SECTION 2. STORAGE BATTERIES11-5
11-15. GENERAL11-5
11-16. BATTERY CHARGING11-5
11-17. BATTERY FREEZING11-5
11-18. TEMPERATURE CORRECTION11-6
11-19. BATTERY MAINTENANCE11-7
11-20. ELECTROLYTE SPILLAGE11-10
11-21. NOXIOUS FUMES11-10
11-22. INSTALLATION PRACTICES11-10
11-23.–11-29. [RESERVED.]11-12
SECTION 3. INSPECTION OF EQUIPMENT INSTALLATION11-13
11-30. GENERAL11-13
11-31. INSTALLATION CLEARANCE PROVISIONS11-13
11-32. WIRES, WIRE BUNDLES, AND CIRCUIT PROTECTIVE DEVICES11-13
11-33. ALTERNATOR DIODES11-13
11-34. STATIC ELECTRICAL POWER CONVERTERS11-13
11-35. ACCEPTABLE MEANS OF CONTROLLING OR MONITORING THE
ELECTRICAL LOAD11-14
11-36. ELECTRICAL LOAD DETERMINATION11-14
11-37. JUNCTION BOX CONSTRUCTION11-15
11-38.–11-46. [RESERVED.]11-15
SECTION 4. INSPECTION OF CIRCUIT-PROTECTION DEVICES11-16
11-47. GENERAL11-16
11-48. DETERMINATION OF CIRCUIT BREAKER RATINGS11-16
11-49. DC CIRCUIT PROTECTOR CHART11-16
11-50. RESETTABLE CIRCUIT PROTECTION DEVICES11-17
11-51. CIRCUIT BREAKER USAGE11-17
11-52. CIRCUIT BREAKER MAINTENANCE11-18
11-53. SWITCHES11-18
11-54. RELAYS11-22
11-55. LOAD CONSIDERATIONS11-23
11-56. OPERATING CONDITIONS FOR SWITCHES AND RELAYS11-23
11-57.–11-65. [RESERVED.]11-23
SECTION 5. ELECTRICAL WIRE RATING11-24
11-66. GENERAL11-24
11-67. METHODS FOR DETERMINING CURRENT CARRYING CAPACITY OF
WIRES11-28
11-68. INSTRUCTIONS FOR USE OF ELECTRICAL WIRE CHART11-29
11-69. COMPUTING CURRENT CARRYING CAPACITY11-33
11-70.–11-75. [RESERVED.]11-40
SECTION 6. AIRCRAFT ELECTRICAL WIRE SELECTION11-41
11-76. GENERAL11-41
11-77. AIRCRAFT WIRE MATERIALS11-41
11-78. SUBSTITUTIONS11-43
11-79.–11-84. [RESERVED.]11-43
SECTION 7. TABLE OF ACCEPTABLE WIRES11-44
11-85. AIRCRAFT WIRE TABLE11-44
11-86. OPEN AIRFRAME INTERCONNECTING WIRE11-47
11-87. PROTECTED WIRE11-47
11-88. SEVERE WIND AND MOISTURE PROBLEMS (SWAMP)11-47
11-89. SHIELDED WIRE11-47
11-90.–11-95. [RESERVED.]11-48
SECTION 8. WIRING INSTALLATION INSPECTION REQUIREMENTS11-49
11-96. GENERAL11-49
11-97. WIRING REPLACEMENT11-52
11-98. TERMINALS AND TERMINAL BLOCKS11-53
11-99. FUSES AND FUSE HOLDERS11-53
11-100. CONNECTORS11-54
11-101. JUNCTION BOXES, PANELS, SHIELDS, AND
MICRO-SWITCH HOUSINGS11-55
11-102. RIGID METALLIC, FLEXIBLE METALLIC AND RIGID NONMETALLIC
CONDUIT11-55
11-103. JUNCTIONS11-55
11-104. CIRCUIT BREAKERS11-56
11-105. SYSTEM SEPARATION11-56
11-106. ELECTROMAGNETIC INTERFERENCE (EMI)11-56
11-107. INTERFERENCE TESTS11-56
11-108. IDENTIFICATION STENCILS AND PLACARDS ON ELECTRICAL
EQUIPMENT11-57
11-109.–11-114. [RESERVED.]11-57
SECTION 9. ENVIRONMENTAL PROTECTION AND INSPECTION11-58
11-115. MAINTENANCE AND OPERATIONS11-58
11-116. GROUP AND BUNDLE TIES11-58
11-117. MINIMUM WIRE BEND RADII11-59
11-118. SLACK11-59
11-119. DRIP LOOP IN WIRE BUNDLE11-60
11-120. POWER FEEDERS11-61
11-121. RF CABLE11-61
11-122. PRECAUTIONS11-61
11-123. MOISTURE PROTECTION, WHEEL WELLS, AND
LANDING GEAR AREAS11-62
11-124. PROTECTION AGAINST PERSONNEL AND CARGO11-62
11-125. HEAT PRECAUTIONS11-62
11-126. MOVABLE CONTROLS WIRING PRECAUTIONS11-62
11-127. FLAMMABLE FLUIDS AND GASES11-62
11-128.–11-134. [RESERVED.]11-63
SECTION 10. SERVICE LOOP HARNESSES (PLASTIC TIE STRIPS)11-64
11-135. GENERAL11-64
11-136. SUPPORT11-64
11-137. ANTI-CHAFING MATERIAL11-64
