Contents (continued) Paragraph Page
Page xxviii
6-69................................................................................................EXTERNAL SKIN AREAS
.6-15
6-70.....................................................................................WATER ENTRAPMENT AREAS
.6-16
6-71.............................................................................................ENGINE FRONTAL AREAS
.6-16
6-72................................................................ELECTRONIC PACKAGE COMPARTMENTS
.6-16
6-73......................................................................................FLEXIBLE HOSE ASSEMBLIES
.6-16
6-74.......................................................................................................SANDWICH PANELS
.6-16
6-75.........................................................................................................CONTROL CABLES
.6-16
6-76.................................................................................................INTEGRAL FUEL CELLS
.6-16
6-77........................................................................................ ELECTRICAL CONNECTORS
.6-16
6-78.6-88. [RESERVED.]6-16
SECTION 6. CORROSION REMOVAL PROCEDURES
6-89GENERAL
.6-17
6-90................................................................................................ SAFETY PRECAUTIONS
.6-17
6-91..........................................................CORROSION CONTROL WORK PROCEDURES
.6-18
6-92.6-112. [RESERVED.]6-19
SECTION 7. BASIC CORROSION REMOVAL TECHNIQUES
6-113GENERAL
.6-21
6-114................................................................................. PREPARATIONS FOR REWORK
.6-21
6-115........................................................... FAIRING OR BLENDING REWORKED AREAS
.6-21
TABLE 6-1........................... ABRASIVES FOR CORROSION REMOVAL 6-22 FIGURE 6-14...... TYPICAL EXAMPLE OF ACCEPTABLE CLEANUP OF
CORROSION PITS6-23
FIGURE 6-15.BLENDOUT OF CORROSION AS A SINGLE DEPRESSION 6-24 FIGURE 6-16.BLENDOUT OF MULTIPLE PITS IN A CORRODED AREA 6-24
6-116......................................................................CORROSION REMOVAL BY BLASTING
.6-22
6-117...........................................................CLEANERS, POLISHES, AND BRIGHTENERS
.6-22
6-118.................................................................................................STANDARD METHODS
.6-23
6-119.6-131. [RESERVED.]6-24
SECTION 8. ALUMINUM AND ALUMINUM ALLOYS
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Page xxix
6-132GENERAL
.6-25
6-133...................................................SPECIAL TREATMENT OF ANODIZED SURFACES
.6-25
6-134.........................................................REPAIR OF ALUMINUM ALLOY SHEET METAL
.6-25
6-135.CORROSION REMOVAL AROUND COUNTERSUNK FASTENERS IN ALUMINUM ALLOY
.6-26
6-136.EXAMPLES OF REMOVING CORROSION FROM ALUMINUM AND ALUMINUM ALLOYS
.6-26
6-137.6-147. [RESERVED.]6-28
SECTION 9. MAGNESIUM AND MAGNESIUM ALLOYS
6-148GENERAL
.6-29
6.149................... TREATMENT OF WROUGHT MAGNESIUM SHEETS AND FORGINGS
.6-29
6.150.REPAIR OF MAGNESIUM SHEET METAL AFTER EXTENSIVE CORROSION REMOVAL
.6-29
6.151...............................................IN-PLACE TREATMENT OF MAGNESIUM CASTINGS
.6-30
6.152................................. EXAMPLE OF REMOVING CORROSION FROM MAGNESIUM
.6-30
6-153.6-163. [RESERVED.]6-33
Contents (continued) Paragraph Page
Page xxx SECTION 10. FERROUS METALS
6-164GENERAL
.6-35
6-165................................................SPECIAL TREATMENT OF HIGH STRENGTH STEEL
.6-35
6-166..........................................................SPECIAL TREATMENT OF STAINLESS STEEL
.6-35
6-167...................... EXAMPLE OF REMOVING CORROSION FROM FERROUS METALS
.6-36
6-168.6-178. [RESERVED.]6-36
SECTION 11. OTHER METALS AND ALLOYS
6-179..................................NOBLE METAL COATINGS - CLEANUP AND RESTORATION
.6-37
6-180................................................................................COPPER AND COPPER ALLOYS
.6-37
6-181.............................................................................TITANIUM AND TITANIUM ALLOYS
.6-37
6-182.6-192. [RESERVED.]6-38
SECTION 12. PLATED PARTS
6-193................................................................CHROMIUM AND NICKEL PLATED PARTS
.6-39
6-194........................................................................ CADMIUM AND ZINC PLATED PARTS
.6-39
6-195.6-205. [RESERVED.]6-39
SECTION 13. CORROSION PROOFING OF LAND PLANES CONVERTED TO SEA PLANES
6-206GENERAL
.6-41
6-207.....................................................................NECESSARY MINIMUM PRECAUTIONS
