GENERAL AIRCRAFT MAINTENANCE
WORK CENTER RESPONSIBILITIES
Figure 1-2.--Material safety data sheet (page 1).
Figure 1-2.--Material safety data sheet (page 2)--Continued.
OCCUPATIONAL AWARENESS - LEARNING OBJECTIVE
Figure 1-3.--Line characteristics.
Figure 1-3.--Line characteristics--Continued.
Figure 1-5.--Arresting gear system schematic.
Figure 1-6.--Nosewheel steering system schematic.
Figure 1-8.--Hydraulic system schematic.
Figure 1-9.--Installation diagram of a motor-driven hydraulic pump.
Table 1-1.--Troubleshooting Flight Hydraulic Power System
Table 1-2.--Troubleshooting Wheel Brake System
TROUBLESHOOTING AIRCRAFT SYSTEMS
Figure 1-11.--A typical electronic multimeter.
Table 1-4.--Common Military Lubricants and Their Use
Figure 1-12.--Types of grease guns.
Figure 1-13.--Types of lubrication fittings.
Figure 1-15.--Typical lubrication MRC.
Figure 1-15.--Typical lubrication MRC--Continued.
Figure 1-16.--Weight terminology.
Figure 1-17.--Mobile Electronic Weighing System (MEWS).
Figure 1-18.--Stationary pit-type scales.
Weighing Procedure
Figure 1-19.--Wire rope slings.
Figure 1-21.--Combination wire rope and chain sling.
Figure 1-22.--Cross sections of wire rope.
Figure 1-25.--Cable damage resulting from a pulled-through kink
Figure 1-26.--Hand carried axle jack.
Figure 1-27.--Horseshoe axle jack.
Figure 1-30.--Airframe (tripod) jacks.
HANDLING AND MOVEMENT
JACKING PROCEDURES
Figure 1-31.--Carrier tie-downs for aircraft jacking.
Figure 1-32.--Aircraft leveling.
AIRCRAFT CONSTRUCTION AND MATERIALS
Figure 2-2.--Typical fuselage station diagram.
Figure 2-3.--Typical nose station diagram.
Figure 2-4.--Typical wing construction.
Primary Flight Control Systems
Figure 2-5.--Flaperon control system.
Figure 2-6.--Horizontal stabilizer system.
Figure 2-7.--Wing sweep control system (F-14).
Figure 2-8.--Wing oversweep position--manual control (F-14).
Figure 2-9.--Types of flaps.
Figure 2-10.--Typical landing gear system.
Figure 2-11.--Main landing gear.
Figure 2-12.--Shock strut showing internal construction.
Figure 2-15.--Nose gear launch equipment.
Figure 2-16.--H-60 helicopter.
Figure 2-18.--H-60 main rotor blade pressurization system.
Figure 2-21.--H-60 tail pylon.
Figure 2-22.--Five stresses acting on an aircraft.
Figure 2-23.--Engine torque creates torsional stress in aircraft fuselages.
Figure 2-24.--Bending action occurring during carrier
Figure 2-25.--Reinforced plastic.
Contraction and Expansion
QUALITIES OF METALS
METAL WORKING PROCESSES
Figure 2-26.--Cold drawing operation for rods, tubing, and wire.
Table 2-1.--SAE Numerical Index
CHROMIUM-NICKEL OR STAINLESS STEELS
TYPES, CHARACTERISTICS, AND USES
Table 2-2.--Designation for Aluminum Alloy Groups
SHOP CHARACTERISTICS OF ALUMINUM ALLOYS
IDENTIFICATION OF TITANIUM
Magnesium and Magnesium Alloys
SUBSTITUTION AND INTERCHANGEABILITY OF AIRCRAFT METALS
Figure 2-28.--Brinell hardness tester.
Figure 2-29.--Microscope view of impression.
Table 2-4.--Standard Rockwell Hardness Scales
Figure 2-31.--Riehle portable hardness tester.
Figure 2-32.--Barcol portable hardness tester.
Figure 2-34.--Ernst portable hardness tester.
Table 2-6.--Transparent Plastics
REINFORCED PLASTICS
Types of Composite Material
Figure 2-35.--Sandwich construction.
AIRCRAFT HARDWARE
Table 3-1.--Rivet Material Identification
Figure 3-4.--Self-plugging rivet (friction lock).
Figure 3-6.--Sectional view of rivnut showing head and end designs
Figure 3-8.--Hi-lok fastener.
Figure 3-11.--Correct and incorrect grip lengths.
Figure 3-12.--Bolt Heads.
Figure 3-13.--Bolt head markings.
Figure 3-15.--MS bolt part number breakdown.
Figure 3-18.--Self-locking plate nuts.
Figure 3-19.--Sheet spring nut.
Figure 3-22.--Various types of special washers.
Figure 3-24.--Camloc high-stress panel fastener.
Figure 3-25.--Dzus fastener.
Figure 3-27.--Flexible line coupling.
Figure 3-28.--Installation of rigid line couplings.
Figure 3-29.--Safetying a V-band coupling.
Figure 3-31.--Heli-coil insert.
Figure 3-32.--Cable cross section.
Figure 3-34.--Thimble, bushing, and shackle fittings.
Figure 3-37.--Typical cable guides.
Figure 3-38.--Control system components.
Figure 3-40.--Basic types of solderless terminals.
Figure 3-42.--Typical static dischargers.
Table 3-2.--Recommended Torque Values (Inch-Pounds)
Figure 3-43.--Torque wrenches.
Figure 3-46.--Types of cotter pins.
Figure 3-48.--Safetying turnbuckles: (A) Clip-locking method (preferred); (B) wire-wrapped method.
AIRCRAFT METALLIC REPAIR
Figure 4-2.--Rotary rivet cutter.
Figure 4-4.--Bucking bars.
Figure 4-7.--Adjustable stop countersink.
Figure 4-8.--Types of cutting tools.
Figure 4-10.--Rivet gun internal airflow.
Table 4-1.--Approximate Air Pressure for Rivet Guns
Figure 4-14.--Dimple countersinking.
Figure 4-15.--Hot dimpling kit.
Figure 4-17.--Squaring shears.
Figure 4-20.--Hand-operated turret punch.
Figure 4-22.--Cornice brake and operation.
Figure 4-23.--Cornice brake with mold and stock.
Figure 4-27.--Slip-roll forming machine.
Figure 4-28.--Rotary machine.
Figure 4-30.--Bend allowance terms.
Figure 4-32.--Locating bend lines in a brake.
Figure 4-33.--Stakes and stake plates.
Figure 4-34.--Preparation for straight bend by hand.
Figure 4-36.--Forming convex hand bends.
Figure 4-38.--Forming a cylinder.
Figure 4-39.--Rolling a conical shape.
Figure 4-42.--Wiring operation.
Figure 4-44.--Rivet spacing and edge distance.
Figure 4-45.--Incorrect countersinking.
Figure 4-49.--Self-plugging rivet (mechanical lock) pull tool.
Figure 4-50.--Cherrylock guns.
Figure 4-51.--Hydro-shift series gun.
Figure 4-53.--Self-plugging rivet (mechanical lock).
Figure 4-55.--Removing self-plugging rivets (mechanical lock).
AIRCRAFT METALLIC REPAIR
Investigation of Damage
Figure 4-56.--Classifications of damage.
Figure 4-57.--How to use a structural repair manual.
TYPES OF REPAIRS
Figure 4-58.--Lap patch for repairing a crack in stressed skin.
Figure 4-60.--Repair of small holes in skin with flush patch.
Figure 4-61.--Flush rectangular patch.
Figure 4-63.--Chem-Milled skin repair (fuselage pressurized).
Figure 4-64.--Flush access door installation.
Figure 4-65.--Transferring rivet holes.
Figure 4-67.--Stringer repair by patching.
Figure 4-68.--Stringer repair by insertion.
Figure 4-71.--Rib repair by patching.
Figure 4-72.--Forward fuselage (semimonocoque).
Figure 4-73.--Bullet-sealing action.
Figure 4-74.--Self-sealing fuel cell (standard construction).
Figure 4-75.--Bladder cell construction.
