electrical contact. An fuel cells should be full in order to minimize
ordinary ohmmeter set on R x 1 scale, will read a direct the presence of flammable vapors within fuel
short or not more than 1 ohm. cell (for safety purposes) and additionally to
minimize water condensation and subse-
(2) If resistance reading exceeds requirement
quent microbiological growth which results in
of paragraph (I), receptacle must be removed and air-
contamination of the fuel.
craft skin around it must be cleaned of paint and corro-
sion and treated per TM 55-1500-345-23. Reinstall the This procedure should be adhered to at all
receptacle in accordance with MIL-C-83413/ times; except when impending mission
MIL-C-8349. Nut must be tight. requirements shall necessitate a reduced fuel
load or when an aircraft shall require mainte-
(3) Recheck ohmmeter reading as in step(1). If nance to the fuel system.
it does not meet requirement, repeat procedures
a. Open-Port Refueling. Open-port refueling is
(4) Retouch paint as required per TM refueling by inserting an automotive-type nozzle into a fill
55-1500-345-23. port of larger diameter. Most of the Army fueling nozzles
are designed for open-port refueling and must be used
g. Aircraft Fuel Port Testing. Test aircraft fuel port until enough FARE systems are deployed to make open-
ground using the following procedures. port aircraft refueling an obsolete practice. Because the
(1) Use multimeter, TS352B/U, to check the port is larger than the nozzle, fuel vapors can escape
resistance of aircraft fuel port to the skin adjacent to the through the fill port during open-port refueling opera-
fuel port. The contact on the fuel port and aircraft skin tions. Airborne dust and dirt, as well as rain, snow, and
should be free of paint and corrosion for a good electrical ice can get into the fill port during refueling, thus lowering
contact. the quality of the fuel in the tanks and endangering the
aircraft. Spills from overflowing tanks are possible in
(2) Set the multimeter on the RX1 scale. If the open-port refueling. Spills can also be caused by the
measured resistance is greater than 1 OHM, the aircraft sudden pressure surge that comes when pumping from
fuel port must be removed. The aircraft skin around the another nozzle in the system is completed, throwing the
fuel port must be cleaned of paint, corrosion and then whole pressure of the pump to the operating nozzle.
treated in accordance with TM 55-1500-345-23. Rein- Because of these dangers, hot refueling by the open-port
stall fuel port in accordance with the applicable TM method is restricted to combat or vital training or testing
55-1500-345-23 aircraft maintenance manual. use. Refer to FM 10-68.

Change 2 3-9
TM 1-1500-204-23-1

b. Open-Port Hot Refueling. In combat operations, (2) General operation. After the aircraft parks
the open-port method of hot refueling may be used for and its engine or engines are shut down, the rotor blades
helicopters when, in the judgment of the aviation com- are secured, and armaments are set on SAFE, the
mander, the requirements of the tactical mission and the sequence of the refueling operation can start. The follow-
benefits of reducing ground time outweigh the inherent ing procedures are for all aircraft:
risks of this method of refueling. In noncombat situations,
helicopters may be refueled by this method only when (a) Check the interior of the aircraft. No one
there are compelling reasons to do so. For example, should be aboard during refueling unless the pilot or
aviation commanders may decide that hot refueling must copilot are on board to monitor the quantity of fuel to be
be done for purposes of training, or for field testing or loaded. When the D-1 nozzle is used, the only way of
combat testing for development. When the FARE system knowing when to stop flow is for the pilot or copilot to
is used for hot refueling in a training situation, a firewall watch the fuel gauges in the aircraft.
should be built around 500-gallon drums whenever it is (b) Drive the tank vehicle into position in
possible. Refer to FM 10-68. front of the aircraft. Use the sort of approach route shown
NOTE in figure 3-3. Do not drive the refueler directly at the
Nozzles of the open-port type must be held aircraft because brake failure could cause a serious acci-
open by hand throughout use. If any auto- dent.
matic device has been added to the nozzle to (c) Keep a distance of at least 10 feet
hold it open, the device must be removed; if between the refueler and the aircraft. There must be at
notches have been made to hold open, they least 10 feet between the refueler and rotor blades of a
must be filed off. No exceptions to this rule are helicopter. Keep a distance of at least 20 feet between
allowed in aircraft refueling. the exhaust pipe of the pump engine (or truck engine)
c. Rapid Hot Refueling. Aircraft may be rapid (hot) and the aircraft fill port and tank vent as shown in figure
refueled (with engines running), electrical power on, 3-4.
radios on, weapons system on with safety covers/ (d) Park the refueler so that it has a clear
guards/switches in safe position, and with any computer and open path to drive away from the aircraft in an emer-
systems operating that would require reprogramming if gency. Do not detach a tank semitrailer from its tractor
shut down. See the applicable aircraft operator’s manu- when refueling an aircraft; the tractor must be ready to
als (-10 and -CL) for detailed instructions. If rapid (hot) pull the trailer away from the aircraft if the need arises.
refueling is required (prescribed in FM 10-68), ground the
aircraft properly. It is also recommended that the aircraft NOTE
be in a revetment type shelter or separated from fuel If the refueler can be driven into position with-
storage by a fire wall. out backing, do so. If it must be backed toward
the 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
Only emergency radio transmissions should ground guide. Follow signals to guide the final
be made during rapid (hot) refueling. Radio backing approach until signaled to stop at the
switches may electrically arc when being proper distance from the aircraft and its fill
keyed. port and vent, as shown in figure 3-5.
d. Fuel Truck Operations. Fuel truck operations are (e) Stop the refueler engine (unless it pow-
covered in the following paragraphs. ers the pump) and set the brake. Chock the tires of the
refueler and of the aircraft if appropriate.
(1) Fuel truck types. The M49A2C tank truck
with a 1,200 gallon stainless steel tank, the M559 tank (f) Check the fuel in the tank to make sure
truck with a 2,500 gallon stainless steel tank, and the it is the right type for the aircraft. Check the sight glass of
M857 semitrailer with a 5,000 gallon tank are used to fuel the filter/separator to make sure all water has been
Army aircraft. drained out.

3-10 Change 1
 TM 1-1500-204-23-1

Figure 3-3. Fuel Truck Approach Route

Figure 3-4. Fuel Truck Required Spacing

3-11
 TM 1-1500-204-23-1

Figure 3-5. Fuel Truck Backing Approach

(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

(j) Bond the nozzle to the aircraft NOTE

before taking the dust cap off the nozzle and the cap off Personnel who refuel aircraft may not
the fill port. If the aircraft has a receiver for the bond carry lighters or matches on their
plug, use the plug, if not, clip the alligator clip to a bare persons and must not allow anyone
metal part of the aircraft. else to carry a lighter or matches
within 50 feet of an aircraft that is
(k) Open the aircraft fill port and being refueled. Use of exposed-flame
remove the nozzle dust cap. heaters, welding or cutting torches,
and flare pots is forbidden within 50
NOTE feet of refueling operations.
When using an open-port nozzle or the
CCR nozzle adapter, put the nozzle • Do not allow electrically powered tools to be used
well down into the port. Do not open in the refueling area.
the nozzle until it is inside the fill port
When using the CCR nozzle, mate the • Do not allow any metalworking tools to be used
nozzle into the fill port. If they will not within 50 feet of an aircraft being refueled.
latch together, look for dirt in the fill
port or on the nozzle. Wipe the fill • Do not use flashlights within 50 feet of the
port out and clean the nozzle, then refueling operation unless the lights are of the
mate the two together. approved explosion-proof type.

(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.

a. Install drip pans where practicable.

3-14
 TM 1-1500-204-23-1

NOTE nature shall be allowed to contact

Never use flammable solvents to oxygen. Ensure that all components
remove oil spillage. of the systems are free of moisture,
oil and grease at all times. Oxygen is
b. Exercise caution to prevent overfilling or a nonflammable gas, however, it
spilling. supports combustion and lowers the
flash ignition point of all
NOTE combustible materials. Oxygen shall
When oil has been spilled, immediate be handled as a flammable gas.
action shall be taken to remove
spillage from aircraft and adjacent • When an aircraft is being serviced
area. Clean rags may be used to with oxygen within 50 feet of an area
remove oil spillage from the aircraft. where smoking is permitted, NO
Sand, dirt, sawdust, or commercial SMOKING signs shall be placed at a
products may be used to remove oil 50-foot radius around the servicing
spillage from adjacent ground. area. A spark in the servicing area
could cause an explosion and
3-7. Oxygen Servicing. Oxygen servicing requires the damage to equipment.
utmost precautionary measures due to the highly
explosive and flammable capabilities of oxygen. Prior to (1) To prevent overfilling of tanks,
servicing an aircraft oxygen system, personnel shall personnel shall observe aircraft oxygen system gauges at
familiarize themselves with the system, precautions, and all times during servicing operation.
instructions for handling gaseous oxygen, operation of
servicing equipment, and potential hazards involved. (2) Personnel shall be stationed at the
oxygen servicing unit at all times during servicing
CAUTION operation to shut off unit valves immediately upon
Only qualified personnel shall be receiving a command from personnel watching aircraft
authorized to operate equipment for system gauge.
servicing of an aircraft oxygen
system. Damage to system may (3) Service aircraft from cylinders clearly
otherwise result labeled DRY or AVIATOR'S BREATHING OXYGEN.
Other oxygen may have moisture which could cause flow
a. Safety Precautions. Aircraft shall not be stoppage at temperatures below freezing.
serviced with oxygen when any of the following conditions
prevail. (4) Always use a pressure-reducing device
when servicing low-pressure oxygen system from high
• Aircraft electrical switches are on. pressure bottles.
• Ground powered equipment is operating within 50
feet of the servicing area. (5) Fill oxygen system slowly to prevent
• Aircraft is being serviced with fuel, oil, or anti- explosion resulting from heat generated by filling too fast.
icing fluids.
• Any combustible items, such as fluid, etc. , are (6) An aircraft oxygen system not equipped
evident around oxygen servicing equipment. with shutoff devices at cylinders shall be completely
discharged of all pressure prior to removing components.
b. Servicing. General servicing procedures for All electrical power shall be turned off during oxygen
oxygen systems are explained in the following discharge operations.
paragraphs.
(7) Refer to the applicable aircraft
CAUTION maintenance manual for additional information and
maintenance procedures.
• Oxygen equipment shall be kept
clean at all times. No organic matter
or flammable substance of any

3-15
 TM 1-1500-204-23-1

3-8. Hydraulic Fluid Servicing. Hydraulic fluid a. Safety Procedures. Safety procedures prior
servicing precautions are explained in the following to starting, during starting, during engine operation, and
paragraphs. after operating engines are covered in the following
paragraphs.
WARNING
To avoid contamination, do not use (1) Safety procedures prior to starting. The
previously opened cans of hydraulic following safety procedures should be accomplished prior
fluid. A new sealed can of fluid must to starting.
be opened and used. When opening
can, clean top, and use a clean (a) Head aircraft so that exhaust
sharp, unplated instrument to blast is directed to least inhabited areas.
prevent contamination.
(b) Place approved chocks fore and
a. Do not overfill reservoir or spill fluid in aft of main landing gear wheels.
surrounding areas. When fluid is spilled, absorb with
clean rags. (c) Clear aircraft and surrounding
areas of covers, tools, rags, work stands etc , and remove
b. When filling reservoirs, extreme care shall be mooring ropes.
taken to ensure that no dirt or foreign matter enters the
system. (d) Secure access doors by closing
or removing prior to ground testing turbine-powered
c. Refer to applicable aircraft maintenance aircraft engines.
manual for additional servicing and maintenance
instructions. Use only specified hydraulic fluid. (e) Do not allow personnel on any
external portion of an aircraft during engine start or
3-9. Pneumatic System Servicing. Safety precautions operation.
for servicing pneumatic reservoirs are contained in the
following paragraphs. (f) Station ground crew member,
equipped with a carbon dioxide or equivalent fire
a. Never use pressure oxygen to inflate gear extinguisher to one side and forward of engine being
shock struts, pressure accumulators, etc. started. This crew member will observe for fire and fire
hazards, such as fuel from overflow lines, fuel/oil leakage,
b. Use only clearly labeled compressed air chock slippage, and other irregular conditions.
cylinders or compressed air hoses of known origin.
CAUTION
c. Ensure that locking mechanism on aircraft If aircraft utility fire extinguisher is
valve stem is engaged prior to installing hose to valve utilized for an engine start, another
stem. Always engage locking mechanism after servicing. fire extinguisher, rated capacity of
10-B or more, will be located within
d. Fill system slowly to reduce heat generated 50 feet of all fixed or rotary wing
by filling too rapidly. Army aircraft. Fire fighting capability
must be maintained.
e. Exercise care not to overcharge the system.
NOTE
f. Completely discharge pressure prior to If ground crewmember does not have
removing a component from the system. radio communication, he must stand
in view of aircraft operator.
3-10. Engine Operation. For operation and specific
instructions on a particular fixed or rotary wing Army (g) When appropriate, station a
aircraft, refer to the applicable maintenance manual. responsible ground crewmember off to one side, away
Safety procedures and general operating procedures for from danger areas, and aft of operating turbine powered
reciprocating and turbine engines are contained in the aircraft, to warn approaching traffic. Use a danger flag
following paragraphs. when necessary.

3-16
 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

NOTE (3) Shutdown. Shut down turbine

engines in accordance with the applicable maintenance
• Starting oil pressure may exceed manual.
standard oil pressure gauge limits.
This condition is not considered 3-11. Runup and Taxiing. Nonrated personnel who
dangerous unless the pressure start, run, warmup test, taxi or otherwise operate aircraft
remains high. Takeoff should be on the ground will be fully qualified, demonstrate
delayed until oil pressure drops with satisfactory ability, and be authorized to perform such
range, as specified in applicable duties, in accordance with AR 95-1. Nonrated personnel
maintenance manual. cannot run up rotary wing aircraft under any condition.
General safety procedures, taxiing, and postflight and
parking are covered in the following paragraphs.
• A hot start occurs when the engine
starts, but the exhaust gas
a. Safety Procedures. General safety
temperature exceeds specified limits.
procedures for runup and taxiing are provided in the
This is usually caused by an following steps.
excessively rich fuel air mixture
entering the combustion chamber. (1) Chock aircraft securely before
The fuel to the engine should be attempting an engine runup.
shut off immediately.
(2) Check runup area carefully to prevent
• False or hung starts occur when the propeller or jet blast from throwing ice and snow on other
engine starts normally but the rpm aircraft.
remains at some low value rather
than increasing to the normal NOTE
starting rpm. This is often the result Some instruments will give erroneous
of insufficient power to the starter, or readings due to cold. These readings
the starter cutting off before the can be compensated for or corrective
engine starts self-accelerating. In action may be taken. For specific
this case, the engine should be shut instruments and their characteristics,
down. consult applicable maintenance
manual.
(2) Ground checks. To ensure proper
operation, perform the following procedures before taxiing (3) Position ground crew to ensure
or takeoff. adequate guidance when aircraft is maneuvered close to
other aircraft, buildings, or obstructions, or in gusty or high
(a) Inspect all aircraft systems and winds.
surfaces, with emphasis on systems and surfaces directly
affected by low temperatures. (4) Check that brakes are not frozen, and
that aircraft will roll before attempting to taxi from parking
(b) Inspect controls and trim tabs for space.
freedom of movement.
(5) Free tires that have become frozen to
CAUTION surface by application of heat or over-inflation. Do not
Do not apply heat directly or too allow heat to exceed 160°F (71°C).
rapidly against windshield and
windows as there is danger of NOTE
cracking, crazing, and discoloration. Immediate freeing action cannot be
expected from tires that have been
(c) Inspect cabin heat, defrosting, over-inflated. A time period of one-
and anti-icing systems. half to one hour may be necessary
for tires to become free.
(d) Inspect hydraulically-operated
equipment. Cycle system several times if sluggish
operation is evident.

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 2 3-19/(3-20 blank)

 TM 1-1500-204-23-1

CHAPTER 4

AIRCRAFT STORAGE AND SHIPMENT

4-1. General. The following paragraphs provide 4-5. Inspection of Stored Aircraft. All aircraft placed
information on the preparation of Army aircraft for in storage shall be carefully inspected at regular intervals
shipment and storage. of 60 days or less, depending on local conditions. Stored
aircraft shall be corrosion-treated if this precaution is
4-2. Categories of Storage. The length of time that the found necessary when conducting inspection for
aircraft will be inactive will determine which of the corrosion. Particular attention shall be given to those
following categories of storage will be used. areas where moisture deposits will not evaporate rapidly.
Normally, corrosion will not be as prevalent on painted
a. Flyable Storage. Flyable storage is the surfaces as on unpainted surfaces. The commanding
prescribed procedure to maintain a stored aircraft in officer of the storage facilities shall be responsible for
operable condition. Next to daily use, this category of establishing a program of periodic inspections of stored
storage keeps the aircraft in the best possible condition. aircraft in addition to the prescribed inspections listed
All scheduled preventative maintenance will be performed below.
on aircraft in flyable storage, and periodic operation of the
aircraft and all systems is required. There is no time limit a. Ensure proper preservation and ventilation of
on flyable storage. aircraft and take immediate action to correct all
unsatisfactory conditions.
b. Short Term Storage. Short term storage is
used to store an aircraft for a period not to exceed 45 b. Ensure drainage holes on underside of
days. Aircraft in short term storage require extensive fuselage, wing, center section, and control surfaces
preservation but very little periodic attention. remain unobstructed.

c. Intermediate Storage. Intermediate storage is c. When canvas covers are used for protection,
used to store aircraft for a period of 46 to 180 days. they shall have drainage holes installed at locations where
Aircraft in intermediate storage require very extensive water would tend to accumulate.
preservation but minimal periodic attention.
d. During hot weather, spot checks shall be
d. Long Term Storage. Procedures for made among each type and model of stored aircraft to
long term storage are not available for the storage of determine maximum interior temperatures encountered.
Army aircraft if storage beyond 180 days is required, the This shall be accomplished by hanging a standard
aircraft will be depreserved, returned to flyable status, thermometer in the interior of aircraft, and recording
operated, and represerved in accordance with this readings during the hottest parts of day. When
chapter. temperature exceeds 160°F (71°C), action shall be taken
to ventilate aircraft.
4-3. Responsibility. The Commanding Officer shall be
responsible for initiating action to place aircraft in storage e. To aid ventilation on aircraft employing
in accordance with this chapter. The type of storage used astrodomes, astrodome may be removed and replaced
shall be selected based on the length of time the aircraft with a covered flue.
will be inactive.
f. Forced ventilation may be employed when
4-4. Preparation of Aircraft for Storage. When the other methods of ventilation are not adequate to prevent
decision is made to place aircraft in flyable, short term, or sweating in interior of aircraft and resulting accumulation
intermediate storage, the aircraft will be prepared in of condensation and mildew.
accordance with the applicable Aviation Unit Maintenance
(AVUM) technical manuals. Authorization to take g. Exterior locks, ground wires, chocks, mooring
deviation from published procedures will be obtained, in ropes, rods, and eyes shall be inspected every 30 days
writing, from Commander, U S. Army Aviation Systems and immediately after aircraft has been subjected to high
Command, ATTN AMSAV-SDP, 4300 Goodfellow Blvd, velocity winds (exceeding 40 mph). Pulled rods or
St Louis, MO 63120-1798.

4-1
 TM 1-1500-204-23-1

deteriorated locks, ground wires, chocks, mooring ropes, d. Operational Check. Perform Maintenance
and rods shall be replaced. Operational Check (MOC) and/or Maintenance Test Flight
(MTF) as required in accordance with TM 55-1500-328-
NOTE 25.
Under some conditions, corrosion
may attack the metal through the 4-9. Shipment of Aircraft. Step by step procedures for
paint. In such cases, the affected the preparation, loading, tiedown, and unloading of Army
areas will be indicated by blisters or aircraft for shipment by vessel, truck, and cargo aircraft
a scaly appearance of the paint. are provided in the Preparation for Shipment Manual
applicable to the aircraft. Authority to take deviation from
4-6. Maintenance of Stored Aircraft. Precautions shall the procedures in the applicable Preparation for Shipment
be taken to ensure that adequate maintenance will be Manual must be obtained, in writing, from Commander, U.
accomplished to maintain the aircraft in the proper state S. Army Aviation Systems Command, ATTN. AMSAV-
of preservation in accordance with applicable aircraft SDP, 4300 Goodfellow Blvd, St. Louis, MO 63120-1798,
maintenance manual. For aircraft in flyable storage, AUTOVON 693-2372, Commercial (314) 263-2372.
calendar and dual criteria inspections will be completed
as they become due. 4-10. Preservation and Packaging of Aircraft
Components. General information on the preservation
4-7. Entries In Aircraft Forms. When an aircraft is and packaging of Army materiel is provided by TM 746-
placed in storage, process DA Form 2408 series forms in 10, Marking, Packaging and Shipment of Supplies and
accordance with DA PAM 738-751. Include an entry Equipment: General Packaging Instructions for Field
indicating the type of storage, the date placed in storage, Units Detailed information is provided by TM 38-230-1
and the date represervation is due. and TM 38-230-2, Preservation of Materiel Preservation,
Volumes I and II, respectively.
4-8. Removal of Aircraft from Storage. When an
aircraft is removed from storage, the inspection and a. Special Reusable Containers. Preservation
maintenance performed will be dependent on the type of and packaging instructions for major aircraft components
storage the aircraft has been in. that have special reusable containers are contained in the
applicable Aviation Unit Maintenance (AVUM) Technical
a. Depreservation. Depreserve aircraft in Manual.
accordance with applicable AVUM technical manuals.
b. Packaging Procedures. Aircraft components
b. Inspection. Perform preventative will normally be shipped in the same packaging the
maintenance daily inspection and all calendar and dual replacement component was received in. When this is
criteria inspections that are due. not possible and assistance is required in determining the
preservation and packaging of a specific component,
c. Maintenance. Correct aircraft deficiencies as contact Commander, U. S. Army Aviation Systems
required. Command, ATTN. AMSAV-SDP, 4300 Goodfellow Blvd,
St Louis, MO 63120-1798.

4-2
 TM 1-1500-204-23-1

CHAPTER 5

MARKING OF AERONAUTICAL ITEMS

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.

• Serviceable Tag-Materiel (DD Form 1574) and

Serviceable Label Materiel (DD Form 1584-1).

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- NOTE
rior surface application as governed by MIL-D-8634 and Apply pressure lightly to permit easy removal
MIL-D-8635 respectively. Prior to application of decals, of backing; reimmerse decals from which
the following instructions shall apply to assure proper backing is not easily removed.
adhesion:
(c) Perform minor alignment with fingers,
a. Clean all surfaces thoroughly with a clean cloth then remove water by gently blotting decal and adjacent
dampened with aliphatic naphtha, Federal Specification area with a soft, absorbent cloth. Remove air or water
TT-N-95, to remove grease, oil, wax, or other foreign bubbles trapped under decal by wiping carefully toward
matter. nearest edge of decal with cloth. Allow decal to dry.
b. Wipe area with a clean, dry cloth to remove
dampness and residue, then seal porous surfaces and (d) Paint area surrounding decal and outer
sand rough surfaces. perimeter of decal with a coat of oil-type varnish, TT-
V-109. Apply varnish in a 1/4- to 1/2-inch wide stripe to
c. Remove excess paper and film from decals which prevent peeling.
have trim lines.
(2) Removal. Remove paper decals by rubbing
6-2. Decal Types. Decals approved for use on Army decal with a cloth dampened with lacquer thinner, Fed-
aircraft are of three types: paper (lacquer), vinyl film and eral Specification TT-T-266, or methylethyketone, ASTM
metal. Application and removal of decals are explained D740.
in the following paragraphs. b. Vinyl Film Decals. Application and removal pro-
a. Paper Decals. Application and removal proce- cedures are explained in the following paragraphs.
dueres are explained in the following paragraphs. (1) Application. Apply vinyl film decals in accor-
(1) Application. Apply paper decals in accor- dance with the following procedures:
dance with the following procedures:
(a) Separate paper backing from plastic
(a) Immerse paper decals in clean water film.
for one to three minutes.
NOTE
NOTE
Remove paper backing adhering to the
Allowing decals to soak longer than three adhesive by rubbing the area gently with a
minutes will cause the backing to separate clean cloth saturated with water; remove
from the decal while immersed; allowing small piece of remaining paper with masking
decals to soak less than one minute will tape.
result in the backing not separating from
decal. (b) Place vinyl film, adhesive side up, on a
clean porous surface such as wood or blotter paper.
(b) Place one edge of decal on prepared
receiving surface and press lightly, then slide paper (c) Apply cyclohexanone, or equivalent, in
backing from beneath decal. firm, even strokes, to adhesive side of decal.

6-1
 TM 1-1500-204-23-1

NOTE 3 Remove cellophane backing, but do

Reactivate adhesives which have dried not touch adhesive,
with cyclohexanone,or equivalent, prior to
installation. Adhesive may be reactivated NOTE
as many as three times without damage to Apply a few drops of aliphatic naphtha, Fed-
adhesive capability. Adhesives which are eral Specification TT-N-95, to the adhesive
reactivated will be allowed to air-dry thor- when room temperature is below 72°F
oughly before application. (22°C).
(d) Position decal in proper location, while
4 Position one edge of decal onto pre-
adhesive is still tacky, with only one edge contacting pared receiving surface. On large foil sheet, place center
prepared surface. onto receiving surface and work outward from center to
(e) Work roller across decal with overlap- edges.
ping strokes until all air bubbles are removed.
5 Remove all air pockets by rolling firmly
with a rubber roller, and press all edges tightly against
receiving surface to ensure good adhesion.
Drycleaning solvent is flammable and sol- (b) Removal. Remove metal decals by
vent vapors are toxic. Use P-D-680, Type moistening edge of foil with aliphatic naphtha, Federal
II Solvent in a well-ventilated area. Keep Specification TT-N-95, and peeling decal from adhering
away from open flames. Avoid prolonged surface.
solvent contact with skin.
(2) Removal. Remove vinyl film decals by plac- (2) Paper-backing adhesive type. Application
ing, a cloth saturated with cyclohexanone, or methyle- and removal of paper-backing adhesive are explained in
thylketone, ASTM D740, on decal and scraping film with the following paragraphs.
a micarta scraper. Remove remaining adhesive by wip-
ing with a cloth dampened with drycleaning solvent, Fed- (a) Application. Apply metal decals with
eral Specification P-D-680. paper backing adhesive in accordance with the following
procedures:
c. Metal Decals. Metal decals come in three types:
cellophane-backing adhesive type, paperbacking adhe- 1 Remove paper backing from decal.
sive type, and no adhesive type. Application and removal
procedures for each type are explained in the following 2 Apply very light coat of cyclohexanone,
paragraphs. or equivalent, to adhesive.
(1) Cellophane-backing adhesive type.
Application and removal of cellophane-backing adhe- 3 Position decal in proper location while
sives are explained in the following paragraphs. adhesive is still tacky with only one edge contacting pre-
pared surface.
(a) Application. Apply metal decals with
cellophane-backing adhesive in accordance with the fol- 4 Work roller across decal with overlap-
lowing procedures: ping strokes until all air bubbles are removed.
1 Immerse decal in clean, warm water
for one to three minutes. (b) Removal. Remove metal decals by
moistening edge of foil with aliphatic naphtha, Federal
2 Remove from water and dry carefully Specification TT-N-95, and peeling decal from adhering
with a clean cloth. surface.

6-2 Change 2
 TM 1-1500-204-23-1

(3) No adhesive type. Application and (3) Systems not referenced. A white tape
removal of no adhesive are explained in the following with black lettering will be used for coding lines of
paragraphs. systems such as the vacuum system not referenced in
figure 6-1.
(a) Application. Apply decals with no
adhesive in accordance with the following procedures. Table 6-1. Colors and Codes

1 Apply one coat of cement, Code

Federal Specification MMM-A-1617, to decal and Code Color Specification No.
prepared receiving surface.
Light blue ANA Bulletin 166 501
2 Allow cement to dry until both Light green ANA Bulletin 166 503
surfaces are tacky. Light yellow ANA Bulletin 166 505
International
3 Apply decal and roll down to orange ANA Bulletin 166 508
remove air pockets. Insignia red ANA Bulletin 166 509
Maroon ANA Bulletin 166 510
4 Remove excess adhesive with Insignia white ANA Bulletin 166 511
a cloth dampened with aliphatic naphtha, Federal Aircraft gray ANA Bulletin 166 512
Specification TT-N-95. Gloss black ANA Bulletin 166 515
Brown Federal Standard 595 10049
(b) Removal. Remove metal decals
by moistening edge of foil with aliphatic naphtha, Federal
Specification TT-N-95, and peeling decal from adhering
(4) Type of tape. Aircraft tubing identification
surface.
marker tape (non-corrosive, heat, cold and solvent
resistant), MIL-T-9906 conforming to MS87033, shall be
6-3. Application and Installation of Identification
used
Tapes. The Army uses two types of identification
systems to code the plumbing lines and electrical conduits b. Solid Color Band System. This alternate
of aircraft. The two systems used are the printed- system consists of the use of one, two, or three bands of
symbolized tape system (the preferred method), and the 1/2-inch wide solid colored tape wrapped on various lines
solid color band, (the alternate method). Identification for identification. This system is shown in figure 6-2.
tapes will be applied to plumbing lines and electrical
conduits of all Army aircraft. (1) Tape colors. Colors for tapes used in
this system shall conform to color codes in ANA Bulletin
a. Printed-Symbolized System. This latest and 166 and Federal Standard No 595 (refer to table 6-1).
preferred system utilizes printed colored tape (one inch
wide) with geometrical symbols. The main function of the (2) Tape spacing. When more than one
line is printed on the tape. Printing will be in accordance color of tape is required, tapes shall be placed
with MIL-STD-1247. Colors will be in accordance with approximately 1/16 inch apart. When one color is used
ANA Bulletin 166 and Federals Standard 595 (refer to but more than one tape is required, tapes shall be placed
table 6-1). approximately 1/8 inch apart.
(1) Colored tapes. Colored tapes as shown (3) Type of tape. Type II pressure-
in figure 6-1 shall be used to identify aircraft system lines. sensitive tape, A-A-113, shall be used for this system.
(2) Line content. Identification of system c. Application of Identification Tapes. The
line content or subsidiary functions may be indicated by application and use of both identification systems are the
additional words or abbreviations printed on a second same, and the following paragraphs are applicable to both
tape adjacent to first tape or, alternatively, interposed systems.
between words descriptive of main function.

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

Figure 6-1. Color-Coded Tapes

6-4
 TM 1-1500-204-23-1

PIPE LINE SYSTEMS COLOR CODE

Figure 6-2. Solid Color Band System

6-5
 TM 1-1500-204-23-1

(1) Secondary lines. Filler, vent, and drain CAUTION

lines will be identified by colors of the plumbing system The low flash point of solvents make
for which they function. them a fire hazard, therefore, employ
utmost care when using them.
(2) Location of bands. One band will be Damage may otherwise result.
located on each tube segment of 24 inches or less when
both ends of the segment are within the same (1) Clean areas to be banded with aliphatic
compartment. One band shall be located at each end of naphtha, Federal Specification TT-N-95, or drycleaning
tube segments longer than 24 inches. When the tube solvent, Federal Specification P-D-680.
segment passes through more than one compartment or
bulkhead, additional bands will be applied to the tube so (2) Coat exterior surfaces of metal tubing
that a minimum of one band is visible in each when necessary, with epoxy primer, MIL-P-23377, prior to
compartment or on each side of the bulkhead. application of tape.

(3) Tapes in engine compartment. Tapes (3) Install tape not having clear acetate
shall not be used on fluid lines in the engine compartment covering by tightly wrapping 1 1/4 turns of tape around the
where there is a possibility of the tape being drawn into part being banded and press firmly to ensure adhesion.
the engine intake. When tape cannot be employed, Apply one coat of clear lacquer, Federal Specification TT-
suitable paints conforming to the color codes in table 6-1, L-32, over band and extend 1/4 inch beyond tape edges.
and having no injurious effect on the metal used for the
lines, shall be used for identification purposes. When (4) Install tape having clear acetate
paints are used, the geometrical symbols may be omitted. covering by tightly wrapping 1 1/4 turns of tape around the
part being marked and press firmly to ensure adhesion.
(4) Warning symbol. Warning symbol
tapes, as shown in figure 6-1, shall be applied adjacent to
the identification tape on those lines containing fluids
considered to be dangerous to maintenance personnel.
Warning tapes shall be used when applicable on both
identifying systems. Warning tape shall be 3/8 inch wide.

d. Installation of Identification Tapes. Installation

of identification tape consists of the following procedures:

WARNING
Drycleaning solvent is flammable
and solvent vapors are toxic. Use P-
D-680, Type II Solvent in a well-
ventilated area. Keep away from
open flames Avoid prolonged
solvent contact with skin.

6-6
 TM 1-1500-204-23-1

CHAPTER 7

GENERAL RECIPROCATING ENGINE MAINTENANCE

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.

a. Types. Types of aircraft reciprocating 7-3. Reciprocating Engine Theory. A reciprocating

engines used by the Department of the Army are the (internal-combustion) engine is a device for converting
radial type and the opposed type Radial-type engines heat energy into mechanical energy. Gasoline is
have the crankcase in the form of a circle, as shown in vaporized and mixed with air, forced or drawn into a
figure 7-1. The cylinders extend out from the housing in cylinder, compressed by a piston, and then ignited by an
the same manner as the spokes of a wheel Cylinders are electric spark. The conversion of the resultant heat
arranged evenly in the same circular plane and all pistons energy into mechanical energy and then into work is
are connected to a 360-degree crankshaft. Opposed-type accomplished in the cylinder. The operating cycle of an
engines have cylinder banks arranged an two rows internal combustion reciprocating engine, as shown in
directly opposite each other with a crankshaft in the figure 7-3, includes the series of events required to induct,
center as shown in figure 7-2. Pistons are connected to compress, ignite, burn, and expand the fuel-air charge in
the single crankshaft. This type engine may be mounted the cylinder, and to scavenge or exhaust the byproducts
with cylinders vertical or horizontal. of the combustion process. When the compressed
mixture is ignited, the resultant gases of combustion
expand very rapidly and force the piston to move away
from the cylinder head. This downward motion of the
piston, acting on the crankshaft through the connecting
rod, is converted to a circular or rotary motion by the
crankshaft.

7-4. Major Engine Components. Major engine

component types and maintenance are described in the
following paragraphs.

a. Crankcases. The crankcase encloses the

various mechanisms surrounding the crankshaft. The
crankcase provides a tight enclosure for the lubricating oil
and supports various external and internal mechanisms it
contains the bearings in which the crankshaft revolves
and provides support for attachment of cylinder
Figure 7-1. Radial-Type Engine assemblies. Finally, it provides mountings for attachment
to the aircraft, and by reason of its strength and rigidity, it
prevents misalignment of the crankshaft and its bearings.
The following paragraphs describe crankcase types and
general maintenance.

7-1
 TM 1-1500-204-23-1

Figure 7-2. Opposed-Type Engine

(1) Types. Opposed-type and radial-type

engine crankcases are described in the following
paragraphs.

(a) Opposed-type crankcases. The

crankcases used on engines opposed vary in form but in
general they are approximately cylindrical. One or more
sides are surfaced to serve as a base to which the
cylinders are attached by means of capscrews, bolts, or
studs. The crankshaft is carried in a position parallel to
the longitudinal axis of the crankcase and is generally
supported by a main bearing between each throw. See
figure 7-4.

(b) Radial-type crankcases. Radial-

type engine crankcases, as shown in figure 7-5, vary in
size and number of sections. Four common sections are
described by the following paragraphs.

1 Nose section. The nose

section is usually made of an aluminum alloy and is
fastened to the power section by studs and nuts or caps
and screws. Most nose sections support the propeller
thrust bearing, propeller governor drive shaft, and the
propeller reduction gear assembly. Various other engine
accessories are sometimes attached.
Figure 7-3. Reciprocating Engine Operating
Cycle (Four-Stroke)

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.

3 Supercharger section The

supercharger section is normally located immediately
behind the main power section and may be of either one-
piece or two-piece construction. Its principal function is to
house the blower or supercharger impeller and diffuser
vanes There are openings on the outside circumference
of the housing for attaching the individual induction pipes,
a small opening for the attachment of the manifold
pressure line, and internal-passages which lead to the
supercharger drain valve.

4 Accessory section The accessory

section provides mounting pads for the accessory units
such as the fuel pumps, vacuum pumps, lubricating-oil
pumps, tachometer generators, generators, magnetos,
starters, two-speed supercharger control valves,

Figure 7-4. Opposed-Type Crankcase

Figure 7-5. Radial-Type Crankcase

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

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

7-4
 TM 1-1500-204-23-1

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

c. Bearings. A beanng is any surface which

supports, or is supported by, another surface. A good
bearing must be composed of a metal that is strong
enough to withstand the pressure imposed on it and
should permit the other surface to move with a minimum
of friction and wear. The parts must be held in position
within very close tolerances to provide efficient and quiet
operation, and yet allow freedom of motion. To
accomplish this, and at the same time reduce friction of
moving parts so that power loss is not excessive,
lubricated bearings of many types are used.

(1) Types. The three different types of

bearings in general use are plain, roller and ball They are
shown in figure 7-8 and described in the following
paragraphs.

(a) Plain bearings. Plain bearings are

usually made of nonferrous metals, such as silver,
bronze, aluminum, and various alloys of copper, tin, or
lead. Plain bearings are generally used for the
crankshaft, cam ring, camshaft, connecting rods, and the
Figure 7-8. Bearing Types
accessory drive shaft bearings.

(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

Figure 7-9. Connecting Rod Assemblies

7-7
 TM 1-1500-204-23-1

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

(2) Maintenance. Cylinder maintenance NOTE

procedures are explained in the following paragraphs. All Dark stains adjacent to the cylinder
openings to a cylinder must be completely closed and head and barrel seam must not be
sealed during the compression and power strokes In order misinterpreted. During engine
to maintain proper compression and thus prevent power operation, the high temperature
loss. The requirements for proper sealing are: good thread lubricant used during barrel
piston rings with no leakage between pistons and walls of and head assembly may be extruded
the combustion chamber, tightly closing. Intake and at the seam leaving a heavy
exhaust valves, and proper valve timing to ensure highest discoloration. Such a condition is In
efficiency obtainable when engine is operating at its no way hazardous to engine
normal rpm. Compression loss at any of these points operation, therefore, verification of
results in reduced engine efficiency. Early detection and
cylinder failure must be by means
correction of these faults will prevent cylinder breakdown.
other than stains alone. A cylinder
Since most engine difficulties can be traced to a small
should be removed for head
number of cylinders, engine malfunction can be corrected
by locating defective cylinders and taking corrective separation only if it displays visible
action. Each phase of cylinder operation, such as damage and/or fails the normal
compression, fuel mixture, or ignition, must function compression test.
properly to maintain cylinder compression.

7-8
 TM 1-1500-204-23-1

(a) Identification. Cylinders will be color

coded around the barrel between the attaching flange and
the lower barrel cooling fin with a 1/2-inch wide band of
enamel, heat-stable, cadmium sulphide paint (see figure
7-12). The cylinder sizes and colors are listed below

Standard Cylinder - Aluminum or Black

Chrome Plated - International Orange

0.010 Inch Oversize - Green

0.015 Inch Oversize - Gray

0.020 Inch Oversize - Yellow

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.

When propeller is rotating in the normal

direction, the operator must be alert for any sign Figure 7-12. Marking of Cylinder
of piston being forced against high
compression, evidenced by a sudden
resistance, slowdown, or stoppage which would
indicate an excess amount of liquid in the lower
cylinder

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.

Liquid locks are also caused by oil in intake

pipes as a result of preservation, fuel
discharged into the intake system while
crankshaft is not rotating, or oil flowing from
push rod housing into rocker box, then seeping
through intake or exhaust valve guides into
intake or exhaust ports.

Due to the mechanical advantage of a long

propeller blade and the fact that two or more
men per blade are used for propeller pull
through, possibility of bending a rod by manual
pull-through is more likely than by starter pull
through. This is particularly true when a partial
liquid lock is present, since the piston with a
partial liquid lock will be very near the top of the
stroke when force. Is required to rotate the
crankshaft against the liquid lock Liquid lock
may bend the connecting rod slightly, but not
enough to move the lower piston ring out of the
cylinder skirt, on the downward stroke, in which
case internal failure may occur within the next
50 hours.

If liquid lock is suspected, remove a spark plug

from cylinder involved and allow liquid to drain
out. Turn propeller several revolutions to make
certain all liquid has drained from cylinder and
induction lines, then install clean spark plug.

(c) Valve blowby. Valve blowby is

Indicated by a hissing or whistling sound when engine is
pulled through by propeller, turned with starter, or while
idling at low speed. Correct valve blowby by first
checking valve clearance and adjust as necessary. If
valve clearance is excessive, proceed using the following
procedures.

NOTE
If valve is stuck in the valve guide,
correct clearance cannot be
determined.

1 Stake valve by placing a fiber drift

Figure 7-13. Liquid Lock
on rocker arm and valve stem, and then drift with a
hammer.

7-10
 TM 1-1500-204-23-1

NOTE 7 Analyze compression reading

When adjusting clearance and obtained.
staking valve do not correct blowby
and raise compression above 8 Determine average cylinder
minimum value as specified. In the compression values by totaling all cylinder compressions
applicable maintenance manual, and dividing total obtained by number of cylinders. If any
replace cylinder as described in one cylinder is 20 percent below the average, or If any
applicable maintenance manual. one cylinder is below the minimum compression value for
that engine, that cylinder must be replaced.
(d) Compression test. A cylinder
compression test locates defective cylinders. NOTE
Replacement of these defective cylinders will prevent an A variance of any one cylinder of 20
unsatisfactory condition from progressing to the point of percent below the average of all
complete cylinder failure and eventual engine failure. cylinder compression readings of
Cylinders with compression below standard shall be engine being checked warrants
replaced, thus preventing the use of engines with a large additional investigations. Two
variation of compression between individual cylinders. additional checks should be made
prior to any detailed work to verify
CAUTION information obtained In first
Ensure that Ignition switch is placed compression check.
in OFF position after engine warmup
has been accomplished. Damage 9 The following conditions may
may otherwise result possibly affect engine compression.

1 When engine Is cold, operate it a Incorrect valve tappet clearances

short time to ensure that cylinder walls and piston rings
are properly lubricated. Worn, scuffed, or damaged pistons

2 Remove one spark plug from each Broken piston nng

cylinder and insert compression tester.
Excessive wear of piston rings and cylinder
3 Either disconnect starter booster walls
coil or ground all disconnected spark plug lead.
Burned or warped valves
4 Place throttle in FULL open
position, keep fuel tank selector valve closed. Carbon particle between face and seat of
valve
5 Use battery cart or auxiliary power
unit to provide power for energizing engine starter. Incorrect valve timing

6 Using engine starter, crank engine NOTE

at least four revolutions. When a compression test on one or
more cylinders of any row of
NOTE cylinders is needed, the compression
The tester contains a restrictive of all cylinders on the affected row
orifice to eliminate acceleration will be tested, compression reading
errors, and two compression totaled, and minimum compression
impulses are required to obtain an established in the same manner as
accurate compression reading. when checking compression on all
cylinders

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

1 Remove rocker box covers on In cases where engine roughness is

cylinders with low compression. encountered at more than one
speed, or there is an indication that
2 Turn crankshaft until piston is on a cylinder ceases to operate at idle
top dead center of compression stroke and check intake speed or higher speeds, it will be
and exhaust valves for clearance. desirable to run engine at each of
these speeds and perform a cold
3 When valves are held open due to cylinder check to pick out all dead
negative clearance, adjust valves to proper clearance. or intermittently operating
cylinders.
4 Check for excessive leakage past
piston by squirting engine oil into cylinder, pulling engine In cases where lower output or
through compression stroke, and then checking
engine vibration is encountered at
compression.
speeds above 1600 rpm, when
operating with ignition switch on
5 Continue cylinder In service if
compression Is up to required minimum. BOTH, engine should be run at the
speed where the difficulty Is
(f) Cold cylinder check. The tendency encountered until cylinder head
for any cylinders to be cold or only slightly warm indicates temperature reaches 302 to 338°F
lack of combustion or incomplete combustion within the (150 to 170°C), or until temperature
cylinder. Perform this check using an approved cold has stabilized at a lower value.
cylinder indicator.
5 Stop engine by moving mixture
1 Head aircraft into wind to minimize control to IDLE CUT-OFF position When engine ceases
irregular cooling of Individual cylinders. firing, turn off both individual and master Ignition
switches.
2 Open cowl flaps.
6 Measure and record relative
NOTE temperatures of each cylinder, starting with any cylinder
Do not close cowl flaps under any and proceeding In numerical order around engine, by
circumstances, as the resulting heat pressing tip of Indicator pickup rod of cold cylinder tester
will affect the readings obtained and against each cylinder.
overheat the ignition leads.
NOTE
3 Start engine. After engine is It is essential that a firm contact be
running, place ignition switch to position where excessive made at the same relative location on
rpm drop is obtained. In cases where an excessive rpm each cylinder in order to obtain
drop has occurred on both magnetos, or where excessive temperature value This measurement
manifold pressure is obtained at a given rpm, perform must be performed in the shortest
check twice, once on LEFT and once on RIGHT position. possible time after engine ceases firing.

4 Operate engine at roughest speed 7 Recheck cylinders that have low

between 1200 and 1600 rpm or at rpm up to Ignition values and two cylinders having highest readings to
check speed until a cylinder head temperature reading determine amount of cooling during check.

8 Compare temperature readings

obtained In order to determine which cylinders are dead
or operating intermittently.

7-12
 TM 1-1500-204-23-1

9 Examine magneto ground leads to CAUTION

determine that RIGHT switch position fires front plugs and Do not damage adjacent fins
LEFT switch position fires rear plugs. Make this Inadequate cylinder cooling may
examination prior to changing spark plugs, making result.
ignition harness test on cylinders which are operating, or
are operating intermittently. In addition, examine ignition 1 Repair cracked, nicked, or broken
leads. cooling fins by profiling damaged area using a file to
smoothly round all edges. Corners shall have at least a
NOTE 1/4-inch radius and removed area nut shall not exceed
In cases where the cylinder is one percent of the total fin area.
completely dead on the BOTH
position, the difficulty may be due to NOTE
incorrect valve clearances, impeller oil Magnetic or dye-penetrant inspect fins
seal leaks, leaking intake pipes, or lack that are profiled to outside of dome to
of compression (blowby). ensure that crack does not extend into
cylinder dome.
10 Repeat cold cylinder check for
other magneto positions on Ignition switch when 2 Repair broken or loose studs in
necessary. Additional cold cylinder checks will be tapped hole by using helical inserts.
conducted at different speeds in event any roughness Is
still encountered during ignition system check NOTE
When more than two adjacent nuts are
NOTE known to have been loose during
Cooling of the engine between checks engine operation, or when more than
is not necessary as airflow created by two adjacent studs have failed,
propeller and cooling effect of cylinder will be replaced and all studs
incoming fuel-air mixture into cylinder on the cylinder mounting pad
will be sufficient to cool any cylinders replaced.
which are functioning on one check
and fail to function on the following 3 Place cover on a surface plate and,
check. using a feeler gauge, measure clearance between surface
plate and rocker box cover mounting surface. Refer to
(g) Chalk test. The chalk test should be the applicable maintenance manual for allowable limits.
used when the cold cylinder tester is not available. Test
using the following procedures. NOTE
Accomplish procedures 4, 5, and 6
1 Mark each cylinder with a piece of when surface does not meet specified
white marking chalk, A-A-320. limits.

2 Run engine as outlined in 4 Place a small amount of valve

paragraph (e) above. grinding compound, A-A-1203, on a lapping plate.

3 Examine each mark after engine NOTE

shutdown. Cylinders having marks unchanged In color In the event no grinding compound is
are dead or operating intermittently. The marks for a available, a fine abrasive cloth, Federal
normal operating cylinder will change to a pink color. Specification P-C-451, may be used.
(h) Cylinder repair. Cylinder repair can
be accomplished by using the following procedures as
applicable

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 rings 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

High oil consumption

Excessive valve guide clearance

Loose intake pipe flanges

Loose or defective spark plug inserts (steel or

brass)

External damage, such as cracks

Spark plug copper runout

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

Figure 7-14. Valve Types

7-14
 TM 1-1500-204-23-1

uniform. Temperature changes affect air-cooled 1 Sodium-filled valves definitely

engines to a greater extent than other engines, and there determined to be nonrepairable as a result of cracked or
must be sufficient valve clearance to prevent valve from broken stems shall be processed for disposition In
holding open when extreme cold is encountered, since accordance with procedures established by Part 3,
holding open will make cold weather starting extremely Chapter XV, DOD directive 4160 21M. Disposal of these
difficult. Inadequate clearance or excessive clearance is nonrepairable valves shall be affected by one of the
conducive to valve failure; therefore, proper settings are following methods.
essential to engine operation.
Burial, at least 30 inches below ground level, in
(a) Measuring and adjusting valve a select location where future excavation is
clearance When rough engine operation, backfiring, loss unlikely.
of compression, hard starting, or any malfunction which
can be attributed to improper operation or clearance of By dumping at sea.
valves occurs, valve clearance shall be measured and
adjusted, using the following procedures 2 Values determined to be suitable
for reclamation shall be prepared for shipment in
1 Measure and adjust valve accordance with provisions of AR 746-1.
clearance in accordance with specific instructions
contained In applicable engine maintenance manual. (c) Establishing crankshaft position using
top center indicator and protractor. The proper crankshaft
2 Locate top dead center piston position must be established prior to checking or setting
position. valves using the following procedures.

3 Use feeler gauge (shaped so that 1 Determine ratio of top center

end of gauge can be slipped in a straight line between indicator, as shown in figure 7-15, pointer travel to
valve and rocker arm roller or adjusting screw) specified crankshaft travel.
in tools section of maintenance manual.
2 Install Indicator in either spark plug
NOTE hole of number one cylinder.
Do not use excessive force to insert
gauge between valve stem and 3 Adjust arm of indicator so that full
adjustment screw or rocker arm roller. scale deflections will be obtained as piston moves through
its full stroke.
4 Adjust valve clearances found to be
out of adjustment according to specific procedures in 4 Install protractor and pointer
engine maintenance manual. specified in engine maintenance manual on one of engine
accessory drive pads.
(b) Reclamation and disposition of
sodium-filled valves. The reclamation procedure for 5 Rotate crankshaft in normal
sodium-filled valves consists primarily of rebuilding the direction of rotation until piston is coming up on
facing of exhaust valves and repairing the stems compression stroke.

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 turning 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

11 Back up crankshaft and rotate it

forward in direction of rotation until protractor pointer
indicates top dead center (in degrees).

12 Loosen pointer and set to zero

without moving crankshaft.

NOTE
When reinstalling pointer, allow for
gear backlash by moving pointer
opposite its direction of rotation.

13 Recheck top dead center position

to ensure that a given piston position will result In equal
protractor readings before and after zero mark.

(d) Establishing crankshaft position upon

piston position indicator. The following steps outline
another method of establishing the crankshaft position.

Figure 7-16. Installation of Piston Position Indicators

7-16
 TM 1-1500-204-23-1

6 Set calibrated scale until zero mark NOTE

on scale and scribe on pointer are aligned. When using timing marks to position
the crankshaft, sight straight across
7 Move pointer back to top of slot or the stationary pointer or mark on the
until it contacts pivot arm. nose section to the other mark. Any
angle incurred in sighting will cause
8 Turn crankshaft in direction error when positioning the crankshaft.
opposite normal rotation until pivot arm returns to top of
slot. h. Accessories. Accessory units such as fuel
pumps, vacuum pumps, oil pumps, generators,
9 Recheck zero mark of calibrated alternators, magnetos, starters, filters, superchargers, and
scale against reference mark on slide pointer. turbochargers are attached to the engine. Refer to the
applicable maintenance manual for specific maintenance
10 Move slide pointer to top of slot or procedures
until it contacts pivot arm.
i. Ignition System. The ignition system must deliver
11 Rotate crankshaft In direction of a high-tension spark to each cylinder of the engine in
rotation. Movement of slide pointer by the pivot arm will firing order at a predetermined number of degrees ahead
Indicate crankshaft position In relation to true top dead of true top dead center. Voltage output of the system
center on the calibrated scale. must be such that the spark will jump the spark plug gap
under all operating conditions with no tendency for
(e) Alternate methods of locating leaky electrical leaks. Timing and replacement of parts make
intake exhaust valves. Alternate methods of locating up most of the Ignition system maintenance.
leaky intake and exhaust valves are listed In the following
paragraphs. (1) Magneto system. The magneto, a special type of
engine-driven ac generator, uses a permanent magnetic
1 Engine run test. Prior to stopping source. The magneto develops the high voltage which
engine, run it up to 1000 rpm and move mixture control to forces a spark to jump across the spark
IDLE CUT-OFF. The engine will turn over six or more
revolutions after combustion ceases. A very slight
burning of an exhaust valve will be evidenced by a
pronounced slush from the affected cylinder This sound
occurs each second revolution of the engine.

2 Wheeze test Perform wheeze test

for locating leaky intake and exhaust valves by pulling
piston to top dead center, locate faulty valve by listening
for noise in exhaust collector or Intake duct which
indicates air leaking past respective valve.

3 Compressed air test Admit

compressed air into cylinder through spark plug hole
Restrain piston at top of dead center Locate leaking valve
by listening for noise in exhaust collector and intake duct.

(f) Built-m timing marks. Some engines

have reference timing marks built into the engine, as
shown in figure 7-17. Engines without a propeller
reduction gear will have the timing mark, a scribe mark or
a pin, on the propeller shaft and a corresponding Figure 7-17. Built-In Timing Marks
reference mark on the surface of the nose section next to
the shaft. Refer to the applicable maintenance manual
for location of such marks.

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.

1 Check breaker point 7 If necessary, adjust magneto so

adjustments, breaker point dwell on master cam lobe, and that timing light indicates points are beginning to open at
distributor alignment check. proper firing position.

2 Use reference marks on breaker (d) Install and time low-tension Ignition
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.

(b) Time high-tension Ignition system 1 Depress magneto timing plunger

magneto-to-engine, at a definite crankshaft position as and turn magneto shaft until plunger engages fully In
follows. notch of magneto shaft.

1 Position crankshaft to timing or 2 Position magneto In place while

spark advance position using a piston position indicator holding plunger.

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 (b) Repair or replace defective parts as
magneto, while continuing rotation of engine, until timing necessary. Keep all parts clean and free of foreign
plunger is fully engaged. matter.

5 See that timing indicator shows NOTE

correct degree of advanced timing. The high-tension system manifold Is
never taken apart in the field, as this
(2) Ignition harness. The ignition will destroy the elastic gel seal.
harness, as shown in figure 7-18, contains an insulated
wire for each cylinder that the magneto serves In the 1 Clean dirt and grease from harness
engine. One end of each wire Is connected to the by wiping with a clean, dry cloth.
distributor block and the other end is connected to the
proper spark plug. The Ignition harness serves a dual 2 Clean terminals with acetone,
purpose. It supports the wires and protects them from Federal Specification O-A-51.
damage by engine heat, vibration, or weather. It also
serves as a conductor for stray magnetic fields that NOTE
surround the wires as they momentarily carry high-voltage Replace ignition harness leads when
current. By conducting these magnetic lines of force to more than three wire strands are
the ground, the ignition harness cuts down electrical broken in one inch of harness length
interference with the aircraft radio and other electrically or if Insulation is damaged
sensitive equipment. When the radio and other electrical
equipment are protected in this manner, the ignition (c) Perform a high-voltage breakdown
harness wiring is said to be a shield. Without this test when an ignition malfunction occurs and after cable
shielding, radio communication would become virtually replacement in rewireable harness or leads. Use an
impossible. The ignition harness check consists of a approved high-voltage tester, and test for serviceability as
visual and an electrical check using the following follows.
procedures.
1 Remove all leads from spark plugs.
(a) Examine all accessible parts of
distributors, harnesses, and leads for chafing, broken 2 Remove spark plug elbow
insulators, corrosion, moisture, damaged or dirty assembly from ignition lead.
terminals, and security of mounting at the time specified
in the applicable maintenance manual. 3 Examine lead insulation for
evidence of chafing, breaks, or holes. Replace parts as
required.

4 Ground all leads, except one for

number 1 cylinder, to engine.

5 Connect ground lead of tester to

engine, and connect high-tension lead to number 1
cylinder lead.

6 Test and record any leakage

detected.

7 Test remaining leads.

8 When two leads from same

distributor show leakage, remove ground from both leads
Figure 7-18. Ignition Harness
and repeat test. When leakage is stopped by removing
ground from other lead, leakage is probably between.

7-19
 TM 1-1500-204-23-1

two leads (in distributor block). When disconnecting chamber. Inside the combustion chamber it provides an
ground of other lead does not stop leakage, check for air gap across which this Impulse can produce an electric
leaks between Individual leads and shielding. spark to ignite the fuel-air charge. For spark plug service,
maintenance Instructions, and list of approved spark
NOTE plugs, refer to TM 55-2925-200-25.
Rotate crankshaft to a position that
will eliminate distributor finger (4) Ignition switches. All units in an aircraft
leakage. ignition system are controlled by an Ignition switch in the
cockpit. The type of switch used varies with the number
9 When a recheck indicates that of engines on the aircraft and the type of magnetos used.
distributor block may be at fault, scrub thoroughly with All switches, however, turn the system off and on In much
acetone, Federal Specification O-A-51, dry thoroughly, the same manner. The Ignition switch is different in at
and apply a thin coat of wax Mix 1 part wax to 5 parts least one respect from all other types of switches In that
trichloroethylene, Federal Specification O-T-634, when the Ignition switch Is In the OFF position, a circuit is
maintained at a temperature of 130 to 140°(54 to 60°C). completed through the switch to ground In other electrical
switches, the OFF position normally breaks or opens the
10 Repeat steps 1 through 9 above. circuit. The following procedures are for Ignition switches
general maintenance.
(d) The low-tension system operates at
relatively low voltages (150 to 400 volts) and is not (a) Replace defective switches and
seriously affected by moisture. Check system as follows. broken ground wires.

1 Check all accessible parts of (b) Tighten all loose switch and cable
harness and leads for chafing, broken conduit, corrosion, terminal attaching nuts.
or misaligned pins in electrical connectors at intervals
specified in inspection requirements manual. (c) For specific details on any ignition
switch, refer to applicable maintenance manual.
CAUTION
Do not attempt to repair harness (5) Booster system. Starting aids such as an
without the proper special tools. induction vibrator or booster coil must be used to provide
Damage to harness may otherwise enough voltage to the spark plug. The induction vibrator
result. (or starting vibrator), as shown in figure 7-19, consists
essentially of an electrically operated vibrator, a
2 Tighten all loose connectors and condenser, and a relay These units are mounted on a
tape over frayed sections of nylon covered harness base plate and enclosed In a metal case. The booster
coil assembly as shown in figure 7-20, consists of two
3 Test all low tension wiring and coils wound on a soft Iron core, a set of contact points,
distributor blocks, connection plates, etc, for continuity. and a condenser. General maintenance of the booster
Test Insulation resistance with a tester capable of system is described in the following procedures.
delivering 1000 volts dc (maximum) at 1 milliampere, or
an ohmmeter (20,000 ohms per volt). The insulation (a) Repair Induction vibrators In
resistance should exceed 1 megohm, unless otherwise accordance with the applicable maintenance manual and
specified table 7-1.

(3) Spark plugs. The function of the spark plug (b) Replace defective booster coils and
in an ignition system is to conduct a short impulse of high all broken or frayed wiring Tighten all loose connections.
voltage current through the wall of the combustion
(c) Replace magneto if impulse coupling
is defective.

7-20
 TM 1-1500-204-23-1

(d) Test ignition booster system for 3 Reconnect spark plug and ground
proper operation as follows: plug shell to engine.

1 Remove front spark plug from most 4 Place carburetor in IDLE CUT-OFF
accessible cylinder. position.

2 Turn crankshaft until piston is 5 Place main fuel valve in CLOSED

observed to be in top position on compression stroke. position.

Figure 7-19. Induction Vibrator

7-21
 TM 1-1500-204-23-1

Figure 7-20. Booster Coil

7-22
 TM 1-1500-204-23-1

Table 7-1. Repairing Induction Vibrators

Trouble Probable cause Remedy

Unit fails to function Not grounded Ensure mounting bolts

contact grounding plate.

Loose or disconnected Ensure terminal clip is secured

positive cable to positive cable and positive
terminal post.

Loose or disconnected Ensure both cables are secured

MAG or IGN. SW TERMINALS to terminal nuts with springs.
Tighten nuts until a firm contact
is made with the terminal.

Dirt between points Draw paper, Federal Specification

UU-P-268, dipped in trichloro-
ethylene O-T-634, across points
and air dry.

6 Turn fuel booster pump to OFF position. cases of complete internal failure or expiration of
operating time limits (Refer to AR 750-23).
7 Turn ignition switch to BOTH position.
a. Expiration of Operating Time Limit. Engine
8 Place master Ignition switch in ON removal and replacement shall be accomplished in
position. accordance with TM 55-1500-328-25 when normal
Maximum Allowable Operating Times (MAOT) are
9 Engage starter, observing all ground accumulated In accordance with the applicable aircraft -
safety rules. 20 maintenance manual (Chapter 3, Section IV).

10 Note continual flow of high voltage across b. Sudden Engine Stoppage. Sudden stoppage is
spark plug points. defined as the complete stalling of the engine due to a
propeller or rotor accident or gear box failure. Such
7-5. Engine Removal Criteria. The life of an aircraft engines shall be replaced.
engine between overhauls is dependent upon many
factors, such as quality of original manufacture or last NOTE
overhaul, the type of operation being accomplished, and Replace engine when engine is
the efficiency of preventive maintenance. It is possible stalled by propeller or rotor striking
to establish a maximum expected life of an engine an immovable object, such as a ramp
based on service records and engineering data. At or building or when engine is
overhaul depots, it has been found that many engines operating at any rpm and is stalled
are changed needlessly. A complete investigation of suddenly due to some Internal cause
the engine should be made before removal, except in such as gear box or crankshaft
failure.

7-23
 TM 1-1500-204-23-1

c. Sudden Reduction in Engine RPM. When the NOTE

propeller or rotor strikes a small object which results in a
sudden reduction In engine rpm, the engine shall be • When there is runout of more than
thoroughly checked using the following procedures: 0.015 inch full indicator reading of
crankshaft or propeller drive shaft at
(1) Make a thorough external examination of front cone seat location, remove
engine crankcase and nose section to determine engine. Even though runout of
whether any parts have been damaged. When damage crankshaft or propeller drive shaft at
is found which cannot be corrected by line maintenance, front cone seat is less than 0 015
remove engine. inch full indicator reading, examine
rear cone seat location.
(2) Remove magnetic sump plugs, If present,
and engine oil screens or filters. Examine for presence
• When any runout is found at rear
of metal particles.
cone seat location, which Is not In
(3) Remove engine sump plugs, drain oil into same plane as runout at front cone
a clean container, strain through a clean cloth, and seat location, remove engine.
examine cloth and strained oil for metal particles.
• When crankshaft or propeller drive
NOTE shaft runout does not exceed these
limits, install serviceable propeller
• Metal particles found In the sumps or and make an additional check by
In oil screens or filters will not be tracking propeller at tip in same
considered the results of an Internal plane perpendicular to axis of
failure caused by sudden stoppage, rotation to assure that blade track
since the screens or filters are tolerance Is within limits.
located at the oil inlet to the engine.
Sudden stoppage, therefore, will not (7) Start engine and examine for smooth
permit circulation of the oil to the operation and adequate power output. When engine
extent that metal particles would be operates properly during this ground check, shut engine
off and again examine oil system for metal particles.
deposited on the screens or filters.

• When heavy metal particles are

found In the oil, It indicates a definite
engine failure, and engine must be
removed. However, when metal
particles present are similar to fine
filings, continue examination of
engine to determine its serviceability.

(4) Remove propeller and examine

crankshaft, or propeller drive shaft on reduction-gear
engines, for misalignment.

(5) Clamp a test indicator to nose section of

engine and remove front or outside spark plugs from all
cylinders on radial engines and top spark plugs on all
opposed engines.

(6) Turn crankshaft and observe if crankshaft

or propeller shaft runs out at either front or rear propeller
cone seat location, as shown In figure 7-21.
Figure 7-21. Checking Propeller Shaft Runout

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

f. Significance of Metal Particles. Generally, when 4 If more than 2 additional steel

metal particles are found and kind of metal present is flakes or 15 aluminum flakes are found during screen
determined, serviceability of engine will depend upon and sump inspection after engine runup, remove engine.
quantity and form of metal. Granular metal particles, in If less than these quantities are found, engine may be
any amount greater than a trace, require a very careful released for service in accordance with the applicable
inspection of engine, as presence of these particles is maintenance manual.
usually an indication of an impending failure. Each kind
of metal, however, must be judged individually. NOTE
Paragraphs (1) through (5) are intended as a guide in Ring fuzz may be on oil sump plug of
judging serviceability of engine after kind of metal has any normal engine. These very fine
been determined. hairlike particles are the result of
normal seating of piston rings and
(1) Steel particles. When steel particles are cylinders and are not cause for any
found in splinter or In granular form, the engine must be concern regarding serviceability of
removed Thin steel flakes, when found In quantities not engine.
greater than 20 flakes, may not require engine removal.
A small quantity of steel flakes will not cause engine (2) Tin particles. Tin in any quantity may be
bearing failure. When thin steel flakes accompanied by disregarded. Since tin is used only in plating engine
aluminum flakes are found, these flakes are probably parts and in thickness not greater than 0.0005 inch,
the result of a warped piston ring land or hole burned in granular tin will not be found.
a piston. Replacement of a defective piston and
cylinder assembly will correct the difficulty. When (3) Aluminum particles. When aluminum
not accompanied by aluminum flakes, it Is possible that particles are found, perform the following procedures:
steel flakes are from foreign matter introduced into
engine through oil tank. (a) When granular aluminum particles
are found, proceed as follows:
(a) Test engine in accordance with the
applicable maintenance manual If more than five NOTE
additional flakes are found on oil screen and sump The presence of aluminum particles
inspection after runup, remove engine. If five or less
in granular form may be an
flakes found, the engine may be released for service in
indication of piston failure
accordance with the applicable maintenance manual.
1 Inspect cylinders by visual
(b) When not more than 20 thin steel
examination of cylinder bores and a compression check
flakes are found and they are accompanied by thin
in an effort to locate a faulty piston.
aluminum flakes, proceed as follows
2 When not more than two faulty
1 Carefully inspect cylinders by
pistons are found, faulty pistons and cylinder assemblies
visual examination of cylinder bore and by compression
will be changed before continuing with procedure.
check In an effort to locate faulty piston. A bright streak
When more than two faulty pistons are found by
along cylinder barrel or any evidence of scuffing would
inspection, remove engine. After faulty pistons and
be an indication of a warped piston ring land. Warped
cylinder assemblies have been changed, or when no
lands are predominant In winter operations and occur
faulty pistons are found, continue with procedure.
most frequently on lower cylinders.
3 Drain oil system, flush oil tank,
2 When not more than two faulty
and clean oil screens.
cylinders are found, replace faulty piston and cylinder
assemblies before continuing with procedure. When
4 Test engine in accordance with
more than two faulty cylinders are found by inspection,
the applicable maintenance manual.
remove engine.

3 After faulty cylinders have been

changed or when no faulty cylinders are found, test
engine In accordance with the applicable maintenance
manual.

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.

NOTE (5) Copper or bronze particles. Copper or

Aluminum flakes may not necessarily bronze particles, in granular form and in quantities
require engine removal In winter greater than a few particles, indicate disintegration of a
operations, when warped piston ring bushing or valve guide and engine must be removed.
lands are frequent, considerable Copper or bronze flakes, in quantities not exceeding 10
quantities of aluminum from pistons flakes, do not necessarily indicate part failure. Bronze
flakes may be formed in small quantities through normal
may be discharged Into engine oil
seating of bushings or valve guides. Larger quantities
system. It will be necessary to
of copper or bronze flakes, however, may Indicate
exercise judgment before continuing
excessive loss of bushing metal and engine must be
with the following procedure, for removed as a precautionary measure.
Instance, if oil sump or screen is
found choked with a mass of g. Additional Metal Particles Test. This test is
aluminum flakes or particles, made to subject engine to sufficient operations to cause
regardless of size, it will probably be any additional metal in oil system to collect on oil screen
necessary to remove engine even and in main sump and also to reveal any Incipient
though faulty piston can be located. trouble. This additional metal will determine whether
engine needs to be removed or allowed to continue In
1 Make a careful Inspection of service Test using the following procedures.
cylinders by examination of cylinder bores and a
compression check In an effort to locate faulty piston. (1) Drain and flush external oil system

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

between pump and main bearing is negligible. (d) Lubricant characteristics. An

However, centrifugal force increases oil pressure at increase in oil viscosity decreases oil consumption only
crankpins which increases flow through the bearings and up to the point at which the slower draining of the more
sprays more oil on cylinder walls. The rings do not viscous oil from the cylinder wall, and tendency of the
follow the cylinder as closely at higher speeds, and a rings to ride over the oil film causes more oil to pass the
greater amount of oil Is passed to the combustion piston and flow into the combustion chamber
chamber instead of being scraped back to the
crankcase. (2) Aircraft range as related to oil
consumption. Remove an engine if oil consumption is
(b) Engine temperature. High engine high enough to limit range of aircraft. Variations In oil
temperature and low oil viscosity tend to increase losses system capacity of different aircraft causes maximum oil
of oil from crankcase seals and breathers. Oil loss consumption to vary according to type aircraft and type
increases due to increased blowby, or gas flow, past of mission being performed (see figure 7-22).
piston rings at higher engine speeds. Blowby raises
crankcase pressure and forces oil or oil vapor out of the 7-6. Engine Conditioning. Engine conditioning
crankcase. provides a standard method for detecting engine
malfunctioning prior to development of serious trouble
(c) Engine wear. Engine wear in the and establishes a systematic routine for keeping the
form of worn bearings increases clearance and allows engine in condition to provide maximum trouble-free
increased oil loss. Worn pistons and cylinders provide performance. The types of engine conditioning are
space for thicker oil films and increase loss due to complete engine conditioning and minor engine
failure of rings to seal. conditioning.

Figure 7-22. Oil Consumption Chart

7-29
 TM 1-1500-204-23-1

a. Complete Engine Conditioning. Complete through 15 and 17, table 7-2. The readings obtained are
engine conditioning is a complete investigation of the recorded in the flight log only when engine performance
condition of an engine and correction of any difficulty is unsatisfactory.
detected. Complete engine conditioning will be given
engines being overhauled with the exception of idle 7-7. Air Induction System. The air Induction system
mixture and speed, fuel, oil, and water pressure supplies air to the carburetor or master control. It forms
adjustments, and final check and adjustment of the a long curved channel which conducts air and fuel-air
engine after the engine is installed on the aircraft. mixture to the supercharger section. The channel
Perform this conditioning using the Instructions consists of an air scoop, temperature controlling device,
contained In table 7-2. and a thermometer General maintenance procedures
are explained in the following paragraphs.
b. Minor Engine Conditioning. Minor engine
conditioning is the investigation and correction of any a. Inspection. Maintenance. Cleaning. and
malfunction revealed during flight or through the cockpit Replacement. Perform the following procedures for
checks (daily, intermediate, and complete cockpit general inspection, maintenance, cleaning, and
checks). Perform the following procedures for minor replacement of air induction system components:
engine conditioning:
(1) Check induction system for foreign matter
(1) Perform a complete cockpit check (steps and articles to prevent such Items from damaging
6 through 14, table 7-2) when a new engine Is Installed, impeller or clogging air passages.
when an aircraft is removed from storage, at each major
and minor Inspection, and when minor conditioning fails (2) Install flexible channel, joining certain
to correct a malfunction. The engine cockpit check will types of Induction systems together, In such a manner
be handled in the following manner: to prevent flexible channel from being sucked down and
restricting air flow.
(a) Record all readings on cockpit
check sheet as shown in figure 7-23. (3) Correct leaks In Induction systems soon
as possible after detection, as fuel-air mixture will be
(b) File form In aircraft flight log folder adversely affected.
for future reference by both maintenance and flight
personnel. (4) Clean air filters at intervals specified in
applicable maintenance manual using the following
NOTE procedures:
The daily check will be carried out by
the air crew and will only be WARNING
recorded in the flight log when Dry-cleaning solvent is flammable
performance is unsatisfactory. The and solvent vapors are toxic. Use P-
serviceability of the engine is D-680, Type II Solvent in a well-
established by the air crew by ventilated area. Keep away from
comparing its readings against those open flames. Avoid prolonged
recorded on the complete cockpit solvent contact with skin.
check made by the maintenance
crew. (a) Immerse filter in dry-cleaning
solvent, Federal Specification P-D-680, and agitate to
(2) Perform steps 6 through 13, 15, and 17, remove all imbedded dirt particles.
table 7-2.
(b) Drain by placing on a 25-degree
(3) Perform intermediate check after last angle draining rack and allowing to dry thoroughly.
flight of day. The check may be made any time after
the last flight of the day and before the next flight by (c) When completely dry, immerse filter
either the air crew or maintenance personnel. Any In a mixture of 1 part corrosion-preventive compound,
difficulties encountered during flight are corrected at this MIL-C-5545, and three parts lubricating oil, MIL-L-6082,
time. The intermediate check is outlined in steps 12 Grade 1120, at a temperature of 70°F (21°C) for 2 to 5
minutes.

7-30
 TM 1-1500-204-23-1

Table 7-2. Engine Conditioning Table

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 2 Compression Test cylinder compression. Complete Maintenance

Test Conditioning

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 5. Spark Plug Install new or reconditioned set of Complete Maintenance

Installation spark plugs. Conditioning

Step 6. Check for Pull propeller through to deter- Complete Maintenance

Hydraulic Lock mine whether combustion cham- Conditioning
bers are clear.

Cockpit Check Air Crew

Daily Check Air Crew

Step 7. Blowby Check While performing step 6, listen for Complete Maintenance
an extended hissing sound from Conditioning
exhaust stack or stacks.

Cockpit Check Air Crew

Daily Check Air Crew

Step 8. Engine Start Start engine. Complete Maintenance

Conditioning

Cockpit Check Air Crew

Daily Check Air Crew

7-31
 TM 1-1500-204-23-1

Table 7-2. Engine Conditioning - CONT

Complete
conditioning When Personnel
steps Procedure performed responsible

Step 9. Engine Warmup Warm up engine at smoothest Complete Maintenance

specified rpm, oil pressure per- Conditioning
mitting. Continue warmup until
normal operating temperatures Cockpit Check Air Crew
are obtained as Indicated by
green arc on gauges. Daily Check Air Crew

Step 10. Power Check Set engine at specified rpm Complete Maintenance
setting. Allow engine and instru- Conditioning
ments to stabilize.

Manifold pressure readings for Cockpit Check Air Crew

different engines of the same type
and model installed on the same type Daily Check Air Crew
aircraft should not vary over 1 inch
Hg at a given rpm when checks are
performed at the same geographical
location.

A higher than normal manifold pressure

indicates engine is not operating
properly.

In case of high manifold pressure, take

manifold pressure readings at several
lower rpm settings to establish rpm
manifold pressure pattern for engine. See
performance chart for rpm-manifold pres-
sure relationships for current aircraft.

Step 11. Ignition System After completing step 10, perform Complete Maintenance
Check step 17. Conditioning

Cockpit Check Air Crew

Daily Check Air Crew

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

Figure 7-2. Engine Conditioning - CONT

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

Cockpit Check Air Crew

Intermediate Air Crew or

Maintenance

Step 15. Acceleration Perform acceleration and decelera- Complete Maintenance

and Deceleration Check tion checks. If turbosupercharger Conditioning
is installed, check with turbosuper-
charger off. Cockpit Check Air Crew

Daily Check Air Crew

Intermediate Air Crew or

Maintenance

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

Table 7-2. Engine Conditioning - CONT

Complete
conditioning When Personnel
steps Procedure performed responsible

Step 16. Engine Backfire Place turbosupercharger in OFF

Test - continued position. Carburetor air filters
should be by passed.

Set engine at specified rpm setting.

Move carburetor mixture control to
AUTO-LEAN. Move ignition switch
from BOTH to RIGHT and then to
LEFT for a sufficient length of time
in each position to permit engine
operation to stabilize. When moving
ignition switch from BOTH TO RIGHT
or LEFT, a high rmp drop will nor-
mally occur.

If the engine does not backfire from

either switch position, it is considered
satisfactory in this test. If it backfires,
one or more phases of engine
operation are not correct.