11-138. STRAIN RELIEF11-64
11-139. “SERVICE LOOP”11-64
11-140.–11-145. [RESERVED.]11-65
SECTION 11. CLAMPING11-66
11-146. GENERAL11-66
11-147. WIRE AND CABLE CLAMPS INSPECTION11-66
11-148.–11-154. [RESERVED.]11-69
SECTION 12. WIRE INSULATION AND LACING STRING TIE11-70
11-155. GENERAL11-70
11-156. INSULATION MATERIALS11-70
11-157. STRIPPING INSULATION11-70
11-158. LACING AND TIES11-71
11-159. INSULATION TAPE11-74
11-160.–11-166. [RESERVED.]11-74
SECTION 13. SPLICING11-75
11-167. GENERAL11-75
11-168.–11-173. [RESERVED.]11-75
SECTION 14. TERMINAL REPAIRS11-76
11-174. GENERAL11-76
11-175. ATTACHMENT OF TERMINALS TO STUDS11-77
11-176. STUDS AND INSULATORS11-77
11-177. WIRE TERMINALS AND BINDING POSTS11-78
11-178. CRIMP ON TERMINAL LUGS AND SPLICES (pre-insulated crimp type)11-78
11-179. LOCK WASHERS FOR TERMINALS ON EQUIPMENT11-79
11-180.–11-184. [RESERVED.]11-79
SECTION 15. GROUNDING AND BONDING11-80
11-185. GENERAL11-80
11-186. GROUNDING11-80
11-187. BONDING11-82
11-188. BONDING INSPECTION11-82
11-189. BONDING JUMPER INSTALLATIONS11-84
11-190. CREEPAGE DISTANCE11-89
11-191. FUEL SYSTEMS11-89
11-192. ELECTRIC SHOCK PREVENTION BONDING11-89
11-193. LIGHTNING PROTECTION BONDING11-89
11-194. LIGHTNING PROTECTION FOR ANTENNAS AND AIR DATA PROBES . 11-90
11-195. STATIC-DISCHARGE DEVICE11-90
11-196. CLEANING11-90
11-197. HARDWARE ASSEMBLY11-90
11-198.–11-204. [RESERVED.]11-91
SECTION 16. WIRE MARKING11-92
11-205. GENERAL11-92
11-206. WIRE IDENTIFICATION11-92
11-207. IDENTIFICATION AND INFORMATION RELATED TO THE WIRE AND
WIRING DIAGRAMS11-92
11-208. PLACEMENT OF IDENTIFICATION MARKINGS11-92
11-209. TYPES OF WIRE MARKINGS11-93
11-210. HOT STAMP MARKING11-94
11-211. DOT MATRIX MARKING11-94
11-212. INK JET MARKING11-94
11-213. LASER MARKING11-95
11-214. IDENTIFICATION SLEEVES11-95
11-215. IDENTIFICATION TAPE11-95
11-216. OPERATING CONDITIONS11-96
11-217. INSTALLATION OF PRINTED SLEEVES11-96
11-218. IDENTIFICATION OF WIRE BUNDLES AND HARNESSES11-96
11-219. TERMINAL MARKING SLEEVE AND TAGS11-97
11-220. SLEEVES AND CABLE MARKERS SELECTION11-98
11-221. TEMPORARY WIRE AND CABLE MARKING PROCEDURE11-103
11-222. MARKER SLEEVE INSTALLATION AFTER PRINTING11-103
11-223.–11-229. [RESERVED.]11-104
SECTION 17. CONNECTORS11-105
11-230. GENERAL11-105
11-231. SELECTION11-105
11-232. TYPES OF CONNECTORS11-105
11-233. VOLTAGE AND CURRENT RATING11-111
11-234. SPARE CONTACTS (FUTURE WIRING)11-111
11-235. INSTALLATION11-112
11-236. FEED-THROUGH BULKHEAD WIRE PROTECTION11-113
11-237. SPECIAL PURPOSE CONNECTOR11-113
11-238. POTTING COMPOUNDS11-113
11-239. POTTING CONNECTORS11-113
11-240. THROUGH BOLTS11-114
11-241.–11-247. [RESERVED.]11-114
SECTION 18. CONDUITS11-115
11-248. GENERAL11-115
11-249. SIZE OF CONDUIT11-115
11-250. CONDUIT FITTINGS11-115
11-251. CONDUIT INSTALLATION11-115
11-252. RIGID CONDUIT11-115
11-253. FLEXIBLE CONDUIT11-116
11-254.–11-259. [RESERVED.]11-117
SECTION 19. UNUSED CONNECTORS AND UNUSED WIRES11-118
11-260. GENERAL11-118
11-261. QUICK REFERENCE CHART11-118
11-262. UNPRESSURIZED AREA CONNECTORS11-118
11-263. PRESSURIZED AREAS11-120
11-264.–11-270. [RESERVED.]11-120
SECTION 20. ELECTRICAL AND ELECTRONIC SYMBOLS11-121
11-271. GENERAL11-121
11-272. SYMBOLS11-121
11-273.–11-283. [RESERVED.]11-134
