Contents (continued) Paragraph Page
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
Contents (continued) Paragraph Page
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
Contents (continued) Paragraph Page
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
Contents (continued) Paragraph Page
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
Contents (continued) Paragraph Page
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
FIGURE 8-8..........................T YPICAL METHOD OF CLAMPING LEADS 8-15
Contents (continued) Paragraph Page
Page xl
8-19................................................................................................ MAGNETO INSPECTION
.8-15
FIGURE 8-9. ..................................................NORMAL CONTACT POINT 8-16 FIGURE 8- 10............................. POINT WITH MINOR IRREGULARITIES 8-16 FIGURE 8- 11...............................POINT WITH WELL-DEFINED MOUND 8-16
8-20.................................................................................... MAGNETO-TO-ENGINE TIMING
.8-17
8-21.8-29. [RESERVED.]8-17
SECTION 2. FUEL SYSTEMS
8-30GENERAL
.8-19
8-31...........................................................................................FUEL LINES AND FITTINGS
.8-19
FIGURE 8- 12........................ LOCATION OF CLAMPS AT TUBE BENDS 8-20
8-32.............................................................................................. FUEL TANKS AND CELLS
.8-19
8-33..................................................FUEL TANK CAPS, VENTS, AND OVERFLOW LINES
.8-20
8-34......... FUEL CROSS-FEED, FIREWALL SHUTOFF, AND TANK SELECTOR VALVES
.8-21
8-35...................................................................................................................FUEL PUMPS
.8-21
8-36................................................................. FUEL FILTERS, STRAINERS, AND DRAINS
.8-21
8-37................................................................................................... INDICATOR SYSTEMS
.8-22
8-38..................................................................................... FUEL SYSTEM PRECAUTIONS
.8-22
8-39.8-44. [RESERVED.]8-22
SECTION 3. EXHAUST SYSTEMS
8-45GENERAL
.8-23
8-46................................................................... MUFFLER/HEAT EXCHANGER FAILURES
.8-23
FIGURE 8-13.TYPICAL MUFFLER WA LL FATIGUE FAILURE AT EXHAUST OUTLET.
(A. COMPLETE MUFFLER ASSEMBLY WI TH HEAT SHROUD REMOVED; B.
..................................................................... DETAIL VIEW OF FAILURE.)
8-23 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--24 FIGURE 8-15.TYPICAL MUFFLER WALL FATIGUE FAILURE. (A. COMPLETE
MUFFLER ASSEMBLY
Contents (continued) Paragraph Page
Page xli WITH HEAT SHROUD PARTIALLY RE MOVED; B. DETAILED VIEW OF FAILURE.) 8-25 FIGURE 8-16.TYPICAL FATIGUE FAILURE OF MUFFLER END PLATE AT STACK INLET 8-25
8-47....................................................................................... MANIFOLD/STACK FAILURES
.8-23
8-48...................................................................................INTERNAL MUFFLER FAILURES
.8-23
FIGURE 8-17.SECTION OF A MU FFLER SHOWING TYPICAL INTERNAL
BAFFLE FAILURE8-25
FIGURE 8-18........... LOOSE PIECES OF A FAILED INTERNAL BAFFLE 8-25 FIGURE 8-19.FAILED INTERNAL BAFFLE PARTIALLY OBSTRUCTING THE
MUFFLER OUTLET8-27
FIGURE 8-20.FAILED INTERNAL BA FFLE COMPLETELY OBSTRUCTING THE
MUFFLER OUTLET8-27
FIGURE 8-21A. ....................EXAMPLE OF EXHAUST OUTLET GUARD 8-27 FIGURE 8-21B.EXAMPLE OF EXHAU ST OUTLET GUARD INSTALLED 8-27
8-49INSPECTION
.8-26
FIGURE 8-22........ EFFECT OF IM PROPERLY POSITIONED EXHAUST
PIPE/MUFFLER CLAMP8-28
FIGURE 8-23. .........................................PRIMARY INSPECTION AREAS 8-28
Contents (continued) Paragraph Page
Page xlii
8-50REPAIRS
.8-26
8-51TURBO-SUPERCHARGER
.8-27
8-52................................................................................................AUGMENTOR SYSTEMS
.8-28
8-53.8-70. [RESERVED.]8-28
SECTION 4. REPAIR OF METAL PROPELLERS
8-71GENERAL
.8-29
8-72...............................................................................................................STEEL BLADES
.8-29
8-73...............................................................................ALUMINUM PROPELLER REPAIRS
.8-29
FIGURE 8-24.METHOD OF REPAIRING SURFACE CRACKS, NICKS, ETC.,
ON ALUMINUM-ALLOY PROPELLERS8-30
FIGURE 8-25.CORRECT AND INCO RRECT METHOD OF REWORKING
LEADING EDGE OF ........................................................... ALUMI NUM-ALLOY PROPELLERS 8-30 FIGURE 8-26.METHOD OF REPAIRI NG DAMAGED TIP OF ALUMINUM-
ALLOY PROPELLERS8-31
8-74................................................................................................................REPAIR LIMITS
.8-31
FIGURE 8-27. EXAMPLE 1. DETERMINE THE REPAIR WIDTH LIMITS.