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

Figure 7-23. Engine Conditioning Cockpit Check Sheet

7-35
 TM 1-1500-204-23-1

(d) Place filter on a 25-degree angle NOTE

draining rack in a room where temperature is 70°F Exhaust ducts, waste gates, nozzle
(21°C) and allow to drain for 2 to 4 hours. Drain boxes, and turbines are subjected to
accordion-pleated filters for 8 hours. extremely high temperatures. For
this reason, cracks develop because
(e) When necessary, use forced of the continued expansion and
draining after gravity draining has been accomplished contraction of the metal as
by using a 1/16-inch orifice and 100 psi air temperature. temperature changes occur.
(5) Adjust carburetor air doors so they 7-8. Exhaust System. The exhaust system conducts
operate freely through full range of travel or to position exhaust gases from the engine to the atmosphere with
selected as specified in applicable maintenance manual. minimum exhaust back pressure. Short exhaust stacks
are incorporated on some engines, while others join a
(6) Replace damaged intake pipes. Detect collector ring which expels exhaust gases through a tail
leaks in Intake pipes by presence of fuel stains at pipe. Perform the following general maintenance
cylinder Impeller end When leakage is found after 25 procedures on exhaust systems:
hours of operation (since new), loosen intake pipe
packing nuts. Replace any defective packing and a. Check ball joints for excessive or insufficient
retighten nuts. clearances, and retighten or replace ball joints as
necessary to obtain free movement.
NOTE
Do not tighten packing nuts without b. Replace all parts that have hot spots or damage
loosening and examining the beyond repair.
packing first.
c. To prevent exhaust port studs from seizing, and
b. Turbocharger and Supercharger Maintenance. to retard corrosion, apply a special lubricant as follows:
Visual inspection of all visible parts should be
accomplished daily to observe oil leaks, exhaust leaks, (1) When engine or cylinder is removed or
cracks in the metal of hot sections, loose or insecure installed, apply light coating of 10 percent molybdenum
units, and other unacceptable conditions. Refer to the disulphide lubricant, MIL-M-7866, and 90 percent
applicable maintenance manual for specific grease, MIL-G-3545, to threads of cylinder exhaust port
maintenance procedures. Ensure the following Items studs.
are checked.
(2) To retard corrosion of nuts, apply this
• Mounting of all units mixture to exterior of exhaust port stud nuts.

• 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 depreserved to changes in rpm, other than those within allowable limits,
make them operational after they have been preserved result.
for extended storage. Observe the following
precautions. (2) When difficulty is encountered with PD
and PR series Injection-type carburetors, attributed to
• Depreserve float-type carburetors which do sticking or binding of automatic mixture control unit,
not employ diaphragms by flushing float clean unit as follows:
chamber with the type of fuel used to operate
applicable engine, then drain oil and fuel (a) Remove unit from carburetor, being
mixture from float chamber. Flush until all careful not to remove seal or lockwire or loosen siphon
trace of preservative oil is removed. locking nut.

• Depreserve diaphragm-type carburetors by WARNING

draining oil from fuel chambers and passages Dry-cleaning solvent is flammable
and flushing with fuel. Fill carburetor with and solvent vapors are toxic. Use P-
type of fuel to be used to operate applicable D-680, Type II Solvent In a well-
engine. Soak diaphragm for at least 8 hours. ventilated area. Keep away from
This restores fuel diaphragms to normal open flames Avoid prolonged
operating condition. solvent contact with skin.

c. Adjusting Idle Mixture and Idles Speed If an (b) Wash bushing with dry-cleaning
engine will not respond to idle mixture and speed solvent, Federal Specification P-D-680.
adjustment, it is an Indication that some other phase of
engine operation is incorrect. Adjust idle mixture and (c) Dry thoroughly with compressed air.
idle speed using the following procedures.
(d) Polish bushing sleeve with crocus
(1) Make idle mixture adjustments with oil cloth, Federal Specification P-C-458, until it is bright.
and cylinder head temperatures at normal values.
(e) Blow out any polishing dust that
(2) Back idle speed stop off so that idle speed tends to cling to inside walls.
Is controlled during adjusting procedure by manually
controlling throttle. WARNING
Dry-cleaning solvent is flammable
(3) Retard throttle to designated rpm. and solvent vapors are toxic Use P-
D-680, Type II Solvent in a well-
(4) Screw idle mixture in or out in small ventilated area. Keep away from
increments as required until proper idle mixture is open flames. Avoid prolonged
established.
solvent contact with skin.
(5) After each idle mixture adjustment,
(f) Clean needle with dry-cleaning
increase power to field barometric pressure for
solvent, Federal Specification P-D-680, and dry with
approximately 1 minute to clean intermittent firing spark
compressed air
plugs caused by excessively rich or lean mixture.
(g) When needle is corroded, clean
(6) Set idle speed stop to desired rpm.
with dry-cleaning solvent, Federal Specification P-D-
680, dry with compressed air, polish with crocus cloth,
d. Repair or Replacement. Repair or replace
Federal Specification P-C-458, and lubricate with grease
carburetor using the following procedures:
molybdenum disulfide MIL-G-21164.
(1) When improper operation of float-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

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 mounting system is limited to
will apply. the following steps.
(1) Swing engine into position with a suitable (1) Repair distorted, bent, cracked, or chafed
hoist and Install engine mounting bolts. Tighten areas.
mounting bolts to specified torque value.

(2) Connect magneto ground wire, install

properly prepared carburetor, and connect fuel lines.

7-39
 TM 1-1500-204-23-1

NOTE (5) Secure all loose metal components to the

Excessive damage requires container with tape, PPP-T-60, to prevent a possible
replacement. spark during shipment.

(2) Tighten loose mountings to obtain torque b. Preservation of Operable Engines to be

values specified In maintenance manual. removed for Overhaul. Engines to be removed from
aircraft for overhaul, that can be operated without
(3) Repair or replace vibration isolators that further damaging the engine or any of its parts, shall be
show any evidence of radial slippage. preserved using the following procedures

(4) Properly secure all engine mount retaining CAUTION

bolts with safety wire. While injecting the preservation
compound, be sure none of the
(5) Replace vibration isolators when metal or compound is injected into airstream
rubber parts indicate sagging or deterioration. of the carburetor or master control.
Do not inject the compound
7-12. Preservation of Reciprocating Engines. upstream of the throttle valve.
Corrosion of aircraft metals and alloys is primarily a light Damage may otherwise result.
against moisture. There are two main types of surface
corrosion, direct chemical attack on metal, and (1) Drain oil system and refill with corrosion
electrochemical action In which the metal being preventive MIL-C-6529, Type II.
corroded becomes a part of an electrolytic cell In the
presence of moisture. Both reactions are effectively NOTE
retarded In the absence of moisture. Corrosion will not Type II corrosion preventive consists
occur in a clean atmosphere when moisture is not of a ready mixed blend of 1 part
permitted to reach the metal surface. Preserve corrosion preventive, MIL-C-6529,
reciprocating engines using the following paragraphs. Type 1 and 3 parts new lubricating
oil, MIL-L-6082, Grade 1100.
a. Preservation of Accident-Involved Engines.
Engines removed from an aircraft that has been (2) Prior to starting engine for final run,
involved in an accident In which engine failure or connect discharge nozzle.
malfunction Is known or suspected to have been a factor
should not be treated with corrosion protective. No NOTE
attempt should be made to operate, motor, or
Discharge nozzles shall conform to
disassemble an accident-involved engine. All accident
designs set forth in figure 7-24 and
involved engine must be transported to an overhaul
depot or a designated investigation area within 10 days be modified in length and thread
after the accident. The accident-involved engine shall configuration to suit engine type and
be preserved using the following procedures. point of application.

(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

Figure 7-24. Discharge Nozzle for Corrosion Preventive Mixture

(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.

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 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 thrust 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.

(1) Drain fuel from engine-driven fuel pump and

flush interior with lubricating oil, MIL-L-6081, grade
1010, while rotating engine crank-shaft. Seal fuel lines
with suitable plugs.

7-43
 TM 1-1500-204-23-1

(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.

(b) Install cylinder exhaust outlet cover between NOTE

exhaust stack opening and exhaust stack flange. Aground runup shall be
accomplished on the seventh day of
NOTE idleness. When runup cannot be
Engines with Individual exhaust accomplished on the seventh day,
stacks have stacks removed and a the crankshaft shall be pulled
cylinder exhaust outlet cover through and cylinders sprayed as
installed between exhaust stack outlined in paragraph 7-11b. Storage
flange and cylinder exhaust outlet. of aircraft engines in this manner
shall not exceed 14 days.
(c) Fabricate covers locally.
(3) Upon conclusion of a ground runup on engines
(10) Seal all openings such as distributor vents and In flyable storage, make entries on applicable DA Forms
engine breathers with moisture proof plugs and covers 2408-13.
Pressure sensitive tape, Federal Specification PPP-T-
60, (red) may be used NOTE
Check the applicable aircraft
(11) Cover all engines installed on aircraft using maintenance manual for specific
engine covers furnished with aircraft. Provide lower instruction pertaining to Flyable
portion of cover with a drain hole to prevent Storage.
accumulations of water.
7-13. Depreservatlon of Reciprocating Engines.
(12) Locally fabricate placard for engines with The instructions contained In this section shall be
propellers installed, and conspicuously display placard followed prior to making the initial start to newly installed
on propeller blade. Placard shall have following engines and engines installed in aircraft being removed
information from temporary and Indefinite storage, regardless of
time In storage.
DO NOT TURN PROPELLER
ENGINE PRESERVED IN ACCORDANCE NOTE
WITH APPLICABLE MAINTENANCE INSTRUCTIONS Newly installed engines shall be
given a depreservation run as soon
e. Flyable Storage. Engine installed on aircraft which as possible, but not later than 4
will not be flown for an Indefinite period of time, but are hours after preoiling has been
maintained in a flyable status or undergoing short-term accomplished. If more than 4 hours
maintenance, shall be treated as follows: has elapsed since preoiling engine,
complete preoiling procedure shall
(1) Engine serviced with normal lubricant shall be
again be accomplished.
given a ground runup each third day of Idleness.
a. Preoiling. Proper preoiling lubricates internal gears
NOTE
and bearings, expels air from internal oil passages, and
The runup consists of engine
averts internal engine failures due to lack of lubrication.
operation at a speed greater than idle
Accomplish preoiling either indoors or by applying
for a period of 5 minutes or until engine preheat prior to preoiling when operating in
highest allowable oil inlet temperature below 0°F (-18°C). For preoiling engines
temperature is attained. Every 14 on aircraft using the diverter-segregator oil system, it is
days a 15-minute normal ground necessary to follow special instructions contained in
preflight shall be accomplished. applicable aircraft maintenance manual. Preoil using
the following procedures:

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 TM 1-1500-204-23-1

NOTE (2) Preoil engine by one of the following methods:

Engines need not be preoiled after
oil change or after oil system CAUTION
components have been disconnected Devices having heating elements in
for normal maintenance. However, direct contact with preoiling mixture
after oil change or after or oil shall not be used Damage may
disconnecting oil system otherwise result
components located in the system
between oil tank and engine oil (a) Preoil engine having a dry sump-type oil
pump, it will be necessary to system using a pressure tank.
disconnect oil inlet line at the pump
and drain a sufficient amount of oil (b) Preoil engine having a wet sump by rotating
from the line to determine there is no crankshaft with starter and utilizing normal engine oil
obstruction or air in the system. supply and oil pump to provide pressure

(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
 TM 1-1500-204-23-1

Figure 7-25. Percent Dilution Versus Temperature for Grade 1100 Oil

(c) Connect preoiler to preoiling fitting. NOTE

Newly installed engines will be given
(d) Rotate engine with starter and commence an initial start as soon as possible,
preoiling until oil is flowing freely from sump plug holes but not later than 4 hours after
and pressure Is indicated on oil pressure gauge in preoiling has been accomplished.
aircraft. When any period of time in excess of
4 hours has elapsed since engine
(e) Cease operation and replace sump plugs. was preoiled, complete preoiling
procedure shall again be
(f) Remove rocker box covers from number one accomplished before attempting
cylinder or both top covers on double row engines and initial start of engine.
continue preoiling until oil is obtained from all rocker
arms that have been removed. b Depreservation Run. The depreservation run
eliminates the necessity of removing or draining Intake
(g) Disconnect preoiler and reinstall all parts pipes prior to installation of engine in the aircraft.
removed. Perform depreservation run using the following
procedures:

7-46
 TM 1-1500-204-23-1

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)
 TM 1-1500-204-23-1

CHAPTER 8

GENERAL TURBINE ENGINE MAINTENANCE

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
 TM 1-1500-204-23-1

Figure 8-1. Centrifugal-Flow Engine

Figure 8-2. Axial-Flow Engine

8-2
 TM 1-1500-204-23-1

• 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.

CAUTION • When possible, gloves shall be worn. Wash or

Inlet duct runup screens shall not be change gloves daily.
installed and removed with engine
operating above Idle rpm Loose • Hands shall be thoroughly washed before
Items of clothing shall not be worn eating, drinking, smoking, or using toilet.
and objects which might be drawn
into the Intake ducts shall not be • Scrub body thoroughly each day.
carried when installing or removing
screens. Damage to the engine may 8-5. Turbine Engine Design and Construction. A
otherwise result. typical turbine engine consists of an air inlet,
compressor section, combustion section, turbine
• Inlet duct runup screens may be section, exhaust section, accessory section, and the
left off during taxiing to and from necessary systems for starting, lubrication, fuel supply,
takeoff position when and auxiliary purposes, such as anti-icing, cooling, and
requirements or existing pressurization. The major components of all turbine
conditions make the use of engines are basically the same; however, the
screens impractical Since nomenclature of the component parts of various engines
specific conditions warranting currently In use will vary slightly due to the difference In
removal of screens as specified manufacturer terminology. These differences are
above cannot be predetermined, reflected in the applicable maintenance manuals.
specific conditions may be
a. Inlet Ducts. There are two basic types of inlet
determined by each command as
ducts, the single entrance and the divided entrance
necessary to conduct their
duct. Single entrance inlet ducts are used with axial-
operation Approval of screen
flow engines, as shown in figure 8-3, to obtain maximum
removal should include any
ram pressure through straight flow. Divided entrance
additional precautions necessary inlet ducts, as shown in figure 8-4, provide the
to assure safe operation of opportunity to diffuse the incoming air so It enters the
engine. plenum chamber with the low velocity required to utilize
a centrifugal-flow engine inlet ducts may be classified
j. Use only nonmetallic-head hammers when as:
required to install parts on engine.
• Nose Inlets, located in the nose of the
k. When possible, use appropriate hoist or lifting yoke fuselage or powerplant pod or nacelle.
on heavy or bulky parts, such as tailpipes.
• Wing inlets, located along the leading edge of
I. Tighten jack screws, attaching screws, bolts, and
the wing, usually at the root for single-engine
nuts In small increments on opposite planes.
installations.
WARNING
• Annular inlets, encircling, In whole or in part,
Lead poisoning is an accumulative
the fuselage or powerplant pod or nacelle.
disease that can be fatal. Preventive
rather than curative measures shall
• Scoop inlets, which project beyond the
be stressed.
immediate surface of the fuselage or nacelle.
m. A turbine engine that has operated on fuel
containing tetraethyl lead may have a yellow powder on • Flush Inlets, which are recessed in the side of
those sections that are exposed to combustion gases. the fuselage, powerplant pod, or nacelle.
for example, tail pipes and combustion chambers.
Extreme care shall be used by all personnel handling

8-3
 TM 1-1500-204-23-1

Figure 8-3. Single Entrance Inlet Duct (Axial-Flow Engine)

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.

(1) Centrifugal-flow compressor. The centrifugal-

flow compressor consists basically of an Impeller (rotor),
a diffuser (stator), and a compressor manifold, as shown
In figure 8-6. The compressor achieves its purpose by
picking up the entering air and accelerating it outwardly
by centrifugal action.

(2) Axial-flow compressor. In the axial-flow engine,

the air is compressed while continuing in its original
direction of flow, thus avoiding the energy loss caused
by turns. From inlet to exit the air flows along an axial
Figure 8-4. Divided Entrance Inlet Duct path and is compressed at a ratio of approximately
(Centrifugal-Flow Engine) 1.25.1 per stage. The axial-flow compressor has two
main elements, a rotor and a stator, as shown in figure
8-7. The rotor has blades fixed on a spindle. These
b Particle Separators. Particle separators, as shown
blades Impel air rearward in the same manner as a
in figure 8-5, prevent foreign particles from entering the
propeller because of their angle and airfoil contour. The
compressor section of turbine engines. Air enters the
rotor, turning at high speed, takes In air at the
engine through the swirl frame. Swirl vanes direct the
compressor inlet and impels it through a series of
air into a rotating or swirling pattern. Sand, dust, and
stages. The action of the rotor increases the
other foreign objects are separated by centrifugal action.
compression of the air at each stage and accelerates it
These objects are carried to the outer section of the
rearward through several stages With this increased
main frame and into the scroll case. Particles are drawn
velocity, energy is transferred from the compressor to
from the scroll case by the blower and are blown out the
the air in the form of velocity energy. The stator blades
aircraft discharge duct. The relatively clean air that
act as diffusers at each stage, partially converting high
remains after particles are separated is carried to the
velocity to pressure. Each consecutive pair of rotor and
front frame deswirl vanes, which straighten the air flow
stator blades constitutes a pressure stage. The number
before it enters the compressor inlet.
of rows of blades (stages) is determined by the amount
of air and total pressure rise required. The greater the
c. Compressor Section. The compressor section of a
number of stages, the higher the compression ration.
turbine engine has many functions. Its primary
functions is to supply air in sufficient quantity to satisfy
the requirements of the combustion burners. The
compressor must increase the pressure of the mass of

8-4
 TM 1-1500-204-23-1

Figure 8-5. Particle Separator

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
 TM 1-1500-204-23-1

Figure 8-6. Centrifugal-Flow Compressor Components

g. Exhaust Section. The exhaust section of a turbine following paragraphs.

engine is made up of several components, each of
which has its individual functions. Although the (1) Governors. The speed-sensitive control and
components have individual purposes, they also have speed-set governor are discussed in the following
one common function. they must direct the flow of hot paragraphs.
gases rearward in such a manner as to prevent
turbulence and at the same time Impart a high final or (a) Speed-sensitive control. The speed-sensitive
exit velocity to the gases. control, as shown in figure 8-11, is mounted on the
tachometer pad of the accessories housing. It contains
h. Accessory Section. The accessory section of a three switches which are actuated at certain speeds by a
turbine engine has various functions. The primary flyweight system. During a start, one switch turns on the
function is to provide space of the mounting of fuel and ignition, parallels fuel pump elements,
accessories necessary for operation and control of the energizes the starting fuel enrichments system when
engine. Generally, it also includes accessories fuel enrichment switch is on, and closes the drip valve.
concerned with the aircraft, such as electric generators Another switch shuts off the ignition, deenergizes the
and fluid power-pumps Secondary functions include drip valve (which is then held closed by fuel pressure),
acting as an oil reservoir and/or oil sump, and housing and shifts the fuel pumps from parallel to series
the accessory drive gears and reduction gears. operation. Still another switch shifts the temperature
datum control from start limiting and limits the
i. Governors and Fuel Controls. Governors and fuel temperature datum valve to a certain reduction of
controls used on turbine engines are explained in the engine fuel flow.

8-6
 TM 1-1500-204-23-1

(b) Speed-set governor. The speed-set governor,

as shown in figure 8-12, controls the position of the
governor servo. It is a centrifugal, permanent-droop
type governor driven by the engine high-speed rotor (N2)
through a gear train. As engine speed increases, the
fly-weights tend to move outward, lifting the speed set
pilot valve. Conversely, when engine speed decreases,
the fly-weights move inward and the pilot valve is
lowered. The power lever in the cockpit positions the
speed-setting cam in the fuel control unit to manipulate
a system of levers and thus control the compression of
the speeder spring. The speeder spring exerts force on
the speed-set pilot valve. The condition of on-speed
indicates the speeder spring force and the flyweight
force are equal.

(2) Fuel controls. Fuel controls can be divided into

two basic groups hydromechanical and electronic. The
fuel control senses power lever position, engine rpm,
either compressor inlet pressure or temperature, and
burner pressure of compressor discharge pressure.
These variables affect the amount of thrust that an
engine will produce for a given fuel flow.

(a) Hydromechanical fuel controls.

Hydromechanical fuel controls are extremely
complicated and are composed of speed governors,
servo systems, sleeve and pilot valves, feedback or
follow up devices, and metering systems.

(b) Electron/c fuel controls Electronic fuel

controls contain the same Items as the hydromechanical
fuel control as well as amplifiers, thermocouples, relays,
electrical servo systems, switches, and solenoids.
Figure 8-7. Rotor and Stator Components of an
Axial-Flow Compressor

Figure 8-8. Can-Type Combustion Chamber Arrangement

8-7
 TM 1-1500-204-23-1

Figure 8-9. Can-Type Combustion Chamber

Figure 8-10. Turbine Assembly Elements

8-8
 TM 1-1500-204-23-1

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

Figure 8-11. Speed-Sensitive Control

8-9
 TM 1-1500-204-23-1

Figure 8-12. Speed-Set Governor

8-10
 TM 1-1500-204-23-1

Figure 8-13. One Side of a Typical Ignition System

(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

Figure 8-14. Typical Igniter Plugs

8-12
 TM 1-1500-204-23-1

until troubleshooting determines the cause of the

excessive ITT. New ITT baseline values for HIT should
be established after performing a baseline engine
performance check. A new engine performance check
should be made when an engine Is changed, when the
fuel control unit is adjusted or replaced, or when repairs
are made to the engine hot section.

c. Hot Start Inspection. A hot start occurs when

exhaust gas temperature exceeds normal starting
temperature limit.

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
 TM 1-1500-204-23-1

Figure 8-16. Duplex Fuel Nozzle

8-14
 TM 1-1500-204-23-1

Figure 8-17. Compressor Blade Damage

f. Compressor Cleaning. Compressor cleaning • Weld cracks in combustion chambers that do

consists of internal washing of the compressor with a not exceed repair limitations, using method and
cleaning compound which is intended for use on an procedure which keeps distortion to a minimum.
engine displaying definite evidence of performance
deterioration due to an accumulation of foreign material • Replace any turbine wheel blade found to have
deposits on the compressor blading. Refer to the be out of repair limits. Check applicable
applicable maintenance manual for specific procedures. maintenance manual. Turbine blades will only
be changed in matched pairs.
g. Cold Section Maintenance. Maintenance to cold
section components consists of repairing and replacing • Replace tailpipes when cracked, bent, or
components as outlined In the specific engine distorted.
maintenance manual.
j. Turbine and Exhaust Maintenance.
h. Compressor. Blade Inspection and Repair. Maintenance of the turbine and exhaust components
Compressor blades should be inspected for cracks, consists of repairing and replacing components as
nicks, scores, scratches, buckling, and burns, as shown outlined in the specific engine maintenance manual.
in figure 8-17. Minor damage can be repaired if the
damage can be removed without exceeding the k. Ignition System Maintenance. Maintenance of
allowable limits established by the manufacturer. the ignition system consists primarily of cleaning,
Typical compressor limits are shown In figure 8-18. Inspection, and replacement of components as
Repair In accordance with the applicable maintenance explained by the following paragraphs.
manual.
(1) Wiring harness. Perform wiring harness
i. Hot Section Maintenance. The following are maintenance as explained by the following procedures:
repairs that can be made to the hot section of a turbine
engine:

8-15
 TM 1-1500-204-23-1

Figure 8-18. Typical Compressor Blade Repair Limits

8-16
 TM 1-1500-204-23-1

WARNING
Dry-cleaning solvent is flammable 3 Replace igniter plugs that fail to
and solvent vapors are toxic. Use P- produce continuous and regular sparking
D-680, Type II Solvent in a well-
ventilated area. Keep away from (3) Ignition exciter. Refer to the applicable
open flames. Avoid prolonged maintenance manual for Ignition exciter maintenance.
solvent contact with skin.
I. Turbine Bearing Maintenance. Turbine engine
(a) Clean lead assembly with dry-cleaning bearings shall be inspected, removed, and replaced in
solvent, Federal Specification P-D-680. Replace any accordance with the applicable maintenance manual.
lead having fraying shielding, bent or mutilated socket
contacts or contact pins, and worn or stripped threads on m. Thermocouple Maintenance. Replace
coupling nuts. thermocouple leads that Indicate a short or an open
condition. Clean carbon from thermocouples by dipping
NOTE in carbon removing compound, MIL-C-19853, and
Minor chafing or fraying to the extent wiping deposit away with a clean cloth.
of not more than three broken
strands in one inch of harness length n. Oil Consumption Check oil consumption in
accordance with the applicable maintenance manual.
is permissible, providing there is no
The following formula can be used to calculate oil
damage to the underlying insulation.
consumption in cc per hour.
(b) Clean control harness leads with
cc of oil added x 60 min
methylethylketone, Federal Specification TT-M-261, dry
Recorded operating time 1 hr
with air blast. Replace harness when it is found to be
in minutes
open or shorted.
= Oil consumption time in cc/hr
(2) Igniter plugs. Perform igniter plug
maintenance as explained by the following procedures.
o. Fuel System. Fuel system maintenance shall
be accomplished in accordance with the applicable
(a) Keep all igniter unit connections tight
maintenance manual. General maintenance procedures
and all leads and conduit free from abrasions or other
are described in the following paragraphs.
damage Accomplish the following steps when igniter
plugs fail to spark.
(1) Fuel control inspection and adjustment.
Fuel control inspection and adjustment are explained in
1 When two igniter plugs fail to
the following paragraphs.
spark, replace one plug and energize system. When
plug sparks, replace other plug and retest Replace
(a) Fuel control inspection. Perform the
igniter unit when plug fails to spark.
following procedures when inspecting fuel controls:
2 When one plug fails to spark
1 Inspect housing for cracks and
and a new plug does not remedy defect, replace igniter
leakage.
plug lead. If plug still fails to spark, replace igniter unit
2 Inspect strainer element for
(b) Igniter plugs not heard firing when
nicks, tears, punctures, and broken wires.
engine is started shall be cleaned or replaced as follows:
3 Inspect springs and balls for
1 Clean barrel of igniter plugs
corrosion
with a wire brush Buff threads with a cloth wheel. Do
not clean nose end and electrode.
4 Inspect cover for nicks, dents,
and scratches.
2 Replace plugs with cracked
insulation, damaged threads or pin contacts, or when
foreign material is found lodged In nose of plug.

8-17
 TM 1-1500-204-23-1

(b) Fuel control adjustment. Adjust fuel • Acceleration schedule

control in accordance with the applicable maintenance
manual Typical adjustments are made to the following: (2) Fuel nozzle inspection and cleaning. Inspect
and clean fuel nozzles in accordance with the applicable
• Fuel selector maintenance manual and the following paragraphs.

• Compressor rotor ground idle speed (a) Fuel nozzle inspection. Inspect fuel
nozzles in accordance with table 8-1.
• Air-bleed band closure

• Compressor rotor maximum speed

Table 8-1. Inspection of Primer Nozzles

Inspect Usable limits Max. repairable limits Corrective action

1. Primer nozzle Any amount not Not repairable Replace nozzle

tip for carbon clogging orifice.

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:

a. Cracks None allowed Not repairable Replace retaining nut.

b. Missing or One thread Not repairable Replace retaining nut.

damaged total, missing or
threads. damaged, without
high metal,
If threads can
be used without
cross-threading

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.

d. Distortion Any amount if wrench Not repairable. Replace retaining nut

will fit on nut

e. Discoloration Any amount Not applicable. Not applicable.

f. Nicks and Any number, 1/64 Not repairable Replace retaining nut.
scratches, inch deep, without
except on high metal.
threads

8-18
 TM 1-1500-204-23-1

(b) Fuel nozzle cleaning Clean fuel nozzles are toxic. Use P-D-680, Type II
using the following procedures Solvent in a well-ventilated area.
Keep away from open flames.
WARNING Avoid prolonged solvent contact
Dry-cleaning solvent Is flammable with skin.
and solvent vapors are toxic. Use P-
D-680 Type Solvent in a well- • When using compressed air for
ventilated area. Keep away from cleaning, use approved
open flames Avoid prolonged protective equipment for eyes
solvent contact with skin. and face. Do not use more than
30 psig air pressure. Do not
1 Clean using dry-cleaning direct airstream toward yourself
solvent and a brush or another person. Failure to
comply could result in injury to
2 Remove residue with a clean eyes or skin.
lint-free cloth
(4) Fuel control filter inspection and cleaning.
WARNING Inspect and clean fuel control filter in accordance with
When using compressed air for the applicable maintenance manual and the following
cleaning, use approved protective paragraphs.
equipment for eyes and face. Do not
use more than 30 psig air pressure. (a) Fuel control filter inspection. Inspect
Do not direct air toward yourself or filter for tears, punctures, broken wires, dents,
another person. Failure to comply scratches, and corrosion.
could result in injury to eyes or skin.
In case of injury, get medical (b) Fuel control filter cleaning. Clean filter
attention. using the procedures In paragraph (3)(b)

3 Blow filtered, compressed air (5) Governor control inspection and adjustment.
through primer nozzle. Hold nozzle tip In water, and Inspect and adjust the governor control in accordance
look for stream of air bubbles coming from orifices. The with the applicable maintenance manual.
nozzle is clogged if there is no bubbling. Replace
nozzle if clogged. 8-7. Replacement Criteria for Engines and
Components. Replacement criteria for engines and
(3) Main fuel filter inspection and cleaning. components are explained in the following paragraphs:
Inspect and clean main fuel filter in accordance with the
applicable maintenance manual and the following a Engine Replacement Criteria. The following
paragraphs. conditions require replacement of the engine:

(a) Main fuel filter inspection. Inspect the • When scheduled replacement time Is
main fuel filter for cracks, corrosion, pitting, and element accumulated, as specified In the specific engine
contamination. maintenance manual

(b) Main fuel filter cleaning. Clean filter • When foreign objects enter air Intake and
with a cloth dampened in dry-cleaning solvent. Dry damage compressor.
using compressed air.
• When overspeeding occurs, inspection or
WARNING replacement shall be as indicated In the specific
engine maintenance manual
• Dry-cleaning solvent is
flammable and solvent vapors

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.

8-8. Marking of Defects on Turbine Engines.

Defects In removed parts may be marked by use of a
felt-tip marker.

8-9. Turbine Engine Mounts. A typical engine

mounting system consists of bipod and tripod
assemblies braced by tube assemblies. For specific
details of the system, refer to engine section of the
applicable maintenance manual. Repair bent, distorted,
or chafed areas of mount as specified in the applicable
maintenance manual. After repair of any component of
engine mount, accomplish a thorough visual and
magnetic particle inspection.
Figure 8-19. Turbine Discharge Pressure Pickup
Line
8-10. Preservation and Depreservation of Turbine
Engines. The preservation and depreservation
procedures for each type of turbine engine is specified
In the applicable aircraft maintenance manual

8-11. Removal and Installation of Turbine Engines.

Removal and installation of turbine engines is explained
In the following paragraphs. Refer to the applicable
maintenance manual.

a. Preparation for Removal. Accomplish the

following general steps before removal.

(1) Adequately secure the aircraft either with

wheel chocks or with tiedown provisions; attach ground
wire or cable to aircraft.

(2) Open the nacelle doors and support them

with the struts. Verify that no external power is
connected to the aircraft and that the electric power
switch is off.

(3) Remove the mount access plates from both

sides of the nacelle structure.

Figure 8-20. Electrical Disconnect

8-20
 TM 1-1500-204-23-1

Figure 8-21. Fuel Line Disconnect

(8) Disconnect the power control rod, as shown

in figure 8-22, from the power control lever cross-shaft
linkage at the threaded end disconnect. Secure the
power control rod to the nacelle structure. Figure 8-22. Power Lever Disconnect

b. Removal. The powerplant may be removed c. Preparation for Installation. Installation of

from the aircraft by either of the two methods. One aircraft powerplants will be installed in accordance with
method involves lowering the powerplant from the the applicable maintenance manual.
nacelle by using an engine dolly. The other method
requires hoists and a special sling to lower the d. Installation. Install engine in accordance with
powerplant to a movable engine stand. Refer to the applicable maintenance manual
applicable aircraft maintenance manual.

8-21/(8-2 blank)
 TM 1-1500-204-23-1

CHAPTER 9

GENERAL AIRFRAME MAINTENANCE

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

Figure 9-1. Electric Retraction System

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
 TM 1-1500-204-23-1

Figure 9-2. Hydraulic Landing Gear Retraction System Schematic

9-3
 TM 1-1500-204-23-1

9-4. Troubleshooting of Landing Gear Systems.

The troubleshooting procedures for electrical and
hydraulic landing gear systems is in the applicable
maintenance manuals.

9-5. Shock Struts. Shock struts, as shown in figures 9-

4 and 9-5, are self-contained hydraulic units that support
an aircraft on the ground and protect the aircraft
structure by absorbing and dissipating the tremendous
shock loads of landing. Shock struts must be inspected
and serviced regularly to function efficiently.

a. Shock Strut Operation. The compression stroke

of the shock strut begins as the aircraft wheels touch the
ground, the center of mass of the aircraft continues to Figure 9-3. Landing Gear Safety Circuit
move downward, compressing the strut and sliding the
inner cylinder into the outer cylinder. The metering pin
is forced through the orifice and, by its variable shape,
controls the rate of fluid flow at all points of the
compression stroke. In this manner the greatest
possible amount of heat is dissipated through the walls
of the shock strut. At the end of the downward stroke,
the compressed air Is further compressed, limiting the
compression stroke of the strut. The extension stroke
occurs at the end of the compression stroke as the
energy stored in the compressed air causes the aircraft
to start moving upward in relation to the ground and
wheels. At this instant, the compressed air acts as a
spring to return the strut to normal. It is at this point that
a snubbing or damping effect is produced by forcing the
fluid to return through the restrictions of the snubbing
device (See figure 9-6 ).

b. Shock Strut Servicing. The following

procedures are typical of those used in deflating a shock
strut, servicing with hydraulic fluid, and reinflating

(1) Position the aircraft so the shock struts are

in the normal ground operating position. Make certain
that personnel, workstands, and other obstacles are
clear of the aircraft. (Some aircraft must be placed on
lacks to service the shock struts).

(2) Remove the cap from the air valve.

(3) Check the swivel hex nut for tightness with

a wrench

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

Figure 9-5. Landing Gear Shock Strut of the

Metering Tube Type

(4) If the air valve is equipped with a valve

core, release any air pressure that may be trapped
between the valve core and the valve seat by
depressing the valve core.

(5) Remove the valve core.

(6) Release the air pressure In the strut by

slowly turning the swivel nut counterclockwise.

(7) Ensure that the shock strut compresses as

the air pressure is released. In some cases, it may be
necessary to rock the aircraft after deflating to ensure
compression of the strut.
Figure 9-6. Shock Strut Operation
(8) When the strut is fully compressed, the air
valve assembly may be removed.

(9) Fill the strut to the level of the air valve

opening with an approved type of hydraulic fluid.

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. Brake Systems. Brake system types and general

maintenance are explained In the following paragraphs.

a. Brake Types. The three types of brake systems

in general use are the independent, power control, and
power boost systems. Each is explained in the following
paragraphs.

(1) Independent systems. In general, the

independent brake system is used on small aircraft.
This type of brake system is termed independent
because it has its own reservoir and is entirely
independent of the aircraft main hydraulic system.
Independent brake systems are powered by master
cylinders similar to those used in the conventional
automobile brake system. The system is composed of a
reservoir, one or two master cylinders, mechanical
linkage which connects each master cylinder with its Figure 9-7. Independent Brake System
corresponding brake pedal, connecting fluid lines, and a
brake assembly in each main landing gear wheel as
shown in figure 9-7.

9-7
 TM 1-1500-204-23-1

of brake housing. Brake housings may be either the

one-piece or divided type. Figure 9-10 shows a single
disk brake installed on an aircraft, with the wheel
removed. The brake housing is attached to the landing
gear axle flange by mounting bolts.

(2) Dual-disk brakes. Dual-disk brakes are

used on aircraft when more braking friction Is desired.
The dual-disk brake is very similar to the single-disk
type, except that two rotating disks instead of one are
used.

WARNING
Dry-cleaning solvent is flammable
and solvent vapors are toxic. Use P-
D-680, Type II Solvent in a well-
ventilated area. Keep away from
open flames Avoid prolonged
solvent contact with skin.

c. Brake Assembly Cleaning. Disassemble brake

assembly and clean parts with dry-cleaning solvent,
Federal Specification P-D-680. Clean using a brush or
Figure 9-8. Power Control System air spray. Remove all blistered, chipped, or loose paint.

d. Brake Assembly Inspection. Inspect brake

assemblies using the following general procedures:

(1) Visually Inspect brake housing thoroughly

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
 TM 1-1500-204-23-1

(2) Inspect lining recesses in piston, CAUTION

center carrier, and anvil for indications of wear which Care must be used when installing
could cause loss of lining. Wear of anvil lining recess seals and cups to prevent damage to
circumference in excess of 0.005 inch is cause for feathered edges.
replacement.
(1) Replace all seals, cups, and O-rings
(3) Examine piston cavity for corrosion, on an availability basis when assembling brakes to
excessive wear, or for being out-of-round. When light prevent possible leakage and brake failure.
corrosion extends more than 9/16 inch into piston cavity,
or heavy corrosion Is evident, replace brake assembly. (2) Apply a light coat of insulating and
sealing compound, MIL-I-8660, to surface of piston
NOTE cavity and to O-ring or cup seal.
Corrosion is usually found in carrier
housing and in piston cavities. (3) Replace disks that have cracks
Corrosion in magnesium can be extending through disc. Any single crack that extends
Identified by the rough through thickness of brake disk shall be reason for
honeycombed appearance of the pit. replacement. Minor surface cracks and heat checks are
Pits are usually filled with a yellow or normal and are not cause for replacement.
gray powder. Heavy corrosion is
defined as pits that exceed 0.025 (4) When necessary to replace one lining
inch in diameter or grouped with because of wear, all linings shall be replaced. Replace
three or more pits of any diameter in linings when any lining thickness is less than 1/16 inch,
an area of 1/4 Inch square. or shows indications of being overheated.

e. Corrosion Treatment of Brake Assemblies. g. Brake Assembly Servicing. Service brake

Brake assemblies are manufactured from magnesium, assemblies in accordance with the applicable
aluminum, and steel Most assemblies have magnesium maintenance manual. The following are general
housings which are very susceptible to corrosion, procedures for all aircraft.
especially in piston cavities. Treat the surface using the
following procedures. (1) Check for leaks while system Is under
operating pressure.
(1) Remove sharp edges of corrosion pits
with crocus cloth, Federal Specification P-C-458, NOTE
lubricated with hydraulic fluid, MIL-H-5606.
Tighten loose fittings with the
(2) Rework minor dents, nicks, burrs, or pressure off.
gouges to break all sharp edges of indentations which
might result in a concentration of stress. Use a smooth (2) Check all flexible hoses carefully for
cut hand file to accomplish this, followed by fine swelling, cracking, or soft spots, and replace if evidence
abrasive paper, Federal Specification P-P-101, to of deterioration is noted.
remove tool marks.
(3) Maintain the proper fluid level at all
(3) Condemn brake assemblies that have times to prevent brake failure or the introduction of air
deep scratches, gouges, or cracks exceeding limits into the system.
established In applicable aircraft maintenance manual.
h. Bleeding Brakes. Air in the system is
(4) Accomplish surface treatment as indicated by a spongy action of the brake pedals. If air
outlined in TM 43-0105. is present in the system, remove it by bleeding the
system. There are two general methods of bleeding
f. Repair and Replacement of Brake Assembly brake system. Bleeding from the top downward (gravity
Components. Repair or replace brake assembly method) and bleeding from the bottom upward (pressure
components in accordance with the applicable method). Each method is explained in the following
maintenance manual and the following general paragraphs.
procedures:

9-9
 TM 1-1500-204-23-1

(1) Gravity method. A bleeder hose is attached

to the bleeder valve, and the free end of the hose is
placed in a receptacle containing enough hydraulic fluid
to cover the end of the hose, as shown in figure 9-11.
The air-laden fluid is then forced from the system by
operating the brake. If the brake system is a part of the
main hydraulic system, a portable hydraulic test stand
may be used to supply the pressure. If the system is an
independent master cylinder system, the master cylinder
will supply the necessary pressure. In either case, each
time the brake pedal Is released the bleeder valve must
either be closed or the bleeder hose pinched off;
otherwise, more air will be drawn back into the system.
Bleeding should continue until no more air bubbles
come through the bleeder hose into the container.

(2) Pressure method. In the pressure method, Figure 9-12. Pressure Method of Bleeding Brakes
the air is expelled through the brake system reservoir or
other specially provided location. Some aircraft have a 9-8. Wheel Maintenance. Aircraft wheels are
bleeder valve located in the upper brake line. In using manufactured from magnesium, aluminum, or steel
this method of bleeding, pressure is applied using a alloy. These materials are susceptible to corrosion,
bleed tank, as shown in figure 9-12. A bleed tank is a scoring, and gouging. Corrosion contributes to the high
portable tank containing hydraulic fluid under pressure. replacement rate of wheels. Paint coatings should be
The bleeder tank is equipped with an air valve, air maintained in good condition to prevent corrosion.
gauge, and a connector hose. The connector hose Fatigue cracks and complete wheel failure can result
attaches to the bleeder valve on the brake assembly from inadequate corrosion control, as well as scratches
and is provided with a shutoff valve. Perform this and tool marks in critical stress areas. Care should be
method of bleeding strictly in accordance with the taken to ensure proper usage of tools. Maintain wheels
specific aircraft maintenance manual. using the following paragraphs.

j. Brake System Safety. Follow all safety a. Wheel Cleaning. The following procedures
precautions given by the applicable maintenance describe wheel cleaning.
manual. If It is necessary to approach a wheel with a
hot brake, do so either from directly in front or directly (1) Remove tire, tube, and bearing and
behind the aircraft. disassemble the wheel. See TM 55-2620-200-24 for
demounting procedure.

WARNING
Dry-cleaning solvent is flammable
and solvent vapors are toxic. Use P-
D-680, Type II Solvent in a well-
ventilated area. Keep away from
open flames. Avoid prolonged
solvent contact with skin.

(2) Wash demounted wheel in dry-cleaning

solvent, Federal Specification P-D-680, or
trichloroethylene, Federal Specification O-T-634.

NOTE
Bearings should be cleaned and
Figure 9-11. Gravity Method of Bleeding Brakes repacked if wheel is removed or was
submerged in water.

9-10
 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

Figure 9-13. Aileron Action

Figure 9-14. Elevator Action

9-13
 TM 1-1500-204-23-1

Figure 9-15. Rudder Actlon

(5) Trim tabs. Trim tabs trim the aircraft 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

e. Control Cables. Aircraft control cables are

generally fabricated from carbon steel or corrosion-
resistant steel wire and may consist of either flexible or
nonflexible type construction.

(1) Control cable sizes. Cable size is

measured in diameter as shown in figure 9-18. Control
cables vary in diameter, ranging from 1/16 to 3/8 inch.
Figure 9-18 also shows common cable designations.
Cable designations are based on the number of strands
and the number of wires in each strand.

(2) Control cable inspection and

maintenance. Aircraft cable systems are subject to a
variety of environmental conditions and forms of
deterioration, such as wear, corrosion, and distortion.
The following are general procedures for control cable
inspection and maintenance.

(a) Inspect cables for broken wires by

passing a cloth along length of cable. Cloth will snag
when it passes over broken wire. Figure 9-19 shows
cross sections of a 7x7 and a 7x19 cable.

Figure 9-16. Types of Wing Flaps

Figure 9-18. Cable Cross Sections

Figure 9-17. Trim Tab Assembly

9-15
 TM 1-1500-204-23-1

Figure 9-19. Control Cable Cross Section and Wear Limits

9-16
 TM 1-1500-204-23-1

NOTE 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.

• Wear will normally extend along

the cable equal to the distance
the cable moves at that location
Wear may occur on one side of
the cable only or on its entire
circumference.

• Replace cables when the

Figure 9-20. Typical Breakage Point individual wire in each strand
appears to blend together (outer
wire worn 40 to 50 percent) as
depicted in figure 9-19. Actual
instances of cable wear beyond
recommended point are shown in
figure 9-21.

(c) Move surface controls of the

particular cable to the extremities to reveal the cable in
the pulley contact, fairlead area, or drum.

9-17
 TM 1-1500-204-23-1

Table 9-1. Cable Damage Limits

Cable type Allowable broken wire

7x7 (flexible) 2 per inch of strand, provided not more than 3

exist in that inch of cable

7x19 (flexible) 3 per inch of strand, provided not more than 6

exist in that inch of cable

1x19 (nonflexible) None

(d) If the surface of the cable is (b) Convert indicator reading to

corroded, relieve cable tension and carefully force the tension pounds (see figure 9-22).
cable open by reverse twisting. Visually inspect the
interior. (c) Adjust cable tension to proper
value by either tightening or loosening turnbuckles.
NOTE
Corrosion on the interior strands of (4) Control cable emergency repair. If
the cable constitutes failure, and the possible, duplicate spare cables should be used for
cable must be replaced replacement. When spare cables are not available and
immediate replacement is imperative, use one of the
(e) If no internal corrosion is following methods of splicing.
detected, remove loose external rust and corrosion with
a clean, dry, coarse-weave rag or fiber brush. After CAUTION
thorough cleaning, apply corrosion preventive, MIL-C- Care must be taken that splice does
16173 Grade 2, sparingly. Do not apply the material so not foul fairlead or pulley, nor in any
thick that it will interfere with the operation of cables at other way prevent proper movement
fairleads, pulleys, or grooved bellcrank areas. of the cable

NOTE (a) Woven spliced terminals. Use

Do not use metallic wools or woven spliced terminals on cables 3/32 inch diameter or
solvents to clean installed cables. greater in place of swaged terminals. Fabrication
Use of metallic wool will imbed components needed are shown in table 9-2. Perform
dissimilar metal particles in the the following procedures to fabricate woven spliced
cables and create further corrosion terminals:
problems. Solvents will remove
internal cable lubricant allowing 1 Sweat solder or wrap cable
cable strands to abrade and further prior to cutting to prevent fraying.
corrode.
Table 9-2. Fabrication Components
(3) Control cable tension adjustment. Rig Nomenclature Specification
aircraft as outlined in the applicable aircraft
maintenance manual. After rigging, measure for proper Cable, corrosion-resistant MIL-W-83420
tension on control cables, using a tensiometer. Use the Wire rope, 1 tinned steel MIL-W-83420
following procedures to measure cable tension. Cord, serving V-T-291
Solder, tin-lead QQ-S-571
(a) Place cable under the two
blocks on instrument, and pull lever on side of
instrument down. This pushes up on the center block,
called a riser. The force required to raise the center
block is indicated by a pointer on the scale.

9-18
 TM 1-1500-204-23-1

Figure 9-21. Control Cable Wear Limits

9-19
 TM 1-1500-204-23-1

Figure 9-22. Cable Tensiometer

9-20
 TM 1-1500-204-23-1

2 Secure cable around a 15 After completion of third

bushing or thimble by means of a splicing clamp leaving complete tuck, have the number of wires in each free
8 inches or more of free end. Secure splicing clamp in strand. Make another complete tuck with remaining
a vise with free end to the left of standing wire and away wires.
from operator.
16 At completion of fourth tuck,
3 Select free strand (1, figure again halve number of wires in free strands and make
9-23) nearest standing length and separate this strand one final tuck with remaining wires.
from rest of separate ends.
17 Cut off all protruding strands
4 Insert a marlin-spike under and pound splice with a wooden or rawhide mallet to
first three stands (A, B, and C) of standing length relieve strains in wires.
nearest separated strands of free end and separate
them momentarily by twisting marlin-spike. 18 Serve spice with waxed line
cord. Start 1/4 inch from end of splice and carry
5 Insert free strand (1) under wrapping over loose end of cord and along tapered
three separated strands through opening created by splice to a point between second and third tucks
marlin spike. Pull free strand taut, using pliers.
19 Insert end of cord back
6 Unwind a second strand (2), through last five wrappings and pull snug.
located to left of first strand tucked, and insert this
second strand under first two standing strands (A and 20 Cut off end, and when a
B). thimble is used as an end fitting, bend down points.

7 Loosen third free length 21 Apply two coats of shellac,

strand (3) located to left of first two, and insert it under Federal Specification TT-S-271, to the cord, allowing 2
first standing strand (A). hours between coats.

8 Remove center or core 22 Carefully inspect cable

strand (7) from free end and insert it under same strands and spices for local failure. Weakness in a
standing strands (A and B). woven splice is made evident by a separation of strands
of serving cord.
9 Temporarily secure core
strand to body of standing cable. (b) Wrapped solder splice. The
wrapped solder splice may be used on 1/16-inch cable
10 Loosen strand (6) located to only to fabricate end fittings. The procedure is as
right of first strand (1) and tuck it under last two strands follows (see figure 9-24).
(E and F) of standing cable.
1 Arrange cable and fittings as
11 Tuck fifth free end (5) required, allowing approximately 2 1/4 inches of free
around fifth standing strand (E). Tuck fourth free end end.
(4) around sixth standing strand (F).
2 Place assembly in a splicing
12 Pull all strands snug toward clamp and secure in a vise.
end fitting with pliers. This completes first tuck.
3 Starting as close as practical
13 Begin with first free strand to end fittings, press free end standing lengths of cable
(1) and work in a counterclockwise direction, tucking together tightly, and wrap with a single layer of 0.020
free strands under every other standing strand inch brass or copper wire, Federal Specification QQ-W-
343, leaving a space of approximately 1/8 inch between
14 After completion of every every 1/2 inch of wrapping.
tuck, pull strands taut with pliers. Pull toward end fitting.
NOTE
Care must be exercised to prevent
standing length from twisting during
this operation.

9-21
 TM 1-1500-204-23-1

Figure 9-23. Preparation of Woven Cable Splice

9-22
 TM 1-1500-204-23-1

9 Carefully inspect splice. A

wrapped soldered splice, easily bent with fingers, is
unsatisfactory because of lack of solder penetration.

NOTE
Cracks in solder located between
wrapping wire and short space
provide between wraps is a positive
indication of slippage in wrap
soldered splice.

(5) Testing of cables and splices.

Test all cables and splices prior to installation using the
following procedures:

WARNING
A suitable guard should be placed
over cable, during testing, to prevent
injury in event of cable failure.

(1) Arrange cable to simulate installation,

including pulleys, when required.

(2) Apply test load (refer to Table 9-3) gradually to

one end of the cable for 3 minutes.

Figure 9-24. Wrapped Solder Splice Table 9-3. Cable Test

4 Allow wrapping to extend Cable size

approximately 1/4 inch beyond free end. (inches) Load in pounds1

5 Dip wrapping in tin-lead solder, 1/16 288

Federal Specification QQ-S-571. 3/32 552
1/8 1200
NOTE 5/32 1680
Carefully sweat solder into cable and 3/16 2520
about wrapping 7/32 3360
1/4 4200
6 Apply solder until wrapping wire is 9/32 4800
barely discernible, and ensure that open spaces 5/16 5870
between wrap sections are thoroughly impregnated with 3/8 8640
solder.

7 After splice has cooled, thoroughly 1

60 percent of minimum allowable breaking strength.
wipe clean and remove all solder residue.

8 Wipe cable and impregnate

spliced section with corrosion preventive compound,
MIL-C-16173, Grade I.

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:

(b) Turnbuckle tolerances. (a) Reposition pulleys that do not

Turbuckle tolerances are three visible male (cable align with cables within 2 degrees. Replace inoperative
terminal) threads or four visible female (turnbuckle or other- wise defective pulleys.
barrel) threads, each of which should be free of
evidence of corrosion at the root of the threads. (The (b) Inspect pulleys for roughness,
maximum of four visible female (turnbuckle barrel) sharp edges, and presence of foreign matenal
threads applies only to initial installation of the cable, so embedded in the grooves.
that if the cable stretches, the turnbuckle can be
adjusted to the desired cable tension, at which time, (c) Inspect pulleys for excessive
more or less than four barrel threads may be exposed.) grooving by visual examination of the surface, and by
Safety all turnbuckles. rotating pulley and observing if the cable twists, rotates,
or jumps up and down, as a result of interplay between
(2) Cable terminals. Terminal fittings are the grooves of the pulley and the lay of the cable.
generally of the swaged type. They are available in the
threaded end, fork end, eye end, single-shank ball end, (d) Examine pulley bearings to
and double-shank ball end. The threaded end, fork end, assure proper lubrication, smooth rotation, freedom from
and eye end terminals are used to connect the cable to flat spots, dirt, and paint spray. Inspect pulley bearings
a turnbuckle, bellcrank, or other linkage in the system. for roughness, binding, noise, rust, lubricant leakage,
The ball-end terminals are used for attaching cables to and excessive looseness compared to a new bearing.
quadrants and special connections where space is
limited. Figure 9-26 shows the various types of terminal (e) Maintain pulley alignment to
fittings. Visually inspect and replace clevis or terminals prevent the cable from riding on the flanges and chafing
that are scratched, nicked, dented, corroded, have against guards, covers, or adjacent structure.
stripped threads, or are found bent (distorted).
(f) Check all pulley brackets and
NOTE guards for damage, alignment, and security. Replace if
Minor nicks, scratches, corrosion cracked, corroded, or otherwise damaged.
pits, less than 0.005 inch deep, may
be removed by cleaning and (g) Periodically rotate pulleys,
burnishing smooth, to restore the which turn through a small arc, to provide a new bearing
part to useful service. surface for the cable.

(3) Fairleads. Fairleads, as shown in

figure 9-27, are used to guide cables in a straight line

9-24
 TM 1-1500-204-23-1

Figure 9-25. Turnbuckle Assembly

Figure 9-26. Types of Terminal Fittings

Figure 9-27. Fairleads

9-25
 TM 1-1500-204-23-1

Figure 9-28. Pulley Wear Patterns

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

Figure 9-29. Control Tube Assembly

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.

(b) Repair of control tubes. Control (c) Installation of control tubes.

tubes can be repaired by methods similar to those used Install control tube assembly and rod ends as a unit, and
on structural members. When repairing a control tube, make adjustments at time of installation. Consult
a perfect straightness must be obtained to preserve the applicable aircraft manual for proper dimensions and
full strength of the tube. Sleeve reinforcements may be settings. The following are general procedures:
added to steel tubes with a scarfed or fishmouth cut and
then welded in place. Aluminum alloy tubes can be 1 Install checknut on tube
repaired in the same manner, using rivets for assembly or threaded end of rod, and attach rod end to
attachment. If possible, the tube should be replaced assembly.
and the terminals salvaged. AN490 threaded rod ends
should be replaced because of difficulty in picking up 2 Adjust rod end to obtain
the original rivet holes. correct length of tube assembly Tighten checknut
against rod end to prevent its coming loose.

9-27
 TM 1-1500-204-23-1

NOTE assemblies Rod ends are used to make adjustments in

Type AN943 internally threaded rod control tube length and usually are safetied with a
ends are equipped with a witness checknut or lockwire
hole a short distance from the
threaded end to ensure adequate (a) Inspection of rod ends. Clean and
thread engagement when installed inspect rod ends using the following procedures:
on an externally threaded rod end.
Proper thread engagement is 1 Check for cracks and breaks.
ensured when threads of an
externally threaded rod end can be 2 Check for threaded portion for
seen and a piece of safety wire damaged threads
cannot be passed through the hole.
3 Check for evidence of
If you can pass a piece of 0.020
corrosion.
safety wire through the hole, the rod
is not screwed in far enough 4 Check for bent or misaligned
clevis forks and elongated bolt holes
3 Install tube assembly with
correct bolts, nuts, and washers 5 Thoroughly clean, inspect,
and lubricate bearings in accordance with TM 55-1500-
NOTE 322-25.
When connecting a ball beanng rod
end, install a plain or countersunk (b) Repair of rod ends. Minor repairs
washer, MS20002, of appropriate size maybe accomplished using the following procedures:
under the attaching nut and bolt head
to prevent any possibility of rod end 1 Smooth out small nicks and
slipping off over the bearing retaining scratches with fine abrasive cloth, Federal Specification
nut or bolt head. Attaching nut and P-C-451.
bolt must clamp tightly the inner race
of bearing to face of washer and 2 Correct minor thread
supporting structure. Use caution irregularities by chasing threads with a tap or die.
when installing washers so that full
movement of rod end is not limited. 3 Replace defective bearings.
Nuts and bolts that are only fingertight
do not use the beanng for the purpose 4 Major defects will require
for which it was intended. Control replacement of rod end.
tubes using clevis rod ends may have
washers, if required, installed under (c) Installation of rod ends. Install
bolt and nut heads on outside of fork rod ends and control tube assembly as a unit. Refer to
or between fork and bearing, if space paragraph 9-12f (5)(c).
permits. Tighten nuts to torque values
(7) Bellcranks. Bellcranks, as shown in
shown in applicable aircraft manual.
figure 9-30, change direction of motion and transmit
motion to parts such as control rods, cables, and torque
4 Check for freedom of
tubes Replace all worn, bent, or otherwise defective
movement, full travel, and excessive side play.
bellcranks.
5 Secure rod ends, bolts, and
nuts with applicable safety devices.

(6) Rod ends. Rod ends are used on

push-pull linkage as attachment points and to effect
minor adjustments. Rod ends are available with
threaded, clevis, and bearing ends. Those with
internally threaded shanks are used on threaded control
rods or control tube assemblies which have threaded rod
ends Other rod ends are used to make up control tube
Figure 9-30. Bellcrank

9-28
 TM 1-1500-204-23-1

(8) Mixing units. Mixing units combine four

motions from the cockpit (pitch, roll, yaw, and thrust) NOTE
and convert them into two outputs. Inspect and
maintain in accordance with the applicable maintenance • Heaters with an engine exhaust
manual. heat source require an
operational test for carbon
(9) Drive chains. Replace defective links in monoxide levels upon
chains and maintain in accordance with applicable installation of the heater or
maintenance manual. following extensive heat
exchanger maintenance,
(10) Speed rigs. Speed rigs are fitted in the modification, or suspected
cable assembly for the purpose of making rapid minor malfunction.
adjustments.
• The test will be performed at heat
9-13. Environmental Control Systems. nvironmental
duct opening with the heater full
control systems heat, cool, and remove moisture from
on and the engines operating at
the air supplied to the crew or passenger compartments.
full military power. An indication
of 50 parts per million (ppm/0.005
a. Types. The forced air heating system,
combustion heater, and pressurized system are used by percent) or greater requires
Army aircraft. Each is explained in the following corrective action prior to heater
paragraphs. use. Suggested test equipment
is Detector Kit, Carbon
(1) Forced air heating system. Heated air Monoxide, Colorimetric, NSN
is provided for crew comfort, deicing, defrosting, and 6665-00-618-1482 and Indicator
anti-icing Air is forced into muffs or jackets installed Tubes, Carbon Monoxide, NSN
around the tailpipes The air routed through the muff or 6665-00-276-7545.
jacket picks up heat by convection through the tailpipe
material. The heated air is then routed to an air-to-air (2) Combustion heater. The
heat exchanger before going on to perform various combustion heater provides heat by routing outside air
heating functions. Maintenance to this type of system is past a burner section. The outside air picks up heat by
limited, and will consist of the following: convection from the burner section and is then routed to
perform various heating functions. Maintenance of
WARNING heater between overhauls will normally consist of
Drycleaning solvent is flammable inspection, cleaning, or replacement of parts as
and solvent vapors are toxic Use P- explained in the following procedures:
D-680, Type II Solvent in a well-
ventilated area Keep away from open WARNING
flames. Avoid prolonged solvent Drycleaning solvent is flammable
contact with skin. and solvent vapors are toxic. Use P-
D-680, Type II Solvent in a well-
(a) Wash all metal parts of heating ventilated area. Keep away from
system in drycleaning solvent, Federal Specification P- open flames. Avoid prolonged
D-680. Wash flexible tubing with mild soap, Federal solvent contact with skin.
Specification P-S-620, and water.
CAUTION
(b) Lubricate valve cranks and Do not use a metal instrument, as it
push-pull levers with a small amount of molybdenum- may damage core passage.
disulfide technical powder, MIL-M-7866.
(a) Clean core tip and body of
(c) Pressure-test any repair made spray nozzle with drycleaning solvent, Federal
to heat exchanger tube before installation. A repaired Specification P-D-680. Use a wooden stick to scrape off
tube is considered a temporary measure and will be any dirt remaining on spray nozzle.
replaced when parts become available.

9-29
 TM 1-1500-204-23-1

CAUTION sealed fuselage from cabin superchargers. The

Do not use carbontetrachloride, superchargers deliver a constant volume of air at all
trichloroethylene, or other altitudes up to a designed maximum Air is released from
chlorinated solvents. Otherwise the fuselage by a device called an outflow valve The
damage to filter element may result outflow valve, by regulating the air exit, controls the
pressure within the aircraft. Maintain in accordance with
(b) Clean filter element by passing the applicable maintenance manual.
air or drycleaning solvent, Federal Specification P-D-
680, through it in reverse direction after removal from b. Repair of Flexible Air Ducts. Cracked
filter bowl. When these methods fall to clean element, it flexible air ducts, constructed of fiberglass material, will
should be replaced. be inspected and repaired on the aircraft when
economically feasible. Silicone damage shall not
(c) Use dry, filtered air to blow out exceed 3.0 inches in length and 1.5 inches wide with
any dust that may have accumulated in ignition unit. limits of two repairs per foot of duct or three percent of
Wipe out any oil with a dry, clean cloth. total surface area. Reworked areas will be sanded or
buffed to fair in with adjoining material. Repair flexible
(d) Secure all heater drain plugs air ducts using the following procedures.
with lockwire to prevent loss of plugs and resultant
flame discharge. Prepare drain plugs for safetying as (1) Clean damaged area with Toluene
follows: TT-T-548. Allow cleaned area to air-dry a minimum of
30 minutes.
1 Drill hex head bolts across a
corner with a No 52 drill. (2) Apply to a brush coat of Room
Temperature Vulcanizing (RTV), M IL-A-46146, on
2 Drill countersunk hex head damaged area with a 0.5 inch overlap from edge of
plugs completely through and countersink drilled head damaged area.
90 degrees by 3/32-inch diameter on both sides of plug.
(3) Smooth and cure by air drying a
3 Secure drain plugs to any minimum of two hours at room temperature or until it is
suitable adjacent point using steel wire, ASTM A580 dry to the touch.
ANO A313.
NOTE
NOTE For repair of damage to the
fiberglass cloth, the limitation is no
• Combustion heaters require an more than 10 percent of surface area
operation test for carbon after completion of repair.
monoxide levels upon
installation of the heater or (4) Clean the complete circumference of
following extensive heat
exchanger maintenance, the air duct in the vicinity of damaged area with
modification, or suspected Toluene. Allow cleaned area to air-dry a minimum of 30
malfunction. minutes.

• The test will be performed at a (5) Use brush to apply a thin coat of
heat duct opening with the heater adhesive to the complete circumference of the duct in
full on. An indication of 50 parts the damaged area and smooth out adhesive.
per million (ppm/0.005 percent)
or greater requires corrective
action prior to heater use. (6) Cut a piece of fiberglass cloth, MIL-C-
Suggested test equipment is 9084, of sufficient size to cover the complete
Detector Kit, Carbon Monoxide, circumference of the duct, with a one-inch overlap of the
Colonmetric, NSN 6665-00-618- damaged area.
1482 and Indicator Tubes,
Carbon Monoxide, NSN 666500- (7) Wrap fiberglass cloth around duct and
276-7545.
smooth out.
(3) Pressurized system. A pressurized
(8) Allow to air-dry a minimum of two
system maintains the cabin pressure altitude at a
hours or until dry to touch before handling.
constant value. Pressurized air is pumped into the

9-30
 TM 1-1500-204-23-1

NOTE
Repairs of flexible ducts made of
fiberglass impregnated with
chloroprene shall be made with
adhesive, NSN 8040-00-390-7960 (P/N
Bostick 4006A and 4006B) utilizing
fiberglass cloth. Repairs will be
accomplished in a well-ventilated
area.

9-14. Deicing Systems. Pneumatic deicing systems

use rubber deicers, called boots or shoes, attached to
the leading edge of the wing and stabilizers. The deicers
are composed of a series of inflatable tubes. During
operation, the tubes are inflated with pressurized air,
and deflated in an alternating cycle as shown in figure 9-
31. This inflation and deflation causes the Ice to crack
and break off. The ice is then carried away by the
airstream.

a. Deicing System Precautions. Exercise the

following precautions to assure maximum service life of
deicer shoes:

• Repair all damage promptly.

• Keep deicer shoes free of oil, gasoline, paint

remover, solvents, and other injurious
substances.

• Clean deicer shoes, using a mild soap, A-A-

50, and water solution not exceeding 180°F
(82°C).

• Do not rest ladders of work stands against

leading edges having deicer shoes installed.
Wrap padding around those portions of work
stands which could come in contact with Figure 9-31. Delcer Boot Inflation Cycle
installed deicer shoes.
b. Deicing System Preventive Maintenance.
• Do not drag fuel or oil servicing hoses over Preventive maintenance for deicing systems will entail
the deicer shoes. the following procedures:

• Do not walk or lay tools and objects on upper CAUTION

stretch area of shoes. Deicer shoes, when Do not use excessive amounts of
installed, are under tension and therefore methyl ethyl ketone, as this product
readily susceptible to abrasion. tends to soften rubber.

• Protect deicer shoes from abuse.

9-31
 TM 1-1500-204-23-1

(1) Thoroughly clean affected area using

methyl ethyl ketone, ASTM D 740. (f) Reactivate both cemented
surfaces with a cloth dampened with methyl ethyl
WARNING ketone, and apply patch to deicer shoe, starting at edge
Avoid breathing vapors from and working down carefully to avoid trapping air beneath
cements and solvents utilized during patch.
this operation.
(g) Allow patch to set 15 minutes,
(2) Apply a brush coating of sealing then wipe patch and surrounding area with methyl ethyl
compound, MIL-S-8802, approximately 1/32 inch thick ketone.
over clean area.
(h) Buff and clean a minimum area
(3) Allow sealing compound to dry until of 1/2 inch around patch.
no longer tacky.
(i) Apply a brush coat of sealing
(4) Rub down sealing compound to compound, MIL-S-8802.
remove brush marks and feather edges using abrasive
paper, 400 grit, Federal Specification P-P-101, or NOTE
equivalent.
• Weather-checked surfaces and
(5) Remove powdered sealing compound abraded areas not requiring a
with compressed air or a dry, clean cloth. patch will be treated as outlined
in paragraph 9-14b.
(6) Apply one coat of approved
conductive cement to entire surface of shoe. • Repair cuts, tears, and severe
scuff damage to tube or stretch
c. Deicing System Troubleshooting. A typical area with reinforced (one-way
troubleshooting chart for deicing systems is shown in stretch) neoprene patches.
table 9-4. Damage to nonstretch areas will
be repaired with plain neoprene
d. Deicing System Maintenance. Maintenance patches.
of deicer system consists primarily of the care and
repair of deicing shoes and the replacement of defective (2) Cold patch limits. Limits for cold
component parts The following paragraphs explain patching are as follows:
general maintenance for deicing systems.
(a) Cuts up to one inch on deicer
(1) Patch installation Install patches using shoes attached with fairing strips.
the following procedures:
(b) Cuts up to three inches in length
(a) Thoroughly clean affected area, on deicer shoes attached with cement.
using methyl ethyl ketone, ASTM D 740.
9-15. Fire Detection and Extinguishing Systems.
(b) Buff affected area until Fire detection and extinguishing systems are explained
completely roughened. in the following paragraphs.
(c) Clean buffed area with a clean a. Fire Detection Systems. The fire detection systems
cloth completely dampened with methyl ethyl ketone.
are designed to detect the presence of fire in zones
such as engine compartment and combustion-type
(d) Select a patch of ample size to
heater compartment, and to light a red warning light in
cover damage.
the pilot's compartment in event of fire To detect fires or
overheat conditions, detectors are placed in the various
(e) Apply one coat of Goodrich 60
zones to be monitored. Fires are detected in aircraft
cement, or equivalent, to damaged area and patch, and
using one or more of the following:
allow to dry thoroughly (5 to 10 minutes).

9-32
 TM 1-1500-204-23-1

Table 9-4. Troubleshooting Pneumatic Deicing Systems

Trouble Probable cause Remedy

1. Pressure gauge oscillates a. Faulty lines or connections. Repair or replace lines.

Tighten loose connections.

b. Deicing boots torn or punctured Repair faulty boots.

c. Faulty gauge Replace gauge.

d. Faulty air relief valve Adjust or replace relief valve.

e. Faulty air regulator Adjust or replace regulator.

2. Pressure gauge oscillates; a. Vacuum check valves installed Reinstall correctly.

peaks at a specified pressure improperly
while instrument vacuum
gauge shows no reading

b. Vacuum relief valve Improperly Adjust or replace valve as

adjusted or faulty necessary.

c Faulty lines between pump and Tighten, repair, or replace faulty

gauge lines or connections.

3. Pressure gauge shows no a. Faulty pressure gauge line Repair or replace line.
pressure while vacuum gauge
shown normal reading.

b. Faulty pressure gauge Replace gauge.

c. Pressure relief valve faulty Adjust or replace as necessary.

d. Pressure regulator faulty Adjust or replace as necessary.

4 Cycling period irregular a. Loose or faulty tubing and Tighten, repair, or replace as
connection necessary.

b. Boots torn on punctured Repair faulty boots.

c. Faulty electronic timer Replace timer.

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

Figure 9-33. Kidde Sensing Element

Figure 9-32. Thermal Switch

(2) Thermocouple system. The

thermocouple is constructed of two dissimilar metals such
as chrome and constantan. The point where these metals

9-34
 TM 1-1500-204-23-1

(b) Fenwal system. The Fenwal NOTE

system, as shown in figure 9-34, uses a single wire Limits on the element diameter,
surrounded by a continuous string of ceramic beads in an acceptable dents or kinks, and
Inconel tube. The beads in the Fenwal detector are degree of smoothness of tubing
wetted with a eutectic salt which possesses the contour are specified by
characteristic of suddenly lowering its electrical resistance manufacturers. No attempt should
as the sensing element reaches its alarm temperature. be made to straighten any acceptable
dent or kink, since stresses may be
c. Maintenance of Fire Detection Systems. Inspect set up that could cause tubing
fire detection systems for the following: failure.
• Cracked or broken sections caused by crushing • Loose nuts or broken safety wire at the end of
or squeezing between inspection plates, cow the sensing elements
panels, or engine components.
NOTE
• Abrasion caused by rubbing of element on
Loose nuts should be re-torqued to
cowling, accessories, or structural members
the value specified in the
• Pieces of safety wire or other metal particles manufacturer's instructions. Some
which may short the spot detector terminals. types of sensing element
connections require the use of
• Condition of rubber grommets in mounting copper crush gaskets. These
clamps, which may be softened from exposure gaskets should be replaced any time
to oils, or hardened from excessive heat a connection is separated

• 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.

• Proper sensing element routing and clamping.

Figure 9-34. Fenwal Sensing Element
NOTE
Long unsupported sections may
permit excessive vibration which can
cause breakage. The distance
between clamps on straight runs is
usually about 8 to 10 inches, and is
specified by each manufacturer. At
end connectors, the first support
clamp is usually located about 4 to 6
inches from the end connector
fittings. In most cases, a straight run
of 1 inches is maintained from all
connectors before a bend is started,
and an optimum bend radius of 3
inches is normally adhered to

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

Table 9-5. Troubleshooting of Fire Detection Systems

Trouble Probable cause Remedy

1. Intermittent alarms a. Short In the detector system Repair or replace defective

wiring wiring.

b. Kinks and bends in sensing Repair damaged areas of

element sensing element.

2. False alarms a. Short between loop con- Repair or replace defective

nections and control units wiring.

b. Bent areas of sensing loop in Repair bent areas of sensing

contact with hot parts of the loop.
engine

c. Short In the sensing loop Replace shorted section of

sensing loop.

d. Moisture in detection system Remove moisture contamina-

tion.

3. Failure to obtain an alarm a. Defective test switch or control Replace test switch or control
signal when the test switch unit unit.
Is actuated

b. Lack of electrical power Provide electrical power.

c. Inoperative Indicator light Replace indicator light.

d. An opening in sensing element Repair sensing element or

or connecting wiring connecting wiring.

9-36
 TM 1-1500-204-23-1

(2) Replace sensing element only when decomposition products should

physical damage such as chafing, bending, twisting, or be avoided. CB is a narcotic
breaking has occurred. Replace attaching parts when agent of moderate intensity but
found to be defective. of prolonged duration. It is
considered less toxic than
CAUTION carbon tetrachloride,
Bends will not be less than two methylbromide, or usual
inches in radius. products of combustion. Normal
precautions should be taken
(3) Replace cable detector only when physical while using bromochloromethane
damage such as chafing, bending, twisting, or breaking Including use of oxygen masks
has occurred. Make all bends and routing with fingers when available. Injury to
only. Replace attaching parts when found to be defective personnel may otherwise result.
(4) Replace mounting brackets of
• Monobromotrifluoromethane
thermocouple detectors when cracked, corroded, or
(CF3Br) is highly volatile but is
damaged. Replace attaching parts when found to be
defective not easily detected by Its odor.
Although nontoxic, it must be
NOTE considered to be about the same
When replacing thermocouple as other freons and carbon
detector, note which wire is dioxide, causing danger to
connected to identified plug terminal personnel primarily by reduction
of defective unit, and connect of oxygen available for proper
replacement in the same way. breathing. The liquid should not
be allowed to come into contact
f. Testing of Fire Detection System Test fire with skin, as It may cause
detection system using the following procedures frostbite or low temperature
burns.
(1) Test system for proper operation by turning
on power supply and placing FIRE DET TEST switch in g. Fire Extinguishing Systems. The fire extinguisher
test position Red warning light should flash on within 10 system Is the one-shot type consisting of one or more
seconds. Turn switch and power off charged containers of bromochloromethane or
monobromotrifluoromethane (CB and CF3Br), discharging
(2) Test required after repair or replacement of tubing, overboard discharge tube, discharge indicator,
units in fire detector system or when system is Inoperative circuit breakers, and control panel switch. The container
as follows is charged with bromochloromethane or
monobromotrifluoromethane under pressure, which is
• Replace lamp in warning light, when warning discharged through tubing Into the engine compartments
light does not flash on. by actuating FIRE EXT switch to the ON position

• 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

WARNING (2) Inspect overboard discharge indicator for

evidence of system being discharged due to thermal
• Repeated or prolonged exposure expansion.
to high concentrations of
bromochloromethane (CB) or

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.

CAUTION (c) Replace damaged tubing. Use old

Disconnect positive electrical lead on tubing or a piece of string as a pattern in routing new
solenoid valve before removing tubing
container, and do not connect lead
until all circuit tests have been (d) Reuse fittings of hose and tube
completed and firing switch on control assemblies unless damaged
panel is in OFF position. Damage to
equipment may otherwise result. NOTE
Clean and thoroughly flush tubing and
(8) Replace discharged container and bonnet hose prior to installation.
assembly with fully charged assemblies
(e) Replace hoist cable when kinked or
WARNING when cable has broken.
Before attempting to perform
continuity test of the fire extinguishing (f) Replace micronic filters periodically
electric circuit, the extinguisher to assure delivery of uncontaminated fluid
cartridges must be removed to
preclude accidental firing during test (g) Lubricate hoist as prescribed in the
applicable aircraft maintenance manual.
(9) Make a visual inspection of the electrical
circuit wiring for obvious damage. Test the continuity of (2) Testing of hydraulic hoist system. Test
the entire circuit excluding the fire extinguisher container hydraulic hoist system for operation periodically (and
cartridge. when a new unit Is installed in the system) by performing
a functional check using the following procedures:

9-38
 TM 1-1500-204-23-1

NOTE flows from the charged cylinder through the high-pressure

Use an external hydraulic test unit or line to the pressure-reducing valve, which reduces the
the aircraft hydraulic system with pressure to that required at the mask outlets. A calibrated
engine operating orifice in the outlets will control the amount of oxygen
delivered to mask.
(a) Check operation of down-limit switch
by unwinding winch to Its limit to assure that winch will (2) Pressure-demand system. A simple
stop when cable If fully unwound pressure-demand oxygen system is shown in figure 9-36.
Note that there Is a pressure-demand regulator for each
(b) Check operation of up-limit switch by crewmember, who can adjust the regulator according to
running cable until up-limit switch is actuated his requirements.