CHAPTER 12. AIRCRAFT AVIONICS SYSTEMS12-1
SECTION 1. AVIONICS EQUIPMENT MAINTENANCE12-1
12-1. GENERAL12-1
12-2. HANDLING OF COMPONENTS12-1
12-3.–12-7. [RESERVED.]12-1
SECTION 2. GROUND OPERATIONAL CHECKS FOR AVIONICS EQUIPMENT
(ELECTRICAL)12-2
12-8. GENERAL12-2
12-9. INSPECTION OF AVIONICS SYSTEMS12-2
12-10. COMMUNICATION SYSTEMS12-4
12-11. VHF OMNI-DIRECTIONAL RANGE (VOR)12-4
12-12. DISTANCE MEASURING EQUIPMENT (DME)12-4
12-13. AUTOMATIC DIRECTION FINDER (ADF)12-5
12-14. INSTRUMENT LANDING SYSTEMS (ILS)12-5
12-15. MARKER BEACON12-6
12-16. LONG RANGE NAVIGATION (LORAN)12-6
12-17. GLOBAL POSITIONING SYSTEM (GPS)12-6
12-18. AUTOPILOT SYSTEMS12-6
12-19. ALTIMETERS12-7
12-20. TRANSPONDERS12-7
12-21. AUTOMATIC DEPENDENT SURVEILLANCE-BROADCAST (ADS-B)12-8
12-22. EMERGENCY LOCATOR TRANSMITTERS (ELT)12-8
12-23. INSPECTION OF ELT12-8
12-24. FLIGHT DATA RECORDER (FDR)12-9
12-25. COCKPIT VOICE RECORDERS (CVR)12-10
12-26. WEATHER RADAR12-11
12-27. RADOME INSPECTION12-11
12-28. DATABUS12-11
12-29. ELECTRIC COMPATIBILITY12-11
12-30.–12-36. [RESERVED.]12-12
SECTION 3. GROUND OPERATIONAL CHECKS FOR AVIONICS EQUIPMENT
(NON-ELECTRICAL)12-13
12-37. COMPASS SWING12-13
12-38. PNEUMATIC GYROS12-15
12-39.–12-50. [RESERVED.]12-18
SECTION 4. PITOT/STATIC SYSTEMS12-19
12-51. GENERAL12-19
12-52. SYSTEM COMPONENTS12-19
12-53. PITOT/STATIC TUBES AND LINES12-19
12-54. STATIC PORTS AND VENTS12-20
12-55. HEATER ELEMENTS12-20
12-56. SYSTEM INSPECTION12-21
12-57. SYSTEM LEAK TEST12-21
12-58. STATIC SYSTEM TESTS12-21
12-59. TEST PITOT SYSTEM12-22
12-60. MAINTENANCE PRECAUTIONS12-22
12-61. REPLACING LINES12-23
12-62. RELOCATION OF PITOT TUBE12-23
12-63. TROUBLESHOOTING THE PITOT/STATIC PRESSURE SYSTEM12-23
12-64.–12-69. [RESERVED.]12-24
SECTION 5. AVIONICS TEST EQUIPMENT12-25
12-70. GENERAL12-25
12-71. TEST EQUIPMENT CALIBRATION STANDARDS12-25
12-72.–12-83. [RESERVED.]12-26
CHAPTER 13. HUMAN FACTORS13-1
13-1. HUMAN FACTORS INFLUENCE ON MECHANIC’S PERFORMANCE13-1
13-2. THE FAA AVIATION SAFETY PROGRAM13-1
APPENDIX 1. GLOSSARY1
APPENDIX 2. ACRONYMS AND ABBREVIATIONS1
APPENDIX 3. METRIC-BASED PREFIXES AND POWERS OF 101
LIST OF FIGURES
Figure 1-1. Relative shrinkage of wood members due to drying1-5
Figure 1-2. Tapering of faceplate1-5
Figure 1-3. Likely areas to incur structural damage1-15
Figure 1-4. Consideration of grain direction when making scarf joints1-17
Figure 1-5. Method of splicing solid or laminated rectangular spars1-18
Figure 1-6. Method of splicing solid “I” spars1-19
Figure 1-7. Repairs to built-up “I” spar1-20
Figure 1-8. Method of splicing box spar flanges (plate method)1-21
Figure 1-9. Method of splicing box spar webs1-22
Figure 1-10. Method of reinforcing a longitudinal crack and/or local damage in
a solid spar1-24
Figure 1-11. Repair of wood ribs1-26
Figure 1-12. Typical wing compression rib repairs1-28
Figure 1-13. Splayed patch1-30
Figure 1-14. Surface patches1-32
Figure 1-15. Scarf patches (back of skin accessible)1-33
Figure 1-16. Scarf patches (back of skin not accessible)1-34
Figure 1-17. Oval plug patch assembly1-36
Figure 1-18. Round plug patch assembly1-37
Figure 2-1. Fabric seams2-7
Figure 2-2. Typical methods of attaching fabric2-8
Figure 2-3. Exploded side view of rib2-11