Figure 4-76.--Sealing integral fuel cell screws and bolts.
REINJECTING SEALANT
Figure 4-77.--Injection of sealing compound.
REINJECTING SEALANT - Continued
AIRCRAFT NONMETALLIC REPAIR
Removing Scratches From Plastic Surfaces
Figure 5-1.--Proper method of sanding plastic.
Figure 5-4.--Approved edge attachment for solid plastic.
Figure 5-6.--Typical sighting dome attachment.
Figure 5-8.--Ply repair (scrafed method).
Figure 5-9.--Repair of solid laminates (stepped method).
Figure 5-10.--Delaminated ply repair.
Figure 5-11.--Honeycomb-type core repair.
Figure 5-13.--Scarfed repair method.
Figure 5-15.--Foam-type puncture repair.
Figure 5-16.--Sandwich construction puncture repair (honeycomb core).
Figure 5-17.--Balsa wood repair with filler plug and fabric patch
Figure 5-18.--Balsa wood repair with flush patch.
Figure 5-20.--Trailing edge repair (sandwich construction).
Table 5-1.--Aircraft Advanced Composite Application Usage
Figure 5-21.--Design properties comparison.
Kevlar Fibers
CATEGORIES OF COMPOSITE MATERIAL DAMAGE
DAMAGE INSPECTION METHODS
Figure 5-26.--Example of repairable damage on composite material.
Figure 5-27.--Repair zones.
Figure 5-28.--Drill stop.
PERSONNEL HAZARDS
AIRCRAFT PAINTING - LEARNING OBJECTIVE
General Procedures and Precautions for Stripping
Figure 5-29.--Flap brush with mandrel.
Epoxy-Polyamide Primer MIL-P-23377
Du Pont Teflon Filled Polyurethane Paint
Elastomeric Rain Erosion-Resistant Coating MIL-C-7439
Figure 5-31.--Forms of letters and numerals.
Figure 5-32.--National star insignia.
PAINTING EQUIPMENT AND MAINTENANCE PROCEDURES
Figure 5-36.--Faulty spray patterns and how to correct them.
Figure 5-37.--Cleaning pressure-feed spray gun.
Figure 5-41.--Correct and incorrect methods of spraying.
Figure 5-42.--Sectional view of typical spray gun.
APPLICATION OF SEALANTS
Figure 5-44.--Appling sealant.
APPLICATION OF SEALANTS - Continued
NONDESTRUCTIVE INSPECTIONS, WELDING, AND HEAT TREATMENT
NONDESTRUCTIVE INSPECTIONS, WELDING, AND HEAT TREATMENT - Continued
Figure 6-1.--NDI Certification Record (OPNAV 4790/139).
Figure 6-2.--NDI Technician/Operator Work Record (OPNAV 4790/140).
NDI PROGRAM RESPONSIBILITIES
NDI INSPECTION METHODS
Figure 6-3.--Magnetic field surrounding an electrical conductor
Figure 6-9.--Coil creates a longitudinal field to show crack in a part
Figure 6-10.--Diagram of radiographic exposure.
Figure 6-11.--Coupling of search unit to test part for transmission of ultrasonic energy.
Figure 6-16.--Generation of eddy currents in various part configurations
Figure 6-18.--Typical eddy current test probes.
Figure 6-19.--Basic penetrant process.
RECERTIFICATION OF WELDERS
Figure 6-20.--Welding Certification (DD Form 2758).
Figure 6-21.--Welding Examination Record (DD Form 2757) (front).
Figure 6-22.--Welding Examination Record (DD Form 2757) (back).
Figure 6-23.--Portable oxyacetylene welding and cutting equipment
Figure 6-25.--Single-stage oxygen regulator.
Figure 6-26.--Two-stage regulator.
Figure 6-28.--Mixing head for injector-type welding torch.
WELDING (FILLER) RODS
BACKFIRE AND FLASHBACK
Figure 6-30.--Welding light gauge metals.
Figure 6-34.--Four basic welding positions.
Figure 6-36.--Butt joints in light sections.
Figure 6-41.--Edge joints for light sheets and plates.
Figure 6-42.--Corner joints for sheets and plates.
Figure 6-43.--Straight and reverse polarity in electric welding.
Figure 6-44.--Typical water-cooled GTA welding torch.
Figure 6-46.--Breaking the arc.
Figure 6-47.--GMA welding equipment.
Figure 6-48.--Gas metal-arc welding. (A) striking the arc; (B) gun angle.
WELDING SAFETY PRECAUTIONS
WELDING SAFETY PRECAUTIONS. - Continued
HEAT TREATMENT OF METALS
HEAT TREATMENT OF METALS - Continued
FORMS OF HEAT TREATMENT
HEAT TREATMENT OF FERROUS METALS (STEEL)
Table 6-1.--Color Chart for Steel at Various Temperatures
Table 6-2.--Color Chart for Various Tempering Temperatures of Carbon Steel
CASE HARDENING.
HEAT TREATMENT OF NONFERROUS METALS (ALUMINUM ALLOYS)
ANNEALING OF WORK HARDENED MATERIAL
ANNEALING OF WORK HARDENED MATERIAL - Continued
Figure 7-1.--Typical divided (split) wheel assembly.
Figure 7-3.--Typical wheel assembly.
and cap using alternate deflated tire flag.
INTERMEDIATE-LEVEL WHEEL MAINTENANCE
Figure 7-6.--Aircraft tires-tubes-wheels safety poster.
Figure 7-7.--Fuse plugs.
Figure 7-8.--Pressure repacking of wheel bearings.
Matching Wheel Halves
Figure 7-10.--Sectional view of aircraft tire showing construction details.
Figure 7-11.--Sectional view of two aircraft tires showing different construction details.
Figure 7-13.--New tire identification markings.
Figure 7-14.--Rebuilt tire identification markings.
Figure 7-15.--Tire storage rack (varied size tires).
Figure 7-17.--Method of measuring depth of cuts, cracks, and
Figure 7-18.--Aircraft wheel holder and tire bead-breaking machine
Figure 7-20.--Shaft arranged to hold tire bead while removing lockring.
MOUNTING DEMOUNTABLE FLANGE WHEELS
Figure 7-22.--Tire inflator assembly kit.
Figure 7-24.--Inflation safety cage with aircraft tire inflator/monitor attached.
Figure 7-25.--Valve core identification.
Figure 7-26.--Rapid tread wear caused by underinflation.
Table 7-1.--Tolerances for Diameters of Paired Tires in Dual Installations
Figure 7-29.--Inner tube vent ridges.
MOUNTING DIVIDED (SPLIT) WHEELS
BASIC HYDRAULICS
HYDRAULIC CONTAMINATION CONTROL PROGRAM
Figure 8-1.--Periodic fluid surveillance requirements.
TYPES OF CONTAMINATION
Table 8-1.--Particle Contamination Level By Class
Metallic Solid Contamination
Foreign Fluids Contamination
ANALYSIS METHODS LEARNING OBJECTIVE
Figure 8-3.--P/N57L414 contamination analysis kit.
Sample Taking
Figure 8-4.--Contamination analysis kit components.
Test Filter Analysis
ELECTRONIC PARTICLE COUNT ANALYSIS
Figure 8-5.--HDL-440 halogen leak detector in operation.
Figure 8-6.--Fluid flow during decontamination.
Flushing
Purifying
Table 8-3.--Aircraft Decontamination Requirements
Figure 8-7.--Sequence control chart for aircraft system decontamination.
Figure 8-8.--Series 145 and 155 quick-disconnect couplings.
Figure 8-9.--Quick disconnects properly and improperly connected.
Figure 8-10.--Series 320 (Aeroquip) quick disconnect.
Figure 8-12.--Action of O-rings.
Figure 8-13.--O-ring package identification.
Figure 8-14.--Typical O-ring installation and removal tools.
Figure 8-15.--O-ring removal.
Backup Rings
Figure 8-16.--O-ring installation.
Figure 8-17.--Teflon backup ring damages caused by improper handling.
Figure 8-19.--Installation of Teflon backup rings (internal).
Figure 8-20.--Teflon backup ring installation (external).