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 hoist 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

Figure 9-35. Continuous Flow Oxygen System

Figure 9-36. Pressure-Demand Oxygen System

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

• Ground powered equipment is operating

• In aircraft having filler lines and distribution within 50 feet of the servicing area.
lines commonly connected at one end of
cylinder, purging will be accomplished by filling
system with oxygen and then draining system • Aircraft is being serviced with fuel, oil, or anti-
This cycle shall be performed at least three icing fluids
times.

(8) Charging after flight. Charge oxygen

• Any combustible materials, fluids, etc., are
evident around oxygen servicing equipment.
system on aircraft that have had all the oxygen supply
drained during flight within two hours after landing. When

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:

CAUTION a. To clean and deodorize relief tube systems, a

Oxygen equipment shall be kept clean solution of 1 1/2 ounces of MIL-SPEC A-A-1634 general
at all times. No organic matter or purpose deodorant and 5 gallons of water will be used to
flammable substance of any nature wash area around relief tube exit and relief tube entrance.
shall be allowed to contact oxygen.
Ensure that all components of the b. Pour remainder of solution through the tube.
systems are free of moisture, oil, and When an offensive odor remains, use a stronger solution
grease at all times. Oxygen is a and reclean until odor is removed.
nonflammable gas; however, it
supports combustion and lowers the NOTE
flash or Ignition point of all The area of relief tube exhaust will be
combustible materials. Oxygen shall primed with zinc chromate primer,
be handled as a flammable gas. Federal Specification TT-P-1757, and
painted with acid proof lacquer,
(4) To prevent overfilling of tanks, personnel Federal Specification TT-L-54
shall observe aircraft oxygen system gauges at all times
during servicing operation. c. Replace deteriorated hose, broken or damaged
horn, and broken or damaged attaching parts.
(5) Personnel shall be stationed at the oxygen
servicing unit at all times during servicing operation to NOTE
shut off unit valves immediately upon receiving a Install hose so as to eliminate any
command from personnel watching aircraft system gauge. residue pockets.

(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

b. Adjustment of Windshield Wiper System. The

windshield wiper system shall be adjusted as follows:
Drycleaning solvent is flammable and solvent
vapors are toxic. Use P-D-680, Type II Sol-
vent in a well-ventilated area. Keep away
Do not operate wipers on dry glass. from open flames. Avoid prolonged solvent
(1) Loosen locknut on wiper blade, align blade, contact with skin.
and tighten locknut. (g) Remove grease spots with drycleaning
(2) Remove locknut from wiper unit shaft, solvent, Federal Specification P-D-680.
adjust position of arm on shaft to give full sweep on (h) Remove blood stains by use of cold
windshield, and reinstall locknut. water applied with sponge. Remove residue with a 10
(3) Adjust tension nut at base of wiper arm until percent solution of ammonia hydroxide, MIL-STD-612,
blade exerts 1 1/2 to 2 pounds pressure against wind- or a paste of cornstarch, Federal Specification NC-541.
shield. Allow treated area to dry. When cornstarch is used, brush
dried material from fabric.
NOTE
(2) Repair. Repair and patch fabric material of
Measure tension at tip of wiper arm in a direc- troop seats using repair procedures outlined in para-
tion perpendicular to windshield surface. graph 9-22.
9-20. Aircraft Seats. Maintenance of aircraft seats (3) Installation and removal. Follow instruc-
shall be accomplished in accordance with the proce- tions contained in the applicable aircraft maintenance
dures explained in the following paragraphs. manual for installation and removal procedures.
a. Troop Seats. Cleaning, repair and installation b. Metal Seats. Cleaning, repair, and installation
and removal procedures for fabric or cotton canvas troop and removal procedures are explained in the following
seats are explained in the following paragraphs. paragraphs.
(1) Cleaning. Clean troop seats as follows:
(a) Unfold and place parts face up.
(b) Brush with a firm bristle brush to Drycleaning solvent is flammable and solvent
remove excess dirt. vapors are toxic. Use P-D-680, Type II Sol-
vent in a well-ventilated area. Keep away
(c) Prepare a cleaning solution of 1 ounce from open flames. Avoid prolonged solvent
of anionic synthetic detergent (alkyl benzene sulfonate), contact with skin.
Federal Specification P-D-410, per gallon of water.
(1) Cleaning. Clean with clean cloth moistened
(d) Work up heavy suds by repeatedly with drycleaning solvent, Federal Specification P-D-680.
squeezing of a sponge saturated with detergent solution.
Apply heavy suds to soiled areas. (2) Repair Patches and reinforcement repairs
to metal seats will be accomplished in accordance with
(e) Scrub soiled areas briskly, using a firm repair procedures in TM 1-1500-204-23-10.
bristle brush or heavy cloth. Wipe off with a damp cloth.
(3) Installation and removal. Follow instruc-
(f) Allow treated area to dry. Brush to raise tions contained in the applicable aircraft maintenance
nap. manual for installation and removal procedures.

9-43
TM 1-1500-204-23-1

c. Upholstered Seats. Cleaning, repair, and instal- NOTE

lation and removal procedures are explained in ‘the fol- A 24 month service life pertains only to those
lowing paragraphs. covers which are used in an energy attenua-
(1) Cleaning. Clean upholstered seats by using tion application.
cleaning materials and methods as prescribed in para-
graph 9-20a. Replace the original nylon spall shield, or use
new ballistic nylon MIL-C-12369 for replacement.
(2) Repair. Repair small rips or tears with a Apply a thin even coat of contact adhesive EC
sewed or unsewed patch. Attach unsewed patches with 1300L (FSCM 04963) to the tile surface. Allow
adhesive, Federal Specification MMM-A-1617. adhesive to dry until tacky. Carefully mate the
(3) Installation and removal. For instructions spall shield to the tile, working it on by hand
installation and removal, refer to the applicable mainte- pressure. Fit the nylon snugly over the fiberglass
nance manual for particular aircraft. patch (or patches). Do not wrap the spall shield
d. Raschel Knit Seat Covers. Raschel knit seat over the edge of the panel. Tears in the spall
cover maintenance limits are listed below: shield shall not exceed 3 inches. Any unbonded
area of the spall shield, (as evidenced by bulges),
Deterioration or discoloration which indicates a shall not exceed a diameter of 1 inch.
strength decrease to the point where it affects the
integrity of the seat(s) is not allowed. Seat covers made of raschel knit nylon cloth shall
Tears, cuts, or holes greater than 2.5 inch in length have a service life of 24 months. Seat covers that
or diameter are not allowed; the seat should be are not marked with an installation date shall be
replaced assumed to have the same date as the day of
acceptance of the aircraft. Replacement covers
Tears, cuts, or holes less than 2.5 inch in length can shall be marked with contrasting ink conforming
be repaired. Repair is not allowed for seat covers to MIL-l-6903. The size of marking shall be of
with holes, cuts, or tears in raschel kit material that sufficient size and location so that it can easily be
are located close to the seams of the adjoining read. The following is an example of marking
panels and do not allow sufficient space for the installation date: 7 Mar 88
darning procedure. Repair should be used as a
temporary measure until new seat covers or back
covers can be installed. In the fine-mesh duck cloth e. Polyester Fabric Seat Covers (Uh-60). Clean-
surrounding the raschel knit material, tears, cuts ing, repair, and installation and removal procedures for
and holes up to 2.5 inches in length can be polyester fabric seat covers are explained in the following
repaired. A different method for repairing is paragraphs.
required and is as follows:
(1) Cleaning. Clean the polyester fabric seat
Tears, cuts or holes less than 0.5 inch in length may and back using the following procedures:
be repaired by stitching which extends 0.5 inch into (a) Brush fabric with firm bristle brush
the sound material surrounding the damaged area. removing excess dirt.
Tears, cuts or holes of up to 1.0 inch in length may (b) Use enough liquidto allow complete
be repaired with the use of a patch made of the immersion of the seat cover to be washed.
same material as the seat cover. Locate on the (c) Mix 3 ounces of low strength laundry
underside of the damaged area and sew a zigzag soap, Federal Specification P-S-1792, to each gallon of
stitch over the tear area and into patch extending water. Synthetic detergentis permissible as an alterna-
0.5 inch into the sound material surrounding the tive.
damaged area.

Tears, cuts, or holes of 1.0 to 2.5 inches in length

may be repaired with the use of a patch made of the
same material as the seat cover. The patch should
be sized to extend 1.0 inch in all directions to the
damaged area and include 0.50 inch of material to
fold under to finish all the edges of the patch. The
patch should be located on the underside of the
damage area with the folded edges to the inside.
Zig-zag sew the damage area into the patch, fol-
lowed by a minimum of two (2) rows of stitching
around the patch using 6-9 stitches per inch.

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
limit for repair
• To keep out dust, rain, and foreign matter,
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

Figure 9-37. Repair Pattern for Polyester Cloth

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).

NOTE 3 Trim and turn under frayed

To increase life expectancy, protect edges to make a neat and durable repair.
covers against rain, wind, snow, sand,
and mildew when not Installed on 4 Use circular patches on small
aircraft. holes and rectangular patches on larger holes, irregular
snags, or tears.
(a) Remove all possible ropes and
wooden attaching parts. 5 Mend a cluster of holes with
one suitable patch, after first removing damaged area and
(b) Tape or wrap all attaching parts, such turning under all edges.
as buckles, snaps, hooks, and D-rings to prevent tearing
and snagging of covers during soaking or washing. 6 Provide best possible water
drainage by extending patch seams diagonally from
(c) Brush soiled section with firm bristle centerline of cover section whenever possible.
brush to remove excessive soil.
7 Do not extend patches over
(d) Select a container that will hold more than one section of cover (seam to seam).
enough liquid to allow complete immersion of cover to be
washed. 8 Restitch all open seams. Stitch
pattern and type thread will follow as near as possible the
(e) Mix soap solution containing 3 type stitch and thread used in original construction of item
ounces of low strength laundry soap, Federal being repaired.
Specification P-S-1792, to each gallon of water.
Synthetic detergents are permissible when available. (b) Edge damage. Repair edge damage
as follows.
NOTE
The temperature of water should not 1 Repair damaged areas along
exceed 100°F (37°C) edge of covers where grommets or attaching points are
located by folding a piece of material equal to the basic
(f) Immerse one cover at a time in soap material over damaged area by sewing In place.
solution for a period not to exceed 30 minutes.
2 Replace corner areas where
(g) Rinse over In clean water until all attaching points are located by sewing on a patch
soap has disappeared. composed of three thicknesses of material equal to basic
material.
(h) Spread covers on a clean surface to
dry. 3 Replace any worn or missing
webbing keepers, defective elastic webbing, or
(2) Repair. Make prompt repairs to aircraft reinforcement patches.
protective covers to prolong service life. Inspect for

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
from any flame
• Silicon Carbide (SiC)

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:

(a) Fold covers neatly to facilitate easier

and faster installation when covers are needed.

9-48
 TM 1-1500-204-23-1

Table 9-6. Armor Plating Definitions

Terms Definitions

Panel Each individual removal unit or module of the total

assembled armor protective system.

Delamination Any area where the fiberglass ply or plies have

become detached from the binding resign in the
reinforced plastic backing.

Backing The ballistic energy absorber and structural support

system for the brittle ceramic tile. The backing is a
composite of fiberglass lamination impregnated with
plastic resign.

Spall Shield A cover on the ceramic tile to protect crew

members from flying fregments during a ballistic
impact. The spall shield is made of nylon cloth
MIL-C-12369.

(1) Inspect for the following damages which NOTE

cannot be repaired In the following substeps (a) and (b), To check for unbonded tile on armor
the allowable deviation is zero; therefore the panel must having multiple tile sections, lightly tap
be scraped. In the Note following substep (c) an the ceramic surface using a coin Any
acceptance tolerance is specified, therefore, do not scrap area that has a lack of bond between the
panels that are within the allowable tolerance Send panel tile and plastic backing should respond
to a higher level of maintenance for repair. with a dull thud, as opposed to the
higher pitched sound of a well bonded
(a) Inspect all panels for ballistic area However, the distinction between
damage. Do not repair armor panels with any ballistic the bonded and unbonded area will not
damage (direct hit).
always be clearly evident
(b) Inspect for cracked resign or ridges in
NOTE
the backing that show evidence of a structural failure.
To determine a characteristic sound,
compare with a well-bonded area, such
NOTE
as along a panel edge. Press firmly by
This damage will be matched by a tile hand all over the tile surface, observing
crack generally paralleling the failure any tile movement on release of hand
line in the backing This damage may pressure. Outline any unbonded area
occur at a weaker reduced sections of on the face of the tile for reference A
the panel, such as the area around the 100 percent bond between tile and
head Accidental blows from tools or backing Is not required for ballistic
hard objects, and the use of armor efficiency. Do not make allowance for
panels as handholds, are usually the any additional support of the tile by the
cause of this type of damage Do not spall shield. Do not repair armor panels
repair armor panels with any cracked having a total unbonded area In excess
resin or ridges In the backing of 20 percent for each tile section For
monolithic armor (one piece cast tile),
(c) Inspect the panel for unbonded tiles the tile bond as a whole should be
adequate .

9-49
 TM 1-1500-204-23-1

(2) Refer to the repair procedures in temperature as low as 55°F

paragraph 9-23d for inspection of damage and for (13°C), although the time to reach
damage limitations other than those specified. If the a given stage of cure is at least
panel is damaged beyond the limits specified, it cannot be double that required at normal
repaired. room temperature.

c. Adhesives, Resins, and Solvents for Repair of

Armor. The following paragraphs explain adhesives, • The viscosity of the resin may be
resins, and solvents used for repair of armor. too high for some methods of
application. Add methyl ethyl
(1) Adhesives. For adhesives, follow ketone, TT-M-261, up to a
manufacturer instructions concerning storage, agitation, maximum of five percent by
mixing, thinning, temperature, range, fire and health weight of the total solution
hazards, plus contamination by moisture and dust. The content, to lower viscosity.
adhesive used for repair can be applied to the fraying
surfaces by any convenient means that will give a (3) Solvents. For solvents and cleaning
smooth, uniform spread of the adhesive Use methods solutions, observe all of the usual precautions for
such as a brush, a hand roller, an extrusion gun and ventilation to prevent the accumulation of toxic vapors
squeegee Clean all tools Immediately after each use with and to avoid a fire hazard.
Toluol, TT-T-548. Do not let adhesive polymerize (cure)
before cleaning. (4) Instructions for Pro-Seal 890 sealant.
Instructions are as follows:
NOTE
Use Polysulfide Sealing Compound, NOTE
MIL-S-8802, Class A-2 or B-2 for
adhesive Pro-Seal 890 (FSCM 83527) is • Bonding material Pro-Seal 890
a qualified product meeting or consists of two parts: Pro-Seal
exceeding the requirements of MIL-S- 890 Sealant and Pro-Seal 890A
8802. Use Pro-Seal 890, Class B-2 for Curing Agent
application by squeegee or extrusion
gun. Use Pro-Seal 890BT, Class A-2
for application by brush or hand roller. • Both Pro-Seal 890 and its curing
Agent Pro-Seal 890A should be
(2) Resins. Many tertiary amines, phenolic used as received. Do not thin
materials, alcohols and water catalysts accelerate the with solvent.
reaction between the Diethylene Triamine (DTA) curing
agent and EPON resin. Although catalysts are used to
control the curing rate of resins, they reduce the pot life • Curing agent Pro-Seal 890A
of a mixture formulation, such as DTA and EPON Do not contains no solvent to assure a
use any curing agent accelerators Since water is an minimum amount of shrinkage
accelerator, avoid any contact of the mixture formulation when mixed with Pro-Seal 890
with water. Sealant. Pro-Seal 890A contains
an oxidizing compound,
NOTE therefore avoid prolonged
contact with the skin. Wash
• As the room temperature hands thoroughly before eating
decreases the resin curing rate or smoking.
time falls rapid. The DTA curing
agent may be applied at a

9-50
 TM 1-1500-204-23-1

(a) Open curing agent Pro-Seal 890A repairable. You may repair cracks
and thoroughly mix it In the container until it becomes a occurring in the ceramic tile 1/16 of an
smooth paste. inch or less In width, provided that the
backing Is not damaged beyond
(b) Thoroughly mix 10 parts of Pro-Seal repair. Do not repair armor panels
890A to 100 parts of Pro-Seal 890 by weight, or 8.4 parts where a crack (or cracks) wider than
of Pro-Seal 890A to 100 parts of Pro-Seal 890 by volume. 1/16 if an Inch is found. Total
allowable defects are three or less
(c) Carefully fold the material upon itself cracks, chips, or spalls in any 2-inch
and blend for a period of at least five minutes This will square area.
give a satisfactory mix.
(b) Repair cracked tile by bonding a 1/8 inch
NOTE thick sheet of fiberglass, type GEE, MIL-P-18177, over
Avoid violent agitation In order to beat the crack (or Cracks) overlapping the damaged area by
as little air Into mixture as possible three (3) inches on each side, using Polysulfide Sealant
Also, frictional heat developed from Pro-Seal 890 (FSCM 83527).
violent agitation may reduce work life
of the material. (c) Bevel all edges of the fiberglass patch 1/4
Inch deep and 30 degrees from the top surface so the
(5) Curing requirements for Pro-Seal 890 nylon spa shield will fit smoothly over the patch.
sealant (2 cure option). Requirements are as follows:
NOTE
• Mixed, uncured Pro-Seal 890 sealant material For ceramic having raised edges at the
(Class A-2 or B-2) requires 72 hours at room joints, one side of the patch may be
temperature for a full cure. cut short of the 3 inch overlap
requirement. If the crack extends
through a raised edge on the tile,
• If the production schedule is not flexible enough shape the patch, by undercutting, to fit
to allow for the long-time room temperature
over the raised edge. Use good
cure, accelerated step curing conditions may be
judgment in determining this, bearing.
employed to fully cure the sealant material In
In mind that the patch is to restore
four hours at elevated temperatures The step
curing conditions are two hours at 120°F structural integrity of the panel When
(49°C), followed by an additional two hours at patching along a panel edge, cut patch
158°F (70°C). This means that you should use to fit the edge boundary along
two ovens set at the two different temperatures periphery of the tile.
specified to fully cure the uncured material
under accelerated conditions. (d) Remove existing sealant residue from
the tile surface by using a solution consisting of 50
d. Repair of Armor Plating. Specific repairs and percent by volume of Petroleum Distillate Base, TT-T-291
Inspections for armor plating are described in the and Toluol, TT-T-548.
following paragraphs.
(e) Lightly abrade the fiberglass patch
(1) Repair and inspection of cracked tile Repair and ceramic surface surrounding the cracked area where
and Inspection procedures are as follows: the patch (or patches) is to be bonded.

(a) Inspect for cracked tiles. (f) Clean the abraded ceramic and patch
surface using a clean cloth moistened with methyl ethyl
NOTE ketone, TT-M-261. To obtain satisfactory adhesion, apply
Multiple cracks converging at an angle sealant only to a clean dry surface, free of oil and grease.
of 15 degrees or less are not

9-51
 TM 1-1500-204-23-1

NOTE total area greater than 1 square

Do not use reclaimed solvents when inch or a depth exceeding 1/10 of
preparing a surface for bonding. the thickness of the ceramic
material.
(g) Mix Pro-Seal sealant according to
paragraph 9-23c(4).
• Total allowable defects are 3 or
(h) Apply sealant to the ceramic surface, less cracks, chips, or spalls in
and press the fiberglass patch over the crack (or cracks) any 2-inch square area. Edge
to be repaired. chips or spalling are acceptable
without limit within the 3/4-inch
(i) Apply metal clamps or weights to the edge boundary of the tile around
patch to apply contact pressure equal to about five the periphery of the armor panel.
pounds per square inch.
(c) Repair spalled areas or chips
(j) Place pieces of 1/8 inch fiberglass of occurring in the ceramic, if they do not exceed the limits
1/4 inch plywood pads under the clamps to distribute the as specified, by applying Polysulfide Sealant Pro-Seal
clamping force. 890.

NOTE (d) Fill the chipped or spalled areas with

Do not use rigid pads, as these will sealant, smooth flush with the ceramic surface and apply
concentrate the clamping force on the a 1/8 Inch thick fiberglass patch The fiberglass patch
point of contact and may crack the should overlap the chipped or spalled areas by three (3)
ceramic tile. Maintenance activities inches on each side.
having the necessary equipment may
use the vacuum bag method for (e) Bevel all edges of the fiberglass
clamping the patch to the tile surface. patch 1/4 inch deep and 30 degrees from the top surface
The vacuum bag process Is used for so that the nylon spall shield will fit smoothly over the
both fabrication and repair of glass patch.
fabric reinforced plastic sheets. The
process consists of applying pressure NOTE
by vacuum and then curing by infrared For ceramic having raised edges at the
heat lamp or oven. An autoclave Is joints, one side of the patch may be
also used to apply heat and pressure cut short of the three inch overlap
for curing. requirement. If the crack extends
through a raised edge on the raised
(k) Cure Pro-Seal sealant according to edge. When patching along a panel
paragraph 9-23c(5). edge, cut patch to fit the edge
boundary along periphery of the tile.
(2) Repair and inspection of spalled or chipped
(f) Remove existing sealant residue from
tile. Repair and inspection procedures are as follows:
the tile surface by using a solution of 50 percent by
volume of Petroleum Distillate Base, TT-T-291 and
(a) Inspect for spalled or chipped tiles Toluol, TT-T-548.
(b) Repair spalled areas or chips In the (g) Lightly abrade the fiberglass patch,
ceramic tile, except at the tile joints that do not exceed 1 the ceramic surface surrounding the spalled or chipped
square inch, and whose depth (at any point) does not area where the patch (or patches) are to be bonded, and
exceed 1/10 of the thickness of the ceramic material. the inside surface of the chipped or spalled area.
NOTE
• Do not repair armor panels where
spalled areas or chips have a
9-52
 TM 1-1500-204-23-1

(h) Clean the abraded ceramic surface, can be made if a delamination if

including the fiberglass patch and the chipped or spalled longer than 3 inches or if panel has
surface, using a clean cloth moistened with methyl ethyl more than one delamination.
ketone, TT-M-261. To obtain satisfactory adhesion,
apply only to a clean dry surface, free of oil and grease. (b) Remove dirt and grease from the
delaminated cavity before repairing as follows:
NOTE
Do not use reclaimed solvents when 1 Inject methyl ethyl ketone
preparing a surface for bonding. (MEK) TT-M-261, into cavity with a syringe. Let solution
soak for a few minutes to loosen the dirt and grease.
(i) Mix Pro-Seal sealant according to
paragraph 9-23c(4). 2 Draw out the contaminated
MEK with the syringe, or position the panel to allow the
(i) Apply Sealant mixture to the MEK to flow out by gravity. Repeat the procedure until
ceramic surface, but first fill all spalled or chipped areas the cavity is clean.
with sealant and spread flush with the ceramic surface.
3 Volatize the MEK using an
(k) Press the fiberglass patch (or electric hot air gun, or vacuum nozzle directed Into the
patches) over the filled area to be repaired. cavity Continue procedure for 10 to 15 minutes Do not
use compressed air because oil and dirt in the air may
(I) Attach metal clamps or weights to contaminate the cavity.
the patch to apply contact pressure equal to about five
pounds per square Inch. (c) Repair delamination of fiberglass
plies along the edges of the backing by filling the voids
(m) Place pieces of 1/8 Inch fiberglass with epoxy resin using a DTA curing agent Mix 100 parts
of 1/4 inch plywood pads under the clamps to distribute by weight of EPON 828, MIL-R-9300 (FSCM 36131)
the clamping force. with 10 parts by weight of DTA O-D-1271 as follows:

NOTE 1 Inject the resin with a syringe

Do not use rigid pads, as these will until the cavity is filled, then brush the edge surface
concentrate the clamping force on smooth.
the point of contact and may crack
the ceramic tile. Maintenance 2 Attach metal clamps to the
activities having the necessary repaired area to rebond the fiberglass piles.
equipment may use the vacuum bag
methods. 3 Place pieces of 1/8 inch
fiberglass or 1/4 inch plywood pads under the clamps to
(n) Cure Pro-Seal sealant according to distribute the clamping force.
paragraph 9-23c(5).
NOTE
(3) Repair and inspection of delaminated Do not use rigid pads, as these will
edges of backing. Repair and inspection procedures are concentrate the clamping force on
as follows: the point of contact and may crack
the ceramic tile.
(a) Inspect edges of the backing for
delamination of the fiberglass layers. (4) Repair and inspection of internal
delamination of backing. Repair and inspection
NOTE procedures are as follows:
A delamination 3 inches or less in
length may be repaired. No repairs

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).

(d) Slowly inject resin using a syringe

until void is filled and epoxy discharges from opposite
hole. See figure 9-38 Additional holes may be needed if
air entrapment occurs when injecting the resin.

Figure 9-38. Delaminated Repair

9-54
 TM 1-1500-204-23-1

(b) Repair scars, scratches, or surface NOTE

abrasion not penetrating through the facing, or fraying of Patches must form a step pattern as
the edges of the backing by first cleaning the damaged shown in figure 9-39. Steps should
or frayed surface thoroughly and carefully using a clean be at least 1/4 to 1/2 inch long Use a
cloth moistened with methyl ethyl ketone, TT-M-261 (or cutting tool with a controlled cutting
other approved cleaning agent). depth to facilitate the cutout and to
avoid possible damage to the layers
(c) Lightly sand the damaged surface underneath.
using No 280 grit abrasive cloth. Clean the surface
thoroughly using methyl ethyl ketone. Remove moisture (d) Remove these sections by peeling
and solvents completely to prevent Inhibiting the curing from the center and working carefully back to the
of the resin. desired perimeter of the cutout. Cut through the
overlaying ply in a series of cuts.
(d) Apply one or two coats (depending
on seventy of the abrasion or fraying)of epoxy resin NOTE
using DTA cunning agent. Mix 100 parts by weight of Exercise care not to peel back or to
Epon 828MIL-R-9300 (FSCM 36131) with 10 parts by rupture the adhesion of the
weight of DTA O-D-1271. Brush the surface smooth
lamination layers beyond the cutout
Methyl ethyl ketone may be added to lower viscosity of
perimeter.
the solution for brushing using a maximum of 5 percent
by weight
(e) Scrape each step and wipe clean
with a cloth moistened with methyl ethyl ketone TT-M-
(e) Over this coated surface, apply a
261
sheet of cellophane L-C-110, or polyvinyl alcohol (PVA)
film extending 2 or 3 inches beyond the surface.
(f) Cut pieces of fiberglass cloth, type
Cellophane or polyvinyl alcohol film will prevent
181, Cl 2, MIL-C-9084 to extract size, with the weave
exposure to the air, and will provide a smooth bubble-
direction such that they will overlay the original lay-up.
free surface for the resin to cure.
(g) Use the wet lay-up technique.
(f) Tape the cellophane or PVA film in
Place the first ply of precut cloth on a clean lay-up table.
place and work out all air bubbles and excessive resin
Spread 45 to 50 percent of resin by weight on the cloth,
by hand or by using a rubber squeegee.
using a squeegee to thoroughly impregnate all of the
fabric.
(g) Cure at room temperature for 24
hours. After the resin has cured or set, remove the
(h) Lay-up the resin impregnated cloth
cellophane or PVA film for finishing
in the previously prepared cutout, being careful not to
entrap any air under the fabric. Repeat the same
(6) Repair and inspection of cuts and gouges
procedure with the next ply.
in backing Repair and inspection procedures are as
follows
(i) Place the last ply dry in the cutout
after first coating the surface of the previous ply with
(a) Inspect for cuts and gouges in the
resin.
backing using special care to determine extent of the
damage.
(j) Replace each piece of fabric being
careful to maintain the wet resin content (by weight)
(b) Count the number of fiberglass plies
between 45-50 percent. Use resin and curing agent as
that have been damaged as accurately as possible.
specified in paragraph 9-23d(3)(c).
Mark the number on the backing next to the damaged
area.
(k) Cover the repair with cellophane L-
C-110 or polyvinyl alcohol (PVA) film and press down to
(c) Repair cuts or gouges not
smooth the patch and to expel air bubbles.
exceeding three layers of fiberglass by first removing
successive layers of damaged laminate in
(l) Cure at room temperature for 24
approximately oval patches (round corner rectangular
hours. After resign has cured or set, remove cellophane
patches are permissible).
or PVA film for finishing.

9-55
 TM 1-1500-204-23-1

Figure 9-39. Gouge Repair

(m) Sand smooth all repaired areas backing next to the insert Angle the holes toward the
after curing using No. 320-400 grit abrasive cloth. bottom of the insert.

(7) Repair and inspection of threaded inserts (d) Inject bonding compound, Metalset
in backing. Repair and inspection procedures are as A4 (FSCM 90414)with a syringe into one hole. Fill
follows: around insert until compound discharges from second
hole.
(a) Inspect panel for loose inserts
or damaged threads. NOTE
Metalset A4 resin cement is furnished
NOTE as two compounds, Part A (resin) and
Inserts in a composite fiberglass- Part B (hardener). Thoroughly mix
plastic type of backing have a Part A and Part B in a 1 to 1 ratio by
tendency to work loose. It is weight or volume. Allow bonding
important to replace any missing compound to cure at room
insert as the heavy armor panels are temperature for 24 hours. For
severely strained during a shock accelerated curing cure bonding
loading, such as a hard landing. compound at 150°F (660C) for two
hours. Excess Metalset A4 must be
(b) Repair damaged Insert threads, removed before it hardens. Remove
where possible, using the proper sized tap to chase excess resin with Toluol, TT-T-548.
threads.
(e) Replace rubber edge molding
(c) Where an insert is loose, drill after abrading the inside surface using a fine wire wheel
two small holes, 180 degrees apart, in the fiberglass (0.004 inch diameter wire) or abrasive cloth.

9-56
 TM 1-1500-204-23-1

(f) Wipe with a cloth moistened with 9-25. Vibration Isolators. Vibration isolators are shock
methyl ethyl ketone TT-M-261 absorbing mountings which absorb vibrations or
movements of a component. They are utilized with
(g) Apply a sufficient amount of armament equipment, electronic equipment,
contact adhesive 1300Lto cover the inside surface of photographic equipment, instruments, instrument
the rubber and the mating surface. panels, and other like equipment requiring shock
mounting.
(h) Allow adhesive to dry until tacky.
a. Type of Vibration Isolators. Vibration isolators
(i) Carefully fit and press the molding are commonly classified in three types open-type,
over the edge of the panel. closed-type, and combined vibration isolator mounting
base type.
(j) Clean dirt and dust accumulation
from the repaired panel using general purpose (1) Open-type. Open-type vibration isolators
detergent. Do not use methyl ethyl ketone for cleaning are those on which the shock absorbing material is
the fiberglass backing exposed, and are usually so constructed that the load is
supported on rubber in shear (A and B, figure 9-40) or
CAUTION compression (C, figure 9-40).
Prolonged contact of the fiberglass
to methyl ethyl ketone or acetone will (2) Closed-type. Closed-type vibration
result in detenoration of the resin. isolators are those on which the shock absorbing
material is enclosed by a metal cup or housing The
(k) Rinse the washed area with clear shock absorbing material is usually a coil spring, rubber,
water and dry panel with a soft cloth Then permit panel or metal mesh In compression, or a combination of
to dry out thoroughly. these materials as shown in figure 9-41.

(I) Touch up repaired areas of spall (3) Combined vibration isolator mounting
shield and fiberglass backing with acrylic lacquer, MIL-L- base type. Combined vibration Isolator mounting base
81352 type vibration isolators are formed by combining
resilient material such as sponge rubber, metal mesh
(m) Apply a base coat of epoxy primer, pads, or coil springs with a mounting base and
MIL-P-23377. Feather the primer coating onto to supporting structure as shown in figure 9-42.
surrounding color coat.
b. Installation of Vibration Isolators. Installation of
(n) Allow the primer to air dry for a vibration Isolators should be accomplished in such a
minimum of 30 minutes. manner as to allow free movement of mounted
equipment with adequate clearance around brackets,
(o) Apply two coats of acrylic lacquer to piping lines, and other items of equipment. Accomplish
match the original finish color as applicable. the following procedures when Installing vibration
isolators:
9-24. Cargo Tiedown Equipment. Cargo tiedown
equipment devices may be assembled from webbing, (1) Measure vertical and horizontal
nets, rope, cables, or fittings Use snaps, hooks, clamps, clearance between equipment and nearest supporting
buckles or other acceptable fasteners. Install tensioning structure.
devices or other means to provide a method of
tightening and adjusting restraint system. Provide NOTE
covers or guards to prevent damage to or jamming of A vertical and horizontal clearance of
aircraft equipment, structure, or control cables. Inspect 1/16 inch shall be maintained.
and repair In accordance with the applicable Maintain adequate distance between
maintenance manual. mounted equipment and nearest
object (bracket, pipe, line, structure,
etc.).
9-57
 TM 1-1500-204-23-1

(2) Move equipment to extreme positions in or instrument panel), and nearest support structure
every direction to ensure that retaining fasteners are (isolator mounting cup, mounting base, or aircraft
secure and the isolators have not sagged. structure) with vibration isolators with any vertical or
horizontal clearances of less than 1/16 inch.
NOTE
Prior to any attempt to install (2) Move equipment or instrument panel to
vibration isolators, the high, or low extreme positions in every direction to determine if
side, must be found. Each Isolator Isolators have sagged, or retaining rivets or holddown
has a low side and a high, or load screws are loose
side. In some instances, the words
LOAD SIDE will be stamped in the (a) When elastic rubber parts of open-
high side of the isolator to facilitate type vibration isolators are stretched to their extreme
identification. position, examine rubber for cracks, or separation of
rubber to metal bond. Replace isolators with any of
c. Inspection of Vibration Isolators. To prevent these conditions visible.
unsatisfactory isolation and eliminate damage, vibration
isolators shall be inspected and replaced in accordance (b) When equipment on combined
with the applicable phase maintenance inspection vibration isolator mounting base is moved to extreme
checklist. The following are general inspection positions in all directions, examine sponge rubber or
procedures for all types of vibration isolators. metal mesh pads for deterioration and permanent
packing. Replace vibration Isolators with cracked or
(1) Using a standard thickness gauge or 6 deformed pads which seriously affect isolation efficiency
inch scale, measure vertical and horizontal clearance of mounting system.
between isolated load (equipment case, mounting base,

Figure 9-40. Open-Type Vibration Isolators

9-58
 TM 1-1500-204-23-1

Figure 9-41. Closed-Type Vibration Isolators

9-59
 TM 1-1500-204-23-1

Figure 9-42. Combined Vibration Isolator Mounting Base

9-26. Elastic Shock Cord Assemblies Elastic shock NOTE

cord assemblies are explained in the following Sections of cord shipped to service
paragraphs. activities shall have a duplicate tag
affixed to provide information for
a. Inspection and Testing. Inspection and testing reinspection date
of elastic shock cord assemblies are described in the
following paragraphs. • Cords in stock at all activities other than depots
shall be visually inspected for irregularities in
(1) Inspection. All cords installed in aircraft diameter or other evidence of deterioration
shall be visually inspected at each phase maintenance and to see that serviceable parts tag is attached
inspection. Any cord that shows irregularity in diameter as specified.
must be replaced. Cords found to be over five years old
will not be considered serviceable Observe the following • Cords that fail to meet test requirements shall
inspection requirements: not be installed on aircraft, but will be made
available for use on ground equipment or for
other uses
• Cords in stock shall be inspected and tested
every six months as specified below. At the
time a test is made, a serviceable parts tag shall • Cord requiring reinspection will be retested and
be affixed to the spool or cord as follows retagged if facilities are available. If facilities
are not available, cord shall be returned to
INSPECTED depot for reinspection.
DATE..
ACCORDING TO • Cords not suitable nor required for ground
TM 1-1500-204-23-1 equipment or other uses shall be
TO BE REINSPECTED AND RETESTED administratively condemned or condition
6 MONTHS FROM DATE HEREON condemned.

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 an
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.

Table 9-7. Test Loads

Cord Diameter Inches Load pounds

Straight cord 1/4 13

3/8 80
1/2 155
5/8 225
3/4 360

Endless ring bungee 3/8 155

7/16 235
1/2 315
9/16 380
5/8 450
11/16 585
3/4 720
113/16 1000

Elastic Exerciser 3/16 5

5/16 7

9-61
 TM 1-1500-204-23-1

Table 9-8. Color Coding NOTE

Stretch fixtures used to elongate
elastic shock cord will be capable of
Year Identification securely holding ends of cord
without slippage. When elastic
1984 - Yellow shock cord is stretched to twice its
1985 - Black original free length, stretch fixture
1986 - Green shall not damage cord ends.
1987 - Red
1988 - Blue (4) Dip or brush cut ends of elastic shock
1989 - Yellow cord with a coat of sealant MIL-S-4383, and allow to air-
1990 - Black dry.
1991 - Green
1992 - Red NOTE
1993 - Blue Coating should be heavy enough to
prevent raveling of cotton braid
Quarter Identification
(5) Locate lockrings approximately 1/2 inch
January Red from ends of elastic shock cord, however, do not extend
February ends of cord outside body of terminal fastener.
March
(6) Stretch elastic shock cord 50 percent in
April Blue area of lockring or splice location prior to crimping
May lockring in place or serving elastic cord.
June
(7) Crimp lock rings securely in place to form
July Green a continuous ring around elastic shock cord.
August
September (8) Accomplish serving of elastic shock cord
using the following items:
October Yellow
November • Elastic cord, MIL-C-5651
December
• Cotton cord, Style A, No. 10 (Use for serving
NOTE elastic shock cord 1/2-inch and smaller in
For succeeding years and quarters, diameter. )
this cycle repeats.
• Nylon Cord, MIL-C-5040, Type I (Use for
(2) Wrap cord with masking tape prior to serving elastic shock cord larger than 1/2-inch
cutting to prevent raveling of cotton braid during diameter )
subsequent fabrication or handling operations.
NOTE
(3) Stretch elastic shock cord to 2 1/4 times Minimum serving lengths are
its original free length specified in table 9-9.

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

c. Identification. Colored threads in the outer

cover are used to indicate date of manufacture. The (5) Install end fittings back to back on elastic
color code for threads is given in table 9-8. Bungee and shock cord.
shock absorber cords have two threads to indicate year
and one to indicate quarter. Elastic exerciser cords (6) Clamp elastic shock cord in a stretch
have three threads to indicate year and one for quarter. fixture in such a manner that markings for finished
Elastic shock cord, used in some compass mounts, is assembly length and lockring locations are
covered with a solid black braid with no colored thread approximately equal distances between stretch fixture
to indicate date of manufacture. Although these cords jaws.
do not have a limited shelf life, they must pass the
elongation test before installation. (7) Stretch elastic shock cord until distance
between cord markings has increased 50 percent.
d. Fabrication Procedures. Fabricate elastic
shock cord assemblies using the following procedures. (8) Crimp lockrings on cord at marked
locations. Crimp each ring until ring ends are in contact
(1) Cut elastic shock cord a minimum of 4 with each other.
inches longer than required finished assembly length.
(9) Remove elastic shock cord from stretch
(2) Wrap ends of cut elastic shock cord with fixture and cut elastic shock cord approximately 3/4 inch
masking tape to prevent raveling of cotton braid. beyond lockrings.

(3) Center mark required finished assembly NOTE

length on elastic shock cord as shown in figure 9-43. After cutting elastic shock cord, ends
will shrink approximately 1/4 inch.

(10) Dip or brush cut ends of elastic shock

cord with a coat of sealant, MIL-S-4383, and allow to air-
dry. Coating should be heavy enough to prevent
raveling of cotton braid.

(11) Reinstall assembly in stretch fixture, and

Figure 9-43. Marking Elastic Shock Cord pull until finished assembly length has increased 50
percent. Ensure that there is no slippage of lockrings or
end fittings.

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

NOTE • Locate storage area where elastic shock cord

Slight marking on ring caused by and assemblies shall be free of contact with
crimping tool shall not be cause for oil, grease, solvent, fumes, direct sunlight, or
rejection. Cotton braid caught local heat concentrations. Avoid storage
between crimped ends of lockring adjacent to steam pipes, space heaters, or
will not be cause for rejection like conditions.
providing no elastic bands In shock
cord are pinched or cut. • Do not store items containing chemicals
harmful to rubber products near elastic shock
(4) Assure that minimum of 1/2 inch of elastic cord and assemblies.
shock cord extends beyond last wrap of serving cord.
• Store elastic shock cord and assemblies from
(5) Test finished elastic shock cord storage areas for manufacture or delivery on
assemblies as outlined in paragraph 9-26d, step (11). the basis of the oldest material being used
first. This assures that no cord shall spend an
g. Storage of Elastic Shock Cords. In addition to excessive time in storage and thus lessen its
the general storage requirements for rubber items in TM active service life.
1-1500-204-23-6, the following practices shall be
employed during storage of shock absorbers and elastic • Dispense elastic shock cord and assemblies
exerciser cords. from storage areas for manufacture or
delivery on the basis of the oldest material
• Store cords so they shall not be subject to being used first. This assures that no cord
stresses. shall spend an excessive time in storage and
thus lessen Its active service life.
• Keep stocks of cord at a minimum, but
consistent with operating requirements.

• Maintain temperature of storage area between

32 and 80°F (0 and 270C) when possible
During summer months, keep elastic shock
cord and assemblies In the coolest part of the
storage area.

9-65/(9-66 blank)
 TM 1-1500-204-23-1

CHAPTER 10

ARCTIC, DESERT, AND TROPIC MAINTENANCE

10-1. General. Arctic, desert, and tropic CAUTION

maintenance, inspections, and operations are explained Do not permit air from heaters with
In the following paragraphs. temperature In excess of 251oF
(122oC) to blast against ignition
10-2. Arctic Maintenance. The following paragraphs harness, flexible hose, self-sealing
contain the basic principles and procedures which are tanks, or other rubberized or fabric
essential for efficient utilization of aircraft, equipment, materials. Damage may otherwise
and personnel in arctic areas. The operation of aircraft result.
In arctic regions is seriously handicapped because of the
effect of the elements on both personnel and (1) Preheat requirements. Engine preheat is
equipment. With a decrease in temperature, an normally required only on reciprocating engines. Jet
increase In time required to perform duties is inflicted engines do not require preheat unless the available
due to reduced flexibility of packings and rubber parts, auxiliary power unit is not sufficient to overcome
higher viscosity of lubricants, and binding of metal parts additional starter loads. Preheat requirements can be
due to contraction. General procedures for all aircraft considerably reduced by following proper oil dilution
are discussed within these paragraphs. For specific procedures.
problems on a particular aircraft or piece of equipment,
refer to the applicable maintenance manual. (2) Preheat for starting . At low temperature,
apply heat to engine as a starting aid. Reduce starter
a. Precautions. Maintenance personnel shall loads by preheating engine, thereby reducing oil
observe the following precautions as a guide to viscosity. Generally, preheat will not be required If
successful performance of duty In severe weather. temperature is above 0°F (-180C) and engine oil has
been properly diluted
(1) Exercise care when stepping or walking
on snow or frost-covered or very cold surfaces. (3) Preheat time. Preheat time required to
Wearing proper shoes will aid In walking on slippery prepare an engine for starting depends on outside air
surfaces and reduce the possibility of injures from temperature, size of engine, heater output, and velocity
slipping. and direction of wind. Also, when oil dilution, method of
preheat application, or use of covers and nose shields
(2) Exercise caution when touching very cold are inefficiently applied, the required preheat time will
metal with bare hands, moisture on hands will tend to be lengthened.
freeze skin to metal. When practical, wear gloves and
cover metal tool handles (4) Preheat application. Apply heat to both
the power and accessory sections until cylinder heat,
(3) Do not exert excessive torque or tension temperature reaches 68°F (20°C). Do not rely entirely
on bolts, nuts, cables, or similar items when making upon temperature gauge as readings may be misleading
repairs on equipment that has been exposed to extreme because of thermocouple being located in path of heater
cold. These items tend to freeze or snap as metal blast. Where heater supply is limited, concentrate heat
expands upon warming. on rear accessory section, particularly main oil drain, oil
lines, and oil sump, with second priority going to nose
b. Preheating. The following paragraphs explain gear, propeller hub, and power section.
general procedures for preheating aircraft and engines.

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.

Figure 10-1. Types of Spray Nozzles

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

(8) Partly open canopy when parking CAUTION

aircraft for the night, or provide some other opening to During thawing operation, no aircraft
prevent accumulation of frost on windows. will be parked within a 100-foot
radius of operation. Damage to
(9) Clean dirt, ice, and grit from landing equipment may otherwise result.
gear struts and hydraulic pistons. Wipe struts with a
clean cloth saturated in hydraulic fluid, MIL-H-5606. (b) Dig pit a minimum of 3 feet
Inspect struts for proper inflation. deep and wide enough to accommodate a 3-foot length
of log or similar object.
(10) Inspect tires for proper Inflation.
(c) Connect rope, insert log or
(11) Install or remove snow and ice- similar object and fill pit with gravel and snow.
grip tires to comply with change of seasons. Use of
snow and ice grip tires on clear, hard surfaced runways 10-3. Desert Maintenance. The following paragraphs
reduces the life and effectiveness of the tires. contain the basic principles and procedures which are
essential for efficient utilization of aircraft, equipment,
(12) In emergency arctic conditions, and personnel in desert areas. In the desert, aircraft
tie down aircraft using trees or the arctic-type mooring can be protected from deterioration problems by using
anchor shown in figure 10-2. The following procedures protective covers, preventive maintenance, and
can be used to construct an arctic-type mooring. maintaining regular inspections. These paragraphs are
not considered as a substitute for detailed maintenance
(a) Thaw ground with fire where pit is to and operating instructions, but as a supplement to each
be dug. aircraft operation and maintenance manual.

Figure 10-2. Arctic-type Mooring

10-6
 TM 1-1500-204-23-1

a. Deterioration Factors. Deterioration problems b. Precautions. Maintenance personnel will

result from sand and dust, high day temperatures, observe the following precautions as a guide to
temperature fluctuations, ultraviolet radiation, and successful performance of duty under desert conditions:
terrain. Considerations for each problem are explained
in the following paragraphs. WARNING
Severe burns can result when bare
(1) Sand and dust. The large quantities of skin touches metal parts of aircraft
loose sand and dust create serious erosion problems for or equipment.
rotor blades, propellers, turbine engine compressors,
windshields and other exposed surfaces of the aircraft • Exercise caution when touching aircraft surfaces or
While sitting on the ground, the aircraft is exposed to metal tools that have been exposed to the sun.
blowing sand and dust from frequent desert windstorms Wear gloves and use mats or pad, when practical, to
and sand and dust clouds created by vehicular traffic prevent burns or blisters.
and operation of other aircraft nearby. Sand and dust
particles collect on all surfaces of the aircraft and will • Use extreme care when handling engine fuel at
penetrate almost any crack or crevice to accumulate temperatures above 120°F (49oC), to prevent
Inside the aircraft. Electronic gear and optical possible sparks and explosion. Open gasoline
equipment are very susceptible to sand and dust. drums with bronze or other nonsparking tools.
Weapons are particularly susceptible since many parts
are often covered with a light coat of lubricant. • Electronic gear and optics must be shielded from
direct sunlight and/or otherwise cooled for efficient
(2) High day temperature. In the desert, operation.
heat creates serious problems for people and
equipment. The temperature inside a parked aircraft c. Inspection and Maintenance. The following
which has been closed up to keep the sand and dust out procedures are for the inspection and maintenance of
can reach temperatures much higher than outside aircraft operating in desert conditions:
temperatures Extreme heat can cause the failsafe
device in electronic gear to shut the equipment off. NOTE
High temperatures can cause lubricants to break down, Aircraft should be cleaned daily
distort seals and gaskets, and result in Increased leaking
Frequent use of a vacuum cleaner will
problems. Other problems due to high temperatures
prevent accumulation of sand and dust
include softening of plastics, high stress on pressurized
in aircraft. Pay particular attention to
containers, and shortened battery life.
abrasion/erosion problems during
(3) Temperature fluctuations Daytime Inspections.
temperatures can reach over 100°F (38°C), while night
time temperatures could reach freezing (or close to it) (1) Inspect bungee cords, seals, tires, etc.,
The condensation resulting from this extreme frequently for blisters and other signs of deterioration.
temperature variation contributes to increased corrosion.
(2) Inspect vibration Isolators every two
(4) Ultraviolet radiation. The abundant weeks and replace where cracking or permanent set is
desert sunlight produces a high level of ultraviolet excessive.
radiation which can cause unprotected plastic
components to become very brittle and easily cracked (3) Keep a chart showing engine oil
Ultraviolet radiation also accelerates deterioration of consumption. A sharp rise on the chart will indicate
nylon webbing used in seats and restraint systems. faulty or inefficient engine operation. An inefficient
engine should not be continually operated. It is better to
(5) Terrain. The terrain causes problems correct the trouble so the engine will operate at peak
with moving aircraft and associated support equipment performance.
on the ground Sand can bog a vehicle or aircraft down
to the axles. A condition known as Cap Rock Is often (4) Inspect, clean, or replace filters at
encountered The terrain appears rocky, however, the regular intervals. Sand and dust quickly choke fuel and
substrate will not support weight and a vehicle can sink oil filters and air cleaners. Keep an adequate reserve
up to the frame when attempting to travel over Cap stock of cleaners and filters.
Rock. Aircraft tires can easily be damaged In rocky
desert terrain.

10-7
 TM 1-1500-204-23-1

(5) Keep parachute pack flaps sealed and

covered when not in use. Seals must be removed NOTE
before takeoff. Ensure that all weather stripping on
doors, panels, covers, etc, is
(6) Inspect and clean flags, control hinges serviceable and that these items are
pulleys, bearings, worm gears, cowl slides, landing gear, adjusted to make proper contact with
and tail wheel assemblies regularly to arrest corrosive sealing surface
action.
(2) Leave canopy partly open, except
(7) Inspect aircraft regularly for adequate during dust or rain storms, to permit circulation of air
lubrication, leakage, contaminated hydraulic fluid, within the flight compartment.
specific cable tension, and condition of materials, such
as rubber and hydraulic equipment. Excess lubricant NOTE
must be wiped off all exposed bearing surfaces, joints, Ensure that sealant Installed around
fittings, components, and fuselage. windows, seams, chin bubbles, and
sheet metal repairs is serviceable.
(8) Carefully smooth pitted propellers (if not
beyond permissible limits) with a fine file and emery (3) Install protective covers and dust
cloth. Remove all rough burrs and ragged edges around excluder plugs on all engine openings, vents, air
pits at frequent intervals. intakes, exhaust outlets, breathers, propeller hubs and
feathering domes, cowls, and other vital openings to
(9) Inspect dead air spaces in wings, prevent entry of sand and dust. Keep aircraft pointed
fuselage, and tail group at regular intervals for into wind when not being serviced or prepared for flight.
accumulation of sand. Remove accumulated sand to
prevent a weight and balance change of aircraft. (4) Run up engine on a hard surface, as
shown In figure 10-3, such as a landing mat, or sand
(10) Clean engines, where possible, with a and dust-free area, to prevent sand blasting, rotor blade,
highpressure spray gun filled with appropriate cleaning propeller, fuselage, and tail surfaces. Landing/taxi area
fluid. should be located as far as possible from maintenance
area and allow as much space between aircraft as
(11) Clean instrument filters thoroughly at tactically feasible.
regular intervals. Replace wornout filters promptly
(5) Never taxi aircraft under its own power
(12) Clean oil and gasoline tanks unless necessary. This will aid preventing pitting of the
periodically, as sand accumulates in corners, seams, rotor blade, propeller, fuselage, and tail surfaces Tow
and bottom of tanks. aircraft, using proper tow fittings. Do not move aircraft
over desert crust or hardpan any more than necessary.
(13) Clean metal parts not In use carefully,
cover with grease, and either wrap or store away from (6) Keep pitot heads and gyro Instrument
sand and dust. venturi covered when not in use.
(14) Clean Plexiglas surfaces with clean (7) Make all possible ground checks before
water. Do not rub Plexiglas surfaces during cleaning nor starting engine. Inspect controls for freedom of
use Plexiglas cleaning kit. movement to ensure no binding is caused by sand.
d. Preventive Maintenance. Accomplish the (8) Do not run up aircraft in such a manner
following preventive maintenance procedures: as to damage other aircraft or injure personnel by blown
sand. Engine should never be run on ground longer
(1) Protect aircraft from excessive surface than necessary. Use ground guides to prevent landing
temperatures by covering with canvas or native matting. gear from resting on sharp rocks while parking aircraft.
Use protective covers as soon as possible prior to
operation. Covers over Plexiglas should be installed so (9) Do all shop (bench) repairs in enclosed
that they do not touch the surface of the glass. Barrier shelter. Never use sand-encrusted tools on aircraft.
material may be installed for this purpose.

10-8
 TM 1-1500-204-23-1

Figure 10-3. Construction of Hard Stands

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. Inspection 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

Table 10-1. Part and Fabrics Affected by Moisture and Fungi

Part or fabric Effects of moisture and fungi

Cotton, Linen, Paper, and Cellulose Derivatives: Insulating and dielectric properties are lost 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.

Metals High temperature and moisture vapor cause

rapid corrosion Fungus and bacterial growth
produce acids and other products which speed
corrosion, etching of surfaces, and oxidation
This interferes with the operation of moving
parts, screws, etc. and causes dust between
terminals, capacitor plates, air condensers, etc,
thus causing noise, loss in sensitivity, and arc-
overs.

Metals Two or more. Different metals which have different potentials

when moisture is present cause electrolysis,
thus causing formation of salts and beep etching
of surfaces as one metal is plated onto the other
This happens at riveted and bolted joints,
bearings, slides, and screw threads.

10-11
 TM 1-1500-204-23-1

Table 10-1. Parts and Fabrics Affected by Moisture and Fungi - CONT

Part or fabric Effects of moisture and fungi

Molded Plastics: Terminal strips and boards, switchboard Machined, sawed, or ground edges or 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.

Soldered joints Excessive soldering flux on terminal boards

holds moisture, which speeds up corrosion and
growth of fungi Soldering irons should not
come in contact with wire insulation.

Wax: For impregnation Fungus-inhibiting waxes which are not clean

support fungi, thus causing destruction of
insulating and protective qualities and permitting
entrance of moisture which destroys parts and
unbalances electrical circuit.

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.

(15) Inspect webbing for wear and fungi.

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

Table 11-1. Test Equipment

Nomenclature NSN

Multimeter, AN/PSM-45 6625-01-139-2512

Test set, AN/PRM-32A 6625-01-013-9900
Test set, AN/R/TS-24 6625-01-128-8588
Test set, strobe 6625-01-085-9669
Test set, TS-2530A/UR 6625-00-238-0223

For flotation equipment

Cleaner, vacuum (not for cleaning purposes) 7910-00-550-9123

C02 Transfer unit 3655-00-288-0309
Manometer 6685-00-526-5323
Scale, dial and beam 6670-00-255-0239
Separator, oil and water 4920-00-242-4100

For oxygen equipment

Parts kit, oxygen mask repair 1660-00-672-3945

Regulator 1660-00-700-9776
Tester, oxygen mask, MQ-1A 1660-01-097-0441
Tester, oxygen regulator 4920-00-128-8584

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

Table 11-2. References for Flight Clothing

Publication Description

TM 10-8400-201-23 Organizational and Direct Support Maintenance Manual:

General Repair Procedures for Clothing and Individual Equipment

TM 10-8400-202-13 Maintenance Instructions for NOMEX Flight Gear Coveralls

Types CWU-27/P and CWU-28P; Gloves, Type GS-FRP-2; Jacket
Flyer’s, Summer, Type CWU-35/P and Winter, Type CWU-45/P
Hood, Flyer’s (CWU-17/P Jacket); Trousers, Flyer’s Extreme Cold
Weather, CWJ-18/P (TO 14P3-1-112)

TM 10-8415-206-12P&P Operator’s and Organizational Maintenance Manual Including Repair

Parts and Special Tools List for Helmet, Flyer’s, Protective, Model
SPH-4 Regular and X-Tra Large

TM 10-8470-202-13 Operation and Service Instructions for Ground and Aircrew

Body Armor (TO 14P3-1-102)

TM 10-8475-200-13 Use, Inspection, Fitting, and Maintenance Instructions for Anti-Expo-

sure Assembly. Type CWU-21/P (TO 14P3-5-81)

TM 10-8475-202-13 Operation, Service and Maintenance Instructions for Quick Donning

Anti-Exposure Flying Coverall, Type CWU-16/P TO 14P3-5-61

TM 10-227 Fitting of Army Uniforms and Footwear

FM 10-16 General Fabric Repair

FM 10-267 General Repair for Clothing and Textiles

FM 21-15 Care and Use of Individual Clothing and Equipment

CTA 50-900 Clothing and Individual Equipment

FED STD 757 Stitches, Seams, and Stitching

FM 1-508 Maintaining Aviation Life Support Equipment (ALSE):
Maintenance Program

11-16. Flotation Equipment. Flotation equipment type of aircraft being flown and the number of aircrew 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

Table 11-3. References for Survival Kits

Publication Description
TM 9-1370-203-20P& P Organizational Maintenance Manual for Military Pyrotechnics

TM 10-8400-201-23 General Repair Procedures for Clothing and Individual Equipment

TM 55-1680-316-10 Operator’s Manual for Rigid Seat Survival Kit and Survival
Vest for OV-1 Aircrews

TM 55-1680-317-23P & P Maintenance Manual for Army Aircraft Survival Kits

TM 55-1680-322-12 Operation and Service for Distress Marker Light, P/N SDU-5/E

TM 55-1680-348-10 Survival Kit, Cold Climate, Individual

TM 55-1680-349-10 Operator’s Manual for Survival Kit, Hot Climate

TM 55-1680-350-10 Operator’s Manual for Survival Kit Overwater, Individual

TM 55-1680-351-10 Operator’s Manual for SRU-21/P Army Vest

FM 1-508 Maintaining Aviation Life Support Equipment (ALSE):

Maintenance Program

FM 10-16 General Fabric Repair

FM 10-267 General Repair for Clothing and Textiles

FM 10-1269 Repair of Canvas and Webbing

FM 21-15 Care and Use of Individual Clothing and Equipment

FED STD 757 Stitches, Seams and Stitching

DA PAM 738-751 Functional Users Manual for the Army Maintenance

Management System-Aviation (TAMMS-A)

TB 9-1300385 Munitions Suspended or Restricted

TB 740-10 Quality Control Depot Storage Standards. Appendix M

Medical Supplies.

DOD Medical Catalog VOL I, VOL II, VOL III MCRL I, II, Ill

DOD 5154.4S DOD Ammunition and Explosives Safety Standards

SB 8-75 SERIES Army Medical Department Supply Information 8-75-1

thru 8-75-35

SB11-6 FSC Class 6135; Dry Battery Supply Data

SB11-30 FSC Class 6135; Dry Battery Management Data

11-6 Change 2
 TM 1-1500-204-23-1

Table 11-3. References for Survival Kits - CONT

Publication Description

SB742-1370-94-721 Signal, Smoke and Illumination, Marine MK13, MOD O

Surveillance Function Test

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

Table 11-4. Liferafts for Aircraft

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

Table 11-5. References for Flotation Equipment

Publication Description

TM 55-1680-321-12 Inspection, Maintenance and Disposition Instructions,

Desalter Kit, Type MK-2

TM 5-4220-202-14/ Maintenance Instructions with Parts Breakdown

TO 14S-1-102 USAF Flotation Equipment

FM 1-508 Maintaining Aviation Life Support Equipment (ALSE):

Maintenance Program

Table 11-6. References for Oxygen Equipment

Publication Description

TM 55-1660-245-13 Maintenance Instructions:

TO 15X-1-1 Oxygen Equipment
NAVAIR 03-50-1

TM 55-1669-247-12 Operation, Fitting, Inspection and Maintenance Instructions

TO 15X-3-6-1 for MBU-12/P Pressure-demand Oxygen Mask.

TM 55-6695-217-13 Operation and Maintenance Instructions for Tester, Oxygen Mask,

Headset, Microphone and Flash Goggles Type MQ-1 A

TM 55-6695-217-23 & P Aviation Unit and Aviation Intermediate Maintenance Repair Parts 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.
e. Controlled Substances. All narcotics and non-
b. First Aid Kit Installation. Maintenance personnel narcotic controlled substances have been deleted from
will insure that serviceable first aid kits are installed in this medical kit. Controlled substances are normally 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

Table 11-7. References for Signaling Devices

Publication Description

TM 9-1300-200 Ammunition, General

TM 9-1300-206 Ammunition and Explosives Standards

TM 9-1300-214 Military Explosive

TM 9-1300-250 Ammunition Maintenance

TM 11-5820-640-15 Operator's, Organizational, Direct Support, General Support Depot

Maintenance Radio Sets AN/URC-10, AN/URC-10A and ACR RT-10

TM 11-5820-640-25P Combined Organizational, DS, GS, and Depot Maintenance Including Repair
Parts and Special Tools List Radio Set AN/URC-10A

TM 11-5820-767-12 Operator's and Organizational Maintenance Manual Including Repair Parts

and Special Tools List; AN/URC-68

TM 11 -5820-767-20P Organizational Maintenance Manual Including Repair Parts and Special

Tools List Radio Set AN/URC-68

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 Manual Including
Repair Parts and Special Tools List for Radio Set AN/PR C90

TM 11-6625-2631-14 Operator's Organizational, Direct Support and General Support Maintenance

Manual for Test Set Battery TS-2530/UR and Test Set TS-2530A/UR

TM 11-6625-2631-40P General Support Maintenance Repair Parts and Special Tools List for Test
Set, Battery TS-2530/UR and TS-2530A/UR

TM 11-6625-2632-14 Operator's Organizational, Direct Support and General Support Maintenance

Manual Including Depot Maintenance Repair Parts and Special Tools List for
Radio Test Set AN/PRM-32

TM 11-6625-2632-14-1 Operator's, Organizational, Direct Support and General Support

Maintenance Manual Radio Set AN/PRM-32A

11-11
 TM 1-1500-204-23-1

Table 11-7. References for Signaling Devices - CONT

Publication Description

TM 11 -6625-2632-24P-1 Organizational, Direct Support, and General Support Maintenance

Repair Parts and Special Tools List for Radio Test Set AN/PRM-32A

SB 11-6 FSC Class 6135, Primary Battery Supply Data

SB 11-30 FSC Class 6135; Primary Battery Management Data

SB 742-1370-94-721 Signal, Smoke and Illumination Marine: AN-MK 13, MOD O (L275)
Ammunition Surveillance Surveillance Procedures

TM 55-1680-317-23 & P Maintenance Manual for Army Aircraft Survival Kits

TM 55-1680-322-12 Operator's and Service, Distress Marker, Light, SDU-5/E

Figure 11-1. First Aid Kit, Airplane (Older Configuration)

11-12
 TM 1-1500-204-23-1

Figure 11-2. First Aid Kit, General Purpose (Newer Configuration)

Figure 11-3. Serviceable Tag-Materiel (DD Form 1574) (Yellow)

11-13
TM 1-1500-204-23-1

f. Inspection. Inspections of first aid kits by ALSE a Replace bandages, dressings, and
medical personnel, or other certified personnel are compresses when there is evidence of mildew, mold, dry
described in the following paragraphs. rot, discoloration, or when instructions are illegible.
(1) Inspection by ALSE, medical or other certi-
b Replace adhesive tape when the
fied personnel. First aid kits will be inspected for ser-
adhesive mass separates from the backing fabric upon
viceability and completeness upon receipt. Inspecting
unwinding (unwinding shall consist of not less than six
personnel will annotate the DD Form 1574 with the date inches nor more than seven inches of length from the
of the shortest expiration dated item contained in the kit. starting end) or when the adhesive mass is not uniform.
This date will be used to schedule the next inspection
due, or when: c Replace petrolatum gauze when
Suspension of the kit, or an item within the kit, is there is evidence of separation or delamination of the
announced by the supporting medical supply offi- package material or evidence of petrolatum seepage.
cer, the US Army Medical Materiel Agency, or the
Medical Supply Bulletin (SB 8-75 SERIES). d Replace ammonia inhalant
ampules when there is evidence of broken glass or the
The kit is turned in by using activities. Using activi- container shows staining marks.
ties will ensure that the kit is removed for inspection
and quality assurance prior to the next inspection e Replace surgical razor blade when
due/overage date or immediately upon receiving there is evidence of rust, corrosion or pitting on the metal
notice from the supporting medical supply officer of surface of the blade.
an applicable item suspension. Personnel may be
medical, ALSE, Tls or safety personnel as autho- f Ensure that a list of contents is
rized in writing by the unit commander. included in the kit. Local reproduction of the listing, Table
11-8 is authorized.
(a) Inspection procedures. ALSE medical
or certified personnel shall accomplish the following g Ensure that component items of
inspection procedures: first aid kit that are deleted through normal supply actions
1 Ensure kit is properly marked using the are replaced or withdrawn from the kit. It is not necessary
appropriate material condition tags and labels listed in to recall the kit in use to effect replacement of deleted
paragraph 5-3. items unless otherwise specified.
2 Replace all expiration dated items with NOTE
less than 12 months shelf/service life whenever possible. Using activities may use the inspection codes
The NEXT INSPECTION DUE DATE annotated on the
identified in DLAM 4155.5, Quality Control,
serviceability tag will be that of the item that has the Depot Serviceability Standards manual, for
shortest expiration date. additional assistance in the identification of
3 Ensure that the kit contains no Sched- serviceable/non-serviceable medical mate-
ule II controlled medical items unless a current MACOM rial contained in the first aid kit.
authorization is on file.
(2) Inspection by maintenance personnel.
4 Ensure that contents of the kit are com-
Installed First Aid Kit will be inspected by maintenance
plete and serviceable. personnel at the Preventive Maintenance Daily inspec-
5 Ensure that items are inspected in tion as prescribed in the applicable aircraft Preventive
accordance with the following inspection tests. Maintenance Daily (PMD) inspection checklist.

11-14 Change 2
 TM 1-1500-204-23-1

NOTE g. Sealing. The following paragraphs describe the

If a seal has been broken, and no kit is imme- materials and procedures used to seal first aid kits.
diately available, a circled red X status symbol
will be entered in block 16 and a statement ( 1) Materials. Requisition the following materi-
entered in Part I, Fault Information Section of
DA Form 2408-13-V DA Form 2408-13-1-E als through normal supply channels:
(Aircraft Inspection and Maintenance
Record) restricting the aircraft to a specified l Seal, lead, 3/8-inch-diameter, 1/8-inch-thick, with
number of passengers until a serviceable kit 5-1/2-inch 27 AWG single-crimped copper wire,
is installed. Kits on which seal has been bro- NSN 5340-00-391-4240.
ken will be turned in to designated ALSE per-
sonnel for a replacement kit.
l Flat-head pin, NSN 5315-00-989-7631.
When kit is due for an inspection or kit is con-
sidered unserviceable due to missing or illeg-
ible materiel condition tag, torn case, broken l Seal, anti-pilferage, NSN 5340-00-779-3516
seal, or (on older design) incomplete side (alternate seal).
pocket contents, etc., inspector will remove
DD Form 1574 (Serviceable Tag-Materiel)
l Copper wire, NSN 5340-00-391-4240.
and retag kit with DD Form 1577-2 Unservice-
able (Repairable) Tag-Materiel, as shown in
figure 11-4.

Figure 11-4. Unserviceable (Repairable) Tag-Materiel (DD Form 1577-2) (Green).

Change 2 11-15
TM 1-1500-204-23-1

NOTE (c) Slip free end of sealing wire through

If copper wire, NSN 5340-00-391-4240, is not hole in end of flat-head pin already installed in loop and
available, use copper wire, pull wire through until lead seal is against end of pin.
NSN
6145-00-234-4991, and lead seal NSN (d) Continue by passing free end of wire
5340-00-598-3417. Use press seal NSN through one of the holes in seal and pull wire so that seal
5120-00-221-1668 for crimping the lead seal. is held tightly against end of pin.
(2) Sealing procedures. Accomplish the follow- (e) Proceed, by passing end of wire
ing procedures when sealing first aid kits: through hole of materiel condition tag.
(f) Position tag along with wire, approxi-
(a) Complete DD Form 1574 in accordance mately one inch away from seal, continue by passing the
with DA PAM 738-751. free end of wire through one of the holes in the lead seal.
NOTE (g) Extend wire so that both wires from tag
The inspection DUE DATE will be no longer to seal are even, then take free end of wire, and pass it
than the first item with an expiration period. through hole in materiel condition tag again.
That date will become the DUE DATE for the (h) Crimp seal, then twist materiel condi-
next inspection. tion tag three or four times. This will create a loop that will
hold tag in position.
Supplies of Materiel Condition Tags will be
requisitioned through normal publication (i) After completing the resealing action,
channels. position tag to the double edge of fabric, as shown in
figure 11-5, with a minimum of two staples from a stan-
(b) Reseal kit by closing zipper and placing dard office type stapler. This action is intended to reduce
slide fastener tab in down and locked position, and install the inadvertent loss of the tag due to wind movement
flat-head pin into slide fastener loop. when operating aircraft with door/windows open.

Figure 11-5. Properly Attached Flat-Head Pin, Lead Seal, and Identification Tag.

11-16 Change 1
 TM 1-1500-204-23-1

NOTE (c) Using the instructions from paragraph

Only one strand of 27 AWG is to be put g for the sealing and tagging of the kits.
through the lead seal. Using more than a (d) Describing what effects outdated or
single strand of 27 AWG wire could make the contaminated components would have on an injured or
breaking of the seal more difficult and hinder wounded person.
ready accessibility to the first aid compo-
nents. (2) Certification. Upon successfully completing
Any slack in wire between lead seal and end the course of instruction, will be noted on a memorandum
of pin is to be avoided; however, do not place from the certifying individual to the unit commander con-
pin under such extreme tension that the pos- cerned.
sibility of accidental breakage is increased. NOTE
h. Replacement of Components. A kit will be con- Under no circumstances will personnel, other
sidered unserviceable after the expiration date of the first than ALSE qualified, authorized under the
item that expires within the kit, or when the DD Form guidance of this paragraph, maintain other
1574 tag is missing, or the seal is missing. The kit will be ALSE equipment including those first aid kits
retagged with a DD Form 1577-2 tag and the inspector in survival kits in accordance with AR 95-3.
will annotate in Reason for Repairable Condition block,
Inspection Due, per paragraph 11-19f or the applicable 11-20. Nuclear, Biological, and Chemical Equip
aircraft maintenance manual. Kits requiring replacement ment. Unit chemical personnel are supposed to sup-
of items will be reconstituted by authorized unit ALSE/ port training and maintenance of all Nuclear, Biological,
Certified personnel in accordance with the list of items and Chemical (NBC) equipment. If the ALSE technician
contained inside each kit and with DOD Medical Catalog. has been assigned this task, particularly the aircrew
Replenishment items will be requested from the support- members equipment, the ALSE technician should
ing medical supply officer. become very proficient in the care, use, inspection, repair
i. First Aid Kit Components. First aid kit items or replacement of NBC equipment and train the aircrew-
required are listed in table 11-8 and references in table members in the care and use of their NBC equipment.
11-9. NBC equipment consists basically of the following: a
breathing apparatus, mask with filters to eliminate air-
j. Inspection Training Procedures. Only those per- borne chemicals, protective clothing to protect the indi-
sonnel medically trained (MOS 91B, C or 91Q) and quali- viduals from airborne chemicals, cooling apparatus to
fied, or ALSE school trained (with an ASI of Q2), may cool the individuals body while wearing the protective
certify and instruct other unit personnel in the inspection clothing, and warning devices to alert personnel of con-
of first aid kit, general purpose, panel mounted, aircraft. tamination by chemicals of the air in the immediate vicin-
ALSE personnel school trained, with an ASI of Q2, will ity, or dangerous radiation levels in the area. Table 11-10
not be subject to retraining at the unit level. Only certified gives references for NBC equipment.
ALSE, medical or other certified personnel will be
appointed on unit orders by the Commander, to perform a. Inspection. Inspections will be accomplished in
inspections on the first aid kit, general purpose aircraft. accordance with the applicable TM, TO, NAVAIR for the
(1) Training. Training will consist of the follow- particular item involved.
ing using an aircraft first aid kit: b. Repair. Repairs will be accomplished in accor-
(a) Using the instruction from paragraph f dance with the applicable TM, TO, or NAVAIR for the item
for inspection procedures. at the authorized maintenance level.
(b) Using the instructions from paragraph f c. Cleaning. Cleaning will be accomplished in
and TB 740-10, Appendix M, for the replacement of time accordance with the applicable TM, TO or NAVAIR for the
expired components of the first aid kit. particular item needing to be cleaned.

Change 2 11-17
TM 1-1500-204-23-1

Table 11-8. First Aid Kit Components

Shelf
life
Stock No. Nomenclature Unit Quantity (months)

6545-00-912-9860 Case, medical instrument and supply set, EA 1 Conditional

nylon non-rigid, No. 2, 7-1/2 inches long
by 4-3/8 inches wide by 4-1/2 inches high
Inside upper, pocket
PG 10 Conditional
6505-00-106-0875 Ammonia inhalant solution, aromatic
15 to 22 PCT Ammonia and 35 to 40
PCT Ethyl Alcohol

6510-00-200-3075 Compress and bandage, camouflaged, PG 1 Conditional

2 by 2 inches, 4S

6510-00-201-1755 Bandage, muslin, compressed, camouflaged, EA 1 Conditional

37 by 37 by 52 inches.

6510-01-112-6414 Gauze, petrolatum, 3 by 36 inches, 3s PG 3 Conditional

6515-00-754-0426 Blade, surgical prep razor, straight single PG 1 Conditional

edge, 5s

Inside lower, pocket

6510-01-060-1639 Adhesive tape, surgical, camouflaged, PG 3 36
1 inch by 2 yards

6510-00-159-4883 Dressing, first aid, field, camouflaged, EA 3 Conditional

4 by 7 inches

6545-00-853-6309 First aid kit, eye dressing EA 1 36

In outside, pocket
(If old type case is used)
6510-01-010-0307 Providone-iodine solution, USP, 10 PK 10 36
percent pads, individually packaged

6510-00-200-3185 Bandage, gauze, compressed, EA 2 Conditional

camouflaged, 3 inches by 6 yards

6510-00-913-7909 Bandage, adhesive, 3/4 by 3 inches EA 18 36

(When newer kit is used, these three
items will be located in lower pocket)

6515-01-364-8554 Glove, Patient Examining PG 48

(Glove is placed inside of
Dential Prosthesis Bag)

6520-00-926-9041 Bag, Dental Prosthesis PG Conditional

11-18 Change 3
 TM 1-1500-204-23-1

Table 11-9. References for First Aid Kits

Publication Description

DOD Medical Catalog VOL I, Identification/Management Data

VOL II, Sets, Kits, and Outfits
VOL III, MCRL 1, II, & III

SB 8-75-Series Army Medical Department Supply Information 8-75-1 thru 8-75-33

TB 740-10 Quality Control Depot Storage Standards, Appendix M,

Medical Supplies

Table 11-10. References for Nuclear, Biological, and Chemical Equipment

Publication Description

TM 3-4230-216-10 Operator's Manual for Decontaminating Kit, Skin M258A1, and

Training Aid Skin Decontaminating M581A

TM 3-4240-280-10 Operator's Manual for Mask Chemical-Biological: Aircraft ABC-M24

and Accessories Mask Chemical-Biological, Tank M24/M24A1 and
Accessories

TM 3-4240-280-23 & P Organizational and Direct Support Maintenance Manual Including

Repair Parts and Special Tools List Mask Chemical-Biological:
Aircraft ABC-M24 and Accessories and Mask, Chemical-Biological,
Tank, M25/M25A1 and Accessories

TM 3-4240-312-12 & P Aviation Unit Maintenance, Chemical-Biological Mask Aircrew M43

TM 55-1660-248-12 Operation and Maintenance Instructions Aircrew

Chem-Defense Ensemble

FM 3-3 NBC Contamination Avoidance

FM 3-4 NBC Protection

FM 3-5 NBC Decontamination

FM 3-6 Field Behavior of NBC Agents (including smoke and incindaries)

FM 3-10 Employment of Chemical Agents

FM 3-100 NBC Operations

11-19
 TM 1-1500-204-23-1

11-21. Restraint Equipment. Restraint equipment, as

used in this section, includes safety lap belts, shoulder
harnesses, and other fabric devices used in Army
aircraft for personnel restraint purposes. Restraint
equipment is to be installed as directed in the applicable
maintenance manual. On all pilot/copilot and crewman
seat belts, the safety belt release handle should point to
the left.