Figure 2-4. Standard external modified seine knot used for single and
double rib lacing2-12
Figure 2-5. Starting stitch for rib lacing2-13
Figure 2-6. Standard single-loop lacing2-14
Figure 2-7. Standard knot for double-loop lacing2-15
Figure 2-8. Standard double-loop lacing (optional)2-16
Figure 2-9a. Alternate sequence to tie a modified seine knot for rib lacing2-17
Figure 2-9b. Alternate sequence to tie a modified seine knot for rib lacing2-18
Figure 2-9c. Alternate sequence to tie a modified seine knot for rib lacing2-19
Figure 2-10. Splice knot2-20
Figure 2-11. Blindstitch lacing square knot secured with half hitches2-21
Figure 2-12. Fabric attachment spacing2-23
Figure 2-13. Repair of tears in fabric2-39
Figure 2-14. Hand-stitch detail2-40
Figure 3-1. Typical laminate (facing) repair3-2
Figure 3-2. Typical core and facing repair3-3
Figure 3-3. Typical stepped joint repair3-3
Figure 3-4. Preparing the fiberglass sandwich3-5
Figure 3-5. Scarfed repair to a nonstructural laminated fiberglass component3-6
Figure 3-6. Symmetrical layup same as original number of plies, plus one extra ply3-7
Figure 3-7. Typical scarf joint repair3-8
Figure 3-8. Carefully cut through each layer of fiberglass cloth and
remove it from the damaged area3-9
Figure 3-9. Sample bagging layup cross-section3-10
Figure 3-10. Typical types of core replacement3-14
Figure 3-11. Typical undercut core material cavity3-15
Figure 3-12. Cross-section of bonded and bolted overlap repairs3-15
Figure 3-13. Honeycomb core removal3-16
Figure 3-14 Removing honeycomb core from a tapered control surface3-16
Figure 3-15. Removal of core with core knife3-17
Figure 3-16. Details of core repair3-18
Figure 3-17. Hanging of acrylic sheets3-21
Figure 3-18. Drill having an included angle of approximately 150º,
used to drill acrylic plastics3-24
Figure 3-19. Unibit drill for drilling acrylic plastics3-24
Figure 3-20. Applying pressure to acrylic plastics3-25
Figure 3-21. Stop-drilling cracks3-26
Figure 3-22. Surface patches3-27
Figure 3-23. Plug patch repair3-28
Figure 3-24. Temporary repairs to cracked windshields or windows3-31
Figure 4-1. Comparison of indentation made by Knoop and Vickers
indenters in the same work metal and at the same loads4-10
Figure 4-2. Setback for a 90-degree bend4-17
Figure 4-3. Methods of determining setback for bends other than 90 degrees4-19
Figure 4-4. Rivet identification and part number breakdown4-21
Figure 4-5. Rivet hole spacing and edge distance for single-lap sheet splices4-25
Figure 4-6. Riveting practice and rivet imperfections4-26
Figure 4-7. Self-plugging friction-lock cherry rivets4-27
Figure 4-8. Mechanical-lock (Bulbed CherryLOCK) cherry rivet4-29
Figure 4-9. CherryMAX rivet4-30
Figure 4-10. Olympic-Lok rivet4-31
Figure 4-11. Huck rivet4-32
Figure 4-12. Typical repair method for tubular members of aluminum alloy4-34
Figure 4-13. Typical repair for buckled or cracked metal wing rib cap strips4-36
Figure 4-14. Typical metal rib repairs4-37
Figure 4-15. Typical repairs of trailing edges4-38
Figure 4-16. Typical repairs of stressed sheet metal coverings4-39
Figure 4-17. Typical stringer and flange splices4-44
Figure 4-18. Example of stringer splice (material: 2017 alloy)4-45
Figure 4-19. Application of typical flange splices and reinforcement4-46