Table 8-4.--Protective Caps and Plugs
Figure 8-21.--Typical blank-off plates.
FLUID SERVICING AND SUPPORT EQUIPMENT
Figure 9-1.--Insertion of can into Hydraulic Servicing Unit H-250-1.
Figure 9-2.--Model HSU-1 fluid service unit.
Figure 9-3.--Model 310 fluid service cart.
PORTABLE HYDRAULIC TEST STANDS
Figure 9-4.--A/M27T-5 portable hydraulic power supply, rear and right-hand side view.
Table 9-1.--A/M27T-5 Main Control Panel Controls and Indicators
Table 9-1.--A/M27T-5 Main Control Panel Controls and Indicators--Continued.
Table 9-1.--A/M27T-5 Main Control Panel Controls and Indicators--Continued.
Figure 9-7.--Primary control panel controls and indicators.
Table 9-3.--Primary Control Panel Controls and Indicators
Table 9-4.--Secondary Control Panel Controls and Indicators
Figure 9-9.--Test stand operating modes.
Operational Checks
STATIONARY HYDRAULIC TEST STANDS
Figure 9-10.--Model HCT-10 hydraulic and pneumatic component test stand.
AIR BLEEDING
Figure 9-11.--Reservoir level changes (reservoir sink) presence of air in system.
RECIRCULATION CLEANING
Figure 9-12.--Fluid purification system.
PURIFYING
HOSE AND TUBING FABRICATION AND MAINTENANCE
Figure 10-2.--Synthetic rubber hose identification.
HOSE ASSEMBLY HARDWARE
Figure 10-3.--Synthetic hose fittings--(Continued).
Figure 10-3.--Synthetic hose fittings--(Continued).
Figure 10-4.--Teflon hose fittings.
Table 10-1.--Hose Fitting Color and Material Code
Figure 10-5.--Hose assembly identification tags.
Figure 10-7.--Hose fabricating machines.
Figure 10-9.--Synthetic rubber medium-pressure hose assembly.
Figure 10-10.--Determining hose assembly length.
Figure 10-15.--Firesleeve.
Table 10-3.--Proof Pressure Test Media
Figure 10-16.--Aircraft hose burst test stand (Greer).
Table 10-5.--Function of Controls and Instruments
Figure 10-19.--Controls and instruments.
Table 10-6.--Functions of Controls and Instruments
CGS SCIENTIFIC TEST PROCEDURES
Checking For Wear and Deterioration
Table 10-7.--Hose Minimum Bend Data
Figure 10-20.--Hose twist.
Figure 10-24.--"N" factor for flexing bends.
Acceptance Life and Shelf Life for Synthetic Rubber Hose and Hose Assemblies
Table 10-9.--Corrosion-Resistant Steel Tubing
Table 10-10.--Aluminum Alloy Tubing Applications
Figure 10-25.--Typical styles of MS fittings.
Figure 10-26.--Typical styles of AN fittings.
Figure 10-27.--Typical style of Permaswage fittings.
Figure 10-28.--Typical style of Dynatube fittings.
Figure 10-31.--Properly deburred tubing.
Figure 10-34.--Bending tubing with hand-operated tube bender.
Figure 10-36.--Tube flaring tool (single-flare).
Figure 10-38.--Tube position and resulting flare.
Table 10-13.--Tube Projection from Sleeve Pilot
Table 10-14.--Minimum Inside Diameter of Tubing
Table 10-15.--Prime and Paint for Tube Assemblies
Figure 10-41.--Fluid line identification application.
Figure 10-43.--Color-coded functional identification tapes.
Figure 10-43.--Color-coded functional identification tapes--Continued.
Table 10-16.--Hazards Associated with Various Fluids
Figure 10-44.--Damaged fittings.
Figure 10-45.--Correct and incorrect methods of installing flared fittings.
Table 10-17.--Maximum Distance Between Supports for Aluminum Tubing
Figure 10-48.--Reworking damaged fittings.
Table 10-18.--Tube Assembly Failures and Recommended Repair Methods
Figure 10-50.--Permaswage Tool Kit D10031-812S.
Figure 10-55.--Male and female repair fitting installation.
Figure 10-60.--Swaging and repair tool kit.
TUBING AND TUBE ASSEMBLIES MAINTENANCE PROCEDURES
BASIC ACTUATING SYSTEMS
Figure 11-2.--Double-acting, piston-type, actuating cylinders.
Figure 11-3.--Cutaway of a single-action, ball-lock actuating cylinder.
Control Surface Actuating Cylinder
Figure 11-4.--Typical finger-lock actuating cylinder.
Figure 11-5.--Control surface actuating cylinder.
HYDRAULIC MOTORS
Figure 11-6.--Typical hydraulic motor.
Figure 11-8.--Cutaway view of selector valve body.
Figure 11-9.--Working view of a poppet-type selector valve.
Figure 11-10.--Slide-type selector valve.
Solenoid-Operated Selector Valve
Figure 11-11.--Solenoid-operated selector valve.
Figure 11-12.--Typical check valve.
Figure 11-13.--Typical sequence valve.
Figure 11-14.--View of priority valve.
Figure 11-15.--Shuttle valve.
Maintenance of Shuttle Valves
Figure 11-16.--Restrictors.
Figure 11-17.--Pressure-reducing valve operational schematic.
Figure 11-18.--Fuse, operational view.
BASIC HYDRAULIC/PNEUMATIC AND EMERGENCY POWER SYSTEMS
Figure 12-1.--Basic open-center hydraulic system.
Closed-Center System
figure 12-2.- Closed- center hydraulic system schematic.
EMERGENCY POWER SYSTEMS
Nonpressurized Reservoirs
Figure 12-3.--Hydraulic reservoir instruction plate.
Figure 12-4.--Nonpressurized reservoir.
Figure 12-7.--Air-pressurized reservoir and components.
Figure 12-8.--Chemical air drier.
Figure 12-10.--Air relief valve.
Figure 12-12.--Typical fluid-pressurized reservoir.
Figure 12-13.--Double-action hydraulic hand pump.
Figure 12-14.--Gear-type power pump.
Figure 12-15.--Partial cutaway view of piston-type pump.
Figure 12-16.--Internal features of the Stratopower pump.
Figure 12-19.--Pressure control mechanism.
Figure 12-20.--Fluid flow.
Figure 12-21.--Motor-driven variable displacement piston pump.
Figure 12-22.--Motor-driven variable displacement piston pump schematic.
Figure 12-23.--Pump compensation. (A) full flow position; (B) reduced flow; (C) minimum flow.
Main System Relief Valves
Figure 12-24.--System relief valve.
Figure 12-25.--Typical thermal relief valve.
Figure 12-26.--Motor operated shutoff valve.
Figure 12-27.--Electric solenoid shutoff valve.
HYDRAULIC FLUID COOLERS
Figure 12-28.--Hydraulic fluid cooler.
Figure 12-29.--Fin tubing assembly installation.
Figure 12-30.--Hydraulic manifold assembly.
Figure 12-32.--Hydraulic filter assembly.
Fin Tubing Types
Figure 12-33.--Hydraulic filter assembly incorporating differential pressure indicator.
Spherical Type
Figure 12-34.--Pressure accumulator, spherical and cylindrical types.
Figure 12-35.--Accumulator air charge valve and gauge installation.
Figure 12-36.--Bourdon tube.
Figure 12-39.--Gauge and pressure transmitter snubber.
Figure 12-40.--Schematic diagram of typical emergency power system (electric-motor driven).
Figure 12-41.--Ram air turbine hydraulic pump assembly.
Figure 12-42.--Ram air turbine-control system schematic.
Figure 12-44.--Air cylinder.
Figure 12-45.--Pneumatic storage cylinder inflation chart
LANDING GEAR SYSTEMS
LANDING GEAR SYSTEMS OPERATION
Figure 13-2.--Nose gear up cycle schematic.
Figure 13-3.--Landing gear warning and position indicator.
Figure 13-4. - Emergency landing gear extension system.
Figure 13-5.--Main gear door latch mechanisms.
Figure 13-6.--Landing gear door latch installation.
Figure 13-8.--Landing gear shock strut (metering pin type).