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

(e) Inertia reels, check for damage, security,

NOTE
positive locking and unlocking, manual lock-unlock
control for proper operation. No cleaning is authorized to inertia
(f) Examine restraint system attaching points reel webbing strap.
to aircraft. Check for loose bolts, deformity, corrosion or
sharp and jagged edges which may damage webbing. (1) Prepare a concentrated soap and hot
water solution, using laundry soap chips, Federal
b. Repair. Broken or missing stitches can be Specification P-S-1792, or equivalent. Cool the solution
repaired using a sewing machine in accordance with the to approximately 120°F (49°C), prior to application.
following repair requirements
(2) Dampen an approved clean brush, such
• If five or more stitches are broken or loose as NSN 7920-00-244-7431, with the soap solution and
within one linear inch, restitching is required. rub lightly over the affected surface area.
NOTE (3) Rinse the webbing thoroughly with clear,
lukewarm water.
When restitching safety belts,
restraint harness, hoist operators (4) Place webbing In open air or a drying
harness, gunners harness, stitch room to dry.
directly over the original stitching
NOTE
and follow the original stitch pattern
as closely as possible. Do not expose the wet webbing to
freezing temperatures or to direct
• Only one repair per stitch pattern is sunlight during cleaning, drying, or
authorized. Restitching should be
storage. Redying or painting is
accomplished with thread which matches the
prohibited
color of the original stitching, when possible.
Restitching should be locked by over stitching (5) After cleaning visually inspect in
each end of the stitch formation by 1/2 inch. accordance with paragraph a.
All stitching shall be with nylon thread
conforming to Spec V-T-295, thread size, NOTE
stitching pattern and stitches per inch shall be Belts utilized in aircraft conducting
I.A.W. original construction. salt water pick-up training shall be
• Restitching should be locked by over stitching washed in fresh water and corrosion
each end of the stitch formation by 1/2 inch. preventive compound (MIL-C-81309,
NSN 8030-00-938-1947) shall be
• All stitching shall be with nylon thread applied to metal components
conforming to Spec V-T-295, thread size,
stitching pattern and stitches per inch shall be d. Replacement Equipment determined to be
In accordance with original construction. unserviceable by visual inspection will be replaced.
Unserviceable equipment will be disposed of through
c. Cleaning. Cleaning of personnel restraint normal disposal channels to the nearest property
equipment will be accomplished when webbing is soiled disposal activity. The following personnel restraint
using the following procedures equipment having dacron or nylon webbing is to be
CAUTION replaced if determined to be unserviceable.

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.

Figure 11-7. Shoulder Harness Webbing Retarder Spring Installation

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.

8 Ensure that shoulder harness webbing (2) Installation or replacement of snap

is centered on adjuster plate locking bar and can be safety pin. Install or replace snap safety pin on
adjusted, (fig. 11-7). personnel restraint harness as follows:

(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.

Figure 11-8. Seat belt webbing retarder spring installation

11-24
 TM 1-1500-204-23-1

(c) Cut a five-inch length of 0.080-inch

diameter corrosion-resistant wire (NSN 9505-00-
8924616), and construct a safety pin as shown in figure
11-10.

(d) Cut a 15-inch length of type III nylon cord

(NSN 4020-00-246-0688). Remove the inner core
threads and sear the ends of the cord.

(e) Pass half of the cord length through the

safety pin loop. Tie a square knot up against the loop. Figure 11-10. Snap Hook Safety Pin Construction
Tie another square knot about 4-1/2 inches from Details
previously tied knots.

(d) Pass one loose end of the cord through

the snap where the webbing Is attached. Tie the two
cord ends together with a square knot as shown in figure
11-11. Tie an overhand knot in each loose end of cord.

11-22. Personnel Parachute and Parachute Harness.

Inspection criteria, procedures, and report for the
personnel parachute assembly and parachute harness
are explained in the following paragraphs.

a. Inspection Criteria. Any of the equipment listed

below which is in use, installed in aircraft as extra
equipment, located in an aviation unit ready-for-use
facility, or in the possession of aircraft crew members
will be inspected on a routine basis every 30 days and
prior to issue for use. When an aviation unit Is not
conveniently located, E.G. on same installation as their
supporting parachute packing activity, designated
parachute inspectors will check and ensure that
shelf/service life items are withdrawn from use at the
end of their service life in accordance with TB 43-0002-4
and will sign the required document to support turn-in of Figure 11-11. Safety Pin Retaining Cord Secured
expired items. to Snap Hook

Figure 11-9. Snap Hook Safety Guard Drill Details

Change 1 11-25
 TM 1-1500-204-23-1

ORIGINAL SEAT BELT LATCH

MODIFIED SEAT BELT LATCH

NOTE:
DIMENSIONS ARE IN INCHES

Figure 11-12. Seat Bet Latch Modification

11-26
 TM 1-1500-204-23-1

NOTE (a) Remove DA Form 3912 from

• Aircrew members who perform flight assembly log record and survival manual pocket.
duties away from home station or Check record for date of last pack. An emergency-
assigned unit will ensure that type personnel parachute which has exceeded 120
Individual emergency type days (200 days for MK-J5 ejection seat parachute)
parachutes and harnesses are since the last pack will be considered unserviceable.
inspected every 30 days by qualified Process for repack according to step j. After
parachute inspectors. However, if a determining the last pack date, return the form to the
situation occurs which precludes log record and survival manual pocket.
inspection due to a lack of qualified
NOTE
parachute inspection, personnel,
An emergency type chest parachute
parachutes and harnesses may
has two parachute log records. One
continue to be used until arrival at a
log record is located on the
facility which can satisfy the
parachute pack, and the other is
inspection criteria, as soon as
found on the harness. Each of these
practical. In no case will the 30 day
log records shall be maintained. On
inspection requirement exceed 60
an emergency type back parachute,
days.
the log record may be located either
• Unit commanders/aviation life
on the pack right wing flap or on the
support personnel will ensure that
pack bottom stiffener panel.
individual emergency type
parachutes, i.e., seat, back, chest, or
(b) Ensure that a copy of TM 10-
ejection seat type including drogue
1670-1 is located in the log record and survival
chutes and harnesses when separate
manual pocket. On a chest parachute assembly, the
from the parachute, I.E. chest technical manual will be found in the pocket on the
harnesses and ejection seat parachute harness.
harnesses, including seat belts, (c) Without opening the pack,
when integrated into the harness visually check external condition of pack and harness
such as the MK-J5D parachute for defects or deterioration of webbing, canvas fabric,
system, will be inspected every 30 or stitching, and broken or loose tacking.
days by an individual qualified to (d) Check metal components for
perform 30-day parachute cracks or rust. Check ripcord housing for dents or
inspections. These personnel will breaks.
have been trained in parachute (e) Inspect the two canopy release
inspection methods by a qualified assemblies, if applicable, to ensure that each release
parachute rigger. This training will is assembled and locked properly.
be documented in individual training (f) Inspect ripcord grip pocket to
folders and designated as parachute ensure the ripcord grip is secure and the grip
inspectors on unit orders by the protrudes enough to allow immediate accessibility.
aviation unit commander. Ensure that removal of ripcord is not obstructed by
• Generic Description of Equipment misplaced stitching or tacking and that harness chest
(1) Parachutes, personnel, strap on back parachute is not routed through ripcord
emergency type: back, chest and grip.
seat types. (g) Ensure that each pack opening
(2) Parachutes, personnel and spring band is connected. Check the elasticity of each
drogue, ejection seat type. band.
(3) Harnesses, personnel parachute, (h) Open ripcord protector flap and
inspect ripcord pins for proper seating in the pack
used with above parachutes.
release cones. Ensure that pins are not bent or
corroded. On back of personnel parachute, each
b. Inspection Procedures. Inspection procedures
ripcord pin shall extend 3/4 inch beyond pack release
for personnel parachute assemblies and the MK-J5
cone (measuring from top of pin to eye of cone).
ejection seat personnel parachute harness are explained
in the following paragraphs.
(1) Personnel parachute assemblies.
Inspection procedures for emergency type personnel
parachute assemblies including back, seat, and chest
types are as follows:
Change 1 11-27
 TM 1-1500-204-23-1
(i) On back personnel parachute, grasp (f) Check elastic webbing retainers for cuts,
harness webbing at a point on the lift web above the frays, tears, loose or broken stitching, and loss of
ripcord grip pocket. Pull against the weight of pack elasticity.
assembly to ensure the ripcord pins will not move from
the prepositioned location given in (h) above. NOTE
An MK-J5 ejection seat personnel
(j) If after completing steps (a) thru (i) above,
parachute harness with any defects
it is determined conditions exist which require repair,
repack, or more extensive Inspection, prepare DD Form above will be considered
1577-2 as shown in DA PAM 738-751. Attach form to unserviceable. Process for
the item. The item then shall be segregated from evacuation according to step (1) (j).
serviceable items by a physical barrier and evacuated to A harness which is considered
a parachute maintenance facility. An emergency type serviceable will have the inspection
personnel parachute which is considered serviceable will recorded as described in paragraph
have the inspection recorded as described in paragraph c, and the harness will be returned to
c, and the parachute will be returned to service. service.

(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

Table 11-11. Consolidated List of ALSE References

Publication Description

Army Regulations (AR)

AR 25-400-2 The Modern Army Record Keeping Systems (Marks)
AR 32-15 Classification and Inspection
AR 40-5 Preventive Medicine
AR 40-8 Temporary Flying Restrictions Due to Exogenous Factors
AR 40-61 Medical Logistics Policies and Procedures
AR 40-501 Standards of Medical Fitness
AR 40-656 Veterinary Surveillance Inspection of Subsistence
AR 40- 657 Veterinary Medical Food Inspection and Laboratory Service
AR 40-660 DOD Hazardous Food and NON Prescription Drug Recall System
AR 95-1 Army Aviation Flight Regulations
AR 95-3 General Provisions; Training, Standardization and Resource
Managements
AR 190-11 Physical Security of Arms, Ammunition, and Explosives
AR 310-70 Equipment Interservicing of Technical Manuals and Related Technology
AR 340-1 Records Management Program
AR 350-30 Code of Conduct/Survival, Evasion, Resistance, and Escape (SERE)
Training
AR 385-32 Protective Clothing and Equipment
AR 385-64 Ammunition and Explosives Safety Standards
AR 385-95 Army Aviation Accident Prevention
AR 700-89 Identification, Control, and Utilization of Shelf Life Items
AR 710-1 Centralized Inventory Management of the Army Supply System
AR 710-2 Supply Policy Below the Wholesale Level
AR 725-50 Requisitioning, Receipt, and Issue System

11-29
 TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References- CONT

Publication Description

Army Regulations (AR) - CONT

AR 750-1 Army Material Maintenance Policies

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

Department of Defense Publications (DOD Pub)

DOD 4160.21-M Defense Utilization and Disposal Manual

DOD 5154 4S DOD Ammunition and Explosives Safety Standards

Defense Logistics Agency

DLAM 4155 5 Quality Control Depot Serviceability Standards (Medical Supplies),

Appendix M

Medical Catalog Containing VOL I, VOL II, VOL III

NOTE

Department of Defense Customer Assistance Program

call Autovon 284-7871. They will mail copies

FED STD 757 Stitches, Seams, and Stitching

Technical Manual (TM)

TM 3-4230-216-10 Operator's Manual for Decontaminating Kit Skin: M25H1 and

Training Aid, Skin Decontaminating M58A1

TM 3-4240-212-14&P Operator's Organizational, Direct Support and General Support

Maintenance Manual (Including Repair Parts and Special Tool List)
Breathing Apparatus, Oxygen Generating, M20

TM 5-803-4 Planning of Army Aviation Facilities

TM 5-4220-201-12 Operator's and Organizational, Maintenance, Life Preserver, Underarm,
Parachutist (B-7)

11-30
 TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References-- CONT

Publication Description

Technical Manual (TM) (Cont)

TM 5-4220-202-14 Maintenance Instructions with Parts Breakdown USAF Flotation

Equipment (TO. 14S-1-102)
TM 9-1290-333-15 Operators, Organizational, Direct Support, General Support, and
Depot Maintenance Manual (Including Repair Parts and Special
Tools List) Compass Magnetic Unmounted M2
TM 9-1300-206 Ammunition and Explosives Standards
TM 9-1370-203-34&P Direct Support and General Support Maintenance Manual
(Including Repair Parts and Special Tools List) Military Pyrotechnics
TM 9-1370-206-10 Operator's Manual: Pyrotechnic Signals
TM 9-4940-461-15P Operator's Organizational, DS, GS, and Depot Maintenance
Repair Parts and Special Tools List for Separator Oil and Water,
Spray Gun, Wall MTD
TM 10-1670-1 Survival and Emergency Use of the Parachutes (AFP 64-15)
TM 10-1670-250-20 Organizational Maintenance Manual (Including Repair Parts
and Special Tools List). Parachute System Used w/Martin
Baker MK-J5D Ejection Seat
TM 10-1670-213-10 Operator's Manual for Parachute Personnel, Types 28 Foot
Diameter, Back, 28 Foot Diameter, Chest; NB-8 Back and Martin
Baker Ejection Seat Harnesses
TM 10-1670-251-12 Operator's and Organizational Maintenance Manual (Including,
Repair Parts and Special Tool List). Lowering Device, Cargo and
Personnel, 500 LB Capacity
TM 10-1670-262-12 Operator's and Organizational Maintenance Manual (Including, Repair
Parts and Special Tools List)' For Personnel Stabo Extractson System
and Cargo and Personnel Lowering Anchor Device
TM 10-3530-202-24 Organizational and Field Maintenance Manual Sewing Machines
for the Repair of Parachutes and Allied Equipment
TM 10-8400-201-23 Organizational and Direct Support Maintenance Manual General
Repair Procedures for Clothing and Individual Equipment
TM 10-8415-206-12&P Operator's and Organizational Maintenance Manual (Including
Repair Parts and Special Tools List). For Helmet, Flyer's Protective,
Model SPH-4 Regular and X-Tra Large

11-31
 TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References -CONT

Publication Description

Technical Manual (TM) - CONT

TM 10-8475-200-13 Use, Inspection, Fitting, and Maintenance Instructions for Anti-Exposure

Assembly, Type CWU-21/P or CWU-21A/P(TO 14P3-5-81)
TM 10-8475-202-13 Operation, Service and Maintenance Instructions for Quick Donning
Anti-Exposure Flying Coveralls Assembly. Type CWU-16/P
(T O 14P3-5-61)
TM 11-5820-640-15 Operator's Organizational, Direct Support, General Support, and Depot
Maintenance Manual: Radio Sets, AN/URC-10A, AN/URC-10A, and
ACR RT-10
TM 11-5820-767-12 Operator's and Organizational Maintenance Manual Including Repair
Parts and Special Tools List, Radio Set, AN/URC-68
TM 11-5820-767-34 Direct Support and General Support Maintenance Manual Including
Repair Parts and Special Tools List (Including Depot Maintenance
Repair Parts and Special Tools) for Radio Set, AN/URC-68
TM 11-5820-800-13&P Operator's and Organizational Maintenance Manual, (Including
Repair Parts and Special Tools List) Radio Set AN/PRC-90
TM 11-5965-279-13P Operator's Organizational and Direct Support Maintenance Repair
Parts and Special Tools List for Headset-Microphone Kit MK-896/AIC
for Helmet, Flyers Protective SPH-4
TM 11-5965-285-23 Organizational and DS Maintenance Manual (Including Repair Parts
and Special Tools List) Headset Microphone 19LB-87
TM 11-6625-2631-14 Operator's Organizational, Direct Support and General Support
Maintenance Manual Including Repair Parts and Special Tools
List. Test Set, TS-2530/UR and TS-2530A/UR
TM 11-6625-2632-14 Operator's Organizational, Direct Support and General Support
Maintenance Manual (Including Depot Maintenance Repair Parts
and Special Tools) For Radio Set AN/PRM-32
TM 38-711-2 Standard Army Intermediate Level Supply Subsystem (SAILS)
Procedures for Customers
TM 55-1660-247-12 Operation, Fitting, Inspection and Maintenance Instructions with
Illustrated Parts Breakdown for MBU-12/P Pressure Demand
Oxygen Mask
TM 55-1680-316-10 Operator's Manual for Rigid Seat Survival Kit and Survival Vest
for OV-1 Aircraft

11-32
 TM 1-1500-20423-1

Table 11-11. Consolidated List of ALSE References - CONT

Publication Description

Technical Manual (TM) - CONT)

TM 55-1680-317-23P&P Organizational and DS Maintenance Manual Including Repair

Parts and Special Tools List for Army Aircraft Survival Kits
TM 55-4240-284-12&P Operating and Maintenance Manual, Rescue Seat, Forest
Penetrating Including Repair Parts and Special Tools List
TM 55-1680-248-10 Operator’s Manual: Survival Kit, Cold Climate, Individual
TM 55-1680-249-10 Operator’s Manual: Survival Kit, Hot Climate, Individual
TM 55-1680-350-10 Operator’s Manual: Survival Kit, Overwater, Individual
TM 55-1680-351-10 Operator’s Manual for SRU-21/P Army Vest, Large/Small
TM 55-1680-322-12 Operations and Service, Distress Marker, Light Part No. SDU-5/E
TM 750-244-1 -2 Procedures for the Destruction of Life Support Equipment to
Prevent Enemy Use
TM 750-244-1-5 Procedures for Destruction of Aircraft and Associated Equipment
to Prevent Enemy Use

Field Manuals (FM)

FM 1-100 Combat Aviation Operations

FM 10-16 General Fabric Repair
FM 10-267 General Repair for Clothing and Textiles
FM 20-151 Aircraft Emergency Procedures Overwater
FM 21-15 Care and Use of Individual Clothing and Equipment
FM 21-76 Survival
FM 38-725-23 Logistic Codes NICP/Depot and DS/GS/lnstallation

Technical Bulletins (TB)

TB CML 93 Adapter, Compressed Air Breathing Apparatus, M4 (End Item Code

201) and Detector Kit, Carbon Monoxide, Colormeter, M23
TB 9-1300-385 Munitions: Suspended or Restricted
FM 1-508 Maintaining Aviation Life Support
Equipment (ALSE): Maintenance Program

Change 2 11-33
TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References - CONT

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

Table 11-11. Consolidated List of ALSE References - CONT

Publication Description

Supply Bulletins (SB) - CONT

SB 708-6 Federal Item Directory for Supply Cataloging

SB 708-21 Federal Supply Classification; Part 1 -Groups and Classes (Cataloging
Handbook H2-1)
SB 708-22 Federal Supply Classification; Part 2 Numeric Index of Classes (Cataloging
Handbook H2-2) (GSA-FSS-H2-2)
SB708-41/SB 708-42 Federal Supply Code for Manufacturers; United States and Canada-Name to
Code (Cataloging Handbook H4-1) (GSA-FSS-H4-1/H4-2)
SB 708-43 Cataloging Handbook H4/H8 Commercial and Government Entity (GAGE)
SB 742-1 Ammunition Surveillance Procedures
SB742-1370-94-721 Signal, Smoke and Illumination, Marine: AN-MK 13 MOD O Ammunition
(DODAC 1370-L 275) Surveillance Procedures

Supply Catalogs (SC)

SC5180-91-CL-R07 Tool Kit, Electronic Equipment, TK-105/G

SC5180-91-CL-R13 Tool Kit, Electronic Equipment, TK-101/G

Department of the Army Supply Catalogs (Federal)

C 1 ARMY Introduction to the Federal Supply Catalog and Related Publications

C 6500-AL Federal Supply Catalog: Alphabetical Index (Medical Materiel)

Change 2 11-35
TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References - CONT

Publication Description

Department of the Army Supply Catalogs (Federal) - CONT

C 6505-GL FSC Glossary of Colloquial Names and Therapeutic Index (FSC Class 6505)
MCRL-1 Master Cross Reference List - 1, Cross Reference from Part Number to NSN
MCRL-2 Master Cross Reference List - 2, Cross Reference from NSN to
Part Number
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, Subsistence

Department of the Army Pamphlets (PAM)

PAM 25-30 Consolidated Index of Army Publications and Blank Forms
PAM 310-10 The Standard Army Publications System (STARPUBS) User’s Guide
PAM 310-13 Posting and Filing Publications
PAM 700-3 Why and How to Use SF 364 to Report Package Discrepancies
PAM 710-2-1 Using Unit Supply System Manual Procedures
PAM 738-751 Functional User’s Guide to the Army Maintenance Management
System-Aviation (TAMMS-A)

Common Tables of Allowance (CTA)

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)

11-36 Change 2
 TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References - CONT

Publication Description

Air Force Technical Orders (TO)

TO: 0-1-01 Numerical Index
TO: 0-1-02 Numerical Index
TO: 00-5-1 Technical Order System
TO: 00-5-2 Technical Order Distribution System
TO: 00-35A-39 Instructions for Procurement, Issue, Use and Maintenance of Medical Kits
TO: 11A-1-1 Ammunition Restricted or Suspended
TO: 11A10-24-7 Storage and Maintenance Procedures, Pyrotechnics
TO 12R2-2PRC90-2 PRC-90 Survival Radio
TO 12R2-2PRC90-3 PRC-90 Survival Radio
TO 12R2-2PRC90-4 PRC-90 Survival Radio
TO 14S-1-102 Maintenance Instructions with Parts Breakdown USAF Flotation Equipment
TO: 14S1-4-1 Distillation Kit
TO: 14S10-2-2-SDU-5/E Marker Distress Light
TO: 14S1-4-22 Desalting Kit
TO 15X1-1 Oxygen Equipment
TO: 15X1-4-2-4 Bail Out Bottles (Parts Manual)
TO: 15X1-4-2-12 Bail Cut Bottles (Maintenance Manual)
TO: 15X3-3-4-3 MB4 Diluter Demand
TO: 15X5-3-6-1 MBU-12/P Pressure-Demand Oxygen Mask Operation, Fitting, Inspection
and Maintenance Instructions with Illustrated Parts Breakdown
TO: 15X5-4-1-101 Oxygen Mask Connector (CRU-60/P)

11-37
TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References - CONT

Publication Description

Naval Publications

Department of the Army (DA) Forms

DA Form 12-R Request for Establishment of a Publications Account
DA Form 12 Series Requirements for DA Publications
DA Form 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

11-38 Change 2
 TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References- CONT

Publication Description

Department of the Army (DA) Forms - CONT

DA Form 2028 Recommended Changes to Publications and Blank Forms

DA Form 2062 Hand Receipt/Annex Number

DA Form 2063-R Prescribed Load List (LRA)

DA Form 2064 Document Register for Supply Actions

DA Form 2402 Exchange Tag

DA Form 2404 Equipment Inspection and Maintenance Worksheet

DA Form 2405 Maintenance Request Register

DA Form 2407 Maintenance Request

DA Form 2407-1 Maintenance Request - Continuation Sheet

DA Form 2408-21 Life Raft Inspection Record

DA Form 2408-22 Helmet and Oxygen Mask/Connector Inspection Record

DA Form 2408-23 Survival Radio/Emergency Locator Transmitter (ELT) Inspection Record

DA Form 2408-24 Survival Kit Inspection and Maintenance Record

DA Form 2408-25 Mesh Net Survival Vest Inspection Record

DA Form 2408-26 Life Preserver Inspection Record

DA Form 2408-27 Life Preserver Data

DA Form 2408-28 Oxygen Console Service Record

DA Form 2408-29 Anti-Exposure Coveralls Inspection Record

DA Form 2696-R Operational Hazard Report

DA Form 2765-1 Request for Issue or Turn-In

DA Form 3161 Request for Issue or Turn-In

DA Form 3749 Equipment Receipt

DA Form 4569 USAPC Requisition Code Sheet

11-39
 TM 1-1500-204-23-1

Table 11-11. Consolidated List of ALSE References - CONT

Publication Description

Department of Defense (DD) Forms - CONT

DD Form 173/1 Joint Message Form

DD Form 448 Military Interdepartmental Purchase Request

DD Form 1348 DOD Single Line Item Requisition System Document (MANUAL)

DD Form 1348-1 DOD Single Line Item Release/Receipt Document

DD Form 1348-6 DOD Single Line Item Requisition System Document (MANUAL-LINE FORM)

DD Form 1574 Serviceable Tag-Materiel

DD Form 1574-1 Serviceable Label-Materiel

DD Form 1575 Suspended Tag-Materiel

DD Form 1575-1 Suspended Label-Materiel

DD Form 1576 Test/Modification Tag-Materiel

DD Form 1576-1 Test/Modification Label-Materiel

DD Form 1577 Unserviceable (Condemned) Tag-Materiel

DD Form1577-1 Unserviceable (Condemned) Label-Materiel

DD Form 1577-2 Unserviceable (Repairable) Tag-Materiel

DD Form 1577-3 Unserviceable (Repairable) Label-Materiel

Standard Forms (SF)

SF 364 Report of Discrepancy (ROD)

SF 368 Quality Deficiency Report (Category II)

11-40
 TM 1-1500-204-23-1

CHAPTER 12

PYROTECHNICS

12-1. General. The following paragraphs 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

12-6. Pyrotechnic Pistols. The pyrotechnic pistol fires WARNING

devices such as flares. The following procedures are for Handle pyrotechnic flares with the
the maintenance of these pistols: same care as high explosives.
Personnel injury may result from
a. Clean and oil pistol thoroughly after firing, improperly handled flares.
using lightweight preservative lubricating oil, MIL-L-
7870. Also, perform this maintenance function at regular c. Protect flares and signals from moisture.
inspection intervals as prescribed in aircraft
organizational maintenance manual. NOTE
Open all containers which show
b. Daily maintenance is required under dusty, signs of dampness or moisture.
wet, or salt. air conditions. Destroy contents when there is
evidence of moisture.
12-7. Pyrotechnics Storage and Handling. Existing
safety requirements and precautions shall be complied d. Disassembly of flares is strictly prohibited.
with by all personnel handling pyrotechnic signal flares.
This type pyrotechnic is hazardous due to the nature of e. Do not use flares when dented or deformed.
its explosive, flammable, or toxic filler. The following
precautions in handling. signals and flares used in f. Avoid any rough handling, throwing, or
pyrotechnic pistols will be followed in order to prevent dropping of pyrotechnics.
personal injuries.
g. Remove flares and signals from aircraft that
a. Store flares and signals in a dry, well- are parked in maintenance or storage hangars, and from
ventilated place, out of direct rays of sun and protected survival kits placed in storage.
against excessive or variable temperatures.

b. Post NO SMOKING signs in storage area.

Change 1 12-2
 TM 1-1500-204-23-1

CHAPTER 13
AIRCRAFT CLEANING
13-1. General. Proper and frequent cleaning is the (1) Prior to lubricating any components or
most important part of a corrosion control program. Fre- parts, remove all foreign matter from joints, fittings, and
quency of cleaning and related treatment will depend on bearing surfaces. Cleaning cloth CCC-C-46 shall be
type of aircraft and local conditions. All aircraft shall be used for this purpose. Clean up all spilled or excess oil
washed and cleaned every 30 days, unless aircraft are or grease. Some solvents can damage rubber, neo-
stationed within two miles of salt water. Extended or low prene, and electrical insulation. They can also damage
level operations over salt water require daily fresh water paint and should be removed as soon as possible.
rising. External corrosion prone areas will require more
frequent cleaning. (2) To protect against cleaning solution entrap-
ment, inspect all lubrication points that have exposure
type lubrication fittings. Lubricate those that have not
been regularly lubricated in accordance with the applica-
ble maintenance manual.
Do not use synthetic wiping cloths with highly (3) Close all doors and emergency openings.
flammable solvents having a flash point of
100°F (37.8°C) or less, such as aliphatic (4) Make sure that all drain holes are clear by
naphtha TT-N-95. Static electricity may build inserting a probe such as a pipe cleaner, except where
up and cause ignition. pressurized flapper valves are located.
b. Cleaning Methods. Various cleaning methods
are explained in the following paragraphs. The method
used depends upon the availability of tap water.
Do not use aircraft cleaning compounds (1) Waterless wipedown. Waterless wipedown
MIL-C-43616 or MIL-C-25769 at strength procedures will be used when water is not available for
other than specified because this will damage rinsing or when cold weather prevents the use of water.
aircraft finish and components. Do not allow The preferred waterless wipedown method for removing
cleaning solutions to dry on aircraft surface. soils and corrosive salt residues is accomplished using
NOTE the following procedures.

Use only authorized cleaning materials and

equipment.
13-2. Cleaning Practices and Procedures. The fol-
lowing paragraphs explain preparation for cleaning,
cleaning methods, cleaning of corrosion prone areas, Open all circuit breakers associated with bat-
and post-cleaning. tery power prior to application of
MIL-C-43616 cleaning compound. This
a. Preparation for Cleaning. Prepare aircraft for compound is flammable.
cleaning by accomplishing the following procedures:
When using cleaning compounds MIL-
C-25769, MIL-C-43616 or MIL-C-85570,
wear faceshield or goggles, rubber gloves
and coveralls. These compounds are toxic
Make sure that static vents are not fouled by and can cause skin irritation.
tape adhesive transfer. Cover static vents
with a properly sized disc of suitable material, (a) Spray the exterior surfaces of the air-
then apply masking tape. Fouled vents will craft with water emulsion cleaning compound
give wrong readings. MIL-C-43616.

Change 2 13-1
TM 1-1500-204-23-1

(b) When the foam begins to break, wipe

cleaner and soil from the surface.
(c) Rinsing with a cloth wet with fresh water
following the use of MIL-C-43616 is desirable. Open all circuit breakers associated with bat-
tery power prior to application of
(d) Rinse the cleaned surface with fresh MIL-C-43616 cleaning compound. This com-
water when water becomes available. pound is flammable.
(2) Detergent cleaning with limited water. When using cleaning compounds MIL-
When limited water is available, the following no rinse C-25769, MIL-C-43616 or MIL-C-85570,
procedures may be used: wear faceshield or goggles, rubber gloves
and coveralls. These compounds are toxic
and can cause skin irritation.
(a) Mix one part of aircraft cleaner
MIL-C-43616 or MIL-C-25769 with nine parts water.
Open all circuit breakers associated with bat- (b) Apply the mixture using foaming equip-
tery power prior to application of ment with aircraft washing kit or fiber brush.
MlL-C-43616 cleaning compound. This com-
pound is flammable. (c) To prevent streaking, start at the lower
surfaces, working upward and out. Scrub the surface
When using cleaning compounds MIL- with the washing-kit or fiber brush.
C-25769, MIL-C-43616 or MILC-85570,
wear faceshield or goggles, rubber gloves
and coveralls. These compounds are toxic
and can cause skin irritation.
Do not rinse aircraft with a solid stream of
(a) Mix one part of aircraft cleaning com- water. Use a soft, spray pattern to avoid dam-
pound MIL-C-43616 or MIL-C-25769 and nine parts of aging fragile sections or causing water intru-
water in a bucket. sion.
(b) Apply the cleaner with a scrub brush, (d) Rinse away the loosened soil and
sponge, rag, or cleaning and polishing pad. Apply to one cleaner with a stream of water. For rinsing, a rubber
small area at a time. padded 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 having
a fan spray nozzle. Direct water at an angle between 15
NOTE and 30 degrees from the surface to rinse it. Continue
For soils that are resistant to the limited water rinsing until all evidence of cleaner and soils have been
procedure, clean again with a mixture of one removed from aircraft.
part cleaner in four parts water.
(5) Deluge rinsing. To prevent buildup of salt
(d) Apply MIL-C-81309 Type II and wipe deposits, the deluge rinse facilities shall be used as fre-
with a clean dry cloth. quently as possible.
(3) Water detergent cleaning (preferred NOTE
method). Where water of suitable quality is available for Use of deluge rinsing facilities does not
rinsing purposes, the following procedures shall be used: replace aircraft washing requirements.

13-2
 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.

Change 3 13-3/(13-4 blank)

 TM 1-1500-204-23-1

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

ATOMIZATION - The process of changing liquid particles to a fine spray.

BONDING - Two or more layers held together by adhesive.

DATUM - A reference used as a basis for calculating or measuring.

DESICCANT - A drying agent that absorbs moisture.

FOD - Foreign Object Damage.

GROUNDING - Electrically connecting an object with the earth.

HYPOXIA- A deficiency of oxygen reaching the tissues of the body.

OHM - A measurement of electrical resistance.

PHENOLIC - A cotton fabric filled with a phenolc resin to form a hard material.

SERVING - The process of winding wire tightly around cable for protection.

SPECIFIC GRAVITY - Ratio of solid or liquid density compared to pure water.

VAPORIZATION - The process of converting a liquid into a vapor.

VISCOSITY - A fluid's Internal resistance to flow.

Glossary 1/(Glossary 2 blank)

 TM 1-1500-204-23-1

INDEX

VOLUME 1

Subject 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

Approach Route, Fuel Truck............................................................................................................................. F3-3

Arctic-Type Mooring ....................................................................................................................................... F10-2
Armor Plating ................................................................................................................................................... 9-23
Adhesives, Resins, and Solvents for Repair of Armor ............................................................................9-23c
Armor Plating Inspection and Repair Definitions ....................................................................................9-23a
General Inspection of Armor Plating ......................................................................................................9-23b
Repair of Armor Plating .........................................................................................................................9-23d
Armor Plating Definitions.................................................................................................................................. T9-8
Armor Plating Inspection and Repair Definitions..............................................................................................9-23a
Arctic Maintenance........................................................................................................................................... 10-2
Anti-Icing, Deicing, and Defrosting.........................................................................................................10-2d
Precautions............................................................................................................................................10-2a
Preflight.................................................................................................................................................10-2c
Preheating .............................................................................................................................................10-2b
Prevention and Removal of Snow, Ice, and Frost Deposits ....................................................................10-2e
Preventive Maintenance.................................................................................................................................. 10-2f
Arctic, Desert, and Tropic Maintenance, General ............................................................................................. 10-1
Assemblies, Connecting Rod............................................................................................................................ F7-9
Assemblies, Elastic Shock Cords ..................................................................................................................... 9-26
Assembly, Cylinder . ...................................................................................................................................... F7-11
Assembly, Turbine, Elements......................................................................................................................... F8-10
Aviation Life Support Maintenance, General .................................................................................................... 11-1
Axial Flow Compressor, Rotor and Stator Components of ................................................................................ F8-7
Axial-Flow Engine ............................................................................................................................................ F8-2

Backing Approach, Fuel Truck ......................................................................................................................... F3-5

Balance (of Tires and Tubes) ............................................................................................................................9-9c
Balancing Equipment .................................................................................................................................2-2l, 2-3l
Basic Mechanical Failure . ................................................................................................................................7-5k
Basis of Issue, First Aid Kits ..........................................................................................................................11-19a
Bearing Types.................................................................................................................................................. F7-8
Bearings............................................................................................................................................................7-4c
Bleeding Brakes .................................................................................................................................................9-7i
Booster Coil ................................................................................................................................................... F7-20
Brake Assemblies ............................................................................................................................................ 9-7b
Brake Assembly Adjustment............................................................................................................................. 9-7g
Brake Assembly Cleaning .................................................................................................................................9-7c
Brake Assembly Inspection .............................................................................................................................. 9-7d
Brake Assembly Servicing................................................................................................................................ 9-7h
Brake System Safety..........................................................................................................................................9-7j

Index 2
 TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1

Subject Paragraph
Figure, Table
Number
B - Continued

Brake Systems................................................................................................................................................... 9-7

Bleeding Brakes........................................................................................................................................9-7i
Brake Assemblies ................................................................................................................................... 9-7b
Brake Assembly Adjustment ................................................................................................................... 9-7g
Brake Assembly Cleaning ........................................................................................................................9-7c
Brake Assembly Inspection..................................................................................................................... 9-7d
Brake Assembly Servicing ...................................................................................................................... 9-7h
Brake System Safety ................................................................................................................................9-7j
Brake Types ........................................................................................................................................... 9-7a
Corrosion Treatment of Brake Assemblies .............................................................................................. 9-7e
Repair and Replacement of Brake Assembly Components ...................................................................... 9-7f
Brake Types..................................................................................................................................................... 9-7a
Built-in Timing Marks ..................................................................................................................................... F7-17

Cable Cutter Cartridges.................................................................................................................................... 12-5

Cable Damage Limits....................................................................................................................................... T9-3
Cable Test ....................................................................................................................................................... T9-5
Can-Annular Combustion Chamber Components and Arrangement ................................................................. F8-9
Can-Type Combustion Chamber Arrangement ................................................................................................. F8-8
Can-Type Combustion Chamber ...................................................................................................................... F8-9
Carbon Monoxide Detection ............................................................................................................................3-12c
Carburetion and Fuel Injection ........................................................................................................................... 7-9
Adjusting Idle Mixture and Idles Speed ....................................................................................................7-9c
Depreservation ....................................................................................................................................... 7-9b
Inspection ............................................................................................................................................... 7-9a
Installation ............................................................................................................................................... 7-9f
Preservation ........................................................................................................................................... 7-9e
Repair or Replacement ........................................................................................................................... 7-9d
Cargo Tiedown Equipment ............................................................................................................................... 9-24
Cartridges, Cable Cutter................................................................................................................................... 12-5
Cartridges, External Storage ............................................................................................................................ 12-4
Cartridges, Fire Bottle ...................................................................................................................................... 12-3
Categories of Storage ........................................................................................................................................ 4-2
Flyable Storage ...................................................................................................................................... 4-2a
Intermediate Storage ...............................................................................................................................4-2c
Long Term Storage................................................................................................................................. 4-2d
Short Term Storage ................................................................................................................................ 4-2b
Centrifugal-Flow Compressor Components ...................................................................................................... F8-6
Centrifugal-Flow Engine ................................................................................................................................... F8-1

Index 3
 TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1

Subject Paragraph
Figure, Table
Number

C - Continued

Chain Hoists..................................................................................................................................................... 2-3e

Checking Propeller Shaft Runout ................................................................................................................... F7-21
Cleaning, Flight Clothing ...............................................................................................................................11-14c
Cleaning, Flotation Equipment ......................................................................................................................11-16e
Cleaning Methods ...........................................................................................................................................13-2b
Cleaning, Nuclear, Biological, and Chemical Equipment ...............................................................................11-20c
Cleaning of Corrosion Prone Areas .................................................................................................................13-2c
Cleaning, Oxygen Equipment........................................................................................................................11-17c
Cleaning Practices and Procedures.................................................................................................................. 13-2
Cleaning Methods..................................................................................................................................13-2b
Cleaning of Corrosion Prone Areas........................................................................................................13-2c
Post-Cleaning ........................................................................................................................................13-2d
Preparation for Cleaning . ......................................................................................................................13-2a
Cleaning, Restraint Equipment .....................................................................................................................11-21c
Cleaning Safety................................................................................................................................................ 13-3
Cleaning, Signaling Devices..........................................................................................................................11-18c
Cleaning, Survival Kits..................................................................................................................................11-15c
Cleaning, Tires and Tubes ............................................................................................................................... 9-9a
Clothing, Flight................................................................................................................................................11-14
Cockpit Check Sheet, Engine Conditioning .................................................................................................... F7-23
Coding, Color (Elastic Shock Cords) ................................................................................................................ T9-8
Coil, Booster .................................................................................................................................................. F7-20
Cold Section Maintenance................................................................................................................................ 8-6g
Color Band, Solid, System ............................................................................................................................... F6-2
Color Coding (Elastic Shock Cords) ................................................................................................................. T9-8
Color-Coded Tapes .......................................................................................................................................... F6-1
Combustion Chamber, Can-Type ..................................................................................................................... F8-9
Combustion Chamber, Can-Type, Arrangement ............................................................................................... F8-8
Combustion Section ......................................................................................................................................... 8-5e
Complete Engine Conditioning ......................................................................................................................... 7-6a
Component Replacement Criteria .................................................................................................................... 8-7b
Components and Airflow of a Double-Annular Chamber ................................................................................ F8-10
Components and Arrangement, Can-Annular Combustion Chamber .............................................................. F8-11
Components, Fabrication (for Cables) .............................................................................................................. T9-2
Components, First Aid Kits ............................................................................................................................ T11-8
Compressed Air and Water Outlets ................................................................................................................... 2-2f
Compressed Air Panels..................................................................................................................................... 2-3f
Compressor Blade Damage ........................................................................................................................... F8-17
Compressor Blade Inspection and Repair......................................................................................................... 8-6h
Compressor Blade Repair Limits, Typical....................................................................................................... F8-18
Compressor Cleaning........................................................................................................................................ 8-6f

Index 4
 TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1

Subject Paragraph
Figure, Table
Number

C - Continued

Compressor Section .........................................................................................................................................8-5c

Compressor, Centrifugal-Flow, Components .................................................................................................... F8-6
Conditioning, Engine ................................................................................................................................. 7-6, T7-2
Connecting Rod Assemblies ............................................................................................................................ F7-9
Connecting Rods.............................................................................................................................................. 7-4d
Consolidated List of ALSE References . .............................................................................................11-23, T11-11
Construction of Hard Stands........................................................................................................................... F10-3
Consumable Materials........................................................................................................................................ 1-3
Consumption, Oil, Chart................................................................................................................................. F7-22
Control Cables ...............................................................................................................................................9-12e
Control System Components........................................................................................................................... 9-12f
Control Systems, Environmental ...................................................................................................................... 9-13
Control, Speed-Sensitive ............................................................................................................................... F8-13
Controlled Substances, First Aid Kits ............................................................................................................11-19e
Controls, Flight................................................................................................................................................. 9-12
Corrosion Preventive Mixture, Discharge Nozzle for ..................................................................................... F7-24
Corrosion Treatment of Brake Assemblies ....................................................................................................... 9-7e
Covers, Protective ........................................................................................................................................... 9-22
Crankcase Opposed-Type................................................................................................................................ F7-4
Crankcase, Radial-Typpe ................................................................................................................................ F7-5
Crankcases ..................................................................................................................................................... 7-4a
Crankshaft, Opposed-Type (Six-Cylinder) (Six-Throw) ..................................................................................... F7-6
Crankshaft, Radial-Type (Single-Throw) .......................................................................................................... F7-7
Crankshafts ..................................................................................................................................................... 7-4b
Criteria, Fitting Area ........................................................................................................................................11-10
Criteria, Storage Area ...................................................................................................................................... 11-9
Cntena, Work Area .......................................................................................................................................... 11-8
Cylinder Assembly ......................................................................................................................................... F7-11
Cylinder, Marking of ....................................................................................................................................... F7-12
Cylinders 7-4f

Damage Limits, Cable...................................................................................................................................... T9-1

Damage, Compressor Blade .......................................................................................................................... F8-17
Decal Types ....................................................................................................................................................... 6-2
Metal Decals............................................................................................................................................6-2c
Paper Decals . ........................................................................................................................................ 6-2a
Vinyl Film Decals.................................................................................................................................... 6-2b
Defects of Turbine Engines, Marking of.............................................................................................................. 8-8
Definitions, Armor Plating ................................................................................................................................ T9-6
Deicing System Maintenance ..........................................................................................................................9-14d

Index 5
 TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1

Subject Paragraph
Figure, Table
Number
D - Continued

Deicing System Precautions............................................................................................................................9-14a

Deicing System Preventive Maintenance ........................................................................................................9-14b
Deicing System Troubleshooting .....................................................................................................................9-14c
Deicing Systems ............................................................................................................................................. 9-14
Deicing System Maintenance.................................................................................................................9-14d
Deicing System Precautions .................................................................................................................9-14a
Deicing System Preventive Maintenance...............................................................................................9-14b
Deicing System Troubleshooting............................................................................................................9-14c
Depreservation................................................................................................................................................. 4-9a
Depreservation of Installed Reciprocating Engines, Supplemental Instructions................................................. 4-10
Depreservation (of Carburetors) ....................................................................................................................... 7-9b
Depreservation of Reciprocating Engines ........................................................................................................ 7-13
Depreservation Run...............................................................................................................................7-13b
Preoiling ................................................................................................................................................7-13a
Depreservation Run .......................................................................................................................................7-13b
Desert Maintenance ......................................................................................................................................... 10-3
Deterioration Factors .............................................................................................................................10-3a
Inspection and Maintenance .................................................................................................................10-3c
Precautions............................................................................................................................................10-3b
Preventive Maintenance . ......................................................................................................................10-3d
Design and Construction, Turbine Engine........................................................................................................... 8-5
Designation Examples...................................................................................................................................... 8-2b
Designation Examples (Reciprocating Engines) ............................................................................................... 7-2b
Details, Snap Hook Safety Guard Drill ........................................................................................................... F11-9
Details, Snap Hook Safety Pin Construction................................................................................................. F11-10
Detection and Extinguishing Systems, Fire....................................................................................................... 9-15
Deterioration Factors ......................................................................................................................................10-3a
Devices, Signaling ..........................................................................................................................................11-18
Diffuser Section . ............................................................................................................................................. 8-5d
Discharge Pressure Pickup Line, Turbine ....................................................................................................... F8-21
Disconnect, Electrical..................................................................................................................................... F8-22
Disconnect, Fuel Line .................................................................................................................................... F8-23
Disconnect, Power Level................................................................................................................................ F8-24
Divided Entrance Inlet Duct (Centrifugal-Flow Engine) ..................................................................................... F8-4
Double-Annular Chamber, Components and Airflow of a................................................................................ F8-10
Duplex Fuel Nozzle ....................................................................................................................................... F8-18
Dust and Dirt Control..................................................................................................................................2-2i, 2-3i

Index 6
 TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1

Subject Paragraph
Figure, Table
Number

Earth Ground Testing .......................................................................................................................................3-4c

Earth Grounds.................................................................................................................................................. 3-4b
Ejection Seats ................................................................................................................................................. 12-2
Elastic Shock Cord Assemblies ........................................................................................................................ 9-26
Fabncation Procedures ..........................................................................................................................9-26d
Fabrication Requirements......................................................................................................................9-26b
Identification .........................................................................................................................................9-26c
Inspection and Testing ..........................................................................................................................9-26a
Process Control ..................................................................................................................................... 9-26f
Serving Elastic Shock Cord ...................................................................................................................9-26e
Storage of Elastic Shock Cords..............................................................................................................9-26g
Electrical Disconnect...................................................................................................................................... F8-20
Electncal Hoist System ..................................................................................................................................9-16b
Electncal Safety . ............................................................................................................................................. 2-5a
Electrical Utilities .....................................................................................................................................2-2g, 2-3g
Emergency Evacuation of Aircraft from Hangar .................................................................................................2-6i
Emergency Extension Systems . ...................................................................................................................... 9-3b
Engine Components, Major (Reciprocating Engines).......................................................................................... 7-4
Engine Conditioning ................................................................................................................................. 7-6, T7-2
Complete Engine Conditioning ............................................................................................................... 7-6a
Minor Engine Conditioning ..................................................................................................................... 7-6b
Engine Conditioning Cockpit Check Sheet .................................................................................................... F7-23
Engine Mounting Systems ............................................................................................................................... 7-11
Engine Operation ............................................................................................................................................ 3-10
Reciprocating Engines . .........................................................................................................................3-10b
Safety Procedures . ...............................................................................................................................3-10a
Turbine Engines.....................................................................................................................................3-10c
Engine Overspeed ............................................................................................................................................7-5l
Engine Removal Criteria (Reciprocating Engine)................................................................................................ 7-5
Additional Metal Particles Test ............................................................................................................... 7-5g
Basic Mechanical Failure ........................................................................................................................7-5k
Engine Overspeed . ..................................................................................................................................7-5l
Excessive Maintenance .......................................................................................................................... 7-5n
Excessive Manifold Pressure ................................................................................................................. 7-5m
Excessive Oil Consumption .................................................................................................................... 7-5o
Excessive Spark Plug Copper or Silver Runout ..................................................................................... 7-5h
Expiration of Operating Time Limit ......................................................................................................... 7-5a
Identification of Metal Particles ............................................................................................................... 7-5e
Low Cylinder Compression .......................................................................................................................7-5i
Metal Particles in Oil .............................................................................................................................. 7-5d
Parts Failure ............................................................................................................................................7-5j
Significance of Metal Particles ................................................................................................................ 7-5f

Index 7
 TM 1-1500-204-23-1

INDEX - CONT

VOLUME 1

Subject Paragraph
Figure, Table
Number

E - Continued

Sudden Engine Stoppage . ..................................................................................................................... 7-5b

Sudden Reduction In Engine RPM...........................................................................................................7-5c
Engine Replacement Criteria ........................................................................................................................... 8-7a
Engine Types and Designations .................................................................................................................. 7-2, 8-2
Designation Examples ...................................................................................................................7-2b, 8-2b
Types .............................................................................................................................................7-2a, 8-2a
Engine, Axial-Flow ........................................................................................................................................... F8-2
Engine, Centrifugal-Flow .................................................................................................................................. F8-1
Engine, Opposed-Type .................................................................................................................................... F7-2
Engine, Turbine, Theory..................................................................................................................................... 8-3
Engines and Components, Replacement Criteria for .......................................................................................... 8-7
Entries in Aircraft Forms..................................................................................................................................... 4-7
Entries, Method of Accomplishing ...................................................................................................................... 5-4
Environmental Control .................................................................................................................................... 2-2m
Environmental Control Systems ....................................................................................................................... 9-13
Repair of Flexible Air Ducts . .................................................................................................................9-13b
Types ....................................................................................................................................................9-13a
Equipment, Flotation . .....................................................................................................................................11-16
Equipment Maintenance Forms........................................................................................................................ 2-4d
Equipment Mounted In Mobile Shelters .............................................................................................................2-3c
Equipment, Nuclear, Biological, and Chemical ...............................................................................................11-20
Equipment, Oxygen ........................................................................................................................................11-17
Equipment, Restraint ......................................................................................................................................11-21
Equipment, Test............................................................................................................................................. T11-1
Equipment, Training .......................................................................................................................................11-12
Excessive Maintenance.................................................................................................................................... 7-5n
Excessive Manifold Pressure ......................................................................................................................... 7-5m
Excessive Oil Consumption.............................................................................................................................. 7-5o
Excessive Spark Plug Copper or Silver Runout................................................................................................ 7-5h
Exhaust Section ............................................................................................................................................... 8-5g
Exhaust System ................................................................................................................................................. 7-8
Expiration of Operating Time Limit .................................................................................................................. 7-5a
External Storage Cartridges ............................................................................................................................. 12-4

Fabncation Components (for Cables) ............................................................................................................... T9-2

Fabrication of Ground Cable ........................................................................................................................... 3-4d
Fabrication of Static Grounding Cable Assembly.............................................................................................. F3-1
Fabrication Procedures ..................................................................................................................................9-26d
Fabrication Requirements (Elastic Shock Cords).............................................................................................9-26b

Index 8
 TM 1-1500-204-23-1

INDEX
VOLUME 1
Paragraph,
Figure, Table
Subject Number
F - Continued

Fingertip Clearance, Measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6

Fire Bottle Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Fire Detection and Extinguishing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Fire Detection Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15a
Fire Extinguishing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15g
Maintenance of Fire Detection Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15c
Maintenance of Fire Extinguishing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15h
Repair or Replacement of Fire Detection Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15e
Testing of Fire Detection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15f
Troubleshooting of Fire Detection Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15d
Types of Fire Detection Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15b
Fire Detection Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15a
Fire Detection Systems, Troubleshooting of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-5
Fire Extinguisher Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-3
Fire Extinguishing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15g
FireSafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5c
First Aid Kit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-8
First Aid Kit, Airplane (Older Configuration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-1
First Aid Kit, General Purpose (Newer Configuration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11-2
First Aid Kit, References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-9
First Aid Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19
Basic of lssue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19a
Controlled Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19e
First Aid Kit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19i
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19c
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19f
Inspection Training Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19j
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19b
Protection of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19d
Replacement of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19h
Sealing.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19g
Fitting Area Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
Flammable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3n
Flat-Head Pin, Lead Seal, and Identification Tag, Properly Attached . . . . . . . . . . . . . . . . . . . . . F11-5
Flight Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14c
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14a
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14b
Flight Clothing References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-2
Flight Control Operating Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12d
Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5C(5)F2-3

Change 2 Index 9
TM 1-1500-204-23-1

INDEX- CONT
VOLUME 1
Subject Paragraph,
Figure, Table
Number

F - Continued

Flightline Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2g

Flightline Operations General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Flightline Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Flightline Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2g
Foreign Object Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2b
Hearing Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2a
Parking and Mooring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2e
Preparation of Aircraft for Storms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2f
Reflectorizing of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2h
Safety Around Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2d
Safety Around Helicopters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2c
Float Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Flotation Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3c, 11-16
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16e
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16c
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16a
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16d
Storage in Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16b
Flotation Equipment References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T11-5
Flyable Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2a. 7-12e
Flyable Storage for Depreservation of Installed Reciporcating Engines . . . . . . . . . . . . . . . 4-10a
Flyable Storage for Preservation of Installed Reciporcating Engines . . . . . . . . . . . . . . . . . 4-5a
Foreign Object Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2b
Foreign Object Damage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6e
Form Entries for Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Fuel Line Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-21
Fuel Nozzle, Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-16
Fuel Nozzle, Simplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-15
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6o
Fuel Systems.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5k
Fuel Truck Approach Route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-3
Fuel Truck Backing Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-5
Flue Truck Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5d
Fuel Truck Required Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3-4
G

General Position Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3d

General Airframe Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
General Inspection of Armor Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23b

PIN: 070482-002
Index 10
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VOLUME 1

Subject Paragraph
Figure, Table
Number

G - Continued

General Maintenance of Shock Struts .............................................................................................................. 9-5d

General Procedures (Turbine Engine Inspection and Maintenance).................................................................. 8-6a
General Procedures (Ground Handling)............................................................................................................ 3-3a
General Purpose First Aid Kit (Newer Configuration)...................................................................................... F11-2
General Reciprocating Engine Maintenance Practices ...................................................................................... 7-1
General Turbine Engine Maintenance ................................................................................................................ 8-1
General, Aircraft Cleaning................................................................................................................................ 13-1
General, Aircraft Storage and Shipment............................................................................................................. 4-1
General, Application and Removal of Decals ..................................................................................................... 6-1
General, Arctic, Desert, and Tropic Maintenance ............................................................................................. 10-1
General, Aviation Life Support Maintenance .................................................................................................... 11-1
General, Flightline Operations............................................................................................................................ 3-1
General, Hangar and Shop Operations............................................................................................................... 2-1
General, Marking of Aeronautical Items ............................................................................................................. 5-1
General, Pyrotechnics ...................................................................................................................................... 12-1
Governor, Speed-Set .................................................................................................................................... F8-12
Governors and Fuel Controls .......................................................................................................................... 8-51
Grade 1100 Oil, Percent Dilution Versus Temperature for .............................................................................. F7-25
Ground Handling ................................................................................................................................................ 3-3
General Procedures................................................................................................................................ 3-3a
Pushing ..................................................................................................................................................3-3c
Standard Visual Signals.......................................................................................................................... 3-3d
Towing.................................................................................................................................................... 3-3b
Ground Receptacle Criteria .............................................................................................................................. 3-3e
Ground Receptacle Testing .............................................................................................................................. 3-4f
Grounding Receptacle Installation, Aircraft....................................................................................................... F3-2
Grounding Requirements ................................................................................................................................ 3-4a

Handling, Ground ............................................................................................................................................... 3-3

Hangar and Shop Operations, General............................................................................................................... 2-1
Hangar and Shop Safety ................................................................................................................................... 2-5
Electrical Safety ..................................................................................................................................... 2-5a
Fire Safety ..............................................................................................................................................2-5c
Machine Tool Safety .............................................................................................................................. 2-5b
Hard Stands, Construction of ......................................................................................................................... F10-3
Harness, Ignition ............................................................................................................................................ F7-18
Health Indication Test . .................................................................................................................................... 8-6b
Hearing Protection ........................................................................................................................................... 3-2a
Hoist Systems ................................................................................................................................................. 9-16
Electrical Hoist System ..........................................................................................................................9-16b
Hydraulic Hoist System..........................................................................................................................9-16a

Index 11
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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

Identification, First Aid Kits ...........................................................................................................................11-19c

Identification of Elastic Shock Cords ...............................................................................................................9-26c
Identification of Metal Particles ....................................................................................................................... 7-5e
Identification Tag, Flat-Head Pin, Lead Seal, Properly Attached .................................................................... F11-5
Identification Tapes, Application and Installation of ............................................................................................ 6-3
Application of Identification Tapes ....................................................................................................................6-3c
Installation of Identification Tapes ................................................................................................................... 6-3d
Printed-Symbolized System ............................................................................................................................. 6-3a
Solid Color Band System ................................................................................................................................. 6-3b
Igniter Plugs, Typical...................................................................................................................................... F8-14
Ignition Harness ............................................................................................................................................. F7-18
Ignition System . ................................................................................................................................................7-4i
Ignition System Maintenance ...........................................................................................................................8-6k
Ignition System, Typical, One Side of a ......................................................................................................... F8-13
Ignition Systems.................................................................................................................................................8-5j
Indicator, Top Center .................................................................................................................................... F7-15
Induction Vibrator .......................................................................................................................................... F7-19
Induction Vibrators, Repairing .......................................................................................................................... T7-1
Induction, Air, System ........................................................................................................................................ 7-7
Inlet Duct, Divided Entrance (Centrifugal-Flow Engine) .................................................................................... F8-4
Inlet Duct, Single Entrance (Axial-Flow Engine) .............................................................................................. F8-3
Inlet Ducts........................................................................................................................................................ 8-5a
Inspection ....................................................................................................................................................... 4-9b
Inspection (Carburetors) .................................................................................................................................. 7-9a
Inspection (First Aid Kits) .............................................................................................................................. 11-19f
Inspection (Flight Clothing)............................................................................................................................11-14a
Inspection (Flotation Equipment) ..................................................................................................................11-16c
Inspection (Nuclear, Biological, and Chemical Equipment)............................................................................11-20a
Inspection (Oxygen Equipment) ....................................................................................................................11-17a
Inspection (Restraint Equipment) ..................................................................................................................11-21a
Inspection (Signaling Devices) .....................................................................................................................11-18a
Inspection (Survival Kits) ..............................................................................................................................11-15a

Index 12
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VOLUME 1

Subject Paragraph
Figure, Table
Number

I - Continued

Inspection (Tires and Tubes) ............................................................................................................................ 9-9b

Inspection and Maintenance (Desert) ..............................................................................................................10-3c
Inspection and Maintenance, Turbine Engine ..................................................................................................... 8-6
Inspection and Preventive Maintenance, (Tropics) .........................................................................................10-4a
Inspection and Testing (Elastic Shock Cords)..................................................................................................9-26a
Inspection Criteria, Personnel Parachute and Parachute Harness .................................................................11-22a
Inspection of Flight Controls............................................................................................................................9-12b
Inspection of Primer Nozzles............................................................................................................................ T8-1
Inspection of Stored Aircraft ............................................................................................................................... 4-5
Inspection of Vibration Isolators.......................................................................................................................9-25c
Inspection Procedures, Personnel Parachute and Parachute Harness ...........................................................11-22b
Inspection Report, Personnel Parachute and Parachute Harness ..................................................................11-22c
Inspection Training Procedures, First Aid Kits ................................................................................................11-19j
Inspection, Maintenance, Cleaning, and Replacement (Reciprocating Engine) ................................................. 7-7a
Installation (Aircraft Litters) ............................................................................................................................9-21a
Installation (of Carburetors) ............................................................................................................................... 7-9f
Installation (of First Aid Kits) .........................................................................................................................11-19b
Installation (of Turbine Engines)......................................................................................................................8-11d
Installation (Reciprocating Engines) ................................................................................................................7-10d
Installation (Seat Belt Webbing Retarder Spring) ........................................................................................... F11-8
Installation (Shoulder Harness Webbing Retarder Spnng) ............................................................................. F11-7
Installation (Tires and Tubes) .......................................................................................................................... 9-9e
Installation and Removal Procedures (Protective Covers) ...............................................................................9-22a
Installation of Identification Tapes .................................................................................................................... 6-3d
Installation of Piston Position Indicators ......................................................................................................... F7-16
Installation of Vibration Isolators......................................................................................................................9-25b
Intermediate Storage.........................................................................................................................................4-2c
Intermediate Storage for Depreservation of Installed Reciprocating Engines ...................................................4-10c
Intermediate Storage for Preservation of Installed Reciprocating Engines .........................................................4-5c
Intermediate Storage of Engines Mounted on Aircraft......................................................................................7-12d
Isolators, Vibration ........................................................................................................................................... 9-25

Jacking 2-7a
Jacking and Hoisting .......................................................................................................................................... 2-7
Hoisting ................................................................................................................................................. 2-7b
Jacking .................................................................................................................................................. 2-7a

Index 13
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VOLUME 1

Subject Paragraph
Figure, Table
Number

Kit, First Aid . ..................................................................................................................................................11-19

Kits, First Aid ..................................................................................................................................................11-15

Landing Gear Alignment..................................................................................................................................... 9-6

Landing Gear Systems ...................................................................................................................................... 9-2
Landing Gear Systems, Troubleshooting of ....................................................................................................... 9-4
Lead-Acid Batteries (Depreservation)..............................................................................................................4-13e
Life Support Equipment Temporary Storage ...................................................................................................11-13
Liferafts for Aircraft ....................................................................................................................................... T11-4
Lighting 2-3o
Lighting Requirements . ................................................................................................................................... 2-2n
Liquid Lock..................................................................................................................................................... F7-13
Litters, Aircraft.................................................................................................................................................. 9-21
Loads, Test (Elastic Shock Cords).................................................................................................................... T9-7
Locating Dimensions, Lockring....................................................................................................................... T9-10
Location of Static Ground Points ..................................................................................................................... 2-6e
Lock, Liquid ................................................................................................................................................... F7-13
Lockring Locating Dimension ......................................................................................................................... T9-10
Long Term Storage .......................................................................................................................................... 4-2d
Low Cylinder Compression.................................................................................................................................7-5i

Machine Tool Safety ........................................................................................................................................ 2-5b

Maintenance .....................................................................................................................................................4-9c
Maintenance Area ............................................................................................................................................ 11-7
Maintenance of Fire Detection Systems ..........................................................................................................9-15c
Maintenance of Fire Extinguishing Systems . ..................................................................................................9-15h
Maintenance of Oxygen Systems . ..................................................................................................................9-17b
Maintenance of Protective Covers...................................................................................................................9-22b
Maintenance of Shop Equipment........................................................................................................................ 2-4
Equipment Maintenance Forms . ............................................................................................................ 2-4d
Major Repair .......................................................................................................................................... 2-4b
Operator Maintenance ............................................................................................................................ 2-4a
Painting ...................................................................................................................................................2-4c
Maintenance of Stored Aircraft........................................................................................................................... 4-8
Maintenance of Windshield Wiper System . ....................................................................................................9-19a
Maintenance Operational Checks....................................................................................................................3-12b
Maintenance Operational Checks, Test Flights and .......................................................................................... 3-12
Maintenance, Arctic ......................................................................................................................................... 10-2

Index 14
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VOLUME 1

Subject Paragraph
Figure, Table
Number

M - Continued

Maintenance, Desert ....................................................................................................................................... 10-3

Maintenance, Float .......................................................................................................................................... 9-11
Maintenance, Ski ............................................................................................................................................ 9-10
Maintenance, Tropic ........................................................................................................................................ 10-4
Maintenance, Wheel .......................................................................................................................................... 9-8
Major Engine Components (Reciprocating Engines) .......................................................................................... 7-4
Accessones ............................................................................................................................................ 7-4h
Bearings . ................................................................................................................................................7-4c
Connecting Rods .................................................................................................................................... 7-4d
Crankcases............................................................................................................................................. 7-4a
Crankshafts . .......................................................................................................................................... 7-4b
Cylinders ................................................................................................................................................ 7-4f
Ignition System.........................................................................................................................................7-4i
Pistons, Pins, and Rings ........................................................................................................................ 7-4e
Valves ................................................................................................................................................... 7-4g
Major Repair .................................................................................................................................................... 2-4b
Marking of Aeronautical Items, General ............................................................................................................. 5-1
Marking of Cylinder ....................................................................................................................................... F7-12
Marking of Defects on Turbine Engines.............................................................................................................. 8-8
Marking Requirements (Aeronautical Items) ...................................................................................................... 5-2
Marking, Materiel .............................................................................................................................................. 5-3
Materals, Consumable ...................................................................................................................................... 1-3
Materiel Marking ................................................................................................................................................ 5-3
Measuring Fingertip Clearance ...................................................................................................................... F11-6
Metal Decals ....................................................................................................................................................6-2c
Metal Particles in Oil ....................................................................................................................................... 7-5d
Metal Seats ....................................................................................................................................................9-20b
Method of Accomplishing Entries ........................................................................................................................54
Minimum Serving Length ................................................................................................................................ T9-9
Minor Engine Conditioning .............................................................................................................................. 7-6b
Modification, Seat Belt Latch ....................................................................................................................... F11-12
Moisture and Fungi, Parts and Fabncs Affected by.............................................................................. 10-4b, T10-1
Moonng, Arctic-Type .................................................................................................................................... F1 0-2
Mounts, Turbine Engine ..................................................................................................................................... 8-9

Nameplates, Fire Extinguisher .......................................................................................................................... 2-3

New Equipment ............................................................................................................................................ 11-13f
Noise Levels ............................................................................................................................................2-2h, 2-3h
Nosewheel Centering ...................................................................................................................................... 9-3e

Index 15
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VOLUME 1

Subject Paragraph
Figure, Table
Number

N - Continued

Nuclear, Biological, and Chemical Equipment .................................................................................................11-20

Cleaning 11-20c
Inspection .....................................................................................................................................................11-20a
Repair . 11-20b
Nuclear, Biological, and Chemical Equipment References .......................................................................... T11-10

Oil Consumption ............................................................................................................................................. 8-6n

Oil Consumption Chart .................................................................................................................................. F7-22
Oil Servicing ...................................................................................................................................................... 3-6
One Side of a Typical Ignition System............................................................................................................ F8-15
Open Storage Areas.......................................................................................................................................... 2-3r
Open Storage for Repaired Equipment and Consumable Material..................................................................... 2-2r
Open-Port Hot Refueling ................................................................................................................................. 3-5b
Open-Port Refueling . ...................................................................................................................................... 3-5a
Operating Cycle (Four-Stroke) Reciprocating Engine ...................................................................................... F7-3
Operation, Engine ............................................................................................................................................ 3-10
Operational Check .......................................................................................................................................... 4-9d
Operator Maintenance...................................................................................................................................... 2-4a
Operator Position, Painting of Shop Equipment to Highlight ............................................................................ F2-2
Opposed-Type Crankcase................................................................................................................................ F7-4
Opposed-Type Crankshaft (Six-Cylinder) (Six-Throw) ..................................................................................... F7-6
Opposed-Type Engine ..................................................................................................................................... F7-2
Overhead Chain Hoist...................................................................................................................................... 2-2e
Oxygen Equipment ...........................................................................................................................11-13e, 11-17
Cleaning . ............................................................................................................................................11-17c
Inspection ............................................................................................................................................11-17a
Repair .................................................................................................................................................11-17b
Oxygen Equipment References...................................................................................................................... T11-6
Oxygen Servicing............................................................................................................................................... 3-7
Safety Precautions ................................................................................................................................. 3-7a
Servicing ................................................................................................................................................ 3-7b
Oxygen System Types ....................................................................................................................................9-17a
Oxygen Systems.............................................................................................................................................. 9-17
Maintenance of Oxygen Systems...........................................................................................................9-17b
Oxygen System Types...........................................................................................................................9-17a
Servicing of Oxygen Systems................................................................................................................9-17c

Index 16
 TM 1-1500-204-23-1

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VOLUME 1

Subject Paragraph
Figure, Table
Number

Packaging Procedures ....................................................................................................................................4-12b

Painting 2-4c
Painting of Shop Equipment to Highlight Operator Position ............................................................................. F2-2
Paper Decals .................................................................................................................................................. 6-2a
Parachute Harness and Personnel Parachute..................................................................................................11-22
Parking and Mooring ........................................................................................................................................ 3-2e
Parking of Aircraft and Equipment in Hangars .................................................................................................... 2-6
Emergency Evacuation of Aircraft from Hangar ........................................................................................2-6i
Location of Static Ground Points............................................................................................................. 2-6e
Parking of Aircraft in Hangars ................................................................................................................. 2-6b
Parking of Aircraft with Fuel Tanks Less Than Full...................................................................................2-6c
Safety Lanes .......................................................................................................................................... 2-6a
Static Grounding of Aircraft .................................................................................................................... 2-6g
Static Grounding of Ground Support Equipment . ................................................................................... 2-6h
Testing of Static Ground Points ............................................................................................................... 2-6f
Usage of Drip Pans................................................................................................................................. 2-6d
Parking of Aircraft in Hangars .......................................................................................................................... 2-6b
Parking of Aircraft with Fuel Tanks Less Than Full ...........................................................................................2-6c
Particle Separators ................................................................................................................................. 8-5b, F8-5
Parts and Fabncs Affected by Moisture and Fungi .............................................................................. 10-4b, T10-1
Parts Failure ......................................................................................................................................................7-5j
Percent Dilution Versus Temperature for Grade 1100 Oil ............................................................................... F7-25
Permanent Shop Installations............................................................................................................................. 2-2
Adhesive Operations ...............................................................................................................................2-2k
Balancing Equipment.............................................................................................................................. 2-21
Compressed Air and Water Outlets.......................................................................................................... 2-2f
Dust and Dirt Control ................................................................................................................................2-2i
Electrical Utilities .................................................................................................................................... 2-2g
Environmental Control ........................................................................................................................... 2-2m
Lighting Requirements . .......................................................................................................................... 2-2n
Noise Levels .......................................................................................................................................... 2-2h
Open Storage for Repaired Equipment and Consumable Material ........................................................... 2-2r
Overhead Chain Hoist ........................................................................................................................... 2-2e
Shop Equipment Arrangement................................................................................................................ 2-2d
Shop Equipment Required .......................................................................................................................2-2c
Shop Size ............................................................................................................................................... 2-2b
Spray Painting ..........................................................................................................................................2-2j
Storage of Compressed Gases ............................................................................................................... 2-2p
Storage of High-Value Items................................................................................................................... 2-2q
Storage of Shop Stocks, Repair Parts, and Consumable Matenals ......................................................... 2-2o
Typical Layout ....................................................................................................................................... 2-2a

Index 17
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VOLUME 1

Subject Paragraph
Figure, Table
Number

P - Continued

Personnel ........................................................................................................................................................ 11-4

Personnel Parachute and Parachute Harness..................................................................................................11-22
Inspection Criteria................................................................................................................................11-22a
Inspection Procedures . .......................................................................................................................11-22b
Inspection Report ................................................................................................................................11-22c
Pistols, Pyrotechnic.......................................................................................................................................... 12-6
Piston Position Indicators, Installation of ....................................................................................................... F7-16
Piston, Pin, and Ring Assemblies................................................................................................................... F7-10
Pistons, Pins, and Rings .................................................................................................................................. 7-4e
Plating, Armor .................................................................................................................................................. 9-23
Pneumatic Deicing Systems, Troubleshooting ................................................................................................. T9-4
Pneumatic System Servicing ............................................................................................................................. 3-9
Polyester Fabric Seat Covers (UH-60) ...........................................................................................................9-20e
Post- Cleaning ................................................................................................................................................13-2d
Postflight and Parking .....................................................................................................................................3-11c
Power Lever Disconnect ................................................................................................................................ F8-22
Practices and Procedures, Cleaning................................................................................................................. 13-2
Precautions (Arctic Maintenance)....................................................................................................................10-2a
Precautions (Desert Maintenance) ..................................................................................................................10-3b
Precautions (Flotation Equipment) ................................................................................................................11-16a
Precautions, Turbine Engine .............................................................................................................................. 8-4
Preflight (Arctic) ..............................................................................................................................................10-2c
Preheating ......................................................................................................................................................10-2b
Preoillng 7-13a
Preparation for Cleaning .................................................................................................................................13-2a
Preparation for Installation (Reciprocating Engines) ........................................................................................7-10c
Preparation for Installation (Turbine Engines)..................................................................................................8-11c
Preparation for Removal (Reciprocating Engines) ...........................................................................................7-10a
Preparation for Removal (Turbine Engines) ....................................................................................................8-11a
Preparation of Aircraft for Storage...................................................................................................................... 4-4
Preparation of Aircraft for Storms ..................................................................................................................... 3-2f
Preservation (of Carburetors) ........................................................................................................................... 7-9e
Preservation and Depreservation of Turbine Engines....................................................................................... 8-10
Preservation and Packaging of Aircraft Components........................................................................................ 4-10
Packaging Procedures ...........................................................................................................................4-10b
Special Reusable Containers .................................................................................................................4-10a
Preservation of Accident-Involved Engines .....................................................................................................7-12a
Preservation of Inoperable Engines.................................................................................................................7-12c
Preservation of Installed Reciprocating Engines, Supplemental Instructions....................................................... 4-5
Preservation of Operable Engines to be Removed for Overhaul . ...................................................................7-12b
Preservation of Reciprocating Engines ............................................................................................................ 7-12
Flyable Storage ....................................................................................................................................7-12e

Index 18
 TM 1-1500-204-23-1

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VOLUME 1

Subject Paragraph
Figure, Table
Number

P - Continued

Intermediate Storage of Engines Mounted on Aircraft . ..........................................................................7-12d

Preservation of Accident-Involved Engines............................................................................................7-12a
Preservation of Inoperable Engines .......................................................................................................7-12c
Preservation of Operable Engines to be Removed for Overhaul ............................................................7-12b
Prevention and Removal of Snow, Ice, and Frost Deposits .............................................................................10-2e
Preventive Maintenance (Arctic) ..................................................................................................................... 10-2f
Preventive Maintenance (Desert) ....................................................................................................................10-3d
Primer Nozzles, Inspection of........................................................................................................................... T8-1
Printed-Symbolized System ............................................................................................................................. 6-3a
Process Control............................................................................................................................................... 9-26f
Propeller Shaft Runout, Checking .................................................................................................................. F7-21
Properly Attached Flat-Head Pin, Lead Seal, and Identification Tag............................................................... F11-5
Protected Storage Areas .................................................................................................................................. 2-3q
Protection of Contents, First Aid Kits .............................................................................................................11-19d
Protective Covers ........................................................................................................................................... 9-22
Installation and Removal Precautions ....................................................................................................9-22a
Maintenance of Protective Covers .........................................................................................................9-22b
Publications ..................................................................................................................................................... 11-5
Purpose (of Manual)........................................................................................................................................... 1-1
Pushing 3-3c
Pyrotechnic Pistols .......................................................................................................................................... 12-6
Pyrotechnics Storage and Handling.................................................................................................................. 12-7
Pyrotechnics, General ..........................................................................................................................11-13d, 12-1

Radial-Type Crankcase ................................................................................................................................... F7-5

Radial-Type Crankshaft (Single-Throw)............................................................................................................ F7-7
Rapid Hot Refueling ..........................................................................................................................................3-5c
Raschel Knit Seat Covers ...............................................................................................................................9-20d
Reciprocating Engine Maintenance Practices, General ...................................................................................... 7-1
Reciprocating Engine Operating Cycle (Four-Stroke) ....................................................................................... F7-3
Reciprocating Engine Theory ............................................................................................................................ 7-3
Reciprocating Engines ....................................................................................................................................3-10b
References, Consolidated List of ALSE ..............................................................................................11-23, T11-11
References for First Aid Kits........................................................................................................................... T11-9
References for Flight Clothing........................................................................................................................ T11-2
References for Flotation Equipment ............................................................................................................... T11-5
References for Nuclear, Biological, and Chemical Equipment ...................................................................... T11-10
References for Oxygen Equipment ................................................................................................................ T11-6

Index 19
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VOLUME 1

Subject Paragraph
Figure, Table
Number

R - Continued

References for Signaling Devices .................................................................................................................. T11-7

References for Survival Kits........................................................................................................................... T11-3
Reflectorizing of Equipment ............................................................................................................................. 3-2h
Refueling, Aircraft ............................................................................................................................................. 3-5
Relief Tube System ......................................................................................................................................... 9-18
Removal (Aircraft Litters) ...............................................................................................................................9-21b
Removal (of Turbine Engines) ........................................................................................................................8-11b
Removal (Reciprocating Engines) ...................................................................................................................7-10b
Removal and Installation of Reciprocating Engines .......................................................................................... 7-10
Installation ............................................................................................................................................7-10d
Preparation for Installation .....................................................................................................................7-10c
Preparation for Removal .......................................................................................................................7-10a
Removal ...............................................................................................................................................7-10b
Removal and Installation of Turbine Engines ................................................................................................... 8-11
Installation . ...........................................................................................................................................8-11d
Preparation for Installation ....................................................................................................................8-11c
Preparation for Removal .......................................................................................................................8-11a
Removal ...............................................................................................................................................8-11b
Removal of Aircraft from Storage ...................................................................................................................... 4-8
Depreservation ....................................................................................................................................... 4-8a
Inspection ............................................................................................................................................... 4-8b
Maintenance ............................................................................................................................................4-8c
Operational Check . ................................................................................................................................ 4-8d
Repair (Flight Clothing) . ...............................................................................................................................11-14b
Repair (Flotation Equipment) . ......................................................................................................................11-16d
Repair (Nuclear, Biological, and Chemical Equipment) .................................................................................11-20b
Repair (Oxygen Equipment)..........................................................................................................................11-17b
Repair (Restraint Equipment) ........................................................................................................................11-21b
Repair (Signaling Devices) ...........................................................................................................................11-18b
Repair (Survival Kits) ...................................................................................................................................11-15b
Repair and Replacement of Brake Assembly Components................................................................................ 9-7f
Repair of Armor Plating ..................................................................................................................................9-23d
Repair of Flexible Air Ducts.............................................................................................................................9-13b
Repair of Flight Controls .................................................................................................................................9-12c
Repair of Wheels .............................................................................................................................................9-8c
Repair or Replacement (of Carburetors) .......................................................................................................... 7-9d
Repair or Replacement of Fire Detection Components....................................................................................9-15e
Repair Parts Van ............................................................................................................................................. 2-3p
Reparing Induction-Vibrators ........................................................................................................................... T7-1
Replacement (Restraint Equipment) .............................................................................................................11-21d
Replacement Cntena for Engines and Components .......................................................................................... 8-7
Component Replacement Criteria .......................................................................................................... 8-7b