Figure 4-20. Example of intermediate frame stringer splice
(material: 2017-T3 AL alloy)4-50
Figure 4-21. Typical methods of repairing cracked leading and trailing edges and
rib intersections4-51
Figure 4-22. Typical methods of replacing cracked members at fittings4-52
Figure 4-23. Typical methods of repairing cracked frame and stiffener combination4-53
Figure 4-24. Typical repairs to rudder and to fuselage at tail post4-54
Figure 4-25. Typical methods of repairing elongated or worn bolt holes4-56
Figure 4-26. Common defects to avoid when fitting and welding
aircraft certification cluster4-66
Figure 4-27. Lap weld strength calculation4-67
Figure 4-28. Basic gas-welding flames: each has a distinctive shape, color,
and sound; neutral flame is the most used4-68
Figure 4-29. Set TIG welder to DC current, straight polarity for welding
mild steel, stainless steel, and titanium4-69
Figure 4-30. Set TIG to AC current for welding aluminum and magnesium4-70
Figure 4-31. In spot welding, heat is produced by electrical resistance between copper electrodes; pressure is simultaneously applied to electrode tips to force metal together to complete fusing process;
spot-weld nugget size is directly related to tip size4-71
Figure 4-32. Silver brazing joints4-73
Figure 4-33. Electric soldering iron4-74
Figure 4-34. Finger patch repairs for members dented at a cluster4-77
Figure 4-35. Members dented in a bay (repairs by welded sleeve)4-78
Figure 4-36. Welded-patch repair4-79
Figure 4-37. Splicing by inner-sleeve method4-81
Figure 4-38. Splicing by outer-sleeve method (replacement by welded outside sleeve)4-82
Figure 4-39. Tube replacement at a station by welded outer sleeves4-83
Figure 4-40. Splicing using larger diameter replacement tube4-84
Figure 4-41. Repairs at built-in fuselage fittings4-85
Figure 4-42. Streamline tube splice using round tube (applicable to landing gear)4-87
Figure 4-43. Streamline tube splice using split sleeve (applicable to wing and tail
surface brace struts and other members)4-88
Figure 4-44. Streamline tube splice using split insert (applicable to landing gear)4-89
Figure 4-45. Streamline tube splice using plates (applicable to landing gear)4-90
Figure 4-46. Representative types of repairable axle assemblies4-91
Figure 4-47. Landing gear assemblies that cannot be repaired by welding4-92
Figure 5-1. Typical borescope designs5-11
Figure 5-2. Using a flashlight to inspect for cracks5-13
Figure 5-3. Generating an eddy current5-14
Figure 5-4. Detecting an eddy current5-15
Figure 5-5. Typical instrument displays5-15
Figure 5-6. Typical surface cracks5-16
Figure 5-7. Typical subsurface cracks5-17
Figure 5-8. Typical structural corrosion5-18
Figure 5-9. Magnetic field disrupted5-20
Figure 5-10. Crack detection by magnetic particle inspection5-20
Figure 5-11. Circular magnetization5-26
Figure 5-12. Longitudinal magnetization5-27
Figure 5-13. Penetrant and developer action5-33
Figure 5-14. Radiography5-40
Figure 5-15. Ultrasound5-43
Figure 5-16. Pulse-echo and through-transmission ultrasonic inspection techniques5-44
Figure 5-17. Typical portable ultrasonic inspection instrument5-45
Figure 5-18. Example of position fixture and shoe5-46