Figure 13-9.--Landing gear shock strut (metering tube type).
Figure 13-12.--Landing gear drag brace adjustment.
LANDING GEAR SYSTEMS MAINTENANCE
ALIGNMENT AND ADJUSTMENT
Figure 13-13.--Main gear recoil strut piston.
STRUT REMOVAL AND REPLACEMENT
Figure 13-15.--Servicing a landing gear strut.
Figure 13-16.--Landing gear strut servicing instruction plate.
Figure 13-17.--Landing gear shock strut tools.
INTERMEDIATE MAINTENANCE REPAIR AND SEAL REPLACEMENT
Bench Testing
Bench Testing - Continued
BRAKE SYSTEMS
Figure 141.--Typical independent-type brake system.
Figure 14-3.--Gladden master brake cylinder.
Figure 14-5.--Typical power brake control valve system.
Figure 14-6.--Power brake control valve (pressure ball check
Figure 14-7.--Power brake control valve (sliding spool type).
Figure 14-8.--Brake debooster cylinder.
Figure 14-9.--Typical single disc brake installation.
Figure 14-10.--Exploded view of single disc brake assembly.
Figure 14-11.--Dual disc brake.
INDEPENDENT-TYPE BRAKE SYSTEM
Figure 14-12.--Cross-sectional view of multiple disc brake.
Figure 14-13.--Segmented rotor brake--cutaway view.
Figure 14-14.--Power/manual brake systems--schematic.
Figure 14-15.--Wheel brake.
Figure 14-17.--Normal position of automatic adjusting pin.
Figure 14-18.--Bleeding brake system (top-down method).
Figure 14-20.--Use of blowout screen on overheated brakes.
BRAKE SYSTEM COMPONENT MAINTENANCE
Figure 14-21.--Operational test setup--power brake valve.
MASTER BRAKE CYLINDER
Figure 14-22.--Piston, valve, and brake chamber proof test setup diagram
Figure 14-23.--Rod packing, cylinder leakage, and pumping function test.
BRAKE SELECTOR VALVE
Figure 14-24.--Brake selector valve--exploded view.
Figure 14-25.--Brake swivel.
Figure 14-26.--Brake self-adjustment feature--single disc brake.
Figure 14-27.--Cross-sectional view of a single disc brake assembly with captured torquing-type automatic adjuster.
Figure 14-29.--Single disc brake--repair and parts replacement diagram.
POWER BRAKE VALVE
Figure 14-30.--Dual disc brake--repair and parts replacement.
Figure 14-31.--Seal replacement and piston return adjustment.
Figure 14-31.--Seal replacement and piston return adjustment--Continued.
Figure 14-32.--Trimetallic brake assembly.
Figure 14-33.--Trimetallic brake assembly--cross section.
SKID CONTROL SYSTEM MAINTENANCE
Figure 14-34.--Antiskid control valve schematic.
UTILITY HYDRAULIC SYSTEMS
Figure 15-2.--Nosewheel steering system schematic.
Figure 15-3.--Nose gear steering system diagram.
Adjustment of Components
Figure 15-4.--Nosewheel steering system.
ARRESTING HOOK ASSEMBLY INSPECTION LEARNING OBJECTIVE
SINGLE SHANK CENTERING DEVICES
Figure 15-6.--Liquid spring shock assembly.
Figure 15-8.--Centering spring.
Figure 15-9.--Catapult system.
Figure 15-10.--Catapult system hydraulic schematic.
Figure 15-11.--Air refueling probe hydraulic system.
Figure 15-12.--Wing fold schematic (spread and locked condition).
ARRESTING HOOK ASSEMBLY INSPECTION
Figure 15-13.--AC generator drive system.
Figure 15-14.--Ramp servo and actuator.
Figure 15-15.--Variable bellmouth system.
Figure 15-16.--Bomb bay door hydraulic schematic.
Figure 15-17.--Windshield wiper schematic.
Figure 15-18.--Windshield wiper unit.
ARRESTING HOOK ASSEMBLY INSPECTION - Continued
Figure 16-1.--Mechanical (unboosted) flight control system.
Figure 16-2.--Hydraulically powered elevator control system.
Figure 16-3.--Elevator forward bobweight and damper
Figure 16-4.--Elevator aft bobweight and damper assembly.
Figure 16-6.--Stabilizer control system.
Figure 16-7. -- Stabilizer control system schematic.
MANUAL MODE.
Horizontal Stabilizer (Stabilator) Control System (Double Axis)
Figure 16-8.--Hydraulically powered aileron control system.
Figure 16-9.--Aileron power mechanism.
Figure 16-10.--Flaperon control system.
Figure 16-12.--Flaperon control system.
Figure 16-13.--Flaperon autopilot actuator.
Figure 16-14. -- Aileron and spoiler/deflector system.
Spoiler Control System
Figure 16-15.--Rudder control system.
ELECTRONIC PRIMARY FLIGHT CONTROL SYSTEMS
Figure 16-16. --Electronic flight controls.
Figure 16-17.--Backup flight control hydraulic system.
COMPONENTS
PRIMARY FLIGHT CONTROL SYSTEM MAINTENANCE
RIGGING AND OPERATIONAL CHECKS
Figure 16-19.--Aileron throw protractor indications.
Figure 16-20.--Determining serviceable cable.
RIGID CONTROL SYSTEMS
Figure 16-21.--Quick-disconnect procedures.
RIGGING AND ADJUSTING
Figure 16-23.--Cable tensiometer and chart.
Figure 16-24.--Rigging pin set.
Figure 16-25.--Typical throwboard used for rigging rudder and rudder tab controls.
Figure 16-27.--Elevator rigging fixture.
Figure 16-28.--Cable-cutting machine.
Figure 16-29.--Hand-swaging tools--mechanical and pneumatic
Figure 16-31.--Locating the terminal in the swaging tool.
SECONDARY FLIGHT CONTROL SYSTEMS
Figure 16-32.--Flap cylinder, linkage, and selector valve installation.
Figure 16-33.--Wing flap system.
LEADING/TRAILING EDGE WING FLAP SYSTEMS
Figure 16-34.--Flap control circuit.
Figure 16-35.--Flap drive gearbox.
Figure 16-36.--Flap actuator.
Figure 16-37.--Slat drive system.
Figure 16-39.--Wing oversweep position--manual control.
SPEED BRAKE SYSTEM
Figure 16-40.--Speed brake control system.
Figure 16-41.--Wingtip speed brake control system.
Figure 16-42.--Aileron trim control system.
SECONDARY CONTROL SYSTEM MAINTENANCE
MAJOR ASSEMBLY REMOVAL/INSTALLATION
STABILIZERS
AIRFRAME AND CONTROL SURFACE ALIGNMENT
BALANCING CONTROL SURFACES
Figure 16-43.--Transit leveling.
Figure 16-44.--Spirit leveling lugs.
Figure 16-45.--Plumb bob and datum plate leveling.
Figure 16-46.--Structure alignment dimensions.
Figure 16-47.--Alignment data--wing twist check.
Figure 17-1.--Center of pressure.
Figure 17-2.--Torque reaction.
Figure 17-4.--Dissymmetry of lift.
TRANSLATIONAL LIFT
Figure 17-5.--Representative types of naval helicopters.
Figure 17-6.--Flight control systems.
FLIGHT CONTROL SYSTEMS COMPONENTS
Figure 17-7.--Auxiliary servo cylinder.
Figure 17-8.--Primary servo cylinder.
ROTARY-WING MAINTENANCE
Figure 17-9.--Swashplate--cross-sectional and installed view.
ROTOR BLADE TRACKING
Figure 17-10.--Blade tracking--Strobex.
Figure 17-11.--Rotor brake and system schematic.
AUTOMATIC BLADE FOLDING SYSTEM
Figure 17-12.--Automatic blade folding system schematic.
Figure 17-12.--Automatic blade folding system schematic--Continued.
Figure 17-13.--Blade fold cylinder.
Figure 17-14.--Rotor coupling.