Index 20
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VOLUME 1

Subject Paragraph
Figure, Table
Number

R - Continued

Engine Replacement Cntena............................................................................................................................ 8-7a

Replacement Criteria for Wheels .................................................................................................................... 9-8d
Replacement of Components (First Aid Kit) ..................................................................................................11-19h
Required Spacing, Fuel Truck .......................................................................................................................... F3-4
Requirements, Marking (Aeronautical Items) ..................................................................................................... 5-2
Responsibility, Aircraft Storage and Shipment.................................................................................................... 4-3
Restraint Equipment........................................................................................................................................11-21
Cleaning ..............................................................................................................................................11-21c
Inspection ............................................................................................................................................11-21a
Repair .................................................................................................................................................11-21b
Replacement .......................................................................................................................................11-21d
Retractable Landing Gear Systems .................................................................................................................... 9-3
Emergency Extension Systems .............................................................................................................. 9-3b
Gear Position Indicators.......................................................................................................................... 9-3d
Nosewheel Centenng.............................................................................................................................. 9-3e
Retraction Test ........................................................................................................................................ 9-3f
Safety Devices .......................................................................................................................................9-3c
Types ..................................................................................................................................................... 9-3a
Retraction Test (Retractable Landing Gear) ...................................................................................................... 9-3f
Rotor and Stator Components of an Axial-Flow Compressor ............................................................................ F8-7
Runup and Taxiing ........................................................................................................................................... 3-11
Postflight and Parking ...........................................................................................................................3-11c
Safety Procedures ................................................................................................................................3-11a
Taxiing .................................................................................................................................................3-11b

Safety ......................................................................................................................................................... 11-3

Safety Around Airplanes................................................................................................................................... 3-2d
Safety Around Helicopters.................................................................................................................................3-2c
Safety Devices (Retractable Landing Gear Systems) ........................................................................................9-3c
Safety Lanes .................................................................................................................................................... 2-6a
Safety Pin Retaining Cord Secured to Snap Hook ....................................................................................... F11-11
Safety Precautions (Oxygen Servicing) ............................................................................................................ 3-7a
Safety Procedures (Engine Operation) . ..........................................................................................................3-10a
Safety Procedures (Runup and Taxiing) .........................................................................................................3-11a
Safety, Cleaning............................................................................................................................................... 13-3
Safety, Flightlene ............................................................................................................................................... 3-2
Scope (of Manual).............................................................................................................................................. 1-2
Sealing (First Aid Kits)...................................................................................................................................11-19g
Seat Belt Latch Modification......................................................................................................................... F11-12
Seat Belt Webbing Retarder Spnng Installation.............................................................................................. F11-8
Seats, Aircraft . ................................................................................................................................................ 9-20

Index 21
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VOLUME 1

Subject Paragraph
Figure, Table
Number

S - Continued

Seats, Ejection ................................................................................................................................................. 12-2

Separator, Particle ........................................................................................................................................... F8-5
Servicable Tag-Matenel (DD Form 1574) (Yellow) ......................................................................................... F11-3
Servicing (Oxygen) .......................................................................................................................................... 3-7b
Servicing of Oxygen Systems .........................................................................................................................9-17c
Servicing, Hydraulic Fluid ................................................................................................................................. 3-8
Servicing, Oil ..................................................................................................................................................... 3-6
Servicing, Oxygen.............................................................................................................................................. 3-7
Servicing, Pneumatic System ............................................................................................................................ 3-9
Serving Elastic Shock Cord.............................................................................................................................9-26e
Serving Length, Minimum ................................................................................................................................ T9-9
Shipment of Aircraft . ......................................................................................................................................... 4-9
Shock Strut Bleeding ........................................................................................................................................9-5c
Shock Strut Operation...................................................................................................................................... 9-5a
Shock Strut Servicing....................................................................................................................................... 9-5b
Shock Struts....................................................................................................................................................... 9-5
General Maintenance of Shock Struts .................................................................................................... 9-5d
Shock Strut Bleeding ..............................................................................................................................9-5c
Shock Strut Operation ........................................................................................................................... 9-5a
Shock Strut Servicing ............................................................................................................................. 9-5b
Shop and Hangar Safety .................................................................................................................................... 2-5
Shop Equipment Arrangement ................................................................................................................2-2d, 2-3d
Shop Equipment Required ................................................................................................................................2-2c
Shop Equipment, Maintenance of....................................................................................................................... 2-4
Shop Installations, Permanent............................................................................................................................ 2-2
Shop Installations, Temporary ........................................................................................................................... 2-3
Shop Size ...............................................................................................................................................2-2b, 2-3b
Shop, Temporary, Layout................................................................................................................................. F2-1
Short Term Storage ......................................................................................................................................... 4-2b
Short Term Storage for Depreservation of Installed Reciprocating Engines ....................................................4-10b
Short Term Storage for Preservation of Installed Reciprocating Engines.......................................................... 4-5b
Shoulder Harness Webbing Retarder Spring Installation ................................................................................ F11-7
Signaling Devices ...........................................................................................................................................11-18
Cleaning . ............................................................................................................................................11-18c
Inspection ............................................................................................................................................11-18a
Repair..................................................................................................................................................11-18b
Signaling Devices References........................................................................................................................ T11-7
Significance of Metal Particles .......................................................................................................................... 7-5f
Simplex Fuel Nozzle ...................................................................................................................................... F8-17
Single Entrance Inlet Duct (Axial-Flow Engine) ................................................................................................ F8-3
Ski Inspection..................................................................................................................................................9-10a
Ski Maintenance .............................................................................................................................................. 9-10

Index 22
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VOLUME 1

Subject Paragraph
Figure, Table
Number

S -- Continued

Ski Inspection ........................................................................................................................................9-10a

Ski Repair .............................................................................................................................................9-10b
Ski Repair .......................................................................................................................................................9-10b
Snap Hook Safety Guard Drill Details ............................................................................................................ F11-9
Snap Hook Safety Pin Construction Details ................................................................................................. F11-10
Snap Hook Secured to Safety Pin Retaining Cord ........................................................................................ F11-11
Solid Color Band System . ...................................................................................................................... 6-3d, F6-2
Special Repair Equipment and Tools...............................................................................................................11-11
Special Reusable Containers .........................................................................................................................4-12a
Speed-Sensitive Control................................................................................................................................. F8-11
Speed-Set Governor ...................................................................................................................................... F8-12
Spray Nozzles, Types of ............................................................................................................................... F10-1
Spray Painting ...........................................................................................................................................2-2j, 2-3j
Standard Visual Signals .................................................................................................................................. 3-3d
Static Grounding Cable Assembly, Fabncation of............................................................................................. F3-1
Static Grounding of Aircraft ...................................................................................................................... 2-6g, 3-4
Earth Ground Testing...............................................................................................................................3-4c
Earth Grounds . ...................................................................................................................................... 3-4b
Fabrication of Ground Cable................................................................................................................... 3-4d
Ground Receptacle Critena .................................................................................................................... 3-4e
Ground Receptacle Testing ..................................................................................................................... 3-4f
Grounding Requirements ........................................................................................................................ 3-4a
Static Grounding of Ground Support Equipment .............................................................................................. 2-6h
Storage and Handling, Pyrotechnics ................................................................................................................ 12-7
Storage Area Criteria ...................................................................................................................................... 11-9
Storage Categories ............................................................................................................................................ 4-2
Storage in Aircraft, Flotation Equipment........................................................................................................11-16b
Storage of Compressed Gases......................................................................................................................... 2-2p
Storage of Elastic Shock Cords .......................................................................................................................9-26g
Storage of High-Value Items . .......................................................................................................................... 2-2q
Storage of Shop Stocks, Repair Parts, and Consumable Materials................................................................... 2-2o
Stored Aircraft, Inspection of .............................................................................................................................. 4-6
Stored Aircraft, Maintenance of ......................................................................................................................... 4-7
Struts, Shock...................................................................................................................................................... 9-5
Sudden Engine Stoppage................................................................................................................................. 7-5b
Sudden Reduction In Engine RPM ...................................................................................................................7-5c

Index 23
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VOLUME 1

Subject Paragraph
Figure, Table
Number

S - Continued

Survival Kits.......................................................................................................................................11-13a, 11-15

Cleaning ..............................................................................................................................................11-15c
Inspection ...........................................................................................................................................11-15a
Repair .................................................................................................................................................11-15b
Survival Kit References.................................................................................................................................. T11-3
Survival Vests...............................................................................................................................................11-13b
System, Exhaust . .............................................................................................................................................. 7-8
Systems, Brake ................................................................................................................................................. 9-7
Systems, Deicing . ........................................................................................................................................... 9-14
Systems, Hoist . ............................................................................................................................................... 9-16
Systems, Landing Gear ..................................................................................................................................... 9-2
Systems, Oxygen ............................................................................................................................................ 9-17

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
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VOLUME 1

Subject Paragraph
Figure, Table
Number

T - Continued

Typical Shop Layout . ............................................................................................................................. 2-3a

Temporary Shop Layout................................................................................................................................... F2-1
Temporary Storage of Life Support Equipment ...............................................................................................11-13
Flotation Equipment.............................................................................................................................11-13c
New Equipment ................................................................................................................................... 11-13f
Oxygen Equipment ..............................................................................................................................11-13e
Pyrotechnics ......................................................................................................................................11-1 3d
Survival Kits .......................................................................................................................................11-13a
Survival Vests ....................................................................................................................................11-1 3b
Test Equipment ............................................................................................................................................ T.11-1
Test Flights and Maintenance Operational Checks ........................................................................................... 3-12
Carbon Monoxide Detection ..................................................................................................................3-12c
Maintenance Operation Checks ............................................................................................................3-12b
Test Flight Safety .................................................................................................................................3-12a
Test Flight Safety............................................................................................................................................3-12a
Test Loads (Elastic Shock Cords)..................................................................................................................... T9-7
Test, Cable ...................................................................................................................................................... T9-3
Testing of Fire Detection Systems................................................................................................................... 9-15f
Testing of Static Ground Points......................................................................................................................... 2-6f
Theory, Reciprocating Engines .......................................................................................................................... 7-3
Thermocouple Maintenance ............................................................................................................................ 8-6m
Tiedown Equipment, Cargo .............................................................................................................................. 9-24
Timing Marks, Built-In ................................................................................................................................... F7-17
Tires and Tubes ................................................................................................................................................. 9-9
Balance ..................................................................................................................................................9-9c
Cleaning ................................................................................................................................................ 9-9a
Inspection . ............................................................................................................................................. 9-9b
Installation ............................................................................................................................................. 9-9e
Valve Cores............................................................................................................................................ 9-9d
Tools and Special Repair Equipment ..............................................................................................................11-11
Top Center Indicator ..................................................................................................................................... F7-15
Towing 3-3b
Training Equipment ........................................................................................................................................11-12
Troop Seats ....................................................................................................................................................9-20a
Tropic Maintenance.......................................................................................................................................... 10-4
Inspection and Preventive Maintenance ................................................................................................10-4a
Parts and Fabrics Affected by Moisture and Fungi ................................................................................10-4b
Troubleshooting of Fire Detection Systems .......................................................................................... 9-15d, T9-5
Troubleshooting of Landing Gear Systems ........................................................................................................ 9-4
Troubleshooting Pneumatic Deicing Systems................................................................................................... T9-4

Index 25
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VOLUME 1

Subject Paragraph
Figure, Table
Number

T - Continued

Tube, Relief, System........................................................................................................................................ 9-18

Tubes and Tires ................................................................................................................................................ 9-9
Turbine and Exhaust Maintenance ....................................................................................................................8-6j
Turbine Assembly Elements........................................................................................................................... F8-10
Turbine Bearing Maintenance........................................................................................................................... 8-61
Turbine Discharge Pressure Pickup Line ....................................................................................................... F8-19
Turbine Engine Analysis Ground Testing ......................................................................................................... 8-6d
Turbine Engine Design and Construction............................................................................................................ 8-5
Accessory Section ................................................................................................................................. 8-5h
Combustion Section................................................................................................................................ 8-5e
Compressor Section ...............................................................................................................................8-5c
Diffuser Section ...................................................................................................................................... 8-5d
Exhaust Section...................................................................................................................................... 8-5g
Fuel Systems...........................................................................................................................................8-5k
Governors and Fuel Controls .................................................................................................................. 8-51
Ignition Systems . .....................................................................................................................................8-5j
Inlet Ducts . ............................................................................................................................................ 8-5a
Particle Separators ................................................................................................................................. 8-5b
Turbine Section ....................................................................................................................................... 8-5f
Turbine Engine Inspection and Maintenance ..................................................................................................... 8-6
Cold Section Maintenance . .................................................................................................................... 8-6g
Compressor Blade Inspection and Repair .............................................................................................. 8-6h
Compressor Cleaning .............................................................................................................................. 8-6f
Foreign Object Damage Inspection......................................................................................................... 8-6e
Fuel System . ......................................................................................................................................... 8-60
General Procedures................................................................................................................................ 8-6a
Health Indication Test ............................................................................................................................. 8-6b
Hot Section Maintenance..........................................................................................................................8-6i
Hot Start Inspection . ...............................................................................................................................8-6c
Ignition System Maintenance ...................................................................................................................8-6k
Oil Consumption . ................................................................................................................................... 8-6n
Thermocouple Maintenance .................................................................................................................. 8-6m
Turbine and Exhaust Maintenance ....................................................................................................................8-6J
Turbine Bearing Maintenance........................................................................................................................... 8-61
Turbine Engine Analysis Ground Testing.......................................................................................................... 8-6d
Turbine Engine Maintenance, General .............................................................................................................. 8-1
Turbine Engine Mounts ..................................................................................................................................... 8-9
Turbine Engine Precautions ............................................................................................................................... 8-4
Turbine Engine Theory....................................................................................................................................... 8-3
Turbine Engines ..............................................................................................................................................3-10c
Turbine Engines, Preservation and Depreservation of ..................................................................................... 8-10
Turbine Engines, Removal and Installation of .................................................................................................. 8-11

Index 26
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VOLUME 1

Subject Paragraph
Figure, Table
Number

T - Continued

Turbine Section ................................................................................................................................................ 8-5f

Turbocharger and Supercharger Maintenance.................................................................................................. 7-7b
Types (of Reciprocating Engines)..................................................................................................................... 7-2a
Types (of Turbine Engines) ............................................................................................................................. 8-2a
Types and Designations, Engine ....................................................................................................................... 7-2
Types and Designations, Engine ....................................................................................................................... 8-2
Types of Bearing.............................................................................................................................................. F7-8
Types of Decals ................................................................................................................................................. 6-2
Types of Environmental Control Systems........................................................................................................9-13a
Types of Fire Detection Systems.....................................................................................................................9-15b
Types of Flight Controls ..................................................................................................................................9-12a
Control Cables.......................................................................................................................................9-12e
Control System Components ................................................................................................................ 9-12f
Flight Control Operating Systems ..........................................................................................................9-12d
Inspection of Flight Controls .................................................................................................................9-12b
Repair of Flight Controls .......................................................................................................................9-12c
Types ....................................................................................................................................................9-12a
Types of Retractable Landing Gear Systems.................................................................................................... 9-3a
Types of Spray Nozzles ................................................................................................................................. F10-1
Types of Valves ............................................................................................................................................ F7-14
Types of Vibration Isolators ............................................................................................................................9-25a
Typical Compressor Blade Repair Limits ....................................................................................................... F8-18
Typical Igniter Plugs....................................................................................................................................... F8-14
Typical Layout .........................................................................................................................................2-2a, 2-3a

Unserviceable (Repairable) Tag-Materiel (DD Form 1577-2) (Green) ............................................................ F11-4

Upholstered Seats...........................................................................................................................................9-20c
Usage of Drip Pans . ........................................................................................................................................ 2-6d

Valve Cores .................................................................................................................................................... 9-9d

Valve Types .................................................................................................................................................. F7-14
Valves 7-4g
Vibration Isolators ............................................................................................................................................ 9-25
Inspection of Vibration Isolators .............................................................................................................9-25c
Installation of Vibration Isolators ............................................................................................................9-25b
Types of Vibration Isolators....................................................................................................................9-25a

Index 27
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VOLUME 1

Subject Paragraph
Figure, Table
Number

V - Continued

Vibrator, Induction.......................................................................................................................................... F7-19

Vinyl Film Decals ............................................................................................................................................. 6-2b

Wheel Cleaning . ............................................................................................................................................. 9-8a

Wheel Inspection ............................................................................................................................................ 9-8b
Wheel Maintenance ........................................................................................................................................... 9-8
Repair of Wheels.....................................................................................................................................9-8c
Replacement Criteria for Wheels ............................................................................................................ 9-8d
Wheel Cleaning ...................................................................................................................................... 9-8a
Wheel Inspection .................................................................................................................................... 9-8b
Windshield Wiper System ................................................................................................................................ 9-19
Adjustment of Windshield Wiper Systems ............................................................................................9-19b
Maintenance of Windshield Wiper Systems . .........................................................................................9-19a
Wiper, Windshield, System .............................................................................................................................. 9-19
Work Area Criteria .......................................................................................................................................... 11-8

Index 28
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VOLUME 2

Subject Paragraph
Figure, Table
Number

Absorbing Units, Dampening and .................................................................................................................... 4-19

Acceptable and Unacceptable Tube Bends ..................................................................................................... F4-5
Accumulator, Cylindrical .............................................................................................................................. F4-118
Accumulator, Operation .................................................................................................................................4-15b
Accumulator, Spherical ............................................................................................................................... F4-119
Accumulators .................................................................................................................................................. 4-15
Accumulator Operation .........................................................................................................................4-15b
Maintenance .........................................................................................................................................4-15c
Types ...................................................................................................................................................4-15a
Actuating Cylinder, Double-Action (Extension) ............................................................................................ F4-134
Actuating Cylinder, Double-Action (Retraction) ............................................................................................ F4-135
Actuating Cylinder, Single-Action ................................................................................................................ F4-133
Actuating Cylinders (Actuators) ......................................................................................................................4-16g
Actuators, Troubleshooting ............................................................................................................................ T4-42
Adjuster Valve, Brake .................................................................................................................................. F4-157
After Swage Dimensions ............................................................................................................................... F4-86
Air Cylinder, Spherical ................................................................................................................................... F4-95
Air Cylinders, Hydraulic Reservoirs ...............................................................................................................4-11 h
Air Filters .......................................................................................................................................................4-12e
Air Valve Cores, High-Pressure ................................................................................................................... F4-174
Aircraft Brake Systems .................................................................................................................................... 4-18
Brake Deboosters .................................................................................................................................4-18c
Helicopter Rotor Brake Systems ...........................................................................................................4-18d
Maintenance of Brake Systems .............................................................................................................4-18e
Wheel Brake Assemblies ......................................................................................................................4-18b
Wheel Brake Systems ..........................................................................................................................4-18a
Alignment, Tube and Fitting .......................................................................................................................... F4-14
Alignment, Tubing ......................................................................................................................................... F4-20
Aluminum Protective Dust Plug and Moisture Seal ........................................................................................ F4-54
AN Flared Fitting Identification ........................................................................................................................ T4-9
Application of Mechanical Advantage .............................................................................................................. F2-5
Application of Swaged Tubing Repairs ............................................................................................................ 4-9a
Applications of MIL-H-83282 ...............................................................................................................4-21c, T4-43
Aromatic And Heat-Resistant Hose, MIL-H-6000 ........................................................................................... F4-35
Aromatic, Flame, and Oil-Resistant Hose, MIL-H-7938 ................................................................................. F4-36
Aromatic-Resistant Hose, Flame and MIL-H-8794 ......................................................................................... F4-34
Aromatic-Resistant Hose, Nonself-Sealing, MIL-H-5593 ................................................................................ F4-37
Aromatic-Resistant Hose, Self-Sealing, MIL-H-7061 ..................................................................................... F4-38
Assembly Clearance, Nipple ......................................................................................................................... F4-47
Assembly of High-Pressure Tetrafluoroethylene (Teflon)
Hose Assemblies .....................................................................................................................................4-5j
Assembly of Medium-and Low-Pressure Hose Assemblies ............................................................................ F4-43

Index 29
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VOLUME 2

Subject Paragraph
Figure, Table
Number

A - Continued

Assembly of Medium - Pressure Tetrafluoroethylene (Teflon)

Hose Assemblies ................................................................................................................................... 4-51
Assembly Surface, Nipple ............................................................................................................................. F4-46
Assembly, V-Ring Packings in Various Positions of ....................................................................................... F4-71

Backup Ring Installation, Double ................................................................................................................... F4-76

Backup Ring Installation, Single ..................................................................................................................... F4-75
Backup Ring, Teflon, Installing ...................................................................................................................... F4-73
Backup Ring, Teflon, Reversing Spiral of ...................................................................................................... F4-74
Backup Ring, Teflon, Stretching .................................................................................................................... F4-72
Backup Rings .................................................................................................................................................... 4-8
Identification .......................................................................................................................................... 4-8a
Installation ............................................................................................................................................44-8b
Backup Rings, Leather, Installation of ........................................................................................................... F4-77
Baffles and Fins .............................................................................................................................................4-11c
Baffles, Fins, and Finger Strainer, Reservoir with .......................................................................................... F4-91
Ball Size, Inspection, Chart ........................................................................................................................... T4-13
Band Identification, Solid Color ....................................................................................................................... F4-2
Band Location, Tube Insertion ....................................................................................................................... T4-37
Basic Swage Tool Assembly Showing Lower Die Block
Assembly and Position of Fitting Locator ............................................................................................. F4-84
Bead Dimensions .......................................................................................................................................... F4-13
Beaded Tubing Joints ...................................................................................................................................... 4-2h
Beading Large Tubing ................................................................................................................................... F4-11
Bend Radii for Conduit and Fluid Lines ........................................................................................................... T4-1
Bend Radii of Hose for Fuel, Oil, and Coolant Systems ................................................................................. T4-32
Bending Machine, Bending Tube with .............................................................................................................. F4-4
Bending Tube with Bending Machine ............................................................................................................... F4-4
Bending Tubing................................................................................................................................................ 4-2e
Bends, Installation of Flexible Hose ..................................................................................................................4-2c
Bent-Axis Constant-Volume Pump .............................................................................................................. F4-101
Bleeding Brake Hydraulic System ............................................................................................................... F4-160
Blocked Flowing Hydraulic Fuse .................................................................................................................. F4-142
Boss Installation, Torque Valves for ................................................................................................................ T4-7
Brake Assembly, Disc ................................................................................................................................. F4-151
Brake Assembly, Disc, Cross Section .......................................................................................................... F4-152
Brake Bleeding, Gravity Method for ............................................................................................................. F4-161
Brake Hydraulic System, Bleeding .............................................................................................................. F4-160
Brake System, Rotor Blade ......................................................................................................................... F4-159
Brake Systems, Aircraft ................................................................................................................................... 4-18

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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

Chafing, Installation of Flexible Hose ............................................................................................................... 4-6f

Check Valve, Orifice ................................................................................................................................... F4-128
Check Valve, Simple ................................................................................................................................... F4-127
Check Valves .................................................................................................................................................4-16c
Checking Swaged Joint with D9892 Inspection Gauge .................................................................................. F4-85
Chipless Cutter............................................................................................................................................... F4-81
Clamp Sizes, Support (For Use with MIL-H-38360 Hose of Teflon) ................................................................ T4-29
Cleaning (of 55-Gallon Drums) ........................................................................................................................ 3-3b
Cleaning Tubing............................................................................................................................................... 4-2b
Clogged Filters In Differential Pressure Indicator ......................................................................................... F4-100
Clogged Fluid Filter ....................................................................................................................................... F4-98
Closed Center Hydraulic System ....................................................................................................................4-17b
Combination Bulkhead and Universal Fitting Assembly ................................................................................. F4-27
Complex Shock Strut (Metering Pin) . .......................................................................................................... F4-171
Complex Shock Strut (Plunger) ................................................................................................................... F4-172
Components, MS Fitting and .......................................................................................................................... F4-17
Compound Master Cylinder ......................................................................................................................... F4-149
Computation of Force, Area, and Pressure ...................................................................................................... 2-1b
Computation of Volume, Area, and Length of Stroke ........................................................................................2-1c
Computing Force, Pressure, and Area ............................................................................................................. F2-1
Computing Volume, Length, and Area ............................................................................................................. F2-2
Conduit and Fluid Lines, Bend Radii for ........................................................................................................... T4-1
Connections, Tubing-to-Tubing ..................................................................................................................... F4-22
Constant-Volume Pump, Bent-Axis ............................................................................................................. F4-101
Constant Volume Pump Foot Valve ............................................................................................................ F4-104
Constant Volume Pump (Piston Installation) ................................................................................................ F4-102
Constant Volume Pump (Piston Operation) ................................................................................................. F4-103
Consumable Materials........................................................................................................................................ 1-3
Contamination, Fluid .......................................................................................................................................... 2-4
Contamination Prevention ................................................................................................................................2-4c
Control Units, Flow .......................................................................................................................................... 4-16
Control Valve, Power Brake (Brake Applied) ............................................................................................... F4-152
Control Valve, Power Brake (Brake Released) ............................................................................................ F4-153
Control Valve, Solenoid-Actuated (De-energized) ....................................................................................... F4-126
Control Valve, Solenoid-Actuated (Energized) ............................................................................................. F4-125

Index 31
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VOLUME 2

Subject Paragraph
Figure, Table
Number

C - Continued

Control Valves ...............................................................................................................................................4-16b

Conversion of Aircraft to Fire-Resistant Hydraulic Fluid ................................................................................... 4-21
Applications of MIL-H-83282 .................................................................................................................4-21c
Conversion Procedures .........................................................................................................................4-21e
Hydraulic Fluid MIL-H-5606 ..................................................................................................................4-21a
Hydraulic Fluid MIL-H-83282 ................................................................................................................4-21b
Non-Applicability of MIL-H-83282 .........................................................................................................4-21d
Operating Temperature Limitations ....................................................................................................... 4-21f
Conversion Procedures (MIL-H-5606 to MIL-H-83282) ...................................................................................4-21e
Coupling Bulge, Low-and Medium-Pressure Hose Assemblies ...................................................................... F4-44
Coupling Bulge, MIL-H-7061 Hose Assembly ................................................................................................ T4-30
Couplings, Quick-Disconnect ........................................................................................................................... 4-10
Cross Section, Piston Damper ..................................................................................................................... F4-163
Cross Section, Vane Damper ...................................................................................................................... F4-168
Cutoff Factor, MIL-H-8788 or MIL-H-8790 (in Inches) .................................................................................... T4-15
Cutoff Factors, MIL-H-38360 Hose (in Inches)................................................................................................ T4-27
Cutoff Factors, Teflon Hose (in Inches) .......................................................................................................... T4-22
Cutter, Chipless ............................................................................................................................................. F4-81
Cutting Flexible Hose, Knife for ..................................................................................................................... F4-39
Cutting, Marking Tube Prior to ....................................................................................................................... F4-46
Cutting, Tube with Tube Cutter ........................................................................................................................ F4-3
Cutting Tubing ................................................................................................................................................. 4-2d

Damaged Fittings .......................................................................................................................................... F4-29

Dampening and Absorbing Units ..................................................................................................................... 4-19
Hydraulic Damper ..........................................................................................................................................4-19a
Liquid Springs ...................................................................................................................................4-19c, F4-174
Shock Struts ...................................................................................................................................................4-19b
Damper, Piston ........................................................................................................................................... F4-162
Damper, Vane ............................................................................................................................................. F4-166
Data Drawing, Tube Bend ............................................................................................................................... F4-6
Detecting Fluid Contamination ........................................................................................................................ 2-4a
Determining Hose Assembly Length .............................................................................................................. F4-40
Determining Tube Thickness and Burst Pressure .......................................................................................... T4-11
Devices for Regulating Pressure ..................................................................................................................... 4-14
Pressure Gauges ...........................................................................................................................................4-14a
Pressure Reducing Valves .............................................................................................................................4-14d
Pressure Relief Valves ...................................................................................................................................4-14c
Pressure Switches ..........................................................................................................................................4-14b

Index 32
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VOLUME 2

Subject Paragraph
Figure, Table
Number

D - Continued

Differential Pressure Indicator (Clogged Filters) ............................................................................................ F4-99

Differential Pressure Indicator (Normal Flow) .............................................................................................. F4-100
Dimensions, After Swage .............................................................................................................................. F4-86
Dimensions, Beading .................................................................................................................................... F4-13
Dimensions for Double-Flared Tubing ............................................................................................................. F4-8
Dimensions for Single-Flared Tubing .............................................................................................................. F4-7
Disc Brake Assembly .................................................................................................................................. F4-154
Disc Brake Assembly Cross Section ............................................................................................................ F4-155
Distance Between Supports for Fluid Tubing, Maximum ................................................................................ T4-12
Double Backup Ring Installation .................................................................................................................... F4-76
Double Lap Flare, Tubing with ....................................................................................................................... F4-11
Double-Action Actuating Cylinder (Extension) ............................................................................................. F4-134
Double-Action Actuating Cylinder (Retraction) ............................................................................................. F4-135
Double-Action Hand Pump .......................................................................................................................... F4-111
Double-Flared Tubing, Dimensions for . ........................................................................................................... F4-8
Dual Internal O-Ring Removal ...................................................................................................................... F4-64
Dual Parking Brake Valve ........................................................................................................................... F4-156
Dual Parking Brake Valve (Off) .......................................................................................................... F4-157
Dual Parking Brake Valve (On) ................................................................................................................... F4-158
Dust Cap (AN-SAE Function), Plastic Protective ........................................................................................... F4-56
Dust Cap, Plastic Protective .......................................................................................................................... F4-55
Dust Cap, Steel Protective ............................................................................................................................ F4-53
Dust Plug and Moisture Seal, Aluminum Protective ....................................................................................... F4-54
Dust Plug and Moisture Seal (AN-SAE Threaded) Plastic Protective ............................................................. F4-51
Dust Plug and Moisture Seal, Steel Protective .............................................................................................. F4-52

Ease of Installation (of Hydraulic Systems) ......................................................................................................2-2c

Ease of Operation (of Hydraulic Systems) ....................................................................................................... 2-2b
Efficiency (of Hydraulic Systems) .................................................................................................................... 2-2a
Elliptical Rings ..................................................................................................................................... 4-7b, F4-70
External O-Ring Installation ........................................................................................................................... F4-69
External O-Ring Removal (Spoon-Type Tools) .............................................................................................. F4-65
External O-Ring Removal (Wedge-Type Tools) ............................................................................................ F4-66

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

Index 33
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VOLUME 2

Subject Paragraph
Figure, Table
Number

F - Continued

Field Fabrication of High-Pressure Hose Assemblies .................................................................................... F4-41

Filter Element Bypass Valve, Hydraulic Reservoirs ........................................................................................ 4-11f
Filter Elements, Hydraulic Reservoirs .............................................................................................................4-11e
Filter Elements, Hydraulic Systems Filters .....................................................................................................4-12c
Filter Elements, Reservoir with ...................................................................................................................... F4-94
Filter, Fluid, Assembly ................................................................................................................................... F4-96
Filters, Hydraulic System ................................................................................................................................ 4-12
Finger Strainers, Hydraulic Reservoirs ..........................................................................................................4-11 d
Fingertight-Plus Turns Methods, Hose Clamp Tightening .............................................................................. T4-10
Fingertight-Plus Turns Methods, Hose Clamp Tightening, Beaded Tubing ....................................................... F4-3
Fitting Dimensions After Swaging .................................................................................................................. T4-39
Fittings 4-3
Flared Fittings ................................................................................................................................................. 4-39
Flareless Fittings ............................................................................................................................................. 4-3a
Oxygen System Tapered Pipe Thread ............................................................................................................. 4-3b
Rosan Fluid Fittings ......................................................................................................................................... 4-3f
Straight Pipe Thread ........................................................................................................................................4-3c
Universal Fittings AN 832, AN 833, and AN 834, High Pressure .................................................................. 4-3e9A
Universal Fittings AN 832, AN 833, and AN 834, Low Pressure ....................................................................... 4-3d
Fittings, Damaged ......................................................................................................................................... F4-29
Fittings, Tubing ............................................................................................................................................. F4-15
Flame and Aromatic Resistant Hose, MIL-H-8794 ......................................................................................... F4-34
Flame, Aromatic, and Oil-Resistant Hose, MIL-H-7938 ................................................................................. F4-36
Flared Fitting Identification, AN ....................................................................................................................... T4-9
Flared Fittings ................................................................................................................................................. 4-3g
Flareless Fitting Installation, Bulkhead ................................................................................................. F4-24, T4-4
Flareless Fittings ............................................................................................................................................. 4-3a
Flareless Fittings, MS .................................................................................................................................... F4-18
Flaring Tubing................................................................................................................................................... 4-2f
Flexible Hose Assemblies
Assembly of High-Pressure Tetrafluoroethylene (Teflon)
Hose Assemblies ...............................................................................................................................4-5j
Assembly of Medium-Pressure Tetrafluoroethylene (Teflon)
Hose Assemblies ...............................................................................................................................4-5i
Identification of Flexible Hose ................................................................................................................ 4-5a
Identification Tags for Field Fabricated Hose Assemblies ........................................................... 4-5g, F4-42
Instructions for Assembly of High-Pressure (3000 psi)
Hose Assemblies MS28759 and MS28762 ...................................................................................... 4-5e
Instructions for Assembly of Medium-Pressure, MS28741, and
Low-Pressure, AN6270, Hose Assemblies ....................................................................................... 4-5h
Instructions for Repair of Flexible Rubber Hose ..................................................................................... 4-5d
Proof Testing of Flexible Hose Assemblies ............................................................................................. 4-5f

Index 34
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VOLUME XX

Subject Paragraph
Figure, Table
Number

F - Continued

Replacement of Flexible Hose ................................................................................................................4-5c

Self-Sealing Hose for Aromatic Fuel, MIL-H-7061 ...................................................................................4-5k
Storage of Hose and Hose Assemblies .................................................................................................. 4-5b
Use of Dust Plugs, Dust Caps, and Moisture Seals ................................................................................ 4-51
Flexible Hose, Installation of ............................................................................................................................. 4-6
Floating Piston Shock Strut ......................................................................................................................... F4-173
Floating Piston Shuttle Valve ...................................................................................................................... F4-132
Flow Control Units ........................................................................................................................................... 4-16
Actuating Cylinders (Actuators) .............................................................................................................4-16g
Check Valves .......................................................................................................................................4-16c
Control Valves ......................................................................................................................................4-16b
Hydraulic Fuses .....................................................................................................................................4-16k
Hydraulic Servos ......................................................................................................................4-16i, F4-138
Irreversible Valves.....................................................................................................................4-16j, F4-139
Maintenance of Hydraulic Flow Control Units ........................................................................................4-161
Priority Valves ......................................................................................................................................4-16e
Rachet Valve ........................................................................................................................................4-16h
Selector Valves ....................................................................................................................................4-16a
Sequence Valves ..................................................................................................................................4-16d
Shuttle Valves ...................................................................................................................................... 4-16f
Fluid Contamination .......................................................................................................................................... 2-4
Contamination Prevention ......................................................................................................................2-4c
Detecting Fluid Contamination ............................................................................................................... 2-4a
System Flushing .................................................................................................................................... 2-4b
Fluid Dispenser, Hydraulic ............................................................................................................................... F3-6
Fluid Filter Assembly ..................................................................................................................................... F4-96
Fluid Filter (Clogged) .................................................................................................................................... F4-98
Fluid Filter (Normal Flow) .............................................................................................................................. F4-97
Fluid-Pressurized Reservoir (Pressurized) ..................................................................................................... F4-93
Fluid-Pressurized Reservoir (Unpressurized) ................................................................................................. F4-92
Full Flow in Hydraulic Fuse .......................................................................................................................... F4-141
Fuse Assembly, Hydraulic ........................................................................................................................... F4-140

Gasket Installation, MS Fitting ....................................................................................................................... F4-19

Gauge, Pressure ......................................................................................................................................... F4-114
General Hydraulic Maintenance Practices ......................................................................................................... 4-1
General Shop Rules (Hydraulic Shop) ............................................................................................................... 3-1
Responsibility .........................................................................................................................................3-1la
Shop Housekeeping ............................................................................................................................... 3-1b
Shop Safety ...........................................................................................................................................3-1id

Index 35
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VOLUME 2

Subject Paragraph
Figure, Table
Number
G - Continued

Shop Tools and Materials .......................................................................................................................3-1c

Gravity Method for Brake Bleeding .............................................................................................................. F4-161

Hand Pump Test Circuit .............................................................................................................................. F4-112

Hand Pumps ..................................................................................................................................................4-13c
Handling of Hydraulic Fluid in 55-Gallon Drums ................................................................................................ 3-3
Cleaning ................................................................................................................................................ 3-3b
Storage .................................................................................................................................................. 3-3a
Transporting Fluid to Aircraft .................................................................................................................. 3-3d
Withdrawing Fluid from Drum .................................................................................................................3-3c
Helicopter Rotor Brake Systems .....................................................................................................................4-18d
High-Pressure Air Valve Cores .................................................................................................................... F4-174
High-Pressure Hose Assemblies, Field Fabrication of ................................................................................... F4-41
High-Pressure Teflon Hose, MIL-H-38360, Field Assembly of ....................................................................... F4-50
High-Pressure Tubing, Repairing.................................................................................................................... F4-33
Hose Assemblies, Flexible ................................................................................................................................ 4-5
Hose Assembly Length, Determining ............................................................................................................. F4-42
Hose Clamp, In Installation of Flexible Hose ................................................................................................... 4-61
Hose Clamp Tightening, Fingertight-Plus Tums Method ................................................................................ T4-10
Hose Clamp Tightening, Fingertight-Plus Tums Method, Beaded Tubing ........................................................ T4-3
Hose Clamp, Tightening, With Socket ........................................................................................................... F4-32
Hose Connections to Engines, Installation of Flexible Hose ............................................................................. 4-6h
Hose Cutoff Factor, MIL-H-8788 or MIL-H-8790 Hose (in Inches) .................................................................. T4-14
Hose Cutoff Factors, MIL-H-38360 Hose (in Inches) ...................................................................................... T4-27
Hose End Fitting and Coupling Nut Installation Torque In Inch-Pounds ......................................................... T4-34
Hose Installation, Flexible Hose ...................................................................................................................... 4-5b
Hose Line Installation Aids for All Types of Hoses ......................................................................................... F4-57
Hose Markings, and Installation of Flexible Hose ..............................................................................................4-6j
Hose, MIL-F-27272, Tetrafluoroethylene (in Inches) ...................................................................................... T4-21
Hose, MIL-H-38360, Tetrafluoroethylene (in Inches) ...................................................................................... T4-27
Hose Restrictions, Installation of Flexible Hose ............................................................................................... 4-6d
Hydraulic Dampers .........................................................................................................................................4-19a
Hydraulic Filler and Bleeder Unit ..................................................................................................................... 3-2a
Hydraulic Fluid (Fire Resistant), Conversion of Aircraft to ............................................................................... 4-21
Hydraulic Fluid in Army Aircraft, Types ............................................................................................................. 2-3
Hydraulic Fluid in 55-Gallon Drums, Handling of ............................................................................................... 3-3
Hydraulic Fluid MIL-H-5606 ............................................................................................................................4-21a
Hydraulic Fluid MIL-H-83282 ..........................................................................................................................4-21b
Hydraulic Fuse Assembly ............................................................................................................................ F4-140
Hydraulic Fuse (Blocked Flow) .................................................................................................................... F4-142
Hydraulic Fuse (Full Flow) ........................................................................................................................... F4-141

Index 36
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VOLUME 2

Subject Paragraph
Figure, Table
Number

H - Continued

Hydraulic Hose Testing Unit ............................................................................................................................ 3-2d

Hydraulic Hose Testing Unit, Typical ............................................................................................................... F3-3
Hydraulic Maintenance Practices, General ........................................................................................................ 4-1
Hydraulic Motor ........................................................................................................................................... F4-113
Hydraulic Motors ............................................................................................................................................4-13d
Hydraulic Packings and O-Rings ....................................................................................................................... 4-7
Elliptical Rings ............................................................................................................................ 4-7b, F4-70
O-Rings ................................................................................................................................................. 4-7a
V-Ring Packings .....................................................................................................................................4-7c
Hydraulic Reservoirs ....................................................................................................................................... 4-11
Air Cylinders ........................................................................................................................................4-11 h
Baffles and Fins ....................................................................................................................................4-11c
Filter Element Bypass Valve ................................................................................................................. 4-11f
Filter Elements ....................................................................................................................................4-11 e
Finger Strainers ...................................................................................................................................4-11 d
Maintenance of Reservoirs ...................................................................................................................4-111
Standpipes ............................................................................................................................................4-11g
Theory of Operation .............................................................................................................................4-11 b
Types of Hydraulic Reservoirs Used in Hydraulic Systems ...................................................................4-11 a
Hydraulic Servos................................................................................................................................4-161, F4-138
Hydraulic System Filler and Bleeder, Typical .................................................................................................. F3-1
Hydraulic System Filters ................................................................................................................................. 4-12
Air Filters ..............................................................................................................................................4-12e
Filter Elements .....................................................................................................................................4-12c
Servicing Filters .................................................................................................................................... 4-12f
Theory of Operation ..............................................................................................................................4-12b
Two-Stage Fluid Filters .........................................................................................................................4-12d
Uses of Filters In Hydraulic Systems .....................................................................................................4-12a
Hydraulic System, Open-Center (Valve Closed) .......................................................................................... F4-143
Hydraulic System, Open-Center (Valve Open) ............................................................................................ F4-144
Hydraulic Systems In Army Aircraft, Use of ....................................................................................................... 2-2
Hydraulic Test Stand, Fixed ............................................................................................................................ 3-2b
Hydraulic Test Stand, Portable, Gasoline Engine-Driven ..................................................................................3-2c
Hydraulic Test Stand, Typical Gasoline Engine-Driven .................................................................................... F3-2

Identification of Backup Rings ......................................................................................................................... 4-8a

Identification of Flexible Hose ......................................................................................................................... 4-5a
Identification of O-Rings ................................................................................................................................ F4-63
Identification Tags for Field Fabricated Hose Assemblies ..................................................................... 4-5g, F4-42
Identification Tape, Printed-Symbol ................................................................................................................. F4-1
In-Line Cam-Operated Selector Valve (Actuator Extending) ........................................................................ F4-123

Index 37
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VOLUME 2

Subject Paragraph
Figure, Table
Number

I - Continued

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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VOLUME 2

Subject Paragraph
Figure, Table
Number
I - Continued

Internal O-Ring Removal (Push-Type Extractor) ........................................................................................... F4-63

Internal O-Ring Removal (Wedge-Type Extractor) ........................................................................................ F4-62
Introduction
Consumable Materials ............................................................................................................................. 1-3
Purpose .................................................................................................................................................... 1-1
Scope ...................................................................................................................................................... 1-2
Irreversible Valves .............................................................................................................................4-16j, F4-139

Jamnut (AN924) Used on Fittings, Torque Values for ...................................................................................... T4-8

Kellogg Stroke Reduction Pump Assembly................................................................................................... F4-109

Kellogg Stroke Reduction Pump (Reduced Output) ..................................................................................... F4-110
Knife for Cutting Flexible Hose ...................................................................................................................... F4-39

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

Index 39
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VOLUME 2

Subject Paragraph
Figure, Table
Number
M - Continued

Hydraulic Test Stand, Fixed ................................................................................................................... 3-2b

Hydraulic Test Stand, Portable, Gasoline Engine-Driven ........................................................................3-2c
Master Gauge Unit .................................................................................................................................. 3-2f
Tube Bending Machine, Hand-Operated ................................................................................................ 3-2e
Marking MS Fittings ...................................................................................................................................... F4-23
Marking, Tube End ........................................................................................................................................ F4-83
Marking with Permaswage Marking Tool, D9862-S, M, and L ........................................................................ F4-82
Master Cylinder, Compound ........................................................................................................................ F4-149
Master Cylinder, Power-Boost (Brake Applied) ............................................................................................ F4-150
Master Cylinder, Power-Boost (Brake Released) ......................................................................................... F4-151
Master Cylinder, Simple .............................................................................................................................. F4-148
Master Gauge Unit ........................................................................................................................................... 3-2f
Master Gauge Unit, Typical ............................................................................................................................. F3-5
Maximum Distance Between Supports for Fluid Tubing ................................................................................. T4-12
Mechanical Advantage ........................................................................................................................... 2-1e, F2-4
Mechanical Advantage, Application of ............................................................................................................. F2-5
Medium-and Low-Pressure Hose Assemblies, Assembly of ........................................................................... F4-45
Medium-Pressure Teflon Hose Assembly Procedure ..................................................................................... F4-48
MIL-H-83282, Applications of ........................................................................................................................ F4-43
MIL-H-83282, Non-Applicability of....................................................................................................... 4-21d, T4-44
MIL-H-83282, Operating Temperature Limitations of ..................................................................................... T4-45
Minimum Bend Radii of Hose for Fuel Oil, and Coolant Systems .................................................................. T4-32
Motor, Hydraulic .......................................................................................................................................... F4-113
Motors, Pumps and ......................................................................................................................................... 4-13
MS Fitting and Components .......................................................................................................................... F4-17
MS Fitting Gasket Installation ........................................................................................................................ F4-19
MS Fittings, Marking ..................................................................................................................................... F4-23
MS Flared Swivel Connectors Torquing, and Installation of Flexible Hose ........................................................4-6k
MS Flareless Fittings ..................................................................................................................................... F4-18
MS Turns and Torque Valves ........................................................................................................................ F4-21
MS21921 Coupling Nut, Torque Values for ...................................................................................................... T4-5
MS33514 Fitting End, Installation of .............................................................................................................. F4-25

Nipple Assembly Clearance .......................................................................................................................... F4-47

Nipple Assembly Surface .............................................................................................................................. F4-46
Non-Applicability of MIL-H-83282 ...................................................................................................... 4-21 d, T4-44
Nonself-Sealing, Aromatic and Heat-Resistant Hose, MIL-H-6000 ................................................................. F4-35
Nonself-Sealing, Aromatic-Resistant Hose, MIL-H-5593 ................................................................................ F4-37
Normal Flow in Differential Pressure Indicator ............................................................................................... F4-99
Normal Flow in Fluid Filter ............................................................................................................................ F4-97

Index 40
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VOLUME 2

Subject Paragraph
Figure, Table
Number
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

O-Ring Identification ...................................................................................................................................... F4-59

O-Ring Installation, External .......................................................................................................................... F4-69
O-Ring Installation, Internal (Metallic Sleeve) ................................................................................................ F4-68
O-Ring Installation, Internal (Paper Cover) .................................................................................................... F4-69
O-Ring, Removal of ...................................................................................................................................... F4-60
O-Ring Removal, Dual Internal ..................................................................................................................... F4-64
O-Ring Removal, External (Spoon-Type Extractor) ....................................................................................... F4-65
O-Ring Removal, External (Wedge-Type Extractor) ...................................................................................... F4-66
O-Ring Removal, Internal (Pull-Type Extractor) ............................................................................................ F4-61
O-Ring Removal, Internal (Push-Type Extractor) .......................................................................................... F4-63
O-Ring Removal, Internal (Wedge-Type Extractor) ....................................................................................... F4-62
O-Rings ......................................................................................................................................................... 4-7a
Open-Center Hydraulic System (Value Closed) ........................................................................................... F4-143
Open-Center Hydraulic System (Value Open) ............................................................................................. F4-144
Operating Pressure (psi) for MIL-H-7061, Proof Test and ............................................................................... T4-31
Operating, Proof, and Burst Test Pressures for AN6270 Hose
Assembly using MIL-H-5593 Low Pressure Hose ................................................................................. T4-19
Operating, Proof, and Burst Test Pressures for MIL-H-83796
Medium Pressure Hose Assembly, Lightweight .................................................................................... T4-17
Operating, Proof, and Burst Test Pressures for MIL-H-83797
Medium Pressure Hose ........................................................................................................................ T4-18
Operating, Proof, and Burst Test Pressures for MS28741 Medium
Pressure Hose Assemblies, using Single Wire Braid Hose,
Military Specification MIL-H-8794 ........................................................................................................ T4-16
Operating, Proof, and Burst Test Pressures for MS28759 and
MS28762 Hose Assemblies using MIL-H-8788 High Pressure Hose ..................................................... T4-15
Operating Temperature Limitations (of Hydraulic Fluid) .................................................................................. 4-21f
Operating Temperature Limitations of MIL-H-83282 ...................................................................................... T4-45
Orifice Check Valve .................................................................................................................................... F4-128
Oxygen System Tapered Pipe Thread ............................................................................................................. 4-3b

Packing and Lubricant Selection ..................................................................................................................... T4-6

Packings and O-Rings, Hydraulic ...................................................................................................................... 4-7

Index 41
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VOLUME 2

Subject Paragraph
Figure, Table
Number
P - Continued

Parking Brake Valve, Dual .......................................................................................................................... F4-156

Parking Brake Valve, Dual (Off) .................................................................................................................. F4-157
Parking Brake Valve, Dual (On) .................................................................................................................. F4-158
Pascal's Law .......................................................................................................................................... 2-1d, F2-3
Permaswage Fittings, Typical Styles of ......................................................................................................... F4-78
Permaswage Marking Tool, D9862-S, M, and L, Marking with ....................................................................... F4-82
Permaswage Repair with D10000 Series Tooling-Tube
Material and Maximum Operating Pressure Limitations (psi) ................................................................ T4-35
Petroleum-Base Fluid (Hydraulic) .................................................................................................................... 2-3b
Pipe Thread, Straight Thread and ................................................................................................................. F4-26
Piston Damper ............................................................................................................................................ F4-162
Piston Damper Cross Section ...................................................................................................................... F4-163
Piston Damper, Nose Landing Gear with ..................................................................................................... F4-164
Piston Dampers, Main Rotor Assembly with ................................................................................................ F4-165
Piston-Type Pressure Switch ....................................................................................................................... F4-115
Plastic Protective Dust Cap ........................................................................................................................... F4-55
Plastic Protective Dust Cap (AN-SAE Friction) .............................................................................................. F4-56
Plastic Protective Dust Plug and Moisture Seal (AN-SAE Threaded) ............................................................. F4-51
Pneudraulic Systems, Types of ....................................................................................................................... 4-17
Closed-Center Hydraulic .......................................................................................................................4-17b
Open-Center Hydraulic .........................................................................................................................4-17a
Pneumatic System ................................................................................................................................4-17c
Pneudraulics Theory and Basic Principles ......................................................................................................... 2-1
Computation of Force, Area, and Pressure ............................................................................................ 2-1b
Computation of Volume, Area, and Length of Stroke ..............................................................................2-1c
Mechanical Advantage ................................................................................................................. 2-1e, F2-4
Pascal's Law ................................................................................................................................. 2-1d, F2-3
Qualities of Hydraulic Fluid ................................................................................................................... 2-1 a
Use of Air in Hydraulic Systems .............................................................................................................. 2-1f
Pnuematic System ..........................................................................................................................................4-17c
Power Brake Control Valve (Brake Applied) ................................................................................................ F4-152
Power Brake Control Valve (Brake Released) ............................................................................................. F4-153
Power Pumps .................................................................................................................................................4-13a
Power-Boost Master Cylinder (Brake Applied) ............................................................................................. F4-150
Power-Boost Master Cylinder (Brake Released) .......................................................................................... F4-151
Precautions
for Hydraulic Fluid Selection and Contamination .................................................................................... 2-3d
for Repair of Tubing Assemblies ............................................................................................................ 4-4a
Pressure Gauge .......................................................................................................................................... F4-114
Pressure Gauges ...........................................................................................................................................4-14a
Pressure Reducing Valve ...............................................................................................................................4-14d
Pressure Relief Valves ...................................................................................................................................4-14c
Pressure Switch, Piston-Type ...................................................................................................................... F4-115

Index 42
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VOLUME XX

Subject Paragraph
Figure, Table
Number

P - Continued

Pressure Switches ..........................................................................................................................................4-14b

Pressure-Actuated Sequence Valve ............................................................................................................ F4-130
Pressure-Reducing Valve ............................................................................................................................ F4-117
Pressures, Proof Test, High-Pressure Teflon Hose Assemblies ..................................................................... T4-30
Pressures, Proof Test, Medium-Pressure Teflon Hose Assemblies ................................................................ T4-23
Printed-Symbol Identification Tape .................................................................................................................. F4-1
Priority Valve .............................................................................................................................................. F4-131
Procedures, for Use of Test Stands ................................................................................................................4-20b
Proof Test and Operating Pressure (psi) for MIL-H-7061 ............................................................................... T4-31
Proof Test Pressures, High-Pressure Teflon Hose Assemblies ...................................................................... T4-28
Proof Test Pressures, Medium-Pressure Teflon Hose Assemblies ................................................................. T4-23
Proof Test Torque Values MS Flared Swivel Nut Fittings
(Reference AND10064) ........................................................................................................................ T4-20
Proof Testing of Flexible Hose Assemblies ...................................................................................................... 4-5f
Properly Burred Tube ...................................................................................................................................... F4-9
Pump Assembly, Kellogg Stroke Reduction ................................................................................................. F4-109
Pump, Constant Volume, Bent-Axis ............................................................................................................ F4-101
Pump, Constant Volume, Foot Valve .......................................................................................................... F4-104
Pump, Constant Volume, (Piston Installation) .............................................................................................. F4-102
Pump, Constant Volume, (Piston Operation) ............................................................................................... F4-103
Pump, Hand, Double-Action ........................................................................................................................ F4-111
Pump, Hand, Test Circuit ............................................................................................................................ F4-112
Pump, Kellogg Stroke Reduction (Reduction Output) .................................................................................. F4-110
Pump, Stratopower Effective Stroke (Full Flow) .......................................................................................... F4-105
Pump, Stratopower Effective Stroke (Zero Flow) ......................................................................................... F4-106
Pump, Vickers Stroke Reduction (Full Flow) ................................................................................................ F4-108
Pump, Vlckers Stroke Reduction (Zero Flow) .............................................................................................. F4-107
Pumps and Motors .......................................................................................................................................... 4-13
Hand Pumps .........................................................................................................................................4-13c
Hydraulic Motors ...................................................................................................................................4-13d
Maintenance of Power Pumps ..............................................................................................................4-13b
Power Pumps .......................................................................................................................................4-13a
Purpose (of Manual) .......................................................................................................................................... 1-1

Qualities of Hydraulic Fluid ............................................................................................................................. 2-1a

Quick-Disconnect Couplings ............................................................................................................................ 4-10
Inspection .............................................................................................................................................4-10b
Installation ............................................................................................................................................4-10a

Index 43
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VOLUME XX

Subject Paragraph
Figure, Table
Number
R

Rachet Valve .................................................................................................................................................4-16h

Rachet Valve (Moving) ................................................................................................................................ F4-137
Rachet Valve (Static) .................................................................................................................................. F4-136
Radial Cam-Operated Selector Valve .......................................................................................................... F4-124
Recommended (Permaswage) Repair Methods, Failure Modes and .............................................................. F4-79
Regulating Pressure, Devices for .................................................................................................................... 4-14
Relief Valve, System ................................................................................................................................... F4-116
Repair
of High-Pressure Tubing Assemblies ......................................................................................................4-4c
of Low-Pressure Tubing Assemblies ...................................................................................................... 4-4b
of Tubing Assemblies .............................................................................................................................. 4-4
Repair of Low-Pressure Tubing ..................................................................................................................... F4-30
Repair of Tubing Assemblies ............................................................................................................................. 4-4
Precautions ............................................................................................................................................ 4-4a
Repair of High-Pressure Tubing Assemblies ...........................................................................................4-4c
Repair of Low-Pressure Tubing Assemblies ........................................................................................... 4-4b
Template . .............................................................................................................................................. 4-4d
Repairing High-Pressure Tubing .................................................................................................................... F4-33
Replacement of Flexible Hose .........................................................................................................................4-5c
Reservoir, Fluid-Pressurized (Pressurized) .................................................................................................... F4-93
Reservoir, Fluid-Pressunzed (Unpressurized) ................................................................................................ F4-92
Reservoir with Baffles, Fins and Finger Strainer ............................................................................................ F4-91
Reservoir with Filter Elements ....................................................................................................................... F4-94
Reservoirs, Hydraulic ...................................................................................................................................... 4-11
Responsibility (for Hydraulic Shop Rules) ........................................................................................................ 3-1a
Reversing Spiral of Teflon Backup Ring ........................................................................................................ F4-74
Rings, Backup ................................................................................................................................................... 4-8
Rotary-Type, Closed-Center Selector Valve ................................................................................................ F4-120
Rotor Blade Brake System .......................................................................................................................... F4-159

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

Index 44
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VOLUME 2

Subject Paragraph,
Figure, Table
Number

S - Continued

Selector Valves .................................................................................................................................. 4-16a

Self-Sealing, Aromatic-Resisting, Hose MIL-H-7061 ........................................................................... F4-38
Self-Sealing, Hose for Aromatic Fuel, MIL-H-7061 ............................................................................. 4-5k
Separable Fittings, Utilizing 0.150 Tube End Gap Tolerance on ......................................................... F4-89
Sequence Valve, Landing Gear System Using Mechanically Actuated ............................................... F4-129
Sequence Valve, Pressure-Actuated .................................................................................................. F4-130
Sequence Valves . .............................................................................................................................. 4-16d
Servicing Filters ................................................................................................................................. 4-12f
Shaped Fittings, Utilizing 0.300 Inch Tube End Gap Tolerance on ..................................................... F4-92
Shock Strut, Complex (Metering Pin) ................................................................................................. F4-171
Shock Strut, Complex (Plunger) ......................................................................................................... F4-172
Shock Strut, Floating Pin .................................................................................................................... F4-173
Shock Strut, Simple ........................................................................................................................... F4-170
Shock Struts ....................................................................................................................................... 4-19b
Shop Equipment, Maintenance ........................................................................................................... 3-2
Shop Housekeeping (Hydraulic Shop) . ............................................................................................... 3-1b
Shop Rules, General (Hydraulic Shop) ............................................................................................... 3-1
Shop Safety (Hydraulic Shop) ............................................................................................................ 3-1c
Shop Tools and Materials (Hydraulic Shop) ........................................................................................ 3-1d
Shuttle Valve, Floating-Piston ............................................................................................................ F4-132
Shuttle Valves .................................................................................................................................... 4-16f
Simple Check Valve ........................................................................................................................... F4-127
Simple Master Cylinder . ..................................................................................................................... F4-148
Simple Shock Strut ............................................................................................................................ F4-170
Single Backup Ring Installation .......................................................................................................... F4-75
Single Flared Tubing, Dimensions for ................................................................................................. F4-7
Single-Action Actuating Cylinder ........................................................................................................ F4-133
Size (of Hydraulic Systems) ............................................................................................................... 2-2d
Solenoid-Actuated Control Valve (De-energized) ............................................................................... F4-126
Solenoid-Actuated Control Valve (Energized) ..................................................................................... F4-125
Solid Color Band Identification ........................................................................................................... F4-2
Spherical Accumulator ....................................................................................................................... F4-119
Spherical Air Cylinder ......................................................................................................................... F4-95
Spool-Type, Open-Center, Selector Valve (Closed) ............................................................................ F4-121
Stabilizer Bar with Vane Dampers ...................................................................................................... F4-169
Standard Union Fittings, Tube Insertion Limits when Using ................................................................ F4-90
Standard Union Fittings, Utilizing 0.300 Inch Tube End Gap
Tolerance with ............................................................................................................................. F4-87
Standpipes ......................................................................................................................................... 4-11g
Steel Protective Dust Cap .................................................................................................................. F4-53
Steel Protective Dust Plug and Moisture Seal .................................................................................... F4-52
Storage of Hose and Hose Assemblies ............................................................................................... 4-5b
Storage (55-Gallon Drums) ................................................................................................................ 3-3a

Index 45
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VOLUME 2

Subject Paragraph,
Figure, Table
Number

S - Continued

Straight Pipe Thread .......................................................................................................................... 4-3c

Straight Thread and Pipe Thread ....................................................................................................... F4-26
Stratopower Effective Stroke Pump (Full Flow) .................................................................................. F4-105
Stratopower Effective Stroke Pump (Zero Flow) ................................................................................. F4-106
Stretching Teflon Backup Ring ........................................................................................................... F4-72
Support Clamp Sizes (for Use with MIL-H-27267 Hose of Teflon) ....................................................... T4-24
Support Clamp Sizes (for Use with MIL-H-38360 Hose of Teflon) ....................................................... T4-29
Support, of Flexible Hose ................................................................................................................... 4-6e
Swage Tool Assembly Showing Lower Die Block Assembly and
Position of Fitting Locator, Basic .................................................................................................. F4-84
Swaged Joint, Checking, with D9892 Inspection Gauge ...................................................................... F4-85
Swaged Tubing Repairs ..................................................................................................................... 4-9
Application.................................................................................................................................... 4-9a
Inspection of Swaged Joint .......................................................................................................... 4-9g
Swaging Operation ...................................................................................................................... 4-9f
Technique .................................................................................................................................... 4-9b
Tube Cutting ................................................................................................................................ 4-9c
Tube Debumng ............................................................................................................................ 4-9d
Tube End Preparation .................................................................................................................. 4-9e
Swaging, Fitting Dimensions After ...................................................................................................... T4-39
Swaging Operation ............................................................................................................................. 4-9f
Synthetic-Base Fluid MIL-H-83282 ..................................................................................................... 2-3c
System Flushing ................................................................................................................................ 2-4b
System Relief Valve ........................................................................................................................... F4-116
Systems and Repairs, Tubing.............................................................................................................. 4-2

Tallwheel Liquid Spring ...................................................................................................................... T4-176

Technique, Swaged Tubing Repairs ................................................................................................... 4-9b
Teflon Hose Assembly Procedure, Medium-Pressure ......................................................................... F4-48
Teflon Hose Cutoff Factures (in Inches) ............................................................................................. F4-23
Teflon Hose, Field Disassembly of ..................................................................................................... F4-47
Teflon Hose Installation Procedures, Right and Wrong ....................................................................... F4-49
Temperature Protection and Installation of Flexible Hose ................................................................... 4-6g
Template for Repair of Tubing Assemblies ......................................................................................... 4-4d
Test Pressures, Operating, Proof, and Burst, for AN6270 Hose
Assembly using MIL-H-5593 Low Pressure Hose ......................................................................... T4-19
Test Pressures, Operating, Proof, and Burst, for MIL-H-83796
Medium Pressure Hose Assembly ................................................................................................ T4-17
Test Pressures, Operating, Proof, and Burst, for MIL-H-83797
Medium Pressure Hose ................................................................................................................ T4-18
Test Pressures, Operating, Proof, and Burst, for MS28741 Medium

Index 46
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VOLUME 2

Subject Paragraph,
Figure, Table
Number
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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VOLUME 2

Subject Paragraph,
Figure, Table
Number
T- Continued

Tubing Assemblies, Repair of ............................................................................................................. 4-4

Tubing Damage ................................................................................................................................. 4-2c
Tubing End Clearance for Low-Pressure Tubing-Repair ..................................................................... F4-31
Tube Fittings ...................................................................................................................................... F4-15
Tubing Identification ........................................................................................................................... 4-2b
Tubing Repairs, Swaged .................................................................................................................... 4-9
Tubing Systems and Repairs .............................................................................................................. 4-2
Beaded Tubing Joints .................................................................................................................. 4-2h
Bending Tubing............................................................................................................................. 4-2e
Cleaning Tubing ........................................................................................................................... 4-2g
Cutting Tubing ............................................................................................................................. 4-2d
Flaring Tubing .............................................................................................................................. 4-2f
Installation of Beaded Tubing........................................................................................................ 4-2j
Installation of Flared Tubing ......................................................................................................... 4-2i
Tubing Damage ........................................................................................................................... 4-2c
Tubing Identification ..................................................................................................................... 4-2b
Types............................................................................................................................................ 4-2a
Tubing with Double Lap Flare ............................................................................................................. F4-11
Tubing-to-Tubing Connections ............................................................................................................ F4-22
Two-Stage Fluid Filters ...................................................................................................................... 4-12d
Types of Accumulators ....................................................................................................................... 4-15a
Types of Hydraulic Fluid Used in Army Aircraft .................................................................................. 2-3
Petroleum-Base Fluid .................................................................................................................. 2-3b
Precautions .................................................................................................................................. 2-3d
Synthetic-Base Fluid MIL-H-83282 ............................................................................................... 2-3c
Vegetable-Base Fluid.................................................................................................................... 2-3a
Types of Hydraulic Reservoirs Used in Hydraulic Systems ................................................................. 4-11a
Types of Pneudraulic Systems ........................................................................................................... 4-17
Types of Tubing Systems and Repairs ............................................................................................... 4-2a
Typical Gasoline Engine-Driven Hydraulic Test Stand ........................................................................ F3-2
Typical Hydraulic Hose Testing Unit ................................................................................................... F3-3
Typical Hydraulic System Filler and Bleeder ...................................................................................... F3-1
Typical Master Gauge Unit ................................................................................................................. F3-5
Typical Styles of Permaswage Fittings . .............................................................................................. F4-78

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

Index 48
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VOLUME 2

Subject Paragraph,
Figure, Table
Number

U - Continued

Procedures .................................................................................................................................. 4-20b

Safety .......................................................................................................................................... 4-20a
Uses of Filter in Hydraulic Systems .................................................................................................... 4-12a
Uses of Hydraulic Systems in Army Aircraft ....................................................................................... 2-2
Ease of Installation ...................................................................................................................... 2-2c
Ease of Operation ........................................................................................................................ 2-2b
Efficiency ..................................................................................................................................... 2-2a
Lubrication ................................................................................................................................... 2-2e
Size ............................................................................................................................................. 2-2d
Utilizing 0.150 Inch Tube End Gap Tolerance on Separable Fittings .................................................. F4-89
Utilizing 0.300 Inch Tube End Gap Tolerance on Shaped Fittings ...................................................... F4-88
Utilizing 0.300 Inch Tube End Gap Tolerance with Standard Union Fittings ........................................ F4-87
V-Ring Packings .......................................................................................................................... 4-7c
V-Ring Packings in Vanous Positions of Assembly ....................................................................... F4-71
Valve A, Closed ........................................................................................................................... F4-145
Valve B, Open ............................................................................................................................. F4-146
Valve C, Open ............................................................................................................................. F4-147
Valve, Pressure-Reducing ............................................................................................................ F4-117
Valve, Priority .............................................................................................................................. F4-131
Valve, Ratchet (Moving) .............................................................................................................. F4-137
Valve, Ratchet (Static) ................................................................................................................. F4-136
Valve, Priority .............................................................................................................................. F4-131
Vane Damper ............................................................................................................................... F4-166
Vane Damper Cross Section ........................................................................................................ F4-167
Vane, Dampers, Nose Landing Gear ............................................................................................ F4-168
Vane, Dampers, Stabilizer Bar ..................................................................................................... F4-169
Vegetable-Base Fluid (Hydraulic) ................................................................................................. 2-3a
Vickers Stroke Reduction Pump (Full Flow) ................................................................................. F4-108
Vickers Stroke Reduction Pump (Zero Flow)................................................................................. F4-107
Volume, Length, and Area, Computing ......................................................................................... F2-2

Wheel Brake Assemblies ................................................................................................................... 4-18b

Wheel Brake Systems ........................................................................................................................ 4-18a
Wheel Brake Systems, Troubleshooting ............................................................................................. T4-41
Withdrawing Fluid from Drum ............................................................................................................. T3-3c

Index 49/(index 50 blank)

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VOLUME 3

Subject Paragraph,
Figure, Table
Number
A
Aeroquip Corporation Series 3700 and 3750 Quick Thread Couplings ................................................ 2-5h
Auxiliary (Booster) Fuel Pump ............................................................................................................ F2-4
AVGAS Identification ......................................................................................................................... T2-2

Ball Lock-Type Coupling .................................................................................................................... F2-19

Bladder-Type Fuel Cells, Serviceable Limits ...................................................................................... T2-6
Bridging, Sealant ................................................................................................................................ F2-12

Can and Drum Marking ...................................................................................................................... F2-23

Characteristics of Vaporization ........................................................................................................... F2-1
Clamp Location for Tube Bends ......................................................................................................... F2-3
Closed-Circuit Fuel Receiver Installation ............................................................................................ F2-20
Closed-Circuit Refueling Receptacles ................................................................................................ 2-51
Cold Weather Maintenance, Oil Systems ........................................................................................... 3-61
Consumable Materials ........................................................................................................................ 1-3
Contaminant Characteristics (of Fuel), Visual ..................................................................................... T2-3
Contamination of Fuels ...................................................................................................................... 2-4
Contamination Prevention ............................................................................................................ 2-4e
Microbiological Growths ............................................................................................................... 2-4c
Solids............................................................................................................................................ 2-4b
Uses of Additives to Prevent Microbiological Growths .................................................................. 2-4d
Water ........................................................................................................................................... 24a
Contamination Prevention (for Fuels) ................................................................................................. 2-4e
Coupling
Ball Lock -Type ............................................................................................................................ F2-19
Full Gnp PustuPull-TypeF ............................................................................................................ 2-17
lnst-O-Matic Push/Pull Type ......................................................................................................... F2-16
Quick-Threading/lndicating Type .................................................................................................. F2-15
Screw-Type .................................................................................................................................. F2-14
Straight Flow Balin Valve-Type .................................................................................................... F2-18
Covered Storage of Oils ..................................................................................................................... 3-7a

DA Form 1804 (Petroleum Sample) ................................................................................................... F2-22

Drain Containers (Fuel Systems), Safety Precautions and Procedures ............................................... 2-2e
Dry-Sump Lubrication System for Reciprocating Engines ................................................................... F3-3
Dry-Sump Lubrication System for Turbine Engines ............................................................................ F3-5

Index 51
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VOLUME 3

Subject Paragraph,
Figure, Table
Number
E

Engine Oils
Reciprocating ............................................................................................................................... T3-1
Turbine ......................................................................................................................................... T3-2
Engine-Driven Fuel Pump ............................................................................................................ F2-5

Fasteners ............................................................................................................................................ F2-9

Fillet Seal Deflection .......................................................................................................................... F2-13
Filter, Oil ............................................................................................................................................ F3-6
Float Switch Unit ................................................................................................................................ F2-7
Float Switches .................................................................................................................................... 2-5e
Flushing Oil Systems ......................................................................................................................... 3-6j
Fuel Cells and Tanks .......................................................................................................................... 2-5f
Fuel Identification ............................................................................................................................... 2-3
Aviation Gas ................................................................................................................................ 2-3b
Turbine Fuels ............................................................................................................................... 2-3a
Fuel Lines .......................................................................................................................................... 2-5a
Fuel Lines and Drains, Safety Precautions and Procedures ................................................................ 2-2a
Fuel Pump ..........................................................................................................................................
Auxiliary........................................................................................................................................ F24
Engine-Driven............................................................................................................................... F2-5
Fuel Pumps ........................................................................................................................................ 2-5b
Fuel Receiver Installation (Closed-Circuit) .......................................................................................... F2-20
Fuel Strainers ..................................................................................................................................... 2-5d, F2-6
Fuel Sumps ........................................................................................................................................ 2-5c
Fuel System Maintenance .................................................................................................................. 2-5
Aeroquip Corporation Series 3700 and 3750 Quick Thread Couplings .......................................... 2-5h
Closed-Circuit Refueling Receptacles .......................................................................................... 2-5i
Float Switches ............................................................................................................................. 2-5e
Fuel Cells and Tanks ................................................................................................................... 2-5f
Fuel Lines .................................................................................................................................... 2-5a
Fuel Pumps ................................................................................................................................. 2-5b
Fuel Strainers .............................................................................................................................. 2-5d
Fuel Sumps ................................................................................................................................. 2-5c
Fuel System Troubleshooting ....................................................................................................... 2-5j
Testing Fuel Systems and Tanks/Cells for Leaks ......................................................................... 2-59g
Fuel System Schematic, Typical ........................................................................................................ F2-21
Fuel System Troubleshooting ............................................................................................................. 2-5j
Fuel System Troubleshooting, Typical, Chart ..................................................................................... T2-9
Fuel Systems
Contamination of Fuels ................................................................................................................ 2-4
Fuel Identification ........................................................................................................................ 2-3

Index 52
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VOLUME 3

Subject Paragraph,
Figure, Table
Number

F - Continued

Fuel System Maintenance ............................................................................................................ 2-5

General ........................................................................................................................................ 2-1
Handling and Storage of Fuels ..................................................................................................... 2-6
Safety Precautions and Procedures ............................................................................................. 2-2
Fuel Tanks, Integral ........................................................................................................................... F2-8
Full Gnp Push/Pull-Type Coupling ...................................................................................................... F2-17

Gear-Type Oil Pump .......................................................................................................................... F3-13

General
Fuel Systems ............................................................................................................................... 2-1
Oil Systems ................................................................................................................................. 3-1

Handling and Storage of Fuels ........................................................................................................... 2-6

Marking......................................................................................................................................... 2-6c
Receipt ........................................................................................................................................ 2-6a
Storage Practices ......................................................................................................................... 2-6b
Handling and Storage of Oils .............................................................................................................. 3-7
Covered Storage .......................................................................................................................... 3-7a
Outside Storage ........................................................................................................................... 3-7b
Heat Exchanger Cooler, Turbine Engine Fuel Oil ............................................................................... F3-1

Identification of AVGAS ..................................................................................................................... T2-2

Identification of Oils ........................................................................................................................... 3-4
Reciprocating Engines ................................................................................................................. 3-4a
Turbine Engines ........................................................................................................................... 3-4b
Inspection Valves, Quick-Disconnect Coupling ................................................................................... T2-8
Inst-O-matic Push/Pull-Type Coupling ................................................................................................ F2-16
Integral Fuel Tanks ............................................................................................................................ F2-8

Jet Fuel Used in Army Aircraft (MIL-T-5624), Critical Characteristics

and Specification Requirements for ............................................................................................. T2-1

Index 53
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VOLUME 3

Subject Paragraph,
Figure, Table
Number

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

Oil Contamination .............................................................................................................................. 3-5

Prevention ................................................................................................................................... 3-5c
Solids ........................................................................................................................................... 3-5b
Use of Brayco 599 3-5d
Water ........................................................................................................................................... 3-5a
Oil Cooler, Reciprocating Engine ....................................................................................................... F3-10
Oil Coolers, Maintenance ................................................................................................................... 3-6g
Oil Fitter ............................................................................................................................................. F3-6
Oil Filter, Spacers and Screens Type ................................................................................................. F3-7
Oil Filters, Maintenance ..................................................................................................................... 3-6c
Oil Jets, Maintenance ......................................................................................................................... 3-61
Oil Lines, Maintenance ....................................................................................................................... 3-6b
Oil Pressure Relief Valves ................................................................................................................. F3-12
Oil Pump ............................................................................................................................................ F3-13
Oil Screen Types ............................................................................................................................... F3-9
Oil Screens, Maintenance .................................................................................................................. 3-6d
Oil Systems
General ........................................................................................................................................ 3-1
Handling and Storage of Oils ....................................................................................................... 3-7
Identification of Oils ..................................................................................................................... 3-4

Index 54
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VOLUME 3

Subject Paragraph,
Figure, Table
Number

O - Continued

Oil Contamination ........................................................................................................................ 3-5