8-32 FIGURE 8-28.EXAMPLE 2. DETE RMINE THE REPAIR THICKNESS LIMITS 8-34
8-75.....................................................................................STEEL HUBS AND HUB PARTS
.8-33
8-76.....................................................................PROPELLER HUB AND FLANGE REPAIR
.8-33
FIGURE 8-29. REPAIR OF FIXED-P ITCH HUB AND PROPELLER WITH
ELONGATED OR DAMAGED BOLT HOLES8-35
8-77......................................................................................................CONTROL SYSTEMS
.8-34
8-78........................................................................................................ DEICING SYSTEMS
.8-34
8-79.8-90. [Reserved.]8-35
SECTION 5. INSPECTION OF PROPELLERS
8-91GENERAL
.8-37
TABLE 8-2.SAMPLE MANUFACT URER’S PROPELLER INSPECTION CHECKLIST 8-38
8-92............................................WOOD OR COMPOSITION PROPELLERS AND BLADES
.8-37
8-93............................................................................ METAL PROPELLERS AND BLADES
.8-38
8-94........................................................................................................... PROPELLER HUB
.8-39
8-95......................................................................................... TACHOMETER INSPECTION
.8-40
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Page xliii
8-96.8-106. [RESERVED.]8-40
SECTION 6. PROPELLER TRACKING AND VIBRATION
8-107GENERAL
.8-41
8-108................................................................................ PROPELLER TRACKING CHECK
.8-41
FIGURE 8-30. PROPELLER TRACKI NG (WOOD BLOCK OR COWLING
FIXTURE SHOWN)8-42
8-109VIBRATION
.8-41
8-110.8-129. [RESERVED.]8-42
Contents (continued) Paragraph Page
Page xliv Chapter 9. Aircraft Systems And Components SECTION 1. INSPECTION AND MAINTENANCE OF LANDING GEAR
9-1GENERAL
.9-1
9-2................................................................................................... GENERAL INSPECTION
.9-1
9-3....................................................................................... CLEANING AND LUBRICATING
.9-1
9-4.............................................................................................. FIXED-GEAR INSPECTION
.9-1
TABLE 9-1. ...........................................BUNGEE CORD COLOR CODES 9-2
9-5........................................................INSPECTION OF RETRACTABLE LANDING GEAR
.9-3
9-6.................................................................................................. EMERGENCY SYSTEMS
.9-3
9-7..................................................................................... LANDING GEAR COMPONENTS
.9-4
9-8.....................................................................................TIRE AND TUBE MAINTENANCE
.9-5
9-9............................................................................................................FLOATS AND SKIS
.9-6
FIGURE 9-1. ............................................A TYPICAL SKI INSTALLATION 9-6
9-10..................................................... INSPECTION AND REPAIR OF FLOATS AND SKIS
.9-7
9-11...................................................................... TYPES OF LANDING GEAR PROBLEMS
.9-8
FIGURE 9- 2....................................................... TYPICAL BOLT CRACKS 9-8 FIGURE 9- 3...............................TYPICAL CRACKS NEAR BOLT HOLES 9-8 FIGURE 9-4. ........................................... TYPICAL BOLT HOLE CRACKS 9-9 FIGURE 9- 5................................................TYPICAL ROD-END CRACKS 9-9 FIGURE 9-6........ TYPICAL TORQUE TUBE BOLT HOLE ELONGATION 9-9
9-12.................................................................................................SPECIAL INSPECTIONS
.9-9
9-13..................................................................................................... RETRACTION TESTS
.9-9
9-14................................................................................... TIRE INSPECTION AND REPAIR
.9-9
FIGURE 9-7.EXAMPLES OF TREAD W EAR INDICATING OVER-INFLATION
AND UNDER-INFLATION9-11