Figure 5-19. Example of the use of a transducer positioning fixture5-46
Figure 5-20. Example of a typical reference standard5-47
Figure 5-21. Examples of bonded structure configurations and
suggested inspection coverage5-50
Figure 5-22. Sample of special tap hammer5-55
Figure 6-1. Simplified corrosion cell showing conditions which must exist for
electrochemical corrosion6-1
Figure 6-2. Elimination of corrosion by application of
an organic film to metal surface6-2
Figure 6-3. Corrosion attack6-5
Figure 6-4. General surface corrosion6-5
Figure 6-5a. Pitting corrosion (external view)6-6
Figure 6-5b. Pitting corrosion (magnified cross-section)6-6
Figure 6-6. Concentration cell corrosion6-7
Figure 6-7. Active-passive cell6-8
Figure 6-8. Filiform corrosion6-8
Figure 6-9. Intergranular corrosion of 7075-T6 aluminum adjacent
to steel fastener6-9
Figure 6-10. Exfoliation corrosion6-10
Figure 6-11. Galvanic corrosion of magnesium adjacent to steel fastener6-10
Figure 6-12. Stress corrosion cracking6-11
Figure 6-13. Fretting corrosion6-13
Figure 6-14. Typical example of acceptable cleanup of corrosion pits6-26
Figure 6-15. Blendout of corrosion as a single depression6-27
Figure 6-16. Blendout of multiple pits in a corroded area6-28
Figure 7-1. Typical aircraft bolt markings7-6
Figure 7-2. Torque wrench with various adapters7-8
Figure 7-3. Securing screws, nuts, bolts, and snaprings7-19
Figure 7-3a. Wire twisting by hand7-19
Figure 7-4. Use of a typical wire twister7-21
Figure 7-4a. Securing oil caps, drain cocks, and valves7-22
Figure 7-5. Safety-wiring procedures7-23
Figure 7-5a. Safety-wiring procedures7-24
Figure 7-5b. Safety-wiring procedures7-25
Figure 7-6. Securing with cotter pins7-26
Figure 7-7. Alternate method for securing with cotter pins7-26
Figure 7-8. Flexible cable cross-section7-29
Figure 7-9. Nonflexible cable cross-section7-31
Figure 7-10. Insertion of cable into terminal7-33
Figure 7-11. Gauging terminal shank after swaging7-34
Figure 7-12. Typical cable splices7-34
Figure 7-13. Typical terminal gauge7-35
Figure 7-14. Typical thimble-eye splice7-38
Figure 7-15. Typical terminal gauge7-38
Figure 7-16. Cable inspection technique7-40
Figure 7-17. Cable wear patterns7-41
Figure 7-18. Worn cable (replacement necessary)7-42
Figure 7-19. Internal end view of cable wear7-42
Figure 7-20. Pulley wear patterns7-44
Figure 7-21. Corrosion7-45
Figure 7-22. Manufacturer’s wire splice7-45
Figure 7-23. Turnbuckle thread tolerance7-47
Figure 7-24. Safetying turnbuckles7-49
Figure 7-25. Securing turnbuckles7-51
Figure 7-26. Clip-type locking device7-52
Figure 7-27. Assembling and securing clip-locking turnbuckles7-53
Figure 8-1. Schematic of differential pressure compression tester8-9
Figure 8-2. Chart of spark plug temperature ranges8-11
Figure 8-3. Hot and cold spark plugs8-12
Figure 8-4. Spark plug reach8-13
Figure 8-5. Method of checking spark plug gap8-13
Figure 8-6. Typical carbon-fouled spark plug8-15
Figure 8-6a. Typical lead-fouled spark plug8-15
Figure 8-6b. Typical oil-fouled spark plug8-16
Figure 8-6c. Typical spark plug with cracked core nose8-17
Figure 8-6d. Typical worn out spark plug8-17
Figure 8-6e. Typical spark plug with bridged electrodes8-18
Figure 8-7. Spark plug well flashover8-19