.6-41
6-208...............................................................................RECOMMENDED PRECAUTIONS
.6-41
6-209.6-219. [RESERVED.]6-42
SECTION 14. HANDLING AND CARE OF AIRCRAFT RECOVERED FROM WATER
IMMERSION
6-220GENERAL
.6-43
6-221...................................................... INITIAL FRESH WATER OR DETERGENT WASH
.6-43
6-222......................................................RECIPROCATING ENGINES AND PROPELLERS
.6-43
6-223AIRFRAME
.6-43
6-224.6-234. [RESERVED.]6-44
Chapter 7. Aircraft Hardware, Control Cables, And Turnbuckles SECTION 1. RIVETS
7-1GENERAL
.7-1
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Page xxxi
7-2.............................................................................................. MATERIAL APPLICATIONS
.7-1
7-3.7-13. [RESERVED.]7-2
SECTION 2. SCREWS
7-14GENERAL
.7-3
7-15................................................................................................ STRUCTURAL SCREWS
.7-3
7-16........................................................................................................ MACHINE SCREWS
.7-3
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Page xxxii
7-17... PANHEAD SCREWS (NAS600 THROUGH NAS606, NAS610 THROUGH NAS616, ....................................................................NAS623, AND NAS1402 THROUGH NAS1406)
.7-3
7-18...............................................................................................SELF-TAPPING SCREWS
.7-3
7-19............................................................................................................. WOOD SCREWS
.7-4
7-20.7-33. [RESERVED.]7-4
SECTION 3. BOLTS
7-34GENERAL
.7-5
7-35BOLTS
.7-5
7-36IDENTIFICATION
.7-5
FIGURE 7- 1................................TYPICAL AIRCRAFT BOLT MARKINGS 7-6
7-37.................................................................................................................GRIP LENGTH
.7-5
7-38..........................................................................LOCKING OR SAFETYING OF BOLTS
.7-6
7-39..........................................................................................................................BOLT FIT
.7-6
7-40TORQUES
.7-6
FIGURE 7-2................TO RQUE WRENCH WITH VARIOUS ADAPTERS 7-8 TABLE 7-1.........RECOMMENDED TORQUE VALUES (INCH-POUNDS) 7-9
7-41.......................... STANDARD AIRCRAFT HEX HEAD BOLTS (AN3 THROUGH AN20)
.7-7
7-42........................................................DRILLED HEAD BOLTS (AN73 THROUGH AN81)
.7-7
7-43...............................................................................................................ENGINE BOLTS
.7-7
7-44.........................................................................................CLOSE-TOLERANCE BOLTS
.7-9
7-45.INTERNAL WRENCHING BOLTS (NAS144 THROUGH NAS158 AND NAS172 THROUGH
NAS176)7-10
7-46.INTERNAL WRENCHING BOLTS (MS20004 THROUGH MS20024) AND SIX HOLE, ............................... DRILLED SOCKET HEAD BOLTS (AN148551 THROUGH AN149350)
.7-10
7-47. TWELVE POINT, EXTERNAL WRENCHING BOLTS, (NAS624 THROUGH NAS644)
.7-10
7-48...........................................................CLOSE-TOLERANCE SHEAR BOLTS (NAS434)
.7-10
7-49............................................................................................... NAS6200 SERIES BOLTS
.7-10
7-50......................................................................CLEVIS BOLTS (AN21 THROUGH AN36)
.7-10
7-51.............................................................................EYEBOLTS (AN42 THROUGH AN49)
.7-10
7-52.7-62. [RESERVED.]7-10
Contents (continued) Paragraph Page
Page xxxiii SECTION 4. NUTS
7-63GENERAL
.7-11
7-64.................................................................................................... SELF-LOCKING NUTS
.7-11
TABLE 7-2.MINIMUM PREVAILING TORQUE VALUES FOR REUSED SELF- LOCKING NUTS 7-12
7-65................................................................................NUT IDENTIFICATION - FINISHES
.7-11
7-66.....................................................................................................CASTLE NUT (AN310)
.7-12
7-67...........................................................................CASTELLATED SHEAR NUT (AN320)
.7-13
7-68................................................................................... PLAIN NUT (AN315 AND AN335)
.7-13
7-69........................................................................LIGHT HEX NUTS (AN340 AND AN345)
.7-13
7-70.......................................................................................................CHECKNUT (AN316)
.7-13