Oil Systems Maintenance . ........................................................................................................... 3-6
Preservation ................................................................................................................................ 3-8
Safety Precautions and Procedures ............................................................................................. 3-2
Types of Oil ................................................................................................................................. 3-3
Oil Systems Maintenance ................................................................................................................... 3-6
Cold Weather Maintenance .......................................................................................................... 3-61
Flushing Oil Systems . .................................................................................................................. 3-6
Magnetic Plugs and Chip Detectors . ............................................................................................ 3-6f
Oil Coolers ................................................................................................................................... 3-6g
Oil Filters ..................................................................................................................................... 3-6c
Oil Jets ........................................................................................................................................ 3-6i
Oil Lines ...................................................................................................................................... 3-6b
Oil Screens .................................................................................................................................. 3-6d
Oil Tanks ..................................................................................................................................... 3-6e
Pressure Devices ......................................................................................................................... 3-6h
Prevention of Sludge Buildup ....................................................................................................... 3-6k
Types of Oil Systems ................................................................................................................... 3-6a

Particle Size, Micron .......................................................................................................................... F2-2

Personal Precautions and Procedures, Fuel Systems ......................................................................... 2-2f
Petroleum Sample Form DA 1804 ...................................................................................................... F2-22
Preservation of Oil Systems ............................................................................................................... 3-8
Pressure Devices ............................................................................................................................... 3-6h
Prevention (of Oil Contamination) ...................................................................................................... 3-5c
Prevention of Sludge Buildup ............................................................................................................. 3-6k
Purpose of Manual ............................................................................................................................. 1-1

Quick-Disconnect Coupling Inspection Valves .................................................................................... T2-8

Quick Threading/lndicating Type Coupling ......................................................................................... F2-15

Ratios (for Dye Mixing) ...................................................................................................................... T2-7

Receipt (of Fuel Containers) ............................................................................................................... 2-6a
Reciprocating Engine Oil Cooler ........................................................................................................ F3-10
Reciprocating Engines, Identification of Oils for ................................................................................. 3-4a
Relief Valves, Oil Pressure ................................................................................................................ F3-12

Index 55
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VOLUME 3

Subject Paragraph,
Figure, Table
Number

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

Index 56
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INDEX- CONT

VOLUME 3

Subject Paragraph,
Figure, Table
Number

Use of Brayco .................................................................................................................................... 3-5d

Use Temperature Chart, Turbine Engine Oil ....................................................................................... F3-1
Uses of Additives to Prevent Microbiological Growth (in Fuels) .......................................................... 2-4d

Valve, Surge, Example of .................................................................................................................. F3-14

Vaporization Characteristics, Fuel ...................................................................................................... F2-1
Visual Contaminant Characteristics, Fuel ............................................................................................ T2-3

Water (Contamination of Fuel) ........................................................................................................... 2-4a

Water (Contamination of Oil) ............................................................................................................. 3-5a
Wet-Sump Lubrication System for Reciprocating Engines .................................................................. F3-2
Wet-Sump Lubrication System for Turbine Engines ........................................................................... F3-4
Work Stands (Fuel Systems), Safety Precautions and Procedures ..................................................... 2-2d

Index 57/(Index 58 blank)

 TM 1-1500-204-23-1

INDEX- CONT

VOLUME 4

Subject Paragraph,
Figure, Table
Number

AC Meter ............................................................................................................................................ 2-6h

Airspeed Indicator .............................................................................................................................. F4-11
Test Tolerances ........................................................................................................................... T4-1
Alternating Current, Basic Principles and Theory for ........................................................................... 2-3
Alternating Current, Cycle .................................................................................................................. F2-2
Altimeter ............................................................................................................................................ 4-3g, F4-13
Ammeter ............................................................................................................................................ 2-6d
Automatic Wire Marking Machines ..................................................................................................... F3-2

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

Centigrade-Fahrenheit Conversion Chart ........................................................................................... T4-13

Circuit Breakers .................................................................................................................................. 3-1 n
Circuit, Thermocouple ........................................................................................................................ F3-13
Circuits, Basic .................................................................................................................................... 2-5
Cleaning Apparatus, Mercury ............................................................................................................. F4-3
Compass
Alignment, B-16 Master Sighting Method ..................................................................................... F4-23
Correction Card ........................................................................................................................... F4-20
Rose ............................................................................................................................................ F4-21
Components, of Electrical Systems .................................................................................................... 3-4
Compound Circuits ............................................................................................................................. 2-5c, F2-7
Conduits ............................................................................................................................................. 3-1j
Connectors
Inspection of ................................................................................................................................ 3-3b
Installation of (on Wires) .............................................................................................................. 3-3c
MS ............................................................................................................................................... F3-4
Potting ......................................................................................................................................... F3-7
Rectangular Shell ........................................................................................................................ F3-6
Subminiature ............................................................................................................................... F3-5
Consumable Materials ........................................................................................................................ 1-3

Index 59
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VOLUME 4

Subject Paragraph,
Figure, Table
Number

C - Continued

Continuity Tester ................................................................................................................................ 2-6b, F2-8

Copper Wire Strippers ........................................................................................................................ T3-1
Correction Card, Compass ................................................................................................................. F4-20
Counter Drum Pointer Altimeter ......................................................................................................... F4-13
Friction Stop and Jump Error ....................................................................................................... T4-8
Pressure Altitude Difference ........................................................................................................ T4-10
Scale Error ................................................................................................................................... T4-6
Static Friction Error (Vibrator Inoperative) .................................................................................... T4-9
Test Tolerances ........................................................................................................................... T4-7
Cycle of Alternating Current . .............................................................................................................. F2-2

D'Arsonval Meter ................................................................................................................................ 2-6c, F2-9

DD Form 1613 (Pilot Compass Correction Card) ................................................................................ F4-22
Dead Weight Testers ......................................................................................................................... 4-2d
Direct Current Wave Form ................................................................................................................. F2-1
Direct Current, Basic Principles and Theory for .................................................................................. 2-2
Direct Reading Pressure Indicator ...................................................................................................... 4-3h
Tolerances ................................................................................................................................... T4-11
Dual Synchronous Rotor Tachometer Wiring Diagram
(Grounded Two-Wire System) ...................................................................................................... F4-17
Dual Synchronous Rotor Tachometer Wiring Diagram
(Ungrounded Three-Wire System) ............................................................................................... F4-16

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

Index 60
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VOLUME 4

Subject Paragraph,
Figure, Table
Number

E - Continued

Switches ...................................................................................................................................... 3-4i

Thermocouples ............................................................................................................................ 3-4m
Voltage Regulators ...................................................................................................................... 3-4a
Electrical System Troubleshooting ..................................................................................................... 3-2
Electrodynamic Meters ....................................................................................................................... 2-6i
Equipment, Measuring ....................................................................................................................... 2-6
Equipment Safety
Electric Shop ............................................................................................................................... 2-1c
Instrument Shop .......................................................................................................................... 4-1c

Fahrenheit-Centigrade Conversion Chart ........................................................................................... T4-13

Fire Safety
Electric Shop ............................................................................................................................... 2-1d
Instrument Shop .......................................................................................................................... 4-1d
Frequency Meters .............................................................................................................................. 2-6m
Friction Stop and Jump Error, Counter Drum Pointer Altimeter .......................................................... T4-8
Friction Test Tolerances, Three Pointer Altimeter ............................................................................... T44
Fuse and Fuse Holders ...................................................................................................................... 3-1h

Gauge, Wire ...................................................................................................................................... F3-1

General Shop Rules, Electric Shop .................................................................................................... 2-1
Equipment Safety ........................................................................................................................ 2-1c
Fire Safety ................................................................................................................................... 2-1d
Maintenance of Shop Equipment ................................................................................................. 2-1e
Responsibility ............................................................................................................................... 2-1a
Shop Housekeeping ..................................................................................................................... 2-1b
General Shop Rules, Instrument Shop ............................................................................................... 4-1
Equipment Safety ........................................................................................................................ 4-1c
Fire Safety ................................................................................................................................... 4-1d
Responsibility ............................................................................................................................... 4-1a
Shop Housekeeping ..................................................................................................................... 4-1 b

Hand Wire Marking Machine .............................................................................................................. F3-3

Index 61
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VOLUME 4

Subject Paragraph,
Figure, Table
Number
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

Index 62
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VOLUME 4

Subject Paragraph,
Figure, Table
Number
I - Continued

Remote Reading Pressure Indicators ............................................................................................ 4-3i

Repair and Replacements ............................................................................................................ 4-3s
Tachometer Systems ................................................................................................................... 4-3j
Thermocouple Temperature Indicators ......................................................................................... 4-3l

Vacuum System and Instrument Testing ...................................................................................... 4-3n

Vertical Speed Indicators .............................................................................................................. 4-31, F4-12
Inverter ............................................................................................................................................... F3-9
Jetcal System Tester........................................................................................................................... 3-1l
Junctions............................................................................................................................................. 4-21, F4-6

Kapton Wiring ..................................................................................................................................... 3-1o

Leak Test Connections

Pitot ............................................................................................................................................. F4-8
Static ............................................................................................................................................ F4-9
Lighting System Troubleshooting Chart ............................................................................................... T3-4

Magnetic Compass.............................................................................................................................. 4-3o, F4-19

Maintenance of Instruments and Instrument Systems ......................................................................... 4-3
Maintenance of Shop Equipment, Electrical Shop .............................................................................. 2-1e
Maintenance of Shop Equipment, Instrument Shop ............................................................................ 4-2
Dead Weight Testers ................................................................................................................... 4-2c
Jetcal System Tester ................................................................................................................... 4-2i, F4-6
Manometer ................................................................................................................................... 4-2a,F4-1
Pitot Static System Tester ............................................................................................................ 4-2h
Portable Instrument Field Tester .................................................................................................. 4-2e
Scorsby Base................................................................................................................................ 4-2g, F4-5
Tachometer Test Stand ................................................................................................................ 4-2d
Turntable Instrument Tester ......................................................................................................... 4-2f, F4-4
Vacuum Chambers ...................................................................................................................... 4-2b
Manometer ......................................................................................................................................... 4-2a, F4-1
Manometer Reading Level ................................................................................................................. F4-2
Marking of Wires with Marking Machine ............................................................................................. 3-1f

Index 63
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VOLUME 4

Subject Paragraph,
Figure, Table
Number

M - Continued

Materials, Consumable ....................................................................................................................... 1-3

Measuring Equipment ........................................................................................................................ 2-6
AC Meters .................................................................................................................................... 2-6h
Ammeter ...................................................................................................................................... 2-6d
Continuity Tester .......................................................................................................................... 2-6b
D'Arsonval Meter ......................................................................................................................... 2-6c
Electrodynamic Meters ................................................................................................................ 2-6i
Frequency Meters ........................................................................................................................ 2-6m
Meter Safety Precautions ............................................................................................................. 2-6n
Multimeter .................................................................................................................................... 2-6g
Ohmmeter ................................................................................................................................... 2-6f
Rectifier Meter ............................................................................................................................. 2-6j
Test Lights ................................................................................................................................... 2-6a
Varmeter ...................................................................................................................................... 2-6l
Voltmeter ..................................................................................................................................... 2-6e
Wattmeter .................................................................................................................................... 2-6k
Mercury Cleaning Apparatus .............................................................................................................. F4-3
Meter, D'Arsonval ............................................................................................................................... 2-6c, F2-9
Meter Safety Precautions ................................................................................................................... 2-6n
Microswitch ........................................................................................................................................ F3-11
MS Connectors ................................................................................................................................... F3-4
Multimeter .......................................................................................................................................... 2-6g

Ohmmeter .......................................................................................................................................... 2-6f

Operational Check (of Electrical Systems) ......................................................................................... 3-2a
Outside Air Temperature Gauges ....................................................................................................... 4-3m

Parallel Circuits .................................................................................................................................. 2-5b, F2-6

Pilot Compass Correction Cards, DD Form 1613 ................................................................................ F4-22
Pitot
Leak Test Connections ................................................................................................................. F4-8
Static System ............................................................................................................................... 4-3c, F4-7
Static System Heater ................................................................................................................... 4-3d
Static System Tester .................................................................................................................... 4-2h
Tube ............................................................................................................................................ F4-10
Position Indicating Systems and Indicators ......................................................................................... 4-3r
Potting Connectors ............................................................................................................................. F3-7
Precautions (for Troubleshooting Electrical Systems) ......................................................................... 3-2b

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Subject Paragraph
Figure, Table
Number

P - Continued

Pressure Altitude Difference

Counter Drum Pointer Altimeter............................................................................................................ T4-10
Three Pointer Altimeter........................................................................................................................... T4-5
Purpose (of Manual) .......................................................................................................................................... 1-1

Reading Level, Manometer . ............................................................................................................................ F4-2

Recommended Sizes of Marking Type ............................................................................................................ T3-2
Rectangular Shell Connectors ......................................................................................................................... F3-6
Rectifier Meter ...................................................................................................................................................2-6j
Relays, Typical ................................................................................................................................................ F3-8
Remote Indicating Compass ........................................................................................................................... 4-3p
Wiring Diagram ................................................................................................................................... F4-24
Remote Reading Pressure Indicator ..................................................................................................................4-3i
Tolerances ........................................................................................................................................... T4-12
Repair and Replacements, Instruments and Instrument Systems .....................................................................4-3s
Replacement Criteria for Wires and Cables ..................................................................................................... 3-1b
Responslbllty
for Electric Shop Rules .......................................................................................................................... 2-1a
for Instrument Shop Rules ...................................................................................................................... 4-1a
Rose, Compass ............................................................................................................................................. F4-21
Rotary-Selector Switch................................................................................................................................... F3-12

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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Subject Paragraph
Figure, Table
Number

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

Tachometer Systems .........................................................................................................................................4-3j

Tachometer Wiring Diagram
Dual Synchronous Rotor (Grounded Two-Wire System) ....................................................................... F4-17
Dual Synchronous Rotor (Ungrounded Three-Wire System) ................................................................ F4-16
Synchronous Rotor (Grounded Two-Wire System) ............................................................................... F4-15
Synchronous Rotor (Ungrounded Three-Wire System).......................................................................... F4-14
Terminals and Terminal Blocks ....................................................................................................................... 3-1g
Test Lights ...................................................................................................................................................... 2-6a
Test Tolerances
Airspeed Indicator .................................................................................................................................. T4-1
Counter Drum Pointer Altimeter ............................................................................................................. T4-7
Three Pointer Altimeter .......................................................................................................................... T4-3
Tester, Continuity ................................................................................................................................... 2-6b, F2-8
Thermocouple Circuit .................................................................................................................................... F3-13
Thermocouple Temperature Indicators ............................................................................................................ 4-31
Three Pointer Altimeter ................................................................................................................................. F4-13
Friction Test Tolerances ........................................................................................................................ T4-4
Pressure Attitude Difference .................................................................................................................. T4-5
Scale Error ............................................................................................................................................ T4-2
Test Tolerances ..................................................................................................................................... T4-3
Toggle Switch ............................................................................................................................................... F3-10
Toggle Switches ............................................................................................................................................. 3-1m
Troubleshooting Electrical Systems ................................................................................................................... 3-2
Operational Check ................................................................................................................................. 3-2a
Precautions ............................................................................................................................................ 3-2b
Tube, Pitot .................................................................................................................................................... F4-10
Turntable Instrument Tester .................................................................................................................... 4-2f, F4-4
Typical Electrical System Schematic ............................................................................................................... F2-4
Typical Ignition System Troubleshooting Chart ................................................................................................ T3-3
Typical Lighting System Troubleshooting Chart ............................................................................................... T3-4
Typical Relays ................................................................................................................................................. F3-8

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VOLUME 4

Subject Paragraph
Figure, Table
Number

Vacuum Chambers ......................................................................................................................................... 4-2b

Vacuum System and Instrument Testing ......................................................................................................... 4-3n
Varmeter ...........................................................................................................................................................2-6l
Vertical System Indicators ..................................................................................................................... 4-3f, F4-12
Voltmeter ........................................................................................................................................................ 2-6e

Wattmeter ........................................................................................................................................................2-6k
Wave Form, of Direct Current ......................................................................................................................... F2-1
Wire Gauge .................................................................................................................................................... F3-1
Wire Identification ........................................................................................................................................... 3-1d
Wire Marking Machines
Automatic ........................................................................................................................................................ F3-2
Hand F3-3
Wire Sizes .......................................................................................................................................................3-1c
Wire Strippers, for Copper Wire ...................................................................................................................... T3-1
Wire Stripping ................................................................................................................................................. 3-1e
Wiring Diagram, Remote Indicating Compass ............................................................................................... F4-24
Wiring Diagram Symbols, Charts, and Schematics ......................................................................................... F2-3
Wiring Diagram Symbols, Charts, and Schematics ........................................................................................... 2-4

Index 67/(Index 68 blank)

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Subject Paragraph
Figure, Table
Number

Aerodynamic Balancing ..................................................................................................................................2-13b

Alignment, Rotor Blade ................................................................................................................................... 3-14
Angle of Bend, Measuring ............................................................................................................................... F2-6
Anti-Icing ........................................................................................................................................................ 2-1 b
Anti-Icing System, Typical ............................................................................................................................. F2-12

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

Classification, Propeller ..................................................................................................................................... 2-5

Cleaning (of Rotors) .......................................................................................................................................3-11b
Cleaning, Powertrain Components of ................................................................................................................ 4-5
Collective Pitch Control .......................................................................................................................... 3-5b, F3-5
Components, Drive ........................................................................................................................................... 4-4
Configurations, Helicopter ................................................................................................................................. 3-4
Construction (of Tail Rotor Blades) .................................................................................................................. 3-9b
Consumable Materials ....................................................................................................................................... 1-3

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Subject Paragraph
Figure, Table
Number

C - Continued

Control System, Helicopter .............................................................................................................................. F3-1

Controllable Pitch Propeller ............................................................................................................................. 2-6b
Cyclic Pitch Control ................................................................................................................................ 3-5a, F3-4

Damaged Square Tip Repair ........................................................................................................................... F2-5

Damaged Tip Repair ....................................................................................................................................... F2-4
Defects, Propeller .................................................................................................................................... 2-9, T2-2
Deicing ...........................................................................................................................................................2-18c
Description, Propeller ........................................................................................................................................ 2-6
Drive Components ............................................................................................................................................ 4-4
Clutches ................................................................................................................................................ 4-4b
Drive Shafting ......................................................................................................................................... 4-4f
Engine Cooling Fans .............................................................................................................................. 4-4d
Freewheeling Units .................................................................................................................................4-4c
Gearboxes ............................................................................................................................................. 4-4a
Rotor Brakes .......................................................................................................................................... 4-4e
Drive Shafting .......................................................................................................................................... 4-41, 4-5
Dynamic Balancing ......................................................................................................................................... 2-13

Efficiency, Engine ............................................................................................................................................. 2-8

Efficiency, Propeller .......................................................................................................................................... 2-7
Electrical Deicing System, Typical .................................................................................................................. F2-1
Electronic Blade Tracker ................................................................................................................................3-17b
Electronic Blade Tracking Equipment............................................................................................................. F3-12
Engine Cooling Fans ................................................................................................................................ 4-4d, 4-5
Engine Efficiency .............................................................................................................................................. 2-8
Mechanical Efficiency . ........................................................................................................................... 2-81
Thermal Efficiency ................................................................................................................................. 2-80
Volumetnc Efficiency ..............................................................................................................................2-8c
Extremely Low Frequency Vibration ................................................................................................................ 3-16

Feathering Propeller .......................................................................................................................................... 2-6

Fiberglass Blade Repair .................................................................................................................................3-12b
Flight Controls, Helicopter ................................................................................................................................. 3-5

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Subject Paragraph
Figure, Table
Number

F - Continued

Fixed - Pitch Propeller ..................................................................................................................................... 2-6a

Flag and Pole .................................................................................................................................................3-17a
Flapping Action, Blade (Vertical Plane) ........................................................................................................... F3-7
Freewheeling Units ....................................................................................................................................4-4c, 4-5
Fully Articulated Rotor ......................................................................................................................................3-6c
Fully Articulated Rotor Head ........................................................................................................................... F3-6

Gearboxes ..............................................................................................................................................4-4a, 4-5a

General (Blade Balance) ................................................................................................................................3-10a
General (Tall Rotor Hubs) ............................................................................................................................... 3-8a
General Shop Rules ................................................................................................................................... 2-2, 3-2
................................................................................................................................................................. 4-2
Responsibility ................................................................................................................................2-2a, 3-2a
............................................................................................................................................................... 4-2a
Shop Housekeeping ......................................................................................................................2-2b, 3-2b,
............................................................................................................................................................... 4-2b
Shop Safety ..................................................................................................................................2-2c, 3-2c,
................................................................................................................................................................4-2c
Shop Tools and Materials .............................................................................................................2-2d, 3-2d,
............................................................................................................................................................... 4-2d
General, Powertrain Maintenance Practices and Procedures ............................................................................. 4-1
General, Propeller Maintenance Practices and Procedures . .............................................................................. 2-1
General, Rotor Maintenance Practices and Procedures ..................................................................................... 3-1
Governed Propellers, Rigging .......................................................................................................................... 2-16
Governor, Woodward .................................................................................................................................... F2-10
Governors, Propellers ..................................................................................................................................... 2-15

Hartzell Constant-Speed Propeller ......................................................................................................... F2-2, 2-6c

Hartzell Pitch Change Mechanism ................................................................................................................... F2-1
Helicopter Configurations .................................................................................................................................. 3-4
Single Rotor............................................................................................................................................ 3-4a
Tandem Rotor ........................................................................................................................................ 3-4b
Helicopter Control System ............................................................................................................................... F3-1
Helicopter Flight Controls .................................................................................................................................. 3-5
Collective Pitch Control ........................................................................................................................... 3-b
Cyclic Pitch Control ............................................................................................................................... 3-5a
Swashplate ..............................................................................................................................................3-5c

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Subject Paragraph
Figure, Table
Number

H - Continued

Throttle Control ...................................................................................................................................... 3-2d

Torque Control ....................................................................................................................................... 3-2e
Helicopter Vibrations ....................................................................................................................................... 3-16
Extreme Low Frequency Vibration ........................................................................................................3-16a
Low Frequency Vibration ......................................................................................................................3-16b
Medium Frequency Vibration ................................................................................................................3-16c
High Frequency Vibration .....................................................................................................................3-16d

Icing, Propeller ................................................................................................................................................ 2-18

Icing Types ....................................................................................................................................................2-18a
Inspection (of Rotors) .....................................................................................................................................3-11c
Insallation (of Governors)................................................................................................................................2-16b
Installation, Propeller ....................................................................................................................................... 2-14
Integrated Oil Control Assembly ..................................................................................................................... 2-15f

Low Frequency Vibration ................................................................................................................................3-16b

Main Rotor Assemblies ..................................................................................................................................... 3-6

Fully Articulated Rotor ............................................................................................................................3-6c
Rigid Rotor ............................................................................................................................................ 3-6a
Semi-Rigid Rotor ................................................................................................................................... 3-6b
Main Rotor Blade Terms ................................................................................................................................. T3-1
Main Rotor Blades ............................................................................................................................................. 3-7
Blade Classification Data ....................................................................................................................... 3-7d
Blade Construction .................................................................................................................................3-7c
Nomenclature ........................................................................................................................................ 3-7b
Types ..................................................................................................................................................... 3-7a
Main Rotor Hub and Blade Assembly ............................................................................................................ F3-10
Main Rotor Hub and Blade Removal ............................................................................................................... F3-9
Main Rotor Painting ........................................................................................................................................3-13a
Mass Balance Weights (Bars) ........................................................................................................................3-10b
Materials, Consumable ...................................................................................................................................... 1-3
Measuring Angle of Bend ................................................................................................................................ F2-6
Mechanical Efficiency ..................................................................................................................................... 2-8a
Medium Frequency Vibration ..........................................................................................................................3-16c

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Subject Paragraph
Figure, Table
Number

M - Continued

Metal Blade Repair .........................................................................................................................................3-12a

Metal Propellers (Preservation and Storage) ..................................................................................................2-19b
Minor Defects (in Propellers) ..........................................................................................................................2-12a
Model Designation (Propellers Governors) .....................................................................................................2-15b
Model Number, Propeller ................................................................................................................................ T2-1

Nomenclature (for Main Blades) ...................................................................................................................... 3-7b

Oil Control Plugging .......................................................................................................................................2-16a

Oil Coolers ...................................................................................................................................................... 4-5g
Oil Filters .........................................................................................................................................................4-5c
Oil Lines .......................................................................................................................................................... 4-5b
Oil Pumps ........................................................................................................................................................ 4-5f
Oil Screens ..................................................................................................................................................... 4-5d
Operation Checks (of Governors) ...................................................................................................................2-16d

Painting, Rotor Blade ...................................................................................................................................... 3-13

Pitch Change Mechanism, Hartzell .................................................................................................................. F2-1
Pitch Control, Collective .................................................................................................................................. F3-5
Pitch Control, Cyclic ........................................................................................................................................ F3-4
Powertrain ......................................................................................................................................................... 4-3
Single Rotor Powertrain ......................................................................................................................... 4-3a
Tandem Rotor Powertrain ...................................................................................................................... 4-3b
Powertrain Maintenance Practices and Procedures ........................................................................................... 4-1
Powertrain, Single Rotor ........................................................................................................................... 4-3a, F4
Powertrain, Tandem Rotor ..................................................................................................................... 4-3b, F4-2
Preservation and Storage, Propeller ................................................................................................................ 2-19
Preservation and Storage, Rotor Blade ........................................................................................................... 3-18
Pnnciples of Operation and Design of Rotor Systems ........................................................................................ 3-3
Procedures, Troubleshooting (Propeller System) ............................................................................................. 2-10
Procedures, Troubleshooting (Rotor Systems) ................................................................................................. 3-15
Propeller Balancing ......................................................................................................................................... 2-13
Aerodynamic Balancing ........................................................................................................................2-13b
Blade Tracking ......................................................................................................................................2-13d
Dynamic Balancing ...............................................................................................................................2-13c

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Subject Paragraph
Figure, Table
Number

P - Continued

Static Balancing ....................................................................................................................................2-13a

Propeller Classification ...................................................................................................................................... 2-5
Pusher Propeller .................................................................................................................................... 2-5b
Tractor Propeller .................................................................................................................................... 2-5a
Propeller Cleaning ..........................................................................................................................................2-11b
Propeller defects ...................................................................................................................................... 2-9, T2-2
Propeller Description ......................................................................................................................................... 2-6
Controllable-Pitch Propeller ................................................................................................................... 2-6b
Feathering Propeller .............................................................................................................................. 2-6e
Fixed-Pitch Propeller ............................................................................................................................. 2-6a
Hartzell Constant-Speed Propeller ..........................................................................................................2-6c
Reverse-Pitch Propeller .......................................................................................................................... 2-6f
Turboprop Propeller ............................................................................................................................... 2-6d
Propeller Efficiency ........................................................................................................................................... 2-7
Propeller Governors ........................................................................................................................................ 2-15
Integrated Oil Control Assembly ........................................................................................................... 2-15f
Model Description .................................................................................................................................2-15b
Principles of Operation .........................................................................................................................2-15a
Single Capacity Governors ...................................................................................................................2-15c
Turbo Prop Overspeed Governors ........................................................................................................2-15e
Turbo Prop Governors ..........................................................................................................................2-15d
Propeller Icing ................................................................................................................................................. 2-18
Anti-Icing ..............................................................................................................................................2-18b
Deicing .................................................................................................................................................2-18c
Icing Types ....................................................................................................................................................2-18a
Propeller Inspection .......................................................................................................................................2-11c
Propeller Installation ........................................................................................................................................ 2-14
Propeller Maintenance Practices and Procedures .............................................................................................. 2-1
Propeller Model and Blade Designation ............................................................................................................. 2-4
Propeller Model Number ................................................................................................................................. T2-1
Propeller Preservation and Storage ................................................................................................................. 2-19
Metal Propellers ....................................................................................................................................2-19b
Wood Propellers ...................................................................................................................................2-19a
Propeller Removal .........................................................................................................................................2-11a
Propeller Removal, Cleaning and Inspection ................................................................................................... 2-11
Propeller Cleaning ................................................................................................................................2-11b
Propeller Inspection ..............................................................................................................................2-11c
Propeller Removal ................................................................................................................................2-11a
Propeller Repair .............................................................................................................................................. 2-12
Bends and Twist ...................................................................................................................................2-12c
Minor Defects .......................................................................................................................................2-12a
Tip Damage ..........................................................................................................................................2-12b

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Subject Paragraph
Figure, Table
Number

P - Continued

Propeller RPM Adjusting Screw ..................................................................................................................... F2-11

Propeller Theory ............................................................................................................................................... 2-3
Propeller Tracking ........................................................................................................................................... F2-9
Purpose (of Manual)........................................................................................................................................... 1-1

Refinishing (Rotor Blades) ..............................................................................................................................3-13d

Reflector Blade Tracking ............................................................................................................................... F3-13
Removal (of Rotors) .......................................................................................................................................3-11a
Removal, Main Rotor Hub and Blade .............................................................................................................. F3-9
Repair of Surface Defects (Propeller) .............................................................................................................. F2-3
Repair, Propeller ............................................................................................................................................. 2-12
Responsibility (for General Shop Rules) ..................................................................................................2-2a, 3-2a
............................................................................................................................................................... 4-2a
Reverse-Pitch Propeller .................................................................................................................................... 2-6f
Rigging (of Governors)....................................................................................................................................2-16c
Rogging Governed Propellers ......................................................................................................................... 2-16
Installation ............................................................................................................................................2-16b
Oil Control Plugging ..............................................................................................................................2-16a
Operation Checks .................................................................................................................................2-16d
Rigging .................................................................................................................................................2-16c
Rigid Rotor ...................................................................................................................................................... 3-6a
Rotor Assemblies, Main .................................................................................................................................... 3-6
Rotor Blade Alignment .................................................................................................................................... 3-14
String Method .......................................................................................................................................3-14b
Telescopic Method ................................................................................................................................3-14a
Rotor Blade Painting ....................................................................................................................................... 3-13
Main Rotor Painting ..............................................................................................................................3-13a
Refinishing ............................................................................................................................................3-13d
Spot Painting ........................................................................................................................................3-13c
Tail Rotor Painting ................................................................................................................................3-13b
Rotor Blade Preservation and Storage ............................................................................................................ 3-18
Rotor Blade Repair .......................................................................................................................................... 3-12
Fiberglass Blade Repair ........................................................................................................................3-12b
Metal Blade Repair ...............................................................................................................................3-12a
Rotor Blade Tracking ........................................................................................................................... 3-17, F3-11
Electronic Blade Tracker .......................................................................................................................3-17b
Flag and Pole .................................................................................................................................................3-17a
Tall Rotor Tracking .........................................................................................................................................3-17c
Rotor Brakes ...........................................................................................................................................4-4e, 4-5k

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Subject Paragraph
Figure, Table
Number

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

Scope (of Manual) ............................................................................................................................................. 1-2

Semi-Rigid Rotor ............................................................................................................................................. 3-6b
Shop Housekeeping ................................................................................................................................2-2b, 3-2b
............................................................................................................................................................... 4-2b
Shop Rules, General ................................................................................................................................... 2-2, 3-2
................................................................................................................................................................. 4-2
Shop Safety ............................................................................................................................................2-2c, 3-2c
................................................................................................................................................................4-2c
Shop Tools and Materials ........................................................................................................................2-2d, 3-2d
................................................................................................................................................................. 4-2
Single Capacity Governors .............................................................................................................................2-15c
Single Rotor .................................................................................................................................................... 3-4a
Single Rotor Configuration .............................................................................................................................3-10c
Spanwise Balance Weights ............................................................................................................................3-13c
Spot Painting (Rotors) ....................................................................................................................................3-13c
Square Tip, Damaged, Repair ......................................................................................................................... F2-5
Static Balancing .............................................................................................................................................2-13a
String Method .................................................................................................................................................3-14b
Surface Defects (Propeller), Repair of ............................................................................................................. F2-3
Swashplate ......................................................................................................................................................3-5c

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VOLUME 5

Subject Paragraph
Figure, Table
Number

Tail Rotor Blades .............................................................................................................................................. 3-9

Balance ..................................................................................................................................................3-9c
Construction .......................................................................................................................................... 3-9b
Trammeling ............................................................................................................................................ 3-9d
Types ..................................................................................................................................................... 3-9a
Tail Rotor Hubs ................................................................................................................................................. 3-8
General .................................................................................................................................................. 3-8a
Types ..................................................................................................................................................... 3-8b
Tail Rotor Painting .........................................................................................................................................3-13b
Tall Rotor Tracking ..............................................................................................................................3-17c, F3-14
Tandem Rotor ................................................................................................................................................. 3-4b
Tandem Rotor Configuration ........................................................................................................................... F3-3
Telescopic Method .........................................................................................................................................3-14a
Terms, Main Rotor Blade ................................................................................................................................ T3-1
Theory, Propeller .............................................................................................................................................. 2-3
Thermal Efficiency .......................................................................................................................................... 2-8b
Three-Blade Balance Check ............................................................................................................................ F2-8
throttle Control ................................................................................................................................................ 3-5d
Tip Damage ...................................................................................................................................................2-12b
Tip, Damaged, Repair ..................................................................................................................................... F2-4
Torque Control ................................................................................................................................................. 3-5e
Tracking Weights ...........................................................................................................................................3-10d
Tracking, Propeller .......................................................................................................................................... F2-9
Tracking, Tail Rotor ....................................................................................................................................... F3-14
Tractor Propeller ............................................................................................................................................. 2-5a
Trammeling (of Tail Rotor Blades) .................................................................................................................. 3-9d
Trim Tabs ......................................................................................................................................................3-10e
Troubleshooting Procedures (Propeller System) .............................................................................................. 2-10
Troubleshooting Procedures (Rotor Systems) ......................................................................................... 3-15, T3-2
Troubleshooting Procedures for Hamilton Standard 53C51-23 ........................................................................ T2-3
Troubleshooting Procedures for Hartzell HC93Z20-2C Propeller ..................................................................... T2-5
Troubleshooting Procedures for Hartzell HCB3TN-3 Propeller ......................................................................... T2-5
Turboprop Overspeed Governors ...................................................................................................................2-15e
Turboprop Governors .....................................................................................................................................2-15d
Turboprop Propeller ........................................................................................................................................ 2-6d
Two-Blade Balance Check. .............................................................................................................................. F2-7
Types (of Main Rotor Blades) .......................................................................................................................... 3-7a
Types (of Tail Rotor Blades) ............................................................................................................................ 3-9a
Types (of Tail Rotor Hubs) .............................................................................................................................. 3-8b
Typical Anti-Icing System .............................................................................................................................. F2-12
Typical Electrical Deicing System .................................................................................................................. F2-13

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VOLUME 5

Subject Paragraph
Figure, Table
Number

Valves ............................................................................................................................................................. 4-5e

Vibrations, Helicopter ...................................................................................................................................... 3-16
Volumetnc Efficiency .......................................................................................................................................2-8c

Wood Propellers (Preservation and Storage) .................................................................................................2-19a

Wood Propellers ............................................................................................................................................. 2-17
Inspection Requirements ......................................................................................................................2-17a
Refinishing ............................................................................................................................................2-17d
Repair ...................................................................................................................................................2-17c
Replacement Criteria ............................................................................................................................2-17b
Woodward Governor . .................................................................................................................................... F2-10

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Subject Paragraph
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 Base Adhesive, MIL-A-8576, Type I, Solvent Type .............................................................. 6-2b
Acrylic Monomer Base Adhesive, MIL-A-8576, Type I, Solvent Type .............................................................. T6-1
Adhesive and Cements ...................................................................................................................................... 6-2
Acrylic Monomer and Polymer Base Adhesive, MIL-A-8576, Type II, Non-Solvent ...........................................6-2c
Acrylic Monomer Base Adhesive MIL-A-8576,Type I, Solvent Type ....................................................... 6-2b
Cement Pnmer . ..................................................................................................................................... 6-21
Cement Types ....................................................................................................................................... 6-2a
Chemigum Coating Cement ................................................................................................................... 6-2d
Colored Cement .................................................................................................................................... 6-2e
Composite Adhesives ........................................................................................................................... 6-2m
Deicer 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-1 39, 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
Identification .......................................................................................................................................... 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 MIL-S-8802 ......................................................... T6-4

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Subject Paragraph
Figure, Table
Number

A - Continued

Assemblies, Channel ..................................................................................................................................... F2-19

Authority for Substitutions and Interchangeability of Material (Air Items) ........................................................... 1-3
AVSCOM, Responsibilities of ............................................................................................................................ 1-5

Blind Rivets ....................................................................................................................................................... 2-8

Bolt and Screw Markings ................................................................................................................................. T2-1
Bolt Diameter by Part Number ........................................................................................................................ T2-2
Bolt, Drilled Head ............................................................................................................................................ F2-3
Bolt Head Identification ................................................................................................................................... 2-2d
Bolt Hole Location by Letter ............................................................................................................................ T2-4
Bolt Identification, Hexagon Head ................................................................................................................... F2-2
Bolt Length by Dash Number ........................................................................................................................... T2-5
Bolt Material by Letter Preceding Dash Number . ............................................................................................. T2-3
Bolt Substitution, Huck and Hi-Lok .................................................................................................................. T2-6
Bolt-End Description ....................................................................................................................................... F2-1
Bolted Joint with Oversize Hole ..................................................................................................................... F2-13
Bolts ................................................................................................................................................................. 2-2
Aluminum Bolts ..................................................................................................................................... 2-2n
Bolt Head Identification .......................................................................................................................... 2-2d
Clevis Bolts ................................................................................................................................... 2-2j, F2-7
Close Tolerance Bolts ............................................................................................................................ 2-2g
Drilled Head Bolts ................................................................................................................................... 2-2f
External Wrenching Bolts ............................................................................................................. 2-21, F2-6
Eye Bolts ...................................................................................................................................... 2-2k, F2-8
Fitting Structural Bolts ........................................................................................................................... 2-2q
Hexagon Head Bolts .............................................................................................................................. 2-2e
Huck Bolts (Lockbolt) ............................................................................................................................. 2-2p
Installation and End Description ............................................................................................................. 2-2b
Internal Wrenching Bolts ............................................................................................................... 2-2h, F2-5
Jo-Bolts ................................................................................................................................................. 2-2o
Locking or Safetying ...............................................................................................................................2-2c
Self-Locking Bolts ......................................................................................................................... 2-21, F2-9
Substitutions for Huck, Hi-Lock, and NAS Bolts ...................................................................................... 2-2r
Substitutions for Jo-Bolts and V-Bolts ............................................................................................2-2s, T2-7
Tee-Head Bolts ..................................................................................................................................... 2-2m

Camloc Fasteners ................................................................................................................................ 2-9b, F2-61

Castellated Nuts .............................................................................................................................................. 2-3b

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Subject Paragraph
Figure, Table
Number

C - Continued

Castle Nut, Airframe ...................................................................................................................................... F2-22

Castle Nut, Shear .......................................................................................................................................... F2-23
Cells, Fuel and Oil ............................................................................................................................................. 3-4
Cement Primer ................................................................................................................................................ 6-21
Cement Types ................................................................................................................................................. 6-2a
Cements and Adhesives .................................................................................................................................... 6-2
Changes to Department of Army Publications, Recommended .......................................................................... 1-6
Channel Assemblies ...................................................................................................................................... F2-19
Characteristics of Catalyst Cured Sealants .......................................................................................................6-3c
Characteristics of Drying Sealants ................................................................................................................... 6-3b
Characteristics of Pliable Sealants .................................................................................................................. 6-3a
Checknut, Plain.............................................................................................................................................. F2-24
Checknuts ........................................................................................................................................................2-3c
Chemigum Coating Cement ............................................................................................................................ 6-2d
Cherrylock Rivets .......................................................................................................................................... F2-56
CherryMAX Rivets.......................................................................................................................................... F2-55
Cross Reference (Part Number/Military Standard Part Number, CherryMAX Rivets ............................. T2-11
Clamp Identification ........................................................................................................................................ 2-6a
Clamp, Loop-Type Bonding ........................................................................................................................... F2-42
Clamp, Loop-Type Support ........................................................................................................................... F2-45
Clamp Types ................................................................................................................................................... 2-6b
Clamps ............................................................................................................................................................. 2-6
Clamp Identification ............................................................................................................................... 2-6a
Clamp Types ......................................................................................................................................... 2-6b
Clamps, Hose ............................................................................................................................................... F2-43
Clamps, Tube ................................................................................................................................................ F2-44
Clevis Bolts ............................................................................................................................................. 2-2j, F2-7
Clevis Pins............................................................................................................................................ 2-7a, F2-46
Close Tolerance Bolt, Countersunk ................................................................................................................. F2-4
Close Tolerance Bolts ..................................................................................................................................... 2-2g
Coding, Color .................................................................................................................................................. T3-1
Color Code (for Aluminum Alloys) ................................................................................................................... T4-4
Color Coding ................................................................................................................................................... T3-1
Colored Cements ............................................................................................................................................ 6-2e
Common Solid Shank Rivets ........................................................................................................................... 2-8a
Composite Adhesives ..................................................................................................................................... 6-2m
Considerations to be Taken Before Torquing ..................................................................................................2-18b
Consumable Items ............................................................................................................................................ 7-2
Consumable Items List ...................................................................................................................................... 7-3
Consumable Items Part 1 ...................................................................................................................... 7-3a
Consumable Items Part 2 ....................................................................................................................... 7-3b
Consumable Materials ....................................................................................................................................... 1-7
Cord Identification ........................................................................................................................................... 3-5a
Cord Inspection ................................................................................................................................................ 3-5b

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Subject Paragraph
Figure, Table
Number

C - Continued

Cord Storage ................................................................................................................................................... 3-5d

Cord Testing ....................................................................................................................................................3-5c
Cord, Test Loads ............................................................................................................................................. T3-2
Corrosion Resistance (of Rivets) ..................................................................................................................... 2-8d
Cotter Pin Installation .......................................................................................................................... 2-17a, F2-77
Cotter Pins ........................................................................................................................................... 2-7g, F2-52
Countersunk Close Tolerance Bolt .................................................................................................................. F2-4
Countersunk Washer ..................................................................................................................................... F2-34
Cross Reference of Old and New Color Code (for Aluminum Alloys) ............................................................... T4-5
Cross Reference (Part Number/Military Standard Part Number) CherryMAX Rivets ...................................... T2-11
Cure Time (Room Temperature), Sealing Compound MIL-S-8802 .................................................................. T6-4
Curing (of Adhesives, Sealants, and Cements) . .............................................................................................. 6-1d

Deicer Repair Cement...................................................................................................................................... 6-21

Deicer Shoe Electrical Conducting Neoprene Surface Coat Cement ................................................................ 6-2f
Description of Bolt-Ends .................................................................................................................................. F2-1
Designation Conversions (Old to New), Aluminum Alloy .................................................................................. T4-2
Designation for (Aluminum) Alloy Groups ........................................................................................................ T4-1
Diameter by Part Number, Bolt ....................................................................................................................... T2-2
Dill Lok-Skru .........................................................................................................................................2-9c, F2-62
Drilled Head Bolts ................................................................................................................................... 2-2f, F2-3
Dzus Fasteners .................................................................................................................................... 2-9a, F2-60

Electrical Screws .............................................................................................................................................. 2-5f

Engine Self-Locking Nut ................................................................................................................................ F2-20
Example of Color Marking (for Aluminum Alloys) ............................................................................................ F4-1
External Wrenching Bolts ........................................................................................................................ 2-2i, F2-6
Eye Bolts ................................................................................................................................................ 2-2k, F2-8

Fastener, Lockring .......................................................................................................................................... 2-15

Fasteners .......................................................................................................................................................... 2-9
Camloc . ...................................................................................................................................... 2-9b, F2-61
Dill Lok-Skru .................................................................................................................................2-9c, F2-62
Dzus Fasteners ........................................................................................................................... 2-9a, F2-60
Interlocking Slide ........................................................................................................................ 2-9e, T2-12
Snap and Curtain ................................................................................................................................... 2-9d

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Subject Paragraph
Figure, Table
Number

F - Continued

Fillister Head Screws ..................................................................................................................................... F2-39

Fitting Identification ........................................................................................................................................2-16a
Fitting Structural Bolts ..................................................................................................................................... 2-2q
Fittings ................................................................................................................................................. 2-16, T2-18
Fitting Identification ..............................................................................................................................2-16a
Special Fitting Types ............................................................................................................................2-16b
Fitting Material Code ..................................................................................................................................... T2-17
Fittings, Typical ............................................................................................................................................. F2-76
Flat-Head Screws .......................................................................................................................................... F2-37
Floating Anchor Nuts ..................................................................................................................................... F2-17
Flush Head Jo-Bolt ........................................................................................................................................ F2-10
Forming Titanium and Titanium Alloys ............................................................................................................ 4-5a
Fuel and Oil Cells ................................................................................................................................................34
Fuel Cell Identifications ......................................................................................................................... 3-4a
Fuel Cell Storage ................................................................................................................................... 3-4b
Oil Cell Identification ...............................................................................................................................3-4c
Oil Cell Storage ..................................................................................................................................... 3-4d
Fuel Cell Identification ..................................................................................................................................... 3-4a
Fuel Cell Storage ............................................................................................................................................ 3-4b

Gasket and Packing Identification ................................................................................................................... 3-6b

Gasket and Packing Types .............................................................................................................................. 3-6a
Gasket and Packings ........................................................................................................................................ 3-6
Gasket and Packing Identification .......................................................................................................... 3-6b
Gasket and Packing Types .................................................................................................................... 3-6a
Storage ...................................................................................................................................................3-6c
General
Adhesive Sealants, and Cements ............................................................................................................ 6-1
Consumable Materials .............................................................................................................................. 7-1
Hardware ................................................................................................................................................. 2-1
Metals ...................................................................................................................................................... 4-1
Phenolic and Plastic Materials ................................................................................................................. 5-1
Rubber Materials ..................................................................................................................................... 3-1
General Purpose Synthetic Rubber Base Cement MIL-Spec MMM-A-1617 ..................................................... 6-2g
General Usage (of Rivets) ................................................................................................................................2-8c
Gnp Length (for Bolts) ..................................................................................................................................... 2-2a

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Subject Paragraph
Figure, Table
Number

Handling of Aluminum Alloys .......................................................................................................................... 4-2b

Hardware General ............................................................................................................................................. 2-1
Heat Treatment of Rivets ................................................................................................................................. 2-8f
Helical Insert and Tools Data ........................................................................................................................ T2-15
Helical Insert National Fine Thread Sizes ...................................................................................................... T2-14
Helical Insert Part Numbers ........................................................................................................................... T2-13
Helical Thread Inserts ..................................................................................................................................... 2-11
Insert Tolerance ....................................................................................................................................2-11c
Inspection Criteria for Helical Springs ...................................................................................................2-11d
Installation of Helical Insert ...................................................................................................................2-11e
Installation of Spark Plug Helical Insert .................................................................................................2-11h
Installation of Twinsert ...........................................................................................................................2-11i
Oversize Insert and Twinsert Kits ..........................................................................................................2-11k
Removal of Helical Insert ...................................................................................................................... 2-11f
Removal of Twinsert ..............................................................................................................................2-11j
Types ...................................................................................................................................................2-11a
Hexagon Head Bolt Identification .................................................................................................................. F2-11
Hexagon Head Bolts ....................................................................................................................................... 2-2e
Hi-Shear Rivets .................................................................................................................................... 2-8h, F2-54
High Tensile Washer ..................................................................................................................................... F2-33
Hinge Pins ....................................................................................................................................................... 2-7f
Hole Location by Letter, Bolt ........................................................................................................................... T2-4
Hose Clamp .................................................................................................................................................. F2-43
Huck and Hi-Lock Bolt Substitution ................................................................................................................. 12-6
Huck Bolts (Lockbolt) ...................................................................................................................................... 2-2p
Huck Rivet .................................................................................................................................................... F2-57

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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Subject Paragraph
Figure, Table
Number

I - Continued

Inspection of Rubber Materials ........................................................................................................................ 3-1b

Inspection of Titanium and Titanium Alloys ..................................................................................................... 4-5b
Installation Data, Spacer ............................................................................................................................... F2-69
Installation of Helical Insert ............................................................................................................................2-11e
Installation of Spark Plug Helical Insert ..........................................................................................................2-11h
Installation of Twinsert .........................................................................................................................2-11i, F2-66
Installation, Stud ........................................................................................................................................... F2-65
Installation, Stud and Grommet ..................................................................................................................... F2-59
Installing New Stud ........................................................................................................................................2-10b
Interlocking Slide Fasteners ................................................................................................................. 2-9e, T2-12
Internal Wrenching Bolts ....................................................................................................................... 2 -2h, F2-5
Internal Wrenching Nuts .................................................................................................................................. 2-3h

Jamnuts .......................................................................................................................................................... 2-3d

Jo-and V-Bolts Substitution ...................................................................................................................22-2s, T2-7
Jo-Bolts ........................................................................................................................................................... 2-20
Flush Head .......................................................................................................................................... F2-10
Hexagon Head ..................................................................................................................................... F2-11
Millable Head ....................................................................................................................................... F2-12
Joint with Oversize Hole, Bolted .................................................................................................................... F2-13

Length by Dash Number, Bolt .......................................................................................................................... T2-5

Length Measurement (of Screws) .................................................................................................................... 2-5b
Light Hexagon Nuts .............................................................................................................................. 2-3e, F2-25
Locking of Safetying Bolts ............................................................................................................................... 2-2b
Lockpins ............................................................................................................................................... 2-7e, F2-51
Lockring ........................................................................................................................................................ F2-74
Lockring Fastener ........................................................................................................................................... 2-15
Lockring Principle .......................................................................................................................................... F2-75
Lockwasher, Spit ........................................................................................................................................... F2-30
Lockwashers ................................................................................................................................................... 2-46
Lockwashers, Teeth-Type ............................................................................................................................. F2-31
Lockwire Installation .......................................................................................................................................2-17b
Lockwiring Oil Caps, Drain Cocks, and Valves .............................................................................................. F2-79
Lockwiring Screws, Nuts, and Bolts ............................................................................................................... F2-78
Lockwiring, Speed Rig ................................................................................................................................... F2-81
Lockwiring Turnbuckes ................................................................................................................................... 2-17f
Loop-Type Bonding Clamp ............................................................................................................................ F2-42
Loop-Type Support Clamp ............................................................................................................................ F2-45

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VOLUME 6

Subject Paragraph
Figure, Table
Number

Machine Screws ............................................................................................................................................ F2-38

Magnesium Alloys ............................................................................................................................................. 4-3
Identification .................................................................................................................................. 4-3a, T4-7
Storage....................................................................................................................................................4-3c
Testing. .................................................................................................................................................. 4-3b
Maintenance Activities, Responsibility of ........................................................................................................... 1-4
Marking Steel Alloys ........................................................................................................................................ 4-4b
Marking Titanium Alloys .................................................................................................................................. 4-5d
Markings, Bolt and Screw ................................................................................................................................ T2-1
Material, by Letter Preceding Dash Number, Bolt ............................................................................................ T2-3
Materials, Consumable ...................................................................................................................................... 1-7
Materials Used in Fabrication (of Rivets) ........................................................................................................... 7-1
Metals, General ................................................................................................................................................. 4-1
Millable Hexagon Head Jo-Bolt ..................................................................................................................... F2-12
Minimum Breakaway Torque for Used All-Metallic and Nonmetallic Self-Locking Nuts .................................... T2-8
Mixing (Adhesives, Sealants, and Cements) ...................................................................................................6-1 c

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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Subject Paragraph
Figure, Table
Number

O - Continued

Other Adhesives. ............................................................................................................................................ 6-2 n

Oversize Insert and Twinsert Kits ...................................................................................................................2-11k

Packings, Gaskets and ...................................................................................................................................... 3-6

Part Number Breakdown, Spacer .................................................................................................................. F2-68
Part Numbers, Helical Insert .......................................................................................................................... T2-13
Phenolic and Plastic Materials, General ............................................................................................................ 5-1
Phenolic Compositions ...................................................................................................................................... 5-2
Identification .......................................................................................................................................... 5-2a
Storage ...................................................................................................................................................5-2c
Usage ..................................................................................................................................................... 5-2b
Pin, Threaded Taper ..................................................................................................................................... F2-48
Pins ................................................................................................................................................................. 2-7
Clevis Pins ................................................................................................................................. 2-7a, F2-46
Cotter Pins .................................................................................................................................. 2-7g, F2-52
Hinge Pins .............................................................................................................................................. 2-7f
Lockpins ..................................................................................................................................... 2-7e, F2-51
Safety Retaining Pins ..................................................................................................................2-7c, F2-49
Spring Pins ................................................................................................................................. 2-7d, F2-50
Taper Pins ............................................................................................................................................. 2-7b
Pins, Plain Taper ........................................................................................................................................... F2-47
Plain Washers ...................................................................................................................................... 2-4a, F2-29
Plastic Materials ................................................................................................................................................ 5-3
Identification ................................................................................................................................. 5-3a, T5-1
Storage....................................................................................................................................................5-3c
Types .................................................................................................................................................... 5-3b
Plate Nut, Self-Locking .................................................................................................................................. F2-16
Practices for Installation of Cotter Pins and Lockwire ...................................................................................... 2-17
Cotter Pin Installation ................................................................................................................ 2-17a, F2-77
Double-Twist Method ............................................................................................................................2-17c
Lockwire Installation .............................................................................................................................2-17b
Lockwiring Turnbuckles ......................................................................................................................... 2-17f
Rod End Safetying (Key Type NAS 559) ................................................................................... 2-17h, F2-82
Safetying Emergency Devices ..............................................................................................................2-17e
Securing Electrical and Electronic Connectors ......................................................................................2-171
Single-Wire Method ..............................................................................................................................2-17d
Speed Rig Safetying .............................................................................................................................2-17g
Precautionary Measures (for Adhesives, Sealants, and Cements) ................................................................... 6-1a
Preload Indicating Washers ........................................................................................................................... F2-35
Preparation of Surface (for Adhesives, Sealants, and Cements) ..................................................................... 6-1b
Principle of Lockring ...................................................................................................................................... F2-75
Purpose (of Manual) .......................................................................................................................................... 1-1

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Subject Paragraph
Figure, Table
Number

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

SAE Numbers Used in Identification of Steels ................................................................................................. T4-8

Safety Retaining Pins ............................................................................................................................2-7c, F2-49
Safetying Emergency Devices .......................................................................................................................2-17e
Scope (of Manual) ............................................................................................................................................. 1-2
Screw Heads ................................................................................................................................................... 2-5a
Screws ............................................................................................................................................................... 2-5
Electrical Screws .................................................................................................................................... 2-5f
Length Measurement ............................................................................................................................. 2-5b

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Subject Paragraph
Figure, Table
Number

S - Continued

Machines Screws ........................................................................................................................ 2-5d, F2-38

Screw Heads ......................................................................................................................................... 2-5a
Self-Tapping Screws ................................................................................................................... 2-5e, F2-40
Structural Screws .........................................................................................................................2-5c, F2-36
Screws, Fillister Head .................................................................................................................................... F2-39
Screws, Flat-Head ......................................................................................................................................... F2-37
Screws, Nuts, and Bolts, Lockwiring of .......................................................................................................... F2-78
Screws, Round-Head Machine ...................................................................................................................... F2-41
Sealants ............................................................................................................................................................ 6-3
Anaerobic Adhesive MIL-R-46082 .......................................................................................................... 6-31
Characteristics of Catalyst Cured Sealants .............................................................................................6-3c
Characteristics of Drying Sealants ......................................................................................................... 6-3b
Characteristics of Pliable Sealants ......................................................................................................... 6-3a
Sealing Compound, MIL-S-7126 ............................................................................................................. 6-3f
Sealing Compound, MIL-S-8784 ............................................................................................................ 6-3d
Sealing Compound, MIL-S-8802 ............................................................................................................ 6-3e
Semi-Solid Synthetic Rubber Sealant for Engine Firewalls .................................................................... 6-3h
Semi-Solid Synthetic Rubber Sealant, MIL-A-7126, for Hot-Air Ducts .................................................... 6-3g
Sealing Compound, MIL-S-7126 ...................................................................................................................... 6-3f
Sealing compound, MIL-S-8784 ...................................................................................................................... 6-3d
Sealing Compound, MIL-S-8802 ..................................................................................................................... 6-3e
Application Time (Room Temperature) .................................................................................................. T6-4
Cure Time (Room Temperature) ............................................................................................................ T6-5
Securing Electrical and Electronic Connectors .................................................................................................2-17i
Selection of Helical Inserts .............................................................................................................................2-11 b
Self-Locking Bolts .................................................................................................................................. 2-21, F2-9
Self-Locking Engine Nut ................................................................................................................................ F2-20
Self-Locking Nut Installation Limits ................................................................................................................ F2-21
Self-Locking Nuts ............................................................................................................................................ 2-3a
Self-Locking Plain Nut ................................................................................................................................... F2-15
Self-Locking Plate Nut ................................................................................................................................... F2-16
Self-Locking Thin Nut..................................................................................................................................... F2-14
Self-Tapping Screws ............................................................................................................................ 2-5e, F2-40
Semi-Solid Synthetic Rubber Sealant for Engine Firewalls .............................................................................. 6-3h
Semi-Solid Rubber Sealant, MIL-A-7126, for Hot-Air Ducts ............................................................................. 6-3g
Shear Castle Nut ........................................................................................................................................... F2-23
Sheet Spring Nuts ................................................................................................................................ 2-3g, F2-27
Shelf Life (of Adhesive, Acrylic Monomer and Polymer Base
Adhesive, MIL-A-8576, Type II, Non-Solvent) ........................................................................................ T6-3
Shelf Life (of Adhesive, Acrylic Monomer Base Adhesive,
MIL-A-8576, Type I, Solvent Type) ........................................................................................................ T6-1
Shock Absorber and Elastic Exerciser Cords ..................................................................................................... 3-5
Cord Identification .................................................................................................................................. 3-5a
Cord Inspection....................................................................................................................................... 3-5b

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Subject Paragraph
Figure, Table
Number

S - Continued

Cord Storage ......................................................................................................................................... 3-5d

Cord Testing ...........................................................................................................................................3-5c
Single-Wire Method .......................................................................................................................................2-17d
Snap and Curtain Fasteners ............................................................................................................................ 2-9d
Spacer Identification ......................................................................................................................................2-12a
Spacer Installation ..........................................................................................................................................2-12b
Spacer Installation Data ................................................................................................................................ F2-69
Spacer Part Number Breakdown ................................................................................................................... F2-68
Special Fitting Types ......................................................................................................................................2-16b
Special Washers ..............................................................................................................................................2-4c
Specific Gravity Ranges (for Adhesives and Cements) ................................................................................... T6-2
Speed Rig Lockwiring .................................................................................................................................... F2-81
Speed Rig Safetying ......................................................................................................................................2-17g
Split Lockwasher ........................................................................................................................................... F2-30
Spring Pins .......................................................................................................................................... 2-7d, F2-50
Steel Alloys ....................................................................................................................................................... 4-4
Identification .......................................................................................................................................... 4-4a
Marking .................................................................................................................................................. 4-4b
Steel, Identification of ................................................................................................................................... T4-10
Storage
of Aluminum Alloys .................................................................................................................................4-2c
of Gaskets and Packing ..........................................................................................................................3-6c
of Magnesium Alloys ...............................................................................................................................4-3c
of Phenolic Compositions .......................................................................................................................5-2c
of Plastic Materials .................................................................................................................................5-3c
of Rubber Materials ............................................................................................................................... 3-1a
Strength (of Rivets) ......................................................................................................................................... 2-8e
Structural Screws ..................................................................................................................................2-5c, F2-36
Stud and Grommet Installation ...................................................................................................................... F2-59
Stud Installation ............................................................................................................................................ F2-65
Stud Removal ............................................................................................................................................... F2-64
Stud Types .................................................................................................................................................... F2-63
Studs .............................................................................................................................................................. 2-10
Installating New Stud ............................................................................................................................2-10b
Removal of Bent, Damaged, or Broken Studs .......................................................................................2-10a
Styles of Plate Nuts ....................................................................................................................................... F2-18
Substitution and Interchangeability of Material (Air Items), Authority for ............................................................ 1-3
Substitution and Interchangeability (of Rivets) ................................................................................................. 2-8g
Substitutions for Huck, Hi-Lok, and NAS Bolts .................................................................................................. 2-2r
Substitutions for Jo-Bolts, and V-Bolts .....................................................................................................2-2s, T2-7

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Subject Paragraph
Figure, Table
Number

Taper Pin Washer ......................................................................................................................................... F2-32

Taper Pins ...................................................................................................................................................... 2-7b
Tee-Head Bolts .............................................................................................................................................. 2-2m
Teeth-Type Lockwashers .............................................................................................................................. F2-31
Temper Designations (of Aluminum Alloys) ..................................................................................................... T3-3
Terminals, Turnbuckle ................................................................................................................................... F2-72
Test Loads (of Cords)....................................................................................................................................... T3-2
Testing of Magnesium Alloys ........................................................................................................................... 4-3b
Thin Nut, Self-Locking ................................................................................................................................... F2-14
Threaded Taper Pins ..................................................................................................................................... F2-48
Tie Rod Terminal Fittings ................................................................................................................... 2-13b, F2-71
Tie Rods .......................................................................................................................................................... 2-13
Identification ..........................................................................................................................................2-13a
Tie Rod Terminal Fitting ........................................................................................................... 2-13b, F2-71
Tire Identification ............................................................................................................................................. 3-2a
Tire Storage ..................................................................................................................................................... 3-2b
Tires ................................................................................................................................................................. 3-2
Tire Identification ................................................................................................................................... 3-2a
Tire Storage ........................................................................................................................................... 3-2b
Titanium and Titanium Alloys ................................................................................................................. 4-5, T4-11
Forming ................................................................................................................................................. 4-5a
Identification ...........................................................................................................................................4-5c
Inspection .............................................................................................................................................. 4-5b
Marking ................................................................................................................................................. 4-5d
Tools Data, Helical Insert and ....................................................................................................................... T2-15
Tools Data, Metri-Thread Insert and .............................................................................................................. T2-16
Tools Data, Twinsert and ............................................................................................................................... T2-17
Torque ............................................................................................................................................................ 2-18
Considerations to be Taken Before Torquing ........................................................................................2-18b
Recommended Torque Values ..............................................................................................................2-18c
Torque Definitions ................................................................................................................................2-18a
Torque Definitions ..........................................................................................................................................2-18a
Torque for Used All-Metallic and Nonmetallic Self-Locking Nuts,
Minimum Breakaway ............................................................................................................................. T2-8
Torque Values, Nut, Recommended ................................................................................................................ T2-9
Tube Clamps.................................................................................................................................................. F2-44
Tube Identification ........................................................................................................................................... 3-3a
Tube Storage .................................................................................................................................................. 3-3b
Tubes ................................................................................................................................................................ 3-3
Tube Identification ................................................................................................................................. 3-3a
Tube Storage ......................................................................................................................................... 3-3b
Turnbuckle Assemblies, Typical .................................................................................................................... F2-80
Turnbuckle Inspection ....................................................................................................................................2-14b
Turnbuckle Installation ...................................................................................................................................2-14a

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Figure, Table
Number

T - Continued

Turnbuckle Terminals .................................................................................................................................... F2-72

Turnbuckles .................................................................................................................................................... 2-14
Turnbuckle Inspection ...........................................................................................................................2-14b
Turnbuckle Installation ..........................................................................................................................2-14a
Twinsert and Tools Data ................................................................................................................................ T2-16
Twinsert Installation ...................................................................................................................................... F2-66
Types of Aluminum Alloys ............................................................................................................................... T4-6
Types of Helical Inserts ..................................................................................................................................2-11a
Types of Plastic Materials ............................................................................................................................... 5-3b
Types of Rivnuts ........................................................................................................................................... F2-58
Typical Fittings............................................................................................................................................... F2-76
Typical Turnbuckle Assemblies ..................................................................................................................... F2-80

Usage (of Phenolic Compositions) ................................................................................................................... 5-2b

Washer, Countersunk .................................................................................................................................... F2-34

Washer, High Tensile .................................................................................................................................... F2-33
Washer, Taper Pin ........................................................................................................................................ F2-32
Washers ............................................................................................................................................................ 2-4
Lockwashers .......................................................................................................................................... 2-4b
Plainwashers .............................................................................................................................. 2-4a, F2-29
Special Washers .....................................................................................................................................2-4c
Washers, Preload Indicating .......................................................................................................................... F2-35
Wingnuts ............................................................................................................................................... 2-3f, F2-26

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Subject Paragraph
Figure, Table
Number

Advantages (of Radiography) ............................................................................................................................ 5-3

Advantages (of Ultrasonic Inspection) ............................................................................................................... 6-2
Amperage (Circular Magnetization) ................................................................................................................. 4-9b
Amperage (Longitudinal Magnetization) .........................................................................................................4-10b
Angle Beam Method ........................................................................................................................................ 6-9b
Application, Field. .............................................................................................................................................. 7-4
Application of Cleaner ....................................................................................................................................3-14b
Application of Developer ................................................................................................................................3-14e
Applications (of Longitudinal Magnetization) ...................................................................................................4-10c
Applications (of Radiography) ........................................................................................................................... 5-5
Applying Transparent Tape ............................................................................................................................4-12b
Availability of Penetrants ................................................................................................................................. 3-8b

Basic Principles of Penetrant Inspection ............................................................................................................ 3-3

Basic Terminology (of Magnetism) .................................................................................................................... 4-3
Ferromagnetic Metals ............................................................................................................................ 4-3a
Leakage Field ........................................................................................................................................ 4-3b
Magnetic Substances ............................................................................................................................. 4-3d
Magnetic Flux ........................................................................................................................................ 4-3e
Magnetism...............................................................................................................................................4-3c
Permeability ............................................................................................................................................ 4-3f
Residual Magnetism .............................................................................................................................. 4-3g
Retentivity ............................................................................................................................................. 4-3h
Basic Testing Methods (Ultrasonics) .................................................................................................................. 6-4
Beam Divergence ............................................................................................................................................6-7c
Best Access to Object ...................................................................................................................................... 5-6f
Black Light .....................................................................................................................................................3-11d

Calibration of Ultrasonic Equipment ................................................................................................................ 6-10

Capabilities and Limitations (Magnetic Particle Inspection) ................................................................................ 4-5
Changing Magnitude of Current ........................................................................................................................7-5c
Characteristics, Transmission ............................................................................................................................ 6-7
Circular Magnetization ...................................................................................................................................... 4-9
Amperage .............................................................................................................................................. 4-9b
Technique .............................................................................................................................................. 4-9a
Compatibility ................................................................................................................................................... 3-8a
Conditions Not Requiring Demagnetization ....................................................................................................4-13b
Consumable Materials ....................................................................................................................................... 1-3
Continuous Method .......................................................................................................................................... 4-8b

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Subject Paragraph
Figure, Table
Number

C - Continued

Couplants ........................................................................................................................................................ 6-8d

Current and Particle Application ........................................................................................................................ 4-8
Continuous Method ......................................................................................................................................... 4-8b
Field Direction ........................................................................................................................................4-8c
Field Measurement ................................................................................................................................ 4-8d
Residual Method .................................................................................................................................... 4-8a
Sensitivity Level .................................................................................................................................... 4-8e
Currents, Eddy .................................................................................................................................................. 7-3

Data, Use of ...................................................................................................................................................... 2-6

Defects, Honeycomb, Fiberglass, and Composite ........................................................................................... T2-2
Definitions (Magnetic Particle Inspection Terms) ............................................................................................4-11a
Degree of Sensitivity ........................................................................................................................................ 5-6d
Demagnetization ............................................................................................................................................. 4-13
Conditions Not Requiring Demagnetization ...........................................................................................4-13b
Limits of Demagnetization ....................................................................................................................4-13d
Reasons for Demagnetization ...............................................................................................................4-13a
Techniques for Demagnetization ...........................................................................................................4-13a
Destructive Tests ............................................................................................................................................ 2-4a
Detection Standards (Radiation) ...................................................................................................................... T5-1
Detection, Flaw ........................................................................................................................................ 2-7, T2-1
Developer Application .....................................................................................................................................3-10j
Developer Draining ........................................................................................................................................3-10k
Developer Dwell Time ....................................................................................................................................3-101
Disadvantages (of Radiography) ....................................................................................................................... 5-4
Disadvantages (of Ultrasonic Inspection) ........................................................................................................... 6-3
Draining .........................................................................................................................................................3-10e
Dry Particle Indications ..................................................................................................................................4-12c
Drying .............................................................................................................................................................3-10c

Eddy Current Inspection, Uses of .................................................................................................................... T7-1

Eddy Current Test Set Model ED-520 ................................................................................................................ 7-5
Changing Magnitude of Current ..............................................................................................................7-5c
Needle Defections ................................................................................................................................. 7-5d
Operation ............................................................................................................................................... 7-5a
Testing Procedure ................................................................................................................................. 7-5b
Eddy Currents ................................................................................................................................................... 7-3
Electrical Precautions .....................................................................................................................................5-11d
Electromagnetic Inspections, General ............................................................................................................... 7-1

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Subject Paragraph
Figure, Table
Number

E - Continued

Emulsifier Application .....................................................................................................................................3-10g

Emulsifier Draining..........................................................................................................................................3-10h
Emulsifier Dwell Time ....................................................................................................................................3-101
Equipment (Longitudinal Magnetization) .........................................................................................................4-10d
Evaluate Discontlnuity ....................................................................................................................................3-14g
Exposure ......................................................................................................................................................... 5-8a
Exposure and Processing, Film ......................................................................................................................... 5-8
Exposure Limits .............................................................................................................................................5-11 b

Ferromagnetic Metals ..................................................................................................................................... 4-3a

Field Application ............................................................................................................................................... 7-4
Field Direction ..................................................................................................................................................4-8c
Field Measurement ......................................................................................................................................... 4-8d
Filing Radiographs .......................................................................................................................................... 5-10
Film Exposure and Processing .......................................................................................................................... 5-8
Exposure ............................................................................................................................................... 5-8a
Processing ............................................................................................................................................. 5-8b
Film Placement ............................................................................................................................................... 5-6b
Film Processing, Manual ................................................................................................................................. F5-1
Fixing Indications with Lacquer .......................................................................................................................4-12a
Flaw Detection .......................................................................................................................................... 2-7, T21
Fluorescent Indications ..................................................................................................................................4-12e
Fluorescent Penetrant Inspection, Specific Procedures for .............................................................................. 3-11
Fluorescent Penetrant Processes ..................................................................................................................... 3-13
Fluoroscopy .................................................................................................................................................... 5-7a
Fundamentals of Magnetic Particle Inspection ................................................................................................... 4-4

General (Inspection Techniques) ..................................................................................................................... 5-6a

General Penetrant Inspections .......................................................................................................................... 3-1
General Procedures for Penetrant Inspection .................................................................................................... 3-6
General Shop Rules .......................................................................................................................................... 2-2
Maintenance of Shop Equipment ........................................................................................................... 2-2e
Responsibility ........................................................................................................................................ 2-2a
Shop Housekeeping ............................................................................................................................... 2-2b
Shop Safety ............................................................................................................................................2-2c
Shop Tools and Materials ...................................................................................................................... 2-2d
General, Electromagnetic Inspections ................................................................................................................ 7-1
General, Magnetic Particle Inspections ............................................................................................................. 4-1
General, Nondestructive Inspection ................................................................................................................... 2-1

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Subject Paragraph
Figure, Table
Number

G - Continued

General, Radiography ....................................................................................................................................... 5-1

General (Radiography Safety and Equipment) ...............................................................................................5-11a
General (Ultrasonic Inspection Equipment) ..................................................................................................... 6-8a
General, Ultrasonic Inspections ......................................................................................................................... 6-1

Honeycomb, Fiberglass, and Composite Defects ............................................................................................ T2-2

Importance of Skilled Operators ........................................................................................................................ 3-5

Indicators, Magnetic Particle ........................................................................................................................... 4-11
Inspection (Penetrant) ....................................................................................................................................3-12a
Inspection and Interpretation ........................................................................................................................... 3-12
Inspection .............................................................................................................................................3-12a
Interpretation .........................................................................................................................................3-12b
Inspection Conditions .....................................................................................................................................3-11a
Inspection of Bar Stock .................................................................................................................................... 6-9f
Inspection of Metal Plates and Sheets ............................................................................................................. 6-9e
Inspection of the Part ..................................................................................................................................... 3-14f
Inspection of Tubes and Pipes ........................................................................................................................ 6-9g
Inspection Preparation ...................................................................................................................................... 4-6
Inspection Process, Selection of ........................................................................................................................ 3-9
Inspection Techniques ....................................................................................................................................... 5-6
Best Access to Object ............................................................................................................................. 5-6f
Degree of Sensitivity .............................................................................................................................. 5-6d
Film Placement ..................................................................................................................................... 5-6b
General ................................................................................................................................................. 5-6a
Source-to-Film Distance .........................................................................................................................5-6c
Thickness Measurement ........................................................................................................................ 5-6e
Inspection, Penetrant, Types and Methods ...................................................................................................... T3-2
Inspection, Ultrasonic, Equipment ..................................................................................................................... 6-8
Inspection, Ultrasonic, Techniques .................................................................................................................... 6-9
Inspections, Types of ........................................................................................................................................ 2-4
Interpretation and Inspection ........................................................................................................................... 3-12
Interpretation (Penetrant Inspection) ..............................................................................................................3-12b
Interpretation (Radiographic) .................................................................................................................... 5-9, 5-9a

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Subject Paragraph
Figure, Table
Number

Lamb Waves ................................................................................................................................................... 6-6d

Leakage Field ................................................................................................................................................. 4-3b
Lighting and Facilities .....................................................................................................................................3-11c
Limitations (Penetrant Inspection) ..................................................................................................................... 3-4
Limitations and Capabilities (Magnetic Particle Inspection) ................................................................................ 4-5
Limits of Demagnetization ..............................................................................................................................4-13d
Longitudinal Magnetization .............................................................................................................................. 4-10
Amperage..............................................................................................................................................4-10b
Applications ..........................................................................................................................................4-10c
Equipment ............................................................................................................................................4-10d
Technique .............................................................................................................................................4-10a
Longitudinal Waves.......................................................................................................................................... 6-6a

Magnetic Flux .................................................................................................................................................. 4-3e

Magnetic Particle Indicators ............................................................................................................................ 4-11
Definitions .............................................................................................................................................4-11a
Steps of Inspection ...............................................................................................................................4-11b
Magnetic Particle Inspection, Fundamentals of ................................................................................................. 4-4
Magnetic Particle Inspections, General ............................................................................................................. 4-1
Magnetic Substances ...................................................................................................................................... 4-3d
Magnetism .......................................................................................................................................................4-3c
Magnetism, Theory of ....................................................................................................................................... 4-2
Magnetization, Circular . .................................................................................................................................... 4-9
Magnetization, Longitudinal ............................................................................................................................. 4-10
Maintenance of Shop Equipment ..................................................................................................................... 2-2e
Manual Film Processing .................................................................................................................................. F5-1
Materials, Consumable ...................................................................................................................................... 1-3
Methods of Application (Magnetic Particles) .................................................................................................... 4-7b
Methods of Application, Particles and ................................................................................................................ 4-7
Methods of Recording Indications (Magnetic Particle Inspection) .................................................................... 4-12
Applying Transparent Tape ...................................................................................................................4-12b
Dry Particle Indications .........................................................................................................................4-12c
Fixing Indications with Lacquer .............................................................................................................4-12a
Fluorescent Indications .........................................................................................................................4-12e
Photographing Indications ..................................................................................................................... 4-12f
Wet Particle Indications ........................................................................................................................4-12d
Minimum Penetration Time For Penetrants ..................................................................................................... T3-1
Misinterpretation (Radiographic) ...................................................................................................................... 5-9b
Modes of Vibration ............................................................................................................................................. 6-6
Lamb Waves ......................................................................................................................................... 6-6d

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Subject Paragraph
Figure, Table
Number

M - Continued

Longitudinal Waves ............................................................................................................................... 6-6a

Rayleigh Waves .....................................................................................................................................6-6c
Transverse Waves ................................................................................................................................. 6-6b

Nature of Sound Waves .................................................................................................................................... 6-5

NDI Shop Requirements .................................................................................................................................... 2-3
Need for Both Types of Tests ...........................................................................................................................2-4c
Needle Deflections .......................................................................................................................................... 7-5d
Nondestructive Inspection, General ................................................................................................................... 2-1
Nondestructive Tests ....................................................................................................................................... 2-4b

Operation (Eddy Current Test Set) .................................................................................................................. 7-5a

Operative Precautions ..................................................................................................................................... 3-7b

Particle Application, Current and ....................................................................................................................... 4-8