AUTOMATIC BLADE FOLDING SYSTEM - Continued
GLOSSARY
GLOSSARY- Continued
GLOSSARY- Continued
WORK CENTER RESPONSIBILITIES
Figure 1-2.--Material safety data sheet (page 1).
Figure 1-2.--Material safety data sheet (page 2)--Continued.
OCCUPATIONAL AWARENESS - LEARNING OBJECTIVE
Figure 1-3.--Line characteristics.
Figure 1-3.--Line characteristics--Continued.
Figure 1-5.--Arresting gear system schematic.
Figure 1-6.--Nosewheel steering system schematic.
Figure 1-8.--Hydraulic system schematic.
Figure 1-9.--Installation diagram of a motor-driven hydraulic pump.
Table 1-1.--Troubleshooting Flight Hydraulic Power System
Table 1-2.--Troubleshooting Wheel Brake System
TROUBLESHOOTING AIRCRAFT SYSTEMS
Figure 1-11.--A typical electronic multimeter.
Table 1-4.--Common Military Lubricants and Their Use
Figure 1-12.--Types of grease guns.
Figure 1-13.--Types of lubrication fittings.
Figure 1-15.--Typical lubrication MRC.
Figure 1-15.--Typical lubrication MRC--Continued.
Figure 1-16.--Weight terminology.
Figure 1-17.--Mobile Electronic Weighing System (MEWS).
Figure 1-18.--Stationary pit-type scales.
Weighing Procedure
Figure 1-19.--Wire rope slings.
Figure 1-21.--Combination wire rope and chain sling.
Figure 1-22.--Cross sections of wire rope.
Figure 1-25.--Cable damage resulting from a pulled-through kink
Figure 1-26.--Hand carried axle jack.
Figure 1-27.--Horseshoe axle jack.
Figure 1-30.--Airframe (tripod) jacks.
HANDLING AND MOVEMENT
JACKING PROCEDURES
Figure 1-31.--Carrier tie-downs for aircraft jacking.
Figure 1-32.--Aircraft leveling.
AIRCRAFT CONSTRUCTION AND MATERIALS
Figure 2-2.--Typical fuselage station diagram.
Figure 2-3.--Typical nose station diagram.
Figure 2-4.--Typical wing construction.
Primary Flight Control Systems
Figure 2-5.--Flaperon control system.
Figure 2-6.--Horizontal stabilizer system.
Figure 2-7.--Wing sweep control system (F-14).
Figure 2-8.--Wing oversweep position--manual control (F-14).
Figure 2-9.--Types of flaps.
Figure 2-10.--Typical landing gear system.
Figure 2-11.--Main landing gear.
Figure 2-12.--Shock strut showing internal construction.
Figure 2-15.--Nose gear launch equipment.
Figure 2-16.--H-60 helicopter.
Figure 2-18.--H-60 main rotor blade pressurization system.
Figure 2-21.--H-60 tail pylon.
Figure 2-22.--Five stresses acting on an aircraft.
Figure 2-23.--Engine torque creates torsional stress in aircraft fuselages.
Figure 2-24.--Bending action occurring during carrier
Figure 2-25.--Reinforced plastic.
Contraction and Expansion
QUALITIES OF METALS
METAL WORKING PROCESSES
Figure 2-26.--Cold drawing operation for rods, tubing, and wire.
Table 2-1.--SAE Numerical Index
CHROMIUM-NICKEL OR STAINLESS STEELS
TYPES, CHARACTERISTICS, AND USES
Table 2-2.--Designation for Aluminum Alloy Groups
SHOP CHARACTERISTICS OF ALUMINUM ALLOYS
IDENTIFICATION OF TITANIUM
Magnesium and Magnesium Alloys
SUBSTITUTION AND INTERCHANGEABILITY OF AIRCRAFT METALS
Figure 2-28.--Brinell hardness tester.
Figure 2-29.--Microscope view of impression.
Table 2-4.--Standard Rockwell Hardness Scales
Figure 2-31.--Riehle portable hardness tester.
Figure 2-32.--Barcol portable hardness tester.
Figure 2-34.--Ernst portable hardness tester.
Table 2-6.--Transparent Plastics
REINFORCED PLASTICS
Types of Composite Material
Figure 2-35.--Sandwich construction.
AIRCRAFT HARDWARE
Table 3-1.--Rivet Material Identification
Figure 3-4.--Self-plugging rivet (friction lock).
Figure 3-6.--Sectional view of rivnut showing head and end designs
Figure 3-8.--Hi-lok fastener.
Figure 3-11.--Correct and incorrect grip lengths.
Figure 3-12.--Bolt Heads.
Figure 3-13.--Bolt head markings.
Figure 3-15.--MS bolt part number breakdown.
Figure 3-18.--Self-locking plate nuts.
Figure 3-19.--Sheet spring nut.
Figure 3-22.--Various types of special washers.
Figure 3-24.--Camloc high-stress panel fastener.
Figure 3-25.--Dzus fastener.
Figure 3-27.--Flexible line coupling.
Figure 3-28.--Installation of rigid line couplings.
Figure 3-29.--Safetying a V-band coupling.
Figure 3-31.--Heli-coil insert.
Figure 3-32.--Cable cross section.
Figure 3-34.--Thimble, bushing, and shackle fittings.
Figure 3-37.--Typical cable guides.
Figure 3-38.--Control system components.
Figure 3-40.--Basic types of solderless terminals.
Figure 3-42.--Typical static dischargers.
Table 3-2.--Recommended Torque Values (Inch-Pounds)
Figure 3-43.--Torque wrenches.
Figure 3-46.--Types of cotter pins.
Figure 3-48.--Safetying turnbuckles: (A) Clip-locking method (preferred); (B) wire-wrapped method.
AIRCRAFT METALLIC REPAIR
Figure 4-2.--Rotary rivet cutter.
Figure 4-4.--Bucking bars.
Figure 4-7.--Adjustable stop countersink.
Figure 4-8.--Types of cutting tools.
Figure 4-10.--Rivet gun internal airflow.
Table 4-1.--Approximate Air Pressure for Rivet Guns
Figure 4-14.--Dimple countersinking.
Figure 4-15.--Hot dimpling kit.
Figure 4-17.--Squaring shears.
Figure 4-20.--Hand-operated turret punch.
Figure 4-22.--Cornice brake and operation.
Figure 4-23.--Cornice brake with mold and stock.
Figure 4-27.--Slip-roll forming machine.
Figure 4-28.--Rotary machine.
Figure 4-30.--Bend allowance terms.
Figure 4-32.--Locating bend lines in a brake.
Figure 4-33.--Stakes and stake plates.
Figure 4-34.--Preparation for straight bend by hand.
Figure 4-36.--Forming convex hand bends.
Figure 4-38.--Forming a cylinder.
Figure 4-39.--Rolling a conical shape.
Figure 4-42.--Wiring operation.
Figure 4-44.--Rivet spacing and edge distance.
Figure 4-45.--Incorrect countersinking.
Figure 4-49.--Self-plugging rivet (mechanical lock) pull tool.
Figure 4-50.--Cherrylock guns.
Figure 4-51.--Hydro-shift series gun.
Figure 4-53.--Self-plugging rivet (mechanical lock).
Figure 4-55.--Removing self-plugging rivets (mechanical lock).
AIRCRAFT METALLIC REPAIR
Investigation of Damage
Figure 4-56.--Classifications of damage.
Figure 4-57.--How to use a structural repair manual.
TYPES OF REPAIRS
Figure 4-58.--Lap patch for repairing a crack in stressed skin.
Figure 4-60.--Repair of small holes in skin with flush patch.
Figure 4-61.--Flush rectangular patch.
Figure 4-63.--Chem-Milled skin repair (fuselage pressurized).
Figure 4-64.--Flush access door installation.
Figure 4-65.--Transferring rivet holes.
Figure 4-67.--Stringer repair by patching.
Figure 4-68.--Stringer repair by insertion.
Figure 4-71.--Rib repair by patching.
Figure 4-72.--Forward fuselage (semimonocoque).
Figure 4-73.--Bullet-sealing action.
Figure 4-74.--Self-sealing fuel cell (standard construction).
Figure 4-75.--Bladder cell construction.