Figure 8-8. Typical method of clamping leads8-20
Figure 8-9. Normal contact point8-21
Figure 8-10. Point with minor irregularities8-21
Figure 8-11. Point with well-defined mound8-21
Figure 8-12. Location of clamps at tube bends8-24
Figure 8-13. Typical muffler wall fatigue failure at exhaust outlet. (A. Complete muffler
assembly with heat shroud removed; B. Detail view of failure)8-28
Figure 8-14. Typical muffler wall failure. (A. Complete muffler assembly with heat shroud removed; B. Detail view of failure; C. Cross-section of
failed muffler)8-29
Figure 8-15. Typical muffler wall fatigue failure. (A. Complete muffler assembly
with heat shroud partially removed; B. Detailed view of failure)8-30
Figure 8-16. Typical fatigue failure of muffler end plate at stack inlet8-30
Figure 8-17. Section of a muffler showing typical internal baffle failure8-31
Figure 8-18. Loose pieces of a failed internal baffle8-31
Figure 8-19. Failed internal baffle partially obstructing the muffler outlet8-32
Figure 8-20 Failed internal baffle completely obstructing the muffler outlet8-32
Figure 8-21a. Example of exhaust outlet guard8-33
Figure 8-21b. Example of exhaust outlet guard installed8-33
Figure 8-22. Effect of improperly positioned exhaust pipe/muffler clamp8-34
Figure 8-23. Primary inspection areas8-35
Figure 8-24. Method of repairing surface scratches, nicks, etc., on
aluminum-alloy propellers8-38
Figure 8-25. Correct and incorrect method of reworking leading edge of
aluminum-alloy propellers8-38
Figure 8-26. Method of repairing damaged tip of aluminum-alloy propellers8-39
Figure 8-27. Example 1: Determine the repair width limits8-40
Figure 8-28. Example 2: Determine the repair thickness limits8-41
Figure 8-29. Repair of fixed-pitch hub and propeller with elongated or
damaged bolt holes8-43
Figure 8-30. Propeller tracking (wood block or cowling fixture shown)8-50
Figure 9-1. A typical ski installation9-7
Figure 9-2. Typical bolt cracks9-9
Figure 9-3. Typical cracks near bolt holes9-10
Figure 9-4. Typical bolt hole cracks9-10
Figure 9-5. Typical rod-end cracks9-10
Figure 9-6. Typical torque tube bolt hole elongation9-11
Figure 9-7. Examples of tread wear indicating overinflation and underinflation9-13
Figure 9-8. Hose assembly instructions (can be used for low-pressure hydraulic fluid,
and oil line applications)9-25
Figure 9-9. Proper hose installations9-28
Figure 9-10. Minimum bend radii9-29
Figure 9-11. Suggested handling of preformed hose9-31
Figure 9-12. Minimum bend radii–Teflon hose9-32
Figure 9-13. Inflation valve9-37
Figure 9-14. Repair dimensions9-43
Figure 9-15. Oxygen cylinder damage9-49
Figure 9-16. Cylinder brackets and clamps9-50
Figure 10-1. Typical datum locations10-2
Figure 10-2. Illustration of arm (or moment arm)10-3
Figure 10-3. Example of moment computation10-3
Figure 10-4. Empty weight center of gravity formulas10-4
Figure 10-5. Empty weight and empty weight center of gravity tailwheel type aircraft10-5
Figure 10-6. Empty weight and empty weight center of gravity
nosewheel type aircraft10-6
Figure 10-7. Operating center of gravity range10-7
Figure 10-8. Weighing point center line10-8
Figure 10-9. Empty weight and empty weight center of gravity when
aircraft is weighed with oil10-11