Particles .......................................................................................................................................................... 4-7a
Particles and Methods of Application ................................................................................................................. 4-7
Methods of Application .......................................................................................................................... 4-7b
Particles ................................................................................................................................................ 4-7a
Penetrant Application .....................................................................................................................................3-10d
Penetrant Application (Type I, Method C) .......................................................................................................3-14c
Penetrant Inspection, Basic Principles of ........................................................................................................... 3-3
Penetrant Inspection, General Procedures for ................................................................................................... 3-6
Penetrant Inspection, Type I, Method C ........................................................................................................... 3-14
Penetrant Inspection Types and Methods ........................................................................................................ T3-2
Penetrant Inspections, General ......................................................................................................................... 3-1
Penetrant Inspections, Precautions in ................................................................................................................ 3-7
Penetrants, Minimum Penetration Time for ..................................................................................................... T3-1
Penetrants, Quality Control of ........................................................................................................................... 3-8
Penetration Times .......................................................................................................................................... 3-10f
Permeability...................................................................................................................................................... 4-3f
Personnel Requirements. ................................................................................................................................... 2-5
Photographing Indications .............................................................................................................................. 4-12f
Portable X-Ray Units ....................................................................................................................................... 5-7b
Pre-operative Precautions ............................................................................................................................... 3-7a
Precautions in Penetrant Inspections ................................................................................................................. 3-7

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Subject Paragraph
Figure, Table
Number

P - Continued

Operative Precautions ........................................................................................................................... 3-7b

Pre-operative Precautions ..................................................................................................................... 3-7a
Safety Precautions ................................................................................................................................. 3-7d
Temperature Limitations .........................................................................................................................3-7c
Precleaning.....................................................................................................................................................3-10b
Precleaning Process (for Type C Penetrant) ...................................................................................................3-14a
Preparation, Inspection ..................................................................................................................................... 4-6
Pretesting .......................................................................................................................................................3-10a
Pretesting, Precleaning, Drying, Application, and Removal ............................................................................. 3-10
Developer Application ............................................................................................................................3-10j
Developer Draining ...............................................................................................................................3-10k
Developer Dwell Time ..........................................................................................................................3-101
Draining ................................................................................................................................................3-10e
Drying ...................................................................................................................................................3-10c
Emulsifier Application .........................................................................................................................3-109g
Emulsifier Draining ...............................................................................................................................3-10h
Emulsifier Dwell Time ............................................................................................................................3-10i
Penetrant Application ............................................................................................................................3-10d
Penetration Times ................................................................................................................................ 3-10f
Precleaning ..........................................................................................................................................3-10b
Pretesting .............................................................................................................................................3-10a
Removal Methods ............................................................................................................................... 3-10m
Processing ...................................................................................................................................................... 5-8b
Purpose (of Electromagnetic Inspections) ......................................................................................................... 7-2
Purpose (of Manual) .......................................................................................................................................... 1-1
Purpose (of Penetrant Inspections) .................................................................................................................... 3-2
Purpose (of Radiography) ................................................................................................................................. 5-2

Quality Control of Penetrants ............................................................................................................................ 3-8

Availability ............................................................................................................................................. 3-8b
Compatibility .......................................................................................................................................... 3-8a

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Subject Paragraph
Figure, Table
Number

Radiation Detection Standards ........................................................................................................................ T5-1

Radiation Detectors ........................................................................................................................................5-11c
Radiographic Interpretation ............................................................................................................................... 5-9
Interpretation ......................................................................................................................................... 5-9a
Misinterpretation .................................................................................................................................... 5-9b
Radiographs, Filing ......................................................................................................................................... 5-10
Radiography, General ....................................................................................................................................... 5-1
Radiography Safety Precautions and Equipment.............................................................................................. 5-11
Electrical Precautions ...........................................................................................................................5-11d
Exposure Limits ....................................................................................................................................5-11b
General ................................................................................................................................................5-11a
Radiation Detectors ..............................................................................................................................5-11c
Rayleigh Waves ...............................................................................................................................................6-6c
Reasons for Demagnetization ........................................................................................................................4-13a
Recording Indications, Methods of (Magnetic Particle Inspection) ................................................................... 4-12
Reflection......................................................................................................................................................... 6-7a
Refraction and Mode Conversion .................................................................................................................... 6-7b
Relative Response of Survey Meters .............................................................................................................. T5-2
Removal of Developer ...................................................................................................................................3-14h
Removal of Excess Penetrant ........................................................................................................................3-14d
Removal Methods (Penetrants) ..................................................................................................................... 3-10m
Requirements, Personnel .................................................................................................................................. 2-5
Residual Magnetism ........................................................................................................................................ 4-3g
Residual Method ............................................................................................................................................. 4-8a
Responsibility (for Shop Rules) ....................................................................................................................... 2-2a
Retentivity ....................................................................................................................................................... 4-3h

Safety Precautions .......................................................................................................................................... 3-7d

Safety Precautions and Equipment ................................................................................................................. 5-10
Scope (of Manual) ............................................................................................................................................. 1-2
Search Units ................................................................................................................................................... 6-8b
Selection of Inspection Process ......................................................................................................................... 3-9
Sensitivity Level .............................................................................................................................................. 4-8e
Shop Housekeeping ........................................................................................................................................ 2-2b
Shop Requirements, NDI ................................................................................................................................... 2-3
Shop Rules, General ......................................................................................................................................... 2-2
Shop Safety .....................................................................................................................................................2-2c
Shop Tools and Materials................................................................................................................................. 2-2d
Skilled Operators, Importance of ....................................................................................................................... 3-5
Sound Waves, Nature of ................................................................................................................................... 6-5
Source-to-Film Distance ...................................................................................................................................5-6c
Special Techniques (Radiography) .................................................................................................................... 5-7

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Subject Paragraph
Figure, Table
Number

S - Continued

Fluoroscopy ........................................................................................................................................... 5-7a

Portable X-Ray Units ............................................................................................................................. 5-7b
Specific Procedures for Fluorescent Penetrant Inspection ............................................................................... 3-11
Black Light.............................................................................................................................................3-11d
Inspection Conditions ............................................................................................................................3-11a
Lighting and Facilities ...........................................................................................................................3-11c
Surface Preparation .......................................................................................................................................3-11b
Steps of Inspection (Magnetic Particle Inspection) ..........................................................................................4-11b
Straight Beam Method .................................................................................................................................... 6-9a
Surface Preparation ..............................................................................................................................3-11b, 6-9d
Surface Wave Method .....................................................................................................................................6-9c
Survey Meters, Relative Response of ............................................................................................................. T5-2

Technique (of Circular Magnetization) ............................................................................................................. 4-9a

Technique (of Longitudinal Magnetization) .....................................................................................................4-10a
Techniques for Demagnetization ....................................................................................................................4-13c
Techniques, Inspection ...................................................................................................................................... 5-6
Techniques, Special (Radiography) ................................................................................................................... 5-7
Temperature Limitations ..................................................................................................................................3-7c
Terminology, Basic (of Magnetism) ................................................................................................................... 4-3
Test Set, Eddy Current, Model ED-520 .............................................................................................................. 7-5
Testing Methods, Basic (Ultrasonics) ................................................................................................................. 6-4
Testing Procedure (Eddy Current) ................................................................................................................... 7-5b
Theory of Magnetism ........................................................................................................................................ 4-2
Thickness Measurement .................................................................................................................................. 5-7e
Transducers .....................................................................................................................................................6-8c
Transmission Characteristics ............................................................................................................................. 6-7
Beam Divergence ...................................................................................................................................6-7c
Reflection ............................................................................................................................................... 6-7a
Refraction and Mode Conversion ........................................................................................................... 6-7b
Transverse Waves .......................................................................................................................................... 6-6b
Type I, Method C Penetrant Inspection ............................................................................................................ 3-14
Application of Cleaner ...........................................................................................................................3-14b
Application of Developer .......................................................................................................................3-14e
Evaluate Discontinuity ..........................................................................................................................3-14g
Inspection of the Part ............................................................................................................................ 3-14f
Penetrant Application ............................................................................................................................3-14c
Precleaning Process .............................................................................................................................3-14a
Removal of Developer...........................................................................................................................3-14h
Removal of Excess Penetration ............................................................................................................3-14d

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Subject Paragraph
Figure, Table
Number

T - Continued

Types of Fluorescent Penetrant Processes ...................................................................................................... 3-13

Types of Inspections ......................................................................................................................................... 2-4
Destructive Tests ................................................................................................................................... 2-4a
Need for Both Types of Tests .................................................................................................................2-4c
Nondestructive Tests ............................................................................................................................. 2-4b

Ultrasonic Equipment, Calibration of ................................................................................................................ 6-10

Ultrasonic Inspection Equipment ....................................................................................................................... 6-8
General ................................................................................................................................................. 6-8a
Search Units .......................................................................................................................................... 6-8b
Transducers.............................................................................................................................................6-8c
Ultrasonic Inspection Techniques ...................................................................................................................... 6-9
Angle Beam Method .............................................................................................................................. 6-9b
Inspection of Bar Stock............................................................................................................................ 6-9f
Inspection of Metal Plates and Sheets ................................................................................................... 6-9e
Inspection of Tubes and Pipes ............................................................................................................... 6-9g
Straight Beam Method ........................................................................................................................... 6-9a
Surface Preparation ............................................................................................................................... 6-9d
Surface Wave Method ............................................................................................................................6-9c
Ultrasonic Inspections, General ......................................................................................................................... 6-1
Use of Data ....................................................................................................................................................... 2-6
Uses of Eddy Current Inspection ..................................................................................................................... T7-1

Vibration, Modes of ........................................................................................................................................... 6-6

Wet Particle Indications .................................................................................................................................4-12d

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Subject Paragraph
Figure, Table
Number

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

Care and Use of Equipment. .............................................................................................................................. 2-4

Bandsaws .............................................................................................................................................. 2-4b
Drilling Machines ................................................................................................................................... 2-4a
Grinders .................................................................................................................................................. 2-4f
Lathes .....................................................................................................................................................2-4c
Milling Machines .................................................................................................................................... 2-4d
Shapers ................................................................................................................................................. 2-4e
Cleaning
Aluminum Welding ................................................................................................................................. 3-5b
Magnesium Welding .............................................................................................................................. 3-6a
Consumable Materials ....................................................................................................................................... 1-3
Corrosion-Resistant Steel and Nickel Chromium Alloy Welding ......................................................................... 3-7

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Subject Paragraph
Figure, Table
Number

C - Continued

Arc Welding ........................................................................................................................................... 3-7d

Distinguishing Corrosion-Resistant Steels and Nickel-Base Alloys ......................................................... 3-7a
Gas Welding ...........................................................................................................................................3-7c
Special Welding Considerations ............................................................................................................ 3-7b
Spot Welding ......................................................................................................................................... 3-7e
Welding Stresses and Distortion ............................................................................................................. 3-7f
Corrosion-Resistant Steel Arc Welding ............................................................................................................ 3-7d
Corrosion-Resistant Steel Gas Welding ............................................................................................................3-7c
Corrosion-Resistant Steel Spot Welding .......................................................................................................... 3-7e
Corrosion-Resistant Steels and Nickel Alloys,
Relation Between Sheet Thickness and Current Required
for Metallic Arc Welding of ..................................................................................................................... T3-8
Corrosion-Resistant Steels and Nickel-Base Alloys,
Relation Between Sheet Thickness and Current Required
for Inert-Arc Welding of ......................................................................................................................... T3-9
Counterboring and Spotfacing ..........................................................................................................................2-6c
Cut-off Type Bandsaw ..................................................................................................................................... F2-3

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

Electric Arc Welding Equipment ...................................................................................................................... 3-3b

Electric Arc Welding Equipment ...................................................................................................................... F3-2
Electrodes .............................................................................................................................................. 3-4a ,T3-1
Equipment Safety .............................................................................................................................................2-2c

Fire Safety ...................................................................................................................................................... 2-2d

Flames, Gas Welding ...................................................................................................................................... F3-4
Fluxes ..............................................................................................................................................................3-4c

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Subject Paragraph
Figure, Table
Number

Gas Welding .................................................................................................................................................... 3-3a

Gas Welding Equipment .................................................................................................................................. F3-1
Gas Welding Equipment, Guide to Regulation of ............................................................................................. T3-5
Gas Welding Flames........................................................................................................................................ F3-4
General
Machine Shop Practices ........................................................................................................................... 2-1
Weld Shop Practices ................................................................................................................................ 3-1
General Layout Practices ................................................................................................................................. 2-5a
Grinder............................................................................................................................................................. F2-7
Grinder Wheel Installation................................................................................................................................ F2-8
Grinding Machines
Care and Use........................................................................................................................................... 2-4f
Safety Precautions.................................................................................................................................. 2-3b
Wheel Installation ................................................................................................................................... F2-8
Guide to Regulation of Gas Welding Equipment .............................................................................................. T3-5

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

Lapping ............................................................................................................................................................ 2-6d

Lathes .............................................................................................................................................................. F2-4
Care and Use...........................................................................................................................................2-4c
Safety Precautions...................................................................................................................................2-3c
Laying Out and Mounting Work .......................................................................................................................... 2-5
General Layout Practices........................................................................................................................ 2-5a
Mounting................................................................................................................................................. 2-5b

Machine Safety Precautions............................................................................................................................... 2-3

Drilling Machines .................................................................................................................................... 2-3a
Grinding Machines.................................................................................................................................. 2-3b
Lathes......................................................................................................................................................2-3c
Milling Machines ..................................................................................................................................... 2-3d

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Subject Paragraph
Figure, Table
Number
M - Continued

Miscellaneous Machine Tools .................................................................................................................. 2-3f

Portable Machine Tools .......................................................................................................................... 2-39
Shapers and Planers............................................................................................................................... 2-3e
Machine Settings for Arc Welding Magnesium ................................................................................................. T3-6
Machine Shop Practices
Care and Use of Equipment...................................................................................................................... 2-4
General .................................................................................................................................................... 2-1
Laying Out and Mounting Work................................................................................................................. 2-5
Machine Safety Precautions ..................................................................................................................... 2-3
Shop Rules ............................................................................................................................................... 2-2
Special Operations on Drilling Machines................................................................................................... 2-6
Magnesium Arc Welding ...................................................................................................................................3-6c
Magnesium Gas Welding ................................................................................................................................. 3-6b
Magnesium Spot Welding ................................................................................................................................ 3-6d
Magnesium Welding .......................................................................................................................................... 3-6
Arc Welding.............................................................................................................................................3-6c
Cleaning ................................................................................................................................................. 3-6a
Gas Welding........................................................................................................................................... 3-6b
Spot Welding.......................................................................................................................................... 3-6d
Metallic Arc Welding of Corrosion-Resistant Steels and Nickel Alloys,
Relation Between Sheet Thickness and Current Required for ................................................................. T3-8
Milling Machines
Care and Use.......................................................................................................................................... 2-4d
Safety Precautions.................................................................................................................................. 2-3d
Miscellaneous Machine Tools, Safety Precautions................................................................................... 2-3f
Mounting Work ....................................................................................................................................... 2-5b

Portable Machine Tools, Safety Precautions .................................................................................................... 2-3g

Post Brazing and Silver Soldering Cleaning ......................................................................................................3-9c
Purpose of Manual ............................................................................................................................................. 1-1

Reaming .......................................................................................................................................................... 2-6a

Relation Between Sheet Thickness and Current Required for
Inert-Arc Welding of Corrosion-Resistant Steels and
Nickel-Base Alloys .................................................................................................................................. T3-9
Relation Between Sheet Thickness and Current Required for
Metallic Arc Welding of Corrosion-Resistant Steels and
Nickel Alloys ........................................................................................................................................... T3-8

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Subject Paragraph
Figure, Table
Number

R - Continued

Responsibility
Machine Shop Rules, for......................................................................................................................... 2-2a
Welding Shop Rules, for ......................................................................................................................... 3-2a
Rod Information, Welding ................................................................................................................................ T3-2

Safety, Welding Shop .......................................................................................................................................3-2c

Schematic, Welding Equipment ....................................................................................................................... F3-3
Scope of Manual ................................................................................................................................................ 1-2
Shaper ............................................................................................................................................................. F2-6
Shapers and Planers, Safety Precautions......................................................................................................... 2-3e
Shapers, Care and Use .................................................................................................................................... 2-4e
Shop Housekeeping
Machine Shop......................................................................................................................................... 2-2b
Welding Shop ......................................................................................................................................... 3-2b
Shop Rules, Machine Shop ................................................................................................................................ 2-2
Equipment Safety ....................................................................................................................................2-2c
Fire Safety.............................................................................................................................................. 2-2d
Responsibility ......................................................................................................................................... 2-2a
Shop Housekeeping................................................................................................................................ 2-2b
Shop Rules, Welding Shop ................................................................................................................................ 3-2
Responsibility ......................................................................................................................................... 3-2a
Safety......................................................................................................................................................3-2c
Shop Housekeeping................................................................................................................................ 3-2b
Silver Soldering................................................................................................................................................ 3-9b
Special Operations on Drilling Machines ............................................................................................................ 2-6
Bear Roll Staking.................................................................................................................................... 2-6e
Counterboring and Spotfacing..................................................................................................................2-6c
Lapping................................................................................................................................................... 2-6d
Reaming................................................................................................................................................. 2-6b
Tapping .................................................................................................................................................. 2-6a
Special Welding Considerations, Corrosion-Resistant Steel and Nickel
Chromium Alloy Welding ........................................................................................................................ 3-7b
Starting Electric Arc, Brush Method.................................................................................................................. F3-5
Stress Relieving Treatment .............................................................................................................................. T3-7

Tapping............................................................................................................................................................ 2-6a
Treatment, Stress Relieving ............................................................................................................................. T3-7
Types of Alloys, Aluminum............................................................................................................................... 3-5a

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Subject Paragraph
Figure, Table
Number

T - Continued

Types of Welding ............................................................................................................................................... 3-3

Electric Arc Welding ............................................................................................................................... 3-3b
Gas Welding........................................................................................................................................... 3-3a
Spot Welding...........................................................................................................................................3-3c
Typical Machine Setting for Spot Welding Aluminum Alloys ............................................................................ T3-4

Vertical-Contour Bandsaw ................................................................................................................................ F2-2

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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Subject Paragraph
Figure, Table
Number

Accuracy Limits, Torque Tool........................................................................................................................... T8-1

Action of Preload Indicating Washers............................................................................................................. F8-30
Adjustable Hook Spanner Wrench.................................................................................................................. F4-39
Adjustable Reamer......................................................................................................................................... F4-92
Adjustable Wrench......................................................................................................................................... F4-25
Adjusting the Snap Gauge.............................................................................................................................. F3-65
Adjustment of Spray Pattern ............................................................................................................................ F5-4
Air Blow Cleaning Gun ................................................................................................................................... F5-13
Air Compressors, Typical ............................................................................................................................... F9-14
Aircraft Landing Gear Jack............................................................................................................................. F9-10
Aircraft Pre-Heater ......................................................................................................................................... F9-15
Alternate Method for Tightening to 15 Degree Wrench Arc............................................................................. F8-25
Angle Extension Torque Wrench Attachment ................................................................................................. F8-20
Angle, Checking............................................................................................................................................. F3-19
Application of Blade Pitch for Certain Materials.............................................................................................. F4-98
Application of Force, Improper ....................................................................................................................... F8-19
Applying Paint at an Angle, Effect of ................................................................................................................ F5-6
Army Aviation, Types of Tools Used in............................................................................................................... 2-2
Attachment - Offset Reverse Extension, Torque Wrench ............................................................................... F8-17
Audible-Indicating Torque Wrench ................................................................................................................... F8-4
Automatic Center Punch ................................................................................................................................ F4-60
Awl 4-6, F4-48
Awl, Scribing with an ...................................................................................................................................... F4-49

Ball Peen Hammer........................................................................................................................................... F4-1

Beading Large Tubing .................................................................................................................................. F4-124
Bench Vise............................................................................................................................................ 4-8a, F4-53
Bench Vise, Using a ......................................................................................................................................... 4-54
Bender, Tube ............................................................................................................................................... F4-117
Bending Tube Tool..........................................................................................................................................4-123
Bending Tube............................................................................................................................................... F4-118
Bevel Protractor ............................................................................................................................................. F3-12
Bits, Drill .......................................................................................................................................................... 4-13
Blade Set, Hacksaw ....................................................................................................................................... F4-97
Bobs, Plumb ............................................................................................................................................. 3-3, F3-6
Body Hammer.................................................................................................................................................. F4-2
Box-End Wrench Offset ................................................................................................................................. F4-23
Box-End Wrenches ........................................................................................................................................ F4-22
Boxes, Tool........................................................................................................................................................ 2-9
Boxes, Typical Tool.......................................................................................................................................... F2-1
Breast Drill ..................................................................................................................................................... F4-80
Brown and Sharpe Tapered Reamer .............................................................................................................. F4-94

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Subject Paragraph
Figure, Table
Number

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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Subject Paragraph
Figure, Table
Number

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

Deflecting Beam Torque Wrench ..................................................................................................................... F8-2

Deicer Boot Pliers ............................................................................................................................................ 7-12
Deicer Boot Pliers, Using ............................................................................................................................... F7-19
Deicer Boot Roller............................................................................................................................................ 7-14
Depth Gauge, Micromete ............................................................................................................................... F3-48
Depth Gauge, Rule ........................................................................................................................................ F3-47
Depth Gauge, Vernier .................................................................................................................................... F3-49
Depth Gauges .................................................................................................................................................. 3-11
Depth Micrometer .......................................................................................................................................... F3-36
Description
Leather Punch.................................................................................................................................................. 7-13
Determining Correct Torque Value ..................................................................................................................... 8-4
Determining Depth with the Square Head....................................................................................................... F3-20

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Subject Paragraph
Figure, Table
Number

D - Continued

Diagonal Cutting Pliers................................................................................................................................... F4-42

Dial Indicator Installed on Propeller Shaft....................................................................................................... F3-75
Dial Indicators .................................................................................................................................................. 3-20
Dies ........................................................................................................................................................... F4-104
Dies, Taps and ................................................................................................................................................. 4-18
Diestock ....................................................................................................................................................... F4-105
Divider, Spring ............................................................................................................................................... F3-21
Divider, Wing ................................................................................................................................................. F3-22
Dividers.............................................................................................................................................................. 3-7
Dividers, Scribing a Circle with....................................................................................................................... F3-23
Double Cutting Shears ..................................................................................................................................... 4-21
Double-Flaring Tool...................................................................................................................................... F4-122
Drawfiling....................................................................................................................................................... F4-78
Dressing a Grinding Wheel .............................................................................................................................. F6-6
Drill Bit, Machine Grinding a........................................................................................................................... F4-85
Drill Bit, Typical.............................................................................................................................................. F4-83
Drill Bits ........................................................................................................................................................... 4-13
Drill Grinding Gauge, Using............................................................................................................................ F4-89
Drill Jaws, V-Grooves in................................................................................................................................. F4-82
Drill Sizes......................................................................................................................................................... T4-2
Drill, Breast .................................................................................................................................................... F4-80
Drill, Hand...................................................................................................................................................... F4-81
Drill, Pneumatic.................................................................................................................................................. 5-7
Drilling, Center Punch for ............................................................................................................................... F4-84
Drills, Electric..................................................................................................................................................... 6-3
Drills, Hand ...................................................................................................................................................... 4-12
Drills, Pneumatic............................................................................................................................................ F5-15
Drive Punch ................................................................................................................................................... F4-61

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Subject Paragraph
Figure, Table
Number

Effect of Applying Paint at an Angle ................................................................................................................. F5-6

Electric Drills............................................................................................................................................. 6-3, F6-2
Electric Grinders ................................................................................................................................................ 6-4
Engine Maintenance Stand .............................................................................................................................. F9-3
Engine Trailer ................................................................................................................................................ F9-12
Equipment, Lubricating .................................................................................................................................. F9-20
Extension Rods for Inside and Depth Micrometers ......................................................................................... F3-37
Extension, Proper Application of Force When Using ...................................................................................... F8-18
Extractor, Cotter Pin................................................................................................................................ 7-7, F7-11
Extractor, Tap .............................................................................................................................................. F4-109
Extractors, Spiral Screw ............................................................................................................................... F4-108
Extractors, Straight Screw............................................................................................................................ F4-107

Face Pin Spanner Wrench ............................................................................................................................. F4-38

Faulty Patterns and Suggested Corrections.................................................................................................... F5-10
File Cleaner ................................................................................................................................................... F4-79
File Handle, Use of ........................................................................................................................................ F4-75
File Nomenclature.......................................................................................................................................... F4-65
File Teeth Spacing and Fineness ................................................................................................................... F4-67
File Teeth, Single- and Double-Cut ................................................................................................................ F4-66
File, Curved Tooth ......................................................................................................................................... F4-74
File, Flat......................................................................................................................................................... F4-70
File, Half-Round............................................................................................................................................. F4-73
File, Mil .......................................................................................................................................................... F4-69
File, Round .................................................................................................................................................... F4-72
File, Square ................................................................................................................................................... F4-71
File, Triangular............................................................................................................................................... F4-68
Files ............................................................................................................................................................... 4-11
Filing for a Flat Surface.................................................................................................................................. F4-77
Fillet and Radius Gauges ...................................................................................................................... F3-73, 3-19
Fillet and Radius Gauges, Using .................................................................................................................... F3-74
Fingers, Mechanical ................................................................................................................................ 7-8, F7-12
Fishing Tool, Valve Stem .......................................................................................................................... 7-5, F7-9
Flanged Ring Gauge ...................................................................................................................................... F3-56
Flares, Single and Double ............................................................................................................................ F4-119
Flaring Tools .................................................................................................................................................... 4-25

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Subject Paragraph
Figure, Table
Number

F - Continued

Flat File.......................................................................................................................................................... F4-70

Flat Parts, Gauging ........................................................................................................................................ F3-66
Flat Surface, Filing for a................................................................................................................................. F4-77
Flat-Nose Pliers .............................................................................................................................................. F444
Flush Cutting................................................................................................................................................ F4-113
Flushing Paint Gun with Thinner or Solvent (Cup) ............................................................................................ F5-7
Flushing Paint Gun with Thinner or Solvent (Pressure Tank or Gravity Bucket)................................................ F5-8

Gauge Tolerances, Ring................................................................................................................................... T3-1

Gauge Tolerances, Snap.................................................................................................................................. T3-2
Gauge Types, Ring ........................................................................................................................................ F3-57
Gauge, Flanged Ring ..................................................................................................................................... F3-56
Gauge, Plug..................................................................................................................................................... 3-14
Gauge, Surface..................................................................................................................................... F3-45, 3-10
Gauge Thread................................................................................................................................................ F3-52
Gauges, Ring ........................................................................................................................................ F3-55, 3-15
Gauges, Snap ....................................................................................................................................... F3-59, 3-16
Gauges, Thread ............................................................................................................................................... 3-13
Gauging Flat Parts ......................................................................................................................................... F3-66
General
Electrical Power Tools .............................................................................................................................. 6-1
General Maintenance Tools ...................................................................................................................... 4-1
Ground Support Equipment ...................................................................................................................... 9-1
Measuring Tools ....................................................................................................................................... 3-1
Special Aircraft Tools................................................................................................................................ 7-1
Storage of Ground Support Equipment ..................................................................................................... 9-6
Tool Procedures and Practices ................................................................................................................. 2-1
Torque Tools and Torque Principles and Procedures ................................................................................ 8-1
Use Torque Multiplier............................................................................................................................ F8-21
General, Ground Support Equipment ................................................................................................................. 9-1
Grinder, Pneumatic ............................................................................................................................................ 5-8
Grinders ........................................................................................................................................................... F6-4
Grinding Wheel Installation .............................................................................................................................. F6-5
Grinding Wheel, Dressing a ............................................................................................................................. F6-6
Grinding, Screwdriver Tip............................................................................................................................... F4-19
GSE - Three Color Camouflage Pattern ........................................................................................................... T9-1
Guns, Paint ........................................................................................................................................................ 5-3

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Subject Paragraph
Figure, Table
Number

Hacksaw Blade Set ........................................................................................................................................ F4-97

Hacksaw Blade, Installing a............................................................................................................................ F4-99
Hacksaw, Proper Way to Hold a................................................................................................................... F4-100
Hacksaws.............................................................................................................................................. 4-17, F4-96
Half-Pound File .............................................................................................................................................. F4-73
Hammer Face Substances, Soft-Faced............................................................................................................ T4-1
Hammer, Ball Peen.......................................................................................................................................... F4-1
Hammer, Body................................................................................................................................................. F4-2
Hammer, Lead or Copper................................................................................................................................. F4-5
Hammer, Riveting ............................................................................................................................................ F4-3
Hammer, Setting.............................................................................................................................................. F4-4
Hammer, Soft-Faced........................................................................................................................................ F4-6
Hammers and Mallets ........................................................................................................................................ 4-2
Hand Drill....................................................................................................................................................... F4-81
Hand Drills ....................................................................................................................................................... 4-12
Hand Grinding of Cutting Edge....................................................................................................................... F4-87
Hand Grinding of Heel to Cutting Edge........................................................................................................... F4-88
Hand Seamer and Groover .............................................................................................................................. 4-27
Handle and Wedges, New.............................................................................................................................. F4-11
Handle, Hinged .............................................................................................................................................. F4-29
Handle, Ratchet ............................................................................................................................................. F4-27
Handle, Removing Broken ............................................................................................................................. F4-10
Handle, Sliding T-Bar ..................................................................................................................................... F4-28
Handle, Speed ............................................................................................................................................... F4-30
Heel Angle, Measuring ................................................................................................................................... F4-90
Height Gauge, Typical.................................................................................................................................... F3-51
Height Gauges ................................................................................................................................................. 3-12
Typical.................................................................................................................................................. F3-51
Hermaphrodite Calipers ................................................................................................................................. F3-27
Hexagonal Setscrew Wrench (Allen Wrench) ................................................................................................. F4-31
Hinged Handle ............................................................................................................................................... F4-29
Hole Gauges, Small .............................................................................................................................. 3-22, F3-79
Hollow Punch ................................................................................................................................................. F4-64
Hook Spanner Wrench ................................................................................................................................... F4-36
Hub Nut Torque Multiplier .............................................................................................................................. F8-22

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Subject Paragraph
Figure, Table
Number

Identification of Parts of Reamers .................................................................................................................. F4-91

Improper Application of Force ........................................................................................................................ F8-19
Individual Flaring Tool.................................................................................................................................. F4-121
Inside Micrometer .......................................................................................................................................... F3-35
Installation of Preload Washer on a Bolt......................................................................................................... F8-32
Installation of Preload Washers on a Stud...................................................................................................... F8-31
Installing a Hacksaw Blade............................................................................................................................. F4-99
Installing Protractor Head on Rule.................................................................................................................. F3-17
Installing Wooden Wedge .............................................................................................................................. F4-12

Jack Hydraulic Schematic Diagram.................................................................................................................. F9-6

Jack, 3-Ton, Tripod .......................................................................................................................................... F9-9
Jack, 5-Ton, Tripod .......................................................................................................................................... F9-8
Jack, 10-Ton, Self-Contained ......................................................................................................................... F9-11
Jack, 12-Ton, Tripod ........................................................................................................................................ F9-7
Jack, Aircraft Landing Gear............................................................................................................................ F9-10
Jobber's (Machine) Reamer ........................................................................................................................... F4-93

Knife, Putty .................................................................................................................................................... F4-52

Knife, Utility ................................................................................................................................................... F4-50
Knives................................................................................................................................................................ 4-7
Knives, Pocket ............................................................................................................................................... F4-51

Laying Out Angle ........................................................................................................................................... F3-24

Lead or Copper Hammer.................................................................................................................................. F4-5
Leather Punch.................................................................................................................................................. 7-13
Level Condition ................................................................................................................................................ F3-5
Level
Machinist's Level .................................................................................................................................... F3-2
Master Precision Level ........................................................................................................................... F3-1
Mechanic's Level .................................................................................................................................... F3-4
Striding Level ......................................................................................................................................... F3-3
Levels ................................................................................................................................................................ 3-2
Locating Diameter of Cylinder ........................................................................................................................ F3-15
Lockwire Pliers...................................................................................................................................... 7-11, F7-16

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Subject Paragraph
Figure, Table
Number

L - Continued

Long-Nose Pliers............................................................................................................................................ F4-43

Loosening Protractor Adjustment Screws ....................................................................................................... F3-18
Lubricants for Tapping and Die-Cutting Threads............................................................................................... T4-3
Lubricating Equipment ................................................................................................................................... F9-20

Machine Grinding a Drill Bit............................................................................................................................ F4-85

Magnet, Telescoping ............................................................................................................................... 7-9, F7-14
Maintenance Platform, Type B-1 ...................................................................................................................... F9-1
Maintenance Stand, Type B-4A........................................................................................................................ F9-2
Maintenance Stand, Engine ............................................................................................................................. F9-3
Mallet, Rawhide ............................................................................................................................................... F4-7
Mallet, Rubber.................................................................................................................................................. F4-8
Mallet, Tinner's................................................................................................................................................. F4-9
Mallets, Hammers and ....................................................................................................................................... 4-2
Marking.............................................................................................................................................................. 9-5
Marking a Square Line ................................................................................................................................... F3-13
Marking Diameter of Cylinder......................................................................................................................... F3-16
Master Precision Level..................................................................................................................................... F3-1
Materials, Consumable....................................................................................................................................... 1-3
Measuring Control Surface Angle at Full Throw................................................................................................ F7-3
Measuring Heel Angle .................................................................................................................................... F4-90
Measuring Hole with a Small Hole Gauge ...................................................................................................... F3-80
Measuring Hole with Telescoping Gauge........................................................................................................ F3-78
Measuring Sheet Metal and Wire ................................................................................................................... F3-72
Mechanic's Level.............................................................................................................................................. F3-4
Mechanical Fingers ................................................................................................................................. 7-8, F7-12
Mechanist's Scribers ........................................................................................................................................ F3-7
Micrometer Depth Gauge ............................................................................................................................... F3-48
Micrometer with Extension Rod, Using Inside................................................................................................. F3-40
Micrometer, Reading a Vernier....................................................................................................................... F3-43
Micrometers ....................................................................................................................................................... 3-9
Depth.................................................................................................................................................... F3-36
Extension Rods for Inside and Depth .................................................................................................... F3-37
Inside.................................................................................................................................................... F3-35
Outside................................................................................................................................................. F3-34
Parts of a Micrometer ........................................................................................................................... F3-41
Reading a Measurement on a Micrometer ............................................................................................ F3-42
Reading a Metric Micrometer........................................................................................................ 3-9f, F3-44
Using Inside.......................................................................................................................................... F3-38
Using Outside ....................................................................................................................................... F3-39

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Subject Paragraph
Figure, Table
Number

M - Continued

Mill File .......................................................................................................................................................... F4-69

Mixing, Painting Requirements........................................................................................................................... 9-3
Multipliers, Torque ............................................................................................................................................. 8-9

New Handle and Wedges............................................................................................................................... F4-11

Nippers and Pincers ............................................................................................................................ F4-111, 4-22
Nitrogen Servicing Unit .................................................................................................................................. F9-17
Nomenclature, File......................................................................................................................................... F4-65
Nonconcentric Attachments to Torque Wrench............................................................................................... F8-16
Nozzle Position to Produce Vertical Fan........................................................................................................... F5-3

Offset Screwdriver ......................................................................................................................................... F4-15

Oil Spray Gun ................................................................................................................................................ F5-11
Oil Spray Guns................................................................................................................................................... 5-4
Open-End Wrench ......................................................................................................................................... F4-20
Open-End Wrench Jaw Offset........................................................................................................................ F4-21
Operation and Use, Torque Wrench ................................................................................................................... 8-5
Operation of Vernier Calipers ......................................................................................................................... F3-31
Outside Micrometer........................................................................................................................................ F3-34
Oxygen Servicing Unit ................................................................................................................................... F9-24

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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Subject Paragraph
Figure, Table
Number

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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Subject Paragraph
Figure, Table
Number

P- Continued

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

Radius Gauges, Fillet and ................................................................................................................................ 3-19

Ratchet Handle .............................................................................................................................................. F4-27
Ratchet Screwdrivers ..................................................................................................................................... F4-16
Rawhide Mallet ................................................................................................................................................ F4-7
Reading a Measurement on a Micrometer...................................................................................................... F3-42
Reading a Measurement on a Vernier Caliper ................................................................................................ F3-32
Reading a Metric Caliper................................................................................................................................ F3-33
Reading a Metric Micrometer ......................................................................................................................... F3-44
Reading a Vernier Micrometer........................................................................................................................ F3-43
Reamer, Adjustable........................................................................................................................................ F4-92
Reamer, Brown and Sharpe Tapered ............................................................................................................. F4-94
Reamer, Jobber's (Machine) .......................................................................................................................... F4-93
Reamer, Repairman's Hand ........................................................................................................................... F4-95
Reamers .......................................................................................................................................................... 4-14
Reamers, Identification of Parts of ................................................................................................................. F4-91
Recommended Torque Values ......................................................................................................................... T8-2
Reflectorizing and Checkered Flags ................................................................................................................... 9-4
Removing Broken Handle .............................................................................................................................. F4-10

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Subject Paragraph
Figure, Table
Number

R - Continued

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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Subject Paragraph
Figure, Table
Number

S - Continued

Setscrew Wrench (Allen Wrench) Hexagonal ................................................................................................. F4-31

Setting Hammer............................................................................................................................................... F4-4
Setting Height on a Surface Gauge ......................................................................................................3-10c, F3-46
Setting Protractor with Flight Control Surface in Neutral Position ..................................................................... F7-2
Setting the Center Head................................................................................................................................. F3-14
Shears and Double Flares ............................................................................................................................ F4-119
Shears, Double Cutting .................................................................................................................................... 4-21
Sheet Metal and Wire Gauge ................................................................................................................ F3-72, 3-18
Sheet Metal and Wire, Measuring .................................................................................................................. F3-72
Shop Practices................................................................................................................................................... 2-8
Simple Calipers.............................................................................................................................................. F3-24
Single- and Double-Cut File Teeth ................................................................................................................. F4-66
Sizes, Drill........................................................................................................................................................ T4-2
Slide Caliper .................................................................................................................................................. F3-28
Sliding T-Bar Handle ...................................................................................................................................... F4-28
Slip-Joint Pliers .............................................................................................................................................. F4-41
Small Hole Gauge, Measuring Hole with a ..................................................................................................... F3-80
Small Hole Gauges ............................................................................................................................... F3-79, 3-22
Snap Gauge for Checking Diameters ............................................................................................................. F3-64
Snap Gauge for Checking Dimension Between Surfaces ............................................................................... F3-62
Snap Gauge for Checking Flat or Cylindrical Work......................................................................................... F3-63
Snap Gauge, Adjusting the............................................................................................................................. F3-65
Snap Gauge, Progressive .............................................................................................................................. F3-61
Snap Gauge, Solid Nonadjustable.................................................................................................................. F3-60
Snap Gauges ........................................................................................................................................ F3-59, 3-16
Tolerances.............................................................................................................................................. T3-2
Soaking a Paint Gun ........................................................................................................................................ F5-9
Sockets .......................................................................................................................................................... F4-26
Soft-Faced Hammer......................................................................................................................................... F4-6
Soft-Faced Hammer Face Substances............................................................................................................. T4-1
Soldering Tools ..................................................................................................................................... F7-22, 7-16
Solid Nonadjustable Snap Gauge................................................................................................................... F3-60
Solid Steel Plumb Bobs.................................................................................................................................... F3-6
Solvent, Cleaning Gun ................................................................................................................................... F5-12
Spacing and Fineness, File Teeth .................................................................................................................. F4-67
Special Aircraft Tools, General........................................................................................................................... 7-1
Speed Handle ................................................................................................................................................ F4-30
SPEM Stand .................................................................................................................................................... F9-4
Spiral Screw Extractors ................................................................................................................................ F4-108
Spray Gun, Oil ............................................................................................................................................... F5-11
Spray Guns, Oil.................................................................................................................................................. 5-4
Spray Pattern ................................................................................................................................................... F5-2
Spray Pattern, Adjustment of ........................................................................................................................... F5-4

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Subject Paragraph
Figure, Table
Number

S - Continued

Spring Divider ................................................................................................................................................ F3-21

Spring-Joint Calipers...................................................................................................................................... F3-25
Square
Carpenter's ........................................................................................................................................... F3-10
Combination ......................................................................................................................................... F3-11
Square File .................................................................................................................................................... F4-71
Square Head, Determining Depth with the...................................................................................................... F3-20
Square Line, Marking a .................................................................................................................................. F3-13
Squares ............................................................................................................................................................. 3-6
Stand, SPEM ................................................................................................................................................... F9-4
Stand, Type D5B Hydraulic Test ...................................................................................................................... F9-5
Storage of Ground Support Equipment............................................................................................................... 9-6
Straight Screw Extractor............................................................................................................................... F4-107
Striding Level................................................................................................................................................... F3-3
Stroke Technique, Correct and Incorrect .......................................................................................................... F5-5
Suggested Corrections, Faulty Pattern and .................................................................................................... F5-10
Surface Gauge................................................................................................................................................. 3-10
Setting Height on a ............................................................................................................................... F3-46

Tap Extractor ............................................................................................................................................... F4-109

Tap Extractor, Use of ................................................................................................................................... F4-110
Tap Wrenches.............................................................................................................................................. F4-103
Tapes and Rules ................................................................................................................................................ 3-5
Tapes, Typical.................................................................................................................................................. F3-8
Tapping and Die-Cutting Threads, Lubricants for.............................................................................................. T4-3
Tapping, Correct Drill Sizes for .................................................................................................................... F4-102
Taps and Dies .................................................................................................................................................. 4-18
Taps ........................................................................................................................................................... F4-101
Telescoping Gauge, Measuring Hole with....................................................................................................... F3-78
Telescoping Gauges ............................................................................................................................. 3-21, F3-77

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Subject Paragraph
Figure, Table
Number

T - Continued

Telescoping Magnet ................................................................................................................................ 7-9, F7-14

Tensiometer..................................................................................................................................................... F7-4
Tensiometer Reading in Pounds, Conversion of............................................................................................... F7-6
Tensiometer, Cable............................................................................................................................................ 7-3
Tensiometer, Using a ....................................................................................................................................... F7-5
Testing of Torque Tools ..................................................................................................................................... 8-7
Thickness Gauge .................................................................................................................................. 3-17, F3-70
Thread Chasers................................................................................................................................... 4-19, F4-106
Thread Gauge................................................................................................................................................ F3-52
Thread Gauges ................................................................................................................................................ 3-13
Three-Jaw Chuck and Chuck Key..................................................................................................................... F6-3
Three-Prong Grounded Plug ............................................................................................................................ F6-1
Tightening Preload Washers .......................................................................................................................... F8-33
Tightening to 15-Degree Wrench Arc ............................................................................................................. F8-24
Tightening to 30-Degree Wrench Arc ............................................................................................................. F8-27
Tightening to 60- or 120-Degree Wrench Arc ................................................................................................. F8-26
Tightening to 90- or 180-Degree Wrench Arc ................................................................................................. F8-28
Tinner's Mallet.................................................................................................................................................. F4-9
Tolerances
Ring Gauges.................................................................................................................................. 3-15, T3-1
Snap Gauges.......................................................................................................................................... T3-2
Tool Boxes......................................................................................................................................................... 2-9
Tool Care ........................................................................................................................................................... 2-3
Tool Safety ........................................................................................................................................................ 2-7
Tool Selection ......................................................................................................................................................24
Tool Selection ................................................................................................................................................. 10-2f
Tool Use ............................................................................................................................................................ 2-6
Tool, Double Flaring..................................................................................................................................... F4-122
Tool, Individual Flaring Tool......................................................................................................................... F4-121
Tool, Tube Bending.......................................................................................................................................... 4-26
Tools, Combination Flaring .......................................................................................................................... F4-120
Tools, Flaring ................................................................................................................................................... 4-25
Tools, Pneumatic ............................................................................................................................................... 5-1
Tools, Soldering .................................................................................................................................... F7-22, 7-16
Torque Multiplier Power Wrench ........................................................................................................... 8-10, F8-23
Torque Multiplier, General Use....................................................................................................................... F8-21
Torque Multiplier, Hub Nut ............................................................................................................................. F8-22
Torque Multipliers .............................................................................................................................................. 8-9
Torque Procedures Without a Torque Wrench ................................................................................................. 8-11
Torque Tool Accuracy Limits............................................................................................................................ T8-1
Torque Tools, Care of ........................................................................................................................................ 8-6

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Subject Paragraph
Figure, Table
Number

T - Continued

Torque Tools, Testing of .................................................................................................................................... 8-7

Torque Tools, Types of ...................................................................................................................................... 8-2
Torque Value, Determining Correct .................................................................................................................... 8-4
Torque Values, Recommended ........................................................................................................................ T8-2
Torque Wrench Attachment - Offset Reverse Extension ................................................................................ F8-17
Torque Wrench Attachment, Angle Extension ................................................................................................ F8-20
Torque Wrench Attachments, Concentric ....................................................................................................... F8-15
Torque Wrench Operation and Use .................................................................................................................... 8-5
Torque Wrench Selection................................................................................................................................... 8-3
Torque Wrench - Deflecting Beam with Indicating Dial (Direct Reading with
Audible Signal), Type I, Class 2, Style B................................................................................................. F8-8
Torque Wrench - Deflecting Beam with Indicator Plate (Direct Reading with
Feel Impulse and Audible Signal), Type I, Class 1, Style B ..................................................................... F8-6
Torque Wrench - Deflecting Beam with Indicator Plate (Direct Reading),
Type I, Class 1, Style A .......................................................................................................................... F8-5
Torque Wrench - Rigid Case with Indicator Dial (Direct Reading) Type II, Style A ............................................ F8-9
Torque Wrench - Rigid Case with Indicator Dial, Presetting Torque Dial
(Direct Reading with Audible Signal),Type II, Style B ............................................................................ F8-10
Torque Wrench - Rigid Case with Presetting Dial (Direct Reading with
Flashlight Signal), Type II, Style C........................................................................................................ F8-11
Torque Wrench - Rigid Case, Micrometer-Style Torque Presetting, Audible
Signal, Plain Head Type Ill, Class 1 ...................................................................................................... F8-12
Torque Wrench - Rigid Case, Micrometer-Style Torque Presetting,
Audible Signal, Ratchet Reversible Head, Type III, Class 2 .................................................................. F8-13
Torque Wrench - Rigid Case, Preset Torque, Audible Signal, Type V ............................................................ F8-14
Torque Wrench, Audible-Indicating .................................................................................................................. F8-4
Torque Wrench, Deflecting Beam .................................................................................................................... F8-2
Torque Wrench, Nonconcentric Attachments to.............................................................................................. F8-16
Torque Wrench, Rigid Frame ........................................................................................................................... F8-3
Torque Wrenches - Deflecting Beam with Indicating Dial (Direct Reading),
Type I, Class 2, Style A .......................................................................................................................... F8-7

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Subject Paragraph
Figure, Table
Number

T - Continued

Tow Vehicle, Type MB-4 ................................................................................................................................ F9-21

Towbar........................................................................................................................................................... F9-16
Trailer, Engine ............................................................................................................................................... F9-12
Trammel ........................................................................................................................................................ F3-30
Transfer Calipers............................................................................................................................................ F3-26
Transfer Punch .............................................................................................................................................. F4-63
Triangular File................................................................................................................................................ F4-68
Tripod Jack, 3-Ton ........................................................................................................................................... F9-9
Tripod Jack, 5-Ton ........................................................................................................................................... F9-8
Tripod Jack, 12-Ton ......................................................................................................................................... F9-7
Tube Beading Tool.............................................................................................................................. 4-26, F4-123
Tube Bender ................................................................................................................................................ F4-117
Tube Benders................................................................................................................................................... 4-24
Tube Cutter, Cutting Tube............................................................................................................................ F4-116
Tube Cutters ................................................................................................................................................ F4-115
Tube Cutters, Pipe and .................................................................................................................................... 4-23
Tube, Bending.............................................................................................................................................. F4-118
Tubing, Beading Large ................................................................................................................................. F4-124
Turnbuckle Wrench................................................................................................................................... 7-4, F7-8
Type I, Class 1, Style A Torque Wrench - Deflecting Beam with Indicator Plate
(Direct Reading) ..................................................................................................................................... F8-5
Type I, Class 1, Style B Torque Wrench - Deflecting Beam with Indicator
Plate (Direct Reading and Feel Impulse and Audible Signal) .................................................................. F8-6
Type I, Class 2, Style A Torque Wrenches - Deflecting Beam with
Indicating Dial (Direct Reading) .............................................................................................................. F8-7
Type I, Class 2, Style B Torque Wrench - Deflecting Beam with Indicating
Dial (Direct Reading with Audible Signal)................................................................................................ F8-8
Type II Style A Torque Wrench - Rigid Case with Indicator Dial (Direct Reading) ............................................. F8-9
Type II, Style B Torque Wrench - Rigid Case with Indicator Dial, Presetting
Torque Dial (Direct Reading with Audible Signal).................................................................................. F8-10
Type II, Style C Torque Wrench - Rigid Case with Presetting Dial
(Direct Reading with Flashlight Signal).................................................................................................. F8-11
Type III, Class 1 Torque Wrench Rigid Case, Micrometer-Style Torque
Presetting, Audible Signal, Plain Head.................................................................................................. F8-12
Type III, Class 2 Torque Wrench - Rigid Case, Micrometer-Style Torque
Presetting, Audible Signal, Ratchet Reversible Head ............................................................................ F8-13
Type B-1 Maintenance Platform ....................................................................................................................... F9-1
Type B-4A, Maintenance Stand........................................................................................................................ F9-2
Type D5B Hydraulic Test Stand ....................................................................................................................... F9-5

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Subject Paragraph
Figure, Table
Number

T - Continued

Type MB-4 Tow Vehicle ................................................................................................................................. F9-21

Type V Torque Wrench - Rigid Case, Preset Torque, Audible Signal ............................................................. F8-14
Types of Ground Support Equipment ................................................................................................................. 9-9
Types of Tools Used in Army Aviation................................................................................................................ 2-2
Types of Torque Tools ....................................................................................................................................... 8-2
Typical Air Compressors ................................................................................................................................ F9-14
Typical Aircraft Pre-Heater............................................................................................................................. F9-15
Typical Cable Rigging Tension Chart ............................................................................................................... F7-7
Typical Cranes and Hoists.............................................................................................................................. F9-18
Typical Drill Bit............................................................................................................................................... F4-83
Typical Height Gauge..................................................................................................................................... F3-51
Typical Paint Gun............................................................................................................................................. F5-1
Typical Rule ..................................................................................................................................................... F3-9
Typical Tapes................................................................................................................................................... F3-8
Typical Tool Boxes........................................................................................................................................... F2-1

Use of Tap Extractor .................................................................................................................................... F4-110

Using a Bench Vise ........................................................................................................................................ F4-54
Using a Crowfoot Wrench .............................................................................................................................. F7-21
Using a File Handle........................................................................................................................................ F4-75
Using a Tensiometer ........................................................................................................................................ F7-5
Using a Thickness Gauge............................................................................................................................... F3-71
Using a Vernier Depth Gauge......................................................................................................................... F3-50
Using Carnage Clamp .................................................................................................................................... F4-56
Using Deicer Boot Pliers ................................................................................................................................ F7-17
Using Deicer Boot Roller ................................................................................................................................ F7-19
Using Drill Grinding Gauge............................................................................................................................. F4-89
Using Fillet and Radius Gauges ..................................................................................................................... F3-74
Using Inside Micrometer................................................................................................................................. F3-38
Using Inside Micrometer with Extension Rod.................................................................................................. F3-40
Using Leather Punch...................................................................................................................................... F7-18
Using Offset Screwdriver ............................................................................................................................... F4-18
Using Outside Micrometer.............................................................................................................................. F3-39
Using Ring Gauges ........................................................................................................................................ F3-58
Using Thread Gauges .................................................................................................................................... F3-53
Usual Cutting Edge and Heel Angles.............................................................................................................. F4-86

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Subject Paragraph
Figure, Table
Number

V-Grooves in Drill Jaws.................................................................................................................................. F4-82

Vacuum Cleaner, Pneumatic.............................................................................................................................. 5-6
Valve Repair Tool ................................................................................................................................... 7-6, F7-10
Valve Stem Fishing Tool ........................................................................................................................... 7-5, F7-9
Vernier Caliper ............................................................................................................................................... F3-29
Vernier Caliper, Operation of.......................................................................................................................... F3-31
Vernier Caliper, Reading a Measurement on a ............................................................................................... F3-32
Vernier Depth Gauge ..................................................................................................................................... F3-49
Vernier Depth Gauge, Using a........................................................................................................................ F3-50
Vertical Fan, Nozzle Position to Produce.......................................................................................................... F5-3
Vise, Bench.................................................................................................................................................... F4-53
Vise-Grip Pliers .............................................................................................................................................. F4-47

Washer on a Bolt, Installation of Preload........................................................................................................ F8-32

Washers on a Stud, Installation of Preload..................................................................................................... F8-31
Washers, Action of Preload Indicating............................................................................................................ F8-30
Washers, Preload Indicating........................................................................................................................... F8-29
Washers, Tightening Preload ......................................................................................................................... F8-33
Water Pump Pliers......................................................................................................................................... F4-46
Wedge, Installing Wooden ............................................................................................................................. F4-12
Wing Divider .................................................................................................................................................. F3-22
Wire Gauge, Sheet Metal and ............................................................................................................... 3-18, F3-72
Wire, Cutting................................................................................................................................................ F4-112
Wrench Arc, Alternate Method for Tightening to 15 Degree............................................................................ F8-25
Wrench Arc, Tightening to 15-Degree ............................................................................................................ F8-24
Wrench Arc, Tightening to 30-Degree ............................................................................................................ F8-27
Wrench Arc, Tightening to 60- or 120-Degree ................................................................................................ F8-26
Wrench Arc, Tightening to 90- or 180-Degree ................................................................................................ F8-28
Wrench Jaw Offset, Open-End....................................................................................................................... F4-21
Wrench, Adjustable........................................................................................................................................ F4-25

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Subject Paragraph
Figure, Table
Number

W - Continued

Wrench, Adjustable Hook Spanner................................................................................................................. F4-39

Wrench, Combination .................................................................................................................................... F4-24
Wrench, Crowfoot .......................................................................................................................................... F7-20
Wrench, Face Pin Spanner ............................................................................................................................ F4-38
Wrench, Hook Spanner. ................................................................................................................................. F4-36
Wrench, Open-End ........................................................................................................................................ F4-20
Wrench, Pin Spanner ..................................................................................................................................... F4-37
Wrench, Torque Multiplier Power ..................................................................................................................... 8-10
Wrench, Turnbuckle.................................................................................................................................. 7-4, F7-8
Wrench, Use of Box-End................................................................................................................................ F4-33
Wrench, Use of Open-End ............................................................................................................................. F4-32
Wrench, Use of Socket .................................................................................................................................. F4-34
Wrenches........................................................................................................................................................... 4-4
Wrenches, Box-End ....................................................................................................................................... F4-22
Wrenches, Crowfoot......................................................................................................................................... 7-20
Wrenches, Proper Procedure for Pulling Adjustable ....................................................................................... F4-35
Wrenches, Tap............................................................................................................................................. F4-103

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Subject Paragraph
Figure, Table
Number

Abrasion Resistance...........................................................................................................................................5-2l
Acceptability Limits, Rivet .............................................................................................................................. F7-22
Acceptable Spotweld Spacing .........................................................................................................................12-6a
Access Door, Flush .......................................................................................................................................... F8-8
Acrylic Plastic, Minimum Annealing Time....................................................................................................... T10-4
Acrylic Plastics, Drill for.................................................................................................................................. F10-3
Acrylic Plastics, Oven Temperatures for......................................................................................................... T10-1
Addition of Weights.........................................................................................................................................11-4c
Adhesives and Resins ........................................................................................................................................ 9-4
Application.............................................................................................................................................. 9-4e
Combination or Two-Step Adhesives ...................................................................................................... 9-4b
High-Temperature Setting Adhesives...................................................................................................... 9-4a
Room Temperature Setting Adhesives.....................................................................................................9-4c
Storage................................................................................................................................................... 9-4d
After Deburring............................................................................................................................................... F7-50
Aging Time and Temperature (Aluminum Alloys) .............................................................................................. 5-7f
Aircraft Mating Jig ............................................................................................................................................ F8-1
Aircraft Metals, Shaping ..................................................................................................................................... 6-2
Aircraft Plastics, General.................................................................................................................................. 10-1
Aircraft Structures, General................................................................................................................................ 4-1
Airframe Sheet Metal Repair, General................................................................................................................ 8-1
Airframe Sheet Metal, Basic Principles of Repair ............................................................................................... 8-2
Airplane Structural Parts .................................................................................................................................. F4-5
Airplanes (Fuselage) ........................................................................................................................................ 4-2b
Alclad Alloys, Reheat Treatment of ................................................................................................................ T5-12
Alclad Construction .......................................................................................................................................... F5-8
Allowable Percentage of Defective Spotwelds.................................................................................................12-6b
Allowance, Bend, 90-Degree Bend ................................................................................................................... F6-3
Allowance, Bend, Table.................................................................................................................................... T6-1
Alloy Characteristics and Uses (Aluminum) ...................................................................................................... 5-7b
Alloying ............................................................................................................................................................ 5-4a
Alloying Elements (for Steel)............................................................................................................................ 5-6b
Alloying Elements, Major.................................................................................................................................. T5-5
Alloys, Aluminum ............................................................................................................................................... 5-7
Alloys, Copper.................................................................................................................................................. 5-10
Alloys, Magnesium ............................................................................................................................................. 5-8
Alloys, Metals and .............................................................................................................................................. 5-4
Alloys, Titanium ................................................................................................................................................. 5-9
Alternate Transparent Plastic Plug Repair .....................................................................................................10-13b
Aluminum Alloy Designations and Conversions to 4 Digit System .................................................................... T5-6
Aluminum Alloy Facing Material....................................................................................................................... 9-3a
Aluminum Alloy Rivets, Single Shear, Strength of............................................................................................ T7-2
Aluminum Alloy Sheet Substitution.....................................................................................................................5-7i

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Figure, Table
Number

A - Continued

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

Balance Considerations, Surface...................................................................................................................... 11-2

Balanced and Unbalanced Conditions ............................................................................................................ F11-4
Balancing Jig, Field-Expedient ....................................................................................................................... F11-6
Balancing Principles......................................................................................................................................... 11-3
Effects of Moments................................................................................................................................11-3a
Effects of Weight and Distance..............................................................................................................11-3b
Band Saw......................................................................................................................................................... 3-5d
Band Saw, Contour ........................................................................................................................................ F3-27
Bandsaw Widths for Various Radii of Cuts (of Plastic).................................................................................... T10-3
Bar Folding Machine ............................................................................................................................. 3-6a, F3-31
Bars, Bucking................................................................................................................................................... F7-6
Basic Part Numbers, Jo-Bolt .......................................................................................................................... F7-81
Basic Principles of Repair (of Airframe Sheet Metal) .......................................................................................... 8-2

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Subject Paragraph
Figure, Table
Number

B - Continued

Maintaining Original Contour .................................................................................................................. 8-2b

Maintaining Original Strength.................................................................................................................. 8-2a
Minimizing Weight ...................................................................................................................................8-2c
Beaded Skin, Patch Repairs to....................................................................................................................... F8-57
Beads, Crimps, Relief Holes, and Riveted Angles, Nose Rib Using ................................................................ F6-22
Bearing Strength (Pounds) ............................................................................................................................... T7-3
Bench Grinder................................................................................................................................................ F3-30
Bench Shears........................................................................................................................................ 3-4e, F3-11
Bend Allowance ............................................................................................................................................... 6-3b
Bend Allowance Table...................................................................................................................................... T6-1
Bend Allowance, 90-Degree Bend .................................................................................................................... F6-3
Bending................................................................................................................................................... 5-3e, F5-5
Bending Sheet ................................................................................................................................................... 6-3
Bend Allowance ...................................................................................................................................... 6-3b
Brake or Sight Line ................................................................................................................................. 6-3d
Duplicating Patterns................................................................................................................................ 6-3g
Flat Pattern Layout ................................................................................................................................. 6-3e
Locating Brake or Sight Line .................................................................................................................... 6-3f
Radius of Bend ....................................................................................................................................... 6-3a
Setback ...................................................................................................................................................6-3c
Blanket and Seals ............................................................................................................................................ 9-9e
Blind-Type Lockbolt Numbering System......................................................................................................... T7-24
Blind-Type Lockbolt, Installation..................................................................................................................... F7-77
Blind-Type Lockbolts, Drilling Procedures for ................................................................................................. T7-30
Blind-Type Lockbolts, Grip Range for............................................................................................................. T7-27
Block, Bumping.............................................................................................................................................. F6-26
Blocks, Forming ............................................................................................................................................. F3-23
Bolt and Rivet Mounting (on Transparent Plastics) ........................................................................................10-16c
Bolt Installation, Typical (in Transparent Plastic) .......................................................................................... F10-17
Bonded Former Assemblies ............................................................................................................................. 9-6p
Bonded Former Repair (Cap) ......................................................................................................................... F9-13
Bonded Former Repair (Web) ........................................................................................................................ F9-14
Bonded Magnesium Panel Repair .................................................................................................................... F9-3
Bonded Magnesium Panels.............................................................................................................................. 9-6d
Bonded Stiffeners .............................................................................................................................................9-6c
Bonding Procedures........................................................................................................................................10-11
Bonding Procedures for Acrylic Plastic MIL-P-5425 .............................................................................10-11a
Bonding Procedures for Acrylic Plastic MIL-P-8184 .............................................................................10-11b
Bonding Procedures for Acrylic Plastic MIL-P-5425.......................................................................................10-11a
Bonding Procedures for Acrylic Plastic MIL-P-8184.......................................................................................10-11b
Bowed Steel Tubes, Straightening.................................................................................................................. F8-64
Box Beam Wing Construction ........................................................................................................................ F4-10
Brake Line, Locating, in the Brake.................................................................................................................. F6-11
Brake or Sight Line.................................................................................................................................. 6-3d, F6-5

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Subject Paragraph
Figure, Table
Number

B - Continued

Brake or Sight Line of Flange, Locating.......................................................................................................... F6-10

Brake, Cornice ............................................................................................................................................... F3-32
Brass and Mild Steel, Hardness Conversion for.............................................................................................. F5-15
Bucking Bar Weights, Recommended .............................................................................................................. T7-6
Bucking Bars.................................................................................................................................................... F7-6
Buckles, Working Out .................................................................................................................................... F6-17
Bulkhead and Skin Repair .............................................................................................................................. F8-28
Bulkhead Flanged Member Repairs ............................................................................................................... F8-26
Bulkhead Installation ...................................................................................................................................... F4-18
Bulkhead Repair.................................................................................................................................................8-9i
Bulkheads, Frames, and Formers..................................................................................................................... 4-8a
Bumping .......................................................................................................................................................... 6-4a
Bumping Block............................................................................................................................................... F6-26
Bumping, Sandbag......................................................................................................................................... F6-29
Burning (of Plastics) ........................................................................................................................................10-4b
Burrs After Drilling.......................................................................................................................................... F7-49

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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Subject Paragraph
Figure, Table
Number

C - Continued

Chamfered Flanging Block ............................................................................................................................. F6-32

Channel Repair by Insertion ........................................................................................................................... F8-30
Channel Repair by Patching........................................................................................................................... F8-29
Channel, Sample ............................................................................................................................................. F6-6
Characteristics (of Aircraft Plastics).................................................................................................................. 10-2
Characteristics (of Titanium Alloys) .................................................................................................................. 5-9b
Chart, Setback - K -.......................................................................................................................................... T6-2
Chem-Milled Skin Repair ........................................................................................................................ 8-6k, F8-2
Chem-Milling.................................................................................................................................................... 6-2b
Chemical Composition (Copper Alloys) by Trade Name ................................................................................. T5-16
Chemical Reaction (of Plastics).......................................................................................................................10-4e
Cherry Assembly Tools .................................................................................................................................. F7-45
Cherry Grip Gauge 269C3, Use of.................................................................................................................. F7-36
CherryMax Blind Heads, Typical .................................................................................................................... F7-53
CherryMAX Cross Reference (Part Number/Military Standard Part Number) .................................................... T7-9
CherryMAX Drilling Dimensions ..................................................................................................................... T7-15
CherryMAX Inspection...................................................................................................................................... 7-8e
CherryMAX Installation..................................................................................................................................... 7-8d
CherryMAX Part Number Breakdown ............................................................................................................. T7-10
CherryMAX Removal ....................................................................................................................................... 7-8g
CherryMAX Removal ..................................................................................................................................... F7-55
CherryMAX Rivet ........................................................................................................................................... F7-31
CherryMAX Rivets.............................................................................................................................................. 7-8
CherryMAX Inspection ............................................................................................................................ 7-8e
CherryMAX Installation ........................................................................................................................... 7-8d
CherryMAX Removal .............................................................................................................................. 7-8g
CherryMAX Tooling .................................................................................................................................7-8c
CherryMAX Troubleshooting .................................................................................................................... 7-8f
Identification ........................................................................................................................................... 7-8a
Selection ................................................................................................................................................ 7-8b
CherryMAX Rivet Shaving ............................................................................................................................. F7-51
CherryMAX Sleeve Stretch Marks .................................................................................................................. F7-54
CherryMAX Stem and Collar Flushness.......................................................................................................... F7-52
CherryMAX Tooling...........................................................................................................................................7-8c
CherryMAX Troubleshooting .................................................................................................................. 7-8f, T7-17
CherryMAX, Countersinking Dimensions for................................................................................................... F7-46
Circle Snips........................................................................................................................................... 3-4h, F3-14
Circular Damage Repair for Lightly Stressed Areas........................................................................................ F8-46
Circular Damage Repair in Heavily Stressed Area ......................................................................................... F8-51
Circular External Repair ........................................................................................................................ 8-8b, F8-11
Clamp Pliers .................................................................................................................................................... F3-9
Classification of Damage (to Sandwich Construction)......................................................................................... 9-5
Coin-Tapping Technique......................................................................................................................... 9-5a
Dents...................................................................................................................................................... 9-5e

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Subject Paragraph
Figure, Table
Number

C - Continued

Double Skin Damage.............................................................................................................................. 9-5h

Large Single Skin Damage ..................................................................................................................... 9-5g
Missing Core........................................................................................................................................... 9-5b
Scotchply Edge Member and Corfil Edge Filler Damage...........................................................................9-5i
Skin Core Voids.......................................................................................................................................9-5c
Skin Doubler Voids ................................................................................................................................. 9-5d
Small Single Skin Damage ...................................................................................................................... 9-5f
Unbonding and Ply Separation..................................................................................................................9-5j
Class I Damage (of Fiber Laminate)............................................................................................................... F9-19
Class I Repair (of Radomes) ..............................................................................................................................9-9i
Class II Damage (of Fiber Laminate).............................................................................................................. F9-20
Class II or Class III Repair to Plastic with Fluted Core ..................................................................................... 9-9m
Class II or Class III Repair to Plastic with Foamed-In Core .................................................................................9-9l
Class II Repair (of Radomes) .............................................................................................................................9-9j
Class II Repair (of Radomes), Typical Scarf Method for ................................................................................. F9-26
Class III Damage (of Fiber Laminate)............................................................................................................. F9-21
Class III Repair (of Radomes) ...........................................................................................................................9-9k
Classes of Repair (of Fiber Laminate) ...............................................................................................................9-9c
Classification of Damage (Impregnated Glass Cloth Parts) .............................................................................. 9-8a
Classification, of Damage (Airframe Sheet Metal Repair)................................................................................... 8-5
Cleaning (of Glass Windshields) ...................................................................................................................10-17b
Cleaning (Plastic Enclosures)........................................................................................................................10-15a
Cleanliness of Repair Area............................................................................................................................... 9-6a
Cleco Fastener................................................................................................................................................. F3-7
Cleco Fasteners Pliers ..................................................................................................................................... F3-8
Codes, Color (for Aluminum)............................................................................................................................ T5-7
Coin Dimpling ................................................................................................................................................ F7-10
Coin-Tapping Technique .................................................................................................................................. 9-5a
Cold Climate Precautions.............................................................................................................................10-1 5e
Cold Forming (of Plastics)...............................................................................................................................10-7a
Cold-Working ....................................................................................................................................................5-5c
Collar Numbering System, Lockbolt ............................................................................................................... T7-25
Color Codes (for Aluminum)............................................................................................................................. T5-7
Combination or Two-Step Adhesives................................................................................................................ 9-4b
Commonly Used Alloys (Magnesium)............................................................................................................... 5-8b
Completed Double Face Patch Repair ........................................................................................................... F9-27
Compression.................................................................................................................................................... F5-2
Compressive Strength.......................................................................................................................................5-2c
Concave Flange, Forming a ........................................................................................................................... F6-24
Conductivity .................................................................................................................................................... 5-2m
Construction (Sandwich) .................................................................................................................................. 9-1a
Construction Materials (Fuselage) .....................................................................................................................4-2c
Construction, Alclad ......................................................................................................................................... F5-8
Construction, Monocoque................................................................................................................................. F4-1

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Subject Paragraph
Figure, Table
Number

C - Continued

Construction, Rib............................................................................................................................................ F4-13

Construction, Semi-Monocoque ....................................................................................................................... F4-2
Construction, Spar ......................................................................................................................................... F4-12
Consumable Materials........................................................................................................................................ 1-3
Contour Band Saw ......................................................................................................................................... F3-27
Contraction and Expansion Allowances (for Transparent Plastics).................................................................. T10-5
Control Surface, Establishing Neutral Position of............................................................................................ F11-7
Control Surfaces, Flight........................................................................................................................... 4-7, F4-16
Control Surface Static Balance....................................................................................................................... F11-1
Conversions to 4 Digit System, Aluminum Alloy Designations and ................................................................... T5-6
Convex Flange, Forming a............................................................................................................................. F6-25
Copper and Copper Alloys................................................................................................................................ 5-10
Identification ..........................................................................................................................................5-10a
Major Alloying Elements ........................................................................................................................5-10b
Copper, Model BB-75, Hardness Range ......................................................................................................... F5-14
Core Materials.................................................................................................................................................... 9-2
Foamed-In-Place Core Materials .............................................................................................................9-2c
Foamed or Cellular Core Materials ......................................................................................................... 9-2b
Honeycomb Core Materials..................................................................................................................... 9-2d
Natural Core Materials ............................................................................................................................ 9-2a
Cornice Brake ....................................................................................................................................... 3-6b, F3-32
Correcting Oval Shaped Steel Tubing Distortion ............................................................................................ F8-63
Correctly and Incorrectly Driven Rivets ................................................................................................. 7-5a, F7-20
Corrosion ......................................................................................................................................................... 8-3a
Corrosion Resistance (of Aluminum Alloys).......................................................................................................5-7c
Corrosion Resistance ........................................................................................................................................5-2k
Corrosion Treatment ........................................................................................................................................ 8-6h
Countersink, Standard...................................................................................................................................... F7-7
Countersink, Stop............................................................................................................................................. F7-8
Countersinking Dimensions (100 Degrees) for CherryMAX............................................................................. F7-46
Countersinking ............................................................................................................................................... F7-17
Countersinking Practices................................................................................................................................ F7-18
Countersinking, Incorrect................................................................................................................................ F7-47
Countersinks .......................................................................................................................................... 3-4i, F3-15
Countersinks for Shaving, Recommended...................................................................................................... T7-16
Countersunk Head Nominal Diameter CherryMAX Rivet ................................................................................ F7-32
Countersunk Head Oversize Diameter, CherryMAX Rivet .............................................................................. F7-34
Countersunk Head Rivet, Removal of ............................................................................................................ F7-24
Countersunk-Head Rivet Removal ................................................................................................................... 7-6b
Crack or Scratch Repair ................................................................................................................................... F9-5
Crack Repair for Lightly Stressed Areas ......................................................................................................... F8-47
Cracking, Rivet Head ..................................................................................................................................... F7-21
Cracks (in Plastics) .......................................................................................................................................10-12d

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Subject Paragraph
Figure, Table
Number

C - Continued

Crazing .........................................................................................................................................................10-12c
Crimping .................................................................................................................................................64b, F6-12
Crimps and Beads, Nose Rib with .................................................................................................................. F6-21
Cross Reference of Old and New Color Code (for Aluminum) .......................................................................... T5-8
Cross Reference, Old Color Code (Steel)......................................................................................................... T5-3
Cross Reference, CherryMAX (Part Number/Military Standard Part Number) ................................................... T7-9
Curing and Heat Treatment (of Plastics)..........................................................................................................10-10
Annealing ............................................................................................................................................10-10c
Further Treatment................................................................................................................................10-10b
Temperature........................................................................................................................................10-10a
Curved Formed or Extruded Angles ................................................................................................................. 6-5b
Cushion Thickness ......................................................................................................................................... F10-8
Cushion, Formation of, on Acrylic Plastic by Immersion in Cement ................................................................ F10-5
Cutout Repair, Rectangular Damage (Lightly Stressed).................................................................................. F8-44
Cutting Acrylic Plastic Sheets, Types of Circular Saw Blades for.................................................................... T10-2
Cutting Techniques (for Plastics)...................................................................................................................... 10-8
Drilling ................................................................................................................................................... 10-8f
General Precautions ..............................................................................................................................10-8a
Layout ...................................................................................................................................................10-8b
Routers..................................................................................................................................................10-8d
Saws......................................................................................................................................................10-8c
Scribing and Sanding.............................................................................................................................10-8e

Damage (to Sandwich Construction), Classification of........................................................................................ 9-5

Damage Classification ....................................................................................................................................... 8-5
Damage Repairable by Insertion..............................................................................................................8-5c
Damage Repairable by Patching............................................................................................................. 8-5b
Damage Requiring Replacement of Parts ............................................................................................... 8-5d
Negligible Damage ................................................................................................................................. 8-5a
Damage Evaluation.......................................................................................................................................... 8-6b
Damage Inspection ............................................................................................................................................ 8-4
Damage Near Existing Structure (Lightly Stressed), Repair of........................................................................ F8-45
Damage Removal .............................................................................................................................................8-6c
Damage Repair (Impregnated Glass Cloth Parts)............................................................................................. 9-8b
Damage Repair Near Adjacent Member in Heavily Stressed Area.................................................................. F8-52
Damage Repair Near Existing Structure in Heavily Stressed Areas................................................................ F8-49
Damage Repair Near Primary Horizontal Member in Heavily Stressed Area .................................................. F8-50
Damage Repairable by Insertion .......................................................................................................................8-5c
Damage Repairable by Patching ...................................................................................................................... 8-5b
Damage Requiring Replacement of Parts......................................................................................................... 8-5d
Damage, Class I (of Fiber Laminate).............................................................................................................. F9-19
Damage, Class II (of Fiber Laminate)............................................................................................................. F9-20

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Subject Paragraph
Figure, Table
Number

D - Continued

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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Subject Paragraph
Figure, Table
Number

D - Continued

Duplicating Patterns ......................................................................................................................................... 6-3g

Dynamic Balance ............................................................................................................................................11-2b
Dzus Fastener (Stud, Grommet, and Receptacle) .......................................................................................... F7-95
Dzus Fastener (Stud, Grommet, and Receptacle), Installation Tools for ....................................................... F7-104
Dzus Fastener (Stud, Grommet, and Spring).................................................................................................. F7-96
Dzus Fastener Head Styles ............................................................................................................................ F7-97
Dzus Fastener Installation Secondary Procedures........................................................................................ F7-103
Dzus Fastener Installation, Wing-Type ......................................................................................................... F7-102
Dzus Fastener Receptacle, Installation of..................................................................................................... F7-105
Dzus Fastener Stud and Grommet, Installation of ........................................................................................ F7-106
Dzus Fasteners ...............................................................................................................................................7-15a
Dzus Fasteners, Installation of Type A-AJ .................................................................................................... F7-100
Dzus Fasteners, Installation of Type F-FA-FJ............................................................................................... F7-101
Dzus Fasteners, Installation Tools for Type A-AJ and F-FA-FJ....................................................................... F7-98

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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Subject Paragraph
Figure, Table
Number

Face Plies, Replacing .................................................................................................................................... F9-24