Figure 4-76.--Sealing integral fuel cell screws and bolts.
REINJECTING SEALANT
Figure 4-77.--Injection of sealing compound.
REINJECTING SEALANT - Continued
AIRCRAFT NONMETALLIC REPAIR
Removing Scratches From Plastic Surfaces
Figure 5-1.--Proper method of sanding plastic.
Figure 5-4.--Approved edge attachment for solid plastic.
Figure 5-6.--Typical sighting dome attachment.
Figure 5-8.--Ply repair (scrafed method).
Figure 5-9.--Repair of solid laminates (stepped method).
Figure 5-10.--Delaminated ply repair.
Figure 5-11.--Honeycomb-type core repair.
Figure 5-13.--Scarfed repair method.
Figure 5-15.--Foam-type puncture repair.
Figure 5-16.--Sandwich construction puncture repair (honeycomb core).
Figure 5-17.--Balsa wood repair with filler plug and fabric patch
Figure 5-18.--Balsa wood repair with flush patch.
Figure 5-20.--Trailing edge repair (sandwich construction).
Table 5-1.--Aircraft Advanced Composite Application Usage
Figure 5-21.--Design properties comparison.
Kevlar Fibers
CATEGORIES OF COMPOSITE MATERIAL DAMAGE
DAMAGE INSPECTION METHODS
Figure 5-26.--Example of repairable damage on composite material.
Figure 5-27.--Repair zones.
Figure 5-28.--Drill stop.
PERSONNEL HAZARDS
AIRCRAFT PAINTING - LEARNING OBJECTIVE
General Procedures and Precautions for Stripping
Figure 5-29.--Flap brush with mandrel.
Epoxy-Polyamide Primer MIL-P-23377
Du Pont Teflon Filled Polyurethane Paint
Elastomeric Rain Erosion-Resistant Coating MIL-C-7439
Figure 5-31.--Forms of letters and numerals.
Figure 5-32.--National star insignia.
PAINTING EQUIPMENT AND MAINTENANCE PROCEDURES
Figure 5-36.--Faulty spray patterns and how to correct them.
Figure 5-37.--Cleaning pressure-feed spray gun.
Figure 5-41.--Correct and incorrect methods of spraying.
Figure 5-42.--Sectional view of typical spray gun.
APPLICATION OF SEALANTS
Figure 5-44.--Appling sealant.
APPLICATION OF SEALANTS - Continued
NONDESTRUCTIVE INSPECTIONS, WELDING, AND HEAT TREATMENT
NONDESTRUCTIVE INSPECTIONS, WELDING, AND HEAT TREATMENT - Continued
Figure 6-1.--NDI Certification Record (OPNAV 4790/139).
Figure 6-2.--NDI Technician/Operator Work Record (OPNAV 4790/140).
NDI PROGRAM RESPONSIBILITIES
NDI INSPECTION METHODS
Figure 6-3.--Magnetic field surrounding an electrical conductor
Figure 6-9.--Coil creates a longitudinal field to show crack in a part
Figure 6-10.--Diagram of radiographic exposure.
Figure 6-11.--Coupling of search unit to test part for transmission of ultrasonic energy.
Figure 6-16.--Generation of eddy currents in various part configurations
Figure 6-18.--Typical eddy current test probes.
Figure 6-19.--Basic penetrant process.
RECERTIFICATION OF WELDERS
Figure 6-20.--Welding Certification (DD Form 2758).
Figure 6-21.--Welding Examination Record (DD Form 2757) (front).
Figure 6-22.--Welding Examination Record (DD Form 2757) (back).
Figure 6-23.--Portable oxyacetylene welding and cutting equipment
Figure 6-25.--Single-stage oxygen regulator.
Figure 6-26.--Two-stage regulator.
Figure 6-28.--Mixing head for injector-type welding torch.
WELDING (FILLER) RODS
BACKFIRE AND FLASHBACK
Figure 6-30.--Welding light gauge metals.
Figure 6-34.--Four basic welding positions.
Figure 6-36.--Butt joints in light sections.
Figure 6-41.--Edge joints for light sheets and plates.
Figure 6-42.--Corner joints for sheets and plates.
Figure 6-43.--Straight and reverse polarity in electric welding.
Figure 6-44.--Typical water-cooled GTA welding torch.
Figure 6-46.--Breaking the arc.
Figure 6-47.--GMA welding equipment.
Figure 6-48.--Gas metal-arc welding. (A) striking the arc; (B) gun angle.
WELDING SAFETY PRECAUTIONS
WELDING SAFETY PRECAUTIONS. - Continued
HEAT TREATMENT OF METALS
HEAT TREATMENT OF METALS - Continued
FORMS OF HEAT TREATMENT
HEAT TREATMENT OF FERROUS METALS (STEEL)
Table 6-1.--Color Chart for Steel at Various Temperatures
Table 6-2.--Color Chart for Various Tempering Temperatures of Carbon Steel
CASE HARDENING.
HEAT TREATMENT OF NONFERROUS METALS (ALUMINUM ALLOYS)
ANNEALING OF WORK HARDENED MATERIAL
ANNEALING OF WORK HARDENED MATERIAL - Continued
Figure 7-1.--Typical divided (split) wheel assembly.
Figure 7-3.--Typical wheel assembly.
and cap using alternate deflated tire flag.
INTERMEDIATE-LEVEL WHEEL MAINTENANCE
Figure 7-6.--Aircraft tires-tubes-wheels safety poster.
Figure 7-7.--Fuse plugs.
Figure 7-8.--Pressure repacking of wheel bearings.
Matching Wheel Halves
Figure 7-10.--Sectional view of aircraft tire showing construction details.
Figure 7-11.--Sectional view of two aircraft tires showing different construction details.
Figure 7-13.--New tire identification markings.
Figure 7-14.--Rebuilt tire identification markings.
Figure 7-15.--Tire storage rack (varied size tires).
Figure 7-17.--Method of measuring depth of cuts, cracks, and
Figure 7-18.--Aircraft wheel holder and tire bead-breaking machine
Figure 7-20.--Shaft arranged to hold tire bead while removing lockring.
MOUNTING DEMOUNTABLE FLANGE WHEELS
Figure 7-22.--Tire inflator assembly kit.
Figure 7-24.--Inflation safety cage with aircraft tire inflator/monitor attached.
Figure 7-25.--Valve core identification.
Figure 7-26.--Rapid tread wear caused by underinflation.
Table 7-1.--Tolerances for Diameters of Paired Tires in Dual Installations
Figure 7-29.--Inner tube vent ridges.
MOUNTING DIVIDED (SPLIT) WHEELS
BASIC HYDRAULICS
HYDRAULIC CONTAMINATION CONTROL PROGRAM
Figure 8-1.--Periodic fluid surveillance requirements.
TYPES OF CONTAMINATION
Table 8-1.--Particle Contamination Level By Class
Metallic Solid Contamination
Foreign Fluids Contamination
ANALYSIS METHODS LEARNING OBJECTIVE
Figure 8-3.--P/N57L414 contamination analysis kit.
Sample Taking
Figure 8-4.--Contamination analysis kit components.
Test Filter Analysis
ELECTRONIC PARTICLE COUNT ANALYSIS
Figure 8-5.--HDL-440 halogen leak detector in operation.
Figure 8-6.--Fluid flow during decontamination.
Flushing
Purifying
Table 8-3.--Aircraft Decontamination Requirements
Figure 8-7.--Sequence control chart for aircraft system decontamination.
Figure 8-8.--Series 145 and 155 quick-disconnect couplings.
Figure 8-9.--Quick disconnects properly and improperly connected.
Figure 8-10.--Series 320 (Aeroquip) quick disconnect.
Figure 8-12.--Action of O-rings.
Figure 8-13.--O-ring package identification.
Figure 8-14.--Typical O-ring installation and removal tools.
Figure 8-15.--O-ring removal.
Backup Rings
Figure 8-16.--O-ring installation.
Figure 8-17.--Teflon backup ring damages caused by improper handling.
Figure 8-19.--Installation of Teflon backup rings (internal).
Figure 8-20.--Teflon backup ring installation (external).