7-71....................................................................................................... WINGNUTS (AN350)
.7-13
7-72..................................................................................... SHEET SPRING NUTS (AN365)
.7-13
7-73.7-84. [RESERVED.]7-13
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Page xxxiv SECTION 5. WASHERS
7-85GENERAL
.7-15
7-86.........................................................................PLAIN WASHERS (AN960 AND AN970)
.7-15
7-87..........................................................................LOCKWASHERS (AN935 AND AN936)
.7-15
7-88....................................... BALL SOCKET AND SEAT WASHERS (AN950 AND AN955)
.7-15
7-89.....................................................................................TAPER PIN WASHERS (AN975)
.7-15
7-90.7-100. [RESERVED.]7-15
SECTION 6. PINS
7-101..................................................................................................................TAPER PINS
.7-17
7-102............................................................. FLATHEAD PINS (AN392 THROUGH AN406)
.7-17
7-103.................................................................................................COTTER PINS (AN380)
.7-17
7-104................................................................................................................ SPRING PINS
.7-17
7-105.................................................................................................QUICK-RELEASE PINS
.7-17
7-106.7-121. [RESERVED.]7-17
SECTION 7. SAFETYING
7-122GENERAL
.7-19
7-123............................................................................................................... SAFETY WIRE
.7-19
FIGURE 7-3...SECURING SCREWS , NUTS, BOLTS, AND SNAPRINGS 7-20 FIGURE 7-3A . ............................................... WIRE TWISTING BY HAND 7-20
7-124................................................................................ SAFETY-WIRING PROCEDURES
.7-20
7-125..............................................................................TWISTING WITH SPECIAL TOOLS
.7-21
FIGURE 7- 4....................................USE OF A TYPICAL WIRE TWISTER 7-22
7-126...............................................SECURING OIL CAPS, DRAIN COCKS, AND VALVES
.7-21
FIGURE 7-4A. ....SECURING OIL CAPS, DRAIN COCKS, AND VALVES 7-22 FIGURE 7-5. ........................................ SAFETY-WIRING PROCEDURES 7-23 FIGURE 7-5A. ..................................... SAFET Y-WIRING PROCEDURES 7-24 FIGURE 7-5B. ..................................... SAFET Y-WIRING PROCEDURES 7-25
7-127.................................................................................SECURING WITH COTTER PINS
.7-26
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Page xxxv FIGURE 7-6. .........................................SECURING WITH COTTER PINS 7-26 FIGURE 7-7.ALTERNATE METHOD FOR SECURING WITH COTTER PINS 7-26
7-128.7-139. [RESERVED.]7-26
SECTION 8. INSPECTION AND REPAIR OF CONTROL CABLES AND TURNBUCKLES
7-140GENERAL
.7-27
7-141....................................................................................................CABLE DEFINITIONS
.7-27
7-142........................................................................................................FLEXIBLE CABLES
.7-27
TABLE 7-3.FLEXIBLE CABLE CONSTRUCTION AND PHYSICAL PROPERTIES 7-28 FIGURE 7-8. ...................................FLEXIBLE CABLE CROSS SECTION 7-29
7-143............................................................................................NYLON-COATED CABLES
.7-27
7-144...............................................................................................NONFLEXIBLE CABLES
.7-28
TABLE 7-4...NONFLEXIBLE CABLE CONSTRUCTION AND PHYSICAL PROPERTIES 7-29 FIGURE 7- 9............................NONFLEXIBLE CABLE CROSS SECTION 7-29
7-145.............................................................................................CABLE SPECIFICATIONS
.7-29
7-146.................................................................................................CABLE PROOF LOADS
.7-29
7-147.......................................................................................REPLACEMENT OF CABLES
.7-30
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Page xxxvi
7-148.............................................. MECHANICALLY-FABRICATED CABLE ASSEMBLIES
.7-30
TABLE 7-5....... STRAIGHT-SHANK TERMINAL DIMENSIONS. (CROSS REFERENCE AN TO MS:
....... AN-666 TO MS2159, AN-667 TO MS 20667, AN-668 TO MS 20668, ...............................................................................AN- 669 TO MS 21260.)