Facing Materials................................................................................................................................................. 9-3
Aluminum Alloy Facing Material ............................................................................................................. 9-3a
Glass Fiber Mat Facing Material .............................................................................................................. 9-3f
Magnesium Alloy Facing Material ............................................................................................................9-3c
Plywood Facing Material......................................................................................................................... 9-3d
Resin-Impregnated Glass Cloth Facing Material ..................................................................................... 9-3e
Steel Facing Material.............................................................................................................................. 9-3b
Factors in Determining Rivet Length ................................................................................................................ F7-3
Failure, Spotweld ............................................................................................................................................. 12-4
Failure, Spotweld, with No Skin Breaks ............................................................................................................ 12-5
Fastener, Camlock ....................................................................................................................................... F7-107
Fastener, Cleco................................................................................................................................................ F3-7
Fastener, Dzus (Stud, Grommet, and Receptacle) ......................................................................................... F7-95
Fastener, Dzus (Stud, Grommet, and Spring)................................................................................................. F7-96
Fastener, Dzus, Head Styles .......................................................................................................................... F7-97
Fasteners, Hi-Lock ........................................................................................................................................... 7-14
Fasteners, Turn-Lock ....................................................................................................................................... 7-15
Fiber Laminate Material Repair .......................................................................................................................... 9-9
Blanket and Seals................................................................................................................................... 9-9e
Class I Repair ...........................................................................................................................................9-9i
Class II Repair ..........................................................................................................................................9-9j
Class II or Class III Repair to Plastic with Foamed-In Core........................................................................9-9l
Class II or Class III Repair to Plastic with Fluted Core............................................................................ 9-9m
Class III Repair ........................................................................................................................................9-9k
Classes of Repair ....................................................................................................................................9-9c
General Principles of Materials and Repair Procedures .......................................................................... 9-9d
General Repair Consideration................................................................................................................. 9-9g
General Repair Requirements................................................................................................................. 9-9a
Inspection after Repair............................................................................................................................. 9-9r
Materials Used in Repair......................................................................................................................... 9-9b
Parting Films and Compounds................................................................................................................. 9-9f
Procedure for Edge Band Sealing........................................................................................................... 9-9q
Procedure for Obtaining Void-Free Laminate .......................................................................................... 9-9p
Procedure for Preventing Moisture and Oil Contamination...................................................................... 9-9o
Repair of Pre-Drilled Attachment Holes .................................................................................................. 9-9n
Repair Procedures .................................................................................................................................. 9-9h
Field-Expedient Balancing Jig ........................................................................................................................ F11-6
Finishing Procedures.......................................................................................................................................10-14
Ashing .................................................................................................................................................10-14b
Machine Buffing...................................................................................................................................10-14c
Polishing..............................................................................................................................................10-14d
Sanding ...............................................................................................................................................10-14a
First Flange, Layout of ..................................................................................................................................... F6-7

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Subject Paragraph
Figure, Table
Number

F - Continued

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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Subject Paragraph
Figure, Table
Number

F - Continued

Heating for Forming...............................................................................................................................10-7b

Forming Operations ........................................................................................................................................... 6-4
Bumping ................................................................................................................................................. 6-4a
Crimping................................................................................................................................................. 6-4b
Folding ................................................................................................................................................... 6-4e
Shrinking ................................................................................................................................................ 6-4d
Stretching ................................................................................................................................................6-4c
Forming Procedures, Hand ................................................................................................................................ 6-5
Forms (for Plastics).........................................................................................................................................10-7c
Frame and Former Installation ....................................................................................................................... F4-17
Frame and Nonstressed Skin Repair .............................................................................................................. F8-38
Frame and Skin Repair .................................................................................................................................. F8-27
Frame and Stringer Joint, Repair of ............................................................................................................... F8-35
Friction Lock (Self-Plugging Rivets) ................................................................................................................... 7-7
Further Treatment (of Heat-Treated Plastics) ................................................................................................10-10b
Fuselage ............................................................................................................................................................ 4-2
Airplanes ................................................................................................................................................ 4-2b
Construction Materials .............................................................................................................................4-2c
Helicopters ............................................................................................................................................. 4-2a

Gauge, Radius ................................................................................................................................................. F3-6

General Precautions (Cutting Plastics) ............................................................................................................10-8a
General Principles of Materials and Repair Procedures (with Fiber Laminate) .................................................. 9-9d
General Repair Consideration (for Radome Repair) ......................................................................................... 9-9g
General Repair Practices ................................................................................................................................... 8-6
Chem-Milled Skin Repair .........................................................................................................................8-6k
Corrosion Treatment............................................................................................................................... 8-6h
Damage Evaluation ................................................................................................................................ 8-6b
Damage Removal....................................................................................................................................8-6c
Repair Material Selection........................................................................................................................ 8-6d
Repair Parts Layout ................................................................................................................................ 8-6e
Rivet Selection ........................................................................................................................................ 8-6f
Rivet Spacing and Edge Distance........................................................................................................... 8-6g
Riveting ....................................................................................................................................................8-6i
Structural Support During Repair ............................................................................................................ 8-6a
Tolerance .................................................................................................................................................8-6j
General Repair Requirements (Fiber Laminate) ............................................................................................... 9-9a
General Shop Rules (Sheet Metal Shop)............................................................................................................ 2-1
Responsibility ......................................................................................................................................... 2-1a
Shop Housekeeping................................................................................................................................ 2-1b
Shop Safety.............................................................................................................................................2-1c

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Subject Paragraph
Figure, Table
Number

G - Continued

Shop Tools and Materials ....................................................................................................................... 2-1d

General, Aircraft Plastics.................................................................................................................................. 10-1
General, Aircraft Structures................................................................................................................................ 4-1
General, Airframe Sheet Metal Repair................................................................................................................ 8-1
General, Forming ............................................................................................................................................... 6-1
General, Rebalancing Movable Surfaces ......................................................................................................... 11-1
General, Rivets and Riveting Techniques........................................................................................................... 7-1
General, Sandwich Construction Repair ............................................................................................................. 9-1
General, Shop Equipment .................................................................................................................................. 3-1
General, Spotwelds .......................................................................................................................................... 12-1
General, Structural Metals.................................................................................................................................. 5-1
Glass Cloth Repair of Lack-of-Material Damage............................................................................................. F9-18
Glass Cloth Repair of Large Crack or Perforation........................................................................................... F9-17
Glass Cloth Repair of Small Crack ................................................................................................................. F9-16
Glass Fiber Mat Facing Material........................................................................................................................ 9-3f
Glass Windshields...........................................................................................................................................10-17
Cleaning ..............................................................................................................................................10-17b
Inspection ............................................................................................................................................10-17a
Removal and Installation .....................................................................................................................10-17c
Glue Method ...................................................................................................................................................10-9c
Grinder, Bench............................................................................................................................................... F3-30
Grinding and Sanding Machines........................................................................................................................ 3-5f
Grip Lengths for Solid Shank Rivets................................................................................................................. T7-1
Grip Lengths, Hi-Lok ...................................................................................................................................... F7-90
Grip Lengths, Jo-Bolts.................................................................................................................................... F7-82
Grip Range (CherryMAX Rivets) .................................................................................................................... T7-11
Grip Range (Olympic Blind Rivets)..................................................................................................................7-11b
Grip Range for Blind-Type Lockbolts.............................................................................................................. T7-27
Grip Range for Olympic Rivets....................................................................................................................... T7-20
Grip Range for Pull- and Stump-Type Lockbolts............................................................................................. T7-26
Grip Ranges, Sizes, and Diameters of Flush Head Jo-Bolts ........................................................................... F7-83
Grip Ranges, Sizes, and Diameters of Hex Head Jo-Bolts.............................................................................. F7-84
Grip Ranges, Sizes, and Diameters of Millable Hex Head Jo-Bolts................................................................. F7-85

Hammers, Peening with ............................................................................................................................... F7-110

Hand Forming Procedures ................................................................................................................................. 6-5
Curving Formed or Extruded Angles ....................................................................................................... 6-5b
Forming by Bumping .............................................................................................................................. 6-5e
Forming Curved Flanged Parts ............................................................................................................... 6-5d
Forming Flanged Angles..........................................................................................................................6-5c

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Figure, Table
Number

H - Continued

Joggling .................................................................................................................................................. 6-5f

Lightening Holes .................................................................................................................................... 6-5h
Relief Holes ..........................................................................................................................................6-59g
Straight Line Bends . .............................................................................................................................. 6-5a
Hand Router Template for Milling Plug Cavity.............................................................................................. F10-15
Hand Shears ......................................................................................................................................... 3-4d, F3-10
Hand Tools (for Riveting) ................................................................................................................................ 7-4a
Hand-Type Tester, Webster ........................................................................................................................... F5-10
Handling and Storage (of Plastics) .................................................................................................................. 10-5
Hand Tools and Devices ................................................................................................................................... 3-4
Aviation Snips ......................................................................................................................................... 3-4f
Bench Shears ......................................................................................................................................... 3-4e
Circle Snips ............................................................................................................................................ 3-4h
Countersinks ............................................................................................................................................3-4i
Forming Blocks .......................................................................................................................................3-4k
Hand Shears .......................................................................................................................................... 3-4d
Micrometers ........................................................................................................................................... 3-4a
Punches ..................................................................................................................................................3-4j
Radius Gauge......................................................................................................................................... 3-4b
Sheet Metal Holders ................................................................................................................................3-4c
Straight Snips ........................................................................................................................................... 3-4
Hardness Conversion for Aluminum Alloy ...................................................................................................... F5-16
Hardness Conversion for Brass and Mild Steel................................................................................................5-13e
Hardness Conversion for Brass and Mild Steel............................................................................................... F5-15
Hardness Range (for Aluminum) .....................................................................................................................5-13c
Hardness Range (for Copper)..........................................................................................................................5-13d
Hardness Range, Aluminum, Model B............................................................................................................ F5-13
Hardness Range, Copper, Model BB-75 ........................................................................................................ F5-14
Hardness Tester, Rockwell............................................................................................................................. F5-12
Hardness Testing of Metals . ............................................................................................................................ 5-13
Hardness Conversion for Brass and Mild Steel .....................................................................................5-13e
Hardness Range for Aluminum ..............................................................................................................5-13c
Hardness Range for Copper ..................................................................................................................5-13d
Hardness Values for Clad Aluminum Sheet and Plate, and Bare Aluminum Sheet,
Plate, Extrusions, and Forgings .................................................................................................... 5-13f
Rockwell Hardness Test ........................................................................................................................5-13b
Webster Hardness Tester ......................................................................................................................5-13a
Hardness Values, Rockwell, for 0.050 Inch Minimum Thickness Class Aluminum Sheet and Plate ................ T5-20
Hardness Values, Rockwell, for Bare Aluminum Sheet, Plate, Extrusions, and Forgings ................................ T5-21
Hardness Values for Clad Aluminum Sheet and Plate, and Bare Aluminum Sheet,
Plate, Extrusions, and Forgings .................................................................................................... 5-13f
Hardness ...........................................................................................................................................................5-2i
Hat and Longeron Sections ............................................................................................................................ F4-21

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Subject Paragraph
Figure, Table
Number

H - Continued

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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Subject Paragraph
Figure, Table
Number

H - Continued

Installation Tools ...................................................................................................................................7-10c

Removal Procedures ............................................................................................................................. 7-10f
Selection ..............................................................................................................................................7-10b
Hi-Shear Rivets, Removal of ......................................................................................................................... F7-65
High-Temperature Setting Adhesives ............................................................................................................... 9-4a
Hold-Down Plate ........................................................................................................................................... F6-28
Hole and Drill Sizes for Self-Plugging (Friction Lock) Rivets ............................................................................ T7-8
Hole Finder, Use of . ...................................................................................................................................... F8-10
Hole Preparation (for Hi-Lok Fasteners) .........................................................................................................7-14c
Hole Preparation (for Jo-Bolts) .......................................................................................................................7-13e
Hole Size Limits (Olympic Blind Rivets) ..........................................................................................................7-11c
Hole Size Limits for Olympic Rivets ............................................................................................................... T7-21
Hole Sizes and Countersink Diameters, Jo-Bolt ............................................................................................. T7-31
Holes, Relief ................................................................................................................................................. F6-31
Honeycomb Core Materials .............................................................................................................................. 9-2d
Honeycomb Panel Edge, Repair of ................................................................................................................ F9-12
Honeycomb Repair ......................................................................................................................................... F9-2
Honeycomb Skin, Damaged............................................................................................................................. F9-1
Hot Climate Precautions................................................................................................................................10-15d
Hot Working..................................................................................................................................................... 5-5b
Huck Lockbolts ................................................................................................................................................ 7-12
Identification .........................................................................................................................................7-12d
Inspection .............................................................................................................................................7-12h
Installation Procedures ..........................................................................................................................7-12g
Installation Tools ................................................................................................................................... 7-12f
Materials ...............................................................................................................................................7-12b
Removal ................................................................................................................................................7-12i
Selection ...............................................................................................................................................7-12e
Substitution............................................................................................................................................7-12c
Types ....................................................................................................................................................7-12a

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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Subject Paragraph
Figure, Table
Number

I - Continued

Identification of Monel ........................................................................................................................ 5-11 a, T5-17

Identification of Olympic Blind Rivets ............................................................................................................7-11 a
Identification of Rivnuts ................................................................................................................................... 7-9a
Identification of Self-Plugging Rivets ............................................................................................................... 7-7a
Identification of Steel ...................................................................................................................................... 5-6a
Identification of Terms and Symbols (Balancing) ........................................................................................... F11-2
Identification of Titanium Alloys ....................................................................................................................... 5-9a
Identification, Penetrator ............................................................................................................................... F5-11
Inconel ............................................................................................................................................................ 5-12
Identification .........................................................................................................................................5-12a
Methods for Working .............................................................................................................................5-12b
Inconel, Identification of ................................................................................................................................. T5-18
Incorrect Countersinking ................................................................................................................................ F7-47
Industrial Alloys ............................................................................................................................................... 5-4b
Inner Sleeve in Steel Tube, Centering ........................................................................................................... F8-68
Inner Sleeve Splice, Steel Tube ..................................................................................................................... F8-67
Insertion Skin Repair Across Stiffeners in Heavily Stressed Area ................................................................... F8-53
Inspection after Repair (of Radomes) ................................................................................................................ 9-9r
Inspection of Glass Windshields ...................................................................................................................10-17a
Inspection of Hi-Lok Fasteners ....................................................................................................................... 7-14f
Inspection of Hi-Shear Rivets..........................................................................................................................7-10e
Inspection of Huck Lockbolts ..........................................................................................................................7-12h
Inspection of Jo-Bolts .....................................................................................................................................7-13h
Inspection of Olympic Blind Rivets ................................................................................................................. 7-11f
Inspection of Rivets ........................................................................................................................................... 7-5
Inspection of Self-Plugging Rivets .................................................................................................................... 7-7f
Inspection, Damage ........................................................................................................................................... 8-4
Inspection, Structural ........................................................................................................................................ 8-3
Installation Considerations (for Transparent Plastics) . ..................................................................................10-16a
Installation of Blind-Type Lockbolt ................................................................................................................. F7-77
Installation of Dzus Fastener Receptacle...................................................................................................... F7-105
Installation of Dzus Fastener Stud and Grommet ......................................................................................... F7-106
Installation of Hi-Lok Fasteners .......................................................................................................................7-14e
Installation of Huck Lockbolts ..........................................................................................................................7-12g
Installation of Jo-Bolts ....................................................................................................................................7-13g
Installation of Olympic Blind Rivets ................................................................................................................7-11e
Installation of Olympic Rivets ........................................................................................................................ F7-70
Installation of Pull-Type Lockbolt ................................................................................................................... F7-75
Installation of Stump-Type Lockbolt ............................................................................................................... F7-76
Installation of Type A-AJ Dzus Fasteners ..................................................................................................... F7-100
Installation of Type F-FA-FJ Dzus Fasteners ............................................................................................... F7-101
Installation Procedure, Rivnut ........................................................................................................................ F7-59
Installation Procedures for Hi-Shear Rivets . ...................................................................................................7-10d
Installation Procedures for Rivnuts .................................................................................................................. 7-9d

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Subject Paragraph
Figure, Table
Number

I - Continued

Installation Procedures for Self-Plugging Rivets .............................................................................................. 7-7e

Installation Tools for Dzus Fastener (Stud, Grommet, and Receptacle) ....................................................... F7-104
Installation Tools for Hi-Shear Rivets .............................................................................................................7-10c
Installation Tools for Huck Lockbolts .............................................................................................................. 7-12f
Installation Tools for Rivnuts . ...........................................................................................................................7-9c
Installation Tools for Self-Plugging Rivets ........................................................................................................ 7-7d
Installation Tools for Type A-AJ and F-FA-FJ Dzus Fasteners ....................................................................... F7-98
Installation Tools, Rivnut ............................................................................................................................... F7-58
Installation Tools, Self-Plugging Rivet ........................................................................................................... F7-28
Installation, Bulkhead ..................................................................................................................................... F4-18
Installation, Hi-Lok ........................................................................................................................................ F7-93
Installation, Self-Plugging Rivet .................................................................................................................... F7-29
Insulation of Dissimilar Materials ...................................................................................................................... 5-7h
Internal and External Repairs ............................................................................................................................. 8-9
Bulkhead Repair .......................................................................................................................................8-9i
Eliminating Gaps and Leveling Installations ..........................................................................................8-9aa
Floor Channel Repair ............................................................................................................................. 8-9o
Former Repair ........................................................................................................................................ 8-9h
Longeron Repair .................................................................................................................................... 8-9b
Longitudinal Skin Joint ............................................................................................................................ 8-9r
Nonstressed Skin and Frame Repair ...................................................................................................... 8-9q
Patch Repair to Damaged Swage in Aileron and Flap Skin .....................................................................8-9z
Patch Repairs to Beaded Skin .................................................................................................................8-9y
Repair for Damaged Skin Close to a Frame.............................................................................................8-9x
Repair of C rack by Stop-Drilling .............................................................................................................8-9k
Repair of Damaged Channels ..................................................................................................................8-9j
Repair of Damaged Frame or Beam ...................................................................................................... 8-9m
Repair of Dents and Creases ................................................................................................................. 8-91
Repair of Heavily Stressed Support and Stiffener ................................................................................... 8-9v
Repair of Frame and Stringer Joint ........................................................................................................ 8-9n
Rib Repair by Insertion .......................................................................................................................... 8-9g
Rib Repair by Patching ........................................................................................................................... 8-9f
Rivet Spacing, Selection and Acceptability Limits for a Nonstressed Skin Patch ..................................... 8-9t
Skin and Web Repairs ........................................................................................................................... 8-9u
Spar Angle Repair ................................................................................................................................. 8-9d
Spar Repair by Insertion ..........................................................................................................................8-9c
Spar Web Repair .................................................................................................................................... 8-9e
Splice Repair of Hat Section .................................................................................................................. 8-9p
Stressed Skin Repair ............................................................................................................................. 8-9w
Stringer Repair ...................................................................................................................................... 8-9a
Transverse Skin Joint ..............................................................................................................................8-9s
Internal Construction, Wing .................................................................................................................. 4-5b, F4-11
Introduction ........................................................................................................................................................ 1-1

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Subject Paragraph
Figure, Table
Number

J-Section Stringer Splice Repair .................................................................................................................... F8-16

Jigs (Cementing) .............................................................................................................................................10-9i
Jigs for Holding Cemented Assemblies .......................................................................................................... F10-9
Jo-Bolt Basic Part Numbers ........................................................................................................................... F7-81
Jo-Bolt Grip Lengths ...................................................................................................................................... F7-82
Jo-Bolt Hole Sizes and Countersink Diameters .............................................................................................. T7-31
Jo-Bolt Stem Break-Off Limits ....................................................................................................................... F7-87
Jo-Bolt Tooling............................................................................................................................................... F7-86
Jo-Bolt, Flush-Head ...................................................................................................................................... F7-78
Jo-Bolt, Hex Head.......................................................................................................................................... F7-79
Jo-Bolt, Millable Hex Head ............................................................................................................................ F7-80
Jo-Bolts ........................................................................................................................................................... 7-13
Head Type.............................................................................................................................................7-13a
Hole Preparation ...................................................................................................................................7-13e
Identification .........................................................................................................................................7-13b
Inspection .............................................................................................................................................7-13h
Installation .............................................................................................................................................7-13g
Removal ................................................................................................................................................7-13i
Sizes ....................................................................................................................................................7-13c
Tooling ................................................................................................................................................. 7-13f
Uses .....................................................................................................................................................7-13d
Joggling ........................................................................................................................................................... 6-5f
Joggling Die .................................................................................................................................................. F6-30
Joint Allowable Loads (Pounds) Per MIL-HDKB-5 (Rivet) Criteria .................................................................. T7-13

Ketts Saw.............................................................................................................................................. 3-5b, F3-25

Lacing Method ............................................................................................................................................ F10-12

Lack-of-Material Damage, Glass Cloth Repair of ........................................................................................... F9-18
Lap or Scab Patch (Crack) ............................................................................................................................... F8-3
Lap or Scab (Hole) ........................................................................................................................................... F8-4
Lap Patch Edge Distance ................................................................................................................................. 8-7d
Lap Patch Edge Preparation............................................................................................................................. F8-6
Large Crack or Perforation, Glass Cloth Repair of ......................................................................................... F9-17
Large Single e Skin Damage ............................................................................................................................ 9-59
Layout (for Cutting Plastics) . ..........................................................................................................................10-8b
Layout of First Flange ...................................................................................................................................... F6-7
Layout of Third Flange .................................................................................................................................... F6-9
Layout of Web.................................................................................................................................................. F6-8
Layout, Repair ................................................................................................................................................... 7-3
Leveling Installations, Eliminating Gaps and ................................................................................................. F8-59

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Subject Paragraph
Figure, Table
Number

L - Continued

Lightening Holes .............................................................................................................................................. 6-5h

Lightly Stressed Areas, Circular Damage Repair for ...................................................................................... F8-46
Lightly Stressed Areas, Crack Repair for ........................................................................................................ F8-47
Linear Expansion ............................................................................................................................................ 5-2e
Loads, Joint Allowable, (Pounds) Per MIL-HDBK-5 (Rivet) Criteria................................................................. T7-13
Locating Brake Line in the Brake ................................................................................................................... F6-11
Locating Brake or Sight Line . ........................................................................................................................... 6-3f
Locating Brake or Sight Line of Flange .......................................................................................................... F6-10
Location (of Stored Plastics)............................................................................................................................10-5a
Lockbolt Collar Numbering System ................................................................................................................ T7-25
Lockbolt, Blind-Type, Numbering System....................................................................................................... T7-24
Lockbolt, Pull-Type, Numbering System......................................................................................................... T7-22
Lockbolt, Stump-Type, Numbering System .................................................................................................... T7-23
Lockbolts, Huck ............................................................................................................................................... 7-12
Lockbolts, Types of . ...................................................................................................................................... F7-72
Longeron and Hat Sections ............................................................................................................................ F4-21
Longeron and Stringer Installation ................................................................................................................. F4-19
Longeron Repair .............................................................................................................................................. 8-9b
Longitudinal Skin Joint . ......................................................................................................................... 8-9r, F8-39
Loose Jo-Bolt, Removal of ............................................................................................................................. F7-89

Machinability ......................................................................................................................................................5-2j
Machine Buffing ............................................................................................................................................10-14c
Machine Screw Patch................................................................................................................................... F10-14
Machine Screw Repair . ............................................................................................................................... F10-13
Machine, Bar Folding .................................................................................................................................... F3-31
Magnesium Alloy Facing Material......................................................................................................................9-3c
Magnesium Alloys .............................................................................................................................................. 5-8
Commonly Used Alloys........................................................................................................................... 5-8b
Identification .......................................................................................................................................... 5-8a
Methods of Working ................................................................................................................................5-8c
Maintaining Original Contour (Airframe Sheet Metal Repair) ............................................................................ 8-2b
Maintaining Original Strength (Airframe Sheet Metal Repair) ........................................................................... 8-2a
Maintenance of Acrylic Plastic Enclosures on Army Aircraft . ..........................................................................10-15
Cleaning .............................................................................................................................................10-15a
Cold Climate Precautions ...................................................................................................................10-15e
Hot Climate Precautions .....................................................................................................................10-15d
Polishing .............................................................................................................................................10-15b
Waxing ...............................................................................................................................................10-15c
Maintenance of Engine Mounts . .......................................................................................................................4-3c
Maintenance of Shop Equipment........................................................................................................................ 3-2
Major Repair .......................................................................................................................................... 3-2b

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Subject Paragraph
Figure, Table
Number

M - Continued

Operator Maintenance ............................................................................................................................ 3-2a

Storage of Tools, Equipment, and Materials ............................................................................................3-2c
Major Alloying Elements (for Copper) .............................................................................................................5-10b
Major Alloying Elements .................................................................................................................................. T5-5
Major Repair (of Shop Equipment) .................................................................................................................. 3-2b
Malleability ...................................................................................................................................................... 5-2g
Marking Code (Steel), Identification ................................................................................................................ T5-2
Marking Example, Aluminum Identification ...................................................................................................... F5-7
Marking Example, Steel Identification ............................................................................................................. F5-6
Masking (Cementing) . .................................................................................................................................... 10-9f
Masking (Paper)............................................................................................................................................... 10-6
Removal ...............................................................................................................................................10-6a
Replacement . .......................................................................................................................................10-6b
Masking Paper . ..............................................................................................................................................10-5c
Material Substitution (of Metals) .........................................................................................................................5-7j
Material Thickness Variation (and Hi-Lok Rivets) .......................................................................................... F7-91
Material, Drilling . ........................................................................................................................................... F7-68
Material, Patch, Selection ............................................................................................................................... T8-5
Materials (Huck Lockbolts) .............................................................................................................................7-12b
Materials and Use (Solid Shank Rivets) .......................................................................................................... 7-2a
Materials Used In Repair (of Fiber Laminate) ................................................................................................... 9-9b
Materials, Core (Sandwich Construction) ........................................................................................................... 9-2
Materials, Facing ............................................................................................................................................... 9-3
Materials, Substitute (Aluminum) ................................................................................................................... T5-15
Mating Jig, Aircraft .......................................................................................................................................... F8-1
Members, Structural .......................................................................................................................................... 4-8
Metal and Forming Blocks ............................................................................................................................. F6-23
Metal Forming Machines ................................................................................................................................... 3-6
Bar Folding Machine .............................................................................................................................. 3-6a
Cornice Brake......................................................................................................................................... 3-6b
Shrinking and Stretching Machine .......................................................................................................... 3-6d
Slip Roll Former ......................................................................................................................................3-6c
Metal-Covered Wooden Floor Panels, Repair of . .......................................................................................... F9-15
Metal-Covered Wooden Floor Repair ................................................................................................................. 9-7
Negligible Damage ................................................................................................................................. 9-7a
Patching ................................................................................................................................................. 9-7b
Metals and Alloys ............................................................................................................................................... 5-4
Alloying .................................................................................................................................................. 5-4a
Industrial Alloys ........................................................................................................................................54b
Preparing Alloys . ....................................................................................................................................5-4c
Metals, Hardness Testing of ............................................................................................................................. 5-13
Metals, Properties of ......................................................................................................................................... 5-2
Method, Calculation (of Balancing) ................................................................................................................ F11-8
Method, Lacing ........................................................................................................................................... F10-12

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Subject Paragraph
Figure, Table
Number

M - Continued

Method, Scale (of Balancing) ........................................................................................................................ F11-9

Method, Soak ................................................................................................................................................ F10-6
Methods (of Rebalancing) ...............................................................................................................................11-4b
Methods for Working (of Inconel) ...................................................................................................................5-12b
Methods for Working and Uses (of Monel) .....................................................................................................5-11 b
Methods of Working (Magnesium Alloys) .........................................................................................................5-8c
Methods of Working (Titanium Alloys) ..............................................................................................................5-9c
Micrometer ...................................................................................................................................................... F3-5
Micrometers ..................................................................................................................................................... 3-4a
Microshaver ................................................................................................................................................... F7-14
Military Specification Number (of Plastics) ......................................................................................................104a
Millable Hex Head Jo-Bolts, Grip Ranges, Sizes, and Diameters of ............................................................... F7-85
Millable Hex Head Jo-Bolt.............................................................................................................................. F7-80
Minimizing Weight (Airframe Sheet Metal Repair).............................................................................................8-2c
Minimum Annealing Time for Acrylic Plastic .................................................................................................. T10-4
Minimum Rivet Edge Distances ....................................................................................................................... T8-1
Minimum Rivet Shear and Tensile Strength (Pounds) in Steel Coupons ........................................................ T7-12
Missing Core ................................................................................................................................................... 9-5b
Modern Use (Sandwich Construction)................................................................................................................9-1c
Moisture and Contamination, Preventing ....................................................................................................... F9-28
Monel............................................................................................................................................................... 5-11
Identification ......................................................................................................................................... 5-1 a
Methods for Working and Using ...........................................................................................................5-11 b
Monel, Identification of .................................................................................................................................. T5-17
Monocoque Construction ................................................................................................................................. F4-1
Monospar Wing Construction .......................................................................................................................... F4-8
Mount, Engine.................................................................................................................................................. F4-6
Mounts, Engine . ................................................................................................................................................ 4-3
MS 20600 Protruding-Head Rivet Identification ............................................................................................. F7-26
MS 20601 Countersunk-Head Rivet Identification ......................................................................................... F7-27
Multispar Wing Construction ........................................................................................................................... F4-9

Nacelle Structure . ........................................................................................................................................... F4-7

Nacelles ............................................................................................................................................................ 4-4
Natural Core Materials ..................................................................................................................................... 9-2a
Nearest Corresponding Numbers, Specifications, Cross Reference of (Steel) .................................................. T5-4
Negligible Damage (of Metal-Covered Wooden Floor) ..................................................................................... 9-7a
Negligible Damage (to Airframe Sheet Metal) .................................................................................................. 8-5a
Neutral Axis and Stresses Resulting from Bending........................................................................................... F6-2
Nicks and Dents (in Plastics) .........................................................................................................................10-12a
Nominal Diameter, Countersunk Head, CherryMAX Rivet .............................................................................. F7-32
Nominal Diameter, Protruding Head, CherryMAX Rivet.................................................................................. F7-33

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Subject Paragraph
Figure, Table
Number

N - Continued

Non-Destructive Inspection .............................................................................................................................. 8-3f

Non-Powered Metal Cutting Machines ............................................................................................................... 3-3
Rotary Punch.......................................................................................................................................... 3-3d
Scroll Shears .......................................................................................................................................... 3-3b
Squaring Shears .................................................................................................................................... 3-3a
Throatless Shears....................................................................................................................................3-3c
Nonstressed Frame Repair ............................................................................................................................ F8-33
Nonstressed Skin and Frame Repair .................................................................................................... 8-9q, F8-38
Nose Rib Repair ............................................................................................................................................ F8-22
Nose Rib Using Beads, Crimps, Relief Holes, and Riveted Angles ................................................................. F6-22
Nose Rib with Crimps and Beads ................................................................................................................... F6-21
Nose Rib with Relief Holes ............................................................................................................................ F6-20
Nose Rib, Plain . ............................................................................................................................................ F6-19
Numbering System, Hi-Lok ........................................................................................................................... T7-32

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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Subject Paragraph
Figure, Table
Number

O - Continued

Oversize Diameter, Protruding Head, CherryMAX Rivet ................................................................................ F7-35

Pan Void, Repair of ......................................................................................................................................... F9-7

Panel Repair, Bonded Magnesium ................................................................................................................... F9-3
Part Number Breakdown, CherryMAX ............................................................................................................ T7-10
Part Number Cross Reference, Olympic Rivet . ............................................................................................. T7-19
Parting Films and Compounds .......................................................................................................................... 9-9f
Parts Repair, Spotwelded................................................................................................................................. 12-6
Patch Material Selection .................................................................................................................................. T8-5
Patch Repairs to Beaded Skin................................................................................................................8-9y, F8-57
Patch Repair to Damaged Swage In Aileron and Flap Skin ...................................................................8-9z, F8-58
Plywood Facing Material .................................................................................................................................. 9-3d
Patch, Flush..................................................................................................................................................... F8-5
Patch, Flush, Repair Procedure........................................................................................................................ F8-7
Patch, Machine Screw.................................................................................................................................. F10-14
Patch, Overlay, to Reinforce a Crack ........................................................................................................... F10-16
Patches ........................................................................................................................................................... 8-7a
Patching (of Metal-Covered Wooden Floor) ..................................................................................................... 9-7b
Patching Procedures (for Metal-Covered Wooden Floors) ................................................................................8-7c
Patching Procedures (for Acrylic Plastics) . .....................................................................................................10-13
Alternate Transparent Plastic Plug Repair ...........................................................................................10-13b
Transparent Overlay Plastic Patch.......................................................................................................10-13c
Transparent Plastic Plug Repair ..........................................................................................................10-13a
Peening with Hammers . .............................................................................................................................. F7-110
Penetrator Identification ................................................................................................................................. F5-11
Pin Punch ..................................................................................................................................................... F3-20
Piston-Engine Mounts ...................................................................................................................................... 4-3a
Plain Nose Rib ............................................................................................................................................... F6-19
Plastic Joint, Cemented ................................................................................................................................. F10-4
Plastics, Forming of ......................................................................................................................................... 10-7
Plate, Hold-Down .......................................................................................................................................... F6-28
Pliers and Strip Extractor ............................................................................................................................ F7-111
Pliers, Clamp .................................................................................................................................................. F3-9
Pliers, Cleco Fasteners ................................................................................................................................... F3-8
Plies and Core, Replaced............................................................................................................................... F9-23
Pneumatic Rivet Gun Structure...................................................................................................................... F7-12
Pneumatic Rivet Gun, Riveting Procedures Using a ...................................................................................... F7-19
Pneumatic Rivet Guns ................................................................................................................................... F7-11
Polishing (of Acrylic Plastics) ..........................................................................................................10-14d, 10-15b
Portable Power Drills ..................................................................................................................................... F3-28
Position (of Stored Plastics) ............................................................................................................................10-5b
Power Drills, Portable .................................................................................................................................... F3-28

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Subject Paragraph
Figure, Table
Number

P - Continued

Power Tools (for Riveting)................................................................................................................................ 7-4b

Powered Metal Cutting Machines ....................................................................................................................... 3-5
Band Saw . ............................................................................................................................................. 3-5d
Drills and Drill Presses............................................................................................................................ 3-5e
Grinding and Sanding Machines .............................................................................................................. 3-5f
Ketts Saw . ............................................................................................................................................. 3-5b
Reciprocating Saw...................................................................................................................................3-5c
Safety .................................................................................................................................................... 3-5a
Practices, Countersinking............................................................................................................................... F7-18
Precipitation (Aging) Treating Temperatures, Times, and Condition . ............................................................... T5-9
Preparing Alloys ...............................................................................................................................................5-4c
Preparing Materials for Spotwelding ...............................................................................................................12-6d
Press, Drill ..................................................................................................................................................... F3-29
Preventing Moisture and Contamination......................................................................................................... F9-28
Prick Punch.................................................................................................................................................... F3-16
Primary Horizontal Member in Heavily Stressed Area, Damage Repair Near ................................................. F8-50
Principles, Balancing ....................................................................................................................................... 11-3
Procedure for Edge Band Sealing ................................................................................................................... 9-9q
Procedure for Obtaining Void-Free Laminate ................................................................................................... 9-9p
Procedure for Preventing Moisture and Oil Contamination .............................................................................. 9-90
Procedures, Bonding ......................................................................................................................................10-11
Procedures, Cementing ................................................................................................................................... 10-9
Procedures, Finishing......................................................................................................................................10-14
Procedures, Patching . ....................................................................................................................................10-13
Properties of Metals . ......................................................................................................................................... 5-2
Abrasion Resistance ............................................................................................................................... 5-21
Compressive Strength .............................................................................................................................5-2c
Conductivity .......................................................................................................................................... 5-2m
Corrosion Resistance ..............................................................................................................................5-2k
Ductility ................................................................................................................................................... 5-2f
Elasticity ................................................................................................................................................ 5-2d
Hardness .................................................................................................................................................5-2i
Linear Expansion ................................................................................................................................... 5-2e
Machinability.............................................................................................................................................5-2j
Malleability ............................................................................................................................................. 5-2g
Shear Strength ....................................................................................................................................... 5-2b
Specific Gravity ...................................................................................................................................... 5-2n
Tensile Strength .................................................................................................................................... 5-2a
Toughness ............................................................................................................................................. 5-2h
Protective Coatings ......................................................................................................................................... 8-3e
Protruding Head Nominal Diameter CherryMAX Rivet ................................................................................... F7-33
Protruding Head Oversize Diameter CherryMAX Rivet .................................................................................. F7-35
Protruding Head Rivets, Removal of . ................................................................................................... 7-6a, F7-23
Protrusion Limits, Hi-Lok ............................................................................................................................... F7-94

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Subject Paragraph
Figure, Table
Number

P - Continued

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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Subject Paragraph
Figure, Table
Number

R - Continued

Removal (of Hi-Lok Fasteners) .......................................................................................................................7-14g

Removal (of Huck Lockbolts) ..........................................................................................................................7-12i
Removal (of Jo-Bolts) ......................................................................................................................................7-13i
Removal (of Masking) .....................................................................................................................................10-6a
Removal (of Olympic Blind Rivets) .................................................................................................................7-11g
Removal and Installation (of Glass Windshields)...........................................................................................10-17c
Removal of Countersunk Head Rivet ............................................................................................................. F7-24
Removal of Damaged Face Plies by Scarf Method ........................................................................................ F9-25
Removal of Hi-Shear Rivets........................................................................................................................... F7-65
Removal of Loose Jo-Bolt .............................................................................................................................. F7-89
Removal of Protruding Head Rivets ............................................................................................................... F7-23
Removal of Rivets ............................................................................................................................................. 7-6
Removal of Self-Plugging Rivets ................................................................................................................... F7-30
Removal of Tightly Installed Jo-Bolt ............................................................................................................... F7-88
Removal Procedures (Hi-Shear Rivets)........................................................................................................... 7-10f
Removal Procedures (Rivnuts) ........................................................................................................................ 7-9e
Removal Procedures (Self-Locking Rivets) ..................................................................................................... 7-7g
Removal, CherryMAX .................................................................................................................................... F7-55
Removing Damaged Face Plies Using Step Joint Method ............................................................................. F9-22
Removing Olympic Rivet .............................................................................................................................. F7-71
Repair by Insertion, Stringer, When Damage Affects More than One Stringer . .............................................. F8-15
Repair by Insertion, Stringer, When Damage Affects Only One Stringer ....................................................... F8-14
Repair by insertion, Stringer, When Damage Exceeds Two Thirds of One Leg in Width................................. F8-13
Repair by Patching, Stringer .......................................................................................................................... F8-12
Repair for Damaged Skin Close to a Frame .......................................................................................... 8-9x, F8-56
Repair for Heavily Stressed Support and Stiffener ......................................................................................... F8-54
Repair for Short Edge Distance and Broken Spotwelds .................................................................................. F12-7
Repair Layout .................................................................................................................................................... 7-3
Rivet Selection ...................................................................................................................................... 7-3a
Rivet Spacing .........................................................................................................................................7-3c
Rivet Strength ........................................................................................................................................ 7-3b
Rivet Substitutions.................................................................................................................................. 7-3d
Repair Material Selection ................................................................................................................................ 8-6d
Repair Methods for Specified Defects (of Plastics) ..........................................................................................10-12
Cracks ................................................................................................................................................10-12d
Crazing................................................................................................................................................10-12c
Delamination and Discoloration ..........................................................................................................10-12e
Nicks and Dents ..................................................................................................................................10-12a
Scratches ............................................................................................................................................10-12b
Repair of Cracks by Stop-Drilling ...........................................................................................................8-9k, F8-31
Repair of Damage Near Existing Structure (Lightly Stressed)......................................................................... F8-45
Repair of Damaged Channels ............................................................................................................................8-9j
Repair of Damaged Frame or Beam................................................................................................................ 8-9m
Repair of Defective Spotwelds Exceeding Allowable Percentage ....................................................................12-6c

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Subject Paragraph
Figure, Table
Number

R - Continued

Repair of Dents .................................................................................................................................................9-6i

Repair of Dents and Creases ................................................................................................................ 8-91, F8-32
Repair of Double-Skin Damage....................................................................................................................... 9-6m
Repair of Frame and Stringer Joint ...................................................................................................... 8-9n, F8-35
Repair of Heavily Stressed Support and Stiffener ............................................................................................ 8-9v
Repair of Honeycomb Panel Edge ................................................................................................................. F9-12
Repair of Honeycomb Panel Edges ................................................................................................................. 9-60
Repair of Impregnated Glass Cloth Parts .......................................................................................................... 9-8
Repair of Large, Single-Skin Damage ............................................................................................................. 9-61
Repair of Metal-Covered Wooden Floor Panels . ........................................................................................... F9-15
Classification of Damage ........................................................................................................................ 9-8a
Damage Repair . .................................................................................................................................... 9-8b
Repair of Missing Core...................................................................................................................................... 9-6f
Repair of Pan Void .......................................................................................................................................... F9-7
Repair of Pre-Drilled Attachment Holes............................................................................................................ 9-9n
Repair of Sandwich Construction........................................................................................................................ 9-6
Bonded Former Assemblies ................................................................................................................... 9-6p
Bonded Magnesium Panels ................................................................................................................... 9-6d
Bonded Stiffeners . ..................................................................................................................................9-6c
Cleanliness of Repair Area ..................................................................................................................... 9-6a
Quality Assurance for Repair ................................................................................................................. 9-6q
Repair of Dents ........................................................................................................................................9-6i
Repair of Double-Skin Damage ............................................................................................................ 9-6m
Repair of Honeycomb Panel Edges ....................................................................................................... 9-60
Repair of Large, Single-Skin Damage .................................................................................................... 9-61
Repair of Missing Core ........................................................................................................................... 9-6f
Repair of Scotchply Edge Member and Corfil Edge Filler Damage ........................................................ 9-6n
Repair of Skin Core Voids....................................................................................................................... 9-6g
Repair of Skin Doubler Voids . ................................................................................................................ 9-6h
Repair of Skin Panels . ........................................................................................................................... 9-6e
Repair of Small, Single-Skin Damage ......................................................................................................9-6j
Repair of Small, Single-Skin Holes . ........................................................................................................ 9-5f
Sample Honeycomb Repair . .................................................................................................................. 9-6b
Repair of Scotchply Edge Member and Corfil Edge Filler Damage................................................................... 9-6n
Repair of Sharp Dent or Crack in Length of Steel Tubing .............................................................................. F8-66
Repair of Skin Core Doubler Voids .................................................................................................................. 9-6h
Repair of Skin Core Voids ...................................................................................................................... 9-6g, F9-6
Repair of Skin Panels....................................................................................................................................... 9-6e
Repair of Small, Single-Skin Damage ...............................................................................................................9-6j
Repair of Small, Single-Skin Holes....................................................................................................................9-6k
Repair Parts Layout.......................................................................................................................................... 8-6e
Repair Practices, General .................................................................................................................................. 8-6
Repair Procedures (for Radome Repair) . ........................................................................................................ 9-9h
Repair, Channel, by Insertion ......................................................................................................................... F8-30

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Subject Paragraph
Figure, Table
Number

R - Continued

Repair, Channel, by Patching......................................................................................................................... F8-29

Repair, Floor Channel .................................................................................................................................... F8-36
Repair, Former............................................................................................................................................... F8-25
Repair, Honeycomb ......................................................................................................................................... F9-2
Repair, Machine Screw . .............................................................................................................................. F10-13
Repair, Nonstressed Frame............................................................................................................................ F8-33
Repair, Nose Rib ........................................................................................................................................... F8-22
Repair, Rib, by Insertion ................................................................................................................................ F8-24
Repair, Spar Angle ........................................................................................................................................ F8-20
Repair, Spar, by Insertion .............................................................................................................................. F8-19
Repair, Stressed Beam ................................................................................................................................. F8-34
Repair, Trailing Edge . ..................................................................................................................................... F9-4
Repair, Tubing ................................................................................................................................................ 8-11
Repair, Wing Rib ........................................................................................................................................... F8-23
Repairing Aluminum Alloy Parts, Rivet Selection and Spacing When .............................................................. T8-2
Repairing Corrosion-Resistant Steel Parts, Rivet Selection and Spacing When ............................................... T8-3
Repairing Magnesium Alloy Parts, Rivet Selection and Spacing When ............................................................ T8-4
Repairs for Cracks in Radius of Stringer End, Typical . .................................................................................. F8-18
Replaced Plies and Core ............................................................................................................................... F9-23
Replacement (of Masking) . ............................................................................................................................10-6b
Replacement and Repair, Skin ........................................................................................................................ F8-8
Replacing Face Plies .................................................................................................................................... F9-24
Requirements (for Rebalancing) ....................................................................................................................11 -4a
Resin-Impregnated Glass Cloth Facing Material .............................................................................................. 9-3e
Resins, Adhesives and ...................................................................................................................................... 9-4
Responsibility for Shop Rules (Sheet Metal Shop) ........................................................................................... 2-1a
Retainer, Seal ................................................................................................................................................ F8-61
Rib Construction ............................................................................................................................................ F4-13
Rib Repair by Insertion ......................................................................................................................... 8-9g, F8-24
Rib Repair by Patching ..................................................................................................................................... 8-9f
Right and Wrong Methods of Horizontal Stacking of Small (Plastic) Sheets . ................................................. F10-1
Rivet Acceptability Limits .............................................................................................................................. F7-22
Rivet Edge Distance ........................................................................................................................................ F7-4
Rivet Edge Distances, Minimum ..................................................................................................................... T8-1
Rivet Failure ................................................................................................................................................... 7-5b
Rivet Grip Length, Olympic ........................................................................................................................... F7-67
Rivet Gun, Pneumatic, Structure ................................................................................................................... F7-12
Rivet Guns, Pneumatic ................................................................................................................................. F7-11
Rivet Head Cracking ..................................................................................................................................... F7-21
Rivet Head Markings, Solid Shank ................................................................................................................... F7-2
Rivet Heat-Treating...........................................................................................................................................7-2c
Rivet Identification .......................................................................................................................................... 7-2b
Rivet Identification, MS 20600 Protruding-Head ............................................................................................ F7-26
Rivet Identification, MS 20601 Countersunk-Head ........................................................................................ F7-27

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Subject Paragraph
Figure, Table
Number

R - Continued

Rivet Inspection ................................................................................................................................................. 7-5

Correctly and Incorrectly Driven Rivets .................................................................................................. 7-5a
Rivet Failure .......................................................................................................................................... 7-5b
Rivet Inspection Procedures ...................................................................................................................7-5c
Rivet Inspection Procedures..............................................................................................................................7-5c
Rivet Inspection, Hi-Shear.............................................................................................................................. F7-64
Rivet Installation ................................................................................................................................................ 7-4
Hand Tools ............................................................................................................................................. 7-4a
Power Tools ........................................................................................................................................... 7-4b
Riveting Procedure . ................................................................................................................................7-4c
Rivet Length, Factors in Determining . ............................................................................................................. F7-3
Rivet Material Codes, Olympic ...................................................................................................................... T7-18
Rivet Parts, Hi-Shear .................................................................................................................................... F7-60
Rivet Pulling Head Operation, Olympic .......................................................................................................... F7-69
Rivet Removal ................................................................................................................................................... 7-6
Countersunk-Head Rivet Removal.......................................................................................................... 7-6b
Protruding-Head Rivet Removal ............................................................................................................ 7-6a
Rivet Selection...........................................................................................................................................73a, 8-6f
Rivet Selection and Spacing When Repairing Aluminum Alloy Parts................................................................ T8-2
Rivet Selection and Spacing When Repairing Corrosion-Resistant................................................................... T8-3
Rivet Selection and Spacing When Repairing Magnesium Alloy Parts ............................................................. T8-4
Rivet Sets, Hi-Shear ..................................................................................................................................... F7-61
Rivet Shaving, CherryMAX ............................................................................................................................ F7-51
Rivet Shear, Minimum, and Tensile Strength (Pounds) in Steel Coupons....................................................... T7-12
Rivet Spacing.......................................................................................................................................... 7-3c, F7-5
Rivet Spacing and Edge Distance .................................................................................................................... 8-6g
Rivet Spacing for Repair Using Formed Patch ............................................................................................... F8-43
Rivet Spacing for Repair with Double Row of Rivets ...................................................................................... F8-42
Rivet Spacing for Repair with Single Row of Rivets ....................................................................................... F8-41
Rivet Spacing, Selection and Acceptability Limits for a Nonstressed Skin Patch ............................................... 8-9t
Rivet Squeezers............................................................................................................................................. F7-13
Rivet Stem Styles, Olympic............................................................................................................................ F7-66
Rivet Strength .................................................................................................................................................. 7-3b
Rivet Styles and Materials, Solid Shank ........................................................................................................... F7-1
Rivet, CherryMAX ......................................................................................................................................... F7-31
Rivet, Heat-Treatable, Identification of ............................................................................................................ F5-9
Riveting ............................................................................................................................................................8-6i
Riveting Procedure ..........................................................................................................................................7-4c
Riveting Procedures Using a Pneumatic Rivet Gun........................................................................................ F7-19
Rivets and Riveting Techniques, General........................................................................................................... 7-1
Rivets Substitutions.......................................................................................................................................... 7-3d
Rivets, CherryMAX ............................................................................................................................................ 7-8
Rivets, Correctly and Incorrectly Driven ......................................................................................................... F7-20
Rivets, Hi-Shear............................................................................................................................................... 7-10

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Subject Paragraph
Figure, Table
Number

R - Continued

Rivets, Olympic Blind....................................................................................................................................... 7-11

Rivets, Solid Shank ........................................................................................................................................... 7-2
Rivnut Grip Length, Determining ................................................................................................................... F7-57
Rivnut Installation Procedure ........................................................................................................................ F7-59
Rivnut Installation Tools ................................................................................................................................. F7-58
Rivnuts ................................................................................................................................................... 7-9, F7-56
Identification .......................................................................................................................................... 7-9a
Installation Procedures .............................................................................................................................79d
Installation Tools ......................................................................................................................................79c
Removal Procedures .............................................................................................................................. 7-9e
Selection ............................................................................................................................................... 7-9b
Rockwell Hardness Scales, Standard ............................................................................................................. T5-19
Rockwell Hardness Test . ................................................................................................................................5-13b
Rockwell Hardness Tester ............................................................................................................................. F5-12
Rockwell Hardness Values for 0.050 Inch Minimum Thickness Clad Aluminum Sheet and Plate ................... T5-20
Rockwell Hardness Values for Bare Aluminum Sheet, Plate, Extrusions, and Forgings ................................. T5-21
Room Temperature Setting Adhesives ..............................................................................................................9-4c
Rotary Punch ......................................................................................................................................... 3-3d, F3-4
Router Cutter, Typical .................................................................................................................................... F10-2
Routers ..........................................................................................................................................................10-8d

SAE Numbers, Steel ........................................................................................................................................ T5-1

Safety of Powered Metal Cutting Machines ........................................................................................................ 3-5
Sample Channel . ............................................................................................................................................ F6-6
Sample Honeycomb Repair ............................................................................................................................. 9-6b
Sandbag ........................................................................................................................................................ F3-24
Sandbag Bumping ......................................................................................................................................... F6-29
Sanding (Plastics) . .......................................................................................................................................10-14a
Sanding Deep Scratches ............................................................................................................................. F10-11
Sandwich Construction Repair, General ............................................................................................................ 9-1
Construction .......................................................................................................................................... 9-1a
Design . ................................................................................................................................................. 9-1 b
Modern Use ............................................................................................................................................9-1c
Sandwich Construction, Repair of ...................................................................................................................... 9-6
Saw, Ketts...................................................................................................................................................... F3-25
Saw, Reciprocating ....................................................................................................................................... F3-26
Saws (Used to Cut Plastics) . ..........................................................................................................................10-8c
Scab or Lap Patch (Crack) .............................................................................................................................. F8-3
Scab or Lap Patch (Hole) ................................................................................................................................. F8-4
Scale Method (of Balancing) . ........................................................................................................................ F11-9
Scope (of Manual).............................................................................................................................................. 1-2
Scotchply Edge Member and Corfil Edge Filler Damage ....................................................................................9-5i

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Subject Paragraph
Figure, Table
Number

S - Continued

Scratch or Crack Repair .................................................................................................................................. F9-5

Scratches (in Plastics) ..................................................................................................................................10-12b
Scribing and Edge Sanding .............................................................................................................................10-8e
Scroll Shears .......................................................................................................................................... 3-3b, F3-2
Seal Retainer . ................................................................................................................................................. 8-61
Sealant Defects...............................................................................................................................................8-10c
Sealant Repair or Replacement ......................................................................................................................8-10d
Sealing of Hardware .......................................................................................................................................8-10e
Sealing, Structural ........................................................................................................................................... 8-10
Secondary Procedures, Dzus Fastener Installation ...................................................................................... F7-103
Selection of CherryMAX Rivets ........................................................................................................................ 7-8b
Selection of Hi-Lok Fasteners ........................................................................................................................7-14b
Selection of Hi-Shear Rivets ..........................................................................................................................7-10b
Selection of Huck Lockbolts . ..........................................................................................................................7-12e
Selection of Rivnuts. ........................................................................................................................................ 7-9b
Self-Plugging Rivet Installation ...................................................................................................................... F7-29
Self-Plugging Rivet Installation Tools ............................................................................................................. F7-28
Self-Plugging Rivet Selection ...........................................................................................................................7-7c
Self-Plugging Rivet Stem Features ................................................................................................................ F7-25
Self-Plugging Rivets (Friction Lock) ................................................................................................................... 7-7
Identification ........................................................................................................................................... 7-7a
Inspection ................................................................................................................................................ 7-7f
Installation Procedures ........................................................................................................................... 7-7e
Installation Tools .................................................................................................................................... 7-7d
Removal Procedures .............................................................................................................................. 7-7g
Self-Plugging Rivet Selection . ................................................................................................................7-7c
Substitution for Common Rivets ............................................................................................................. 7-7b
Self-Plugging Rivets, Removal of .................................................................................................................. F7-30
Semi-Monocoque Construction ........................................................................................................................ F4-2
Setback ....................................................................................................................................................6-3c, F64
Setback - K - Chart........................................................................................................................................... T6-2
Shaping Aircraft Metals ...................................................................................................................................... 6-2
Chem-Milling .......................................................................................................................................... 6-2b
Forming .................................................................................................................................................. 6-2a
Shear ..................................................................................................................................................... 5-3d, F5-4
Shear Strength................................................................................................................................................. 5-2b
Shear, Hand................................................................................................................................................... F3-10
Shear, Scroll ................................................................................................................................................... F3-2
Shearing Spotwelds ........................................................................................................................................ 12-3
Shears, Bench ............................................................................................................................................... F3-11
Shears, Squaring ............................................................................................................................................ F3-1
Shears, Throatless .......................................................................................................................................... F3-3
Sheet and Plate, Rockwell.............................................................................................................................. T5-20
Sheet Metal Holders .........................................................................................................................................3-4c

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Subject Paragraph
Figure, Table
Number

S - Continued

Sheet Metal, Bending ........................................................................................................................................ 6-3

Sheet Substitution, Aluminum Alloy................................................................................................................ T5-14
Shell, Reinforced, Construction ........................................................................................................................ F4-3
Shop Equipment (Sheet Metal Shop) ................................................................................................................. 2-2
Shop Housekeeping (Sheet Metal Shop) .......................................................................................................... 2-1b
Shop Rules, General (Sheet Metal Shop) .......................................................................................................... 2-1
Shop Safety (Sheet Metal Shop) ............................................................................................................2-1 e, 2-1c
Shop Tools and Materials (Sheet Metal Shop) ................................................................................................. 2-1d
Shop Working Practice (Aluminum Alloys) ........................................................................................................5-7c
Shrinking ...............................................................................................................................................6-4c, F6-14
Shrinking and Stretching Machine ......................................................................................................... 3-6d, F3-34
Shrinking by V-Block Method ......................................................................................................................... F6-15
Shrinking, Forming a Flanged Angle by.......................................................................................................... F6-16
Sight Line, Brake or.......................................................................................................................................... F6-5
Single Row of Rivets, Rivet Spacing for Repair with........................................................................................ F841
Single Shear Strength of Aluminum Alloy Rivets ............................................................................................. T7-2
Sizes (of Jo-Bolts)...........................................................................................................................................7-13c
Sizes of Twist Drills with Decimal Equivalents ................................................................................................. T7-5
Skin and Bulkhead Repair ............................................................................................................................. F8-28
Skin and Frame Repair ................................................................................................................................. F8-27
Skin and Web Repairs . ................................................................................................................................... 8-9u
Skin Core Voids ...............................................................................................................................................9-5c
Skin Core Voids, Repair of ............................................................................................................................... F9-6
Skin Cracks...................................................................................................................................................... 8-3d
Skin Cutout Patching Using Spotwelds............................................................................................................ 12-6f
Skin Cutout Repair Near Stiffener Using Spotwelds .......................................................................................12-6g
Skin Doubler Void Repair (0.255 Inch or Greater) ............................................................................................ F9-8
Skin Doubler Void Repair (Less Than 0.255 Inch) ........................................................................................... F9-9
Skin Doubler Voids .......................................................................................................................................... 9-5d
Skin Joint, Longitudinal .................................................................................................................................. F8-39
Skin Joint, Transverse.................................................................................................................................... F8-40
Skin Patch, Nonstressed, Rivet Spacing, and Acceptability Limits for................................................................ 8-9t
Skin Repair, Chem-Milled ................................................................................................................................ F8-2
Skin Repair, Double (Flush) ........................................................................................................................... F9-10
Skin Repair, Double (Nonflush) ...................................................................................................................... F9-11
Skin Repair, Stressed......................................................................................................................................... 8-7
Skin Replacement............................................................................................................................................ 8-8a
Skin Replacement and Repair ........................................................................................................................... 8-8
Circular External Repair.......................................................................................................................... 8-8b
Skin Replacement .................................................................................................................................. 8-8a
Temporary Patch Repairs .......................................................................................................................8-8c
Skin Wrinkles ...................................................................................................................................................8-3c
Skin, Damaged, Close to a Frame, Repair for . .............................................................................................. F8-56
Skin, Stressed, Repair.................................................................................................................................... F8-55

Index 164
 TM 1-1500-204-23-1

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VOLUME 10

Subject Paragraph
Figure, Table
Number

S - Continued

Sleeve Stretch Marks, CherryMAX ...................................................................................................................... F7-54

Slip Roll Former ......................................................................................................................................... 3-6c, F3-33
Small Crack, Glass Cloth Repair of ..................................................................................................................... F9-16
Small Single Skin Damage..................................................................................................................................... 9-5f
Snips, Aviation .................................................................................................................................................... F3-12
Snips, Circle........................................................................................................................................................ F3-14
Snips, Straight..................................................................................................................................................... F3-13
Soak Method............................................................................................................................................ 10-9b, F10-6
Soaking............................................................................................................................................................... 10-9g
Soaking (Heat Treating) Temperature ................................................................................................................. T5-10
Soaking Time for Solution Treatment of Cast Alloys ........................................................................................... T5-11
Solid Shank Rivet Head Markings .........................................................................................................................F7-2
Solid Shank Rivet Styles and Materials .................................................................................................................F7-1
Solid Shank Rivets.................................................................................................................................................. 7-2
Materials and Use ........................................................................................................................................... 7-2a
Rivet Heat-Treating......................................................................................................................................... 7-2c
Rivet Identification .......................................................................................................................................... 7-2b
Solid Shank Rivets, Grip Lengths for.....................................................................................................................T7-1
Solution Treatment of Cast Alloys, Soaking Time for .......................................................................................... T5-11
Spacing, and Rivet Selection, When Repairing Corrosion-Resistant Steel Parts....................................................T8-3
Spacing, Rivet.......................................................................................................................................................F7-5
Spar Angle Repair...................................................................................................................................... 8-9d, F8-20
Spar Construction ............................................................................................................................................... F4-12
Spar Repair by Insertion............................................................................................................................. 8-9c, F8-19
Spar Web Repair ....................................................................................................................................... 8-9e, F8-21
Specific Gravity..................................................................................................................................................... 5-2n
Specifications, Cross Reference of Nearest Corresponding Numbers (Steel) ........................................................T5-4
Specified Defects (of Plastics), Repair Methods for ............................................................................................. 10-12
Splice Repair of Hat Section ...................................................................................................................... 8-9p, F8-37
Spotfacing........................................................................................................................................................... F7-62
Spotweld Failure ................................................................................................................................................... 12-4
Spotweld Failure with No Skin Breaks ................................................................................................................... 12-5
Spotweld Repair to Crack in Stiffener................................................................................................................... 12-6i
Spotweld Repair to Stiffener................................................................................................................................ 12-6h
Spotwelded Parts Repair....................................................................................................................................... 12-6
Acceptable Percentage of Defective Spotwelds . .......................................................................................... 12-6b
Acceptable Spotweld Spacing ....................................................................................................................... 12-6a
Preparing Materials for Spotwelding ............................................................................................................. 12-6d
Repair for Short Edge Distance and Broken Spotwelds . ............................................................................... 12-6e
Repair of Defective Spotwelds Exceeding Allowable Percentage .................................................................. 12-6c
Skin Cutout Patching Using Spotwelds........................................................................................................... 12-6f
Skin Cutout Repair Near Stiffener Using Spotwelds ...................................................................................... 12-6g
Spotweld Repair to Crack in Stiffener ............................................................................................................ 12-6i
Spotweld Repair to Hole in Stiffener . ........................................................................................................... 12-6h

Index 165
 TM 1-1500-204-23-1

INDEX- CONT

VOLUME 10

Subject Paragraph
Figure, Table
Number

S - Continued

Spotwelds, Drilling ................................................................................................................................................ 12-2

Spotwelds, General ............................................................................................................................................... 12-1
Spotwelds, Shearing ............................................................................................................................................. 12-3
Spring Installation, Standard ............................................................................................................................... F7-99
Squaring Shears ......................................................................................................................................... 3-3a, F3-1
Squeezers, Rivet ................................................................................................................................................ F7-13
Stabilizer, Helicopter .......................................................................................................................................... F4-15
Stacking, Horizontal, of Small (Plastic) Sheets, Right and Wrong Methods of ..................................................... F10-1
Stainless Steel, Drill Angle for ...............................................................................................................................F6-1
Standard Countersink............................................................................................................................................F7-7
Standard Rockwell Hardness Scales ................................................................................................................... T5-19
Standard Spring Installation ................................................................................................................................ F7-99
Standard Tools for Stump-Type Lockbolts........................................................................................................... T7-28
Static Balance..................................................................................................................................................... 11-2a
Static Balance, Control Surface............................................................................................................................ Fl1-1
Steel ....................................................................................................................................................................... 5-6
Alloying Materials ........................................................................................................................................... 5-6b
Identification of Steels..................................................................................................................................... 5-6a
Types of Steels and Their Uses ...................................................................................................................... 5-6c
Steel Facing Material ............................................................................................................................................ 9-3b
Steel Identification Marking Example ....................................................................................................................F5-6
Steel Lockbolt Rivet Gun, Pull- and Blind-Type ................................................................................................... F7-74
Steel SAE Numbers ..............................................................................................................................................T5-1
Steel Tube Fishmouth Splice Using Large Diameter Replacement Tube ............................................................ F8-70
Steel Tube Inner Sleeve Splice ........................................................................................................................... F8-67
Steel Tube Using Outer Sleeve Splice ............................................................................................................... F8-69
Steel Tubing Distortion, Correcting Oval Shaped ................................................................................................ F8-63
Stem and Collar Flushness, CherryMAX.............................................................................................................. F7-52
Stem Break-Off Limits, Jo-Bolt............................................................................................................................ F7-87
Stem Catcher Bag 670A20 ................................................................................................................................. F7-44
Stem Features, Self-Plugging Rivet .................................................................................................................... F7-25
Step Joint Method, Removing Damaged Face Plies Using .................................................................................. F9-22
Stop Countersink ..................................................................................................................................................F7-8
Stop-Drilling, Repair of Cracks by ....................................................................................................................... F8-31
Storage (of Adhesives and Resins) ....................................................................................................................... 9-4d
Storage and Handling (of Plastics) ........................................................................................................................ 10-5
Formed Sections........................................................................................................................................... 10-5d
Location........................................................................................................................................................ 10-5a
Masking Paper ............................................................................................................................................. 10-5c
Position......................................................................................................................................................... 10-5b
Storage of Tools, Equipment, and Materials .......................................................................................................... 3-2c
Straight Line Bends............................................................................................................................................... 6-5a
Straight Snips............................................................................................................................................. 3-4g, F3-13
Straightening Bowed Steel Tubes........................................................................................................................ F8-64

Index 166
 TM 1-1500-204-23-1

INDEX - CONT

VOLUME 10

Subject Paragraph
Figure, Table
Number

S - Continued

Strength, Bearing (Pounds) ...................................................................................................................................T7-3

Stress and Strain Forces ......................................................................................................................................... 5-3
Bending .......................................................................................................................................................... 5-3e
Compression................................................................................................................................................... 5-3b
Shear.............................................................................................................................................................. 5-3d
Tension........................................................................................................................................................... 5-3a
Torsion ........................................................................................................................................................... 5-3c
Stressed Beam Repair ........................................................................................................................................ F8-34
Stressed Skin Repair...........................................................................................................................8-7, 8-9w, F8-55
Flush Access Door .......................................................................................................................................... 8-7d
Open and Closed Skin Area Repair................................................................................................................. 8-7b
Patches........................................................................................................................................................... 8-7a
Patching Procedures....................................................................................................................................... 8-7c
Stresses Resulting from Bending, Neutral Axis and...............................................................................................F6-2
Stretching................................................................................................................................................... 6-4d, F6-13
Stretching Machine, Shrinking and ...................................................................................................................... F3-34
Stretching, Forming a Flanged Angle by.............................................................................................................. F6-18
String Repair by Insertion When Damage Affects Only One Stringer................................................................... F8-14
Stringer and Longeron Installation ....................................................................................................................... F4-19
Stringer Cross-Section, Typical ........................................................................................................................... F4-20
Stringer Repair...................................................................................................................................................... 8-9a
Stringer Repair by Insertion When Damage Affects More than One Stringer ....................................................... F8-15
Stringer Repair by Insertion When Damage Exceeds Two Thirds of One Leg in Width........................................ F8-13
Stringer Repair by Patching................................................................................................................................. F8-12
Stringer Repair with Formed Angle...................................................................................................................... F8-17
Stringer Splice Repair, J-Section......................................................................................................................... F8-16
Stringers and Longerons ....................................................................................................................................... 4-8b
Strip Extractor, Pliers and ................................................................................................................................. F7-111
Structural Inspection ............................................................................................................................................... 8-3
Corrosion ........................................................................................................................................................ 8-3a
Non-Destructive Inspection .............................................................................................................................. 8-3f
Protective Coatings......................................................................................................................................... 8-3e
Skin Cracks .................................................................................................................................................... 8-3d
Skin Wrinkles.................................................................................................................................................. 8-3c
Surface Indications ......................................................................................................................................... 8-3b
Structural Members................................................................................................................................................. 4-8
Bulkheads, Frames, and Formers ................................................................................................................... 4-8a
Stringers and Longerons ................................................................................................................................. 4-8b
Structural Metals, General....................................................................................................................................... 5-1
Structural Parts, Airplane ......................................................................................................................................F4-5
Structural Sealing.................................................................................................................................................. 8-10
Sealant Defects ............................................................................................................................................ 8-10c
Sealant Repair or Replacement .................................................................................................................... 8-10d
Sealing of Hardware ..................................................................................................................................... 8-10e

Index 167
 TM 1-1500-204-23-1

INDEX - CONT

VOLUME 10

Subject Paragraph
Figure, Table
Number

S - Continued

Types of Seals .............................................................................................................................................. 8-10a

Wires and Tubes........................................................................................................................................... 8-10b
Structural Support During Repair........................................................................................................................... 8-6a
Structural Tubing................................................................................................................................................ 8-11 b
Structural Tubing, Example of............................................................................................................................. F8-62
Structure, Nacelle .................................................................................................................................................F4-7
Stud, Camlock, Installation ............................................................................................................................... F7-112
Stump-Type Lockbolt Numbering System ........................................................................................................... T7-23
Stump-Type Lockbolt, Installation of ................................................................................................................... F7-76
Stump-Type Lockbolts, Standard Tools for.......................................................................................................... T7-28
Substitute Materials (Aluminum).......................................................................................................................... T5-15
Substitution (by Huck Lockbolts) ......................................................................................................................... 7-12c
Substitution (of Self-Plugging Rivets) for Common Rivets..................................................................................... 7-7b
Support and Stiffener, Heavily Stressed, Repair for ........................................................................................... F8-54
Supporting Ring, Use of .................................................................................................................................... F7-108
Surface Balance Considerations............................................................................................................................ 11-2
Addition of Weights....................................................................................................................................... 11-4c
Methods........................................................................................................................................................ 11-4b
Requirements ............................................................................................................................................... 11-4a
Surface Indications ............................................................................................................................................... 8-3b
Surface Rebalancing Procedures .......................................................................................................................... 11-4
Dynamic Balance ......................................................................................................................................... 11-2b
Static Balance............................................................................................................................................... 11-2a
Terms and Symbols ...................................................................................................................................... 11-2c

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

Index 168
 TM 1-1500-204-23-1

INDEX - CONT

VOLUME 10

Subject Paragraph
Figure, Table
Number

T - Continued

Tolerance (for Repairs) .......................................................................................................................................... 8-6j

Tool Capacity Chart (for Rivets) .......................................................................................................................... T7-14
Tooling (for Hi-Lok Fasteners) .............................................................................................................................. 7-15
Tooling (for Jo-Bolts) ........................................................................................................................................... 7-13f
Tooling, Jo-Bolt................................................................................................................................................... F7-86
Torsion......................................................................................................................................................... 5-3c, F5-3
Toughness ........................................................................................................................................................... 5-2h
Trailing Edge Repair .............................................................................................................................................F9-4
Transfer Punch ................................................................................................................................................... F3-21
Transfer Punch, Use of .........................................................................................................................................F8-9
Transparent Overlay Plastic Patch .................................................................................................................... 10-13c
Transparent Plastic Plug Repair ........................................................................................................................ 10-13a
Transparent Plastics, Recommended Installation Procedures for ........................................................................ 10-16
Transverse Skin Joint.................................................................................................................................. 8-9s, F840
Treatment, Heat ...................................................................................................................................................... 5-5
Troubleshooting, CherryMAX ............................................................................................................................. T7-17
Tubing Repair ....................................................................................................................................................... 8-11
Engine Mount............................................................................................................................................... 8-11 a
Structural Tubing ......................................................................................................................................... 8-11 b
Turbine-Engine Mounts ......................................................................................................................................... 4-3b
Turn-Lock Fasteners ............................................................................................................................................. 7-15
Camlock Fasteners ...................................................................................................................................... 7-15b
Dzus Fasteners ............................................................................................................................................ 7-15a
Twist Drills with Decimal Equivalents, Sizes of......................................................................................................T7-5
Type of Cement .................................................................................................................................................. 10-9a
Types and Identification (of Aircraft Plastics)........................................................................................................... 1-4
Burning ......................................................................................................................................................... 10-4b
Chemical Reaction........................................................................................................................................ 10-4e
Flexing.......................................................................................................................................................... 10-4d
Military Specification Number ....................................................................................................................... 10-4a
Visual Inspection........................................................................................................................................... 10-4c
Types of Circular Saw Blades for Cutting Acrylic Plastic Sheets ......................................................................... T10-2
Types of Design (Wing)......................................................................................................................................... 4-5a
Types of Heat Treatment....................................................................................................................................... 5-5a
Types of Lockbolts .............................................................................................................................................. F7-72
Types of Seals .................................................................................................................................................... 8-10a
Types of Steel and Their Uses .............................................................................................................................. 5-6c
Typical Bolt Installation (in Transparent Plastic) ............................................................................................... F10-17
Typical CherryMAX Blind Heads ......................................................................................................................... F7-53
Typical Edge Band Sealing ................................................................................................................................. F9-29
Typical Hatch Seal .............................................................................................................................................. F8-60
Typical Repairs for Cracks in Radius of Stringer End .......................................................................................... F8-18
Typical Router Cutter ......................................................................................................................................... F10-2
Typical Scarf Method for Class II Repair (of Radomes) ....................................................................................... F9-26

Index 169
 TM 1-1500-204-23-1

INDEX - CONT

VOLUME 10

Subject Paragraph
Figure, Table
Number

T - Continued

Typical Sighting Dome Edge Attachment .......................................................................................................... F10-20

Typical Stringer Cross Sections........................................................................................................................... F4-20

Unbalanced and Balanced Conditions ................................................................................................................ Fl11-4

Unbonding and Ply Separation ............................................................................................................................... 9-5j
Use of Camlock Punch...................................................................................................................................... F7-109
Use of Hole Finder .............................................................................................................................................. F8-10
Use of Supporting Ring ..................................................................................................................................... F7-108
Use of Transfer Punch ..........................................................................................................................................F8-9
Use of 269C3 Cherry Grip Gauge........................................................................................................................ F7-36
Uses (of Jo-Bolts)................................................................................................................................................ 7-13d

V-Block ............................................................................................................................................................... F3-22

Various Diameter Rivets, Drill Sizes for.................................................................................................................T7-4
Visual Inspection (of Plastics).............................................................................................................................. 10-4c
Void Repair, Skin Doubler (Less Than 0.255 Inch) ................................................................................................F9-9
Void Repair, Skin Doubler (0.255 Inch or Greater).................................................................................................F9-8

Waxing ............................................................................................................................................................. 10-15c

Web Repair, Spar ............................................................................................................................................... F8-21
Webster Hardness Tester.................................................................................................................................... 5-13a
Weight and Distance, Effects of .......................................................................................................................... F11-3
Windshields, Glass.............................................................................................................................................. 10-17
Wing Construction, Box Beam ............................................................................................................................ F4-10
Wing Construction, Monospar ...............................................................................................................................F4-8
Wing Construction, Multispar ................................................................................................................................F4-9
Wing Internal Construction .................................................................................................................................. F4-11
Wing Rib Repair.................................................................................................................................................. F8-23
Wing-Type Dzus Fastener Installation ................................................................................................................. F-102
Wings ..................................................................................................................................................................... 4-5
Internal Construction....................................................................................................................................... 4-5b
Types of Design.............................................................................................................................................. 4-5a
Wires and Tubes................................................................................................................................................. 8-10b

Index 170
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 Use Part II (reverse) for Repair Parts and Spe- DATE
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 The Metric System and Equivalents

Linear Measure Liquid Measure

1 centiliter = 10 milliters = .34 fl. ounce

1 centimeter = 10 millimeters = .39 inch 1 deciliter = 10 centiliters = 3.38 fl. ounces
1 decimeter = 10 centimeters = 3.94 inches 1 liter = 10 deciliters = 33.81 fl. ounces
1 meter = 10 decimeters = 39.37 inches 1 dekaliter = 10 liters = 2.64 gallons
1 dekameter = 10 meters = 32.8 feet 1 hectoliter = 10 dekaliters = 26.42 gallons
1 hectometer = 10 dekameters = 328.08 feet 1 kiloliter = 10 hectoliters = 264.18 gallons
1 kilometer = 10 hectometers = 3,280.8 feet
Square Measure
Weights
1 sq. centimeter = 100 sq. millimeters = .155 sq. inch
1 centigram = 10 milligrams = .15 grain 1 sq. decimeter = 100 sq. centimeters = 15.5 sq. inches
1 decigram = 10 centigrams = 1.54 grains 1 sq. meter (centare) = 100 sq. decimeters = 10.76 sq. feet
1 gram = 10 decigram = .035 ounce 1 sq. dekameter (are) = 100 sq. meters = 1,076.4 sq. feet
1 decagram = 10 grams = .35 ounce 1 sq. hectometer (hectare) = 100 sq. dekameters = 2.47 acres
1 hectogram = 10 decagrams = 3.52 ounces 1 sq. kilometer = 100 sq. hectometers = .386 sq. mile
1 kilogram = 10 hectograms = 2.2 pounds
1 quintal = 100 kilograms = 220.46 pounds Cubic Measure
1 metric ton = 10 quintals = 1.1 short tons
1 cu. centimeter = 1000 cu. millimeters = .06 cu. inch
1 cu. decimeter = 1000 cu. centimeters = 61.02 cu. inches
1 cu. meter = 1000 cu. decimeters = 35.31 cu. feet

Approximate Conversion Factors

To change To Multiply by To change To Multiply by

inches centimeters 2.540 ounce-inches Newton-meters .007062

feet meters .305 centimeters inches .394
yards meters .914 meters feet 3.280
miles kilometers 1.609 meters yards 1.094
square inches square centimeters 6.451 kilometers miles .621
square feet square meters .093 square centimeters square inches .155
square yards square meters .836 square meters square feet 10.764
square miles square kilometers 2.590 square meters square yards 1.196
acres square hectometers .405 square kilometers square miles .386
cubic feet cubic meters .028 square hectometers acres 2.471
cubic yards cubic meters .765 cubic meters cubic feet 35.315
fluid ounces milliliters 29,573 cubic meters cubic yards 1.308
pints liters .473 milliliters fluid ounces .034
quarts liters .946 liters pints 2.113
gallons liters 3.785 liters quarts 1.057
ounces grams 28.349 liters gallons .264
pounds kilograms .454 grams ounces .035
short tons metric tons .907 kilograms pounds 2.205
pound-feet Newton-meters 1.356 metric tons short tons 1.102
pound-inches Newton-meters .11296

Temperature (Exact)

°F Fahrenheit 5/9 (after Celsius °C

temperature subtracting 32) temperature
PIN: 070482-000