9-15..................................................................................................... INFLATION OF TIRES
.9-10
9-16......................................................................................................WHEEL INSPECTION
.9-11
9-17..................................................................................................WHEEL INSTALLATION
.9-11
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Page xlv
9-18.......................................................................................REASSEMBLING THE WHEEL
.9-11
9-19SLIPPAGE
.9-12
9-20.9-24. [RESERVED.]9-12
SECTION 2. HYDRAULIC SYSTEMS
9-25GENERAL
.9-13
9-26....................................................................... PURPOSES OF HYDRAULIC SYSTEMS
.9-13
9-27...................................................................................... TYPES OF HYDRAULIC FLUID
.9-13
9-28...................................................................................HANDLING HYDRAULIC FLUIDS
.9-14
9-29....................................................HYDRAULIC SYSTEM MAINTENANCE PRACTICES
.9-15
9-30...............................................................................HYDRAULIC LINES AND FITTINGS
.9-18
TABLE 9-2. ............................................................................. TUBE DATA 9-19 FIGURE 9-8.HOSE ASSEMBLY INSTRUCT IONS (CAN BE USED FOR LOW
PRESSURE HYDRAULIC FLUID, .................................................................AND OI L LINE APPLICATIONS) 9-21
Contents (continued) Paragraph Page
Page xlvi TABLE 9-3. ..................................... AIRCRAFT HOSE SPECIFICATIONS 9-22 FIGURE 9-9. ........................................PROPER HOSE INSTALLATIONS 9-23 FIGURE 9- 10.........................................................MINIMUM BEND RADII 9-24 TABLE 9-4.BALL DIAMETERS FOR TESTING HOSE RESTRICTIONS OR KINKING 9-25 FIGURE 9-11...........SUGGESTED HANDLING OF PREFORMED HOSE 9-25
9-31.9-36. [RESERVED.]9-25
SECTION 3. EMERGENCY EQUIPMENT
9-37.....................................................................................................................LIFE RAFTS
.9-27
9-38.............................................................................................. LIFE RAFT INSPECTIONS
.9-27
FIGURE 9-12............................................................... INFLATION VALVE 9-29
9-39..........................................................................................SURVIVAL KIT INSPECTION
.9-28
9-40.................................................................................................SPECIAL INSPECTIONS
.9-31
9-41...................................................................................................INSPECTION RECORD
.9-32
9-42...............................................................................................................RAFT REPAIRS
.9-32
FIGURE 9- 13......................................................... REPAIR DIMENSIONS 9-33
9-43........................................................................................................ LIFE PRESERVERS
.9-34
9-44....................................................................................LIFE PRESERVER INSPECTION
.9-35
9-45....................................................................................REPAIR OF LIFE PRESERVERS
.9-36
9-46.................................................................................... MISCELLANEOUS EQUIPMENT
.9-36
9-47........................................................................................................OXYGEN SYSTEMS
.9-37
9-48INSPECTION
.9-37
9-49MAINTENANCE
.9-38
FIGURE 9-14. .......................................... OXYGEN CYLINDER DAMAGE 9-39 FIGURE 9-15. .............................. CYLINDER BRACKETS AND CLAMPS 9-39
9-50......................................................................FUNCTIONAL TESTING AFTER REPAIR
.9-41
9-51...................................................SERVICE REQUIREMENTS --OXYGEN CYLINDERS
.9-41
TABLE 9-5........................................... TABLE OF FILLING PRESSURES 9-43
9-52.9-59. [RESERVED.]9-43