7-31 FIGURE 7-10. .......................... INSERTION OF CABLE INTO TERMINAL 7-31 FIGURE 7-11............. GA UGING TERMINAL SHANK AFTER SWAGING 7-31 FIGURE 7- 12.................................................. TYPICAL CABLE SPLICES 7-32 FIGURE 7-13. ............................................. TYPICAL TERMINAL GAUGE 7-32 FIGURE 7-14. ........................................TYPICAL THIMBLE-EYE SPLICE 7-33 TABLE 7-6. ..............................................COPPER OVAL SLEEVE DATA 7-34 TABLE 7-7. ..............................................COPPER STOP SLEEVE DATA 7-34 FIGURE 7-15. ............................................. TYPICAL TERMINAL GAUGE 7-34
7-149.....................................................................................CABLE SYSTEM INSPECTION
.7-35
FIGURE 7-16. .................................... CABLE INSPECTION TECHNIQUE 7-35 FIGURE 7- 17...................................................CABLE WEAR PATTERNS 7-36 FIGURE 7-18................ WORN CABLE (REPLACEMENT NECESSARY) 7-36 FIGURE 7- 19....................................................INTERNAL CABLE WEAR 7-37 FIGURE 7- 20.................................................PULLEY WEAR PATTERNS 7-38
7-150..................................................................... CORROSION AND RUST PREVENTION
.7-38
FIGURE 7- 21CORROSION
7-39
7-151..............................................................................................................WIRE SPLICES
.7-39
FIGURE 7-22. ....................................MANUFACTURER’S WIRE SPLICE 7-39
7-152................................................................................................ CABLE MAINTENANCE
.7-39
7-153.................................................................................CABLE TENSION ADJUSTMENT
.7-39
7-154.7-164. [RESERVED.]7-39
SECTION 9. TURNBUCKLES
7-165GENERAL
.7-41
7-166.................................................................................... TURNBUCKLE INSTALLATION
.7-41
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Page xxxvii FIGURE 7-23. ..............................TURNBUCKLE THREAD TOLERANCE 7-41
7-167............................................................................................................ WITNESS HOLE
.7-41
7-168.7-178. [RESERVED.]7-41
SECTION 10. SAFETY METHODS FOR TURNBUCKLES
7-179..................................................................................................................... GENERAL.
.7-43
7-180..........................................................................................DOUBLE-WRAP METHOD..
.7-43
FIGURE 7- 24.............................................. SAFETYING TURNBUCKLES 7-44
7-181.............................................................................................SINGLE-WRAP METHOD.
.7-43
7-182................................................................ SAFETY-WIRE SECURED TURNBUCKLES
.7-44
TABLE 7-8........................................ TURNBUCKLE SAFETYING GUIDE 7-45 FIGURE 7- 25................................................SECURING TURNBUCKLES 7-46
7-183.................................................................................... SPECIAL LOCKING DEVICES..