Table 8-4.--Protective Caps and Plugs
Figure 8-21.--Typical blank-off plates.
FLUID SERVICING AND SUPPORT EQUIPMENT
Figure 9-1.--Insertion of can into Hydraulic Servicing Unit H-250-1.
Figure 9-2.--Model HSU-1 fluid service unit.
Figure 9-3.--Model 310 fluid service cart.
PORTABLE HYDRAULIC TEST STANDS
Figure 9-4.--A/M27T-5 portable hydraulic power supply, rear and right-hand side view.
Table 9-1.--A/M27T-5 Main Control Panel Controls and Indicators
Table 9-1.--A/M27T-5 Main Control Panel Controls and Indicators--Continued.
Table 9-1.--A/M27T-5 Main Control Panel Controls and Indicators--Continued.
Figure 9-7.--Primary control panel controls and indicators.
Table 9-3.--Primary Control Panel Controls and Indicators
Table 9-4.--Secondary Control Panel Controls and Indicators
Figure 9-9.--Test stand operating modes.
Operational Checks
STATIONARY HYDRAULIC TEST STANDS
Figure 9-10.--Model HCT-10 hydraulic and pneumatic component test stand.
AIR BLEEDING
Figure 9-11.--Reservoir level changes (reservoir sink) presence of air in system.
RECIRCULATION CLEANING
Figure 9-12.--Fluid purification system.
PURIFYING
HOSE AND TUBING FABRICATION AND MAINTENANCE
Figure 10-2.--Synthetic rubber hose identification.
HOSE ASSEMBLY HARDWARE
Figure 10-3.--Synthetic hose fittings--(Continued).
Figure 10-3.--Synthetic hose fittings--(Continued).
Figure 10-4.--Teflon hose fittings.
Table 10-1.--Hose Fitting Color and Material Code
Figure 10-5.--Hose assembly identification tags.
Figure 10-7.--Hose fabricating machines.
Figure 10-9.--Synthetic rubber medium-pressure hose assembly.
Figure 10-10.--Determining hose assembly length.
Figure 10-15.--Firesleeve.
Table 10-3.--Proof Pressure Test Media
Figure 10-16.--Aircraft hose burst test stand (Greer).
Table 10-5.--Function of Controls and Instruments
Figure 10-19.--Controls and instruments.
Table 10-6.--Functions of Controls and Instruments
CGS SCIENTIFIC TEST PROCEDURES
Checking For Wear and Deterioration
Table 10-7.--Hose Minimum Bend Data
Figure 10-20.--Hose twist.
Figure 10-24.--"N" factor for flexing bends.
Acceptance Life and Shelf Life for Synthetic Rubber Hose and Hose Assemblies
Table 10-9.--Corrosion-Resistant Steel Tubing
Table 10-10.--Aluminum Alloy Tubing Applications
Figure 10-25.--Typical styles of MS fittings.
Figure 10-26.--Typical styles of AN fittings.
Figure 10-27.--Typical style of Permaswage fittings.
Figure 10-28.--Typical style of Dynatube fittings.
Figure 10-31.--Properly deburred tubing.
Figure 10-34.--Bending tubing with hand-operated tube bender.
Figure 10-36.--Tube flaring tool (single-flare).
Figure 10-38.--Tube position and resulting flare.
Table 10-13.--Tube Projection from Sleeve Pilot
Table 10-14.--Minimum Inside Diameter of Tubing
Table 10-15.--Prime and Paint for Tube Assemblies
Figure 10-41.--Fluid line identification application.
Figure 10-43.--Color-coded functional identification tapes.
Figure 10-43.--Color-coded functional identification tapes--Continued.
Table 10-16.--Hazards Associated with Various Fluids
Figure 10-44.--Damaged fittings.
Figure 10-45.--Correct and incorrect methods of installing flared fittings.
Table 10-17.--Maximum Distance Between Supports for Aluminum Tubing
Figure 10-48.--Reworking damaged fittings.
Table 10-18.--Tube Assembly Failures and Recommended Repair Methods
Figure 10-50.--Permaswage Tool Kit D10031-812S.
Figure 10-55.--Male and female repair fitting installation.
Figure 10-60.--Swaging and repair tool kit.
TUBING AND TUBE ASSEMBLIES MAINTENANCE PROCEDURES
BASIC ACTUATING SYSTEMS
Figure 11-2.--Double-acting, piston-type, actuating cylinders.
Figure 11-3.--Cutaway of a single-action, ball-lock actuating cylinder.
Control Surface Actuating Cylinder
Figure 11-4.--Typical finger-lock actuating cylinder.
Figure 11-5.--Control surface actuating cylinder.
HYDRAULIC MOTORS
Figure 11-6.--Typical hydraulic motor.
Figure 11-8.--Cutaway view of selector valve body.
Figure 11-9.--Working view of a poppet-type selector valve.
Figure 11-10.--Slide-type selector valve.
Solenoid-Operated Selector Valve
Figure 11-11.--Solenoid-operated selector valve.
Figure 11-12.--Typical check valve.
Figure 11-13.--Typical sequence valve.
Figure 11-14.--View of priority valve.
Figure 11-15.--Shuttle valve.
Maintenance of Shuttle Valves
Figure 11-16.--Restrictors.
Figure 11-17.--Pressure-reducing valve operational schematic.
Figure 11-18.--Fuse, operational view.
BASIC HYDRAULIC/PNEUMATIC AND EMERGENCY POWER SYSTEMS
Figure 12-1.--Basic open-center hydraulic system.
Closed-Center System
figure 12-2.- Closed- center hydraulic system schematic.
EMERGENCY POWER SYSTEMS
Nonpressurized Reservoirs
Figure 12-3.--Hydraulic reservoir instruction plate.
Figure 12-4.--Nonpressurized reservoir.
Figure 12-7.--Air-pressurized reservoir and components.
Figure 12-8.--Chemical air drier.
Figure 12-10.--Air relief valve.
Figure 12-12.--Typical fluid-pressurized reservoir.
Figure 12-13.--Double-action hydraulic hand pump.
Figure 12-14.--Gear-type power pump.
Figure 12-15.--Partial cutaway view of piston-type pump.
Figure 12-16.--Internal features of the Stratopower pump.
Figure 12-19.--Pressure control mechanism.
Figure 12-20.--Fluid flow.
Figure 12-21.--Motor-driven variable displacement piston pump.
Figure 12-22.--Motor-driven variable displacement piston pump schematic.
Figure 12-23.--Pump compensation. (A) full flow position; (B) reduced flow; (C) minimum flow.
Main System Relief Valves
Figure 12-24.--System relief valve.
Figure 12-25.--Typical thermal relief valve.
Figure 12-26.--Motor operated shutoff valve.
Figure 12-27.--Electric solenoid shutoff valve.
HYDRAULIC FLUID COOLERS
Figure 12-28.--Hydraulic fluid cooler.
Figure 12-29.--Fin tubing assembly installation.
Figure 12-30.--Hydraulic manifold assembly.
Figure 12-32.--Hydraulic filter assembly.
Fin Tubing Types
Figure 12-33.--Hydraulic filter assembly incorporating differential pressure indicator.
Spherical Type
Figure 12-34.--Pressure accumulator, spherical and cylindrical types.
Figure 12-35.--Accumulator air charge valve and gauge installation.
Figure 12-36.--Bourdon tube.
Figure 12-39.--Gauge and pressure transmitter snubber.
Figure 12-40.--Schematic diagram of typical emergency power system (electric-motor driven).
Figure 12-41.--Ram air turbine hydraulic pump assembly.
Figure 12-42.--Ram air turbine-control system schematic.
Figure 12-44.--Air cylinder.
Figure 12-45.--Pneumatic storage cylinder inflation chart
LANDING GEAR SYSTEMS
LANDING GEAR SYSTEMS OPERATION
Figure 13-2.--Nose gear up cycle schematic.
Figure 13-3.--Landing gear warning and position indicator.
Figure 13-4. - Emergency landing gear extension system.
Figure 13-5.--Main gear door latch mechanisms.
Figure 13-6.--Landing gear door latch installation.
Figure 13-8.--Landing gear shock strut (metering pin type).
