CHAPTER 3
GENERAL AIRCRAFT MAINTENANCE
Chapter Objective: Upon completion of this chapter, you will have a working
knowledge of procedures and equipment used for the Tool Control Program. You
will have a basic knowledge of occupational awareness concepts, aircraft
drawings, techniques for troubleshooting, aircraft lubrication requirements,
aircraft weighing and balancing, aircraft hoisting and jacking, and fuel cell
construction and repair.
In this chapter we will discuss the various types of
routine aircraft maintenance performed by the AM
ratings. When performing any type of maintenance, it is
your responsibility to comply with all safety procedures
and tool control requirements. Because no one set of
rules applies to all aircraft, you should refer to the
maintenance instruction manual (MIM) for the tools,
materials, and procedures required for that particular
aircraft or piece of equipment.
TOOL CONTROL PROGRAM
Learning Objective: Recognize the importance
of the Navy's Tool Control Program (TCP).
Major problems, such as aircraft accidents and
incidents, may result from tools left in aircraft after
maintenance has been performed. Tools out of place
may result in foreign object damage (FOD). To reduce
the potential for tool FOD-related mishaps, the Tool
Control Program (TCP) provides a means of rapidly
accounting for all tools after completing a maintenance
task on an aircraft or its related equipment.
TOOL CONTAINERS
The means by which tools can be rapidly
inventoried and accounted for is accomplished by using
silhouetted tool containers. All tools have individual
silhouetted locations that highlight a missing tool. These
containers are called “shadow boxes.” A shadow
(silhouette) of the tool identifies the place where the tool
belongs. The TCP is based on the instant inventory
concept and is accomplished, in part, through the use of
shadow boxes. See figure 3-1. On containers where
silhouetting is not feasible, a note with the inventory and
a drawing of the container is included. Either system
enables the work center supervisor or inspector to
quickly ensure that all tools have been retrieved after a
maintenance action.
The material control officer is responsible for
coordinating the TCP and for ensuring that tools are
procured and issued in a controlled manner consistent
with the approved tool control plan (TCPL). A TCPL
contains information that includes material require-
ments, tool inventories, and detailed instructions for the
implementation and operation of the TCPL for a specific
type/mode of aircraft. But the main responsibility relies
with the work center and quality assurance.
QUALITY ASSURANCE/ANALYSIS
(QA/A) RESPONSIBILITIES
The QA/A division is responsible for monitoring the
overall Tool Control Program in the command. While
monitoring the program or performing “spot checks,”
the QA/A division will ensure that tool control
procedures are being adhered to. Some of the special
requirements are to ensure the following:
1. That all tools are etched with the organization
code, work center, and tool container number.
2. That special accountability procedures are being
complied with for those tools not suitable for etching;
for example, drill bits (too hard) and jewelers
screwdrivers (too small).
3. That work center inventories are being con-
ducted and procedures are being adhered to during work
center audits and periodic spot checks.
4. That all equipment, in the work centers/tool
control centers, requiring calibration is scheduled and
cali- brated at the prescribed interval.
5. That defective tools received from supply are
reported to the Fleet Material Support Office
(FLEMATSUPPO) via CAT II QDRs.
3-1