.7-45
FIGURE 7-26. ........................................... CLIP-TYPE LOCKING DEVICE 7-46
7-184.............................ASSEMBLING AND SECURING CLIP-LOCKING TURNBUCKLES
.7-45
TABLE 7-9................................................ LOCKING-CLIP APPLICATION 7-47 FIGURE 7-27.ASSEMBLING AND SECURI NG CLIP-LOCKING TURNBUCKLES 7-47
7-185.7-195. [RESERVED.]7-47
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Page xxxviii SECTION 11. HARDWARE IDENTIFICATION TABLES
TABLE 7-10................................................................. T ABLE OF RIVETS 7-49 TABLE 7-11.............................................................. T ABLE OF SCREWS 7-50 TABLE 7-12.................................................................. T ABLE OF BOLTS 7-57 TABLE 7- 13.................................................................... TABLE OF NUTS 7-63 TABLE 7-14. ...........................................................TABLE OF WASHERS 7-69 TABLE 7- 15......................................................................TABLE OF PINS 7-71
7-196.7-206. [RESERVED.]7-74
Chapter 8. Engines, Fuel, Exhaust, And Propellers SECTION 1. ENGINES
8-1GENERAL
.8-1
8-2..................................................................................................... SPECIAL INSPECTION
.8-1
8-3.......................................CRANKSHAFT INSPECTION AND REPAIR REQUIREMENTS
.8-3
8-4.................................................. REPLACEMENT PARTS IN CERTIFICATED ENGINES
.8-3
8-5................................................................................... OIL SYSTEM LINES INSPECTION
.8-4
8-6................................................................................................. OIL FILTER INSPECTION
.8-4
8-7.....................................................CYLINDER HOLD-DOWN NUTS AND CAP SCREWS
.8-4
8-8...................................................................................REUSE OF SAFETYING DEVICES
.8-4
8-9..................... SELF-LOCKING NUTS FOR AIRCRAFT ENGINES AND ACCESSORIES
.8-4
8-10METALLIZING
.8-5
8-11PLATING
.8-5
TABLE 8-1.CURRENT ENGINE A ND MAXIMUM PERMISSIBLE CYLINDER
BARREL OVERSIZE8-6
8-12CORROSION
.8-6
8-13..............................................................................................................ENGINE RUN-IN
.8-6
8-14................................COMPRESSION TESTING OF AIRCRAFT ENGINE CYLINDERS
.8-6
FIGURE 8-1.SCHEMATIC OF DI FFERENTIAL PRESSURE COMPRESSION TESTER 8-7
8-15................................................................................................................ SPARK PLUGS
.8-8
FIGURE 8-2......... CHART OF SPARK PLUG TEMPERATURE RANGES 8-9
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Page xxxix FIGURE 8-3. ..........................................HOT AND COLD SPARK PLUGS 8-10 FIGURE 8- 4............................................................SPARK PLUG REACH 8-10 FIGURE 8-5. .....................METHOD OF CHECKING SPARK PLUG GAP 8-10
8-16...........................................................................................OPERATIONAL PROBLEMS
.8-11
FIGURE 8-6......................... TYPICAL CARBON-FOULED SPARK PLUG 8-12 FIGURE 8-6A. ........................... TYPICAL LEAD-FOULED SPARK PLUG 8-12 FIGURE 8-6B. ...............................TYPICAL OIL-FOULED SPARK PLUG 8-13 FIGURE 8-6C. ..TYPICAL SPARK PLUG WITH CRACKED CORE NOSE 8-13 FIGURE 8-6D . ................................ TYPICAL WORN OUT SPARK PLUG 8-14 FIGURE 8-6E. TYPICAL SPARK PL UG WITH BRIDGED ELECTRODES 8-14 FIGURE 8-7. .......................................SPARK PLUG WELL FLASHOVER 8-14
8-17..................................................SPARK PLUG PRE-RECONDITIONING INSPECTION
.8-14
8-18........................................................................... IGNITION HARNESSES INSPECTION
.8-14