Figure 13-9.--Landing gear shock strut (metering tube type).
Figure 13-12.--Landing gear drag brace adjustment.
LANDING GEAR SYSTEMS MAINTENANCE
ALIGNMENT AND ADJUSTMENT
Figure 13-13.--Main gear recoil strut piston.
STRUT REMOVAL AND REPLACEMENT
Figure 13-15.--Servicing a landing gear strut.
Figure 13-16.--Landing gear strut servicing instruction plate.
Figure 13-17.--Landing gear shock strut tools.
INTERMEDIATE MAINTENANCE REPAIR AND SEAL REPLACEMENT
Bench Testing
Bench Testing - Continued
BRAKE SYSTEMS
Figure 141.--Typical independent-type brake system.
Figure 14-3.--Gladden master brake cylinder.
Figure 14-5.--Typical power brake control valve system.
Figure 14-6.--Power brake control valve (pressure ball check
Figure 14-7.--Power brake control valve (sliding spool type).
Figure 14-8.--Brake debooster cylinder.
Figure 14-9.--Typical single disc brake installation.
Figure 14-10.--Exploded view of single disc brake assembly.
Figure 14-11.--Dual disc brake.
INDEPENDENT-TYPE BRAKE SYSTEM
Figure 14-12.--Cross-sectional view of multiple disc brake.
Figure 14-13.--Segmented rotor brake--cutaway view.
Figure 14-14.--Power/manual brake systems--schematic.
Figure 14-15.--Wheel brake.
Figure 14-17.--Normal position of automatic adjusting pin.
Figure 14-18.--Bleeding brake system (top-down method).
Figure 14-20.--Use of blowout screen on overheated brakes.
BRAKE SYSTEM COMPONENT MAINTENANCE
Figure 14-21.--Operational test setup--power brake valve.
MASTER BRAKE CYLINDER
Figure 14-22.--Piston, valve, and brake chamber proof test setup diagram
Figure 14-23.--Rod packing, cylinder leakage, and pumping function test.
BRAKE SELECTOR VALVE
Figure 14-24.--Brake selector valve--exploded view.
Figure 14-25.--Brake swivel.
Figure 14-26.--Brake self-adjustment feature--single disc brake.
Figure 14-27.--Cross-sectional view of a single disc brake assembly with captured torquing-type automatic adjuster.
Figure 14-29.--Single disc brake--repair and parts replacement diagram.
POWER BRAKE VALVE
Figure 14-30.--Dual disc brake--repair and parts replacement.
Figure 14-31.--Seal replacement and piston return adjustment.
Figure 14-31.--Seal replacement and piston return adjustment--Continued.
Figure 14-32.--Trimetallic brake assembly.
Figure 14-33.--Trimetallic brake assembly--cross section.
SKID CONTROL SYSTEM MAINTENANCE
Figure 14-34.--Antiskid control valve schematic.
UTILITY HYDRAULIC SYSTEMS
Figure 15-2.--Nosewheel steering system schematic.
Figure 15-3.--Nose gear steering system diagram.
Adjustment of Components
Figure 15-4.--Nosewheel steering system.
ARRESTING HOOK ASSEMBLY INSPECTION LEARNING OBJECTIVE
SINGLE SHANK CENTERING DEVICES
Figure 15-6.--Liquid spring shock assembly.
Figure 15-8.--Centering spring.
Figure 15-9.--Catapult system.
Figure 15-10.--Catapult system hydraulic schematic.
Figure 15-11.--Air refueling probe hydraulic system.
Figure 15-12.--Wing fold schematic (spread and locked condition).
ARRESTING HOOK ASSEMBLY INSPECTION
Figure 15-13.--AC generator drive system.
Figure 15-14.--Ramp servo and actuator.
Figure 15-15.--Variable bellmouth system.
Figure 15-16.--Bomb bay door hydraulic schematic.
Figure 15-17.--Windshield wiper schematic.
Figure 15-18.--Windshield wiper unit.
ARRESTING HOOK ASSEMBLY INSPECTION - Continued
Figure 16-1.--Mechanical (unboosted) flight control system.
Figure 16-2.--Hydraulically powered elevator control system.
Figure 16-3.--Elevator forward bobweight and damper
Figure 16-4.--Elevator aft bobweight and damper assembly.
Figure 16-6.--Stabilizer control system.
Figure 16-7. -- Stabilizer control system schematic.
MANUAL MODE.
Horizontal Stabilizer (Stabilator) Control System (Double Axis)
Figure 16-8.--Hydraulically powered aileron control system.
Figure 16-9.--Aileron power mechanism.
Figure 16-10.--Flaperon control system.
Figure 16-12.--Flaperon control system.
Figure 16-13.--Flaperon autopilot actuator.
Figure 16-14. -- Aileron and spoiler/deflector system.
Spoiler Control System
Figure 16-15.--Rudder control system.
ELECTRONIC PRIMARY FLIGHT CONTROL SYSTEMS
Figure 16-16. --Electronic flight controls.
Figure 16-17.--Backup flight control hydraulic system.
COMPONENTS
PRIMARY FLIGHT CONTROL SYSTEM MAINTENANCE
RIGGING AND OPERATIONAL CHECKS
Figure 16-19.--Aileron throw protractor indications.
Figure 16-20.--Determining serviceable cable.
RIGID CONTROL SYSTEMS
Figure 16-21.--Quick-disconnect procedures.
RIGGING AND ADJUSTING
Figure 16-23.--Cable tensiometer and chart.
Figure 16-24.--Rigging pin set.
Figure 16-25.--Typical throwboard used for rigging rudder and rudder tab controls.
Figure 16-27.--Elevator rigging fixture.
Figure 16-28.--Cable-cutting machine.
Figure 16-29.--Hand-swaging tools--mechanical and pneumatic
Figure 16-31.--Locating the terminal in the swaging tool.
SECONDARY FLIGHT CONTROL SYSTEMS
Figure 16-32.--Flap cylinder, linkage, and selector valve installation.
Figure 16-33.--Wing flap system.
LEADING/TRAILING EDGE WING FLAP SYSTEMS
Figure 16-34.--Flap control circuit.
Figure 16-35.--Flap drive gearbox.
Figure 16-36.--Flap actuator.
Figure 16-37.--Slat drive system.
Figure 16-39.--Wing oversweep position--manual control.
SPEED BRAKE SYSTEM
Figure 16-40.--Speed brake control system.
Figure 16-41.--Wingtip speed brake control system.
Figure 16-42.--Aileron trim control system.
SECONDARY CONTROL SYSTEM MAINTENANCE
MAJOR ASSEMBLY REMOVAL/INSTALLATION
STABILIZERS
AIRFRAME AND CONTROL SURFACE ALIGNMENT
BALANCING CONTROL SURFACES
Figure 16-43.--Transit leveling.
Figure 16-44.--Spirit leveling lugs.
Figure 16-45.--Plumb bob and datum plate leveling.
Figure 16-46.--Structure alignment dimensions.
Figure 16-47.--Alignment data--wing twist check.
Figure 17-1.--Center of pressure.
Figure 17-2.--Torque reaction.
Figure 17-4.--Dissymmetry of lift.
TRANSLATIONAL LIFT
Figure 17-5.--Representative types of naval helicopters.
Figure 17-6.--Flight control systems.
FLIGHT CONTROL SYSTEMS COMPONENTS
Figure 17-7.--Auxiliary servo cylinder.
Figure 17-8.--Primary servo cylinder.
ROTARY-WING MAINTENANCE
Figure 17-9.--Swashplate--cross-sectional and installed view.
ROTOR BLADE TRACKING
Figure 17-10.--Blade tracking--Strobex.
Figure 17-11.--Rotor brake and system schematic.
AUTOMATIC BLADE FOLDING SYSTEM
Figure 17-12.--Automatic blade folding system schematic.
Figure 17-12.--Automatic blade folding system schematic--Continued.
Figure 17-13.--Blade fold cylinder.
Figure 17-14.--Rotor coupling.
AUTOMATIC BLADE FOLDING SYSTEM - Continued
GLOSSARY
GLOSSARY- Continued
GLOSSARY- Continued